Varun Beverages Pvt. Ltd. is a franchisee of PepsiCo beverages in Nepal. It has a manufacturing plant in Kathmandu with 500 employees. The plant produces carbonated drinks like Pepsi, 7Up, and Mountain Dew as well as non-carbonated drinks like Tropicana and Mirinda. The internship summary describes the company's production processes including syrup preparation, blowing, filling, and packaging lines. It also discusses the plant's utilities like water treatment, power generation, air compression, and quality control procedures. The intern makes recommendations to improve production tracking, health and safety, and maintenance management.

1. Varun Beverages Pvt. Ltd.
PEPSICO NEPAL
Summer Internship (15th May 2019-11th June 2019)
BY
ABISHEC SHAH
16ME206

2. About the company
• The company was incorporated as Varun Beverages Limited on 16 June 1995 at
New Delhi.
• Varun Beverages Ltd, part of the RJ Corp group is the second largest franchisee in
the world (outside US) of carbonated soft drinks ('CSDs') and non-carbonated
beverages ('NCBs') sold under trademarks owned by PepsiCo.
• The company has been associated with PepsiCo since the 1990s and over two and
half decades consolidated its business association with PepsiCo, increasing the
number of PepsiCo licensed territories and sub-territories covered by the company
all across the world.
• As of 2019, there are 20 manufacturing unit in India and one each in Nepal, Srilan
ka, Morroco, Zambia and Zimbabwe.
• Nepal unit was started in 2000 at kathmandu with 90 acre area with an employee
of around 500 working in present time.

3. 01 Pepsi- Classic
cola drink
Pepsi Cola
02
Lemon lime soft drink
Seven up
03
Citrus flavour drink
Mountain Dew
04
Fruit Flavoured drink mostly orange
Mirinda
Products Carbonated Soft drinks

4. Non carbonated Beverages
Tropicana slice
Mango based drink
Seven-up Nimbooz
Real lemon juice

5. Week Task performed
1st week General overview of company
Overview of all production lines
Brief description of Boiler,Air compressor.
Brief description of power house and RO plant
2nd week Brief description of Filler, Washer, conveyor and syrup preparation
Brief description of slice line.
Brief description of carbonated Glass line and PET line
3rd week Quality control overview
Preparation of maintenance data sheet: collecting time, problem, solution and noting
down.
Litre per case calculation from the fuel used in boiler to production upto 15 days
4th week Process of effluent treatment plant
How the inventory store house works.
Description on production and shipping
General management of the whole plant including production to people
Weekly Logsheet

6. Production and shipping
Power house
Storage of Fuels
Boiler
Water treatment
Air compressor
Different Division of plants
Quality and control Maintenance

7. Storage of Fuels
S.
No
.
Tank Capacity
1 CO2 Tank 1 20 m3
2 CO2 Tank 2 20 m3
3 Diesel Tank 1 20389 L
4 Diesel Tank 2 20614 L
5 Diesel Tank3 21751 L
6 FO Tank 1 22 KL
7 FO Tank 2 15 KL
8 FO Tank 3 17 KL
*FO= Furnance oil
Fig: Filling of Carbon Dioxide

8. Power House
 Company consist of 1 transformer and 5 Deisel generator.
 Transformer change 11 kv to 440 kv which is sufficient to run the organization.
 Cooling tower is installed for the cooling purpose inside the generator.
5 Generators 625 KVA
500 KVA
750 KVA
380 KVA
625 KVA

9. Water Treatment
Specifications:
Bore Wells: (3 bore wells, two in use.)
Diameter - 10’’ each
Depth - 150m and 275m.
Depth of pump - 60m and 96m
Flow rate – 25m3/hr and 30m3/hr
Bore well
Raw storage tank
Degasser
Storage tank
Ro storage tank
Filter
UV chamber
Storage
By motor pump
100 kl
chlorine is added
Removing dissolved ga
s and removing smell o
f bore well
Sand filter
Carbon Filter
RO filter
Radiation intensity of
Uv rays should be gre
ater than 60 W/sq.m.

