Industrial Project Report

SOUMYADIP GHOSAL
Final Year B.Tech Student
Department of Food Technology
Haldia Institute of Technology, Haldia
Purba Medinipur, West Bengal (India)
Summer Intern
For Allied Blenders & Distillers Private Limited
(Kalyani Unit)
MR. ARINDAM RAY
Plant HR Manager
Allied Blenders & Distillers Private Limited
Kalyani Industrial Growth Centre, Phase-III
Kalyani, Nadia, West Bengal (India)
Submitted to
Submitted on: 31st August, 2016

ACKNOWLEDGEMENT
It is my pleasure to acknowledge the fact that the Industrial Training,
at Allied Blenders & Distillers (ABD) has enriched my knowledge base
and provided a good exposure to the principle operations of IMFL
manufacturing. It was all possible with the continuous guidance and
support of many teams as well as individuals. This is an opportunity to
acknowledge their immense contributions throughout this event.
I would like to express my sincere gratitude to Mr Arindam Ray ( Plant
HR Manager) and Mr Pratim Pal (Unit-in-charge) for considering me for
providing Summer Internship at the plant.
I would like to show my indebt gratitude to the entire Production
department, headed by Mr Surender Dhariwal (Manufacturing Manager),
Mr Dhanpal Tasewal (On-Site Engineer) and Mr Dileep Singh
(Manufacturing Executive) for inducting me with their skills, knowledge
and experience and helping me during my internship.
The Quality department, led by Mr Lasat Tanu Basu (Reagional Head-
Quality), Mr Amaresh Panja (Blender-Head), Mr Manoj Kumar (QA in-
charge) and Mr Nagendra Kumar Singh (Blender in-charge) and the entire
team deserves an indebt acknowledgement.
I would also like to express my sincere gratitude to Dr Avik Mukherjee
(Professor and Head), Mr Gourab Chatterjee (Assistant Professor), Dr
Sumita Das (Assistant Professor) and the entire department of Food
Technology for supporting constantly and arranging the summer
training successfully.
I would not forget the strength and unconditional support provided by
my parents and inspiring me constantly, making me strong and
determinant during this period.
Lastly, I would like to thank almighty for the successful completion of
the training programme, providing a valuable opportunity to develop a
few of the required sets of skills along with widening the scope for
knowledge.

EXECUTIVE SUMMARY
ABD‘s first company-owned unit in Eastern India, Wales Distillers
Private Limited is dedicated to IMFL manufacturing sold under West
Bengal Excise is prepared by reduction of ENA, distilled through
modern technology with Demineralised water followed by blending of
Caramel, Scotch Malt Spirit and various flavouring spirits. The
manufacturing unit hardly need to compromise with the water quality
due to the presence of its in-house water Demineralization plant.
The admiring task of outsourcing the rarest variety of grain spirits are
undertaken by the distilleries, which are transported to the unit in
tankers crossing through checks at various stages. Similarly, the other
key ingredients are thoroughly scrutinized before reception. The
incoming packaging materials are not an exemption to scrutiny.
Received ENA, free from unacceptable contaminants is reduced with
circulation of demineralized water (strictly maintaining 4:5 ratio )
followed by addition of soluble ingredients such as Caramel, Scotch
Malt Spirit, and flavouring spirits (if required).The Quality Assurance
(QA) team usually maintain a busy schedule during the entire blending
operation as they work to establish the uniformity of the portfolio
brands in order to retain the quality. The blend passes to the Service
Tanks not until QA department‘s green signal and thereafter, reaches
the filling point.
The quality packaging materials, selected through sampling inspection
are stored in isolation and utilized in ―first come-first serve‖ basis. As
soon as the packaging materials are unleashed, the bottles are sorted to
start its journey from rinsers to fillers to meet the blend. After filling,
cap feeding and sealing, the liquor turns out to be a product and head s
ahead on the bottling line. If aseptic packaging is to be considered, the
continuous blend flow from Service Tank to the machine is fused with
an inert fluid (strictly maintaining 4:1 ratio) and aseptically packed in
shelf-stable cartons. The QA department place a high importance level
in assuring the quality throughout the production. The support of the
online-QC team during run-time defects make up for the reduced line
efficiency.
The unit accounts for its responsibility to prevent Environmental
pollution by checking the outgoing effluents to accepted levels through
an installed Effluent Treatment Plant, reducing the chances to
contaminate the surrounding area.
This report is a conscious effort to observe and make a thorough study
of the operations of the unit, catering as an IMFL manufacturer.

PLEADGE OF CONFIDENTIALITY
I heartily respect each and every decisions of ‗Allied Blenders &
Distillers Private Limited‘ that correlates with the Industrial
Training, undertaken as a part of the Summer Internship Programme
of one month. I also understand the fact that there are different
levels of confidentiality in a liquor industry. Therefore, I hereby
take pledge to strictly abide by the rules and regulations of the
company and always honour and maintain the confidentiality of the
company, as a developing professional. I assure to refrain from any
activities that may potentially harm the reputation and goodwill of
the business corporate.
In this context, I would like to mention that being a representative
of my institution ‗Haldia Institute of Technology‘, I feel honoured
and hereby pledge to carry forward the reputation to the industr y
during my internship programme.

TABLE OF CONTENTS
S.L.
Nos. TITLES
PAGE Nos.
START END
1. COMPANY PROFILE 1 3
2. PRODUCT PROFILE 4 9
3. SAFETY ASSURANCE 10 10
4. LEGAL DEFINITIONS 11 16
5. PLANT DESCRIPTION 17 18
6. PRODUCE OF THE UNIT 19 19
7. PRECAUTIONS TO THE UNIT 20 20
8. PRODUCT RAW MATERIALS 21 21
9. EXTRA NEUTRAL ALCOHOL 22 22
10. DEMINERALIZED WATER 23 23
11. WATER DEMINERALIZATION 24 25
12. BLENDING SECTION 26 27
13. WASHING SECTION 28 29
14. BOTTLING SECTION 31 34
15. ASEPTIC PACKAGING 33 34
16. STORAGE AND DESPATCH 35 35
17. EFFLUENT TREATMENT SECTION 36 36
18. QUALITY CONTROL @ RQCL 37 37
19. DRY LABORATORY OPERATIONS 38 42
20. METHODOLOGY OF QUALITY REJECTION 43 43
21. SENSORY LABORATORY OPERATIONS 44 45
22. WET LABORATORY OPERATIONS 46 48
23. CONCLUSION 49 49
24. REFERENCES 50 50

COMPANY PROFILE
The liquor industry can be associated with either unbelievable success
or heart-breaking defeat. A sound recipe that captures the imagination,
and delights the palette is just not enough, rather it is more of a series
of prerequisites that are required to be planned and executed at
corporate level for establishment of a specific brand. There are licenses
to obtain, production to arrange, and logistics to be planned. But Allied
Blenders & Distillers (ABD) overcame all these hurdles and exhibited
its presence in almost all alcohol categories to emerge as one of the
leading IMFL (Indian Manufactured Foreign Liquor) companies that
manufactures and sells alcoholic beverages all by itself.
The emergence of ABD is believed to be around 1990s, when Mr.
Kishore Chhabria, the founder of Allied Blenders & Distillers (ABD),
broked partnership with Vijay Mallya and moved out of Herbertson
with a single brand ―Officer‘s Choice‖ under his belt.
ABD‘s flagship brand, Officer's Choice historically targeted the
economically marginalized sections of the society especially, the daily
wage earners. It made possible for every common man to have a taste of
the best.
In the following years, ABD introduced semi-premium versions of
Officer's Choice namely Officer's Choice Blue, and Officer's Choice
Black to extend its consumer scope. The black variety is a blend
prepared using Indian grain spirits and rare Scotch malts that have
been aged in charred oak barrels. Currently, Officer‘s Choice is
regarded as the largest-selling whisky brand in the world, and is one of
the largest spirits brands exported out of India.
Since the last seven years, the pace of transition for ABD is such that
today, Allied Blenders & Distillers is a multi-brand company with a
strong presence in 23 countries. The other major brands of ABD include
Jolly Roger Rum, Class 21, Wodka Gorbatschow, Officer‘s Choice
Brandy, Lord Master Brandy and Kyron Premium Brandy. ABD has
emerged as the fastest growing spirits company in India with a
compounded growth rate of 26% over the last 3 years.
1

2
Besides, IMFL manufacturing, ABD ventured into the Indian snacks
market with its flagship brand, considering the rich tradition and
culture of Indigenous spices and recognizing the transition in the trend
of taste of the new generation. The initiative received appreciations
from all the sections of the society and helped greatly in revenue
generation.
The Company feels proud in engaging itself in Corporate Social
Responsibility (CSR) through its brands that reflected when Officer‘s
Choice was associated with ‗Salaam India Awards‘-the celebration of
extraordinary acts of courage by ordinary people. Officer‘s Choice Blue
is also on a mission to spread awareness among the consumers to take a
stand against social evils, through the slogan of ‗Raise Your Voice‘.
Officer‘s Choice Black encourages customers to give better than their
best with the slogan of ‗Be More than Big. Be Great.‘ While
accomplishing its corporate goals, the company do not forget to nurture
its workforce by various programmes and initiatives like culture
building initiatives, employees wellness programme and launch of
online e-learning portal-EMPOWER and Portal of Knowledge (pk2), as
an integrated part of ABD Learning Academy.
With 15 sales offices and 50 bottling units (of which 8 are company-
owned), and a pan-India presence, ABD currently enjoys a national
market share of approximately 11% in India‘s alcoholic beverage
industry in FY 2015-16.

