INSWABU - Check List - Sparkling PET - 20190619

Document Name
Document Number
Prepared by
Reviewed by
Approved by
Created On
Revision Number
Revision Date
Classified - Confidential
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Facility Assessment Checklist - Sparkling PET
INSWABU-CHE-04
Amit Garg, Varinder Sharma
Ashok, Ravi, Pallavi, Shailendra, Sharad, Deepak, Lohitaksh, Anudeep
GVS
2015
1
17th June,2019
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Facility Assessment Checklist for CSD PET - GMP and Construction
Facility Name & Address:

Assessed by:
Assessment Date:
Plant Representative:
ITEMS Requirements Reference Category
Location of the plant not near to any local industry which emits objectionable smoke, odors ISO/TS 22002-1:2009 Requirement
or dust
Location of the plant is not near an area of or next to hazardous substances or wastes ISO/TS 22002-1:2009 Requirement
(such as at a gasoline station, dry cleaners, industrial manufacturing facility, or landfill,
garbage dumps, cattle sheds, open sewage drains/Lake?
Site Selection
Production site not near to any production plant which is involved in fermentation or yeast ISO/TS 22002-1:2009 Requirement
processes e.g Sugar , Beer ,Wine , Bread Making etc
Does not contain sources of hazardous substances or wastes, such as a gasoline station, ISO/TS 22002-1:2009 Requirement
dry cleaner, industrial manufacturing plant, or landfill.
Is not in an area with contaminated water. If you’re feeding well water into your water- ISO/TS 22002-1:2009 Requirement
treatment system. make sure you have a demonstrated assurance that the ground water is
not contaminated.
Site is not in an area with drainage problems. Provie the municapl drainage plan around the Business Unit Requirement
Plant site.
Has the area surrounding the well been paved and/or covered with vegetation not requiring Business Unit Requirement
treatment using pesticides or fertilizers?
Was the source water samples drawn and tested by an accredited lab ( BU approved third Business Unit Requirement
party testing Lab) ( IS 10500:2012 [India], BP-SP-184, WHO Ed4 including radioactive)
Source Water
Are the records for the analysis report maintained on file at the plant? Business Unit Requirement
Are the Borewell heads protected by a suitable structure to prevent entry by unauthorized ISO/TS 22002-1:2009 Requirement
individuals, pests and other sources of extraneous matter? IS 14543
If plant his using an alternate water source (e.g. Private wells, tanker water, pre-treatment Business Unit Requirement
plants etc.). Follow BU-specific protocol on New Source water approval.
Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

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Document No : BU- RQ-210~CHK 1
Plant Exterior & Grounds

Does the Plant exterior in order with respect to appearance of building exteriors, yards, ISO/TS 22002-1:2009 Requirement
building interiors, processing areas and storage areas?
Are roads and parking areas are paved and grounds landscaped to limit dust. ISO/TS 22002-1:2009 Requirement
Does the plant have an adequate size storm drainage system? There is no possibility of ISO/TS 22002-1:2009 Requirement
overflow and water logging during heavy rains.
Does the sewage system and sceptic tanks provided are away from the Source water ISO/TS 22002-1:2009 Requirement
supplies and security exists that there is no potential contamination to the aquifer.
Are the buildings and other facilities made of sound construction and are maintained in ISO/TS 22002-1:2009 Requirement
good repair? No temporary constructions, No Asbestos to be used.
Design and construct the plant and grounds area to prevent contamination from entering the ISO/TS 22002-1:2009 Requirement
plant from outside areas.
Plant Area Entrance
Surround the Manufacturing Area's outside walls with an area that has no grass or dirt,so it ISO/TS 22002-1:2009 Requirement
does not harbor insects, vermin, or other pests. Typically, use pebbled rocks, concrete or
asphalt till 3 ft.
Are buildings and facilities kept clean by removing litter and waste and cutting weeds or ISO/TS 22002-1:2009 Requirement
grass within the immediate vicinity of plant buildings.
Place air curtains, quick-opening doors, strip curtains and insect electrocutors at all ISO/TS 22002-1:2009 Requirement
entrances to the plant used often throughout the day. Examples are shipping and receiving
Plant Exteriors
areas (bay loading facilitates to meet bird proofing within the plant)
Is the manufacturing area located in a manner to prevent traffic by nonessential personnel ? ISO/TS 22002-1:2009 Requirement
/ Access is controlled. (Manual / Elelctronic/ Security)
Locate the wood pallet-repair area outside the plant, or in a nearby building. ISO/TS 22002-1:2009 Requirement
Dedicate an area for trash and plant waste that is away from the plant’s main ISO/TS 22002-1:2009 Requirement
buildings.Make sure this area has drainage and a sealed-surface floor that slopes to
prevent standing water. The waste area shall be segregated for waste PET bottles,
closures, labels etc.
Is a dedicated area provided away from the main building for Refuse and plant solid waste ISO/TS 22002-1:2009 Requirement
storage? Is the access for the transport vehicle provided away from the main building ?
Does the plant has a program in place to remove all wastes and rubbish in a timely manner ISO/TS 22002-1:2009 Requirement
to prevent odor development, beverage contamination,and to minimize harborage and
breeding places for insects and rodents ?
Are all openings that surround pipe work ,doors ,windows and ventilation ductwork and false BU-RQ-210 Requirement
ceilings properly sealed.
Provide rodent insect proof screens on all drains leading to outside the factory? ISO/TS 22002-1:2009 Recommended
Does the plant have hired external pest control agency to make it insect and rodent proof? ISO/TS 22002-1:2009 Recommended

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Are all windows, vents and exhaust fan openings provided with screens Opening outside? BU-RQ-210 Requirement
Is adequate water supply from an adequate source provided in all areas where required i.e. BU-RQ-210 Requirement
for cleaning and sanitation, toilets, change rooms and housekeeping activities etc.?
Canopy at loading and unloading area shall be made in such a thay pegions should not Requirement
found place to sit
Processing Areas- Access Control & Hygiene

Physically separate all processing areas from nonprocessing areas of the plant. Entrance to BU-RQ-210 Requirement
the plant from non-processing to processing areas shall through double door.
Is a security card swipe system in place to restrict entry of non-permanent personnels to BU-RQ-210 Requirement
these sensitive areas?
Is there an apperal change area for the visitors before entering the processing areas . ISO/TS 22002-1:2009 Requirement
Is the Hand wash station provided at entrance of all processing areas with hot and cold ISO/TS 22002-1:2009 Requirement
water supply, liquid soap, dryer and hand sanitizer ? Taps and hand wash station should not
be hand operated .
self-draining roofs which do not leak. ISO/TS 22002-1:2009 Requirement
Employee hygiene facilities such as toilets etc should not be located within the BU-RQ-210 Requirement
manufacturing area.
Should have changing facilities to enable the process area personnel to move to the ISO/TS 22002-1:2009 Requirement
production area
in such a way that risk to the cleanliness of their
work wear is minimized (Provide an appron to all process areas personnel). The aprons or
any uiforms shall not have sewn buttons
Are the number of doors and openings between processing areas and other parts of the Business Unit Requirement
plant limited ?
Air curtain at the entrance of all doors, must meet below requirements: Business Unit Requirement
Curtains shall be placed outside the process area entrance.
Air velocity must be minimum 1600 feet per minute when measured 3 feet off the floor
The air column must be 3 inches thick & have a down and out sweep
All wall ledges to be coved 45 deg , so dust doesn’t build up and so no water remains from Business Unit Requirement
condensation or from cleaning and sanitizing. As far as possible the coving should be done
towards the less sensitiv areas.
Put self-closing devices on all doors in processing areas. Business Unit Requirement
Build all doors and windows with tight-fitting frames made of stainless steel or aluminum. Business Unit Requirement
Install only windows that don’t open.
Seal all seams between walls and roofs or floors. Business Unit Requirement
Processing and Filling Areas - Air Handling Units

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For combiblock/ Ergo block rooms in PET Lines : HVAC with 5 to 10 Air changes , Temp ≤
30 deg C, filtered through 5 micron, 10 to 15% Fresh air intake .
Is syrup preparation area provided with AHU for 15 to 20 airchanges through 20 Micron and Business Unit Requirement
positive pressure
Is raw syrup preparation and CIP area provided with AHU for 15 to 20 airchanges through Business Unit Requirement
20 Micron and positive pressure
Is filling room provided with AHU for 15 to 20 airchanges through 20 Micron and positive Business Unit Requirement
pressure
Water supplied to the air wash unit is with 2-3 PPM chlorinated soft water. ( indirect cooling Business Unit Requirement
is recommended)
All AHU Air Filters to be designed with adequate prefilters to prevent frequent choking and ISO/TS 22002-1:2009 Requirement
to facilitate easy cleaning of Filters.
AHUs if use water circulation , same be designed to prevent moisture particles entering the ISO/TS 22002-1:2009 Requirement
duct / Process areas. Also be designated to facilitate auto water level control, easy water
change and cleaning of system.
Does the positive pressure sytem provided is able to exhaust the odors, steam,condensate, ISO/TS 22002-1:2009 Requirement
and fumes generated during production and during CIP? (Review no. of air changes with
cfm meter)
All Filters; Prefilters- 5, 10u & HEPA filter are monitored to provide greater than 99% ISO/TS 22002-1:2009 Requirement
efficiency.
Are gauges provided in the filters on AHU to routinely measure the pressure differential ISO/TS 22002-1:2009 Requirement
across the filters?
All the joints in AHU are thoroughly sealed with silicone sealant to prevent any leakage. ISO/TS 22002-1:2009 Requirement
Are the ducts provided made of G.I. smooth material and is made in small easy ISO/TS 22002-1:2009 Requirement
dismantalable components which can be easily scrubbed clean? Put clean-out doors in all
ducts so you can clean their interiors.
Are the discharge louvers in the process areas of white / off white in color to facilitate easy ISO/TS 22002-1:2009 Requirement
detection of dirt accumulation / Mold growth etc.
Are gauges provided to routinely measure the positive pressure in the processing areas? ISO/TS 22002-1:2009 Requirement
AHUs be suitably located to prevent sucking of Dust, Boiler soot, undesirable odors, ISO/TS 22002-1:2009 Requirement
insects, or verminetc. and easy access for Maintenance / Cleaning.
Place insect- and vermin-proof screens on all openings that take in air or exhaust it to the ISO/TS 22002-1:2009 Requirement
outside.
AHU Body to be powder coated G.I. or M S. Internal surface of AHU to be made in SS 304 ISO/TS 22002-1:2009 Requirement
to prevent corrosion of internal blower assembly
AHU shall be able to maintain 3 deg less than wet bulb temperature ISO/TS 22002-1:2009 Requirement
AHU ducting should not be done in ingredients storage area and process area. In case BU Requirement Requirement
ducting is not avoidable than hygienic design boxing of duct must be done

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Processing Areas- Floors & Drainage

Build floors from an easily cleanable material to a smooth finish that isn’t porous or toxic. ISO/TS 22002-1:2009 Requirement
Common materials include Acid Alkali resistant tiles or concrete coated with an impact
General - Processing areas resistant polymeric material or food grade Epoxy ,which resist water, steam, acids, and hot
alkali solutions.
PU screed / expoxy based flooring are recommended.
Provide enough properly sized drains in floors to handle the worst-case water load. Usually, ISO/TS 22002-1:2009 Requirement
this means at least one floor drain every 30 to 50 m² (300 to 500 square feet). Do not locate
drains beneath equipment.
Slope all floors in the processing areas to be self-draining. Usually, this means a drop of 10 ISO/TS 22002-1:2009 Requirement
to 20 mm per meter .
Are SS water traps of Chilly or equivalent make provided in all drains to prevent off odors? ISO/TS 22002-1:2009 Requirement
Are screen traps provided in all drains to prevent insects entry? ISO/TS 22002-1:2009 Requirement
Provide pipe from drip pans for conveyor lubricants to a drain and not to the floor. Business Unit Requirement
Put drip pans for conveyor lubricant, rinse stations and connect the same to a drain. Business Unit Requirement
Place all pipelines 15-20 cms from the walls to facilitate cleaning Business Unit Requirement
Are areas around pipes or ductwork passing through the walls sealed? ISO/TS 22002-1:2009 Requirement
Drain Covers should be of SS , fixed on a SS metal frame Business Unit Requirement
Do not locate drain below the equipment Business Unit Requirement
Process Areas-Walls & ceilings
Walls and ceillings should be washable,cleanable , non toxic and non porus. The material ISO/TS 22002-1:2009 Requirement
for walls and ceilings should be resistant to the cleaning system applied.
Ceilling of Filling and process room should be walkable type (Insulated puff panels ~60 to ISO/TS 22002-1:2009 Recommended
80 mm thick or RCC, or SS)
Are the walls and ceilings made of white colored material to minimize contrast between ISO/TS 22002-1:2009 Requirement
work and surroundings and to give max lighting for better lighting and reducing shadows?
Protect all conveyor lines ( Slat / air conveyors) moving into or out of the bottling hall well Business Unit Requirement
protected by air curtains, Plastic Strip curtain
Don’t use wood as a construction material or in desks,chairs, and other wooden fixtures in ISO/TS 22002-1:2009 Requirement
the processing area.
Syrup-tank openings or fillers should not be directly located under support beams, pipe Business Unit Requirement
work, or light fixtures?
Are adequate number of Pest repellant with glue traps provided at entrance(outside) of ISO/TS 22002-1:2009 Requirement
each process area for insect control? At a height of 5 ft.
Clearance of 60-120 cm between equipments and nearest wall provided. Business Unit Requirement

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Provide enough hot water hose-down station / or movable onsite hot-water generator in Business Unit Requirement
each processing and filling area?
Provide SS hose hangers and ventilated end caps for the storage of flexible hose , ( Spring Business Unit Requirement
loaded hose hangers is recommended )
Provide stainless steel cabinets for storage of miscellaneous pieces of equipment. Use Business Unit Requirement
storage cabinets that have sloped tops and at least 10 to 15 cm (4 to 6 in.) clearance
between the bottom of the cabinet and the floor to facilitate cleaning.
Processing Areas- lighting Fixtures
Mount all lighting fixtures flush to the ceiling and are provided with protective shields? ISO/TS 22002-1:2009 Requirement
Lighting within the processing areas and outside should meet local regulations for workers ISO/TS 22002-1:2009 Requirement
safety?
Measure light intensity at the working surface from which the task is performed: ISO/TS 22002-1:2009 Requirement
− 300 lux (30 foot-candles) in the shipping, receiving, and
storage areas
− 500 to 800 lux (50-80 foot-candles) in the syrup and filling rooms
- 400 lux (40 foot-candles) in the blowing and packaging rooms
− 750 to 1000 lux (75 to 100 foot-candles) in the laboratory
Plant is not using mercury vapour bulbs. ISO/TS 22002-1:2009 Requirement

Process Areas-Equipment ,Piping and Utensils
Are all equipment pipe work and utensil in contact with ingredients or finished products are Business Unit Requirement
inert to the material handled, easily cleaned, and self-draining?
Are all food contact surfaces should be constructed of corrosion resistant, nontoxic, and Business Unit Requirement
sanitary stainless steel AISI type SS-304 / SS-316 (for handling ambient product) 2B or
better finish and SS-316L(for hot product applications) with a 2B or better finish?
Are all non-product contact surfaces which are exposed to splash, spillage, or soiling and Business Unit Requirement
which require frequent cleaning, constructed of an appropriately corrosion-resistant, non-
absorbent, and smooth material?
Are all stainless steel pipe work passivated before commissioning the equipment? Business Unit Requirement
Are all flexible hoses are of approved materials, if used to transfer ingredients or finished Business Unit Requirement
products? (USFDA/NSF / Food grade certificate )
Is pipe work designed and installed to avoid dead ends or dead legs? [Sweep assessment Business Unit Requirement
report to be done and provided]
Are equipment and pipe work installed to supply enough space for cleaning? Allow 60 to Business Unit Requirement
120 cm (2 to 4 feet) clearance around all equipment for access to clean and maintain it).
Is adequate number of instruments and controls at each processing & storage area used for Business Unit Requirement
regulating, measure and record temperature or other conditions critical for product?
Are all motors, pumps, gearboxes, and tank agitators designed and installed to prevent Business Unit Requirement
contamination?

