In – Plant Training Report from

March 4 to May 4, 2019

Indian Institute of Food Processing Technology, Thanjavur

Affiliated to

Tamil Nadu Agricultural University, Coimbatore

In partial fulfillment for the award of degree of

B. Tech in Food Process Engineering

Under the guidance of

Ms. Tanima Polley , QC Manager

PepsiCo India Holdings Pvt Ltd, Nelamangala, Karanataka

Submitted by,

A. Devi Vishali

Kiran. S
ACKNOWLEDGEMENT

The internship opportunity we have with PepsiCo India Holdings Pvt Ltd,
Nelamangala, Bangalore was a great chance for learning and professional
development. Therefore, we consider our self as very lucky persons as we were
provided with an opportunity to be a part of it. We are also grateful for having a
chance to meet so many wonderful people and professionals who led us though this
internship period.

Bearing in mind previous we are using this opportunity to express our deepest
gratitude and special thanks to the Mr. R Manjunath, HR Manager of PepsiCo India
Holdings Pvt Ltd, Nelamangala who in spite of being extraordinarily busy with his
duties, took time out to hear, guide and keep us on the correct path and allowing
us to carry out our In-plant training at their esteemed organization and
extending during the training.

We express our deepest thanks to Ms. Tanima Polley, QC Manager of PepsiCo

India Holdings Pvt Ltd, Nelamangala for taking part in useful decision & giving
necessary advices and guidance and arranged all facilities to make training
easier. We choose this moment to acknowledge her contribution gratefully.

It is our radiant sentiment to place on record our best regards ,

deepest sense of gratitude to Ms.Shruthi S K ,( QC Incharge Micro lab ) , of the
company.
Mr.Abhishek,(QC Incharge ) ,Mr.Bhagat(QC Incharge ),Mr.Shashidhar(QC
Incharge) Mr.Bhushan , (RMPM Incharge ), Mr.Shubham Sarada,( QC officer ),
Mr. Udesh (QC Officer) ,Mr.Sharad(QC officer) Mr.Anil(QC
officer)Mr.Manjunath(QC officer) Mr.Wable P.K(QC officer)Mr.Anand Reddy
(WTP Incharge) and for all faculty members for their careful and precious
guidance which were extremely valuable for our study both theoretically and
practically. I would like to express my special gratitude and thanks to all the
Operators and Workers for giving us such attention and time.
 I would like to express my sincere thanks to all Quality Assurance and
Quality Control team for great coordination with me and all those people who are
directly or indirectly co-operated with me to make my training successful.

Thank you!

INDEX
S.NO TITLE PAGE NO
1. Introduction
2. Background of the company
3. History of the organization
4. Background of soft drinks
5. Company Profile
6. Organization of the company
7. PepsiCo Mission and Vision
8. PepsiCo Nelamangala Plant Products
9. Raw material Introduction
10. CSD and NCB Water treatment system
11. Water Test methods
12. Processing Aquafina
13. CSD Line Processing
14. Bottle Washer - Flowchart
15. Packaging
16. Storage
17. Warehousing - Introduction
18. Advertising strategy of PepsiCo
19. Conclusion
20. Reference
 Introduction
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.
PepsiCo was formed in 1965 with the merger of the Pepsi-Cola Company and Frito-Lay, Inc.
PepsiCo has since expanded from its namesake product Pepsi to a broader range of food and
beverage brands, the largest of which included an acquisition of Tropicana Products in 1998
and the Quaker Oats Company in 2001, which added the Gatorade brand to its
portfolio.

Pepsi-Cola was created in the late 1890s by Caleb Bradham, a New Bern, N.C. pharmacist.
Frito-Lay, Inc. was formed by the 1961 merger of the Frito Company, founded by
Elmer Doolinin1932,and the H. W.Lay Company, founded by Herman W. Lay, also in
1932.PepsiCo products areenjoyed by consumers one billion times a day in more than 200
countries and territories around the world. PepsiCo generated more than US $63 billion
dollars in net revenue in 2015, driven by a complementary food and beverage portfolio that
includes Frito-Lay, Gatorade, Pepsi-Cola, Quaker and Tropicana. PepsiCo's product portfolio
includes a wide range of enjoyable foods and beverages, including 22 brands that generate
more than US $1 billion dollars each in estimated annual retail sales. At the heart of PepsiCo
is Performance with Purpose our goal to deliver top-tier financial performance while creating
sustainable growth and shareholder value. In practice, Performance with Purpose means
providing a wide range of foods and beverages from treats to healthy eats; finding innovative
ways to minimize our impact on the environment and reduce our operating costs; providing a
safe and inclusive workplace for our employees globally.

PepsiCo, Inc. markets, sells and distributes a wide variety of convenient and enjoyable foods
and beverages through its operations, authorized bottlers, contract manufacturers and other
partners. The company operates in four business units, PepsiCo Americas Foods, PepsiCo
Americas Beverages, PepsiCo Europe and PepsiCo Asia, Middle East and Africa which are
comprised of six reportable segments: Frito-Lay North America, Quaker Foods North
America, Latin America Foods, PepsiCo Americas Beverages, Europe, and Asia, Middle East
and Africa. The Frito-Lay North America segment makes, markets, sells and distributes
branded snack foods. These foods include Lay’s potato chips, Doritos tortilla chips, Cheetos
cheese flavoured snacks, Tostitos tortilla chips, branded dips, Ruffles potato chips,
Fritos corn chips and Santitas tortilla chips. The Quaker Foods North America segment
makes, markets, sells and distributes cereals, rice, and pasta, dairy and other branded
products. Its products include Quaker oatmeal, Aunt Jemima mixes and syrups, Quaker
Chewy granola bars, Quaker grits, Cap’n Crunch cereal, Life cereal, Quaker rice cakes, Rice-
A-Roni side dishes, Near East side dishes and Pasta Roni side dishes. The Latin America
Foods segment makes, markets, sells and distributes a number of snack food brands including
Marias Gamesa, Cheetos, Doritos, Ruffles, Emperador, Saladitas, Elma Chips, Rosquinhas
Mabel, Sabritas and Tostitos, as well as many Quaker-branded cereals and snacks. The
PepsiCo Americas Beverages segment akes, markets, sells and distributes beverage
concentrates, fountain syrups and finished goods under various beverage brands including
Pepsi, Mountain Dew, Gatorade, Diet Pepsi, Aquafina, 7UP, Diet Mountain Dew, Tropicana
Pure Premium, Sierra Mist and Mirinda. The Europe segment makes, markets, sells and
distributes a number of leading snack foods including Lay’s, Walkers, Doritos, Cheetos and
Ruffles, as well as many Quaker-branded cereals and snacks, through consolidated businesses
as well as through noncontrolled affiliates. The Asia, Middle East and Africa segment makes,
markets, sells and distributes a number of leading snack food brands including Lay’s, Chipsy,
Kurkure, Doritos, Cheetos and Smith’s through consolidated businesses as well as through
noncontrolled affiliates.
Background of the Company