3
A D M I R I N G T R A J E C T O R I E S
I N C R E D I B L E J O U R N E Y

PRODUCT PROFILE
Allied Blenders & Distillers (ABD) proudly presents itself as a multi-
brand company initiating from the whisky segments that includes
products like
OFFICER’S CHOICE WHISKY Mature & Rare- A smooth whiskey with a
finely balanced malt blend
Officer‘s Choice Whisky is one of the largest whisky brands in the
world.
Believed to be launched in 1988 and positioned in the regular
whiskey segment.
Conceptualizing ‗Righteousness‘ that encourages consumers to
make the right choice in life and awaken the hidden Officer
within them.
Available across India in attractive packs in 2 ltrs, 750 ml, 500 ml,
375 ml, 180 ml & 90 ml.
It is a market leader in 18 states across India with a national
market share of 40%.
Growing at a CAGR of 14%, over the last 3 years, it has registered
a sale of 25.7 million cases in 2015-2016.
OFFICER’S CHOICE BLUE PURE GRAIN WHISKY- A fine blend of scotch
malts and selected Indian grain spirits
Officer‘s Choice Blue is a premium variant of Officer‘s Choice.
Believed to be launched in mid-2011 and positioned in the regular
whiskey segment.
An elegantly designed, well-shaped pack gives it a premium and
scotch-like look and feel.
Spreading awareness among the consumers to take a stand against
social evils, through the slogan of ‗Raise Your Voice‘.
Available in 2ltrs, 1ltr, 750ml, 375ml, 180ml and 90ml packs.
First brand in the alcoholic beverage industry to introduce the
innovative Twist-Lock and Tear-Off caps.
4

OFFICER’S CHOICE BLACK WHISKY- An authentic and exquisite blend of
Scottish malts from three regions – Highland, Lowland and Speyside
Derives the distinctive taste and character from the charred oak
barrels where it is matured in.
A complex harmony of fruity and floral flavours makes it a rich
and rare blend.
Available in 1ltr, 750ml, 375ml, 180ml and 90ml packs.
Encourages customers to give better than their best with the
slogan of ‗Be More than Big. Be Great.‘
CLASS 21- India’s first grain vodka in the regular segment
Launched with the tagline ―Thank God for 21‖, highlights the fun,
zestful side of being 21.
Stands a class apart from other spirit brands in the category, with
a unique, cutting-edge bottle to capture the imagination of hip
and trendy consumers.
Available in three exciting flavours – Orange, Green Apple and
Fusion.
Its contemporary, modern and immaculate packaging has broken
new ground in the market in terms of design and uniqueness.
Available across India in attractive packs of 750 ml, 375 ml, 180
ml & 90 ml sizes.
Connects with the spirit of today‘s youth generation.
WODKA GORBATSCHOW- Germany’s No.1 brand of vodka, introduced in
India through a joint venture between ABD and Henkell & Co.
Available in three exciting flavours – Green Apple, Orange and
Vanilla.
The unique triple-chill filtration process, carried out at -12oC, has
popularised the brand as one of the ‗purest‘ vodkas in the world.
Exhibits its classy design with an edgy, irreverent and bold
personality.
Available in attractive packs in 750 ml, 375 ml, 180 ml, 90 ml and
60 ml sizes.
Encourages them to play each role with passion, integrity and
above all, Purity.
5

LORD & MASTER BRANDY - ABD’s first foray into the semi-premium
brandy segment
A blend of French grape spirit and exotic natural ingredients.
Available in Kerala, AP and Pondicherry in 1 ltr, 750 ml, 500 ml,
375 ml, 180 ml, 90 ml packs.
The brand is positioned as the ultimate choice for the ‗Man of
Substance‘.
Through a strong visual symbol – the Lion, bringing out
connotations of authority and innate power and helps the
consumer make a statement without being overt.
KYRON PREMIUM BRANDY- an XO blend of French brandy and exotic
ingredients
Creates an aura of French legacy and is a premium brand with a
classy, sophisticated demeanour.
Its warm, deep amber glow and tantalising bouquet emerges from
a melange of exquisite ingredients.
Available in A.P, Kerala, Delhi and Bengaluru in 750 ml, 375ml
and 180 ml packs.
Designed to recreate the experience of French Grandeur, the
bottle has a unique shape that is reminiscent of an era of class and
legacy.
OFFICER’S CHOICE BRANDY- Made from the finest grapes
Specially crafted from the finest variety of grape spirit and high
quality natural ingredients to give a smooth and pleasant flavour
and taste.
Available in attractive packs in 750 ml, 375 ml, 180 ml & 90 ml.
Savour and experience its smooth, pleasant and authentic brand
character.
6

OFFICER’S CHOICE STRONG BEER- Positioned in the strong beer
segment
Made from the best malted Barley, which lends a great flavour,
aroma and appropriate bitterness.
Brewed with special fermenting yeast and lagered at low
temperature to mature for a period of 21 days.
Offers a refreshing taste and is targeted at young consumers of
today.
OC beer has been introduced in UAE, Singapore and Malaysia.
JOLLY ROGER PREMIUM XXX RUM - ABD’s premium offering in the dark
rum segment
Blended with original matured Jamaican pot-still rum and natural
spices, it offers an unmatched quality and exotic taste in every
sip.
Comes in elegantly designed family-shaped bottles with tamper-
proof Guala caps.
Available in select states across India in attractive packs of 1Litre,
750 ml, 500 ml, 375 ml, 180 ml & 90 ml bottles.
Connects with achievement-driven, and distinctiveness-seeking
consumers through the platform of ‗The Winning Spirit‘,
resonates well with their desire to push his boundaries for greater
heights.
OFFICER’S CHOICE WAFERS- Over 30 years of Officer’s Choice promise
Uses best locally grown potatoes, choicest ingredients, spices and
seasonings.
Produced through world class machines, and passes strict
international quality standards and systems like HACPP & FSS.
Fresh from farm to the Officer‘s Choice potato chip bag.
OFFICER’S CHOICE STIXX- Rice crispies (along with corn & gram) made
from all natural ingredients.
Eat-anytime snack is made from locally grown ingredients and
milled at local mills before arriving at the plant.
7

The secret recipe is mixed and then made into our fun-to-eat
STIXX shape that is then fried and howered with the most
awesome spices and seasonings. The freshly cooked and still hot
STIXX are then whisked away to the waiting packing machines on
little bucket elevators and are dropped into our gorgeously
designed STIXX pillow pouch bag in servings.
Ultimately, brightens up your day a little with a lot of flavour.
OFFICER’S CHOICE STIXX- A tribute to the great Indian snacking culture
Made using the same age old rich Indian snacking traditional
recipe with a big new-age Tadka.
Using the best and choicest ingredients, each batch is made by
our master artisans and cooked to perfection before being packed
into convenient pillow pouch bags.
8
W H I S K Y S E G M E N T