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Are drip pans put under all overhead conveyor motors or gearboxes? Business Unit Requirement
Are pumps and agitators sealed to keep lubricant, gear oil, from penetrating or leaking into Business Unit Requirement
a product? Oil / grease used in processing areas must be of food-grade quality
No corrugated types of sheets for ceilings shall be used to avoid accumulation of dirt and Business Unit Requirement
dust etc.
Asphyxiant Gases: Inclusion of Audio visual alarm with oxygen meter in filling halls + Business Unit Requirement
requirements no 40 to 47 of compressed gases.
AHU ducting should not be done in ingredients storage area and process area. In case Business Unit Requirement

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Blowing room be physically separated from other areas . The room to be preferably of Business Unit Requirement
insulated puff panels
Blowing Room be Air-conditioned to ensure Temp of 20 to 25 deg C - with 15-20 air Business Unit Requirement
changes/hour or more as reqd for operating comfort and to avoid foul smell. (ensure a
monitoring device is installed)
Blowing room to be provided with atleast 8 feet glazed tiles on the walls (If not made with Business Unit Requirement
insulated Panels)
Build floors from an easily cleanable material to a smooth finish that isn’t porous or toxic. Business Unit Requirement
Common materials used are glazed tiles, concrete coated with an impact resistant
polymeric material or food grade Epoxy.
Are the floors capable to carry the frequent traffic of handtrolleys? Business Unit Requirement
All lighting flush mounted with safety fixture. Business Unit Requirement
Clearance of 60-120 cm between equipment and nearest wall provided Business Unit Requirement
Are adequate no of Drains provided protected with screen. Slope all floors to be self Business Unit Requirement
draining. Slope to be of 10 mm per meter. There is a provision of collection of condensate
and directed to nearby drain.
Is adequate Lab space and equipment provided in this room to carry out relevant Blown Business Unit Requirement
Bottle tests?
RCC roofing/ walkable false ceiling with no dust accumulation Business Unit Requirement
Is the ceiling provided of a smooth cleanable material either glazed tile or washable paint. Business Unit Requirement
No antifungal paint to be used.
Is the Blowing room layout so designed that traffic from unauthorized person is prevented? Business Unit Requirement
Limit the number of doors and openings between processing areas and other parts of the Business Unit Requirement
plant.
Blowing Room
Put self-closing devices on all doors to this area? Business Unit Requirement
Are proper dispensing-hand sanitizing stations provided at each entrance. Business Unit Requirement
Build all doors and windows with tight-fitting frames made of stainless steel or aluminum Business Unit Requirement
( no wood to be used). No openable Windows
Slope all wall ledges so dust doesn’t build up and no water remains from condensation or Business Unit Requirement
from cleaning and sanitizing.
Blowing room be provided with Day storage area - at least 8-10 hours storage for Preforms Business Unit Requirement
at 20 to 25 deg C, for Preconditioning.
All other Utility requirements including the chiller shall be out side the blowing room. Business Unit Requirement
Bottle conveyor shall not pass though low hygiene zones, e.g. utility section, common
corridors, botle washing area, warehouse, packing areas etc.

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Provide cover and protect preforms sanitarily. Ensure preforms are free from foreign BP-RQ-250 Requirement
material prior to blowing. (Applicable to Block system - No rinse requirement)
Provide proper enclosue of Preform drop to the hopper and transportation to the blower to BP-RQ-250 Requirement
protect from particle contamination (Applicable to Block system - No rinse requirement)
Provide proper enclosure of bottle blowing system and bottle conveying up to filling to BP-RQ-250 Requirement
protect from particle and micro contamination. This includes the top and sides at minimum
(Applicable to Block system - No rinse requirement)
Combiblock room must be physically separated from warehouse to avoid cross-
cotamination, i.e. microbiological, phsycial contamination (dust ingress), fork-lift fumes,
pests, off-odour; for controlled access.
dust etc.
Separate the area with walls or enclose it with chain-link fencing. The water treatment plant Business Unit Requirement
has to be covered.
Design it to prevent or restrict non-essential people from entering.
Design of WTP shall be ensuring pest free enviorment ie Birds,insects etc
Limit the number of doors and openings between the water-treatment area and other parts Business Unit Requirement
of the plant
Build doors and windows with tight-fitting frames made of aluminum or epoxy-coated steel Business Unit Requirement
All the doors equiped with self closing devices. Business Unit Requirement
Area designed to prevent or restrict traffic by non-essential personnel Business Unit Requirement
Cove (add a curved surface) and seal all wall or floor joints to make them easy to clean. Business Unit Requirement
Are all the wall edges sloped to pevent accumulation of dust and debris and facilitate Business Unit Requirement
cleaning.
Floors of plants are easily cleanable and made of quarry tile ,epoxy aggregate or polished Business Unit Requirement
concrete.
Water Treatment Area
Make sure drains are large enough to handle the worst-case water load. Size drains for Business Unit Requirement
back and forward washing of sand filters and carbon purifiers to handle atleast three times
the maximum flow rates of these units.
Floors sloped 10 mm every meter ( Self draining floor ) Business Unit Requirement
All the drains are equipped with screen traps of adequate size to minimize clogging of drain Business Unit Requirement
pipes and to provide accessibility for cleaning.
Ceiling easily cleanable and made of non-porous and non-toxic material. Business Unit Requirement

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Water Treat
No Wooden fixtures such as desks and chairs etc. Business Unit Requirement
All the doors of plant are easily cleanable and made of non-porous and non-toxic material. Business Unit Requirement
Plan opening to reaction tank not located under support beams ,pipie work or light fixtures. Business Unit Requirement
All lines must be colour coded and must be free from dead end,especialy at Pressure Business Unit Requirement
gauges
All frontals of ACF must be of Stainless Steel Business Unit Requirement
All the weldings should be of TIG with argon as inert gas ,there should not be any burrs at Business Unit Requirement
the inner surface of line
The lines must be passivated as per as per KORE requiremnt Business Unit Requirement
Potable water supply system should be separate and lablelled ISO/TS 22002-1:2009 Requirement

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Adequate, suitable and conveniently located changing facilities and toilets should be ISO/TS 22002-1:2009 Requirement
provided in all establishments.
Plants has toilets ( Both for man & women) that are easily accessible, don’t open directly ISO/TS 22002-1:2009 Requirement
into production, processing, storage and packaging area and are equipped with self-closing
devices but should be within 60m of the above areas.
Provide toilets with hot and cold potable water preferably from a combination supply fixture, ISO/TS 22002-1:2009 Requirement
for every ten employees or portion thereof, up to 100 persons. For example, 93 employees
must have ten toilets.
Equip each toilet with: ISO/TS 22002-1:2009 Requirement
− Liquid hand washing Soap and sanitizer
− Disposable hand towels or hot-air dryers (no cloth towels or continuous cloth rollers)
− Covered trash receptacles
-Continious potable water supply
Use easily cleanable, non-porous material to build floors, walls, ceilings, partitions, and ISO/TS 22002-1:2009 Requirement
doors of toilets
Cove (add a curved surface) and seal all joints between the floor and walls of the toilets to ISO/TS 22002-1:2009 Requirement
Personnel Hygiene
ease cleaning.
Slope floors to floor drains and put water traps in the drains to prevent sewer odors. ISO/TS 22002-1:2009 Requirement
Supply enough ventilation to all toilets. Don’t place extraction vents near any air intake that ISO/TS 22002-1:2009 Requirement
could recycle the exhaust into the plant.
Post signs in all toilet facilities for Personal Hygiene Practices. Place signs where they are ISO/TS 22002-1:2009 Requirement
easy to see, such as above sinks or on exit doors.Use local languages or pictorial diagrams
wherever necessary /applicable
Notices should be posted directing personnel to wash their hands after using the toilet. ISO/TS 22002-1:2009 Requirement
Is the change room provided with hand wash station and is equipped with soap, Disposable ISO/TS 22002-1:2009 Requirement
hand towels or hot-air dryers (no cloth towels or continuous cloth rollers)?
Are proper and clean apron / uniform, headgear,beard cover and dedicated footwear ISO/TS 22002-1:2009 Requirement
(safety shoes )provided to workmen?
All employees working in process area should comply to jewllery policy. Business Unit Requirement
Plant personel should cover their hair, beard and mostaches completely and maintains a ISO/TS 22002-1:2009 Requirement
high degree of personal cleanliness while on duty, and at all times while so engaged, wear
cap, dedicated footwear & Apron / uniform
Are all Employees coming in contact with the Product contact surfaces or primary packaging ISO/TS 22002-1:2009 Requirement
material medically examined annually & screened for presence of contagious diseases?
Certificate exists on site.
Are employees instructed to report health conditions that might contaminate food, food ISO/TS 22002-1:2009 Requirement
product surfaces or food packaging materials to their supervisor?
All employees working in process area should wear appron / uniform having no buttons . No ISO/TS 22002-1:2009 Requirement
pockets above vest level.

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Use potable water to generate steam for sanitizing. Business Unit Requirement
General Guidelines Use boiler additives that meet regulatory requirements for use on food contact surfaces , Business Unit Requirement
where culinary steam application is required.refer to BU specific culinary steam
requirements
Utilities
AHU suction ducts should not be located at unhygenic places ie ETP,DG Room,Toilets etc Business Unit Requirement
Cable tray / cable laying design must conform to EDHEG standards http://www.ehedg.org Business Unit Requirement
Doc 44, Hygienic Design Principles for Food Factories, 1st edition Sep 2014
Equip all air compressors with appropriate traps, filters, and dryers. Business Unit Requirement

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Signed Off Organistation chart of the unit Business Unit Requirement

Designated Production Manager Engineering / Science graduate with more than six years Business Unit Requirement
experience & has Technical expertise to run the unit.
Designated QA Manager Food Technologist / Science post graduate with more than six Business Unit Requirement
years experience in similar food industry , separate and independent of Production,
reporting to level of management not conflicted by manufacturing demands. Has authority
to stop the line whenever situation warrants.
Manpower
Adequate manpower as per standard maning provided by BU Business Unit Recomendation
Microbiologist must be trained and certified by EASC Pune Lab Business Unit Requirement
Beverage Sensory Leader must be trained and certified by EASC Pune Lab Business Unit Requirement
All Line Equipments have dedicated well trained Operating staff for atleast two shifts. Business Unit Requirement
Operators for all Line and Process equipment should have OEM training certificate. Business Unit
Plant has adequate number of trained bottle inspectors to follow 10: 20 rotation at each Business Unit Requirement
Inspection station & who are annually tested by a recognized practitioner to meet 20/20
vision.
Has the Training for good Hygiene practices provided for all new staff (include contract) ISO/TS 22002-1:2009 Requirement
Is eating food and storage of personnel belongings prohibited inside the processing areas? ISO/TS 22002-1:2009 Requirement
All toilet floor ceilings constructed with easily cleanable non-porous material. ISO/TS 22002-1:2009 Requirement
All floor to wall junctions sealed / coved to facilitate effective cleaning. ISO/TS 22002-1:2009 Requirement
Slope floors to floor drains and put water traps in the drains to prevent sewer odors. ISO/TS 22002-1:2009 Requirement
Proper arrangement of First aid ISO/TS 22002-1:2009 Requirement
Personnel Facilities
Is their designated and clearly marked covered area for eating food, which is away from the ISO/TS 22002-1:2009 Requirement
plant main building to avoid cross contamination?
Are plant personnel (Temporary/ Permanent) bearing medical certificate for no ISO/TS 22002-1:2009 Requirement
communicable diseases are only allowed into the processing areas?
Is smoking tobacco, chewing tobacco, gum or betel, sneezing and coughing over ISO/TS 22002-1:2009 Requirement
unprotected food strictly prohibited in the factory premises?
Is the access to the processing areas only assigned to visitors if his/her visit is unavoidable? ISO/TS 22002-1:2009 Requirement
Is access to the facility restricted and records kept for the visitors to the Facility? ISO/TS 22002-1:2009 Requirement
Are visitors to the facility informed verbally or by a brochure to comply with the personnel ISO/TS 22002-1:2009 Requirement
practices to be respected by them during their stay?
Does the plant have a designated tour guide / personnel to handle visits by regulatory ISO/TS 22002-1:2009 Requirement
bodies?