Industry Beverages
Food processing
Founded August 28, 1898; 119 years ago
New Bern, North Carolina, United States
Founder Caleb Bradham
Purchase, New York, United States
Area served Worldwide
Indra Nooyi (Chairman
and CEO) Ramon
Revenue US$63.525 billion(2017)[1]
Net income US$10.509 billion(2017)[1]
US$4.908 billion (2017)[1]
US$79.804 billion(2017)[1]
US$10.981 billion(2017)[1]

PepsiCo.com
History of the Organization

PepsiCo entered India in 1989 businesses in and in a short period, has grown into one of the
largest MNC food and beverage the country. PepsiCo’s growth in India has been guided by
“Performance with Purpose”, its goal to deliver top-tier financial performance while creating
sustainable growth and shareholder value. PepsiCo has been consistently investing in India, in
the areas of product innovation, increasing manufacturing capacity, ramping up market
infrastructure, strengthening supply chain and expanding company’s agriculture programme.
The company has built an expansive beverage and snack food business supported by 62 plants
across the country. In two decades, the company has been able to organically grow eight
brands each of which generate Rs. 1000 crores or more in estimated annual retail sales and are
household names, trusted across the country. PepsiCo India’s diverse portfolio reflects its
commitment to nourish consumers with a diverse range of fun and healthier products and
includes iconic brands like Pepsi, Lay’s, Kurkure, Tropicana, Gatorade and Quaker. In addition
to the recently launched Lay’s Maxx, 7UP Revive and Tropicana Slice Alphonso, the portfolio
includes several healthier treats like Quaker Oats, Tropicana juices, rehydrator Gatorade, Tata
Water Plus and Quaker flavoured oats. : PepsiCo India has pioneered and established a model
of partnership with farmers and now works with over 24,000 happy farmers across nine states.
More than 45 percent of these are small and marginal farmers with a land holding of one acre
or less. PepsiCo provides 360-degree support to the farmer through assured buy back of their
produce at pre-agreed prices, quality seeds, extension services, disease control packages, bank
loans, weather insurance, and the latest technological practices. The association with PepsiCo
India has not only raised the incomes of small and marginal farmers, but also their social
standing. In 2009, PepsiCo India achieved a significant milestone, by becoming the first
business to achieve ‘Positive Water Balance’ in the beverage world, and has been Water
Positive since then.
India saved 12.75 billion litres more that it consumed in its manufacturing operations. The
company made this possible through innovative irrigation practices like direct seeding,
community water recharging initiatives, and by reducing the consumption of water in its
manufacturing facilities. PepsiCo is lauded for its efforts for water conservation and has
received numerous awards such as CII National award for water management, Water Digest
award for water practices and Golden Peacock award for water conservation amongst others.
PepsiCo India is focused on reducing its carbon footprint. In 2015, PepsiCo’s India’s Food and
Beverage plants had a 78% and 41% share from renewable energy sources, respectively such
as bio mass and rice husk boilers and wind turbines. Initiatives such as reduction in use of
chemicals, eco-friendly packaging initiatives and efficient waste management help reduce load
on the environment. PepsiCo in partnership with the NGO Exnora and local municipalities has
also been working on a unique waste collection and treatment model programme called
‘Waste-to-Wealth’. The award winning programme has positively impacted more than
5,00,000 people.
Following the successful implementation of the Waste to Wealth model program, PepsiCo
India has handed over four municipalities in Tamil Nadu (Chennai, Nagapattinam, Tenkasi,
Cuddalore) and one municipal corporation in Haryana (Panipat), to the respective authority for
sustained delivery. PepsiCo India provides direct and indirect employment to almost 2,00,000
people. The company believes in providing employment and growth opportunities to local
talent. Its ‘College of Leadership’, ensures early identification of talent, and employees’
focused development through critical experiences. PepsiCo firmly believes that encouraging
diversity means encouraging policies and systems that respect people’s special needs. Not only
does PepsiCo have a vibrant and diverse workforce, it takes the utmost care to make dynamic
business leaders of its employees and foster their career and personal growth through
differentiated experiences and a robust leadership development model.

BACKGROUND OF SOFT DRINKS

Soft drinks are enormously popular beverages consisting primarily of carbonated water, sugar,
and flavourings. Nearly 200 nations enjoy the sweet, sparkling soda with an annual
consumption of more than 34 billion gallons. Soft drinks rank as America's favourite beverage
segment, representing 25% of the total beverage market. In the early 1990s per capita
consumption of soft drinks in the U.S. was 49 gallons, 15 gallons more than the next most
popular beverage, water.
The roots of soft drinks extend to ancient times. Two thousand years ago Greeks and Romans
recognized the medicinal value of mineral water and bathed in it for relaxation, a practice that
continues to the present. In the late 1700s Europeans and Americans began drinking the
sparkling mineral water for its reputed therapeutic benefits. The first imitation mineral water in
the
U.S. was patented in 1809. It was called "soda water" and consisted of water and sodium
bicarbonate mixed with acid to add effervescence. Pharmacists in America and Europe
experimented with myriad ingredients in the hope of finding new remedies for various
ailments. Already the flavoured soda waters were hailed as brain tonics for curing headaches,
hangovers, and nervous afflictions.
Pharmacies equipped with "soda fountains" featuring the medicinal soda water soon developed
into regular meeting places for local populations. Flavoured soda water gained popularity not
only for medicinal benefits but for the refreshing taste as well. The market expanded in the
1830s when soda water was first sold in glass bottles. Filling and capping the gaseous

