A presentation on the industrial training in Shezan International Limited, delivered at University OF Haripur .

1. INDUSTRIAL TRAINING REPORT
AT SHEZAN INTERNATIONAL
DEPARTMENT OF FOOD SCIENCE and TECHNOLOGY, THE UNIVERSITY Of HARIPUR,
HARIPUR
Presenter:
Rao Usama
F16-0005
Supervisor:
Dr. Shehla Sammi
1
Presenter
Sanaullah saeed
F16-0451
Supervisor
Miss shagufta
Presenter
Muhammad Anees
F16-0333
Supervisor
Dr. Inam-u-llah
Presenter
Obaida Wali
F16-0300
Supervisor
Dr. Muhammad Liaquat

2. • Introduction
• Pulp preparation
• Tomato ketchup preparation
• Jams and marmalades
• Mango juices
• Mango squash
• Pickle production
• chutney
• Canning
• Quality control
• Conclusion 2
Outline

3. INTRODUCTION

4. History
• Shezan international limited is a Pakistani beverage manufacturer based in Hattar industrial
estate. It is the largest beverage company in Pakistan. It is the part of shahnawaz group
• The company was incorporated on May30, 1964 as a private limited concern and initially
conceived as a joint venture with Alliance Industrial Development Corporation of U.S.A for
processing citrus and other fruits as well as bottling of juices
• In 1971 the Shahnawaz Group purchased all the shares of Alliance Industrial Development
Corporation with the permission to Pakistan Government and from a joint venture company it
became a fully Pakistani owned company
• In 1980-81 a separate unit was installed in Karachi, which now caters for Karachi, Sind and
export demand
• . A new bottle filling plant was set up in 1983 in the Lahore unit, increasing the capacity five
folds.
• An independent Tetra Brick plant was commissioned in 1987 making the unit leading
manufactures with comprehensive range of production in the fruit processing field in Pakistan

5. Mission
• To provide the highest quality fruits and vegetables related juices and products to retail
and foodservice customers.
• To be the recognized industry leader in quality and service, providing more than expected
for our customers, employees, and stakeholders.

6. Industry Environment
• Shezan is the largest processor of fresh fruits and vegetables in the country
• The processing is carried out by qualified food technologists in Shezan’s ultra modern
plants at Lahore, Karachi and its wholly owned subsidiary.
• Pakistan is blessed with a climate ideally suited to the farming of all kinds of fruits, rich
in taste and flavor, sweet, mellow and juicy
• For centuries Pakistani farmers have been developing newer strains of fruit by grafting
one exotic variety with another.

7. Achievements
• 100% halal products
• HACCP certified
• received the ISO certifications; 9001-2008 and 22000-2005
• received the prestigious Consumer Choice Award in 2013
• Received the Quality Food Products certificate from the Rawalpindi Chamber Of
Commerce.
• Honored by the Karachi Stock Exchange when The Top Companies Award was accepted,
in 1994.

8. Product list
• Shezan international produce a number of products which are listed below
• Beverages
• Squashes and syrups
• Jams, jellies and marmalades
• Ketchup and sauces
• Chinese sauces and vinegar
• Pickles
• Chutneys
• Food essentials

10. CHAPTER 2
PULP PREPARATION

11. MANGO PULP PREPARATION
Sorting
Roller
Conveyer
Brush Washer
Bucket
Elevator
PulperFinisher
Pulp
Collection
Chemical
Mixing
(C7H5NaO2,
K2S2O5)
Pasteurizer
(90-950)
Cooling
(Normal
Temperature)
Packing &
Storage

12. PREPARATION OF TOMATO PULP
Sorting
Washing
(dip washing)
Thermo Break
Chemical
Mixing
(C7H5NaO2,
K2S2O5)
Finisher
Heat
Exchanger
(850)
Evaporator &
Concentrator
Storage