9
B R A N D Y S E G M E N T
V O D K A S E G M E N T
S N A C K S S E G M E N T
R U M S E G M E N T

SAFETY ASSURANCE
Every individual considers safety as his or her primary concern . The
term Safety is not merely about being physically fit rather, it associates
now with many aspects including quality. Therefore, Safety has been
identified as a game changer with a significant role to play in this era
of globalization. In this context, it is worthwhile to claim that safety is
one major characteristic factor who establishes quality.
Recently, the world witnessed some of the safety systems like HACCP,
ISO 22000:2005 to take care of the risks and safety hazards in
manufacturing plants very efficiently. Although, the system demands
several pre-requisite programs before it can function but once, all these
PRPs are checked, the system takes no time to eliminate for the best or
reduce their limits to an accepted level.
Understanding the fact that the liquor industry is prone to frequent
hazards which when uncontrolled can lead to heavy damages in terms
of money and goodwill of the company, ABD has incorporated Safety
Assurance system to each of their processing phases. This strategy
deserves applaud as it integrates quality into the process. By sailing on
their constant innovation, ABD cruises to realize its vision ―To be the
most admired spirits company.‖
While taking plant safety into consideration, it is also a significant area
of concern for a liquor manufacturer like ABD. Like every alcoholic
beverage company, ABD too is in fond of glass bottles as a primary
packaging, due to its inertness, ease of recycling and a classy show
attracting consumers at a glance. So, working with it makes it
susceptible to breakage bringing in various hazards to the system as
well as to the workers and employees. This calls for an effective safety
management strategy to be in place ensuring overall safety of the
working environment.
In addition to plant safety, fire accidents are frequent threats to any
liquor industry due to the fact that these industries deals with spirits
and alcohol, considered as good inflammables. Fire fighting proves to
be another challenge needs combated with. For an efficient safety
management, proper induction, providing safety accessories and
frequent monitoring are inevitable.
10

LEGAL DEFINITIONS
Indian Standard
ALCOHOLIC DRINKS
Indian Made Foreign Liquor:
IMFL is primarily referred to spirits that are produced in foreign
countries and imported to India in bulk quantities and bottled in
an Excise Bonded Warehouse by the Importers such as Gin, Vodka,
Whisky and Brandy.
Rectified Spirit: ‘
Rectified spirit (revised) are considered to be inferior, thus they
fail to qualify for use in the manufacture of alcoholic drinks.
Neutral Spirit:
Neutral spirit is ethanol, which will only have the characteristic
taste and odour of ethanol.
Molasses Neutral Spirit: Neutral spirit made from molasses will be
called Molasses Neutral Spirit.
Grain Neutral Spirit: Neutral spirit made from grain or malt will
be named as Grain Neutral Spirit.
Whisky:
Whisky is a distilled alcoholic liquor possessing the distinctive
colour, aroma and taste of whisky. Whisky shall be made either
from neutral spirit conforming to IS 6613 or rectified spirit, Grade
I, conforming to IS 323 or a mixture of both.
Malt or Grain Whisky: Malt or Grain Whisky shall be the alcoholic
distillate produced from fermented mash of malted or unmalted
cereals or mixture of both. The distillation shall be carried out to a
suitable strength in such a way that the distillate has a distinct
aroma and taste characteristics derived from raw materials or
constituents formed during fermentation.
 Single Malt Whisky: It shall be the alcoholic distillate
produced from fermented mash of malted barley and distilled
in pot still only.
11

Blended Malt or Grain Whisky: Blended malt or grain whisky
shall be a mixture of at least 2 per cent malt or grain whisky with
whisky.
Rum:
Rum is an alcoholic distillate obtained from fermented
sugarcane/sugar beet molasses, possessing distinctive aroma and
taste characteristic of rum.
White Rum: Rum without colour shall be designated as white rum.
Premix Rum: Premix rum shall be alcoholic beverage made out of
rum and flavourings, with or without colour and with or without
added sugar.
NATIONAL AGENCY FOR FOOD AND DRUG ADMINISTRATION
AND CONTROL ACT 1993 (NAFDAC)
(AS AMENDED)
Spirit Drinks Regulations 2005
Blended Spirit:
Blended spirit shall be a spirit obtained from alcohol of
agricultural origin and permitted additives with or without
sugar(s).
Spirit drink: “Spirit drink” means an alcoholic beverage :
intended for human consumption;
having particular organoleptic properties;
peculiar to that class of drinks;
which contains a minimum alcoholic strength of 15% volume; and
shall be produced by one of the following methods -
 directly by distillation, with or without added flavouring from
naturally fermented products, or
 by the maceration of vegetable substances, or
 the addition of flavourings, sugars or other sweetening
products or other agricultural products or a combination of two
or more of the above to ethyl alcohol of agricultural origin, or
12

 by the mixture of a spirit drink with –
 one or more other spirit drinks ethyl alcohol of agricultural
origin; or
 one or more alcoholic drinks; or
 by blending potable ethyl alcohol of agricultural origin with
spirit concentrates, natural flavourings, permitted food colours,
sugars or permitted sweetening agents.
Whisky: Whisky shall –
be a potable alcoholic distillate obtained from a mash of cereal
grain products;
be saccharified by the diastase of the malt contained therewith or
without other natural enzymes;
be fermented by the action of yeast and matured for a period,
contain not less than 37.0 per cent of absolute alcohol by volume.
 Malt Whisky:
Malt whisky shall be the whisky obtained by distillation of a
mash consisting of cereal malt fermented by the action of yeast or
a mixture of such distillate and ethyl alcohol of agricultural
origin.
 Scotch Whisky:
Scotch whisky shall be whisky distilled and matured in Scotland
qualifying in accordance with the laws applicable thereto in
Scotland.
 Irish Whisky:
Irish whisky shall be whisky distilled in Northern Ireland or in
the Republic of Ireland as Irish whisky for domestic consumption
in accordance with the laws applicable thereto in Northern
Ireland or in the Republic of Ireland.
 Canadian Whisky:
Canadian whisky, Canadian rye whisky or rye whisky shall be
whisky distilled in Canada as Canadian whisky for domestic
consumption in accordance with the laws applicable thereto in
Canada.
13

 Blended whisky:
Blended whisky shall be ethyl alcohol of agricultural origin to
which permitted whisky flavours have been added.
Rum: Rum shall –
be a potable alcoholic distillate obtained exclusively from sugar-
cane products;
be fermented by the action of yeast or a mixture of yeast and other
organisms; or
be a mixture of such distillate which has been aged;
have the aromatic characteristics specified to rum and may contain
caramel, may be flavoured with fruit or any other approved
botanical substances/ flavourings; and
 Blended Rum:
Blended rum shall be ethyl alcohol of agricultural origin to which
permitted rum flavours have been added.
Gin:
Gin is the product of the blending of ethyl alcohol of agricultural
origin with natural and/or nature identical flavouring substances.
 Distilled Gin:
Distilled gin shall be the product obtained by the redistillation of
suitable grain, molasses spirit, other carbohydrate with or over
juniper berries:
 may contain other approved aromatic botanical substances; or
 sugar or flavourings; or a mixture of such distillate and ethyl
alcohol of agricultural origin, and
 shall contain not less than 37.0 per cent of absolute alcohol by
volume.
 Dry Gin:
Dry Gin shall be gin to which no sugar has been added.
14

Brandy:
Brandy shall be potable alcoholic distillate of wine, in the
manufacture of which no additional sugar has been used and held
for a period in wooden cask and may -
contain caramel;
be flavoured with fruit, other approved botanical substances,
flavouring, or a mixture of such distillate and ethyl alcohol of
agricultural origin and shall contain not less than 37.0 per cent of
absolute alcohol by volume.
 Cognac Brandy:
Cognac Brandy or Cognac shall be brandy manufactured in the
Cognac district of France for domestic consumption in accordance
with the laws applicable in France.
 Armagnac Brandy:
Armagnac brandy or Armagnac shall be brandy manufactured in
the Armagnac district of France for domestic consumption in
accordance with the laws applicable in France.
 Blended Brandy:
Blended brandy shall be ethyl alcohol of agricultural origin to
which permitted brandy flavours have been added and it may
contain caramel and sugar.
Vodka: Vodka shall –
be the potable alcoholic beverage obtained by the treatment of
grain, potato spirit, molasses spirit with activated charcoal, or the
rectification of ethyl alcohol of agricultural origin, so as to render
the product without distinctive characteristic aroma or taste; and
Caramel:
Caramel shall be prepared from the food grade carbohydrates or
their combinations in the presence of food grade acids, alkalis or
salts. It shall be of four types, namely:—
15