liquid in containers was a difficult process until 1850, when a manual filling and corking
machine was successfully designed. The term "soda pop" originated in the 1860s from the
popping sound of escaping gas as a soda bottle was opened.
New soda flavours constantly appeared on the market. Some of the more popular flavours were
ginger ale, sarsaparilla, root beer, lemon, and other fruit flavours. In the early 1880s
pharmacists experimented with powerful stimulants to add to soda water, including cola
nuts and coca leaves. They were inspired by Bolivian Indian workers who chewed coca leaves
to ward off fatigue and by West African workers who chewed cola nuts as a stimulant. In
1886 an Atlanta pharmacist, John Pemberton, took the fateful step of combining coca with
cola, thus creating what would become the world's most famous drink, "Coca-Cola". The
beverage was advertised as refreshing as well as therapeutic: "French Wine Cola—Ideal Nerve
and Tonic Stimulant." A few years later another pharmacist, Caleb Bradham, created "Pepsi-
Cola" in North Carolina. Although the name was a derivation of pepsin, an acid that aids
digestion, Pepsi did not advertise the beverage as having therapeutic benefits. By the early 20th
century, most cola companies focused their advertising on the refreshing aspects of their
drinks.
As flavoured carbonated beverages gained popularity, manufacturers struggled to find an
appropriate name for the drinks. Some suggested "marble water," "syrup water," and "aerated
water." The most appealing name, however, was "soft drink," adapted in the hopes that soft
drinks would ultimately supplant the "hard liquor" market. Although the idea never stuck, the
term soft drink did.
Until the 1890s soft drinks were produced manually, from blowing bottles individually to
filling and packaging. During the following two decades automated machinery greatly
increased the productivity of soft drink plants. Probably the most important development in
bottling technology occurred with the invention of the "crown cap" in 1892, which successfully
contained the carbon dioxide gas in glass bottles. The crown cap design endured for
70 years. The advent of motor vehicles spawned further growth in the soft drink industry.
Vending machines, serving soft drinks in cups, became regular fixtures at service stations
across the country. In the late 1950s aluminium beverage cans were introduced, equipped with
convenient pull-ring tabs and later with stay-on tabs. Light-weight and break-resistant plastic
bottles came into use in the 1970s, though it was not until 1991 that the soft drink industry used
plastic PET (polyethylene terephthalate) on a wide scale.

COMPANY PROFILE

Company Name : PEPSICO INDIA HOLDINGS PVT

Factory Address : 34TH KM STONE, NH-4, VILLAGE TEPPADA
BEGUR, NELAMANGALA, BANGLORE RURAL, KARANATAKA - 562 123
Established in : SEPTEMBER 1997
Head Office Address : PEPSICO INDIA, LEVEL 3-6, PIONEER SQUARE, SECTOR
62, NEAR GOLF COURSE EXTENSION ROAD, GURUGRAM – 122001, HARYANA
Category : Public
Website : www.PepsiCoindia.com

Plant Overview:-
Plant is always awarded and certified with,
1) AIB- American Institute of Baking.
2) HACCP- Hazard Analysis Critical Control Point.
3) ISO- International Organization For Standerd14001
4) ISO- International Organization For Standard 22000
PEPSICO MISSION & VISION
At PepsiCo they believe that business and society can thrive together. They are guided by
Performance with Purpose: delivering top-tier results in a way that sustains and respects
business, society and the planet.

MISSION:

As one of the largest food and beverage companies in the world, their mission is to provide
consumers around the world with delicious, affordable, convenient and complementary foods
and beverages from wholesome breakfasts to healthy and fun daytime snacks and beverages to
evening treats. They are committed to investing in their people, their company and the
communities where they operate to help position the company for long-term, sustainable
growth.

VISION:

At PepsiCo, they’re committed to achieving business and financial success while leaving a
positive imprint on society – delivering what they call Performance with Purpose.
In practice, Performance with Purpose means providing a wide range of foods and beverages
from treats to healthy eats; finding innovative ways to minimize impact on the environment
and reduce our operating costs; providing a safe and inclusive workplace for their employees
globally; and respecting, supporting and investing in the local communities where they operate.
Wherever they do business, Performance with Purpose is their guide. They believe that
delivering for their consumers and customers, protecting the environment, sourcing with
integrity and investing in their employees are not simply good things to do, but that these
actions fuel their returns and position PepsiCo for long-term, sustainable growth.
OBJECTIVES:

Care for our customers, our consumers and the world we live in.

We are driven by the intense, competitive spirit of the marketplace, but we direct this spirit
toward solutions that benefit both our company and our constituents. We see our success as
inextricably linked to that of our customers, consumers and communities.
Sell only products we can be proud of.

The true test of our standards is our own consumption and endorsement of the products we sell.
Without reservation. Our confidence helps ensure the quality of our products, from the moment
we purchase ingredients to the moment it reaches the consumer's hand.
Speak with truth and candour.

We tell the whole story, not just what's convenient to our individual goals. In addition to being
clear, honest and accurate, we are responsible for ensuring our communications are understood.
Win with diversity and inclusion.

We embrace people with diverse backgrounds, traits and ways of thinking. Our diversity brings
new perspectives into the workplace and encourages innovation, as well as the ability to
identify new market opportunities.
Balance short-term and long-term.

In every decision, we weigh both short-term and long-term risks and benefits. Maintaining this
balance helps sustain our growth and ensures our ideas and solutions are relevant both now and
in the future.
Respect others and succeed together.
STAFFING:
Staffing is a term used in the sphere of employment. It has been applied to more than one
aspect of the working environment. Staffing is the process of acquiring, deploying and
retaining a work force of sufficient quality and quality to create positive impacts on the
organization’s effectiveness.

JOB ANALYSIS:
Job analysis is a family of procedures to identify the content of a job in terms of activities
involved and attributes or job requirements needed to perform the activities.

WORK DESCRIPTION:
Work description is a list of a person might use for general tasks, or functions, and
responsibilities of a person.

WORK SCHEDULE:
It is a list of employees, and associated information, for example; location, working times,
responsibilities for a given time period, example; week, month or sports season. PEPSICO
INDIA HOLDINGS PVT LIMITED have 3 shift in their work schedule. In all the units, work
schedule is from 6am-2pm, 2pm-10pm, and 10pm-6am.

TRAINING:
Training is acquisition of knowledge, skills and competencies as the result of the teaching of
vocational or practical skills and knowledge that relate to specific useful competencies.

