PepsiCo India holdings Pvt. Ltd.

A project report on
Quality control and food safety standards

In Supervision of: Submitted by:

Mr. Karim Rizaul Pradeep Kr.
Singh ( B.Tech Biotech)
Manager (Quality control) Amity
University, Lucknow

Enrollment No. - A7104106076

 Roll No.- LK23061076

Index

1. Acknowledgement

2. Part ‘A’
Total quality management in beverage industry

3. Part ‘B’
Food safety standards in beverage industry
 ACKNOWLEDGEMENT

With deep sense of regard, I take this opportunity of expressing my profound gratitude
and indebtance to Mr. Sanjay Singh (G.M.) and Mr. Ravi Singh, Manager (H.R.),
PEPSICO India Holdings Pvt. Ltd. Jainpur, Kanpur Dehat, for accepting my request and
for providing me this opportunity fo training.

I am also thankful to Mr. Karim Rizaul, HOD

(Quality control) and Miss. Archana Singh (Microbiologist) and all staff members for
providing me invaluable suggestion, guidance and encouragement. Without their
support and encouragement; it would not have been possible for me to complete this
task.

Pradeep Kr. Singh

 Contents

Part ‘a’

Total Quality Management In Beverage Industry

1. Introduction

2. Water treatment plant

3. Making of beverages

4. Microorganism that spoil beverages

5. Pre activities to prevent possible micro damage in beverage industry

6. Microbiological control and sampling program

7. Microbiological media

8. Effluent treatment plant

9. Conclusion
 INTRODUCTION

The term quality is refer to an ongoing analysis of operation to verify goods and
services meet specified standard, or to better answer customer and/or user complaints.
In other words we can say step taken to make sure that a company’s product or services
are of sufficiently high quality this is known as quality assurance. Rapid
industrialization increase wide range of competition to make better customer
satisfaction. They are spending a lot of money on quality assurance of their product.
Today there are many food products and beverages are produced by many industries
and are directly consumed by human. So consumer point of view these products should
be safe for use. It means there should not be any quality assurance is very important in
beverage and food industry.

Quality assurance includes all chemical and microbial

testing in the industries. Sanitation is an important part of the quality because it
prevents the contamination in beverages microbial contamination is reduced by the
effective sanitation procedure. After finished product analysis the raw material is also
analyzed. Here in PEPSICO India Holding Pvt. Ltd. The major effluent is waste water.
The company recycles the water by its own effective effluent treatment plant.
 Water treatment plant

Many people & beverage industry depend throughout the world on underground
sources of drinking water and potable water. Water is major constituent of beverage or
soft drinks. In soft drink industry almost 99% water is used for making soft drinks and
cola and non cola beverage. Untreated ground water is mostly pure and cleaned than
any surface water. The PepsiCo India Holdings Pvt. Ltd. Jainpur has it own source of
water supply.

This plant is also using the ground water by using bore well. However, this water is
now a days polluted by different types of human activities like sewage disposal in
unscientific ways, refuse dumps from yard manures , pesticide and chemical fertilizer
contamination, disposal of hospital water, industrial effluents discharge etc. E. coli and
other bacterial contamination are being reported from ground water sample of different
regions. Heavy metals are also present in different ground water sample collected from
industrial region of India.

Therefore water treatment is necessary for the removal of impurities, micro organism
and heavy metals which cause disease and also alter the product quality of beverage
industries. There are various methods of water treatment like membrane filtration,
reverse osmosis, nano filtration, and ultra filtration and electro dialysis reverse .

Coagulation:
Coagulation is six step process-

1. Mixing tank
2. Flocculation chamber
3. Settling zone
4. Sludge recirculation
5. Sludge discharge
6. Treated water collection

Procedure-
 1. Coagulant, bleaching solution and lime mix together in the reaction tank and
cause almost all of the raw water alkalinity(usually present as bicarbonate) to be
converted to carbonate, which precipitates out of the solution and settle to the
bottom of the tank.
2. At the same time, a floc is formed that in traps calcium carbonate, suspended
solids, oxidized iron and manganese and many other contaminants.
3. This floc grow in size, become heavy and help to alkalinity and impurities to
settles more quickly to the bottom of the reactor (this forms the sludge).
4. If every thing is sized and operated correctly the treated water should easily
reach 35 to 40 mg/l alkalinity and be free of odor, color, turbidity, metals and
many organics.

Reactions:

 Ferric sulphate or ferrous sulphate +chlorine

Ferrous sulphate +Chlorine forms ferric sulphate

Ferrous sulphate + lime forms ferric hydroxide

 Ferric hydroxide diminishes contaminates, color, turbidity, organic matter, microbe

sink to bottom charge neutralization.

Important points:
1. The primary purpose for coagulant addition is to assist in the precipitation of the
insoluble alkaline salts, created by the lime based reaction.
2. The addition of the coagulant will also assist in the removal of turbidity causing particle
such as bacteria, algae and colloids.
3. Two commonly used coagulants are ferrous and ferric sulphate they provide good
coagulation over a wide range of water condition especially at light pH typically
encountered in lime treatment system.
4. Aluminium sulphate or alum can be used but it effectiveness is optimum in the 5.5 to
8.0 pH range which is typically cited as too low for alkalinity reduction this become an
issue when sodium carbonate is used for pH control.

PEPSICO has appreciable plant operating data when alum is used effectively with hydrated
lime at pH value near 10.0. Both ferrous and ferric sulphate requires hydroxide alkalinity in the
form of lime to form the desired hydroxide floc particle.

Coagulation principle:
Coagulation is two step processes:
 1. Charge neutralization: the ferric sulphate salt (coagulation) neutralizes the surface
charge of the suspended solids which are typically negative. This eliminates the natural
repulsive solid of suspended solid.

2. Destabilization: the ferric hydroxide will hydrolyze these neutralized suspended solid
to form insoluble precipitate which will entrap particle and settle out as sludge.

Main product:

PEPSI

7UP

MIRINDA
MOUNTAIN DEW
SLICE
LEHAR SODA

Flow chart of WTP

 Raw water

Coagulation tank

Intermediate tank

Sand filter tank

Activated carbon
purifier tank 1

Activated carbon
purifier tank 2

Treated water

Making of beverage
The first step in making of beverage is making of syrup. The making of syrip is
completed in two steps and these are:

Preparation of simple syrup:

 First accurate amount of treated water heated at 80 °C in a tank.
 Then accurate amount of granulated sugar is added in the tank. Sugar should
be added slowly into treated water.
 While sugar is being added, the tank agitator is in constant operation.
Powered activated carbon is added to the solution and the simple syrup is
agitated so that the carbon is in contact with the syrup for approx 30 min. the
agitation should continue until the sugar is completely dissolved
 After it has been completely dissolved is then filtered through a filter that is
pre coated with diatomeous earth.
 Care is taken to ensure that no carbon or DE is going through the filter by
checking the clarity. If so, the syrup is re-circulated until desired clarity is
obtained.
 When filtrate is done then it is transferred into syrup tank through plate heat
exchanger (PHE) where the temperature of the simple syrup is brought down
to below 25 °C.

Preparation of finished syrup:

Before adding the concentrate it is made sure that the filtered or treated simple syrup is
within specification for color, taste and odor. The temperature should be below 25 °C.

Bottling operation:
Bottles that have returned from market have dirty lots having chipped necks, foreign
particles. These are segregated before feeding in bottle washer to clean them. Cleaned
and microbial free bottles discharged at discharge end of bottle washer.