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Does operation have authorised pest control provider and use only authorised insecticides, ISO/TS 22002-1:2009 Requirement
conforming to local regulations?
Plant must comply to BU specific "Pest control requirement" document Business Unit Requirement
Does Plant have a documented Pest Management program which identifies target pests ISO/TS 22002-1:2009 Requirement
and address plans, methods, schedules, control procedure and where necessary training
requirements.
Pest control Program shall include record of type and qty , and concentration of pesticides ISO/TS 22002-1:2009 Requirement
used, where when and how applied and the target pests.
Are records maintained by Plant management of the assessment by pest control service ISO/TS 22002-1:2009 Requirement
provider before finalizing Pest Control Program?
Are only the Insecticides and Rodenticide specified by Division allowed for use in the ISO/TS 22002-1:2009 Requirement
plants / warehouses? (Any change in the Insecticides /Rodenticide from the list must be
approved by the Div.QA prior to use).
Are MSDS sheets for each of the Pesticide used in the facility provided by Pest Control ISO/TS 22002-1:2009 Requirement
Contractor stating the safety instructions in case of accidental ingestion or inhalation?
Pest Control
Whether a map of facility with identification of pest control activities and agents in each area ISO/TS 22002-1:2009 Requirement
clearly defining the roles and responsibilities of qualified personnel is developed and
displayed?
Plant should have MAP of detectors and traps. ISO/TS 22002-1:2009
Is the overall design of the pest control program effective in preventing potential ISO/TS 22002-1:2009 Requirement
contamination of ingredients and finished product from pests or vermin?
Is the facility and surroundings periodically examined for evidence of infestation by pests ISO/TS 22002-1:2009 Requirement
and vermin?
Are anticoagulant rodenticides type poisons with baits applied only in non production areas ISO/TS 22002-1:2009 Requirement
or outside of plant?
Are there adequate no. of pestoflash or similar physical device used to trap insects or ISO/TS 22002-1:2009 Requirement
vermin in the production, processing & storage areas?
Are dosage and frequency of residual and nonresidual insecticides and rodenticides ISO/TS 22002-1:2009 Requirement
complying with the local regulations and division specifications and documentation of
compliance with applicable laws available?
Is the specific responsibility for the supervision of the pest control program been assigned? ISO/TS 22002-1:2009 Requirement
Microbilogy lab does not open directly into the production area ISO/TS 22002-1:2009 Requirement
Incubation room must be separate from plating (laminar air flow) area in Micro lab
Micro laboratory must have dedicated AC / AHU and position of the AC / AHU louvers must
not be directed towards the Laminar air flow front
All wall edges sloped to prevent accumulation of dust or water and to facilitate cleaning Business Unit Requirement

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All the floors constructed using quary tile or special vinyl type flooring material which are Business Unit Requirement
easily cleanable
Use only counter tops built from smooth, non-porous material that resists stains. Business Unit Requirement
All floor drains equipped with water trap Business Unit Requirement
All drains equipped with trap of adequate size to minimize cloging and provide cleaning Business Unit Requirement
Business Unit Requirement
All walls constructed to 8 feet tiles and painted with approved slow release anti-fungal paint.
All doors constructed by non- porous material Business Unit Requirement
Doors equipped with self closing device Business Unit Requirement
General - Laboratory
Doors installed with tight fittings Business Unit Requirement

Install all fume hoods so they vent outside the plant and away from air intakes that could
recycle the exhaust back into the plant. Be sure these hoods meet local regulations.
Counter tops constructed with smooth ,strain resistant ,non-porous material Business Unit Requirement
Air Conditioned & maintain 20*C Business Unit Requirement
Water facilities to acid /base resistant SS sinks provided Business Unit Requirement
Piped treated water to the laboratory provided. Business Unit Requirement
Storage facilities for all laboratory chemicals and glass ware provided along with a separate Business Unit Requirement
cabinet with controlled access for toxic chemicals.
Adequate storage facilities for retention samples in terms of racks available. Business Unit Requirement
Is an air supply from compressed air provided in the laboratory for conducting secure seal Business Unit Requirement
test?
Provide power to the laboratory through several power lines. Protect these separate lines
from the plant’s other power sources to keep from spiking the laboratory equipment. In
some cases you may need voltage stabilizers or UPS to ensure the equipment wil
dust etc.
Hand Wash stations: Handwash station must be made available for 100% of workmen
moving in production area.

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Present Corrective Responsibil

Target Date
status Action ity

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Assessed by:
Assessment Date:
ITEMS
PET Blower
Revision Date :01/07/2015 # Classified - Confidential

Air Conveyers

yers
Bottle Conveyers
Bottle Rinser
Bottle Filler

Bottle Fil
Capper

code and Label) - Two
re and one for date code Warmer Mix - Processor
Revision Date :01/07/2015

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Full Bottle Inspection (fill height, closure, date code and Label) - Two
Case Packer Coding Machines Labeller individual Inspection one for fill height and closure and one for date code
and Label
Revision Date :01/07/2015

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Case Packe
General
ASSP

Assessed by:
Assessment Date:
Requirements
If Combi block line with no water rinse option is selected, are following additional requirements are in
place
• Does Blower have preform dedusting system with ionised air, ionised air interlock with Blower
• Ensure preforms are free from foreign material prior to blowing.
• Fully enclose the following:
• Preform drop to the hopper and transportation to the blower to protect from particle contamination.
• Bottle blowing system and bottle conveying up to filling to protect from particle and micro contamination.
This includes the top and sides at minimum.
• Transport blown bottles directly to the filler; bottle storage is not a part of the no-rinse system.
• Cover and protect preforms sanitarily. Discard preforms that drop on the floor
Preform de-dusting and closure de-dusting equipment test report & certificate which demonstrate
effective working of de-dusting system must be shared by OEM. OEM must demonstrate the
effectiveness of dust removal during validation run as per BU protocol
Are the critical measurements (such as height, diameters, shoulder contour, and height to the support
ring) of the bottle dimensions are within specifications? (Sampling as per packaging reuirements)
Is the material distribution profile measurement of weight at specific cylindrical segment (such as
shoulder, panel and base) of a bottle always within the specifications? (Sampling as per packaging
reuirements)
Is the bottle wall thickness profile consistency when measured with magnameter is found within specs for
each section and also for the four diametrically opposite readings taken in each section? (Sampling as
per packaging reuirements)
Is the bottle weight, Brimful and fill point capacity of the Blown Bottles agree as per the specs?
Do the bottles pass the drop test?
Do the bottles pass the bottle burst test? All equipment & consumables used must pass the safety
requirements
Is the Top Load on the blown bottle within specs? Record where the bottle failed (i.e. crushed foot,
shoulder dent, etc.)
Is a one spare Mold for each set of mould provided?
Molds set and cavity traceability facility for Blown Bottles.
Is an automated Gaylord dumper provided ?
Is SS Platform for preform loading into the hopper provided, in case of preform supply in small boxes
Preform hopper must be covered to avoid cross contamination with pest / dust ingress
Preform conveyor shall be designed and routed in a way that ensure ease of inspection & cleanability.
Suitable equipment / platform / scafolding arrangement must be available
Empty Bottle Inspection must for line speed >600 bpm
Does the machine have Preform temperature indicator at the entry and exit of the heating oven, and with
interlock to reject preforms at oven exit which have not achieved the desired temperature ?
All lamps must be functional in the oven and sufficient spares kept for contigency
Is the machine provides full security of the thread, finish and the neck area of the preform in the Linear
oven?
Does the machine provide full security from contamination from oil and moisture?
Is the bottle ejection system from the mold prevents deformation of the blown bottle?
Is the temperature settting of Blow Mold provided with minimum accuracy 1 oC?
Are different programmable settings provided wherein a recipe for a particular preform and bottle pack
size can be stored?

Are all process control parameters (preform temp, oven temperature, neck / mould cooling temp. etc.)
are interlocked and can be retreived from the PLC.
Preform loading system be automatic or un-touched by Human hand and properly covered.
Blower be provided with Adequately sized extraction hood above the Blower to extract heat from the
oven. The ducts for the same must be adequately protected to avoid any pest / dust etc. ingress
Air used for preblow & blowing be absolutely Oil & Moisture free and filtered thru 0.2 Micron filters, just
before use.
Moulds used be of Approved make & material with location specific traceability
Suitable safe arrangement be provided to store Moulds in Clean condition. It is recommended to use SS
trolleys with proper paddings & protective covering for mould to be provied in the blowing room
Blower be provided with Deformed Preform Detection & Rejection system before entering the machine.
All Preform & Bottle Neck contact surfaces be of SS 304 / 316, Teflon / EPDM or any equivalents
appropriate for Food Contact applications.
Blower be provided with a suitable system to ensure that bottles are discharged Automatically in to the
Air Conveyor system, un touched by Human hand.
Blower be Provided with a suitable control system to ensure that Preforms & Blown Bottles are not held
any where in the Blower if the Blown bottle conveyor is full.
All Utilities for Blower - like 40 bar / 7 bar compresor, Air Drier, Chilled water Unit etc, be adequately sized
There shall be no system of storing blown bottles if suitable automatic ( Untouched by human hand )
system not provided for collecting & loading to conveyor .
Air recovery is provided in the blower
Online preform inspection for lines for detecting gate area defects, ovality, seal surface inspection, seal
registration inspection, color contamincation, side wall inspection, end cap inspection, preform length,
preform top inspection, barrel etc. Must for lines above 600 bpm
All bottle contact parts be of SS 304 / 316 or Teflon / EPDM or any equivalent for food contact surfaces,
with smooth finish for least friction and easy cleaning.
Air conveyor should be routed through clean areas only, wherever it is leaving the clean area it should be
encased in transparant covers.
Plant to have an air conveyor cleaning program
Support guides for bottle ' neck support rings ' made up of SS 304 and is finished to a frictionless
surface.
Effective particle filters are provided on all air blowers suction end and a defined cleaning and change
frequency must be deifned
Are pressure gauges provided across air filters for periodic monitoring and for maintenance and cleaning
of filters.
Are the air conveyer channels made of SS 304/316 polished to sanitary finish?
Are the guides provided made of smooth teflon material?
Are the conveyors so designed that blown bottles softly impact each other and do not damage each
other during the transfer?
Are the conveyor parts capable to withstand regular cleaning and disinfection with alcohol?
All fans of the blowers are made of fibre glass or aluminium and . Noise level should not be more than 80
db
Bottle side adjustable guides are made of SS 304 and covered with antifriction material.
Bottle combiner and divider ( if any from more than 1 lane ) with flow of bottles regulated by means of
PLC/Logic controlled gates
Air conveyors is designed to ensure no jams of Bottles.
Air conveyors are designed to avoid bottle scratching outside the label panel area especially during line
stop.
Conveyors are designed and adjusted to eliminate the risk of bottle falling down.
Air Conveyor be provided with easy Adjustable fittings to facilitate quick pack changeovers
Are All conveyor metal parts in filling room made of SS 304 or food grade acid resistant material which
can withstand temperatures upto 90*C?

Inspection station be provided of standard design, just before the product is packed in Cartons / Shrink
wraps.( After Coding & Labeling ). Speed not exceeding 200 BPM per station.
Inspectors be provided with chairs having a backrest and footrest with Adjustable height.
Lubricant used for the Conveyor system be specifically approved for PET
Are All conveyor metal parts in filling room made of SS 304 or food grade acid resistant material which
can withstand temperatures upto 90*C?
All guides of conveyor to be teflon coated
Conveyor CIP mechanism or the below chain nozzles for cleaning.
Drip trays installed connected to drains
Centralized Lubrication system installed. Use dry lubrication
No exposed cabling
Are conveyors so designed to ensure there is no undue pressure between bottles in case of conveyor
stoppage and where applicable buffer collection tables are provided?
Is a speed sychronization provided with the Filler speed ?
Rinser product & bottle Contact parts made of SS304/ SS316 /PTFE / EPDM or other approved food
contact material. Smooth 2B or better finish to ensure no microbiological growth?
Rinser /filler/capper should be monobloc
Rinse water pressure shall be 2.5-4 kg/sq.cm or as per manufacturers recommendation.
Rinser should be capable of neck handling
Is no manual handling between bottle blower to rinser is ensured
Is the rinse water used meets the specifications for potability as per IS 10500
Is the residual water in bottles at rinser outlet < 1.5 ml/1000 ml?
Filler / Rinser be interlocked to stop filler, if no water / below min. water pressure
Is the rinse water passed through a 5u filter to arrest all particulates?
Rinser should be capable of handling bottle from neck.
Is the Rinse water chlorinated to 1-3 PPM chlorine level? Does the filling stops if any time the chlorine
level is < 1 ppm?
Is rinse water used should be < 100 ppm total alkalinity and no P alkalinity process water? pH should be
between 6-8
Lubrication to moving parts to be done by approved food grade grease.
Is a CIP connectivity provided for cleaning and sanitation of each rinse nozzle?
Are all containers that have been rinsed & filled previously and returned are removed and destroyed?
They must not be washed, refilled or stored in the production facility.
Is the rinser provieded with special non-clog type rinse nozzles with a validated flow pattern design?
Rinse water recovery tank and pump are provided . Recovered rinse water should go back to backwash
recovery Tank.
Rinser grippers and jet allignment must be in such a way that ensures effcetive rinsing covering all inner
surfaces
Total Bacterial count in Rinse water should be less than 25 per ml.
Is the Filler of Approved Make & Model

Are product Contact surfaces made of SS 304/ SS 316 / PTFE / EPDM or other approved food contact
material
Is the beverage, entering the Filler pass thru SS 316 strainer of 100 mesh
Is the beverage, entering the Filler pass thru Magnetic Strainer -10000 gauss
Is the filler capable of bottle handling thru neck holding.
Filler shall have SS ( glycerin filled ) Temperature and Pressure gauges of at least 3 inch dia. - for easy
visibility
The filler Bowl be provided with motorized height adjustment system for easy change overs.
Filler product inlet to have sanitary sampling point
Filler be provided with Centralized / Easy accessible lubrication system
Filler be provided with Safety doors ( to stop filler if doors not closed )
Filler shall have CIP provision with dummy bottles / CIP cups to ensure CIP return thru individual vent
tubes.
All product contact surfaces of filler shall be capable of withstanding hot caustic (2%) and temp of 95
deg C for 30 mins.

