1

UNIVERSITY DEPARTMENT OF CHEMICAL TECHNOLOGY NORTH MAHARASHTRA UNIVERSITY JALGAON

IN PLANT TRAINING IN BACARDI INDIA PVT. LTD, GOA

Submitted By, Milind S. Gawande Final Yr B .Tech Food U.D.C.T, N.M.U, Jalgaon.
2

ACKNOWLEDGEMENT It was a great experience to do training in Bacardi India .It was a great opportunity to work here to enhance the analytical knowledge in the refreshing alcoholic beverages testing and preparation of various alcohol based products using different flavors. It gives me immense pleasure to express our deep gratitude and heartful thanks to Mr.Dinesh Ramchandran (Production manager) and Mr. Ashish Dhawan (Sr. Executive) at Bacardi India pvt.ltd. who made my dream of pursuing a multinational experience in your prestigious industry come true. Last but not the least would also like to thank, Mr. Damodar Bhaskar Rane(Asst.Maneger-QualityAssurance)Mr. Varinder Bansal (Asst. Maneger Finance) who made our working environment pleasant. I would also like to take this opportunity to thank Mr.Rajesh Dixit for giving me exposure to immense useful information about the liquor industry. I would also like to thank each and everyone at Bacardi India pvt. ltd,Goa who helped me during the internship. I would like to thank Dr. Satyendra Mishra Sir,(Head Of Department), Mr. Vishal Parate Sir (Incharge Of Food Tech.), Dr. M. Talib Sir (Lecturer Of Food Tech.), Mr.M. Pandav Sir (Training Incharge).

INDEX
Sr No. 1. 2. 3. 4. 5. 6. 7. 9. 10. 10. Chapter Name Introduction Process cycle in plant Products of Bacardi Breezer Water Treatment Blending Shop floor Quality Control department CIP ETP Microbiological Breezer Analysis Page No. 4 5 7 12 16 17 21 28 29 of 27

1)Introduction

Bacardi the leading drinks brand, and Bacardi Breezer is one of the most recognized brands amongst 100% of people in our survey know the name, 18-35 year olds and is currently sold in over 90 countries, across 5 continents. It is owned by the worlds largest privately held, family-owned spirits company. This came on the UK market in 1993.It is available in eight flavors: Orange, Watermelon, Lime, Lemon, Pineapple, Cranberry, Peach and Ruby Grapefruit. Furthermore, the brands were soon established and became popular among young people. Currently, women drink Bacardi than men. Bacardi Breezer has been about for ten years at present, it was launched in 1993 in the UK following success in the USA. Originally marketed as a wine cooler it has since found it's own identity with the Latin Spirit for Everyone marketing slogan. Currently, Bacardi Breezer is classed as one of the ever growing range of alcopops - a term coined in the mid nineties to describe a drink which is alcoholic but has the qualities of a pop like drink such as those drunk by younger people, sweet and effervescent. Originally these alcopops were mostly alcoholic lemonades but since it's launch Bacardi Breezer has branched out and is now available in eight different flavors. These flavors are Watermelon, Cranberry, Orange, Lime, Pineapple, Lemon, Peach and Ruby Grapefruit. Each flavor contains natural juice, bacardi rum and sparkling water.

2) Process cycle of an Industry:

Input

Process

Output

Raw Materials , Packing Materials From Suppliers

Factory

Stores

Quality Department

Analysis

Result

Comparison with Specifications

Ok

Not Ok

Accepted

Rejected

Production

Finish Goods

Dispatches to distributor or company bonded warehouse

Retailer

Consumer

3) Products of Bacardi Breezer:

1) Bacardi Breezer Cranbeery:

2) Bacardi Breezer Orange:

3)Bacardi Breezer Lime:

4)Bacardi Breezer Lychee:

5)Jamican Passion:

6) Bacardi Breezer Blackberry:

4) Raw material: In the Production of Alcoholic Beverages, there are three main
ingredients, which are as follows, 1. DM Water 2. Carbon dioxide; 3. Liquid Sugar

WATER (D.M):Water is in beverages manufacture must be free from suspended matters & colouring matter. It should not contain mineral which would interfere with the flavored & colour of the beverages. It should be free from objectionable odors. Water should meet with the specification limits require for the product manufacturing. Production starts with a pure source of water. Regular soft drinks contain 92% water. Drinking water often contains trace amount of various elements that affects its taste. It is noticed that tap water tastes different in various regions of the country. Bottlers use sophisticated filtering & other treatment equipments to remove any residual impurities and to standardize the water used to make soft drinks. That is why our soft drink tastes the same in all over the world.