FOOD SAFETY AND STANDARDS
(FOOD PRODUCTS STANDARDS AND FOOD ADDITIVES)
REGULATIONS, 2011
 Type-I-Plain Caramel:
It shall be prepared by heating carbohydrates with or without acids
or alkalis, or their salts. No. ammonium or sulphite compounds are
used.
 Type-II-Caustic Sulphite Caramel:
It shall be prepared by heating carbohydrates with or without
acids or alkalis or their salt in the presence of sulphite
compounds; no ammonium compounds are used.
 Type - III - Ammonia Process Caramel:
acids or alkalis or their salts in the presence of ammonium
compounds; no sulphites are used.
 Type-IV- Ammonia Sulphite Caramel:
acids or alkalis or their salts in the presence of both sulphite and
ammonium compounds.
16

PLANT DESCRIPTION
Allied Blenders & Distillers Private Limited (ABD Kalyani), formerly
known as Wales Distillers Private Limited is located amongst the scenic
beauty in Kalyani, West Bengal off the Barrackpore-Kalyani Expressway
approximately, 60km from the airport. The plant is proud of its state-
of-the-art infrastructure having a production capacity of 1 lac cases per
month and is strictly allowed to sell its produce under the West Bengal
Excise only. ABD plans to upscale it to 1.5 in the years to come.
The unit operates in General Shifts with a schedule time from 9:00am to
6:00pm along with a lunch break of an hour in between. The initial and
final hours of a day are usually the rush hours as they decide the fate of
production. It is endowed with a good supply of water, used in its
production operations only after demineralization through two of its
units.
The unit is bifurcated into various sections to facilitate sorted work
area, significant to withstand and overcome the pressure of production
with ease. These sections, functioning unanimously and arranging
smooth operations related to IMFL manufacturing can be identified as
namely:
Water Demineralization Section (DM Plant):
It is responsible for the removal of mineral salts from water.
Washing or Rinsing Section:
Here, rinsing of the bottles with DM water is done to stabilize pH.
Blending Section:
Here, unit operations like filtration, reduction, mixing, etc. occurs.
Bottling Section:
It accounts for filling, labelling and packaging of the products.
Regional Quality Control Laboratory (RQCL):
It carries out inspection, tests and analysis to assure quality.
Effluent Treatment Plant (ETP):
It monitors, regulates and prevents environmental contamination
and pollution.
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18
RQCL
RinsingHall
BottleStorage
Water
Demineraliza
tionSection
(NEW)
W a t e r D e mi n e r a l i z a t i o n S e c t i o n
( O L D )
BlendingSection
ReceivingPoint
Product Storage
M a n u fa c t u r i n g
O f fi c e
L I N E 1
L I N E 2
L I N E 3
L I N E 4
L I N E 5 T E T R A PA K
P L A N T L A Y O U T

PRODUCE OF THE UNIT
The plant focuses on some of the renowned and prestigious brands of
the company, which are in great demands in the states of West Bengal.
The products that form the priority in the local and domestic markets in
and around the manufacturing unit are as follows:
OFFICER’S CHOICE WHISKY Mature & Rare
1000 ml pack
500 ml pack
375 ml pack
180 ml pack
90 ml pack
OFFICER’S CHOICE BLUE PURE GRAIN WHISKY
1000 ml pack
750 ml pack
375 ml pack
180 ml pack
OFFICER’S CHOICE BLACK WHISKY
1000 ml pack
750 ml pack
375 ml pack
180 ml pack
JOLLY ROGER PREMIUM XXX RUM
750 ml pack
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PRECAUTIONS TO THE UNIT
Since an industry is involved in manufacturing of a product intended to
satisfy its customers in terms of quality to stay in a healthy status as a
business entity. It follows certain policies and implements them strictly
at its units to safeguard its goodwill in the market.
As an IMFL manufacturing unit, the responsibility to maintain safety
and quality towards all its stake-holders becomes very crucial. Some of
the significant precautions taken by the unit for are as follows:
The entry of inflammable substances (like matchsticks, kerosene, etc.)
is strictly prohibited in the unit.
The entry and exit of individuals are strictly restricted without
appropriate verification of their belongings.
Entry to the unit (especially to the shop floor) is strictly subjected to
the approval of the Department of West Bengal Excise.
The entry of the electronic goods to the unit is strictly prohibited.
Clean and perfect hygienic conditions are to be maintained in the
production area.
Safety precautions are to be taken prior to entering the Washing and
Bottling Hall.
Good Manufacturing Practises (GMP) needs to be exercised and its
implementation to be verified during production.
No kinds of fragrances are allowed within the unit, as the blend may
get affected with it.
Prior to dealing with the manufactured product, one should take
proper precautions to avoid contamination.
Use of cell phones in the Bottling Hall is strictly limited and need to
be checked by the concern authorities.
While working with chemicals, care should be taken so that no
contamination may take place.
Storage Area is to be restricted and monitored with close-circuit
cameras.
The demineralized outlet is to be monitored frequently.
The composition of the key ingredients of the products should not be
disclosed to outside to safeguard its business policies.
20

PRODUCT RAW MATERIALS
Most of the IMFL manufacturers depend heavily on foreign imports
especially, on the European countries such as Scotland, Ireland ,
Netherlands, Spain, etc. for the concentrates constituting the X-factor of
the alcoholic beverages. ABD is not an exception to it.
Besides these flavouring spirits, they possess the support of the
indigenous grain spirits that arrives from various parts of the country,
depending on the suitability of supply and demands and seasonal
variations. The Demineralized water is a basic requirement of a plant as
it cleanses the containers and bottles before filling the blend. It is also
seen to be in action while, it reduce the alcoholic strength of the ENA
charged to the tank. Therefore, a liquor bottling plant needs to be self-
sufficient in terms of the Demineralized water supply. The lovely
colour of the blend is possible due to the deliberate addition and
mixing of the food additive in caramel. A brown to dark brown colour
inculcates the ethnic beauty of flavoured spirits and alcohol.
Extra Neutral Alcohol (ENA), a known ingredient in the IMFLs like
Whisky, Vodka, Gin, Rum, etc. is of special significance. The reason
being the greatest contributor and purest form of alcohol by volume.
Thus, it forms the basis of blending.
The identified key ingredients as the starting raw materials of the
products are as follows:
Extra Neutral Alcohol (ENA)
Demineralized Water (DM water)
Type I, Plain, Caustic Caramel
Scotch and Irish Malts
Flavours (confidential)
21

EXTRA NEUTRAL ALCOHOL
Extra Neutral Alcohol or commonly, ENA is a double rectified alcoholic
distillate having 68.4ºoverproof with 96% of alcohol by volume. It shall
conform to the following requirements to be used for alcoholic drinks,
as specified in IS 6613:2002:
Characteristic Vodka General Product
Relative density at 20/20°C 0.80692 0.80692
Ethanol per cent (v/v at 20°C),
Min
96 96
Miscibility with water Miscible Miscible
Acidity as acetic acid, g/1001,
absolute
alcohol, Mux
1.5 1.5
Methyl alcohol g/100 I of absolute
alcohol, Max
50 50
Permanganate reaction time, in
minutes,
absolute alcohol, Min
30 30
Higher alcohol as iso-amyl alcohol,
g/100 1, absolute alcohol, Max
30 30
ENA, derived mostly from the selected variety of high quality is
procured from the nearby distilleries such as distilleries of IFB Agro
(Nurpur). The procurement entirely depends on the significant factors
like cost, quality, distance from the unit, etc.
ENA, free from impurities (checked using GC chromatography) reaches
the unit through long-distance tankers having five compartments. The
sampling of ENA from each of the five compartments is followed before
acceptance by the unit, which are analysed in various phases . The
sequential phases involved from procurement to acceptance are as
follows:
GC chromatography: done in manufacturing distilleries using GC/MS.
Sensory analysis: doneinthereceivingunitasBouquetandPallettestsbytrainedpanellists.
Strength determination: done in the unit for payment to suppliers.
PRT test: done to check the purity of ENA, indicating using the
delay in colour appearance.
The quality passed bulk ENA is transferred to the ENA tanks at the
receiving point of the unit and the tankers are flagged off for return.
22