ELEMENTS OF STAFFING:

While performing the staffing function the manager has to see that men are fit for jobs and
jobs are not altered for men . The elements are,

1. Effective recruitment and selection.

2. Proper classification of personal and pay fix for them.

3. Proper placement.

4. Adequate and appropriate training for development.

5. Satisfactory and fair transfer and promotion

6. Sound relationship between management and worker.

7. Adequate provision for retirement.

FUNCTIONS OF STAFFING:

•Manpower planning.

•Development.

•Fixing the employment standards.

•Sources.

•Selection and placement.

•Training.

•Co-ordination.

•Promotion.

•Transfer.

•Record maintains regarding the employees.

PEPSICO - NELAMANGALA PLANT PRODUCTS

PepsiCo Nelamangala portfolio includes

Refreshment beverages like

•Pepsi

•Mirinda Orange

•7 up

•Mountain Dew

•Lehar Soda

•Slice (Non-Carbonated beverage)

Hydrating beverage like ;

•Aquafina

•Raw material receipt and storage:

All ingredients must be sourced from PepsiCo approved suppliers. In addition, all ingredients
must consistently comply with their ingredient specifications.
The plant is responsible for ensuring that only the approved materials are

used and that the quality is maintained. To aid suppliers in meeting specifications your plant
must implement feedback mechanism.
Plant is responsible for:

•Accepting materials from approved suppliers.

•Maintaining approximate inventory levels to meet manufacturing requirements.
•Proper storage and handling.

When ingredients arrives to the plant, you must inspect them to ensure

•There is no contamination.
•There is no dirt or debris.
•Containers are undamaged.
•Materials are properly loaded on clean pallet.
•The truck is clean
•All receiving tests and checks for the particular ingredient are conducted.
When storing the material, follow the guidelines

•Don’t store raw materials under direct sunlight, expose to sunlight or outside the
recommended temperature and humidity conditions for that ingredient. See the relevant
ingredient specifications for details of any special storage requirements.
•Always use oldest stocks for first, (first in – first out FIFO), There are some exceptional
situations when juices from a certain time period are needed for blending.
•An appropriate certificate of compliance or certificate of analysis (COC / COA) must be
available with each delivery and shipment of materials.

RAW MATERIAL INTRODUCTION

Raw material used in PepsiCo CSD, which may include one or more of the following
ingredients.
•Water

•Sugar

•Carbon dioxide

•Concentrate (Flavour, colour, preservatives, nutritionals, vitamins, minerals, herbs, non

nutritious sweeteners etc)
SUGAR ANALYSIS
1. FLOC IN GRANULATED SUGAR:- PRINCIPLE:-
With certain sugar an “acid beverage floc” may form in the finished product. Visually this
flock ranges from gelatinous strands dispersed throughout the beverage to fluffy white balls or
flakes in the syrup
PROCESS:-
Prepare 54.5 brix sample
↓
Take 600 gm. Sugar
↓
Make up the volume up to 1100 gm.
↓
Stir it until dissolved
↓
Maintain pH up to 1.50 with orthophosporic acid

↓
Heating on hot plate up to boiling stage
↓
Keep it stable 10days
↓
Observe the Flock

2 .COLOUR AND TURBIDITY:-

The test for sugar is same as that of syrup to check colour and turbidity. Both tests are done on
spectrophotometer. Turbidity is caused by presence of non
–sucrose substances and suspended minerals.
Colour should be maximum 150 IU. Unit of colour is ICUMS (International Commission for
Uniform Method of Sugar analysis).
•Turbidity should be maximum 125 Absorbance units (AU). Formula:-
Colour = IU = AF ×1000b×c
Turbidity = AU = (Aunf-Af) × 1000 b×c
AF = Absorbance of filtered solution at 420 nm. Aunf = Absorbance of unfiltered solution at
420 nm. b = Cell path length in cm (10cm)
c = Concentration in gm. /ml.

B) CO2-
CO2 gas is one of the most important factors governing the appeal of a carbonated beverage.
The correct proportioning of CO2 into beverage enhances both the beverage‟s taste and
appearance. The CO2 purity must be 99.90%
CO2 imparts a pungent, slightly acidic taste to the finished product as well as creating greater
eye appeal. It also acts as preservative.

CO2 purity:

CO2 sample
↓
Collect CO2 in apparatus
↓
Filling of 10% NaOH in apparatus
↓
Passing of NaOH through the whole
↓

Take the reading

CSD &NCB WATER TREATMENT SYSTEM

Water treatment is any process that makes water more acceptable for a specific end-use. The
end use may be drinking, industrial water supply, irrigation, river flow maintenance, water
recreation or many other uses including being safely returned to the environment. Treatment
for drinking water production involves the removal of contaminants from raw water to produce
water that is pure enough for human consumption without any short term or long term risk of
any adverse health effect.
Substances that are removed during the process of drinking water treatment include suspended
solids, bacteria, algae,
viruses, fungi, and minerals such as iron and manganese.

The processes involved in removing the contaminants include physical processes such as
settling and filtration, chemical processes such as disinfection and coagulation and biological
processes such as slow sand filtration.
Measures taken to ensure water quality not only relate to the treatment of the water, but to its
conveyance and distribution after treatment. It is therefore common practice to keep residual
disinfectants in the treated water to kill bacteriological contamination during distribution.

The following processes are used for drinking water treatment

worldwide:
•Pre-chlorination for algae control

•Arresting biological growth

•Aeration along with pre-chlorination for removal of dissolved iron and manganese

•Coagulation for flocculation or slow-sand filtration

•Coagulant aids, also known as polyelectrolytes – to improve coagulation and

for thicker floc formation

•Sedimentation for solids separation that is removal of suspended solids trapped in the floc

•Filtration to remove particles from water

•Disinfection for killing bacteria viruses and other pathogens.