Mixing package
In mixing unit there are two reservoirs: one for syrup and other for treated water. Both
of them are mixed in separate tank with specific ratio of dilution to get beverage. After
that this solution is passed through PHE to cool down at 2to 3 °C,

Then injection of CO2 takes place. It varies according to product requirement. Then
beverage is collected in big tank from where beverage is supplied to filter to be filled in
the bottles and finally passed ahead for crimping, from where after final inspection,
cooling and testing, it is passed for shipping, warehousing and finally for the
marketing.

Concentrate

Flavor Acidulate Additives

Primary Liquid Color

Secondary Dry Antifoam

Preservative

 Flavor contains the oil and that produce the basis of our trademark taste.
 Acidulates provides the sharpness characteristics of soda normally
phosphoric or citric acid based.
 Additives are additional components that vary by product formula.

Syrup batching
Syrup batching is combination of concentrate components and simple syrup. Finished
syrup is sent to proportioning and mixing.

Control point in syrup preparation:

1. Brix for simple

2. Finished syrup:- final volume, brix, control drinks.
3. For increase in the brix added filtered sugar.
4. For decrease in the brix added treated water.
Staging:
Staging is an efficient way to verify that all ingredients are on hand and suitable for use
  Ensure correct amount of concentrate ingredients for the no. of unit o be
batched.
 Inspect for leak and breakage.
 Do not split concentrate package.
 Read label and date code.
 Document on the batch control record.
 Ageing of Pepsi flavor profile.

Purpose of control drink to determine:

 If the syrup mixture is correct.

 If the finished product will meet the target.
 If the test is acceptable.
 Line beverage target for titrable acidity used for diet drinks.
 Line beverage target for brix used for regular drinks.

Control drinks are drink prepared using controlled water and finished syrup. Accurate
batching and control drinks will result in good caffeine results from Pepsico
International Trade sampling program.

Effect of alkalinity and hardness on control drinks and titrable

acidity:

1. Hardness effect TA
 About 0.7 ml increase per 200 ppm.
 If we use the hardness inhibited method for TA. No correction is necessary.

2. alkalinity effects TA
 About 1 ml decrease per 50 ppm.
 Must correct target alkalinity in order to match beverage document TA
target.
3. If we use tripotassium citrate then no need to compensate for hardness effect.

Carbonation in beverage
  It is a process of dissolving CO2 in water (beverage). The purpose of
carbonation is to provide sensory experience, protection from micro
organism and package integrity.

 1 gas volume = the cubic volume of CO2 gas (at standard temperature and
pressure of 0 °C and 1 atms which dissolve in an equal amount of liquid).

 1L CO2 gas + 1L of liquid

 Gas volume are directly proportional to the ratio of temperature and

pressure

The equilibrium pressure in the head space and the temperature of an integrated
container are directly related to the amount of CO2 in the beverage.

Microorganisms that spoil beverage

1. The WHO asserts, “Infectious disease caused by pathogenic bacteria, viruses and
protozoa or by parasites are the most common and widespread health risk associated
with water”.

2. The most notable and widely accepted group of indicator organism is coli form
group, which refers to the gram negative rod shaped bacteria capable of growth in the
presence of bile salts or other surface active agents with similar growth inhibiting
properties and able to ferment lactose at 35- 37 °C with the production of acid, gas and
aldehyde within 24-28 hrs. They are also oxidase negative and non spore forming.

3. Water borne Microorganisms are transmitted as a result of direct contact with fecal
treatment. The fecal thermo-tolerant coliform with E.coli being the most prominent
member, fecal Streptococci and anaerobic spore forming bacteria, the target of which is
primarily Clostridium perfringens.

4. Another Microorganism that has recently become a threat to both the municipal and
industrial water treatment areas is the protozoan, Cryptosporidium Parvium

5. Cryptosporidium Parvium is a protozoan parasite affecting the gastrointestinal tract

of humans and animals. It is shed in the feces in the form of an “oocyst” which has a
hard shell to protect it from the environment. This also makes it highly resistant to
disinfection by chlorine and ozone; although UV disinfection has proven to be
extremely effective at its inactivation.

6. In addition to water borne microorganism, water supplies may also be subjected to

inhabitation by “nuisance microorganism”. These microorganisms, as their name
implies are typically not associated with any direct health effects.

Bacteria in this broad category include the following:

 Iron bacteria-these bacteria incorporate ferrous ion part of their normal

physiological process, and oxidize in to insoluble ferric form.
Genera include: Lepothrix, Clonothrix

 Manganese bacteria- instead of iron, these bacteria may incorporate manganese

and oxidize it.
 Sulphur bacteria – many sub groups of sulphur bacteria exist depending on the
specific sulphur form utilized as nutrient substrate. The more troublesome group
to the beverage water treatment plant is the sulphate reducing bacteria. Since
they produce the malodorous hydrogen sulphide.
 These include the genera Desulfomaculum. Some species of pseudomonas have
been implicated in production of organo-sulphur compounds in water. Besides
these, some other microorganism may also contaminate the beverage. They are:
 a. Other bacteria- thiobacillus, proteus, lactobacillus, vibrio etc.
b. Protozoan- entamoeba histolitica etc.
c. Fungi- yeast, achlya and some other molds etc.
d. Algae- diatoms, volvox etc.

There are many areas that may cause micro contamination in beverage:

 Water- poor filtration and/or polishing can allow foreign matter in to

manufacturing process. This is the main cause of micro contamination in
water.
 Sugar- foreign matter in the sugar can be transferred to the beverage if
not properly filtered. If sugar is not properly stored and handled it may
also cause micro contamination.
 Carbon-dioxide- foreign matter or contaminates in the CO2 supply can
create microbial contamination.
 Concentrate- if the containers of the concentrate are not properly sealed,
it may cause contamination. Also when containers are not properly stored
at low temperature.
 Conversion- if all entrance points to the manufacturing process are not
protected and controlled to prevent foreign matter. All packages are not
properly rinsed prior to filling. Poor application of crown/closure which
leads to loss of CO2.
 Storage and handling- because of poor storage and handling product
that has lost CO2 is more susceptible to microbial growth.
 Unknown other- there are some other unknown reason, which may cause
microbial contamination.

Pre activities to prevent possible micro

damage in beverage industry
SANITATION
Sanitation refers to treating a cleaned surface to destroy contaminant organism and
reduce the total vegetative cell population to a safe level.

Purpose of sanitation:
Sanitation problems have some negative effects on the beverage. The way to avoid the
sanitation problem is to keep the beverage plant, the production and processing
equipments and the beverage ingredients as sanitary as possible at all times. Poor
sanitation can lead to taste problems, appearance discrepancies or spoilage.

Sanitation process:
1. Sanitation of equipments- The most important sanitation program in the
beverage plant deals with the cleaning and sanitizing of those surfaces that come
in contact with syrup, beverage or ingredients used in their preparation. Proper
sanitation performed at the recommended frequency will minimize and most
likely completely eliminate the potential for bacteria, yeasts and mold
reproduction and growth.

The most successful program has been identified as the “Five step” procedure
and this should be used for all syrup and filling room equipments.

a) Rinse- rinse all surface with adequate water until syrup and beverage
residue are removed where possible, warm water is preferred (50- 60 °C
/120-140 °F).
b) Clean – clean with hot detergent. 1-1.5 % caustic soda is used as cleaning
agent. Temperature of cleaning solution should be 60-65 °C.
c) Rinse- rinse with adequate water until the cleaning solution is removed.
d) Sanitize – sanitize with a strong chlorine solution with hot water as
follows: if chlorine, 100 ppm free chlorine for 20 min. if hot water is being
used, then sanitize at 85 °C for 20 min.
e) Rinse – rinse with fully treated water. When chlorine solution has been
used as the sanitizing agent, rinse until all the traces of chlorine has been
removed. When hot water has been used, the equipment should be
gradually cooled to avoid damage.