CARBON DIOXIDE:A colorless & odorless gas, carbon dioxide is essential characterizing ingredient in all carbonated beverages. It is given off when we breathe and is used by plants to produce oxygen. When dissolved in water, carbon dioxide imparts a unique taste , for that reason natural sources of carbonated or effervescent, mineral water were once highly priced, these rare mineral waters also believed to have beneficial medicinal properties. It was the innovative step of adding flavors to these popular soda water that gave birth to the soft drink beverages we enjoyed today. In the early days of soft, drink manufacturing, carbon dioxide was made from sodium salts .This is why carbonated beverages were called as Sodas or Soda Water. Today bottlers buy pure carbon dioxide as a compressed gas in high-pressure cylinders, carbon dioxide gas is absorbed in to the flavored soft drinks in a carbonator just before the container or bottle is sealed. While under pressure and chilled the soft drink may absorb up to four times the beverage volume of carbon dioxide.
10

Sugar:
Sugar & sugar substitutes contribute the sweetness necessary to balance the various ingredients, gives body & mouth feel, & also act as carriers to distribute to flavor component uniformly thoroughly the drink. Generally Invert Sugar is used in the manufacturing of carbonated beverages. The main purpose to used Invert sugar in Carbonated beverages is to avoid the crystallization in the solution . Invert Sugar is more Soluble in than sucrose and is formed by sucrose hydrolysis to yield equal amounts of the monosaccharides glucose and fructose in the process. Formation Of Invert Sugar

C12H22O11 + H2O

C6H12O6+C6H12O6

Sugar component also contributes to the food value of the beverages and, to some extend to the flavor. Sucrose is also most widely used sweeting agent. Some sweeting agent like cyclamates, which were being used formerly are now banned as they are found to be harmful. Because of the high cost of the crystalline sugar, sugar syrups are used as sweetners.Fructose syrups or high fructose corn syrup (HFCS) is used these days. 55% corn syrup has approximately the same sweetness as a sucrose while 90% fructose syrup is approximately 50% more sweet than sucrose. Use of fructose syrup in soft drink manufacture has other advantages; it permits substantial reduction in calorie content of the drinks & also reduces the cost of the drink.

FLAVOUR: One of the major & important ingredients in soft drink is flavoring. Most soft drink bottlers mix many individual flavors to create distinctive taste. Natural flavors in soft drinks come from spices, natural extracts & oils , fruit flavored soft drinks such as orange & lemon lime often contains natural extract .There are also some artificial or manmade flavorings used in soft drinks, nature does not produce enough of some flavors to satisfy worlds demand , Also some natural flavors are limited geographically & seasonally. The different flavors are used in Bacardi breezer like Cranberry, Orange, Lime, Lychee, Jamaican Passion, Blackberry.

COLOURS:-

Many people do not realize how important colour is to taste perception, color affects our physiologically impression of food. If we dont believe it, try eating food in the dark. The colors used in food and beverages come from both natural and synthetic sources. In Bacardi Breezer production only natural colors are being used.

11

Other raw materials

y

y y

Sodium Citrate Citric Acid Invert Sugar

Other Chemicals used y Caustic Soda y Hydro Chloric acid

1) Water treatment plant:Service flow of DM water :-

12

Flow chart:Raw water

D.M. plant

Sand filter

Carbon filter

Cation Filter (Positive charged)

Anion Filter (Negative charged)

Mixed Bed

Ultra violet light to kill microorganisms

lab Analysis

Water is stored in D.M. storage tank

13

Standard operating procedure:1. Check the water level in the raw water sump. 2. Backwash sand filter and carbon filter for 30 min till the water is clear 3. Rinse the entire system for 15 min and check the conductivity, and conductivity meter should not show more than 3 m Siemens/cm2 for cation/anion bed and 2 m Siemens/cm2for mixed bed. 4. Check the quality of water in lab. If quality is acceptable then switch on the U.V. system and flow meter 5. Monitor the conductivity and other parameters every 30 min of operation. Regeneration:Whenever conductivities rise up above the said value for the said bed, regeneration needs to be done. Preparation of solution:Cation:- Take 100 ltr of water and add 67 ltr of HCL, make up to 200 ltr ,mix it and now solution is ready for regeneration for cation bed. Anion:- Take 100 ltr of water add 21.5 kg of caustic soda slowly and dilute it to 200 ltr ,mix throughtly. Now caustic soda solution is ready for regeneration of anion bed. Preparation of solution for mixed bed:Anion:-Take 45 ltr of water and add 4.5 kg of caustic,mix throughtly. Cation:-Take 30 ltr of water and 10 ltr of HCL,mix thoroughly. Above solutions are used separately for regeneration. After regeneration of mixed bed ,air mixing has to be done. After regeneration all the vessel should be rinsed thoroughly and the sample to be tested in lab, and if acceptable the water is collected. U.V. Light:U.V. light is used after passing the water through mixed bed. In this U.V. panel the micro-organisms are killed and this water is then passed through filter having pore size 10 micron. This treated water is used in the production and CIP.This treated water is known as D.M.(De-mineralized water).

