Internship Report at PepsiCola Punjab Beverages (Pepsi) Carbonated Soft Drinks ( Beverages)

1. University of Agriculture Faisalabad
Bsc Food Engineering Internship Report
Student Name: Jahangir Ali
Student ID: 2016-ag-7380
Training Institution:
Punjab Beverages Company Pvt. Ltd Faisalabad
Training Duration: From 27 June 2018 to 28 July 2018
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2. Table of Contents:
Subject Page
a. An introduction to PEPSICO. Internationals…………………………………………………..3
b. Establishment of Punjab Beverages Company………………………………………………...4
c. Departments & Brands of Punjab Beverage Company………………………………………...5
d. Complete working of Quality Control Department……………………………………………6
e. My learning(professional,technical skills etc.) through this internship………………………15
f. SWOT analysis ……………………………………………………………………………….16
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3. a. An Introduction to PEPSICO. Internationals:
PepsiCo, Inc. is an American multinational food, snack, and beverage corporation headquartered in
Purchase, New York. PepsiCo has interests in the manufacturing, marketing, and distribution of
grain-based snack foods, beverages, and other products.
The recipe for the soft drink Pepsi was first developed in the 1880s by Caleb Bradham, a pharmacist
and industrialist from New Bern, North Carolina. He coined the name "Pepsi-Cola" in 1898. As the
cola developed in popularity, he created the Pepsi-Cola Company in 1902 and registered a patent for
his recipe in 1903. The Pepsi-Cola Company was first incorporated in the state of Delaware in
America in 1919. The company went bankrupt in 1931 and on June 8 of that year, the trademark
and syrup recipe were purchased by Charles Guth, who owned a syrup manufacturing business in
Baltimore America. Guth was also the president of Loft, Incorporated, a leading candy
manufacturer, and he used the company's labs and chemists to reformulate the syrup. He further
contracted to stock the soda in Loft's large chain of candy shops and restaurants, which were known
for their soda fountains, used Loft resources to promote Pepsi, and moved the soda company to a
location close by Loft's own facilities in New York City America. In 1935, the shareholders of Loft
sued Guth for his 91% stake of Pepsi-Cola Company in the landmark case Guth v. Loft Inc. Loft
won the suit and on May 29, 1941 formally absorbed Pepsi into Loft, which was then re-branded as
Pepsi-Cola Company that same year. Loft restaurants and candy stores were spun off at this time. In
the early 1960s, Pepsi-Cola's product lines expanded with the creation of Diet Pepsi and purchase of
Mountain Dew.
In 1965, the Pepsi-Cola Company merged with Frito-Lay, Inc. to become PepsiCo, Inc. At the time
of its foundation, PepsiCo was incorporated in the state of Delaware America and headquartered in
Manhattan, New York America. The company's headquarters were relocated to their present
location of Purchase, New York in 1970, and in 1986 PepsiCo was reincorporated in the state of
North Carolina. After 39 years trading on the NYSE(New York Stock Exchange), PepsiCo moved
its shares to Nasdaq(Nasdaq Stock Market is an American stock exchange) on December 20, 2017.
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4. b. Establishment of Punjab Beverages Company:
Punjab Beverages Company Private Limited, Faisalabad (PBC) is one of the leading franchises of
PepsiCo International, which was established in 1974.
The Company is situated at Samundri Road (About 150 Kilometer away from Lahore).
The operations of the company were initially started with one Bredbi branded flling
machine of foreign origin in September 1976 with a CSD (Carbonated Soft Drinks)
production capacity of 2000 crates of 250 ml RB per day having 20 spouts. However at
later stages the machinery and the other production facilities were expanded and
modernized by installing new state-of-the-art machinery which were imported from
Italy, USA, Germany, Australia, France, Belgium, Austria, Canada and Switzerland.
Pepsi Beverages Company (PBC) is Pepsi Cola manufacturing, sales and distribution
operating unit in the Punjab. Its diverse portfolio includes some of the world's most
widely recognized beverage brands, including Pepsi, Mountain Dew, Sting, Miranda,
7up, Tetra pak Aquafna. The operating unit is headquartered in Faisalabad employs
approximately 2,200 people.
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5. c. Departments and Brands of Punjab Beverages Company:
c.1 Departments:
• Human Resource Department
• Finance Department
• Security Department
• Supply Chain Department
Sub departments
1- Production Department 2- Quality Control Department
3- Transport Department 4-Maintenance Department
c.2 Brands:
The product line of PBC:
 Pepsi
 Diet Pepsi
 Mountain Dew
 Miranda
 7UP
 Aquafna
 Sting
 Slice Juice
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6. d. Complete Working of Quality Control Department:
d.1. Processes of production and their quality maintenance:
Following flow diagrams shows the complete sections and working of quality control department
and different Q-C tests are performed to regulate the processes of the different given sections.
The detailed working and Q-C tests of sections given in following flow chart are explained on the
next pages.