This sanitation process offers key advantages:

 Automated step by step procedure can be used to assure that an entire sanitation
is followed with correct flows and holding times.
  Process control will hold temperature at the correct point for hot sanitizing and
will ensure the correct holding time, with less chance of high or low heat zones.
 Sanitation program in operation cannot cross contaminate normal production.

2. Sanitation of bore well- One of the most important aspects of new bore well
construction is the proper sanitizing/disinfecting of the well. The components of
the bore well should be initially sanitized prior to the final setting. This is often
accomplished by light dusting of hypochlorite powder or soaking it in a
hypochlorite solution.

3. Sanitation of water- The coagulation tank or reaction tank is the first piece of
equipment in the water treating plant.

 The FeSO4, lime and chlorine join the raw water as it flows in to the mixing
zone of tank.
 The coagulant, usually FeSO4 with the assistance of the chlorine and lime,
forms a heavy floc, which entraps the particle of debris, dirt, organic matter
and other undesirable material in the water and settles slowly towards the
bottom of the tank.
 While the floc is forming, the lime is causing the alkaline components to
precipitate out of water. They are precipitated towards the bottom of the
tank.
 While the water in the tank flows towards the draw off pipe, because of its
own weight is left behind continually trapping particles of debris as it settles.
 The treated water lows upward toward the treated water draw off pipe and
out of the tank. The chlorine in the coagulation tank, in addition to oxidizing
organic and in organic, reacts with micro organism so that sanitary water is
assured.
 The treated water than flows through a sand filter for straining (removal of
floc particles), a carbon filter to remove chlorine, then micron polisher and
final UV disinfector, which help in reducing the number of microorganism.

Sanitation process applies daily on a periodic basis. There are some key elements of
sanitizing the water treatment system:

 Sand filters and carbon purifiers should be back washed on the daily basis.
The purpose of this backwash is to take debris and sediment out of the beds
and also resettle both the sand and the carbon.
 On periodic basis, the carbon charge should be not water sterilized, the safest
approach of this, when the carbon purifier can with stand at high
 temperature is to fill tank with hot water. Then allow steam at the bottom
until the temperature reaches 75 °C. this temperature should be maintained for
30 min. Then the liquid should be drained slowly and should allow cooling.
 The purpose of steam or hot water is not only kill the microorganism within
the bed of carbon, but also to flush out as much organic materials and
nutrients as possible.
 On a periodic basis, the sand filter should be sanitized.

4. Sanitation of bottles-

 Bottles in feed: This the first chamber of the bottle washing machine. First the
bottles are send inside the chamber.
 Residual draining- This is the next stage where any residue that might be
present inside the bottles is drained by inverting the bottles.
 Pre rinse jet- Here bottles are washed by treated soft water.
 Pre soak- In this region bottles are washed by treated water, which has 1.5%
of caustic for washing and sanitizing purpose. This region should not
maintain the high temperature and high caustic percentage. The temperature
range is 50-55 °C.
 Pre heat rinse- In this region bottles are rinsed with hot water for the removal
of caustic and also for minimizing the microbial contamination.
 Hot caustic tank- After pre heat rinse the bottles come into this tank where
the temperature of the caustic solution is high and the percentage of caustic
solution is maintained higher than 2-2.5% in the presoak region. The
temperature range is 72 to76 °C.
 Hot caustic soak with high pressure jetting- In this region the bottles are
washed with high pressure jetting by which if any foreign matter is present
inside the bottle, may come out.
 Warm caustic tank- In this tank the temperature is kept lower than the hot
caustic tank.
 Warm caustic tank with high pressure jetting- In this region the bottles are
again jetted with pressure to remove any foreign matter inside the bottles.
 Warm water jetting- In this region the bottles are washed with warm water to
low down the temperature of the bottles for avoiding the breakage.
 Caustic carryover water jetting- In this region bottles are jetted for avoiding
the carryover of caustic solution.
 Warm water jetting- This time the bottles are jetted with warm water.
 Warm water soak- here bottles are with warm water soak that have some
percentage of caustic.
 Cold water jetting- This time bottles are just washed with cold water to
maintain the temperature of the bottles.
  Fresh water jetting- This is the last chamber of bottle washing machine. In this
region the bottles are jetted with fresh water. The bottles that come out from
the above process are fully sanitized. The above process takes around 22-33
min to clean a bottle.

5. Sanitation of filling, beverage processing and syrup room - The basic criteria
for sanitary syrup making, processing and filling operation are:

 Equipment for syrup making processing and filling should be maintained in

spotlessly clean and sanitary condition (inside and outside).
 A clean floor that is kept in dries condition and free of beverage /syrup residue
and glass.
 Clean walls and ceiling, free of mold, strain and/or discoloration syrup
condensate.
 Fresh atmosphere based on frequent air changes and low humidity.

The processing area should present a pleasant working environment. The filling area, in
particular requires attention because of the level of activity and need to protect the final
product before the container is sealed.

 Frequent cleaning of process and filling area and maintaining them as dry and
fresh as possible.
 After everyday operation the five step sanitation program should be conducted
on all syrup room processing and filling equipments.
 Where sensitive products are packaged or product without natural protection or
preservative such as sodium benzoate, the step of sanitation procedure should be
executed between product changeovers. Pulp particles are difficult to remove
from stainless steel surface and , if contaminated can transfer that contamination
to different product that follow:

Product that are sensitive or susceptible to spoilage the five step procedure should
be run before production of the sensitive product.

INSECT CONTROL-

The best way of eliminating insects from the bottling plants is to keep the area clean,
free of debris and dry. Insect are more comfortable in wet, high humidity
environment. For flying insect, attraction lamps that kill by electrical shock are
effective and safe.
 RODENT CONTROL-

Important to successful rodent control is limited areas to hide. Drains should be

covered. Areas that are suitable for rodent infestation are difficult to clean. These
should be identified and properly improved. Bait traps can also be used inside the
facility. There are method of discouraging rodents using light and sound.

AIR CHANGES-

Frequent changes of air, particularly in the processing and production are important
in reducing sanitary concern. A fresh, clear and dry room discourages reproduction and
growth of microorganism. Such condition also helps to reduced infestation from
rodents and insects.

UTILTY ROOM-

It should be clean and free of debris. It is particularly important that nothing flammable
should be stored in the utility room. Utility room should have completely unobstructed
floors and easy and secure access.

CO2 equipment and area:

CO2 manifolds, regulators and storage areas should be maintained clean and with
unobstructed access. The area should free of debris.

GENERAL STOARGE:

General storage area requires good housekeeping with particular emphasis on floors,
scrubbers, brooms etc. ongoing sweeping, cleaning of debris should be done on a
needed basis. The entire warehouse area should be cleaned daily and on a weekly basis.
For yard, it is important to keep the area clean and empty of any stored materials and
scrap materials.

SANITIZING AGENT
For the 5 step sanitation program used in the syrup room and for packaging
equipments, the two acceptable alternatives are chlorine and hot sanitizing both
approaches has advantages.

Chlorine: chlorine is the most frequently used sanitizing agent in beverage plants. One
weakness of chlorine is that it cannot penetrate in to crakes in gasket or hard to reach
area unless the equipment is flooded and the problem area are identified and corrected.
Aside from this, chlorine is an excellent sanitizing agent with good kill efficiency. It
should be used at a pH of approx. 6-8. Chlorine gas may offer economic advantages, but
requires special precautionary measures.

Hot sanitizing: it is an excellent sanitizing process with good killing efficiency. One
issue is that the temperature of the area or the surface being sanitized must be heat at
85°C for 15 min to assure kill. An advantage is that the heat tends to penetrate in to
gaskets, cracks and hard areas. After hot sanitizing, the temperature should be bought
to ambient slowly to avoid equipment damage.