14

Process of liquor preparation:1) Blending flow chart:-

D.M. water Sugar syrup Sodium Citrate Rum flavor Citric acid Alcohol 4.8% Key flavor Color

All the above ingredients are subjected for continuous blending for 2&1/2 hr . About 12 hrs are needed for maturation. Here above mixture is kept in concentrated form which controls microbial load. After maturation dilution of above liquor is carried out and sent to further processing.

15

Blending area:-

1-Invert sugar tank 3-Hot water tank 5-Blending tank II 7 to 10-IMFL tank 11 to 17-ENA tank

2-Hot caustic tank 4-Blending tank I 6-D.M. Storage

16

Process Loading Area:-

17

Automatic filling line-240 BPM A)Rinser-Hymech-240 BPM B)Carbonator-Hymech-4.0 KL C)Filler/Crowner-Hymech-240 BPM D)Labeling machine-KHS-240 BPM

2) Carbonation:Distilled blend Cooled up to 20c in PHE Carbonation Carbonation capacity Carbonation Pressure Beverages Temperature 4 KL/Hr 3.2 Kg/Cm3 20C

Carbonation is carried out in carbonator where Co2 gas is added to blended liquor. The main purpose of adding Co2 is for sparkling effect.At low temperature absorptive of co2 gas is maximum hence more co2 will dissolve as compared to normal temperature. To decreased the temp. of blended liquor plate type heat exchanger is used before passing liquor in the carbonator. 2) Rinser :Rinser is the process where bottle are washed out to remove any residual impurity, foreign matter, dust particle which remain in the inside of the glass bottle. Bottles from store are received. Before rinsing the empty inspection of bottle is carried out and the defected bottles are rejected here. The defected bottle will be rejected.

18

In Rinser bottle are cleaned with water by using pressure application. The glass bottle is kept at invert position to clean bottle. The glass bottles are continuously moved on belt conveyors. Capacity of Rinser Rinse time Pressure 220 BPM 6-8 sec 0.9 Kg/Cm3

3) Filler:After proper cleaning of the glass bottle in rinser the bottle is introduced in the filler machine. This filler machine is completely automated. Here the bottles get fixed in the mould which holds the bottle together. The filling tube is inserted in the bottle & liquor is fill up in the glass bottle. During filling process CO2 gas is used to increase the shelf life of final product. Capacity of the filler machine is about 240 BPM. At specific limit filling will be stopped. After filling glass bottle will be sealed with crown. The crown is sealed with using spring tension of the rod. During Filling temp.of the liquor is decreased at 70c. After filling the filled bottles are inspected 2nd Light Inspection: Low filled/ high filled, bottle with foreign particles are rejected during inspection. Here are some rules regarding inspection as follows. 1. Every (Filled/empty) bottle should be inspected. 2. Inspection should be done under illuminated background. 3. Visual inspection person should be trained for efficiency and reliability. 4. Visual inspection person should be allowed frequent breaks from inspection. 5. Bottles which are rejected should be destroyed once the production is complete. 6. Before start up take line clearance from the concerned QA.

19

5) Warming:Sealed bottles coming from crowner are passed through warmer to heat the bottles up to 45 oC . The aim of this process is to make the bottle surface area hot. Because of cool surface of bottle water will condense on the outer surface and hence the ability of the label to stick is decreased .Hence by increasing the temperature the labeling is effectively carried out. Temperature of the warmer Holding period of the warmer 40-450c 15-20 Min

After warming the bottles are inspected at filled inspection-II.