13. Chapter 3
TOMATO KETCHUP PREPARATION

14. Recipe (Approximate)
• Tomato Paste 1000 Kg
• Sugar 135 Kg
• Citric Acid 500-600 Gm
• Potasium Sorbate
• Color Sunset Yellow + Carmosine
• Acetic Acid 2 Kg
• Red Chilies
• Onion
• Salt
• Cinnamon
• Cumin
Procedure
• Heating and agitation
• Until brix 360–370
• Add seasoning to the pan in blended form
• Add color and preservatives at end
• Cooking time 20-25 minutes
• Homogenizing at 100-120 bar pressure

15. Filling
Shrink Wrapping
And Packaging
Quality Standards,
Acidity=1.2-1.4%
Brix=360

16. Chapter 4
Jams And Marmalades

17. Jams
Ingredients
• Fruit pulp
• Sugar
• Pectin
• Color
• Flavor
• Potassium sorbate
• Sodium benzoate
• Citric acid
Procedure
• Heating and agitation
• Addition of sugar
• At 100-1100C, filter the material to next pan
• Addition of pectin solution ( 1:1 sugar and
pectin in hot water at 700-1000C)
• Add color, flavor, citric acid and preservatives
• Brix = 68-69
• pH = 3.0-3.2

18. Marmalade
Ingredients
• Shreds of peels
• Sugar syrup
• Pectin
• Color
• Flavor
• Sodium benzoate
• Citric acid
Procedures
• Prepare sugar syrup at 100-1100C
• Filtration
• Addition of shreds of peel ( boiled in
water for 4 minute)
• Boil mixture of peels and syrup
• Addition of pectin mixture
• Color, flavor, citric acid and
preservatives
• Brix = 68-690
• Ph = 3.0-3.2

19. Chapter 5
Juice Preparation

20. Juice preparation include following procedure
Ingredients
• Mango pulp
• Sugar syrup
• Water
• Color
• Flavor
• Citric acid
• Sodium benzoate(preservative)
• Guar gum(stabilizer)
Quality standards
• Brix = 13-13.50
• Acidity = 0.15-0.17%
• pH = 3.4±0.1
• Volume = 240-245 ml

21. Procedure
Pulp Testing
To Blending
Tank
Syrup
Preparation
Juice Blending Homogenization
Juice Storage
Tank
Bottling

22. Juice Bottling
Loading
Conveyer
Sorting Of
Bottles
Uncaser
Machine
Bottle
Conveyer
Washer
Machine
Water Station
Washed Bottle
Inspection
Filler Feed
Conveyer
Pasteurizer
Filler
Filled Bottle
Inspection
Ink Jet Coder
Outer
Cleaning Of
Bottles
Table
Conveyer
Stacking &
Storage

23. Chapter 6
Squash Preparation

24. Ingredients
• Mango Pulp
• Sugar Syrup
• CMC (Carboxymethyl cellulose)
• Color
• Flavor
• Citric Acid
• Potassium Meta-bisulphite
(Preservative)
Process
• Heating of pulp at 500C
• Filtration of CMC and pulp
• Squash blending; sugar syrup, water, citric acid,
color and flavor
• Standard brix; if less sugar is added and water if high
• Storage tank (cooling)
• Filling
• Capping, labelling and packging

25. Quality standards
• Acidity = 1.5 ± 0.05
• Brix = 500 ± 0.050
• Free SO2 = 400 ± 50 ppm
• Volume = 735 - 740 ml

26. Chapter 7
Pickle Production

27. Procurement And Preservation Of Fruits And
Vegetables For Pickle Production
Preservation Of Mangoes
• Receipt Of Raw Material
• Sorting
• Cutting
• First Salting (10% salt by weight of
mangoes)
• Over Night Stay
• Drainage
• Second Salting
• Brining (15-20% brine solution)
• Storage
Green chilli preservation
• Receipt Of Raw Material
• Sorting
• Salting
• Overnight Stay
• Brining