DEMINERALIZED WATER
Demineralization or deionisation is the process of removing mineral
salts from water by using the ion exchange process.
As the report suggests that the source water contains high degree
of cationic and anionic impurities, rendering it unsuitable for
alcohol reductions as it may possibly catalyse the oxidation-
reduction reactions to give rise to fractions of aldehydes, ketones
and other higher alcohols like amyl alcohol (by the virtue of its
mineral content) besides imparting hardness to water. Moreover,
it may lead to high mineral acidity. This calls for the effective
demineralization operation in a liquor manufacturing unit.
Demineralization involves two ion exchange reactions. Initially,
the cations such as calcium magnesium & sodium are removed by
hydrogen ion (H+). The salts thus converted into their respective
acids by this exchange. The acidic water is then passed through
an anion exchange where the anions such as sulphates chlorides
etc. are removed by HYROXYL (OH-) ions.
The basic Scheme of reactions that takes place during a
demineralization reaction is:
RH + Na+
------- R-Na + H+
(For cation)
R-OH + Cl-
------- R-Cl + OH-
(For anion)
H+
+ OH-
-------- H2o
Characteristics Value
Turbidity 0.2 NTU
TSS 23 ppm
pH at 25ºC 7.5
Conductivity 1142.85 µmhos/cm
Total Dissolved Solids 800 ppm
Total Hardness (as CaCo3) 400 ppm
Iron (as Fe) 1.5 ppm
R A W W A T E R A N A L Y S I S R E P O R T
23

WATER DEMINERALIZATION SECTION
The unit has state-of-the-art water demineralization section to impart
soft water of higher purity where it regulates or rather minimises the
mineral content to an acceptable limit. The significant processes that
make the water demineralization realized:
Oxidation Chamber:
The purpose of the chamber is to oxidize the reactive metals in traces
and minerals in the incoming water source using manganese dioxide
(MnO2) present in the bed in the form of manganese boulders.
Iron Removal Filter:
The Filter accounts for removal of the ferrous salts dissolved in water
using a proper media. It removes suspended Iron through a
sequential series of steps namely, Rinse, Service, Backwash Rinse and
Fast Rinse.
Dual Media Filter:
The filter with a special anthracite media above the conventional
sand media has special surface properties due to which the small
colloidal particles get attached to its surface removing particulates
greater than 30µ. Due to this property, the DMF filter is widely used
in pre-treatment of RO systems releasing water with turbidity less
than 5 NTU.
Activated Carbon Filter:
The Activated Carbon Filter is employed for removal of residual
chlorine, removal of organics and removal of odours. The removal of
contaminants by employing activated carbon is both by a physical
and chemical adsorption. Removal of chlorine by activated carbon is
basically a chemical phenomenon.
C + HOCl = CO+ H+ + Cl-
Reverse Osmosis System:
The system utilizes high pressure-driven high rejection–high flow
membrane process that is capable of separating dissolved solutes
from a solvent (water) through a semi-permeable membrane. It
requires the dosing of ‘Antiscalant’ to inhibit scale formation by concentrated
salt on the membrane.
24

Watersupply
To DAY Tank
Mixed Bed Filter:
The filter-cum-polisher consisting of specially designed vessels in
which SAC and SBA resins are embedded functions to remove the
residual traces of silica and sodium ions (in ppb).
Strong Acid Cation (SAC):
It caters to remove hardness only when SAC resin in Na+ form
whereas, in H+ form, the cations including sodium ions are
exchanged for H+ ions leading to the release of free Co2 by
decationization of alkaline salts in the raw water.
Strong Base Anion (SBA):
These are the resins, usually of two types developing their
functionality from quaternary ammonium salts. Type I, being more
stable is more suitable for total anion removal and dissolved Co2 in
water.
Degasser Tower:
The Degassifier unit facilitates the escape of the dissolved volatile
gaseous pollutants like free Co2 dissolved in water by the application
of blower and then passing it through a series of filters before
emission to the surrounding.
25
P R O C E S S F L O W O F W A T E R D E M I N E R A L I Z A T I O N
Raw
water
Storage
Oxidation
Chamber
Sand
Filter
Dual
Media
Filter
Activated
Carbon
Filter
Sand
Filter
RO
water
Storage
RO
Degasser
Cationic
Bed
Filter
Anionic
Bed
Filter
Mixed
Bed
Filter
DM
Storage
Tank
HPP

BLENDING SECTION
Even today, blending remains more of an art than a science, as leading
players of the game are unwilling to reveal the secrets of blend
formulation. Blending, pioneered by Andrew Usher, in Edinburgh, in
the early 1860s provides the distiller with an opportunity to create a
product with unique and recognizable flavour attributes to attain
product consistency and establish a brand. Thus, Blending is reclaimed
as the heart of the IMFL, owing to the influences of a wide range of
processing and maturation parameters. This operation focuses mainly
on four on areas:
 The flavour specialist
 Strategy
 Practicalities of blending
 Innovation.
These four areas are supervised by a Master Blender, leading the
blending team. A blender, with his loads and loads of experience
utilizes his most-sensitive instrument ‗the nose‘ to judge the overall
flavour profile of the blend.
Allied Blenders & Distillers believes in quality Blending and so, the
unit holds a well established blending section with a good team of self-
efficient blenders. The blending hall comprises of:
 14 Blending Tanks (capacities ranging from 25,800 ltrs to 15,700 ltrs)
 4 Strong Spirit Tanks (capacities ranging from 46,000 ltrs to 10,100
ltrs)
 4 ENA Tanks (capacity around 45,000 ltrs)
The estimation of the blend preparation is done by using the „Blend
Formulae’ which is as follows:
Volume of Blend = (Volume of ENA (in BL)*ºProof (ENA))/Required ºProof
The Formula reveals that, it is the volume of ENA that dictates the
volume of blend. Thereby, the ENA is important in blending operation.
26

The roles of essential components of a blend of the company are
identified as under:
Extra Neutral Alcohol: The base of all the IMFLs having 96% ABV
and 168ºProof.
Demineralized Water: The second constituent of the blending
process, involving reduction of ENA with water and the initial
addition is preferred on the basis of relative density of ENA and
DM. The reduction time is approximately about one and a half
hours.
Type I, Plain-Caustic Caramel: The proportion of the DM water,
added sensibly in the previous step may help in mixing the caramel
concentrate (0.052%) in a knife mixer. The mixture is then, filtered
and through sparkler filters (cartridge filters) and transferred to the
ENA mixture for colour fixation in the blend.
Spirits X and Y: These malts add characteristic flavours and aroma.
After attaining a desired strength, and confirmed by the department
of Excise, stationed at the unit, the spirit (0.64%) is added and
circulated for about an hour.
Flavour Spirits (confidential): Here lies the true uniqueness of the
company‘s portfolio of brands providing an identity to it. After its
addition, the blend is left undisturbed for one to two days for
maturation.
The product Officer‘s Choice Blue is claimed to be manufactured from
the pure grain spirit by the company as a business strategy. Therefore,
the blend is bottled without the addition of the flavour spirits, as used
in the blend of other products.
In this context, it is realized that the vodka does not contain added
caramel and thus, appears to be crystal and clear.
27

Conc.
Caramel
Circulation
Filling Point
Bypass
P R O C E S S F L O W O F B L E N D I N G
28
Blending
Tank
Day
Tank
ENA Tank
Strong
Spirit
Tank
Knife
Mixer
Spirit Circulation