COAGULATION SYSTEM:

In water treatment, coagulation occurs when a coagulant is added to water to "destabilize"

colloidal suspensions.
In a colloidal suspension, particles will settle very slowly or not at all because the colloidal
particles carry surface electrical charges that mutually repel each other. A coagulant (typically
a metallic salt) with the opposite charge is added to the water to overcome the repulsive charge
and "destabilize" the suspension. For example, the colloidal particles are negatively charged
and alum is added as a coagulant to create positively charged ions. Once the repulsive charges
have been neutralized ( since opposite charges attract), the van der Waals force will cause the
particles to cling together (agglomerate) and form micro floc.
Conversely, flocculation involves the addition of polymers that clump the small, destabilized
particles together into larger aggregates so that they can be more easily separated from the
water. Flocculation is a physical process and does not involve the neutralization of charge.
Coagulation may be used in conjunction with flocculation to assist with water clarification.
The coagulation process involves adding iron or salts, such as aluminium sulphate, ferrous
sulphate, calcium hypo chloride or polymers, calcium carbonate to the water. These chemicals
are called coagulants, and have a positive charge. The positive charge of the coagulant
neutralizes the negative charge of dissolved and suspended particles in the water. When this
reaction occurs, the particles bind together, or coagulates (this process is sometimes also called
flocculation). The larger particles, or floc, are heavy and quickly settle to the bottom of the
water supply. This settling process is called sedimentation. After this the water is goes to the
intermediate tank through the influence of gravitational force.

SAND FILTERATION:

A sand bed filter is a kind of depth filter. Broadly, there are two types of filter for separating
particulate solids from fluids:

•Surface filters, where particulates are captured on a permeable surface

•Depth filters, where particulates are captured within a porous body of material.
In addition, there are passive and active devices for causing solid-liquid separation such as
settling tanks, self-cleaning screen filters, hydro cyclones and centrifuges.
There are several kinds of depth filter, some employing fibrous material and others employing
granular materials. Sand bed filters are an example of a granular loose media depth filter. They
are usually used to separate small amounts (<10 parts per million or <10 g per cubic metre) of
fine solids (<100 micrometres) from aqueous solutions. In addition, they are usually used to
purify the fluid rather than capture the solids as a valuable material. Therefore they find most
of their uses in liquid effluent (wastewater) treatment.
Sand bed filters work by providing the particulate solids with many opportunities to be
captured on the surface of a sand grain. As fluid flows through the porous sand along a
tortuous route, the particulates come close to sand grains. They can be captured by one of
several mechanisms:
•Direct collision

•Van der Waals or London force attraction

•Surface charge attraction

ACTIVATED CARBON FILTERS:

Activated carbon filters are generally employed in the process of removing organic compounds
and/or extracting free chlorine from water, thereby making the water suitable for discharge or
use in manufacturing processes. Eliminating organics in potable water, such as humic and
fulvic acid, prevents chlorine in the water from chemically reacting with the acids and forming
trihalomethanes, a class of known carcinogens.
Activated Carbon (AC) filtration, as with any water treatment method, is not capable of
removing every possible type of contaminant. For example, sodium, microbes, fluoride, and
nitrates cannot be removed with AC filtration. Water softening also cannot be achieved with
AC filters. In addition, heavy metals, such as lead, can only be removed with a very specific
kind of activated carbon water treatment, which is typically used only in residential point-of-
use filters.
Coconut shells and coal (anthracite or bituminous) are both organic sources of activated
carbon. Carbon forms when an organic source is burned in an environment without oxygen.
This process leaves only about 30% of the organic mass intact, driving off heavy organic
molecules. Prior to being used for water treatment, the organic mass must then be “activated.”
The process of activation opens up the carbon’s massive number of pores and further drives off
unwanted molecules. The open pores are what allow the carbon to capture contaminants,
known as "adsorption".
There are two main activation methods:
Steam Activation – Steam activation is carried out using steam at temperatures of between
800°C and 1000°C. At these temperatures an instant Water-Gas reaction occurs, gasifying the
carbonized material. Air is then introduced to burn out the gasses, without burning the carbon.
This process produces a graded, screened and de-dusted form of activated carbon. Carbon
activated by steam generally has a fine pore structure, ideal for adsorbing both liquid phase and
vapour phase compounds.
Chemical Activation – With chemical activation the carbon is first filled with a powerful
dehydrating agent, typically a paste form of phosphoric acid (P2O5) or zinc chloride (ZnCl2).
The paste is heated to temperatures between 500°C and 800°C to activate the carbon. Chemical
activation produces activated carbon with a very open pore structure, making it more suitable
for adsorbing large molecules
Activated carbon water treatment is basically used for:

1. Chlorine Removal: Activated carbon may be used to remove chlorine with little
degradation or damage to the carbon. Dechlorination occurs rapidly and flow rates are typically
high. However, this process requires an extensive amount of surface area, and organics in the
water will eventually fill up and block the pores of the carbon. Ultimately, the AC filter will
need to be replaced as its ability to dechlorinate the water will slowly decline. Spent carbon can
be re-activated; however, re-activated filters should only be used in waste-water treatment
applications. One advantage to using AC is its low operating cost and virtual “fail safe”
operation once installed. One disadvantage is that as the chlorine is removed from the topmost
layer of the media, the AC provides a damp environment ideal for the growth and proliferation
of bacteria. Bacteria can cause problems in medical applications, or when using carbon as a
pre-treatment to reverse osmosis.
2. Removal of Organic Matter: As water passes through an activated carbon filter,
organic particles and chemicals are trapped inside through a process known “adsorption”.

The adsorption process depends upon 5 key factors:

1) Physical properties of the activated carbon (surface area and pore size distribution);
2) The chemical makeup of the carbon source (amount of hydrogen and oxygen);
3) The chemical makeup and concentration of the contaminant;
4) Water pH and temperature; and
5) The length of time the water is exposed to the activated carbon filter (called empty bed
contact time or EBCT).

MICRON FILTERS:

Microfiltration is used to treat drinking water: it improves the quality and shelf life of the
water. Microfiltration is a filtration process which removes contaminants from the water by
passage through a microporous membrane. A typical microfiltration membrane pore size range
is 0.1 to 10 micrometres (µm). Increasingly used in drinking water treatment, it effectively
removes major pathogens and contaminants such as Giardia lamblia cysts, Cryptosporidium
oocysts, and large bacteria.
•Sand filter with 2 layers media.
•Filtration up to 5 microns.
•Active carbon filter to remove biocides.
•Backwash system with periodical wash system.
•Micro filtration up to 1 micron.
•Water quality detection at inlet and outlet.
Here we use 5 micron filters for adsorbing carbon contents.