Caustic (NaOH) : hot caustic solution at 60 °C is a powerful cleaning agent and can be
an important sanitation tool when dealing with pulp products. The caustic will
essentially burn pulp products. The caustic will essentially burn pulp residues off
stainless steel surface. Even though hot caustic is an efficient cleaning and sanitizing
agent, a disadvantage is that it is extremely dangerous and hard to rinse. Caution
should be use to make sure that all the caustic is removed from the lines and the rinse
water used to remove it checks out negative to phenolphthalein.

MICROBIAL CONTROLS

Microbial testing does not reduce the need for strict sanitation in the beverage plant.
Instead, it is intended to measure the effectiveness of the plant’s sanitation program.
There are six key areas where periodic microbiological testing offers additional
protection:

 Incoming material such as water and sugar.

  Water and simple syrup after treatment.
 Finished syrup just prior to the packaging line.
 Finished beverage at the time of filling and sample taken from storage on from
the trade.
 Surface testing of equipment and critical process points.
 Packaging: washed bottles, rinsed cans, and transfer tanks.

A minimum sample testing program should include water, sugar, syrup and beverage.
Membrane techniques or standard plating methods are acceptable for total bacteria
counts and for yeast and molds. When checking for coliform in water samples the
membrane technique is strongly recommended.

Membranes allow a longer, more representative sampling is confirmed positive or

negative with single plating. Because of this, possible contamination can be detected
and dealt more readily.

MICROBIOLOGICAL SAMPLING PROGRAM

This type of sampling program should:

 Confirms the sanitation techniques are effective.

 Confirms that raw water is free of serious contamination.
 Assure that the product in the market is safe, stable, legal and will enjoy the
usual shelf life.

WATER TREATMENT SYSTEM: aseptically collect raw water and treated water into
sterilized plastic containers or whirl pack bags. Then analyze by membrane filtration.

SANITATION RINSE WATER: total microbial counts from effectively cleaned and
sanitized equipment surface are in general very low. If counts exceed recommended
limits, thoroughly investigate sanitation practice to determine the deficiencies and
contamination source.

SANITATION RINSE WATER FROM BOTTLING EQUIPMENT: aseptically collect

rinse water (from tanks, pumps etc.) in to a pre sterilized container or whirl pack bag.
Analysis by membrane filtration.
FILTER VALVE SANITATION RINSE WATER: filter valve sanitation rinse water is
the representation of the sanitary condition for the filling process, including rinse and
closure application.

 Use nitrogen or CO2 to pressurize the filter to between 15-25 psi.

 Collect filler valve rinse water from the pressurized filler in sealed finished
product containers that have previously gone through the rinse/washer,
conveyor, filler and capper/crowner/sealing equipment. do not use whirl pack
to collect these sample.
 Invert to mix thoroughly.
 Wipe the external bottle shoulder or pop up cap dip with 70% alcohol.
 Analyze by membrane filtration.

WATER CONTAINING CHLORINE: water containing chlorine must be treated with

sodium thiosulphate to neutralize the chlorine present, allowing for an accurate
microbial count. When sampling water containing chlorine aseptically collect the
sample in a whirl pack bag containing thiosulphate as pre weighted tablet. Analyzed by
membrane filtration.

DRY AND LIQUID SWEETENERS:

 Aseptically weight a representative sample of dry or liquid sweetener into a pre

sterilized plastic container.
 Add sterile phosphate buffered diluents of sterile water.
 Mix thoroughly by shaking vigorously.
 Analyze by membrane filtration.

SIMPLE SYRUP AND FINISHED SYRUP:

 Aseptically place a representative of syrup into a pre sterilized plastic container.

 Analyze by membrane filtration.

FINISHED BEVERAGE:

 Remove sample of bottles directly from the production line or ware house.
 Invert bottles gently several times to ensure contact with all internal surface and
to obtain a representative sample.
 Wipe the bottle shoulder area or can lid and the appropriate opener with 70%
alcohol.
  Open bottle pour the sample beverage. Do not wipe the lip of other containers
with alcohol once opened.
 Analyze by membrane filtration.

WASHED BOTTLE:

 Aseptically take the washed bottle from production line, cover the bottle neck
with the piece of tin foil, which is sanitized with 70% alcohol.
 Open bottle pour the sample beverage. Do not wipe the lip of other containers
with alcohol once opened.
 Analyze by membrane filtration.

CROWN:

 Aseptically take the crown from production line, cover the crown with the piece
of tin foil, which is sanitized with 70% alcohol.
 Open the sterile swab container, grasp the end of the end of the stick and remove
it aseptically.
 Open the container of sterile band buffered diligent; moisten the swab head with
the buffer and press out of the excess solution against the interior portion of the
crown with a rotation motion.
 Return the swab head to the sterile buffer tube; position the swab head in the
tube and break against the lip of the vial, leaving the swab head inside.
 Shake the swab vigorously for 10 sec to dislodge the organism in to the buffer.
 Analyze by membrane filtration.

EFFLUENT TREATMENT PLANT

The effluent received in the effluent water treatment plant is segregated in two different
streams:

Stream 1: pet line effluents, KHS effluent, water treatment room effluent.

Stream 2: syrup room effluent, slice line effluent.

Stream 1 and 2 is subjected directly to an aerobic treatment.

  The effluent is first collected in an aerobic digester. Here 70 to 80 % of load is
decreased. In aerobic digester, filtration chamber is fitted for the filtration of oil
and grease.
 In filter water, we dose DAP, urea, lime and soda. The purposes of dosing DAP
and urea is to provide nutrients and nitrogen.
 Then effluent comes in equalization tank, her sludge is digested in digester.
 Now effluent sends in secondary clarifier. The operation is based on centrifugal
force.
 Again took sludge in digester in form of inlet.
 Then water comes in aeration tank. Here aeration is provided by continuous
agitation.
 Now water comes in intermediate tank.
 Now we collect water for dosing of ferrous, bleaching, lime, soda and poly-
electrolytes.
 Then water subjected to clarifier.
 Now the water comes in treated effluent tank and sends further treatment in
water treatment plant.

Conclusion

It is necessary to provide an environment in which the organism and waste are

maintained in intimate contact in the presence of oxygen. Greater efficiency of
treatment and use for a wide variety if beverage wastes can be excepted when the types
of microorganism responsible for treatment are known and their optimum
environmental condition have been established.

The microbiological analysis is also very important in beverage industry, it can

cause off flavor, bad color, high packaging pressure, slimy texture and many more
problems. This analysis shows the real sanitizing condition of the plant and the
machine. By using swab test, environment air test and finished product microbial
analysis we can check the microbes presence.

The beverage industry sanitation is concerned with aseptic particles in the

preparation, processing and packaging the beverage of a plant, the general cleanliness
and sanitation of plant and premises and the health of employees. Specific duties in
connection with the beverage; the provision of good water supply; prevention of the
contamination of the beverage at all the stages during processing of equipment,
personal and vermin; and supervision of packaging and warehousing of finished
product, the supervision of cleanliness and sanitation of plant and premises.