10. Boiler and Air compressor
Boiler
 Generate steam
 There are 3 Boiler and 2 Boiler use to run daily and one is kept as
spare.
 Uses Deisel and FO fuel.
 Steam is transferred to
• Bottle washer
• Pet line washer
• Glass line( water pre-heating)
• Syrup room
Air compressor
 High pressure air compressor a
nd 3 Low pressure air compres
sor
 KC6 ammonia compressor and
KC4 ammonia compressor
 High pressure is used for Blow
moulding
 Low pressure is used for lubric
ation purpose, cleaining and o
ther need
Fig: Compressor part

11. Date Water cosumption Diesel consumption Water litre/Diesel litre Target
15-May 24000 3669 6.541291905 14
16-May 35000 3817 9.169504847 14
17-May 42000 3832 10.96033403 14
18-May 29000 3360 8.630952381 14
19-May 47000 3428 13.71061844 14
20-May 42000 3436 12.22351572 14
21-May 34000 4555 7.464324918 14
22-May 48000 2606 18.419033 14
23-May 38000 4071 9.334315893 14
24-May 38000 3701 10.26749527 14
25-May 6000 550 10.90909091 14
26-May 30000 2347 12.78227524 14
27-May 29000 2902 9.993108201 14
28-May 23000 2479 9.277934651 14
29-May 19000 2099 9.05192949 14
30-May 18000 2847 6.322444679 14
0
5
10
15
20
Water litre/Diesel litre
Calculation of Water used by boiler per Diesel used

12. Production Process
1.syrup preparation

13. 2.Blow Moulding
Heating chamber
Preform Hopper Preform conveyor Distribution Unit
Unload unitBottleBlow mould
Loading unit
Air conveyorProduction line

14. Slice line(Non carbonated Beverages)
Uncaser
Light Inspectio
n
Pre heater
Bottle washer
200BPM
Light Inspection
( 1and 2)
Filler
250BPM
Tilter
Coder
Light inspectio
n
Packing (Caser)
(Manual)
2nd grade glass
To clean again
3rd grade glass
to waste

15. Glass line (Mountain Dew/Pepsi/7UP)
Light inspecti
on
Packing (Caser)
(Automatic)
Filler
400BPM
CoderBottle washer
600BPM
Light Inspecti
on( 1and 2)
Uncaser
3rd grade
glass
to waste
2nd grade glass
To clean again
Light Inspection

16. Pet line (Mountain Dew/Pepsi/7UP)
Blower for moul
ding
Preform Air conveyor Rinser
FillingCappingWarmer 1Warmer 2
Labeling Coder Light inspection Shrink packer
Shipping

17. Production and shipping and Quality control
1 pallet= 50 case
1 case = 24 glass bottles
1 pallet= 1200 glass bottles
For slice line
• Average production is 8-9 pallet per hour.
For carbonated line
• Average productionn is 16 pallet per hour.
For pet line (2.25 litre bottle)
• 9 bottle in a pack
• 1 pallet have 36 pack.
• 1 pallet have 324 bottle.
• Average production is 8 pallet per hour.
Shipping
 All the pallets are stored in store house.
 According to demand product is shipped on truck.
 Shipping of product is done in ascending order of manufacturing date.
Quality
 Pepsico has set a standard for quality.
 There are 3 metrics for the quality control, they are:
1.Food safety
2.Plant quality
3.Trade quality

18. Maintenance
Line Equipment Problem Root cause correction Corrective action
Mountain dew (
Glass)
Coder Printing not prope
rly
Position disturbance Adjustment to pr
oper position
Moving the arm and pl
acing at proper place
Mountain dew (
Glass)
Filler Escaping of CO2 Mechanical lever da
maged
Correcting the le
ver
Replacement of lever
with new one.
Slice Crowner Cap is not being p
laced at bottle.
Crowner cap carrier Adjusting and b
alancing for pro
per placement
Opening the crowner a
nd correcting it and fix
ing again.
Slice Washer Lifter is not movin
g.
Jam of lifter. Shaft should mo
ve for movemen
t
Belt is moved and is c
orrected.
Air compressor Cooling tower Suction of water is
not done properly
Loosening of the val
ve
Valve should be
properly closed.
Tightening of the valv
e is done.
PET line Conveyor Shaking movemen
t at the end of one
conveyor belt
Breakage of the beari
ng of the shaft
Correcting the s
haft and adjustin
g the shaft at per
fect place
Bringing the new shaft
with proper conditioni
ng of the bearing.

19. Some of the Maintenance work

20. Findings and Recomendation
 Computerized techniques of forecasting and simulations can be used to get the more
accurate desired results.
 To evaluate the exact numbers of bottles filled and palletized per hour, a bottle counter
must be installed after final light inspection.
 At the light inspection, people assigned for inspection of incoming bottles are not so
attentive toward their duty. Sometimes, it has been found that the products are filled i
n dirty bottles.
 There should be installation of automatic light inspection for better efficiency.
 No proper health safety was found in ammonia refrigeration system because ammonia
itself is a health hazardous substance.
 For this purpose, it is better to establish a new health and safety department which can
regulates the matter related to health and safety in planned and organized manner.
 Scheduled maintenance like daily maintenance, weekly maintenance, and monthly maint
enances should be planned and done in a systematic way and in more effective way.