28. Lime Preservation
• Receipt of raw material
• Sorting
• Brining
Berigold Preservation
• Sorting
• Salting
• Overnight Stay
• Brining
Carrot Preservation
• Receipt of raw material
• Peeling
• Cutting into slices
• Salting
• Overnight stay
• Brining

29. Ingredients
• Prepared raw material (mangoes,
lime, green chillies, berigold,
slices of carrot)
• Salt (99% pure)
• Mustard oil
• Spices (red chillies, fenugreek
seed, turmeric, cumin seed, dill
seed, garlic)
• Acids (citric and glacial acetic
acid)
Procedure
• Washing of raw material
• Sorting
• Raw material preparation; cap removing of berigold and
cutting of lime into half)
• Frying in oil
• Addition of spices
• Overnight stay in pan
• Oil separation
• Filling

30. Jar Filling
Oil Addition Material In Jar
Outer
Cleaning
Oil Level
Maintaining
Weighing
Neck
Cleaning
Bottom
Cleaning
Capping
Hot Water
Washing
Drying
Labelling
Packaging
And Stacking
Shrink
Wrapping

31. Chapter 8
Chutney

32. Ingredients
• 1. Plum Pulp
• 2. Dry Plum
• 3. Sugar
• 4. Spices:( Red chilli, Garlic
Paste, cumin and clove, salt)
• 5. Sodium benzoate
Procedure
• Mixing in cooking pan(pulp, spices,
sugar)
• Heating and agitation till brix reaches
76
• Dries plumps are added (washed)
after brix reaches 76
• Two to three boils till brix 72
• Ready for filling and transportation

33. Filling Capping Drying
Labelling
Shrink
Wrapping
Packing
Quality
Standards

34. Chapter 9
Canning

35. Unit Operation In Canning
Preparation Of Raw
Material
Filling
Syruping, Brining
Oiling
Lidding, Clinching Exhausting
Sealing
Heat Processing
Cooling Labelling
Packaging

36. QUALITY CONTROL

37. QUALITY ASSURANCE
• Research and Development is one of the fundamentals of any company. Shezan is one of
those companies that give extra importance to this field.
• Shezan has a state-of-the-art microbiology labs, where food products are examined and
tested and the best quality ingredients are separated
• The physic-chemical analysis of the food products is carried out by the trained lab
attendees to ensure that every food product is in commensurate with its claimed quality.

38. General
• Acidity
• Brix
• pH
• TSS
Water Testing
• Hardness
• Phosphate
• pH
• Sulphide
• Nacl
• Chlorine
• Iron
• TDs
• TSs
• Arsenic
Checking Of Pulp
• Cloud Stability
• (SO2) checking
• Smell
• Taste
• Color
• Fermentation

39. Water Testing

40. Hardness And Its Types
 The hardness of water is due to the presence of soluble bicarbonates, chlorides, and
sulfates of calcium and magnesium. Water which does not give lather with soap is hard
water.
 Types of Hardness
i. Temporary Hardness
ii. Permanent Hardness

41. Procedure:
 Take 100ml water in a beaker.
 Add 2ml Ammonia Buffer into the beaker.
 Add 1-2 drops of Eriochrome Black T.
 Place the beaker into the magnetic stirrer.
 Titrate with ethylenediaminetetraacetic acid (EDTA) 0.02N.
 Note the reading.
 End point is sky blue.
Formula:
Edta used * 20
100

42. pH
 pH of water is a measure of amount of hydrogen ions that is present in the water.
 It determines if the water is alkaline or acidic in nature.
 pH stands for potential of hydrogen.
 As per the World health organization(WHO) value of pH for the water is 6.5 to 8.5.
 pH can be calculated mathematically as
pH = -log[H]

43. Determination of Sulphite(so3)
 Measure 50 ml of the sample in a measuring cylinder.
 Transfer 50 ml of sample into a conical flask.
 Add 1 ml of Hcl 6N into the sample.
 Add 2 ml of starch indicator into the sample.
 Shake to mix solution.
 Titrate with potassium Iodine-Iodate until a faint blue is obtained.
 Note down the volume used.
Sulphite= 20*ml of potassium iodide-iodate used in titration

44. Determination of Chlorine
 Add 5 drops of chlorine reagent 1 in a glass vessel.
 Add 2 drops of chlorine reagent 3 and 3 drops of chlorine 2 in the same vessel.
 Now add water in the vessel and raise up to 5 ml.
 Wait for 2 minutes.
 Compare the colour of solution with the given comparator sheets.
 Note the reading.