Contents

Part ‘B’
Food Safety Standards In Beverage Industry

A. Introduction
B. Discrepancy Matrix Rating System

1. Organization and documentation

2. Personnel

3. Inspection

4. Foreign object management

5. Microbiological control and allergens

6. Pest control

7. Sanitation

8. Maintenance control

9. Facility design

10. Environment and waste management

11. Audit of WTP

C. Conclusion

Introduction

The AIB consolidated standards for beverages plants were published as a tool to permit
beverage (alcoholic, non alcoholic, carbonated, noncarbonated and juices) processors to
evaluate the food safety risks within their operation and to determine the levels of
compliance with the criteria in the standards. The standard contains the criteria and the
rating method used to assassin a numbering numerical score (rating) to the plant. These
criteria are derived from the following good management principles.
 The U.S. Federal
Food Drug and Cosmetic Act (1938); Good Manufacturing Practices, CFR Title 21, Part
no. (1986); U.S. Military sanitary standards: The U.S. Federal Insecticides, Fungicide and
Rodenticide Act; EU regulation no. 178/2002 and EU Regulation no.852/2004; the food
safety Act 1990 (Amendment) Regulation 2004 (U.K.); General Food Regulation
2004(U.K.) and Codex Alimentations Commission Food Hygiene- basic text 1999.

Discrepancy matrix rating system

The PepsiCo/AIB International Global Beverage food safety standards (International)

are a compilation of beverage industry standards and specific requirements of PepsiCo
and PepsiCo International. The audit manual is divided in to two parts:

 The written requirements based on the AIB consolidated standards for beverage
plant.

 PepsiCo minimum mandates and the matrix itself, which defines the point
deduction for each item not meeting the requirements.
Key points to the Audit
The AIB audit is approx. 75 % floor audit and 25% record review. The audit will be a
very comprehensive examination of your equipment, processes, buildings, grounds and
so on.

The Auditors Arrival

The AIB auditor will arrive at your site and conduct a brief introductory meeting with
your plant staff. He/She will explain the expected course of the survey. the audit will
also advise you that he/she will open equipment will require assistance from
maintenance or other personnel. The auditors will not stop production randomly
examine equipment.

The auditor will advise you that wellheads (and other secure areas) will be examined so
appropriate keys or maps should be obtained to expedite the audit. The auditor will
also notify you that he/she will require access to specific product strainers/ filters and
may discuss with you a convenient time foe this task to occur.

The auditor also review with you how AIB rating and matrix ratings are determined.
The auditor may have some additional comments on request that may expedite the
audit process and these will discussed during the opening meeting.

The Plant Audit

The plant audit is not intended to disrupt your production and the auditor will work to
avoid disruption. You should discuss with the auditor if disruptions are occurring so a
different audit route can be followed. The auditor will identify the deficiency or non-
conformance and as an educator, will offer you suggestion for improvement . you Are
not obligated to follow these suggestion. If you disagree with auditors interpretation of
the AIB standard or the PepsiCo requirements, you should discuss with the auditor and
make every effort to agree on the severity of an item. The auditor will provide an audit
summary at the conclusion of each audit day. Understand that the auditor will have a
rating under the conclusion of the survey so do not except to discuss the ratings at these
summary ratings.

Audit conclusion
The audit will conclude with a final meeting, review of the audit findings and ratings. A
draft copy of the report or auditors report will be left immediately, at the conclusion of
this audit, with a final report arriving to you shortly thereafter.

Audit Rating
1. The AIB rating

The AIB consolidated standards for beverage plant has been designed in systematic
manner that allows for effective auditing, and also serve as reference guide when issues
are identified. The standards are divided in to five categories, including a review of the
written food safety programs (adequacy of the food safety program), and proceed to a
closure examination of individual pest control programs, operational method, and
maintenance for food safety and cleaning practices.

Each category has a value of 200 points. Category scores are assigned as follows:

(180-200) minor improvements are needed, but there exists no evident risk or potential
hazard to food safety.

(160-175) some improvements needed to correct potential food safety hazard or

regulatory non compliance that have been noted.

(140-155) serious findings, an important food safety risk or risk of program failure has
been noted.

(<135) unsatisfactory findings, an imminent hazard, program failure, Product

contamination or extreme departure from regulatory standards has been noted.

A score below 135 is any one of the

five categories will result in overall rating of “unsatisfactory”, regardless of the
cumulative total. The auditor’s job is to review all the facts and findings when a
deficiency is identified, so a proper assessment of overall food safety of the plant is
made and a fair rating is assigned. Once the deficiencies in each category are outlined
and the worst issue in each category has been identified, then a rating I finally assigned.
It is the worst issue in that category that will determine the point value, the total no. of
item and the level of severity of the worst item is determine whether the category score
is at the upper or lower end of the scoring range.
The Matrix rating
Also beginning with 1000 points, the matrix is divided in to 11 areas including:

1. organization and documentation

2. personnel
3. inspection
4. foreign object management
5. microbiological control and allergens
6. pest control
7. sanitation
8. maintenance control
9. facility design
10. environmental and waste management
11. minimum mandates

Each deficiency noted during the audit is assigned a point deduction based on where it
is found in the matrix. The left column of t6he matrix is un satisfactory, the center
column is major and the right column is serious. The left most column of the matrix
provides a reference number to the standard, should you require additional points.

The “minimum mandates”, are requirement of PI and a failure with one result in an
unsatisfactory audit report.

Total score of 700 points bare needed to pass the audit so a point value of 305 is use for
assigning satisfactory items (resulting in a rating of 695). For items that fall in the center
column, a point value of 40 points is assigned and for items in the right column 202
points deduction will occur.

Organization and documentation:

 Responsibility and authority for assuring compliance with federal, state,

governmental or any other appropriate regulatory law or guideline shall be
clearly assigned to a component supervisory level persons or persons and a
functional organizational chart shall be maintained.

 The competent supervisory level persons shall ensure that all employees are
aware of their responsibilities and mechanisms are in place to monitor the
effectiveness of their operation. The company does have a system in place to
ensure that it is kept informed of all legislation: food safety issues: legislative,
scientific and technical developments and industry codes of practice.
 There will be a statement showing the commitment of the top level management
of PepsiCo International to food safety.

 Each food plant shall establish a formal food safety committee or establish
regular food safety audits through participation of a multidisciplinary team. A
food safety committee should be multidisciplinary in membership and include
member’s pf the plant leadership team. The committee shall formally meet on a
predetermined frequency.

 All facilities shall establish an appropriate budget and support to maintain the
properly and timely acquisition of food safety related to tools, materials,
equipment, monitoring devices, chemicals and pesticides.

 Facility shall have a system in place to provide safety training to all personnel
including new employees and maintain a record of training completion. This
training will include the written employee policies that have been established for
the company. Refresher training should be done on annual basis.

 Prior to beginning work, temporary personnel and contractors shall be trained

as appropriate, and shall be adequately supervised throughout the working
period. Each food manufacture shall establish a procedure for handling
governmental or regulatory inspectors and third party auditors. This procedure
should include:

a. Person or persons delegated to accompany all inspectors.

b. Company policy regarding photographs.
c. Company policy regarding records and samples.

 A Written policy and procedure on temporary repairs shall be defined at each

plant.

 Finished product shall have permanent and legible code time marks readily seen
by the consumer.

 Records of result of examination copies or supplier guarantees or certification

that verify compliance with federal or other governmental regulation and
PepsiCo requirements.

 Annual WHO based “long list” testing must take place at PepsiCo approved
laboratory.
 There shall be a formal procedure for the audit of incoming and outgoing
delivery vehicles.

 Company shall have a documented supplier approval program.

 A formal recall program shall be maintained and regularly reviewed.

 Each beverage manufacturer shall establish a Hazard analysis critical control

point (HACCP) program. The HACCP system shall be specific to the application,
practical to implement and effective in controlling the identified hazards of the
operation. Through this system, the company shall be able to demonstrate
effective control of all operation undertaken. The seven principle of HACCP shall
be followed.