Filler shall be capable of ensuring consistent Filling Level & Net Content to achieve minimum Cp / Cpk of
1.0
Filler shall have suitable mechanisms - like Pre-evacuation, Bowl air vent release system to ensure Air
Content in product < 2.5 ppm
Filler shall have CO2 Counter pressure system
Bowl Low and High level interlock with machine operation
Suitable safe arrangement in SS to be provided for storing change parts in clean condition within the
clean room. It is recommended to use SS trolleys for change parts
There should not be any water or product stagnation on the table top or any other parts in the filler
Filler shall be sanitary in Construction, cleanable and by Design to produce company products.
For combi blocks filler - if clean air cabinet is selected , fillers shall have positive pressure inside the
filling enclosure as recommended by OEM
Does filler have interlocking for the positive pressure inside block. Filler must stop if it is less than the
positive pressure as recommended by OEM
Capper shall be of Approved Make, Model & Design

Capper shall be part of the filler / Monoblock capper
Online Closure inspection system for all lines to check temper edivence presence & damage, color,
ovality, molding defects, foreign particles etc.
Capper be capable of ensuring closure torque of 12 + / - 2 inch pound on each head, Cpk > 1 ( Target
of 12 should be settable as per closure requirement)
Capper shall be provided with a suitable Reservoir with cover and Elevating mechanism for closures to
be moved to capper Hopper, automatically, as per capper requirements, during operation
Closure Reservoir & Elevating mechanism shall be of SS construction & the same be easily cleanable
and shall protect closure dust if any, contaminating the product.
Are all filler parts (includes capper rinser) polished to 2B or better finish to ensure better microbiological
safety?
Do all Capper heads meets the static torque requirements as specified by the Cap suppplier?
Are gauges provided to help aid Capper height settings?
Do the Top load on the Capper head at the designated setting meets the specs laid by the Cap supplier?
Is a culiniary steam jet directed at the Closure inside provided at the capper chute?
Is a sterile air jet provided to remove the physical dust load from the closure?
Is the Closure Hopper provided outside the clean room fiiling area?
Is the Closure transferred to the Capper by HEPA filtered air conveying system?
Is the bottle protected from turning while Cap application?
Are effective seals provided on each capper head to arrest lubricant/grease leaks which may
contaminate the product?
Is Lubrication to moving parts is done by approved food grade grease?
For High sped combi line , is there a camera based empty closure inspection system in the feed
conveyor ?
Are concealed UV lamps provided on the closure chute to effectively disinfect the closures?
Capper be provided with Motorized height adjustment system for easy change overs.
Closure conveyor shall be designed and routed in a way that ensure ease of inspection & cleanability.
Suitable equipment / platform / scafolding arrangement must be available
Mix - Processor shall be of Approved make & Model and Capacity of adequate capacity to match the line
All Product & Ingredients Contact surfaces be made of SS 304/ SS 316 / PTFE / EPDM or other
approved food contact material
All Pumps shrouds and PHEs cladding are in SS
In PHE the Beverage side pressure shall be higher than Glycol / Coolant side to prevent product
contamination in case of any leaks.
The entire Skid which mounts the necessary components, shall be of SS
UPS be provided to Control Panel.
Mix Processor be sized in such a way that, the flow is always >30 % of the rated Capacity

Same Mix Processor shall not be used for filling Different Packages, at the same time
Mix Processor shall be capable of achieving Product with in a Tolerance of + / - 0.05 for Brix and +
/ - 0.1 for Carbonation
Mix Processor shall be capable of Achieving Cpk > 1 with respect to Brix & Carbonation
Mix Processor shall have suitable Water Deaeration system to ensure not more than 1 ppm Oxygen in
the water
Mix processor have an auto CO2 cut off valve which gets activated in case of filler stoppage
All the components in Mix Processor should be of standard make as specified by specification
documents
Mix Processor shall have built in Safety & Alarm system to protect against fluctuations in CO2 & Air
Pressures and Beverage Temperatures - Blend stop beyond set points.
Mix processor shall ensure Beverage temp. of < 4 Deg C at inlet to Carbonation . Beverage chiller
should be capable to cool the beverage from 30 deg c to 4 deg C
The safety valves / rupture discs provided on pressure vessels be of SS & sanitary design.
Mix Processor shall have a suitable Water Deaeration system to ensure water of < 1.0 ppm DO
Mix processor shall be sanitary in Construction and by Design - suitable to produce company products.
Mix processor shall have CIP provision and system should be able to withstand Caustic solution ( 2 % )
and temp of 95 Deg C for 30 minutes.
Mix Processor shall have CIP cleanable in conjuction with filler only
CO2, Product water, Compressed Air pressure interlocked with the processor to trip the machine in case
of deviation than the set points
The audible alarm provided for product temperature varying from the set points
Processor to be provided with online monitoring and display of Brix and Co2 with Auto cut off capability
for out of specification parameters (Cobrix)
Voltage fluctuation safety
Processor to be provided with online monitoring and display of Brix and Co2 with Controller (Cobrix)
Warmer shall be of Approved Make & Model and Adequate capacity to match the line.
Warmer be capable of controlling the product temp of 22 + / - 2 deg C, at the exit. Beverage temperature
not to exceed 27°C for any product - pack
MOC of Warmer shall be of - SS 304 / 316 , including pumps and circulation lines. Warmer & all weld
joints shall be smooth & sanitary finish for easy cleaning. Bottle transfer chains / drives shall also be of
SS or any suitable materials to avoid rust / corrosion.
Is water heating with steam by indirect heating ( through PHE or THE )
Temperature control and Steam control valve shall be of standard & reputed make to ensure temperature
control of hot water with in + / - 3 deg C of set temperatures. Maximum temperature of any compartment
shall not exceed 40 deg C.
Temperature & pressure displays / indicators of reputed makes be suitably provided for easy
observation.
High and Low Temperature safeties be provided to stop warmer in case of deviations, with Alarm.
Auto liquid level controls with low level safety to stop the warmer with Alarm be provided.
Adequate controls & safeties be provided to ensure that product temp does not exceed 27 deg C,
including stoppage of pump sprays.
Water used in warmer not to exceed 100PPM alkalinity at any point in time, and chlorinated 1 to 3 ppm
soft/ treated water
Warmer be sufficiently be raised to facilitate easy cleaning below and all tanks be provided drain valves
to flush out the tanks fully.
Warmer shall have adequate safeties to avoid damage of bottles due to jamming etc.
Online auto Inspection for Fill level - low & high, 360 degree inspection of Closure, Date Code and Label
for all lines
Is the online electronic inspection unit is provided to ensures 100% inspection?
Fill Level detection Accuracy +2 mm / - 2 mm , with detection accuracy of 99.5 %

Is the unit able to detect and automatically remove botlles 99.9% of the time outside bottles without
closures ?
Is the unit able to detect and automatically remove canted closure > 1 mm with 99.5 % accuracy ?
Is the unit able to detect and automatically remove incorrect tamper evident ring > 1 mm with 99.5 %
accuracy ?
Is the unit able to detect and automatically remove bottles without date Code with 99.9 % detection
accuracy ?
Ovearll False rejection of equipment should not be more than 0.2 %
Before the validation run OEM need to set the line to ensure FBI rejections less than 0.3%
Product trial shall be conducted and data related to packaging, key process parameters must be shared,
before the actual validation run
Is an alarm signal syetem provided to announce the malfunctioning of the machine , and stoppage of
conveyor when inspection machine is malfunctioning .
Are programmable settings controls provided?
Are different programmable settings provided wherein a recipe for a particular preform and bottle pack
size can be stored?
Is the access to the PLC program protected by individual passwords, and consequently limited only to
authorised personnel?
Are all process control parameters can be retreived from the PLC?
Is the machine provided with height adjustment feature?
Is the online electronic inspection unit is provided which ensures inspection of Cap ?
Plant to prepare one set of challenge sample bottles-Uncapped bottles,loose caps, deformed taper proof
rings, non-existent tamper proof rings,tapered application of caps- in various proportions.
Lable Inspection - presence check with 99.9 % detection accuracy
Lable Condition - deviation more than 10 mm - check with detectiona ccuracy of 99.5 %
Labeler shall be of Approved Make, Model & Design and of adequate capacity to match the line
Labeler shall be capable of achieving the wrap around joints with in + / - 2 mm tolerance.
In case of pre- filler labbelling , air used for bottle pressurisation should be sterile air.
Is the machine constructed in a material which is not corrodable and can be easily cleaned out?
Are adequate safety doors provided on the Labeller?
For ERGO block, label inspection system with interlock is must
Does the glue is approved for PET package and ensure adequate bonding.
Labeler shall not damage the Bottles / labels, during the labeling operation.
Speed control based on infeed and discharge bottles
Is the Labeller provided with an electronic bottle counter?
Is the date coder of Approved Makes & Model and of adequate Capacity to match the Line speed.
( Lazer date code for bottle is recommended )
Date coder to be installed after capper and before inline filled bottle inspection ( in case of manual
inspection the date coding can also be done after warmer )
Are air jets provided before the coder for bottle surface drying . Use of Blower instead of compressd air
for energy saving is must .
Pressure switch on airline to Coder with alarm.( If Pneumatic ink Pump ) - For bottles
Is an alarm provided online to announce Date Coder failure and is the same interlocked to conveyor
main drive?
Coding machine capable of meeting Statutory & Company Requirements - For Bottles
Suitable, On Line, Carton / Tray Coder of Approved make & Model be provided of adequate capacity.
Is the Standby Coder for bottle and Carton/trays is available
Should be of Approved make and model. Is must for line speed above 200 bpm
Loading Table designed to cause no jamming of Bottles.
Case packer should not damage the cartons
Should be interlocked with infeed bottles
Should be provided with safety switches
Should be provided with pressure sensors and safety logic in case of damaged crates

Is Case Packer PLC controlled
Is mechanized roller conveyers provided for case conveying
All the drive which are exposed should meet the 360 deg machine safe guarding requirement
No dame to container like PET neck ring shaving in any of the line equipment
1. All conveyor bearing ends should have bearing cover to as a part of machine safeguarding
10. All the platforms provided in the blower, palletizer, line equipment should meet fall protection
requirement e.g. toe guards and swing gates
Interlock of temperature / flow or pressure on the bottom cooling (cold air system) with the filler so that
when the temperature / flow or pressure go beyond the set point then the filler must stop and an alarm
must be activated to address the condition.
AC for plasma and Interlock for AC (if there is any problem of cooling in AC, the Plasmax should stop)-
KHS is working on design for AC. which is expected to be ready by the end of the week. Post which
fabrication(in Germany) and commissioning will be done in plant.
AHU – Visual / alarm control in the filling hall for the operation (on/off) of the AHU and the water levels in
the AHU reservoirs (if no water, then AHU should not run)
Water flow to the base of the mould – interlock of the flow control (currently set at 200 l / min) with that of
the blomax so that any reduction in the flow shall stop the blomax.
Class 10,000 – Since there is a chilled air introduced into the filler block from outside to cool the base of
the bottle, the integrity of the Class 10k filling chamber is lost. It is recommended to have air filters on the
chill air blower air intake to ensure that the air blown into the filler block is of the class 10k quality.
6. Treated water used as lube - As a parallel activity alternate line lube is being developed together
with CCI, TCCC,KHS and Diversey.
HMDSN,HMDSO gas pipe line photo and Written confirmation from OEM that all safety and
environmental controls are provided.
Validation of air rinser as per BP-RQ-250
OTR data ( stressed & unstressed ) for the commercial bottle mold.
7 Days stress crack data (Random bottle samples to be taken from warehouse)
7 Days GV data (Random bottle samples to be taken from warehouse)
Warehouse inspection report – Visually Inspect the finished goods pallet on daily basis till 7 days and
report for Stress crack and leakers.
Transportation trail to be conducted, truck to be covered with heat resistant tarpaulin during the trial and
regular transportation post approval
All interlock as defined in the interlock checklist

Corrective
Reference Category Present status
Action/Details
BP-RQ-250 Requirement (if applicable)

BP-RQ-462 Requirement

Business Unit if required


Business Unit Desired



Business Unit Recommended









if applicable. To be changed
Business Unit
to requirement.
if applicable. To be changed
Business Unit
to requirement.




Business Unit- Equip
Requirement
specs documents










Business Unit recommended

Business Unit recommended





Requirement


Requirement



Responsibility Target Date Est. Cost

Facility Assessment Checklist for CSD PET - Process Equipments

Assessed by:
Assessment Date:
5 tank Auto PLC controlled CIP should be used. logic control should be PLC based for the CIP cycle
sequence with access control password.
CIP system to effectively perform 5 steps CIP cycle.and has option for hot water or cold water flush BP-RQ-750 Requirement
Auto-controls to be provided to ensure detergent concentration, temperature and recirculation time during
the CIP. PLC logic to be integrated to temperature recorder in return CIP line to control the recirculation BP-RQ-750 Requirement
as per specs.
CIP system to be built with safeties by using divert panels to prevent cross connections with other lines /
systems.
Hot water/ Hot lye/Acid tank to be of SS 304 / SS316 polished to 2B finish with cladding. The cladding
provided should be SS 304.
CIP tanks to be provided with a bottom drain valve, man hole, Inspection ladder, low and high level
switches with auto control. Thermowell provided for periodic calibration.
Return CIP line to be provided with screen filters to remove particulate remanant if any. BP-RQ-750 Requirement
Boroscopy for all process pipelines including WTP to be provided before validation run BU Requirement Requirement
Adequate drain size provided for draining the Hot Water/ Lye, Acid and also for the drainage to CIP return
line.
CIP system should have capability to achieve minimum 85 deg C water for Hot water sanitation at return
line. Temperature monitoring and recording facility provided in the return CIP line.
Cleaning & Sanitation
CIP design should permit flow rate not less than 1.5 m/sec in the largest pipelines. If flow rate required for
Equipment or object is more than 1.5 m/ sec by OEM , provide the same.
CIP tanks & Pumps and connected Pipelines be of SS 304 / 316 Quality and correctly sized as per the
CIP requirements.
Provide return CIP connection to each filling valve. CIP cups are provided. BP-RQ-750 Requirement
Is each end equipment provided with an effective detachable Rotary CIP spray ball connection? BP-RQ-750 Requirement
Does the CIP flow cover each and every part of the end equipment? BP-RQ-750 Requirement
Sequence of CIP tanks to avoid contamination BU Requirement Requirement
Mix tank Parts ( Agitators/Jet mix systems, Valves, gaskets) must be monthly dismantled and cleaned. BP-RQ-750 Requirement
Strainers and Magnetic traps before should be dismantled and cleaned manually every day before CIP is
performed.
Filler Valves should be weekly dismantled manually cleaned and then perform the CIP. BP-RQ-750 Requirement
CIP cycle should ensure that Filler snifts are backflushed every day and are weekly dismantled and
manually cleaned.