WASHING SECTION
Washing refers to the process or technique to clean any surface usually
with stream of water. In this particular context, it can be technically
termed as the Rinsing operation taking place because the stream of
fluid is directed towards both the inner and outer surfaces of the
targeted material with a purpose to homogenize the material with a
specific fluid.
The liquor industry depends generally on glass bottles because of its
decorative and royal appeal to the customers. The market return glass
bottles are also utilized (if unbroken) again for bottling of new blend.
This practice not only saves money of the company but also reduces the
load of environmental pollution and saves energy too. But on the other
hand, those market return bottles obviously would contain dirt, mud,
and various foreign particles, forcing rinsing operation mandatory.
The unit, being well equipped with the processing of DM water finds
enough use of it in this section. The process is designed in such a way
that the demineralized water is supplied continuously to the machines
indirectly from the Day Tank, through 10µ cartridge filters, maintaining
a pressure all through. There are two kinds of rinsers installed in the
plant namely:
 Automatic rotary rinsers: The machine named ‗GRIPMATIC‘ having
50 (for Lines 1 & 2) or 40 rotating heads (for Line 3) with an
optimum operational speed ranging from 300 (for Lines 1 & 2) to 180
BPM (for Line 3) efficiently rinses bottles with jet spray of
demineralized water, one from below through the neck opening and
the other from the top to ensure complete homogenization with DM
and remove any particles adhering to the body surface with
pressurized jet flow.
 Semi-automatic rotary rinsers: This machine (for Lines 4 & 5)
operates in the same way as the automatic one except the
differences in design, making it a low operating machine.
Although, the designs of the machines are completely different to each
other, both work on the same technology. The demineralized water is
pumped through a booster pump to the machines from Day Tanks via
an intermediate reservoir having a float valve maintaining a constant
29

water level. The machine receives water supply from two separate
reservoirs for two jet flows.
The technology that the machines follow is to divide one of the channel
flows radially (under centrifugal force) to help obtain the jet at
required positions (usually two). The other channel is left as it is and
used to rinse the outer surface of the bottles by a jet flow from the top
through minute pores or openings. In this way, the bottles come three
times in contact with demineralized jet spray in a cycle of rotation.
In Line 1, the rinsing operation is incorporated along with the filling
and cap sealing operations in a single machine thus, helping to
minimise the man power requirement, loss of money and time and
increasing productivity.
30

BOTTLING SECTION
Bottling deals mainly with the packaging of the blend of the liquor
prepared in an isolated section with a purpose to prepare as a saleable
product. Due to the ever increasing quality awareness amongst the
customers, most of the companies have pulled their shocks up to meet
the stringent specifications as prescribed by the regulatory bodies.
Thus, this section helps to connect with its consumers in a true sen se.
Allied Blenders & Distillers (ABD) nurtures its bottling hall to not only
retain its existing customers but also to attract the new ones. The hall at
the Kalyani unit is equipped with five (5) lines to cater the exponential
demands of the customers. Out of which, three (3) lines are automatic
while the other two are semi-automatic, and these are operated
according to the requirements and suitability. The hall also posses a
state-of-the-art ‗Aseptic compartment‘ with two aseptic packaging
machines aligned serially that aseptically fill 90ml and 180ml OC
whisky.
The rinsed bottles queue themselves and head towards the bottling hall
after making appearance from the rinser machines (except for line 1).
On the other hand, the blend is released from the Day Tanks through
fabric cloth filters (CCP1) to reach the filling machine. Most of the lines
are almost similar in terms of their operation, having the following
processes incorporated into the systems:
Empty Bottle Inspection:
The bottles (both PET and glass) are inspected to promote quality
control and this point acts as Control Point (CP).
Filling:
A little ahead on the line, the bottles encounter filling machines,
responsible for bottling the in-line blend. The unit posses two kinds
of fillers, depending on its:
 Mode of action: gravity filling (for lines 1, 2 and 4) and vacuum
filling (for lines 3 and 5).
Gravity fillers work by the free flowing ability of the blend under
gravity. On the other hand, Vacuum fillers work by creating voids
through negative air pressure application.
31

Cap feeding and Capp sealing:
Cap feeding may be done either manually automatically depending
on the type of machine employed. Capping a bottle though seems to
be an easy job for these machines. But, the varieties of caps make it
complicated. Basically, they are of two types namely Roll-On-Pilfer-
Proof (ROPP) and plastic closures, which dictates the type of capping
machine used. The former gets sealed completely when both the skurt
and thread rollers are in action. But, the sealing of the latter is
achieved by tapping down the closure through the neck making a
constant 5º angle with the closure.
On-line Inspection:
This phase also acts as a CP, where the quality control is achieved
through visual inspection of the bottles along with the blend moving
in a line and examined for minute (quickly noticeable at arms length
when inverted) particles suspended in the blend mainly along with
leakage due to improper sealing. The defective items are isolated for
rework.
Hologram and Label placing:
While, the hologram signifies the government‘s approval of the
product, the label acts as a silent salesman for the company. Both
these operations are performed using the same technology, helped by
a series of rollers. Line 3 is somewhat different and dictated by the
type of the label i.e. gum label (gum added externally).
Mandatory printing:
Print Mandatory consists of Batch number, line number, costs (MRP)
and the date of manufacturing and achieved using Domino. The
printing of the mandatory takes place at three stages i.e. on the
labels, monocases and bulk cases sequentially.
Final End of-line Inspection (EOL):
This phase also acts as a CP where the defects related to labels and
hologram, bottles, closures and on-line blend quality status are
examined.
Packaging and Palletizing:
The palletizing refers to the placing of the cases (packaged) to mobile
vehicles in bulk to transport them to the bond space (storage area).
32

ASEPTING PACKEGING
Aseptic packaging can be defined as the filling of a commercially sterile
product into a sterile container under aseptic conditions and
hermetically sealing the containers so that reinfection is prevented,
making the product shelf-stable at ambient conditions.
The unit is capable to produce aseptic whisky packs of 90ml and 180ml
sizes through its two premier machines Tetra Brik Aseptic.
Principle:
 Inert atmosphere and hermetic sealing (for preservation)
 Volumetric approach (for filling)
 Electrical impulse (for sealing)
 Conductive heating (for strip applicating)
Operating pre-requisites:
 Air Pressure: 7-7.5 kg/cm2
 Water Pressure: 5 kg/cm2
 Nitrogen Pressure: 4 kg/cm2
 Air knife Temperature: 129.3ºc
Procedure:
The six-layered film reaches the strip applicator through a series of
rollers where the plastic strip gets attached to the film into molten state
that passes through an air knife for attaining stability. Gradually, the
shape of the package is formed mainly with the help of crease roller
along its flow. When the film is longitudinally sealed, the blend is
released along with liquid nitrogen (in 9:1 ratio) and then transversal
sealing occurs using conductive heating and each package is isolated by
the knife attached.
Problems related to its operation:
 Huge wastages during a LONG SHORT STOP
 Less flexibility in operation
 Any fluctuation(s) in the conditions leads to SHORT STOP
33

Blend
Bottles
Carton Supply
Closures
Bottle Inspection
Fabric Filter
Plates Supply
Partition Supply
V A C U U M F I L L E R I N A C T I O N
O V E R A L L P R O C E S S F L O W O F B O T T L I N G
34
Filling Capping Cap Sealing
On-line
Inspection
Day
Tank
HologramLabelling
Second
Inspection
Printing
Mandatory
Carton
Forming
Packaging Batch
Printing
Palletizing
EOL
Inspection
Rework

STORAGE AND DESPATCH
The unit has specific storage facilities for packaging materials as well
as for the finished goods (FG) and are identified using stock keeping
units (SKUs) recorded during their arrival at store.
The quality-passed palletized finished goods arrive at the bond store
where they are stacked on the basis of Batch number and variety of the
product. The height of each stack depends on the quantity and the
variety of the product. The content of whisky bottles in a case varies
according to the volume of bottles, is tabulated as follows:
Volume of bottles (ml) Size of bottles
1000 (LITRE) 12
750 (QUART) 20
500 24
375 (PINT) 42
180 (NIP) 48
90 48
The storage area has maximum holding capacity of around 80,000 cases.
But, the actual storage is limited to 55,000 due to certain obligations.
The despatch of the stocks involves several steps:
Stock Check
 Bond (Excise controlled)
 Trade (Licensee controlled)
Transfer of Bond to Trade: requires duty clearance by the distributor,
preparation of requisition by the licensee and conversion of FG from
bond trade to Company trade.
Transfer of FG from company Trade to distributor Trade: requires
issue of various documents to the distributor.
Preparation of documents like invoices and passes.
Only after transfer of goods to distributor trade, the distributor has
permission to access the product from the storage area. The finished
goods are transported from the unit to the distributor through long-
distance transport.
35

EFFLUENT TREATMENT SECTION
The processing unit utilizes huge quantities of water resources in a
regular basis during its manufacturing operations like rinsing, blending,
etc. However, the former operation also involves the discharge or
drainage of the resource to a high level. However, the quality of the
water deteriorates during drainage due to various levels of
contaminations during operation, which when let untreated can lead to
a havoc damage to the surrounding environment. This signifies the set -
up of an effective Effluent Treatment Plant (ETP).
The main identified industrial effluents observed in the processing
waste water of the unit are as under:
 Packaging materials: include broken glass bottles, cc box parts, etc.
 Dissolved chemicals: include acids, bases and salts.
 Dissolved organics: include odoriferous and quaternary compounds.
 Suspended particles: include fibre particles discharged with blend.
 Dissolved gasses: include free Co2 emission.
The treatment of the discharged effluents can be by the help of the
following process flow diagram:
P R O C E S S F L O W O F E F F L U E N T T R E A T M E N T
Drain
water
Storage
Tank 1
Tank 2
Polychloride
Lime
Aluminium
sulphate
Tank 3
Hypochloride
Compressor
ACF
Aeration
Aeration
Aeration
Treated
Water
36