UV FILTERATES:
UV radiation has three wavelength zones: UV-A, UV-B, and UV-C, and it is this last region,
the shortwave UV-C that has germicidal properties for disinfection. A low-pressure mercury
arc lamp resembling a fluorescent lamp produces the UV light in the range of 254 manometers
(nm). A nm is one billionth of a meter (10^-9 meter). These lamps contain elemental
mercury and an inert gas, such as argon, in a UV-transmitting tube, usually quartz.
Traditionally, most mercury arc UV lamps have been the so-called "low pressure" type,
because they operate at relatively low partial pressure of mercury, low overall vapour pressure
(about 2 mbar), low external temperature (50-100oC) and low power. These lamps omit nearly
monochromatic UV radiation at a wavelength of 254 nm, which is in the optimum range for
UV energy absorption by nucleic acids (about240-280nm).

In recent years medium pressure UV lamps that operate at much higher pressures, temperatures
and power levels and emit a broad spectrum of higher UV energy between 200 and 320 nm
have become commercially available. However, for UV disinfection of drinking water at the
household level, the low-pressure lamps and systems are entirely adequate and even preferred
to medium pressure lamps and systems.
This is because they operate at lower power, lower temperature, and lower cost while being
highly effective in disinfecting more than enough water for daily household use. An essential
requirement for UV disinfection with lamp systems is an available and reliable source of
electricity. While the power requirements of low-pressure mercury UV lamp disinfection
systems are modest, they are essential for lamp operation to disinfect water. Since most
microorganisms are affected by radiation around 260 nm, UV radiation is in the appropriate
range for germicidal activity. There are UV lamps that produce radiation in the range of 185
nm that are effective on microorganisms and will also reduce the total organic carbon (TOC)
content of the water. For typical UV system, approximately 95 percent of the radiation passes
through a quartz glass sleeve and into the untreated water. The water is flowing as a thin film
over the lamp. The glass sleeve is designed to keep the lamp at an ideal temperature of
approximately 104 °F.
After that treated water goes to syrup preparation [NCB-slice& CSD GRB] and clean in place
[CIP] that include CSD PET [300 bpm] CSD PET[400bpm]. The treated water has pH 4.0
max, TDS-500 max, Hardness about 150 max, alkalinity 50 max.
Clarifying the water:

The quality of water is crucial to the success of a soft drink. Impurities, such as suspended
particles, organic matter, and bacteria, may degrade taste and colour. They are generally
removed through the traditional process of a series of coagulation, filtration, and chlorination.
Coagulation involves mixing a gelatinous precipitate, or floc (ferric sulphate or aluminium
sulphate), into the water. The floc absorbs suspended particles, making them larger and more
easily trapped by filters. During the clarification process, alkalinity must be adjusted with an
addition of lime to reach the desired pH level.

Filtering, sterilizing, and dechlorinating the water:

The clarified water is poured through a sand filter to remove fine particles of floc. The water
passes through a layer of sand and courser beds of gravel to capture the particles. Sterilization
is necessary to destroy bacteria and organic compounds that might spoil the water's
taste or colour. The water is pumped into a storage tank and is dosed with a small amount of
free chlorine. The chlorinated water remains in the storage tank for about two hours until the
reaction is complete.
Next, an activated carbon filter dechlorinates the water and removes residual organic matter,
much like the sand filter. A vacuum pump de- aerates the water before it passes into a dosing
station.

WATER TEST METHODS:

CSD Beverages use the following water test methods.

•PH

•Total Dissolved Solids (TDS)

•Calcium Hardness

•Total Hardness
•Free Chlorine

•Turbidity

•Slit Density Index

•Manganese

•Coagulation via Jar Testing

•Total Chlorine

•2P-M Alkalinity, PH Indicator Method

•2P-M Alkalinity, PH Electrode Method

•Total Alkalinity, PH Indicator Method

•Total Alkalinity, PH Electrode Method

•Appearance

•Odour

•Colour

Mixing the ingredients:

The dissolved sugar and flavour concentrates are pumped into the dosing station in a
predetermined sequence according to their compatibility. The ingredients are conveyed into
batch tanks where they are carefully mixed; too much agitation can cause unwanted aeration.
The syrup may be sterilized while in the tanks, using ultraviolet radiation or flash
pasteurization, which involves quickly heating and cooling the mixture. Fruit based syrups
generally must be pasteurized.
The water and syrup are carefully combined by sophisticated machines, called proportioners,
which regulate the flow rates and ratios of the liquids. The vessels are pressurized with carbon
dioxide to prevent aeration of the mixture.

Carbonating the beverage:

Carbonation is generally added to the finished product, though it may be mixed into the water
at an earlier stage. The temperature of the liquid must be carefully controlled since carbon
dioxide solubility increases as the liquid temperature decreases. Many carbonators are
equipped with their own cooling systems. The amount of carbon dioxide pressure used depends
on the type of soft drink. For instance, fruit drinks require far less carbonation than mixer
drinks, such as tonics, which are meant to

be diluted with other liquids. The beverage is slightly over-pressured with carbon dioxide to
facilitate the movement into storage tanks and ultimately to the filler machine.
Filling and packaging:

The finished product is transferred into bottles or cans at extremely high flow rates. The
containers are immediately sealed with pressure- resistant closures, either tinplate or steel
crowns with corrugated edges, twist offs, or pull tabs.
Because soft drinks are generally cooled during the manufacturing process, they must be
brought to room temperature before labelling to prevent condensation from ruining the labels.
This is usually achieved by spraying the containers with warm water and drying them. Labels
are then affixed to bottles to provide information about the brand, ingredients, shelf life, and
safe use of the product. Most labels are made of paper though some are made of a plastic film.
Cans are generally pre- printed with product information before the filling stage.
Finally, containers are packed into cartons or trays which are then shipped in larger pallets or
crates to distributors.

PROCESSING - AQUAFINA

Aquafina is a brand of purified bottled water products produced by PEPSICO, consisting of

both unflavoured and flavoured water.

Brand History:

Aquafina was first launched in the US in 1994. With its unique purification system and
great taste, Aquafina soon became the bestselling brand in the country.