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Are Capper Heads and Closure hopper are manually cleaned every day? BP-RQ-750 Requirement
Are there written procedures, including schedules, for cleaning and sanitation? BP-RQ-750 Requirement
Are Frequencies for cleaning & sanitation activities for each piece of equipment defined & Inspections
done periodically to assess the housekeeping of the plant?
Are cleaning and sanitation records kept to demonstrate the effectiveness of the overall program? BP-RQ-750 Requirement
Do microbiological monitoring results and other monitoring results (i.e. residual detergent carry over
tests) indicate that the overall program is effective?
All passivated equipment checked for effectiveness of passivation. BP-RQ-750 Requirement
HMI and SCADA data must me secured continuously in an industrial PC BP-RQ-750 Requirement
CIP log data: CIP data logs must record: Time, Conductivity, temperature, forward and reverse flow rate
and real time CIP step being performed.
Are all equipment coming into contact with ingredients, syrup,or finished product in the course of
RF-MA-100 Requirement
preparation, handling and storage of sanitary design and free draining?
Is there sufficient clearance between the top of tanks and overhead structures, including the ceiling, to
permit access of personnel and equipment for operation, RF-MA-100 Requirement
maintenance, and cleaning and sanitation?
Are all syrup and ready beverage tanks are dome-top design containing no pockets, sags, or joints which
prevent free and complete drainage?
Plant is not splitting the syrup from Batch type raw syrup Tank .
(Splitting of Simple syrup can be done by using an intermediate simple syrup storage tank through mass RF-MA-100 Requirement
flow meter. Simple syrup brix should be more than 60 Bx)
Are all syrup and ready beverage tanks provided sanitary level gauges and are calibrated & also have
sanitary microbiological sampling points?
Are all Simple Syrup tanks provided with jet-type mixers? RF-MA-100 Requirement
Are all stainless steel pipework, Mix tanks, Filler, sterilizer,utensils are passivated before commissioning
the equipment?
Is the Precoat Tank provided has capacity approx two to three times the volume needed to fill the filter
RF-MA-100 Recommended
press and associated pipework?
Are all food contact surfaces made of AISI type 304 or 316 stainless steel with a 2B or better finish.
Ensure they are corrosion resistant, nontoxic, and sanitary?
Only use equipment, pipe work, utensils, and other materials (such as seals or gaskets) that can
Raw Syrup System
withstand hot sanitation at 100°C (212ºF).
Build walls and ceilings from a smooth, easily cleanable material that isn’t porous or toxic. RF-MA-100 Requirement
Digital weighing scale for sugar ( Cap 300 Kgs ; Least Count 1gm) RF-MA-100 Requirement

#
Raw Syrup Syste
Separate Digital weighing scale for auxilliary chemicals like PAC and Filter Aid. RF-MA-100 Requirement

#
Raw Syrup

Raw syrup tank of Adequate capacity and sanitary Design& Construction be made of SS316/ SS304-
2B finish., with suitable insulation . Clading be of SS with welded sanitary finish to prevent water RF-MA-100 Requirement
seepage.
Raw syrup tank be provided with SS hopper / chute assembly with device to prevent entry of steam /
water vapour and SS strainer / mesh to prevent Jute, Gunny bag, nuts / bolts / nails etc, for sugar RF-MA-100 Requirement
dumping
Raw syrup tank be provided with a suitable sanitary system to heat the syrup to 85 deg C ( in not
exceeding one hour) and to maintain the same temperature - with adequate controls & Indicators.
Is the filter press (in SS316/304) large enough to filter the largest expected batch of simple syrup in one
hour with Operating pressure not exceeding 3 kg/cm2 & differential pressure exceeding 1kg/cm2?
Is the filter press equipped to have a facility for smaller batches by using suitable spacers? RF-MA-100 Requirement
Is suitable sanitary cooling system provided with to ensure that the filtered syrup temp at the time of
entering ready syrup tanks, is always less than 25*C?
Is the sugar syrup cooling system provided with pressure measurement gauges on each stage of sysrup
cooling?
Is an accurate water meter with totalizer in SS 304/316 provided to take measured quantity of water in
Raw Syrup tank?
Ready syrup system shall be provided with Mass flow meter of reputed make to measure water
accurately, to prepare ready syrups .
Ready syrup tanks be provided with sanitary & CIPable level glass assembly and shall be Accurately
Calibrated with marking for at least every 50 liters for tanks of 6 KL & lower and 100 liters for larger tanks.
Does the tanks have mass flowmeter of SS in sanitary construction, to accurately measure the raw
syrup for preparing ready beverage.
Ready Syrup system be provided with adequately sized Dry base dissolving system / Concentrate
transfer system with suitable SS pipe connector to tank / RJM , mounted on a freely movable trolley. RF-MA-100 Requirement
Transfer pump out let to have SS 304 / 316 60 mesh strainer.
Is an adequately sized trolley and rack provided in the Ready syrup room for warming/thawing the liquid
conc parts from 4-10*C to ambient temperature?
All Pumps, Pipes & Fittings used in Raw & Ready Syrup systems be of SS 304 / 316 quality with sanitary
design & Construction
Suitably sized Divert panel with adequate ports & dummy plugs ( to close non operation ports be
provided )
eady Syrup Tanks
Ready syrup transfer pump be provided with 30 - 60 mesh SS 304 / 316 strainer at the discharge. RF-MA-100 Requirement

#
Ready Syrup Tanks
Ready syrup discharge out let shall be provided with a suitable sanitary CO2 flushing system RF-MA-100 Requirement
All ready syrup tanks be provided with CO2 blanketing arrangement RF-MA-100 Requirement
Total syrup system be provided with CIP provision RF-MA-100 Requirement
All ready syrup tanks be provided with , suitable dust preventing venting arrangements, which are also
CIPable
Ready syrup room be provided with suitable Ladder / platform to read tank syrup levels. RF-MA-100 Requirement
Is a suitable safe arrangements like a SS catwalk provided to reach the top of the tank ( for inspection,
cleaning etc.)?
Suitable SS Tub / Tray be provided to sanitize SS Pipes / Fittings / Valves etc. RF-MA-100 Desired
Ready syrup tanks be provided with suitable display provision - to hang syrup informations RF-MA-100 Desired
All pumps coming in contact with pulp, simple syrup and final beverage should be of sanitary type
approved for use with food products?Never use bronze pumps, pumps with rubber impellers or rubber RF-MA-100 Requirement
diaphragm pumps.

#
Test the source water against the attributes and frequency in Table 1 (Alkalinity, pH, TDS, Turbidity, BP-RQ-180 Requirement
Coliform, Mesophylic count) at least on a weekly basis to ensure maximum efficiency of the water
treatment system.
Test the source water against the attributes in Table 2 (i.e. TDS, Turbidity, Aluminum, Chlorides, Iron, BP-RQ-180 Requirement
Sulphates, Total Sulphates + Chlorides, Coliforms, E.coli, Mesophylic count, Microcystin-LR) after any
Water Monitoring Requirements
supply disruptions, quality disruptions or natural disasters that could impact the quality of the source
water supply.
Manufacturing operation use historical data from normal operating periods to evaluate the quality of the BP-RQ-180 Recommended
source water and determine the proper actions to take concerning the disruption activity.
Test the treated water against the attributes in Table 2 (i.e. TDS, Turbidity, Aluminum, Chlorides, Iron, BP-RQ-180 Requirement
Sulphates, Total Sulphates + Chlorides, Coliforms, E.coli, Mesophylic count, Microcystin-LR) as per
frequency defined in the table.
Manufacturing plant must monitor the OOS results and report them to BU immediately. BP-SP-184 Requirement
The manufacturing operation must determine the cause of the OOS result and take BP-SP-184 Requirement
necessary corrective actions to bring the OOS result back within specifications.
Determine food safety risk generating in finished product due OOS result , the BP-SP-184 Requirement
manufacturing operation must take immediate action to mitigate the risk in consultation with Bottler
Leadership and BU.
Test the OOS parameter at a minimum of every three months until it demonstrates BP-SP-184 Requirement
compliance for three consecutive testing events.
The following enhanced filtration processes are approved: BP-RQ-180 Requirement

- Coagulation/flocculation followed by sedimentation and granular media filtration
(conventional chemical treatment);
- Direct filtration (injection of coagulant in-line followed by static mixing and deep
bed multimedia filtration);
- Ultrafiltration (less than 20,000 molecular weight cut-off);
- Nanofiltration;
- Reverse osmosis;
- Distillation
Consult with BU for any other treatment system for WTP.
Storage tank for raw water, chlorinated treated water, chlorinated soft water are tiled / epoxy coated and
RF-WA-120 Requirement
vessels of MS are internally food grade epoxy coated
Any plant going for coagulation in WTP shall have separate room for coagulation and chemical dosing BU Requirement Requirement
All tanks and pipelines after chlorinated treated water storage tank / PSF are SS. RF-WA-120 Requirement
tment plant

#

General - Water treatment plant
Ensure the water contacts the chlorine with at least 1 ppm free chlorine for at
least 30 minutes (Ct=30). As a thumb rule, provide minimum raw water storage capacity of 3 times of Bp-RQ-180 Requirement
treatment capacity to achieve required CT value.
Chlorine monitoring and alarms/interlock in raw water tank to ensure required chlorine concentration for
BU Requirement Requirement
disinfection
Water storage covered with lockable covers and insect screens on the air vents to prevent contamination
from airborne material and to ensure the bird proofing
Store jars of liquid chlorine in a self-contained shed with outside ventilation. Make sure you comply with
RF-WA-120 Recommended
local regulations..
Chlorine dosing pumps to storage tanks ( online mechanical diaphragm metering pump ) RF-WA-120 Requirement
Microbiology hygeinic sampling points in SS for all holding tanks and equipments RF-WA-120 Requirement
Lockable top manhole at all storage tanks. RF-WA-120 Requirement
SS Vessels and Pipelines to be passivated before use. RF-WA-120 Requirement
Min 6 air changes required. RF-WA-120
If any toxic/hazardous compound found out of specs in raw water, its online monitoring with
BU Requirement
alarms/interlock should be provided after respective removal process.
All storage tanks should have drain valves or other complete emptying facility and self draining floor /
bottom.
Continuous Coagulation System ( CCS ) of Adequate Capacity be Provided for plants with > 400 BPM
Chemical Coagulation - Continuous
RF-WA-120 Desired
capacity
All Water Contact surfaces be of smooth finish and Epoxy coated ( Solvent free & meant for food
applications )
CCS be designed to ensure min. 4 hrs holding time before water reaches clear water well. RF-WA-120 Requirement
CCS be provided with Automatic Chemical dosing system, with Flexible non PVC hoses meant for food
applications - all pipes suitably supported and with provision for Flushing the suction & to measure the RF-WA-120 Requirement
dosages.
Suitable system be provided to prepare Chemical Solutions of consistent Concentrations. Also Lime
slurry / solution be under continuous agitation while dosing.

#
Chemical Coagulation - Co

Level switches with alarms/interlock in chemical dosing tanks in water treatment to ensure there is
BU Requirement
always chemicals available for dosing.
On line CO2 Injector with suitable pH monitoring system, to automatically maintain pH of 7 to 8 be
RF-WA-120 Desired
provided, post PSF before the water is stored in holding tanks.
Batch Coagulation Tanks of Adequate capacity & Nos. be provided so as to ensure 4 hrs settling time
after Chemical addition. Tanks shall not be Underground.
All Water Contact surfaces be of smooth finish - Glazed Tiled or Epoxy coated ( Solvent free & meant
for food applications )
Chemical Coagulation - Batch

#
All tanks be provided with Dual speed Agitators suitably sized & located to ensure proper mixing - 40 to
Chemical Coagulation - Batch
50 RPM for chemical mixing & reaction and 20 to 25 RPM for Coagulation / floc formation. Both RF-WA-120 Desired
Agitators shall he provided with control system with Automatic timer arrangements for On & Off.
The Tank out lets be suitably located to prevent disturbing the settled Flock while drawing the water thru
Pump - Minimum 9 " from bottom and out let facing the top of the tank. Suitable provision be made to
drain the accumulated floc in the pipe from the tank out let / Pump suction, before starting the Pump for RF-WA-120 Requirement
service. Pump discharge be provided with suitable NRV to prevent disturbing Floc during putting off
Pump / Power failures.
Tank bottom be suitably sloped and drain out let flushed to the floor to thoroughly clean the tank. RF-WA-120 Requirement
Tanks be provided with large manholes - easy openable & lockable , Over flow Pipes to ensure fixed
quantity of water every time with out let facing down the drain & open to drain, with SS wire mesh to RF-WA-120 Requirement
prevent entry of Insects. Provide reasonable head space - at least 6 ".
On line CO2 Injector with suitable pH monitoring system, to automatically maintain pH of 7 to 8 be
RF-WA-120 Desired
provided, post PSF before the water is stored in holding tanks.
Treated filtered water storage provided with adequate capacity to back wash and rinse the ACF and PSF
for treated water system
MOC- MS internal epoxy( solvent free) coated with laterals and frontals made of SS316 RF-WA-120 Requirement
Lateral to have holes (max 6mm size) facing the bottom . Laterals to be equal pitched . RF-WA-120 Requirement
False bottom to be provided with SS 6mm SS plate with concrete grout below. Drain line at the surface of
this concrete grout.
Valves butterfly type ( Audco) with SS plate. RF-WA-120 Requirement
Operational flow rate for PSF - 4.8 m3/hr/m2 RF-WA-120 Requirement
Backwash flow rate 4-6 times forward flow rate. Resin trap nets on backwash line. RF-WA-120 Requirement
Sand Filters
Backwash line to have rotameter and also have sight glass RF-WA-120 Requirement
Air Scouring arrangement with a air blower / non lub air compressor with discharge pressure of 0.3
kg/cm2.
Free board 40-50% of total volume RF-WA-120 Requirement
Online turbidity meter for coagulation/UF based WTP and TDS meter for RO based WTP for continuous
BU Recommended
monitoring and interlock
pH between 6.5 and 8.5 RF-WA-120 Requirement
Automatic back wash process for PSF/ACF filters. This will optimize the backwash frequency and
BU Requirement Recommended
backwash drain to minimize waste water during backwash operations.
Online ORP meter linked to Feed pump to trip in case of chlorine goes out of specification. Business Unit Recommended
MOC- SS316 for treated water with laterals and frontals also of SS316 RF-WA-120 Requirement
MOC- MS epoxy coated / SS304 for raw water and soft water with laterals and frontals of SS316 RF-WA-120 Requirement
Lateral to have holes ( max 6mm size) facing the bottom . Laterals to be equal pitched. RF-WA-120 Requirement
#

Carbon Filters
Maximum Operational flow rate 140 lit/min/m3 of carbon ( contact time > 7.5minute) RF-WA-120 Requirement
Minimum height of carbon bed should be 1.5 meter RF-WA-120 Requirement
Facility for steaming preferably from the top RF-WA-120 Requirement
Steam line has drain valve to drain out condensate RF-WA-120 Requirement
Backwash flow rate 2.5 to 4 times of forward flow rate RF-WA-120 Requirement
Backwash rotameter. Backwash line to have a sightglass RF-WA-120 Requirement
Backwash line connections for TW ACF with treated chlorinated water. RF-WA-120 Requirement
Use of virgin carbon with company approved make and size RF-WA-120 Requirement
Chlorine monitoring and interlocks for residual chlorine after ACF to ensure that there is no residual
BU Requirement
chlorine in treated water.
MOC- SS316 for treated water with laterals and frontals also of SS316 RF-WA-120 Requirement
Lateral to have holes ( max 6mm size) facing the bottom . Laterals to be equal pitched . RF-WA-120 Requirement
Is the LLACF vessle designed for min 15mins contact time. RF-WA-120 Requirement
LLACF

#

Is the carbon contact time with LLACF min 10mins RF-WA-120
LLACF
Facility for steaming preferably from the top RF-WA-120 Requirement

Steam line has drain valve to drain out condensate RF-WA-120 Requirement
Backwash flow rate 2.0 to 2.5 times of forward flow rate RF-WA-120 Requirement
Backwash rotameter. Backwash line to have a sightglass RF-WA-120 Requirement
Backwash line connections for TW ACF with treated chlorinated water. RF-WA-120 Requirement
Backwash as per microbiological monitoring program or pressure differntial above1.5KG Business Unit Requirement
Use of virgin carbon with company approved make and size RF-WA-120 Requirement
Housing - SS 316/304 electopolished, Code 7 company approved housing Business Unit Requirement
Pressure gauges SS and SS microbiological sampling points on upstream and down stream side. Business Unit Requirement
Use of company approved cartridges. End Filter to be 1 micron , Upstream filters depending on the
Polishing filters
particle profile analysis or through T/ Vmax studies.