QUALITY CONTROL @ RQCL
The plant has a federal support of Regional Quality Control Lab
(RQCL) stationed at the unit. It has wide range of responsibilities
starting from the sampling of incoming raw materials and packaging
materials to the quality control of the final products. Its operational
functions are even more diversified by cross-unit checks and sensory
analysis of other tie-up units. In this context, it is significant that RQCL
has provision to validate with reference to its internal standards and
award silver certificate within its internal system of network and is also
ranked 2nd (only after CQCL) as far as internal certificate issuing
authority.
The quality control team works for RQCL to detect quality related
issues in the plant and has the following duties to carry out without
compromising with the quality.
Inspections of the packaging materials are carried out at RQCL,
categorizing defects and following a simple strategy for acceptance
accordingly.
Materials Sampling volume Acceptance Limit
Glass bottles 4% (SKU) <0.05% (critical defects)
PET bottles 4% (SKU) <0.05% (critical defects)
ROPP closures 4% (SKU) 0.00% (critical defects)
Labels 4% (SKU) 0.00% (critical defects)
Monocartons 4% (SKU) 0.00% (critical defects)
CC Boxes 4% (SKU) 0.00% (critical defects)
Similarly, raw material are sampled and inspected with sensory
analysis mainly. The analysis of the raw materials like demineralized
water and caramel involve chemical analysis.
RQCL is partitioned into three respected sections to facilitate free,
competitive and professional work environment. The sections are:
Dry Laboratory: deals with analysis the packaging materials.
Sensory Laboratory: an isolated room for judging sensory attributes.
Wet Laboratory: deals mainly with blend and other raw material
analysis.
37

DRY LABORATORY OPERATIONS
The dry laboratory is concerned with sampling and analysis of
packaging materials like bottles (glass and PET), closures, monocases,
cc boxes, etc. The quality team categorizes defects of a packaging
material into three limits namely:
Critical defects: The defects that cannot be tolerated since it may
cause a potential threat to the customers on use and in turn affect
the reputation of the company and its brands.
Examples - broken bridge, missing mandatory, glass imperfections,
etc.
Major defects: Those defects that can be tolerated to a minimum
permissible limit that maintains stringent quality standards.
Examples – damaged cap, fill height variation, fibre particle, etc.
Minor defects: Those defects that do not harm its consumers at all,
but their control is necessary to protect the goodwill of the
company.
Examples – cut graphics, brush marks, shade variations of labels,
etc.
The work process of the laboratory is described serially on the basis
of packaging materials:
Bottles (glass and PET):
Visual Inspection: refers to the detection of physical appearance
change and categorizing according to the types of defects
(critical/major/minor).
Dimensional Analysis: refers to the conformation of the
dimensions with the internal specifications and standards as
follows-
Parameters (1000ml) Instrument used Range (for glass)
Weight (gm.) Weighing machine 589-591
Brim Full Capacity (ml.) Graduated Flask 1022-1024
Vacuity (ml.) Vernier Callipers 44-46
Major Axis (mm) Vernier Callipers 92.60-93.05
Minor Axis (mm) Vernier Callipers 89.12-89.77
Total Height (mm) Erected Vernier 306-308
38

GO NO-GO Test: quick test for conformance for exact dimensions
of the closures to neck of the bottle. There are two opposite faces
that tests for GO (should conform) and NO-GO (should not
conform).
Apparatus/Models (for NIP) Function
Cap ID Checks cap fitting
Thread OD Checks uniformity in threads
Bottom OD Checks cap locking
Anchorage OD Checks for uniform anchors
Lugs OD Checks for smooth rotation
Closures ((ROPP-28 & 30mm and plastic):
Examples – improper liner, knurl defects, broken bridges, etc.
Dimensional Analysis: refers to the conformation of the
dimensions with the internal specifications and standards as
follows-
Parameters (30mm) Instrument used Range (for ROPP)
Outer diameter (mm) Vernier Callipers 29.48-29.59
Inner diameter (mm) Vernier Callipers 28.67-28.75
Ring Height (mm) Vernier Callipers 5.96-6.04
Width Bridge (mm) Graticule Magnifier 0.9-1.0
EPE Liner (mm) Screw Gauge 1.399-1.420
Metal Thickness (mm) Screw Gauge 0.205-0.209
Closures Pull-Out Test (plastic):
SOP-
 Take a bottle mould of weight 8kg approx.
 Insert the Closure on its neck tightly (seal it).
 Wear protective gloves on the right hands.
 Supporting the right arm on the right leg, hold the mould
in air through its closure at least for 20 seconds.
 If the Closure do not pulls out, the test turns negative,
indicating that the closure is good enough to be sealed.
Light Test: tests the uniformity of the perforation height by
passing light through it in dark condition.
39

Labels and Monocartons:
Examples – excessive ink, colour variations, incorrect texts, etc.
Dimensional Analysis: deals with measuring the dimensions
(length*width) and conform the same to the internal
specifications or standards.
Scuff Resistance:
 Purpose: test the degree of resistance to aberration.
 Instrument: Scuff Resistance Tester
 SOP:
 Cut the labels as a replica of two samples attached to the
instrument (bigger and smaller).
 Switch on the instrument.
 Place the labels in position and lock the positions.
 Place a weight of 2 kg on the top of the instrument.
 Set the number of rotations.
 Press the ‗START‘ button.
At the end of rotations, if the labels are found to be in undisrupted
state, then the test is negative.
Alcohol Resistance Test (also applicable for monocases):
 Purpose: test the reaction or effect of the blend on the label.
 Chemicals: Alcohol (42.8% ABV)
 SOP:
 Take the blend in a beaker.
 Take cotton and dip it in the blend.
 Rub the labels two to three times only in unidirectional
way with the cotton.
At the end of rubbings, if the labels are found to be in undistorted
state, then the test is negative.
Grain Direction Test (for labels):
 Purpose: test for any possibilities for forming arrow heads.
 Material: Flowing water
40

 SOP:
 Hold the label in flowing water in such a manner that it‘s
back side gets wet.
 Hold for at least 10-15 seconds.
 Leave it on a clean dry surface.
After a certain time, if the labels are found to be somewhat folded
toward the front side, then the test is negative.
Corrugated Flute Cartons and its allied material:
CC boxes play an important role, providing good strength and
support against external forces. The tests associated with it are:
Examples – excessive ink, misplaced texts, incorrect texts, etc.
Dimensional Analysis: deals with measuring the dimensions
(length*width*height) and conform the same to the internal
specifications or standards.
Moisture Analysis: deals with measuring the % of water absorbed
and compare the same to the internal specifications or standards.
Bursting Strength:
 Purpose: tests the maximum pressure withstanding capacity.
 SOP:
 Switch ON the instrument.
 Loose the Screw to make space for the carton entry.
 Hold the lower flap of the cc boxes and put it in aligned
with the work area of the instrument.
 Long press the ‗START‘ button until the box tend to burst.
After releasing the ‘START’ button a continuous beep prevails, and
the instrument shows the BS value on the display.
41

Grammage Tester Scuff Tester Bursting Strength Tester
Tester
Grammage Test:
 Purpose: tests the gsm of the material
 Instruments: Hot Air Oven and gsm tester.
 SOP:
 Cut the test material of the dimension (l*l).
 Place it in Hot Air oven at 120ºC for about 2 hours.
 Take the material and dip it in boiling water so that the
layers present in it falls apart on its own overcoming their
adhesiveness.
 Again, put it in it in Hot Air oven at 120ºC for about 6
hours at a stretch.
 Take the layers and test them separately in gsm tester.
The mean of the calculated gsm is regarded as the gsm of the material.
42
D R Y L A B E Q U I P M E N T S

METHODOLOGY OF REJECTION
The packaging materials when rejected due to non-conformance of the
quality specifications undergo a rejection process which is outlined as:
Isolation of the rejected packaging materials.
Communication about the lot and quantity of rejections to the
suppliers.
Crushing all the packaging materials that were isolated due to
quality failure.
In case of closures:
 ROPP closures: They are crushed and the metal portions are
returned to the suppliers.
 Plastic closures: They are crushed and then returned.