Personnel:

a. Suitable and sufficient hand washing facilities shall be provided at the entrance
and at the appropriate points within production areas. These facilities shall be
provided with an adequate water supply maintained at warm water temperature
and supplied with single use towels or air dryers. Hand washing stations shall be
provided where appropriate. Sanitizers for such stations shall be regularly
monitored for proper concentration to ensure effectiveness. Containers for
disposable paper towels should be kept covered.

b. All washroom, washer and locker rooms shall be maintained in a sanitary

manner and kept free from insects, rodents and molds. Open food or drink being
stored in lockers shall be strictly prohibited. “Wash hands” signs shall be
properly displayed in all rest room, lunch rooms and production areas. Where
applicable, the signs shall also be appear over sinks or entry ways to production
areas. Self closing doors shall be provided. These doors shall not open in
production or food handling areas.

c. Personnel practices:

 Responsibility for assuring compliance by all personnel to plant policy

shall be clearly assigned to competent supervisory personnel.

 Employees, contractor and visitors shall practice good personnel hygiene

habits at all time.
  Hand washing shall perform at a frequency that is appropriate and should
be done at any time the hands become soiled. Hands should be washed
before beginning work, after using toilet facilities, eating, drinking,
smoking or otherwise soiling hands. Plants should be encouraged to
monitor the effectiveness of hygiene procedures with regard to hand.

 Employees shall adhere to the following principles when handling raw

materials, work in progress, or uncovered finished products:

1. Wear clean outer garments or uniforms. Suitable footwear shall be worn

within the plant environment. Changing facilities shall be provided for all
personnel, whether employees, visitors or contractors prior to the entry to
production and packing areas and where appropriate, prior to entry to
storage areas. Changing facilities shall be sited to allow personnel direct
access, without recourse to any external area to the appropriate
production: packaging is storage area should be posted.
2. All protective clothing shall be laundered and maintained effectively an
regularly basis.
3. Glove if worn should be subject to adequate control to avoid product
contamination.
4. Ware effective restraints include the hands and beard covers.
5. Remove costume and hand jeweler, including watches, earrings, rings
with settings false fingernails, fingernail polish and dangling jewellary.
Only plain wedding are acceptable, unless prohibited by plant policy or
safety requirements. Any exception top this shall be spelled out in the
company policy and the reasoning behind it explained.
6. Employees in contact with food products should avoid perfume or
aftershave.
7. Hearing protection should be metal detectable, where applicable and
utilized for the intended purpose.
8. Eating food, drinking beverages, chewing gum and using tobacco shall be
restricted to designate areas only.
9. Personnel items such as pen, pencils or thermometers shall be carried in
pockets or pockets below the waist when employees are in production
area.
10. All visitors and contractors shall be required to confirm to company food
safety hygiene policies and the good manufacturing practices (GMP’s).

Inspection:
  Every plant shall conduct monthly audits of the whole facility and grounds
and roof, ensuring that complete audit of the entire facility are conducted not
less than ones per month.

 A multidisciplinary audit team shall be utilized for this audit. Assignments

are located according to areas of responsibility. Record of each audit is an
integral part if this requirements and documentation of specific assignments
and actual accomplishment shall be maintained. Follow up review should be
done to ensure that items are corrected and results kept on file for review.

 Returnable bottles shall be inspected for cleanliness and damage after

leaving the bottle washer, but before filling. This can be accomplished with
trained personnel at a rate of 150 bpm to 200 bpm if electronic bottle
inspection equipment provided.

 Manual inspection is not required with a high speed vision. Liquid

sweetener incoming loads shall be checked for seals, solid, taste, odor,
appearance, temperature and result documented.

Foreign object management:

 Simple sugar (granulated sugar) shall be filtered to 30 microns or less to

remove foreign material such as string, lint, paper etc.( applies to granulated
sugar only would not apply to HFCS or liquid sucrose).

 In-line carbon filters shall be installed for final CO2 polishing. This polishing
step safe guard’s product from trace levels of aromatic hydrocarbons. All
bottles shall be rinsed prior to filling with treated water or air rinsing.

 Aquafina bottles shall be rinsed with ozonated water prior to filling. Carbon
treatment require for all sugars that are out of specification. If carbon treated,
simple syrup data must be provided. A glass and brittle or hard plastic policy
shall be written and implemented.

 The policy should state that no glass and brittle or hard plastic are to be used
in the facility, except where absolutely necessary. The policy should also state
that no glass should be bought into the facility in employees personal effects.
Included in the policy should be a procedure for handling any glass that is
broken in the facility.
 The procedure should also cover any brittle or hard plastic that is broken in a
location where it could jeopardize the product. In addition, a list of essential
glass brittle or hard plastic should be compiled and the items on the list
checked on a regular basis to ensure that any accidental breakage is noted.

 Glass bottle failure procedure shall be posted and followed. Light bulbs,
fixtures, windows, mirrors or other glass suspended products zones, product
areas, ingredients and packaging supplies shall be of the safety types or
otherwise protected to prevent breakage.

 Effective measures shall be taken to prevent the inclusion of the metal, wood,
glass and all other extraneous materials. Foreign material is defined as
anything introduced in the product that is not on the label.

 All such measures shall be monitored and documented regularly. Where

metal detection is appropriate, the company shall establish and implement
procedures for the operation, routine monitoring and testing of the metal and
other foreign body detectors.

 Where metal detection is appropriate. The company shall establish and

implement corrective action and reporting procedure to respond to any
failure of the metal or foreign body detector. These will include the isolation,
quarantine and re-audit of all food produced since the last acceptable test if
the metal or other foreign matter detector.

 For every 15 foreign material items found within the facility in a product zone
during the audit, a 40 points deduction will occur.

 Filters or strainers shall be in line as close to the final fill as feasible. Filter
strainer size shall be as follows:

Carbonated soft drink (CSD) 100 mesh {150 micron)

Gatorade clear 800 mesh (15 micron)

Gatorade cloudy 400 mesh (25-40 micron)

Juices without pulp 8 mesh (2.4 micron)

Juices with added pulp 4 mesh (6.4 micron)

 Vacuums on air deionizers shall be filtered and working effectively.

 Fans and other air lowing equipments shall be located, cleaned and operated in a
manner preventing contamination of raw materials, work in progress, finished
foods, food packaging materials food contact surfaces.

 Flaking rust on equipment or excessive rust build up other than normal mild
oxidation on mild black steel or ferrous metal is prohibited.

 Ingredient containers and finished product containers shall be labeled for their
intended use and used for their intended purpose.

 Equipments, containers and utensils used to convey, process, hold or store raw
material, work in progress, rework or finished foods shall be constructed,
handled and maintained during processing or storage in a manner that prevents
the contamination of raw materials, rework or finished foods, no empty product
bottle or cap that comes in to contact with the floor that shall be used in
production.

A. Conveyers for upright, open and formed containers shall be

protected from washing to capping/seaming operation.
B. Finished product and raw material shall not be stored where
environmental influences (sunlight, moisture etc) will affect
integrity.

 Roof leakage shall be promptly identified and repaired.

 Fixture duct and pipes shall be installed and maintained in such manner that
drips or condensate does not contaminate food, raw material or food contact
surfaces.

 Lighting standards as determined by PepsiCo international shall be provided in

all processing and packaging room. Light bulbs, fixtures, windows, mirrors or
other glass suspended products zones, product areas, ingredients and packaging
supplies shall be of the safety types or otherwise protected to prevent breakage.
Emergency lighting and the headlights on forklifts should also be protected.

 All plants shall have a preventative maintenance program for filler valve parts.

 All plants shall ensure that pumps are adequately maintained to prevent leakage
pump seals or gaskets.
  All plants shall have a lost vent tube policy in place.