TW line - 8/ 10 micron absolute filter
TW line -3/ 5 micron nominal filter
TW line - 1 micron nominal filter
UV between the 3/5micron and 1micron filter. Requirements for UV light is given in separate section.
Soft Water line - 5 microns cartridge filter Business Unit Requirement

Provision for Cleaning and replacement Business Unit Requirement
Connection to CIP just before 1 micron polishing filter. Business Unit Requirement
Differential Pressure Measurement system for the Polishing filter Housing to be installed. The Pressure BU Requirement Requirement
switches to be installed at the inlet and the outlet of each micron filter and interlocked with the forward
pump to ensure tripping of pump in case of high differental pressure or no differential pressure.
Online ORP meter linked to Feed pump to trip in case of chlorine. Business Unit Requirement
Online conductivity meter for TDS monitoring of treated water Business Unit Requirement
Online pH meter with high / low alarms . Business Unit Requirement
Reverse Osmosis
Autoflushing arrangement with permeate water at shutdown. Business Unit Requirement

Pre-treatment system (sand filter, carbon filter & 5 micron filter) Business Unit Requirement
SDI Check kit ( Millipore ) Business Unit Requirement
Colloidal silica within supplier recommendation Business Unit Requirement
Product water storage min 1 hour, chlorinated to 1-3 PPM free chlorine. Business Unit Requirement
Flowmeters / Rotameters on Permeate and reject stream. Business Unit Requirement
Pressure guages available to measure system pressure across each stage/ element. Business Unit Requirement
Membrane cleaning and sanitation facility Business Unit Requirement

#
Use of company approved resin Business Unit Requirement

MS tank with internally food grade epoxy coated / SS tank Business Unit Requirement
Backwash flow rate 2-3 times forward flow rate. Resin trap nets on backwash line. Business Unit Requirement
Softener
Hardness< 10 ppm Business Unit Requirement

Residual chlorine in soft water storage tank should be 1 to 3 ppm Business Unit Requirement
Resin bed depth min 50 cm Business Unit Requirement
Max. operational flow rate 320 lit/min/m2 bed area and maxOBR (Operation between regenerations) 24
hrs
Brine tank to be of FRP / MS epoxy coated with a bottom drain valve- Non agitator design. Business Unit Requirement
Ensure the UV light system measures the ultraviolet transmission (UVT) of

the light or ultraviolet absorbance (UVA) of the water- if this UV is for Primary Disinfection purpose in the BP-RQ-180 Requirement
water treatment process.
Requirement for Intense Ultraviolet (UV) Light: Use an ultraviolet (UV) light system that has been
validated to ensure 4-log inactivation of cryptosporidium and the adenovirus.
Low Pressure UV Light: the UV unit must provide a Reduction Equivalent
Dose (RED) of at least 186,000 μWs/cm2 (186 mJ/cm2) as measured by a BP-RQ-180 Requirement
UV Light System
germicidal sensor (250-280 nm wavelengths) at the end of its life.

Medium Pressure UV Light: the UV unit must provide a Reduction
Equivalent Dose (RED) of at least 120,000 μWs/cm2 (120 mJ/cm2) as measured by a germicidal sensor
(250-280 nm wavelengths) at the end of its
life
For supplimentary treatment ( treated water storage or at end of treatment process ) : system must
provide a Reduction Equivalent Dose (RED) of at least 40,000 μWs/cm2 (40 mJ/cm2) as measured by a
germicidal sensor (250-280 nm wavelengths) at the
end of its life
For supplimentary treatment ( treated water storage or at end of treatment process ) :
Provide monitoring of UV intensity and UV dosage with interlock to stop forward flow in case UV dosage BP-RQ-180 Requirement
is lower than 40 mJ/cm2
Follow BU (updated in Q-Dec) and regulatory requirements, for producing treated water for product
manufacturing using a multiple barrier water treatment system.
Design the multiple barrier water treatment and handling system based on plant SVA report, standard
water treatment design methodology, and source water monitoring data so that treated water meets the
requirements and specifications of BP-RQ-180 and BP-SP-184.
Submit the design to BU for review and inputs.
Conduct source and treated water annual monitoring according tas per BP-SP-184 and submit the
reports to BU.
#
Each step shall be an important contributor to water treatment efficiency and effectiveness which shall be BP-RQ-180 Requirement
certified and acknowledged by External Water consutant (if applicable) amd BU.
Ensure materials authorized for contact with drinking water meet ANSI/NSF Standard 61, as certified by
the National Sanitation Foundation (NSF) or equivalent agency. Examples- Ion-exchange resin, RO / UF BP-RQ-180 Requirement
membranes and filter media.
Use the chemicals from BU-authorized suppliers and chemicals are certified to meet ANSI/NSF Standard BP-RQ-180 Requirement
60, Company specifications, and applicable regulations.
De-gasser and De-Alkalizer and its accessories should be kept in separate room to avoid corrossion of
other plant WTP equipment. The construction material used for de-alkalizer should be compatible to the BU Requirement/recommendati
chemicals used.

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Present status Responsibility Target Date Est. Cost

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ecommendation

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Assessed by:
Assessment Date:
Check Point
AHU
Prefilter & Final filters of all AHU must be intact and good condition. Dust clogging should not be there
Check AHU discharge bellows at the joints for the condition. They must be intact and damage free and
bolted tightly to avoid ingress of outside air
AHU housing, PVC fins & Eliminator must be intact and good condition. No mold growth, excess dust
accumulation
Cooling water must be fresh and without any off smell, color and floating mold / fungal
All AHU's must be designed to achieve minimum number of air changes. Certificate for the air changes
are required to be shared for simple syrup, thawing, ready syrup, filling and blowing room
Cold Room (-18 Degree)

Data logger to be installed for recording temperature. Cold room must be capable of meeting the
requirement of -18 degree C at peak load. Alarm should be fucntional in case temperature goes above
set limit
Adequately defrosting system to be designed, this must esnure that there is no Ice formation on the
cartons, sides, roof and floor of the cold room, potentially this can damage carton and spoil material as
well and can led to safety hazard
Sugar Dumping and Simple Syrup Preparation area
Sugar dumping hopper should be at a raised level to avoid any pest / dust ingress.
Must have defined and documented cleaning protocol for the same
Sumping area walls, floor and other amenities must be in a clean condition, extended spillage may
attract insects and lead to mold buildup
Sugar dumping hopper cover and mesh must be in good shape and intact. No misalignment, opening,
damages
Dumping hopper pit must be in a hygienic condition. Free from any sugar deposits, Insects, water
accumulation and mold growth
Plant should have effective CIP/cleaning system for the pneumatic sugar transfer system.
All pumps and PHE / THE should be in well maintained condition without any leakages, syrup deposits,
dust or mold presence
Sugar transfer duct at the top of Hopper must design in such a way that it can be removed easily for
cleaning, coevers the full man hole and without any nut bolts. Inspect the same for the presence of
mold or hygiene design issue
Sugar dumping and simple syrup area must be free from any off odors, water accumulation, mold at
any surface (drains, ducts, equipment outside, connections and pumps).
Plant must have adequate provision for the hot CIP and should follow the same as per defined
frequency. Check records
Thawing & Pulp Cutting Room
Pulp cutting room must have access controls to prevent entry of any unauthorized personnel.
Should have adequately designed AHU system for controlled environment

The pulp dumping system must have adequately designed CIP system to ensure effcetive cleaning of
each part of the system
Flexi / dismantlable Pipes in use for juice suction should be kept at raised surface or hangers. No
storage diretcly over the floor is allowed
# Classified - Confidential
Thawing room must have racks or other suitable hygienic provision to keep material for thawing. No
storage directly over the floor is allowed
Ready Syrup Tanks
All tanks must have nitrogen or CO2 blanketing
All pumps and PHE / THE should be in well maintained condition without any leakages, syrup /
beverage deposits, dust or mold presence
O2 sensor to be installed at ready syrup room along with alarm. Interlocking with AHU must also be
there so that alarm blows when AHU is not operational
CO2 line and other installation need to be pasivated
Vapor vent to be closed to avoid air ingress
CO2 and auto vent sync system in place
Filling Room
Air conveyor HEPA filters & their housing, AHU discharge and suction ducts / louvers to be checked
physically. There should not be excess dust accumulation or damages
Rinser, filler and capper must be checked and should not have any mold
Rinse water pressure and chlorine level to be suffcient and as per the validated and approved levels
UV for closure disinspection in place, minimum 4 log cycle reduction
Drains, equipment support legs, cables etc. must be free from any dust or mold
All pumps and PHE / THE should be in well maintained condition without any leakages, syrup /
beverage deposits, dust or mold presence
Plant need to conduct risk assessment and make a list of hard-to-access areas and protocol to ensure
sanitation
Lab
Standard weights to be procured for calibrating weighing balances.
SCADA system for logging CIP data in place and operational
Plant shall participate in Juice SPPS and shall buy juice Offnotes
In addition to the routine microbiological analysis mentioned in annexure 1, plant would need to
conduct additional yeast species i.e. Dekkera analysis as mentioned in KORE
Plant shall have facility for Dekkera Testing and required media, glassware shall be available
Rapid Micro test method can be used in lieu of point (b) - this can only be used post completing
equivalence test on the equipment with the commercial product and taking approval from BU QA,
please connect with BU commercialization/ QA team for more details
Concentrate trolley shall have foimaless entry for water and recirculation line to avoid foam during
addition of parts that creates foaming
Design & Process Requirements -
Cold Storage (-18 deg C) :
a. Plant must have a permanent -18 C arrangement on site, adequate enough to store the juice
concentrates just before and during the production runs. Minimum storage capacity of 2 days must be
there.
b. Bulk storage to keep inventory for long term usage can be made in house or with third party frozen
bulk storage arrangement. Data logger must be installed in place to record temp and data to kept
saved for future reference
Isolated thawing room with controlled air (AHU) to meet micro specs as per annex 1. Minimum 15 Air
changes are required
Manufacturing process must meet all applicable KORE / Regulatory requirements
Juice Thawing: To be done 16~24 hrs (or as defined for specific juice in MMI) before usage at ambient
condition in controlled environment.
Once juice drum/pack is opened, it should be consumed within 4 hours
Juice Unloading arrangement required : A Dump Tank, Unloading pump (diaphragm or lobe type ), In
line filter of 20 mesh (0.85 mm), Transfer pump to Blending tank suitable for handling high brix e,g >65
Brix Juice concentrate. All sections should have auto CIP capability, including internal and external
unloading pipe entering into the drums.
Blending: Agitation in Ready Syrup tank must be with RJM and optimize the flow to ensure no / minimal
foaming.
Filling: Regular Counter pressure filling like CSD at 4 to 18 deg C, as per existing Sparkling process
and line capability.
Ready syrup room to have AHU, meeting 15 to 20 air changes through 20 Micron and micro
specifications as per annex 1.
Simple Syrup temperature should be < 25 Deg C while transferring for ready syrup preparation. Sugar
for simple syrup must be manufactured using hot carbon treatment.
Ready syrup tanks should be equipped with CO2 or Nitrogen Blanketing
Shelf life of blended beverage in the tanks will be tentatively 8 hours at ambient, same shall be
validated during the trials.
Closure disinfection - Minimum 5 log reduction when using UV for closure sterilization. UV supplier
must confirm this and provide a “certificate of compliance”
High Pressure Vacuum pump for microbiology testing of final syrup and Juice Concentrate and
beverage to be available
Strainer requirement (as per respective facility check list points of juice and ready syrup transfer)
o Dual stage strainer in juice transfer line with 20 mesh and option of 40 mesh screen to be available at
plant
o Ready syrup transfer line to have 60 mesh strainers.
o All strainers to be cleaned & rinsed manually after production and before start of CIP
Cleaning and Sanitation Requirements – CIP System
CIP should be in auto mode with SCADA logging.
Separate CIP circuits for Juice and CSD is required
In case of single circuit CIP, plant needs to change the caustic while changing over from sparkling with
juice product to normal sparkling product or have a dedicated caustic tank / reclamation tank so that
caustic of CIP after sparkling juice is not used for CSD.
5 step CIP provision for pulp dumping station must be in place and operational
CIP for filler Snift must be integrated in the CIP loop.
The facility must ensure that the line (CIP, Syrup tanks & Circuits, Filling Line) in question is “SWEEP”
certified by BU authorized agencies (not longer than 6 months old) and all identified gaps must be
closed and verified by agency. Plant should have not made any modification post SWEEP assessment,
if any made and can have impact on CIP adequacy then “SWEEP” to be conducted fresh.
5 Step CIP to be carried out at start of production with 90 Deg. C hot water, and 7 Step CIP at end of
production with 90 Deg. C hot water step is required.
Plant having only Sparkling line with 5 step CIP, must add 2 additional tanks for Caustic & Acid when
shifting to sparkling + juice product
Cold CIP is not applicable for this product category.
Cleaning and Sanitation Requirements – COP System
Auto COP system should be in place and working. A dye test needs to be performed through Sealed
Air and installation of additional nozzles as per Sealed Air recommendation. Plant must comply with the
COP protocol as available on the QDEC.
Provision should be in place to flush filling valves with treated water every 2 hours in auto mode
through nozzles fitted around filler.
Regulatory Requirement
The plant must have a FSSAI license to manufacture ‘Carbonated Fruit Beverages’
Reference Category Remarks by KBL
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Observation Evidence for
Target Date Responsibility
(Complinace / Non-Complaince) Closure
Remarks
Facility Assessment Checklist for CSD PET - Lab Equipments

Assessed by:
Assessment Date:
ITEMS Requirements Reference Category Present status
Laboratory shall be provided with running water. At least one of the points shall have
product water.
Adequate work stations, Lockable cupboards, Drawers shall be provided to all QA &
QC staff.
General
Adequate storage facilities for all Lab Chemicals, Glass wares, etc and separate
Cabinet with controlled access for Toxic materials.
Lab be provided with Piped CO2 & Compressed Air Business Unit Desired
Adequate UPS system and Voltage stabilizers be provided for all Critical
Equipments.
Double Glass Water Distillation Assembly of Approved make & Model Business Unit Requirement
Constant temperature water bath with Agitators - SS ( accuracy - 0.5°C) Business Unit Requirement
Digital pH meter with auto calibration and temperature correction (Least count =
0.01 ) - of Approved make & model, Along with Standard Buffers.
Conductivity meter / TDS meter ( least count = 0.01 TDS ) - Approved Make & Model
(Merck- Eutech)
Turbidity meter ( least count = 0.01 NTU ) of Approved make & Model (Hach
SM-PR-455 Requirement
Company Method 8195 / EPA Method 180.1)
Hach chlorine test kit model CN-80 / Lovibond Comparator Disc 3/40 B SM-PR-165 Requirement
Spectrophotometer of Approved make & model, with cuvettes & holders. Business Unit Requirement
SDI test kit of Approved make & model Business Unit Requirement
Jar Test Kit ( for Coagulation WTPs ), of Approved make & model. Business Unit Requirement
Accuvac Ampoules for all standard chemicals Business Unit Requirement
Magnetic stirrer with heater Business Unit Requirement
Densitometer of Approved make & model - Beverage & Syrup Brix measurements.( 2
Nos. if more than 2 lines ) (readable to at least 4 decimal places)
Airstone decarbonation apparatus or Vacuum pump with vacuum gauge - Beverage