In case of Bottles:
 Glass bottles: Broken pieces are only returned for recycling.
 PET bottles: They are Crushed and returned
In case of corrugated cartons
The cartons are torned into pieces before they are returned.
The objective or rather motive behind this process of rejection is that
the supplier may not be able to serve the same material having quality
defects after being rejected due to destruction of its shape.
43

SENSORY LABORATORY OPERATIONS
The evaluation of the flavour of Indian Made Foreign Liquors (IMFL)
by chemical and instrumental methods or routine quality control is not
practicable. The other limitation of instrumental analysis is that it
cannot integrate the flavour impression as is gathered by human senses.
The analysis of quality of IMFL can, therefore, be done conveniently by
sensory evaluation which gives the sum total of interaction of different
flavour components. This evaluation gets more effective with the
experience and routinely arranged trainings. The laboratory follows a
strict routine and has several restrictions in order to avoid any type of
contaminations. The following considerations are relevant in this
regard.
Ideal Laboratory set-up:
 The testing room must be kept as free from odours and sound as
possible. This can be achieved by air conditioning with activated
carbon filters installed in the system.
 The lighting system should provide an adequate comfortable
level of illumination. Special light effects, using coloured filters
or bulbs may be desired to hide irrelevant differences in colour
and other aspects of appearance.
 Individual panel booths are essential to avoid mutual distraction
among panel members.
 There should be an atmosphere of comfort and relaxation in the
testing room.
 The temperature and humidity of the room should be controlled.
 Suitable seats should be provided to give a comfortable posture
while carrying out the tests.
Time of Analysis:
The test should be carried out by the Panelists between 10.30 to
12.30 h. The test should not be carried out when the panelists are
really thirsty.
Rules for sample preparation:
 Arrange a set of watch glass (cover) and testing glass (tulips) for
a sample.
 Rinse the testing glass (tulips) and watch glass with the
particular blend.
44

 First prepare of demineralized water sample along with plain
water sample.
 Prepare a liquor sample by adding 20ml of each blend followed
by demineralized water (in 1:1 ratio).
Rules for sensory analysis:
 Arrange filled testing glass covered with watch glass for a
sample in front of each sample.
 Always start from left-to-right.
 Always start from demineralized water sample (neutral flavours
and no off-odours) as it makes our senses fresh and active.
 Before sensory evaluation of a sample, hold the glass covered
with watch glass and swirl it to homogenize the flavour and
odour.
 Always adhere to the grading scale (employed 5 point scale)
while recording the scores against samples.
In this context, it is learned that sensory analysis is performed to detect
any off-flavours due to the presence of impurities in the blend and the
blend must be completely free from any characteristic tastes like sweet,
sour, bitter, tangy, etc.
R I G H T W A Y O F S E N S O R Y A N A L Y S I S
45

WET LABORATORY OPERATIONS
Wet laboratory or the Chemical Analysis Lab mainly deals with the
analysis of the raw materials which are:
Raw water:
Hardness Test: employing Complexametric method (EDTA)
 Principle: EDTA forms a chelated soluble complex when added to
a solution of certain metal ions.
 Reagents: -
Ammonia buffer of pH 10.
0.02(N) solution of disodium salt of ethylenediamine tetra
acetic acid.
Erichrome black T indicator solution.
 SOP:
 Take 50 ml of sample in an Erlenmeyer flask;
 Add 4 to 6 drops of Eriochrome black T indicator solution.
 Add 1 ml of buffer solution and mix.
 Titrate immediately with EDTA solution till the colour
changes from red to blue.
 Calculations: Total hardness (as CaCO3) =(Titre value)*20=__ppm
Free Chlorine Test: (Free chlorine should be less than 0.2 ppm)
 Reagents: -
Test CHLOR.
 SOP:
 Take 50 ml of sample in an Erlenmeyer flask.
 Take 5 ml of the reagent in a measuring cylinder.
 Add it to the flask along the wall and wait for 1 minute for
colour stabilization.
 Match the colour with the corresponding ppm level marked
on the reagent label.
 Record the value in ppm.
Demineralized water:
Sulphate Test:
 Reagents: -
10% BaCl2 solution.
 SOP:
 Rinse the test tube with DM water.
46

 Add 10ml of DM water in the test tube.
 Add 2 drops of 10% BaCl2 solution to the test tube and
shake well.
 Observe the colour change (milkish white haze develops).
Chloride Test:
 Reagents: - 1% AgNO3 solution
 SOP:
 Add 2 drops of freshly prepared 1% AgNO3 solution to the
test tube and shake well.
 Observe the colour change after vigorous shaking (milkfish-
white haze develops).
Alkalinity Test:
 Reagents: - indicator solution
 SOP:
 Add 2 drops of indicator solution to the test tube and shake
well.
 Observe the colour change and compare against the
standard.
 Record the pH level.
ENA and Blend:
Material/Tests Colour
(Abs)
pH Turbidity
(NTU)
Alcohol %
(ABV)
ENA --- 5.7-5.9 ---- 96.5
OC W 0.858-0.867 4.58-4.62 0.58-0.82 42.8
OC Blue 0.780-0.785 4.52-4.62 0.49-0.58 42.8
OC Black 0.778-0.780 4.52-4.62 0.49-0.58 42.8
*Subject to verification with the internal standards.
47

Type-I Plain, Caustic Caramel:
S.N. Tests Characteristics
1. Colour Bright golden yellow with reddish tinge
2. Appearance Thick homogeneous mixture
3. Odour Characteristic smell of burnt sugar
4. Taste Pleasant bitter odour
5. Sp. Gravity(10%sol) 1.023
6. pH (1% solution) 3.4-3.7
Aseptic Package quality Tests:
S.N. Tests Procedure
1. Crease line
Visual Inspection2. Vertical alignment
3. Horizonal alignment
4. Taste Pleasant bitter odour
5. LS Overlap Measuring Inspection
6. Volume (weight) Weight Measurement
7. Flap Sealing Visual Inspection
8. Rough Check Handling Test
9. Accurate Check Punch Instrument
10. Conductivity Test C-Meter
11. Longitudinal Seal Test Visual Strip Inspection
12. Nitrogen Dissolve Sensory
13. Visual Check Batch Printing
14. Leakage Test Dye Injection
L A Y E R S O F A S E P T I C P A C K A G I N G
48

CONCLUSION
Allied Blenders & Distillers Private Limited, one of the giants in the
field of IMFL manufacturing is appreciated for its vision of continuous
improvement and quest for excellence along its journey towards
becoming the most admired spirits company of the world. Their true
strengths have been their innovative approaches towards product as
well as the system, led by a tremendous team that challenges inflation,
maintains product quality and establish new brands.
The report tries to analyse the operation of the plant that caters
delivery of good quality IMFL brands with quality intact from the
process line to the hands of the consumers in a professional approach.
It also tries to relate manufacturing technologies giving empha sis to
quality assurance with effective management in response to certain
special situations. The report may be seen as a survey of the overall
operations starting from procuring, testing, manufacturing and quality
control and assurance.
The experience at Allied Blenders & Distillers is very precious and
enriching. The training has inculcated knowledge regarding alcoholic
beverages, the necessary skills associated with IMFL manufacturing and
above all, to be a competitive and target-oriented professional, woking
in a team.
49

REFERENCES
 http//www.abdindia.com/
 http//tetrapak.com/
 http//fssai.gov.in/
 Draft_Regulation_on_Food_additives_WTO_23_07_2015
 23 SPIRIT DRINKS REGULATIONS 2005 (NAFDAC)
 IS 6613 (2002): Neutral Spirit for Alcoholic Drinks
 IS 11583 (1986): Method for sensory evaluation of Indian made
foreign liquors (IMFL)
 http//www.tetrapak.com/
 IS 3752 (2005): Alcoholic drinks - Methods of test
 Packaging and Lable020811.pmd by RamKrishan
 Neutral Alcohol Technology by Vogelbusch
 IWSR Reports 2014
 happy-hours-28sep
 Happy_Hours_11th_Issue
 CSC Specifications Manual.doc
 Directorate of Excise, Government of West Bengal
50

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