6)Labelling:After warmer the bottles are subjected for labeling in warmed condition. Different labels are used for different states. During labeling online printing of batch no, MRP, Expiry date and manufacturing date is also get printed on Back label. After labeling inspection of bottles carried out for defective bottles. 7)Packaging and dispatch:After labeling bottles are manually get packed into the corrugated boxes. These packed bottles are also inspected for any damaged label during packing. After that the box is processed for sealing. Once the box gets sealed it get shifted to Excise bonded ware house from where these material get dispatched to different states of the country as per the permit received.

20

QUALITY CONTROL DEPARTMENT Quality is nothing but the Degree of Excellence. Quality Department is responsible for all parameters related to quality from overall process staring from raw materials to finished goods. Quality Department ensures the operations of Inspection of Raw Materials. DM Water Quality Syrup Preparation Online Quality of beverage manufacturing GMP(Good manufacturing Practices). Bacardi breezer is analyzed as per the BIS standards. Following are the parameters which are maintained. 1. 2. 3. 4. 5. 6. 7. 8. Density PH Acidity Brix Alcohol Colour Taste CO2 content

y y y y y

ANALYTICAL METHODS. 1) Invert Sugar analysis Bacardi Company has its own standards for quality of sugar, each delivery: Appearance, Taste, Odour, Colour,Brix(72-74oB),PH(4.5-5.0) and specific gravity. The sample is mixed thoroughly in a container to produce a composite sample.

21

Consignment data collected with the sugar sample includes: - Suppliers name and location - Date and time of delivery - Quantity delivered - Transportation vehicle number The sugar is then tested as per the frequency for the parameters mentioned above. If the sugar is from a new supplier, all parameters are tested according to the Specification (The liquid sugar is then analyzed for each of the above parameters. Sugar lots not meeting the specification are rejected

2) 1. 2. 3.

Carbon dioxide Purity-Must be pure above 99.9% Taste & Odour Should be normal not pungent or like rotten egg. Appearance. The sample is analyzed as per the authorized testing procedures provided by the Division in the Quality Control Manual .The consignment is then either accepted or rejected as per the analysis results.

3) Citric acid1. Purity-It must be above 99% 2. Taste-Should be normal. 4) Sodium citrate1. PH- It should be 8-9 2. Clarity-The liquid should be clear containing sodium citrate, it must not give any suspended particles.

22

 QUALITY CHECKS OF TREATED WATER1. COLOUR : y Indicates generally the presence of undesirable dissolved, colloidal and suspended impurities in the water y Examples: y Iron turns to brown/red. y Manganese makes it black y Organics make it yellow. 2. Taste & Odour : y Indicates generally the presence of undesirable dissolved, such as hydrogen sulphide or sewage contamination. y Important parameter for water quality control in the food and beverage industry. 3. Total Dissolved Solid: y TDS is the measure of inorganic and organic substance contained in a water y Indicates total content of dissolved solids in water y It is determined by TDS meter. y It includes all matter suspended in water that is large enough to be retained on a filter with a given porosity. 4. Turbidity y Turbidity is measure the degree to which the water loses its transparency due to the presence of suspended particles y The WHO establishes that the turbidity of drinking water should not be more than 5 NTU y Indicates level of colloidal matter of organic or inorganic origin y Suspended solids & colloidal matter make water turbid y No quantifiable relationship between turbidity & suspended Solids 5. PH PH is determined by PH meter PH = - log [ H+ ] [ H+ ] is concentration of hydrogen ion mole/l PH of pure water is 7 PH scale ranges between 0 and 14, 7 is neutral point PH below 7 makes water acidic
23

 PH above 7 makes water alkaline 6. ALKALANITY Indicates the quantifiable quantities of bicarbonates, carbonate and hydroxide in water Determined using Phenolphthalein & Methyl orange indicators Phenolphthalein gives the P. alkalinity, P. Alk or P value Methyl orange gives the M. Alkalinity, M. Alk or M value Bicarbonates, carbonate and hydroxide in water are determined from P value and M value by alkalinity relationships Determination of alkalinity: Procedure: Take 100 ml of water sample. Pinch of sodium thiosulphate in that water sample add phenolphthelein indicator and titrate it with 0.2 N H2SO4 up to end point pink colour to colourless is obtained. Mark burette reading in ml and say as P- Alkalinity then add methyl purple indicator and titrate with 0.2 N H2SO4 up to end point colourless to pink colour is obtained.Mark burette reading in ml and say as M- Alkalinity Formula: alkalinity in mg/ L = Burette reading X 10