Deaeration / Decarbonation.
Dissolved Oxygen Meter Business Unit Requirement
Dissolved Oxygen Kit for Specrtophotometric method, other meter with reliable
calibration method

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Zham Gas Volume tester - size to suit all packages ( 2 nos. if more than 2 Lines ) Business Unit Requirement
Pressure gauges 0-60 psi & 0 to 100 psi (for Soda ) with 1 psi Graduation, of
Approved makes, to suit the Gas volume tester - 2 " dial.
Mechanized Bottle shaker with auto timer & cycle controls, of Approved make for Gas
volume tester
Bottle Guard for Gas Volume Testing - Explosion protection Business Unit Requirement
General Lab Equipments
Thermometer 0-120 deg. F ( Non mercury ) with 1° F least count of Reputed makes. Business Unit Requirement
Zham standard Air content tester Business Unit Requirement
Torque tester 0-25 lb / sq.inch of approved make & model - for Screw Cap packages,
with Calibration Kit.
High intensity light - Tensor Business Unit Requirement
Digital Single pan Balance of 3 Kgs Capacity with least count of 0.1 gm for Net
Content measurements - of reputed make.
Digital Single pan Balance of 200 / 500 gms capacity with least count of 1 mg for
preparations standard solutions - of reputed make.
Digital Single pan Balance of 200 gms Capacity with least count of 0.1 mg for
estimation of Sediments in Syrups - of reputed make.
Zahm CO2 Gas Purity Tester with Least Count of 0.01 % in 99 to 100 ml range Business Unit Requirement
Bottle Height Gauges . Business Unit Requirement
Bottles Perpendicularity Tester of Approved make. Business Unit Requirement
Crown / Closure Dia and Height " GO -NO-GO " Gauge of Approved make. Business Unit Requirement
Standard Verniers & Micrometers with least Count of 0.01 mm - of reputed make. Business Unit Requirement
SS level table with adjustable legs & spirit level in the center of reputed make Business Unit Requirement
Anti-vibration table of reputed make. Business Unit Requirement
Secure Seal tester with suitable connectors for Crowns & Closures - Approved
make.
PET Blown Bottle Burst tester (Presto or Sidel) BP-RQ-462 Requirement
Dead weight gauge tester with standard weights for Calibration of pressure gauges -
approved make
Spring Calibration kit for Torque tester for Screw caps. - Approved make Business Unit Requirement
Standard Thermometers - Deg F & C for calibrations Business Unit Requirement
Muffle furnace Business Unit Requirement

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Centrifuge - Manual Business Unit Requirement
Laboratory oven / Drying oven / Hot air oven Business Unit Requirement
Hot plate Business Unit Requirement
Whatman filter paper of all specified code numbers Business Unit Requirement
0.45 micron - Non Sterile White & Black papers ( Syrup release ) Business Unit Requirement
Dry and wet bulb thermometer and humidity chart. Business Unit Requirement
Access to BQMs / QDEC Manuals, Specifications / Standards, Procedures etc. Business Unit Requirement
Dropper for fill height detection of beverage bottles - IPQP of bottles Business Unit Requirement
Microbiological Lab be located in convenient location ( preferably attached to the

main lab ). Inoculation & Incubation area be separated from Autoclave , washbasin Business Unit Requirement
etc.
Sterile Laminar flow unit 3x2 feet for Inoculation of samples - approved makes. Business Unit Requirement
Autoclave of Adequate size of Reputed make. Business Unit Requirement
Bacteriological incubators of adequate size - 3 nos. (One with compressor, to
maintain the temperature below room temperature)
Oven for dry sterilization Business Unit Requirement
Bifocal Microscope of 10X, 40X and 100X (Oil immersion lense) Magnification, with
Microbiological Laboratory
mounting slides, Lamp for bottom illumination, approved stage micrometer and Business Unit Requirement
occular scale.
Membrane filtration assembly including filtration cups, 3 cup manifold, flask, holders,
connector tubes etc - of approved make
Vacuum pump with gauge and connecting tubes, of rep-Reputed makes. Business Unit Requirement
Sterile Membrane filters of 0.45 & 0.8 micron size - approved make Business Unit Requirement
Auto Membrane Dispenser - approved make Business Unit Desired
Flat tip forceps Business Unit Requirement
Air Sampler for Ambient / Atmospheric Microbiological Quality test, of approved
makes
Media for Total plate counts, Yeast and Moulds, Coliforms and Faecal Coliforms -
Approved media with all necessary suppliment chemicals
LPG Cylinder with Regulator, Burners and connecting tubes. Business Unit Requirement
Petridishes - Small & Large of reputed makes Business Unit Requirement
S.S. Pair of Tongs Business Unit Requirement
S.S.Scoops 1,2,5,10,20 ml each Business Unit Requirement
SS. Hot water bath - Reputed make. Business Unit Requirement
S.S.Spatula Business Unit Requirement

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Refrigerator - min. 165L, of standard make Business Unit Requirement
Polariscope with Template, Melinar chart & Defect chart, of approved make, for
Preforms.
Preform Color standards Business Unit Requirement
Preform gate cutter Business Unit Desired
Preform Perpendicularity tester Business Unit Requirement
Preform Neck Dimensions gauge - " GO - NO-GO ", of approved make Business Unit Requirement
Magnifier - 2 to 5 X for neck finish observation, of reputed make Business Unit Desired
Closure - " GO - NO-GO " gauge, of approved make. Business Unit Requirement
Torque tester 0-25 lb / sq.inch of approved make & model - for Plastic Closures for
PET bottles, with Calibration Kit.
Hot wire bottle cutter of Approved make (Sidel or Presto) , suitable for all sizes, for
PET Lab Equipments
sectional weights
Top load Tester for bottles, of approved make with standard calibration kit with
certified weights
Bottle Thickness measuring Magnameter of approved make & Model. Business Unit Requirement
Base clearance Measurement meter of Approved make. Business Unit Requirement
Graduated belt / Pie Tape suitable for all sizes, of approved make. Business Unit Requirement
Vernier height gauge, approved make Business Unit Requirement
Bottle Drop Test Kit ( As per Specifications ) Business Unit Requirement
Side Wall rigidity tester Business Unit Requirement
Weighing Balances - for Blown bottle Sectional wts, Net Contents etc. Business Unit Requirement
GSM tester - Cartoons / Labels, approved make & model Business Unit Requirement
Bursting Strength tester, of approved make & model - For cartons Business Unit Requirement
Carton Compression tester, Business Unit Requirement
IPQP Manual from Div. Packaging, with all Specifications / Standards of Preforms,
Closures, Lables , Cartons etc.
Drawings & Specifications of all Packs, from Div. Packaging Business Unit Requirement
Stress test cabinet to place and check individual bottle during the test to be available Business Unit Requirement
Burettes of Standard sizes like - 25ml, 50 ml, 100 ml etc. Business Unit Yes
s ( Standard & Reputed
Automatic burettes - 3 Nos. . - with Reservoir of at least 1 liter capacity Business Unit Requirement
Pipettes Graduated of different sizes Business Unit Requirement
Pipettes Volumetric of different sizes Business Unit Requirement
Make )

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Glass wares ( Standard & Reputed

Relative density Bottles Business Unit Requirement
Volumetric Flasks Business Unit Requirement
Make )
Measuring Cylinders Business Unit Requirement

Test Tubes Business Unit Requirement
Glass Rods Business Unit Requirement
Erlen Mayer Flask Business Unit Requirement
Beakers Business Unit Requirement
Funnels Business Unit Requirement
Separating Funnels Business Unit Requirement
Vacuum flasks Business Unit Requirement
Digital pH meter with auto calibration and temperature correction ( Least count = 0.01
) - of Approved make & model, Along with Standard Buffers.
Conductivity meter / TDS meter ( least count = 0.01 TDS ) - Approved Make & Model Business Unit Requirement
DO Meter of approved make & Model Business Unit Requirement
ETP Laboratory
Set of Glass wares for all tests Business Unit Requirement

Set of all Reagents & Chemicals for all tests Business Unit Requirement
BOD incubator Business Unit Requirement
COD digester Business Unit Requirement
Weighing balance of 0.1 mg least count Business Unit Requirement
Double distillation apparatus Business Unit Requirement
Drying oven Business Unit Requirement
Vacuum pump Business Unit Requirement
All specified whattman filters Business Unit Requirement
Beverage Sensory Leader

1.Plant must have Trained & certified Beverage sensory leader (BSL) and its Backup.
2.Plant must have all the specific offnote kits ie SSD,Juice,Water.
3. Plant must have trained & screened sensory evaluation panel .
Sensory Lab

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Sensory Facility/Lab
1) Room should be Free of extraneous odors, noise or other distractions where
panelists can do their evaluations independently and quietly. Preferably dedicated
Booths .
2) Light- Bright and evenly illuminated with minimal or no shadows. BP-RQ-650 Requirement
3) AC in the room to maintain (21-25 Degree Centigrade)
Sensory Lab
4) Separate refrigerator for the control sample

5) Storage cupboards for sensory accessories
6)Dedicated sample preperation area
Product Release
1.Use of In/Out ballot for sensory evalution as mentoned in BP-RQ-650
2. Ensure minimum no of panelist for relesae of Finished Product/Semi Finished
Products & Raw materials (FP-3,SFP-2,RM-2)
3. Plant to mainatin reccords of relaese for Finished Product/Semi Finished Products
& Raw materials.
Proficiency Testing
1. Plant must participate in quarterly proficiency testing program BP-RQ-650 Requirement
2.Maninatin records of Participants & their scores .
3. Ensure minimum 75 % score in proficiency testing for all participants

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Corrective Action Responsibility Target Date Est. Cost

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Facility Assessment Checklist for CSD PET - Store and Utilities

Assessed by:
Assessment Date:
Items Requirements Reference Category
Store Beverage Dry /Liquid Base Parts that require temperature 11 to 30 Deg C in a BU-RQ-210 Requirement
separate secured area with a strict controlled access. Provide an area separated by walls/ BP RQ 900
panels.
Store Concentrate Liquid parts in cold-storage area maintained at a steady temperature of 4 BU-RQ-210 Requirement
to 10 Deg C and has a controlled access. Refrigerant should be CFC free. Use HCFC free ES- RQ -200
or HFC free wherever viable alternatives are available. BP RQ 900
Provide racking system or palletised racks to store Liquid concentrate and beverage base BU Requirement Requirement
parts. Only Plastic pallets to be used. The racks to be provided with label tag slots for each
beverage base. If palletised racks are used then sufficient space for movement of battery
operated stacker should be provided. Rack should be powder coated.
Concentrate Storage
Racks provided in the Bev base & Conc room are able to withstand the weight of the packs. BU Requirement Requirement
FEFO(First Expiry First Out) is always maintained. BU Requirement Requirement

Provide at the minimum 30 days of concentrate storage space, or the plant management BU Requirement Requirement
team to sign off its own requirement.
Install and maintain equipment that continuously monitors record dry and liquid storage BU Requirement Requirement
temperatures for accuracy. Install accurate temperature control, equipped with recorders and
alarms.
Provide adequate lighting 300 Lux for required activities and for easy cleaning and ISO/TS 22002-1:2009 Requirement
housekeeping. Equip all light fixures with safety shields.
Build walls and ceilings from a smooth, easily cleanable material that isn’t porous or toxic . ISO/TS 22002-1:2009 Requirement
Install safety devices to prevent someone from being trapped inside. BU Requirement Requirement
Locate ail pallet rows and pallet racking at least BU Requirement Requirement
46cm (18 in.) from walls to facilitate cleaning and
rodent control activities

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Store all ingredients and packaging materials ( excluding glass) in a dedicated ventilated ISO/TS 22002-1:2009 Requirement
General - Ingredient, Packaging and Finished goods covered storage protected from dust, moisture and contamination.
Provide adequate lighting (minimum 300 lux) for required activities and for easy cleaning ISO/TS 22002-1:2009 Requirement
and housekeeping . The lighting fixtures shall be covered.
Fire Retardant Insulation to be done for roof sheets where packaging material, ingredients BU requirement Requirement
and finished goods are stored
Seal all joints between the walls and roof. ISO/TS 22002-1:2009 Requirement
Slope (45 deg) / Coving at all wall ledges to keep dust and trash from building up and make ISO/TS 22002-1:2009 Requirement
cleaning easier.
Build floors from a smooth, easily cleanable material that isn’t porous or toxic. ISO/TS 22002-1:2009 Requirement
Place all pallet rows and pallet racking at least 46 cm (18 inches) from walls to ease cleaning ISO/TS 22002-1:2009 Requirement
and rodent control.
Provide Physical stoppers and yellow marking to ensure the distance from wall. ISO/TS 22002-1:2009 Requirement
Store above the ground to facilitate floor cleaning ISO/TS 22002-1:2009 Requirement
Paint a strip 46 cm (18 in) wide next to the walls, using a high-gloss yellow paint. This is a no ISO/TS 22002-1:2009 Requirement
walking zone. This strip eases cleaning and makes sprayed insecticides work longer.
Equip all light fixtures or light bulbs with safety shields. BU requirement Requirement
Wall should be painted with Vinyle emulsion paint or tiled ? ISO/TS 22002-1:2009 Requirement
Identified area for non confirming material available ? ISO/TS 22002-1:2009 Requirement
Heat insulated tarpaulin for shipping of ASSP FG to be available Business Unit Requirement
Pulp / Juice Store shall be provided by double door entry. One of the doors should be Business Unit Requirement
manual shutter type while the other should be rapid shutter
Store all finished product within the coolest area of the plant,ventialted, where it won’t BU-RQ-210 Requirement
receive direct sunlight. BP RQ 900
Finished goods Storage capacity shall be adequate to hold at least 3 days Production Business Unit Requirement
capacity, with standard storage practices for Sparkling RGB/ PET and Hotfill RGB, 7 days for
Hotfill PET / Tetrapak
Ventilation : Natural or Roof Ventilation is provided ? Business Unit Requirement
Finished Goods
Trasperant FRP sheets for natural lights are provided in the roof ? Business Unit Requirement
Paint a strip 46 cm (18 in) wide next to the walls, using a high-gloss yellow paint. This is a no Business Unit Requirement
walking zone. This strip eases cleaning and makes sprayed insecticides work longer.
Strip Marking for different SKUs provided ? Business Unit Requirement

Provide Physical stoppers and yellow marking to ensure the distance from wall. Business Unit Requirement
Drive in Rack storage for PET and tetrapk is provided Business Unit Recommended
Sufficient number of loading bays to meet the peak day dispatch requirement are provided ? Business Unit Requirement

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Fini
Preferably raised platform , or loading bays are provided for direct loading of pallets or Business Unit Requirement
cases in to the Truck
Finish goods storage area should be free of dust, pests, directly sunlight and rain Business Unit Requirement