AQUAFINA PROCESS – FLOW CHART

Brand Advantage:

Aquafina goes through a five step state-of-the-art purification process to give consumers pure
water and perfect taste.
Aquafina has been built through refreshing and sharp advertising. The ‘What a Body’
campaign has helped the brand to drive premium, modern and youthful imagery in an
otherwise undifferentiated category.
Bottled across India in 19 plants, Aquafina is available across more than half a million outlets.
Catering to diverse consumer needs and occasions, it is available in various pack sizes like
300ml, 500ml, 1 ltr and 2 ltr bottles and in bulk water jars of 25 ltrs.
Aquafina is the face of PepsiCo’s water conservation initiatives and builds awareness about
PepsiCo’s efforts to replenish and restore the water table through its pack labels.
Spring water is derived from an underground formation from which water flows to the Earth's
surface. While spring waters are treated to remove bacteria and possible contaminants, most
spring waters retain many of the Total Dissolved Solids (TDS), trace compounds and other
substances found in the water.
Purified water is sourced from water systems that provide safe drinking water and are regulated
by the Environmental Protection Agency (EPA). This water is then taken through purification
systems designed to remove substances according to Food and Drug Administration (FDA)
standards. Aquafina's state-of-the-art HydRO-7™ purification system employs standards that
are even more stringent that those set by the FDA. Aquafina® delivers pure water with perfect
taste.
TDS is the sum of all solids dissolved in water measured in parts per million (ppm) Examples
of substances that can account for TDS include carbonates, bicarbonates, chlorides, sulphates,
phosphates, nitrates, calcium, magnesium, sodium, potassium, iron, manganese, and a few
others. A TDS meter is used to provide a reading of the dissolved solids in water. FDA
guidelines require that bottled water, excluding mineral water, contain no more than 500 ppm
TDS. For a bottled water to be labelled "purified," it must have TDS of no more than 10 ppm.
Aquafina's average TDS reading is 4 — that's 2.5 times lower than FDA standards and 75%
less than the closest competitive brand.
Aquafina originates from public water sources and is then purified through a rigorous, seven-
step process called HydRO-7™. This is a state- of-the-art process that includes reverse osmosis
and other filtering and purification methods. It removes things like chlorides, salts.
Every bottle of Aquafina is produced at one of our water purification centres through the
HydRO-7™ process. That's how you know you're getting pure water and perfect taste
consistently every time you open an Aquafina. While other brands of bottled water may also
have similar purification steps such as reverse osmosis and ozonation, Aquafina® has an
extensive purification system which involves seven separate steps that together work to deliver
pure Aquafina®. At Aquafina®, we understand that when you pay for bottled water, you
expect consistent purity and great taste. That's why Aquafina® has invested hundreds of
millions of dollars in purification processes and exceeds purity standards set by the federal
government.
Reverse osmosis (RO) uses semi-permeable membranes with smaller pore sizes than
microfiltration, ultrafiltration and nanofiltration to remove unwanted substances in the water,
like sodium and chloride. Aquafina's purification system is designed to remove trace
compounds like carbonates, bicarbonates, chlorides, sulphates, phosphates, nitrates, calcium,
magnesium, sodium, potassium, iron and manganese. These compounds are also referred to as
Total Dissolved Solids (TDS). While some of these compounds, like calcium and potassium,
are necessary for your body, their minute levels in most bottled waters have no impact on
health. Therefore, we remove these compounds to deliver a more pure water.
Our state-of-the-art HydRO-7™ purification system is designed to remove dissolved solids and
organic compounds that may be present in the water.
The reverse osmosis process we use removes these organic compounds, but we also employ
other steps such as carbon filtration, ozonation, and Ultra Violet (UV) light as additional
safeguards.
“Hydro-7 is a state-of the-art process that includes reverse osmosis and other filtering methods.
It removes things like chlorides, salts and other substances that can affect a water’s taste.
That’s how we can ensure that you’ll get a clean, pure taste every time you open a bottle of
Aquafina.”

Fair enough, PepsiCo. Aquafina lists each step of the trademarked Hydro-7 process, and it does
look significantly more involved than your average filter. And consumers should remember
that using public sources for water is not unique to Aquafina. It has to label its bottles P.W.S.,
though that company has its own filtration protocols.
CSD- LINE PROCESSING
Carbonated water constitutes up to 94% of a soft drink. Carbon dioxide adds that special
sparkle and bite to the beverage and also acts as a mild preservative. Carbon dioxide is an
uniquely suitable gas for soft drinks because it is inert, non-toxic, and relatively inexpensive
and easy to liquefy.
The second main ingredient is sugar, which makes up 7-12% of a soft drink. Used in either dry
or liquid form, sugar adds sweetness and body to the beverage, enhancing the "mouth-feel," an
important component for consumer enjoyment of a soft drink. Sugar also balances flavours and
acids.
Sugar-free soft drinks stemmed from a sugar scarcity during World War
II. Soft drink manufacturers turned to high-intensity sweeteners, mainly saccharin, which
was phased out in the 1970s when it was declared a potential carcinogen. Other sugar
substitutes were introduced more successfully, notably aspartame, or Nutra-Sweet, which was
widely used throughout the 1980s and 1990s for diet soft drinks. Because some high
-intensity sweeteners do not provide the desired mouth-feel and aftertaste of sugar, they often
are combined with sugar and other sweeteners and flavours to improve the beverage.
The overall flavour of a soft drink depends on an intricate balance of sweetness, tartness, and
acidity (pH). Acids add a sharpness to the background taste and enhance the thirst-quenching
experience by stimulating saliva flow. The most common acid in soft drinks is citric acid,
which has a lemony flavour. Acids also reduce pH levels, mildly preserving the beverage.
Very small quantities of other additives enhance taste, mouth-feel, aroma, and appearance of
the beverage. There is an endless range of flavourings; they may be natural, natural identical
(chemically synthesized imitations), or artificial (chemically unrelated to natural flavours).
Emulsions are added to soft drinks primarily to enhance "eye appeal" by serving as clouding
agents. Emulsions are mixtures of liquids that are generally incompatible. They consist of
water-based elements, such as gums, pectins, and preservatives; and oil-based liquids, such as
flavours, colours, and weighing agents. Saponins enhance the foamy head of certain soft
drinks, like cream soda and ginger beer.
To impede the growth of microorganisms and prevent deterioration, preservatives are added to
soft drinks. Anti-oxidants, such as BHA and ascorbic acid, maintain colour and flavour.
Beginning in the 1980s, soft drink manufacturers opted for natural additives in response to
increasing health concerns of the public.
PET LINE PRIMARY CODING
For Example
AG . BN . 5281DO1F18 01 . 06 . 18 HH:MM MRP Rs:
AG - Plant identification code BN.5254D - CDV Code, line code
01F18 - Date format
BOTTLE WASHER – FLOW CHART
A reusable bottle is a bottle that can be reused, either for multiple trips to a bottler or is reused
by a household. It is a common example of reusable packaging.
In PEPSICO, TULA is used for bottle washing. There are totally 8 compartments which are
mentioned below. The chemicals added are divo LE, divo NP and caustic for maintaining
EDTA and to inhibit mold growth, for maintaining pH, and to prevent stain. TULA have 45
pockets. After washing process the bottles will go for empty bottle inspection (EBI).