45. Determination of iron
 Take 10 ml of water sample.
 Add iron reagent.
 Mix the solution.
 Compare the solution with the given comparator sheets.
 Note the reading.

46. Determination of Arsenic
 Take 60 ml of water sample in a bottle.
 Add 1-2 drops of arsenic reagent 1(liquid form).
 Add arsenic reagent 2(powder form) by green spoon.
 Add arsenic reagent 3(powder form) by red spoon.
 Mix the solution gently.
 Then take one test strip insert into a screw cap in the order that white dots of screw cap
and blue line of stripe is facing towards us.
 Immediately close cap tightly in reaction bottle and wait for 20 minutes.
 After 20 minutes compare color of reaction zone to color chart.

47. TDS
A TDS meter is a small hand-held device used to indicate the Total Dissolved Solids in a
solution, usually water. Since dissolved ionized solids, such as salts and minerals, increase
the conductivity of a solution, a TDS meter measures the conductivity of the solution and
estimates the TDS from that reading.

48. TSS
Total suspended solids (TSS) is the dry-weight of suspended particles, that are not
dissolved, in a sample of water that can be trapped by a filter that is analyzed using a
filtration apparatus. It is a water quality parameter used to assess the quality of a specimen
of any type of water or water body, ocean water for example, or wastewater after treatment
in a wastewater treatment plant.

49. Determination Of Nitric Strength
 Take 40 ml water in a beaker.
 Add 2 ml nitric sample in to the beaker.
 Add 2-3 drops of phenolphthalein indicator.
 Place the beaker on the magnetic stirrer.
 Turn on the magnetic stirrer.
 Titrate the solution with sodium hydroxide.
 End point pinkish colour.
 Note the reading.

50. Determination Of Caustic Strength
 Take 40 ml water in a beaker.
 Add 10 ml sample of caustic in to the beaker.
 Add 2-3 drops of phenolphthalein indicator.
 Turn on the magnetic stirrer.
 Titrate the solution with H2SO4.
 End point colourless.
 Note the reading.

51. Juice And Pulp Testing

52. Determination of Acidity of juice
 Take 40 ml water in a beaker.
 Take 20 ml juice mixed in the beaker.
 Add 2-3 drops of phenolphthalein indicator.
 Place on the magnetic stirrer and turn on the stirrer.
 Titrate the solution with sodium hydroxide(NAOH).
 End point pinkish colour.
Formula = Naoh USED * 2
sample

53. Determination of Acidity of pulp
 Take 60 ml water in a beaker.
 Add 5 ml pulp in the beaker.
 Add 2-3 drops of phenolphthalein indicator.
 Place the beaker on the magnetic stirrer and turn on the stirrer.
 Titrate the solution with Naoh.
 End point raddish pinkish colour.
Formula = Naoh used * 0.4

54. Determination of S02 in pulp
 Take 60 ml water in a beaker.
 Take 10 ml pulp sample and mixed in the beaker.
 Add 1.5 ml H2SO4.
 Add 1.5 ml starch 1%.
 Add 1g sodium carbonate
 Place the beaker on the stirrer and turn on the stirrer.
 Titrate the solution with iodIne 0.02N ppm.
Formula= iodine used* 64

55. Cloud Stability Test For Pulp
 Take 100 ml water in a conical flask.
 Add 10 ml pulp sample in it.
 Place the sample in microwave oven for 1.5 min at 100C .
 Place the sample at room temperature for 4-5 hours.
 Observe the cloud appear on the top of the table.

56. Conclusion & Suggestions