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Provide Area with an adequate ventilation system - 5 Air changes / Hr ISO/TS 22002-1:2009 Requirement
Build floors from a smooth, easily cleanable material that isn’t porous or toxic.For Sugar Business Unit Requirement
Storage Acid Alkali resistant Tiling is recommnded.
Sugar Store
Typically, Sugar Go down be provided for storing 10 days requirements. Business Unit Requirement
Are plastic pallets provided for Sugar storage? Business Unit Requirement
If rack Palletised rack storage is used, Battery operated stacker is used to handle the pallet Business Unit Requirement
Sugar Store shall be provided by double door entry. One of the doors should be manual Business Unit Requirement
shutter type while the other should be rapid shutter
Store all ingredients and packaging materials in a dedicated ventilated covered storage Business Unit Requirement
Packaging (Crown, closure, Prefrom
protected from dust, moisture and contamination. Is RCC or False Ceiling ,metal roofing
(walls sealed with the roof ) provided ?
Preform storage shall be done at 4-35 deg.C and less than Rh of 50% Business Unit Recommended
Frames, Cardboard boxes (Octabins) and Drop boxes must be stored no BP-RQ-462 Requirement
more than 5, 4 and 5 high when full, respectively.
Lable etc)
Sufficient Storage Area is planned for 15 Days storage of Prefroms ? Business Unit Requirement
Sufficient Storage Area is planned for 15 Days storage of Closure / Crown ? Business Unit Requirement
Sufficient Storage Area is planned for 20 Days storage of Lable/ Sleeves ? Business Unit Requirement
Sufficient Storage Area is planned for 5 to 7 Days storage of Corrugated Box? Business Unit Requirement
Provide Area with an adequate ventilation system - 5 Air changes / Hr (provide natural Business Unit Requirement
ventilation with Exhaust fan and duct)
For shrink sleeve Storage room - suitable ararngement ot keep temperature below 25 deg C Business Unit Requirement
is provided
Is RH meter installed in Corrugated Box storage room ? Business Unit Recommended
Bulk Co2 storage be provided with suitable Transfer system from tankers Business Unit Requirement
CO2 Bulk storage be built as per statutory norms ( CCE ) with valid approval. Business Unit Requirement
CO2 bulk storage to be suitable for minimum 15 days requirement ? Business Unit
Storage - CO2
CO2 Bulk storage / Manifold be provided with suitable Evaporator, PRV / Regulator, Business Unit Requirement
Activated carbon Filter with Particulate Filter, followed by Dominic Hunter Purifier with at
least 1 Micron Filter before connecting to the Process Line.
Bulk storage be provided with suitable Refrigeration system - CFC Free, to prevent loss of Business Unit Requirement
CO2 due to rise in Temp / Pressure.
All CO2 Lines & Fittings shall be of SS 304 / 316 Business Unit Requirement
Access control in the area Business Unit Requirement
No flammable materials / shrubs in the cordened area for CO2 storage Business Unit Requirement

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Plant is equipped with distinct and separate restricted areas(locked or access control) for Business Unit Requirement
Auxiliary Material storage Storage of water treatment chemicals.
Adequate, Dedicated, Covered & restricted areas be Provided for Storage of water Business Unit Requirement
treatment chemicals.
Plant is equipped with distinct and separate restricted areas for Cleaning and sanitizing Business Unit Requirement
compounds.
Plant is equipped with distinct and separate restricted areas for Lubricants and solvents. Business Unit Requirement
Areas where liquid acids and/or caustics are stored, equipped with containment dikes and Business Unit Requirement
proper drains to facilitate removal of spills and easily accessible safety showers and eye
wash stations.
Storage shall be done in a manner to prevent powder dust build up due to use of auxiliary Business Unit Requirement
materials.

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Bulk storage area designed in such a way that it restricts traffic by non-essential personnel. Business Unit Recommended
All access points not enclosed in a limited access area, particularly unloading stations locked Business Unit Requirement
All storage tanks ,transfer systems ,sight glasses and appended fixtures constructed with Business Unit Requirement
approved material.
Storage tank, transfer system and associated materials (seals, gaskets etc. ) are capable of Business Unit Requirement
General bulk storage
with standing hot sanitation.

All liquid storage tank equipped with breathing vents. Business Unit Requirement
All liquid storage tanks equipped with an in-line strainer in the in-feed line. Business Unit Requirement
All storage tank equipped with an entry for inspecting and cleaning. Business Unit Requirement
Storage - Fuel Secondary containment 110% of biggest tank Business Unit Requirement
Storage - Fuel Flame proof electrical fittings in fuel storage Business Unit Requirement
Storage - Fuel Installation as per CCE requirement Business Unit Requirement
All product and ingredient storage tanks equipped with a sampling valve of sanitary design. Business Unit Requirement
All the walls made of non-porous ,non-toxic material and easily cleanable. Business Unit Requirement
All the pallet rows and pallet racking of the plant located 46cm(18in)from walls to facilitate Business Unit Requirement
cleaning and rodent control activities .
Adequate lighting provided for the required activities and to facilitate cleaning and house Business Unit Requirement
keeping activities, adequate.
Mount all lighting fixtures flush to the ceiling, if possible. Business Unit Requirement
All lighting fixtures or light bulbs equipped with protective shields Business Unit Requirement
Plant does not use mercury vapor bulb or mercury containing equipment. Business Unit Requirement
Make sure lighting meets local regulations for worker safety. Business Unit Requirement
Equip all air compressors with appropriate filters and dryers. Business Unit Requirement
Provide roof extractors / ventilators - over Returnable Bottle Washers Business Unit Requirement
Put clean-out doors in all ducts, so you can clean their interiors. Business Unit Requirement
Put traps on air-conditioning systems to catch condensation. Business Unit Recommended
Light intensity 30 cm from light source ranges from 300 lux in shipping, receiving and Business Unit Requirement
storage areas
Light intensity 30 cm from light source ranges from 800 lux in syrup room, filling room and Business Unit Requirement
General - Utility
lab

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General - Utility
Size your ventilation system to remove odors, steam, condensate, and fumes, as Business Unit Requirement
appropriate to each plant area
Ventilation ducts not directly located over tank openings and open containers Business Unit Requirement
Air intake openings equipped with insect/vermin proof screens. Business Unit Requirement
All openings exposed to weather equipped with screen louvers or screen dome chimneys to Business Unit Requirement
prevent entry of dust and rain
Fresh air intakes located at suitable places so as to avoid intake of undesirable odors Business Unit Requirement
,dust ,insects, or vermin into the plant.
Provide enough water to support cleaning and house-keeping activities Business Unit Recommended
Supply enough hand-washing and hose stations. Business Unit Requirement
Steam that is used as a sanitizing agent generated from potable water Business Unit Requirement
Use boiler additives that meet local regulatory requirements for use on food contact Business Unit Requirement
surfaces.
Activated carbon filter used to remove carryover chemicals and rust Business Unit Recommended
Air Compressors shall be of Adequate capacity, Non Lubricated type to ensure Oil free Business Unit Requirement
Compressed Air
The Compressor be provided with necessary auto controls to ensure Adequate, Consistent Business Unit Requirement
Utility - Air compressor
Air pressure as required by various Process Equipments & Dry air with pressure dew point
of 3 deg C for air which is not in direct contact with product and package and pressure dew
point of -40 Deg C for air which is in Direct contact with product and package (refer BP - SP-
136)
Air Compressor / Receiver shall have all necessary safety features / Documents to meet Business Unit Requirement
all Statutory requirements.
Receiver having valid pressure vessel certificate Business Unit Requirement
Compressor trip setting at 110% of receiver max. working pressure Business Unit Requirement
Drier provided Business Unit Requirement
Auto drain system Business Unit Requirement
Adequate Capacity Boiler be provided to meet steam requirements of Bottle Washer ( Cold Business Unit Requirement
start ) ,Syrup, CIP, Warmer etc for simultaneous operations.
Boiler fuel shall be Liquid / Gas like HSD / LDO / FO / LPG / CNG etc. ? (No coal / charcoal Business Unit Requirement
to be used)
Biomass Fule Boiler with Husk / Briqutte / Wood , if allowed as per local PCB norms may be Business Unit Recommended
used ?
Boiler & Steam lines be adequately equipped with Controls , Insulations , Condensate traps Business Unit Requirement
( like High / Low pressure cut offs, PRVs ) to ensure dry steam at required pressures at
use points.
Boiler

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Boiler be provided with adequate safeties to meet Statutory requirements and Operational Business Unit Requirement
Boiler convenience.
Boiler & Installation shall have all necessary Statutory / IBR approvals and meet the PCB / Business Unit Requirement
Environment norms, including valid IBR License.
Boiler feed water additives shall be non Toxic meeting Environmental norms and meant for Business Unit Requirement
Food Industry applications
Safety valve set at 110% of max working pressure Business Unit Requirement
Water level auto control Business Unit Requirement
Fusible plug available Business Unit Recommended
Steam line if above 3.4 kg/sq.cm-IBR approved Business Unit Requirement
Boiler meets all legal requirements Business Unit Requirement
Plant has capability for generation of culinary grade steam wherever used on a product BP-RQ-300 Requirement
contact surface or is a requirement.

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Power Connection / Sanction shall be adequate to operate all Operating loads at a time and Business Unit Recommended
meeting all safeties & Statutory requirements.
All Cables , Fittings / Fixtures be suitably Supported & Protected to avoid accidents. Business Unit Requirement
100 % DG back up with suitable changeover system be provided - DG installation & Business Unit Recommended
Power
Operation shall meet all Statutory requirements.

All cabling thru cable trays / conduits to enclose the cables completely in all processing Business Unit Requirement
areas
DG stack height: H = h + 0.2 x sqrt(KVA), where h is the height of the highest building Business Unit Requirement
PF correction system Business Unit Recommended

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Corrective
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Facility Assessment Checklist for CSD PET - Fountain

Assessed by:
Assessment Date:
Present
status
Canister Washer shall be of Approved Make & Model of adequate capacity - made of SS 304 / Business Unit Requirement
316 with smooth & Sanitary Finish - Including Pumps & Pipe Lines.
Washer be capable of washing the lids & along with O rings. Business Unit Requirement
Washer be capable of operating at 2.5 % caustic at 85 deg C Business Unit Requirement
Canister Washing
Caustic Jet Pressure be min 3 kgs / cm2 and contact time of min. 60 seconds. Business Unit Requirement
Washer shall be provided with Automatic temp controller - + / - 2 deg C and automatic & Business Unit Requirement
variable timer for Jetting, of standard & reputed make.
Final Rinse water be of Potable standards at > 2.5 kgs / cm2 pressure, with 1 - 3 ppm chlorine. Business Unit Requirement
Total bacterial Counts < 25 per ml.
Washed canisters shall have Nil Caustic carry over. Business Unit Requirement
Residual water in the canisters at outlet of washer, shall be < 2 ml/1500 ml Business Unit Requirement
Inspection light with mirror for Canister inspection, be provided. Business Unit Requirement
Canister Depressurization be done in dedicated area away from processing area. Business Unit Requirement
Canister Filling area shall be isolated from wash area. Business Unit Requirement
Canister Filling System be of Approved make & Model and of adequate capacity. Business Unit Requirement
Filling system be provided with Digital Weighing scale of reputed makes, with least count of 5 Business Unit Requirement
gms.
Filling system for Post Mix Canisters be provided with a suitable system - Regulator & pressure Business Unit Requirement
Canister Filling
gauge to top up CO2 of 15 PSI
Filling system for Pre Mix Canisters be provided with suitable Pressurizing system with, venting Business Unit Requirement
system etc. to ensure smooth filling with consistent net content.
All contact parts of Product, CO2 etc shall be of SS 304 / 316, PTFE / EPDM or other approved Business Unit Requirement
food contact materials.

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Document No :
Canister Filli
Present
status
Filling System be suitably built to have hot CIP to ensure thorough Cleaning & sanitation of all Business Unit Requirement
Product & related accessories.
The filled canisters shall meet Statutory / Company Coding requirements. Business Unit Requirement
100 ml. graduated cylinder(Class B accracy) of approved make Business Unit Requirement
250 ml. graduated cylinder(Class B accracy) of approved make Business Unit Requirement
20 oz cup for checking ratio,temp,flow rate etc. Business Unit Requirement
CO2 Wrench for CO2 cylinders Business Unit Requirement
Nozzle Brush for dispenser nozzle cleaning Business Unit Requirement
Fountain Lab Equipments
Calibrated Thermometers-Dial/digital(20 - 70 deg F) Business Unit Requirement

Extraction Tool for LEV maintenance Business Unit Requirement
Post mix valve screwdriver / socket tool for adjusting ratio Business Unit Requirement
Sanitizing Manifold for sanitation Business Unit Requirement
Carbonation Tester -Approved make Business Unit Requirement
Seapartor Assy for ratio checking Business Unit Requirement
Tank Gas Volume Tester (for Premix)-Approved make Business Unit Requirement
Snift Valve for pre-mix filling & canister degassing Business Unit Requirement
Premix Filling Valve / Premix Computer (Scale) Business Unit Requirement
Digital Vernier Caliper Business Unit Requirement
Note: If plant laboratory not located conveniently where microbiological sample ( securely
transported below 10 degC) collection to plating time >8hrs, distribution centres should have all
facilities of plant laboratory including water analysis & microbiological analysis .

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Document No :
Responsibilit Target
Corrective Action
y Date

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Document No :
Responsibilit Target
Corrective Action
y Date

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Document No :

INSWABU - Check List - Sparkling PET - 20190619

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INSWABU - Check List - Sparkling PET - 20190619

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Document Name

Facility Name & Address:

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Plant Exterior & Grounds

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Processing Areas- Access Control & Hygiene

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Processing Areas- Floors & Drainage

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Plant is not using mercury vapour bulbs. ISO/TS 22002-1:2009 Requirement

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Signed Off Organistation chart of the unit Business Unit Requirement

Adequate manpower as per standard maning provided by BU Business Unit Recomendation

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Doors installed with tight fittings Business Unit Requirement

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Present Corrective Responsibil

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 Classified - Internal use_x000D_ Classified - Confidential

Revision Date :01/07/2015 # Classified - Confidential

Revision Date :01/07/2015 # Classified - Confidential

Revision Date :01/07/2015 # Classified - Confidential

Revision Date :01/07/2015 # Classified - Confidential

Revision Date :01/07/2015

Revision Date :01/07/2015

Revision Date :01/07/2015 # Classified - Confidential

Revision Date :01/07/2015 # Classified - Confidential

Revision Date :01/07/2015 # Classified - Confidential

Is the Filler of Approved Make & Model

Revision Date :01/07/2015 # Classified - Confidential

Capper shall be of Approved Make, Model & Design

Revision Date :01/07/2015 # Classified - Confidential

Revision Date :01/07/2015 # Classified - Confidential

Revision Date :01/07/2015 # Classified - Confidential

Revision Date :01/07/2015 # Classified - Confidential

BP-RQ-250 Requirement (if applicable)

Business Unit Requirement

Business Unit Requirement

Business Unit Requirement

Business Unit Requirement

Business Unit Requirement

Business Unit Requirement