PACKAGING:

The wrapping material around a consumer item that serves to contain, identify, describe,
protect, display, promote and otherwise make the product marketable and keep it clean.
It is the technology of enclosing or protecting products for distribution, storage, sale and use.
Non – transitory, semi – permanent or long – term contaminant, holding, leaving, or placement
of goods or materials, usually with the intention of retrieving them at a later time. It does not
include the interim accumulation of a limited amount during processing, maintenance, or
repair.
In PEPSICO, PET is used for aquafina, slice, pepsi, 7up, mirinda and mountain dew. Where as
glass bottles are used for 7up, slice, pepsi, mirinda and lehar soda.
The packaging of containers should protect the latter from contamination and damage and
allow appropriate handling and storing.

STORAGE:
•Space where you put things when they are not being used.
•The state of being kept in a place when not being used: the state of being stored somewhere.
•The act of putting something that is not being used in a place where it is available, where it
can be kept safely, etc.:the act of storing something.

In PEPSICO, beverages are stored at large ware house by maintaining proper temperature.
The end product should be stored and transported under such conditions as will preclude
contamination with and/or proliferation of microorganisms and protect against deterioration of
the product or damage to the container. During storage, periodic inspection of the end product
should take place to ensure that the beverages which are fit for human consumption is
dispatched and that the end-product specifications are complied with.
 WAREHOUSING – INTRODUCTION:

Warehouse management includes the receiving, handling, storage and shipping of the finished
product in the warehouse. To ensure the continued delivery of a safe and high quality product
to the consumer, the entire warehouse staff must support good warehouse practices.
An effective warehouse management program includes:

•An organization chart showing the chain of authority and

responsibility.
•A flow diagram of the receiving, storage, and shipping operation.

•An effective program of follow up and control, including a report system.

•A regular maintenance schedule for warehouse buildings.
•Established good housekeeping and pest control programs. To maintain GMP standards and
thus improve the storage and handling of finished products.
•A periodic review of warehouse layout to ensure efficient space utilization and material
handling, inventory, and safe demand.

RECEVING AND SHIPPING

Careful management of product movement at the plant and warehouse ensures product
freshness. Good stock inventory control includes:
•Ensure that the warehouse is enclosed so that products are not exposed to sunlight or heat.
Excessive heat can cause product deterioration and aging, creating off flavour. The warehouse
should maintain ambient storage and temperature ( 32 0C )
•Ship finished products in a first- in, first-out (FIFO) rotation, to ensure the timely movement
of the oldest inventory stock.
•Ensure pallets are clean and in a good repair, neatly stack empty pallets in the warehouse or in
dock areas to prevent rodent harbourage.
Warehousing storage guidelines:

•Maintain the warehouse temperature between 18 0C and 32 0C with a dry environment ( RH

< 60% ).
•Avoid storing products in the hot areas or near sources of heat. Don’t store products near to
heat generating machinery.
•Avoid windows, sore glass and PET products away from UV radiation from sunlight.
•Avoid storing products outside, where conditions are not controlled.
•Avoid burying or blocking sensitive products.
•Date every pallet. Pallet tags offer quick information for stock rotation and warehouse
auditing.
•Ensure systems are in place for proper stock rotation.

ADVERTISING STRATEGY OF PEPSICO

•Pepsi target audience are mostly teens and young adults and their advertising reflects this is
every possible way.
•The company changes its advertising strategy and images to reflect the target’s interests.
•Pepsi makes sure that the advertisements reflect to the target audience’s interests and
nostalgia.

•The advertising strategy includes cool, hip promos to attract more of the target audience.
•The advertising is the mostly creative and has different elements like music and sports
other than bollywood.
•Pepsi.com also plays an important role in advertising and attracts target audience by giving
access to option like downloads, gaming, music, mixing applications etc…
TYPES OF ADVERTISING

There are several types of advertisements that is used by Pepsi that help expose the products
out to the public. They are;

 Print Advertisement.
 Outdoor Advertisement.
 Broadcast Advertisement.
CONCLUSION

The training in PEPSICO INDIA HOLDING PVT. LTD, gave a good insight on raw material
receiving, processing, quality control, product development and documentation. The
experience that we gained from the training is valuable experienced knowledge and cannot be
obtained from any textbooks. The training gave an ambient opportunity to understand the
various aspects of the soft drink beverages from the raw materials to the final product shipping.
We had also the opportunity to understand the responsibility of different sections in the
organization. The exposure in the quality control lab gave a good skill in the quality analysis of
the raw material and product and give good concept of microbiology. The training gave us a
beautiful and superb first experience and we really enjoyed each moment of the training period.
Moreover the training is excellent arena where we can put our theoretical knowledge to
practice. Whatever we express, it is our sincere gratitude to everyone who helped me to
successfully complete this training program.
REFERENCES:
1. Louis, J.C. The Cola Wars. Everest House, 1980.
2. Mitchell, Alan J., ed. Formulation and Production of Carbonated Soft Drinks. AVI,
1990.
3. Oliver, Thomas. The Real Coke. Random House, 1986.
4. http://www.madehow.com/Volume-2/Soft- Drink.html#ixzz4LFb3AANZ

5. http://www.PepsiCobeveragefacts.com/home/Brands

6. http://www.aquafina.com/en-US/faq.html

7. http://www.PepsiCobeveragefacts.com/Home/Product?formula=4 4316*01*01-
07&form=RTD&size=20

8. https://en.wikipedia.org/wiki/Reuse_of_bottles