7.TOTAL HARDNESS Indicates the quantifiable quantities of calcium and magnesium A part of total hardness is associated with alkalinity in water and is known as alkaline hardness, carbonate hardness or temporary hardness The balance of total hardness is associated with non alkaline ions such as chlorides, sulphates etc. and is known as non-alkaline hardness or permanent hardness Procedure: take 100 ml water sample add 1-2 drops of ammonium buffer and pinch EBT indicator in it. And titrate it with 0.2 N EDTA Solution up to end point colourless to violet colour is obtained. And take burette reading in ml Formula: Totol Hardness in mg/L= Burette reading X 10

24

8. Recidual chlorine: y It indicates concentration of chlorine in liquid water. y It is measured in ppm Specification for treated water
Sr.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PARAMETER APPEARANCE TASTE O ODOUR CLARITY Ph TURBIDITY CONDUCTIVITY ALKALINITY a: Phenolphthalein Alkalinity b: Total Alkalinity HARDNESS TOTAL DISSOLVED SOLIDS FREE CHLORINE CHLORIDE COLIFORMS TOTAL MICROORGANISMS UNIT SPECIFICATION Clear, No visible sediments Tasteless Odourless Clear colourless 5.8 6.8 0-2 0-3 NIL 0-6 NIL 50 NIL NIL NIL 100

NTU mhos / cm mg/l mg/l mg/l mg/l mg/l mg/l CFU/ 250 ml CFU/ml @ 20C

5) PACKAGING MATERILS

1.CARTONS Cartons are also undergone inspection to meet specifications such as dimensions, GSM, printed matter, bursting strength, moisture content. For this cartons are randomly selected from various lots.Each carton box has capacity of 24 bottles.This are supplied from local market.

25

2)Crown corksCrown is made up of tin accompanied with rubber laquer for tight sealing of bottle and also avoids corrosion. 3)Glass bottlesFor the packaging of alcoholic beverages mainly the glass bottles are used which has good barrier properties against moisture and oxygen.The glass bottles are transperant and necked.the general size for bottle is 275 ml and having 40 mm thickness. 6) ON-LINE QUALITY CHECKS FOR GLASS BOTTLES:1. Taste 2. Appearance 3. Brix 4. Gas volume 5. Net Content 6. Crown Crimp 7. Date Coding 8. Density

26

Microbial analysis:Microbial analysis of product is done to find out presence of microorganisms in product. FLOW SHEET OF MICROBIAL ANALYSIS

Preparation of media

Autoclaving the media & plates required

Pouring the media in petri plates(By pour plate technique)

Solidifying the media

Filtering the product to be analyzed (through filter paper .45 micron)

Placing of the filter paper on the media

Incubation (24hrs) at 370

Observe the colonies (if present)

27

CLEANING AND SANITIZATION Cleaning is nothing but the washing of the equipment to remove all unwanted material, where as Sanitation is the treatment of cleaning surfaces and equipments by a process that destroys pathogenic bacteria and substantially reduce the population of all other micro-organisms. Cleaning solutions used in food industries are most commonly aq.solution of biodegradable alkaline detergents. The cleaning agent should be based on caustic soda or tri sodium phosphate. CIPIt is the cleaning and sanitization system where detergents and sanitizing agents with water are circulated through the equipment and lines by pumping or spraying. CIP is categorized in to two types 3step hot water 5step hot caustic In 3 step hot water only hot water is circulated through the lines where as in 3 step hot caustic 2% hot caustic solution (80 c) is circulated through lines and after circulating hot caustic all lines are sanitized with hot water till all caustic residual is removed from line.

28

ETP(Effluent treatment plant): Effluent treatment plant or in short ETP is one of the major and important areas in the bottling plant. Its major function is treating of the effluent generated in the plant operations. Effluent can be defined as anything that effects our environment causing harm where environment is the surroundings where we live in (air, water, nature etc.). The major characteristics of the effluent generated are as follows: y High pH y High TDS y High TSS y High BOD y High COD This effluent if released in the atmosphere into a lake will cause damage. The BOD in the effluent will result in the microorganisms to take dissolved oxygen from water and grow. Thus the DO level in water decreases causing danger to existing aquatic life. The plants so grown are rich in chemicals such as iron etc. which were earlier dissolved in water and if consumed by animals will cause accumulation of heavy metals in their body. This condition is called bio magnification. Thus the release of untreated effluents to water bodies destroys the complete eco-cycle. To avoid all these unwanted results, it is necessary to treat the effluent before releasing it into the environment.

29