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7. d.1.1 Water Treatment:
In this section raw water is treated to required parameters, for beverage production. The following
flow diagram shows the steps & parameters for water treatment. The most important part of water
treatment is reverse osmosis(R-O).
Formally, reverse osmosis is the process of forcing a solvent from a region of high solute
concentration through a semipermeable membrane to a region of low solute concentration by
applying a pressure in excess of the osmotic pressure. The largest and most important application of
reverse osmosis is the separation of pure water from seawater and brackish waters; seawater or
brackish water is pressurized against one surface of the membrane, causing transport of salt-
depleted water across the membrane and emergence of potable drinking water from the low-
pressure side.
The membranes used for reverse osmosis have a dense layer in the polymer matrix—either the skin
of an asymmetric membrane or an interfacially polymerized layer within a thin-film-composite
membrane—where the separation occurs. In most cases, the membrane is designed to allow only
water to pass through this dense layer while preventing the passage of solutes (such as salt ions).
This process requires that a high pressure be exerted on the high concentration side of the
membrane, usually 2–17 bar (30–250 psi) for fresh and brackish water, and 40–82 bar (600–1200
psi) for seawater, which has around 27 bar (390 psi) natural osmotic pressure that must be
overcome. This process is best known for its use in desalination (removing the salt and other
minerals from sea water to produce fresh water).
Q-C Tests:
-Total Dissolved Salts -Total Hardness
-pH - Alkalinity Test
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8. d.1.2 Syrup Room:
In this section granular sugar is converted into water and sugar solution called syrup. Then in this
simple syrup the concentrate and flavor of the required beverage is added and finally a flavored
syrup is made. This final syrup for each beverage has different specifications according to which
their total acidity(T.A) and brix is maintained.
The concentrate and flavor for every beverage are very unique and are directly prepared and
transported from Pepsi headquarters from America.
The following flow diagram shows the sections and processes of syrup room with their specific
functions.
Q-C Tests:
-Brix Test -Total Acidity Test
-cd Test -
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9. d.1.3 Mixer and Carbo-Cooler:
In this section the treated water from water treatment room and flavored syrup from syrup room are
mixed according to definite required proportions in the mixer and then passes on to carbo-cooler for
carbonation.
The brix is controlled in the mixer through a meter called micrometer.
The carbon dioxide percentage is controlled in the carbo-cooler by controlling its head pressure. It
is called carbo-cooler because in this tank two processes occurs. First is cooling at 4°C(ideally at
0°C) through ammonia chiller and then carbon dioxide pressure(55-60 psi) is applied, the cooled
environment aids the mixing of carbon dioxide in the production of beverage.
The brix and carbon dioxide percentage of beverage is maintained in this section. Following are the
parameters:
Micrometer Readings for Brix Control at PBC filling plants
Plant# Pepsi, Dew, 7up Mirinda Sting 7up Free
3 38.5+-0.5 30.0+-0.05 19.0+-0.05
4 35.0 27.5 22.5+-0.1
6 22.0+-0.5 19.0+-0.05 23.0+-0.1 24.0+-0.1
Following flow diagrams shows the mixing and carbonation process.
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10. d.1.4 Filler:
In this section the beverage is filled into the bottles. The bottles may be glass ones or pet ones,
machines used are different for both bottles, but the process of filling is same. First of all when the
bottle is loaded into the machine(filler), a mechanism air tight the bottle and removes the air, then
the (butterfly valves)valves open and carbon dioxide pressure is applied into the bottle through the
vent tubes, when the pressure in the bottle and head of the filler equals the pressure valves open and
beverage is filled in into the bottle. A spreader is attached on the vent tube which spread the
beverage across the bottle equally, this is done to avoid foaming. The vent tubes are used to control
the level(ml) of beverage in the bottles. After this snifting is carried to release the neck pressure of
bottle to avoid the popping of beverage out of the bottle. After the filling process the bottle is passed
on to the crowner(in case of glass bottle) and on to the caper(in case of pet bottle), at these
machines the crown or cap is applied on the bottle and we obtain or final product.
The following diagram shows the filling process of beverage at the filler machine.
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11. The following diagram shows the parts of filler machines section of filling. The complete valves
and and other parts are shown in the following figure.
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12. d.1.5 Glass Bottle Washer:
This is a automatic glass bottle washer. First of all the empty bottles(sorted pallets) are bought from
market. After that they are inspected whether the bottles are washable or not, any foreign matter and
broken bottles like chipped neck and chipped from bottom are separated. Then the bottles are
loaded on to the washer pockets. Then the washer pockets are moved with bottles into the washer
into different sections according to the following flow diagram.
The caustic of washer is changed after one or 2 months when the management get the time for
cleaning but the water based tanks are drained regularly.
After the bottles are washed the bottles are dropped from washer pockets at the other side of washer.
After the final the final visual inspection the bottles are loaded onto the filler.