Microbiological control and allergens:

 Food processing operations shall establish a formalized program for the control
of bacteria, yeasts and molds records of laboratory analysis and environmental
samples shall maintained by the appropriate department. On site laboratory
facilities where provided shall not jeopardize the safety of the product.

 Product contact surfaces and machinery that require sanitizing shall be clean and
sanitized. All establishments using water in there process shall have at a
minimum, a potable water supply from an approved source. For underground
well water supplies, sampling of the water shall be undertaken per PepsiCo
requirements.

 Proper documentation shall be readily available. Every plant must include

minimal treatment media filtration (with coagulation or one micron absolute ),
disinfection, carbon, polisher, UV (for thermally processed beverages,
pasteurization replaces the disinfection step):

a. The wellhead shall be secured to prevent tampering and entry for any foreign
material, if located outside, an enclosure is recommended for the wellhead. The
wellhead shall also be protected from drainage and other run off. A cement
apron, pitched slope similar is recommended.
b. Treated water shall be absolutely safe to drink. Potable water shall be used in
cooling tunnels. Regulatory requirements shall be met.

 HEPA air filters shall be installed on all air intakes where contact with the
product zone occurs.

 Food contact surfaces, utensils and product zones shall be thoroughly cleaned. If
a known allergen is used in any product, the plant shall demonstrate through
testing the absence of the allergen.

 Sanitation rinse water testing shall be conducted routinely as a predictor for

sanitation effectiveness. All liquid sugar storage tanks shall have UV lights in
place and there shall be an annual replacements of the lights documented.
  Walls shall be designed, constructed, finished and maintained to prevent the
accumulation of dirt reduce condensation and mild growth and facilitate
cleaning.

 For low acid products, schedule process( specifying at least the minimum
product sterilization temperature and holds time, maximum flow rates and ph
range of product samples after incubate on and packaging sterilization speeds )
shall be approved by PepsiCo thermal process authority.

a. For low acid products formal change management process to formally approve
process deviation shall be in place.
b. For low acid products a “ a positive release procedure” (verifying the thermal
process parameters, other critical control points, sanitation parameters, finished
product quality results and product incubation results before releasing each lot
of production) shall be in place.

Pest control:
 A formalized preventive pest control program shall be maintained in the facility
by an appointed person. The pest control program may be undertaken by trained
in house personnel or be provided by an outside pest control contractor.

 The facility shall maintain the written procedures outlining the requirements of
the program to reduce the potential for product contamination from pest activity
or use of the material and design to control pest activity.

 Pest control activity shall at all times be conducted in total compliance with the
regulatory requirements of the agency controlling such procedures. In addition,
specific programs and procedures will include as a minimum.

 Pesticide designated for restricted use shall only be used by trained, licensed pest
control technicians, where a license is required by government codes. Pesticides
application made within a facility or on the grounds of the facility will be
undertaken by licensed pest control applicator. Thos applicator can be a outside
contractor or properly licensed or trained in house employee, where such
licensing provisions are required by government codes.

 In the absence of the such regulatory requirements , technician cell demonstrate

they have received proper training in the proper and safe use of pest control
materials by attendance at a recognized seminar or have documented training
and be under the supervision of a licensed technicians, where required by
 government codes. Methyl bromide fumigant shall never be used in a PepsiCo
facility.

 Facility personnel or outside pest control services shall clearly explain how
fogging pesticide are applied in accordance with the product level, i.e. 100ml per
100 cubic meters. For crack and cervices application, they shall explain how and
where they apply the pesticide as per the level.
 Accurate documentation of all pesticide applications, including rodenticides
used in or around the facility shall be maintained. Documentation shall be
maintained in accordance with government regulation and shall include at a
minimum.

a. materials applied
b. target organism
c. amount applied
d. specific area where pesticide was applied
e. method of application
f. rate of application or dosage
g. date and time treated and re entry time after fogging
h. technicians signature

 All pesticide and application equipment shall be properly labeled tom identify the
contents. Insecticides and herbicides each require separate equipment for
application. All equipment used for pesticide application shall be properly
maintained in serviceable condition.

 Pesticides stored in facility shall be stored in a locked enclosure, preferably in an

outside building away from production area. Easily under stable labeling warnings
of the contents and limiting access shall be posted on the exterior entrances to the
enclosure. The storage enclosure shall be adequate in size and construction as well
as ventilated. Herbicides, residual and non residual pesticide material and
application equipment shall be separated by location in cabinets, lockers or caged
areas. The enclosure shall also contain the necessary materials to control spills and
leakage and to avoid injury to personnel.

 Disposal of pesticides, pesticide containers and pesticide residue shall be done in a

manner that meets all regulatory guidelines and shall be consistent with the
instruction included on the label for the material.

 The facility serviced by in house personnel (licensed or plain pesticide technician or

technicians) shall:
 1. Maintain a file of specimen labels and chemical safety data information for each
pesticide used and maintains pesticide usage records as well as records on
maintenance of the safety and protective equipment used.
2. If no specific application instructions are included ion specimen labels, written
procedure for the application of all pesticides shall be maintained and enforced.

Facilities serviced by a contracted licensed pest control company shall maintain the
following:

1. a contract describing the specific services to be rendered, including materials to be

used, methods, precaution and chemical safety data information required by the
government regulations.

2. Sample labels for all pesticides used. Sample labels shall be kept on file for the
time specified by regulatory codes.

3. Accurate and complete services records describing current levels of pest activity
and recommendation for additional efforts needed to correct conditions allowing for
the future pest activity.

4. A copy of current liability insurance and evidence of a current technician license,

where a license is required.

 All facility shall establish effective preventive programs for the elimination of
pest activity. The effectiveness of the programs will be measured by the lack of
evidence of pest activity. Specific procedure includes, but are not limited to:

1. Outside bait station for the control of rats ad mice. The bait stations shall be
installed around the exterior perimeter of the facility at 50-100 foot (15-30 meters)
intervals.
2. Lids to the bait stations shall be locked with devices supplied by or
recommended by the manufacturer. The monitoring devices and appropriate
reusable plastic ties or other easily cut or tempered with materials shall not be
used.
3. Baits used shall be company approved registered rodenticide or monitoring (non
toxic) feeding blocks. No baits shall be used in the facility.

 Records shall be maintained to show the numbers of insects removed from the
monitors. The following designation should be used:

Low : 0-24 insects

Medium : 25-49 insects

 High : 50 and over

 Birds shall be controlled by exclusion, netting, screening, mechanical traps or

avoiders, if legal and practical. The use of avoiders is not permitted inside the
facility.

 Pest monitoring devices and appropriate integrated pest management strategies

should be properly used to provide ongoing monitoring for pest activity and to
design an effective control program to eliminate pests and the potential for pest
activity.

 Drains and drain cleanout shall be clean and free of sewer flies.

 Insects shall not be allowed to develop in electrical panels, equipment housing,

framework etc. insect infestation shall not be allowed above product zones or in
false ceilings.

 Storage practices shall be appropriate to the items being stored. Items shall be
stored at least 18th from walls and ceilings with adequate space.

Sanitation:
 A master sanitation schedule (MSS) shall be established and operated by every
site as a formalized written plan. The document and system identifies what is
cleaned on the site, when it is cleaned and records the satisfactory completion of
the cleaning. It is both a plan of what needs to be done and an easy reference
guide as to the progress of completion. This scheduled should be through and
include the outside ground, all buildings, all services such as drains and
ventilation as well as all plant interior fixtures, fittings and utensils all
production related equipment. The cleaning tasks should be divided into general
areas:

1. Outsides area and ground

2. Outside buildings
3. Interior of main facility – room by room
4. The main production area-surfaces, services, equipment and associated systems.
 5. All product zones, food contact surfaces of equipment, utensils, intermediate
containers, pans, and trays band other main product zones.
6. All non product related materials, such as parts and equipments.