Flow diagram for the washing process of glass bottle in washer:
Q-C Tests:
-Caustic % Test -Caustic pH Test
-Temperature Check -Jet alignment & Pressure Test
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13. d.1.6 Pet Bottle Blow Moulding:
In this section the pet bottles are made from their pre-forms, through heating the pre-form and then
applying the pressure into the preform inside the mould which gives them the final shape of a bottle.
After this the bottles are passed on to the labeller which applies label on the bottles and our final
empty pet bottles are obtained ready for filling.
The following diagram shows the sections and processes of pet bottle making through pre-form:
Q-C Tests:
-Sectional Weight Test(S:P:H=42%:38%:20%) -Burst Test
-Top Load Test -Crack Test
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14. d.2 Regulatory steps for working of Beverage Glass Line:
Rinse Jet Alignment At startup & at minimum 4 hr.(for each washer pocket)
Rinse Jet Pressure At startup & at minimum 4 hr.(1.5 kg/cm²)
Temperature At startup & at minimum 4 hr.(65°C in min.1 NaOH zone)
Caustic % At startup & at minimum 4 hr.(Min. 2% for all except carryover
tank)
Bright Wash % 0.25-0.3 %
Total Acidity First container, last container and after tank change, time to exceed
4 hr. between checks
Pre-Final Rinse Water At startup and and at minimum 4 hr.(Total Cl2 < 1 ppm)
pH =7.5+-0.5 , EDTA>5 ppm
Bottle Soaking Time 6 minutes for 2% NaOH
Caustic Draining
Pre & Final Rinse Tank Cleaning once in a day
Light Inspectors Rotation Rotation after 30 minutes
Methylene Blue Test At startup & at minimum 4 hr.(For each pocket) to check any
fungus in bottle
Caustic Carryover Test At startup & at minimum 4 hr.
Crown Crimpage Frequency At startup & at minimum 4 hr.(value must be between 1.125-1.135
in.)
Secure Seal Test Within a hour of startup & minimum once in a every 8 hr.
5 Steps CIP:
Rinse With Water 10-15 minutes
Cleaning Temperature 50-70°C for 20 minutes with caustic 1.5-2%
Rinse With Treated Water Remove Cleaner, 5-10 minutes
Sanitize Hot Water, 85°C minimum time 15 minutes, chlorine 100ppm with
24-25°C minimum temperature for minimum 20 minutes
Final Rinse Sanitizer removal, bringing the temperature of equipment down
Brix and CO2 specifications:
Brand CO2 Line Target CO2 S Target CO2 USL CO2 LSL Brix
Pepsi 3.7 3.6 3.84 3.35 10.4+-0.2
7up 3.8 3.7 3.94 3.45 10.6+-0.2
M.Dew 3.3 3.2 3.44 2.95 15.0+-0.2
Sting BB 2.7 2.6 2.84 2.35 11.8+-0.2
M.Orange 1.9 1.8 2.04 1.55 13.0+-0.2
Fluid Pepsi 7up M.Dew Sting BB M.Orange CO2
Density 1.0418 1.0418 1.048 1.0607 1.05 0.00196
Weight of filled bottle – Weight of empty bottle – (CO2% x CO2 density x volume of beverage)
Net Content = -----------------------------------------------------------------------------------------------------
Density of required Beverage
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15. e. My Learning (professional, technical skills etc.) Through this Internship:
Through this internship I have learned the following:
• Hygiene and engineering of food processing machines and equipment. For example every
food equipment where the food is in contact with the material, must be made of food grade
material. Like all the containers tanks and other food processing machines like beverage
filler and other syrup processing machines, mixers, carbonation tanks are made up of
Stainless Steel 316L . I have also learned about the machines and pipes(their schedules and
thicknesses) lines system in Punjab Beverages, like what types of valves(butterfly vales,
pressure valves, gate valves, etc) or joints(like argon welding, unions, elbows etc) are used .
• I have also learned about maintaining the standards provided by the food regulation
authorities liki AIB, ISO-22000 and PepsiCo’s own regulation authority PCI. i.e.
maintaining the hygiene and cleaning and sanitation like CIP and COP etc.
• Moreover I have learned all the processes and technical aspects of beverage industry, which
includes water treatment, syrup production, mixing and carbonation, packaging and other
quality parameters, which I have already mentioned in the previous articles.
• During this internship I have learned many professional skills through my seniors, they have
taught me the norms of working in the industry.
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16. f. SWOT Analysis:
Strengths:
High experienced staff involved in production process. Highly motivated staff to provide customer
high quality products to customer. Proper feedback to the top management about the production
issues. Good working atmosphere between management and labour.
Weaknesses:
Poorly skilled labor lowers the quality of product. To much wastage of product which increases
production cost. Hygiene is not maintained all the time except at the time of audits.
Opportunities:
Scope for technology upgrade for better quality and more production. Opportunity to enhance
efficiency, energy issues, pollution issues and other hygiene issues by adopting international
standards.
Threats:
Poor management issues relating labor and other quality and hygiene maintaining problems. If
quality drops it would be a very big threat.
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