 Detailed equipment sanitation standards operating procedure (SOPs) shall be

developed for personnel training maintaining the hygiene level of equipment
sanitation. These written SOPs shall be developed for all items on the MSS and
utilized for cleaning of all equipment used for storage, processing and
packaging, all building areas and for the outside grounds.

Food contact surfaces and machinery:

1. Surfaces that require sanitizing shall be cleaned, sanitized and tested foe adequate
destruction or spoilage of pathogenic microorganism where appropriate.

2. All equipment and plant surfaces shall be clean according to the frequencies in the
beverages sanitation requirements.

3. Food contact surfaces and utensils shall be cleaned on a regular basis and as often as
necessary to eliminate food residue and maintain a good appearance.

4. All equipments shall be clean often enough to prevent any type of insect
development of infestation.

5. Special attention should be given to reducing old product or sticky build up label
with product zones on items such as packaging convey or frame work.

6. To prevent microbial contamination, equipment and utensils shall be cleaned and

sanitized on a predetermined scheduled.

7. Pans trays or other main products zones shall be cleaned frequently enough to
prevent carbon particles from being transferred to products.

8. Approved cleaning compounds and sanitizers used as listed in the approval

sanitation chemical and supplier list.

9. Chemicals properly labeled and stored in a segregated, locked area.

Plants shall have a documented CIP procedure in place:

1. Beverage facility shall demonstrate proper CIP in compliance with PepsiCo
standards.
 2. For CSD, the 5 step (or approved 3 step optimized CIP)process used, including
approved compounds at proper concentration and temperature(examine CIP
temperature on chart or log, CIP chemical concentration verification)
3. The CIP shall be documented.
4. Sanitation specification parameters are recorded: concentration, time, and
temperature and flow rate.
5. For the current CIP, sanitation process frequency, reference the NCB quality
tools.
6. flow rate equal to or greater than required minimum Reynolds number (10o,000)
or 5 feet per second (1.5 m per second)
7. CIP circuits designed for proper drainage, no dead ends, no cross connection and
line disconnects in place where needed.

Liquid sugar storage

 All tanks must be constructed in a manner that prevents rough welds and
the bottom of the storage tanks shall be properly sloped.
 The sucrose system cleaned and sanitized (frequency determined by micro
counts)
 The fructose system cleaned and sanitized (frequency determined by micro
counts)
 The microanalysis data must support frequencies used to clean both systems.

Types of cleaning:
1. Where possible, all toxic chemicals, including cleaning and maintenance
compounds shall be stored in controlled areas.

2. “Deep cleaning” shall be assigned to the appropriate personnel and shall

accomplished by and consistent with the Master Cleaning Schedule or its
equivalent and records shall be kept on file.

3. Equipment and structural “overheads” such as lights, pipes, beams, vent grids
etc. shall be scheduled for deep cleaning according to the MSS to prevent the
development of insects or mold or accumulation of foreign matter.

4. Cleaning equipment and tools shall be supplied and be readily available for use
at all times. All cleaning equipment shall be maintained and stored in such a way
as not contaminate foods or food equipment.
 5. The facility shall have an effective color-coding and/or labeling system for
containers and cleaning utensils, which prevents the potential for cross-
contamination.

6. Separate and distinct cleaning utensils shall be utilized for cleaning food-contact
surfaces (product zones) and structural cleaning.

7. At no time shall cleaning utensils used to clean rest rooms, toilet fixtures, or floor
drains be used for any other cleaning purpose. Janitorial and production tools
shall be separately stored and clearly identified.

8. All cleaning utensils shall be cleaned after use and be properly stored.

9. The use of cleaning tools that can leave debris behind on product zones or area
shall be prohibited unless absolutely necessary, in which case and audit should
occur after their use to ensure that no debris that could contaminate the
products. These include the use of wire brushes, sponges, scrub pads etc.

10. The use of air hoses for cleaning is permitted only for inaccessible equipment
and in conjunction with deep cleaning operation. Compressed air shall not be
used to remove dusty materials or to clean floors while any lines in the same
room are running. Air hoses shall not be placed in product areas. Air hoses shall
not be used while bottles are exposed. No air hoses used around cappers or
filters during production.

11. There shall be sufficient hot water to facilitate effective cleaning of equipment.
However, when water is used for cleaning production areas, it shall be used in
such a way as to not contaminate raw materials, work- in- progress or
production equipment with water droplets, mist or direct contact.

Housekeeping:
1. Ongoing housekeeping operations by production and all support departments
shall be done routinely through out the operating hours to maintain the work
areas in a reasonably sanitary condition. Operational debris should be kept to a
minimum.

2. Daily housekeeping tasks shall be assigned to the appropriate departments and

shall be undertaken to ensure work and support areas are maintained during
normal working hours. All such operational should be undertaken in a manner
to prevent contamination.
 3. Floors should be maintained at a frequency to avoid “surface build-up” which
would be carried into other parts of the facility on shoes, forklifts or other
equipments.

4. There shall be effective control of corrugate dust and contamination in open

product zones.

5. Condensation formation on the overhead building structural ceiling, walls or

pipes shall not be allowed to accumulate in product zones or product areas.

6. Mold, infestation or foreign material shall not be found in product zones.

7. Mold or slime shall not be present in processing/packaging product areas.

8. Bottles and caps shall be covered while in storage.

9. Beverage facilities shall confirm to all the requirements of PepsiCo Standards and
required SOPs for cleaning the cap hopper, sorter and bottle rinser. The bottle
cleaner, cap hopper and sorter shall be visually clean at all times.

10. Beverage facilities shall demonstrate daily check of functionally of bottle rinsers
and qualification status.

No food contact surfaces and ancillary equipments in product areas

Non food contact surfaces shall be cleaned a regular basis and as often as necessary to
eliminate dirt build up, which may constitute a hazard.

Chemicals
1. Only approved bender offering cleaning compounds and sanitizers authorized for
food contact surface shall be used for cleaning. Appropriate verification procedure
or testing shall be done periodically to ensure that the concentration a clean in place
and other cleaning chemical are consistent with the product labeling.

2. When not in use, all cleaning compounds and sanitized shall properly stored in a
locked compartment, away from production and food storage areas

3. All chemicals shall be correctly labeled

People
1. Cleaning operation shall be undertaken by personnel whose training has been
documented.
 2. All cleaning procedure shall be carried out in compliance with applicable safety
laws and regulations and according to formally establish equipment cleaning
procedure. When undertaken safely and compliance with local and national laws
and regulation, all equipment guards, trims and panels shall be removed for audit
and cleaning of the interior of all equipment according to the MSS. All equipment
guards, trims, panels shall be replaced after audit and cleaning of the interior of
equipment.

Records
1. The master sanitation control schedule “MSS” shall be kept up-to-date and will
act as a record of the completion of periodic and deep cleaning.
2. Records shall be made and retained of the compliances of end of run cleaning
and the post cleaning/pre-start-up audit.
3. After routine cleaning of food contact surfaces, an objective measurements, such
as ATP testing, should be undertaken to determine the effectiveness of the
cleaning.

Equipment design
1. Pump design: centrifugal pumps are preferred vs. positive displacement (PD).If
PD pumps are used; the faceplates must be removed for cleaning. In addition, for
PD pumps bypass must be constructed to allow for proper CIP velocities.
2. Transfer pipelines to the batch tanks free of dead legs.
3. Intake pipelines to the storage tanks free of dead legs.
4. The hot soak compartment of the bottle washer shall be monitored for caustic
levels, time and temperature to assure effective sanitation.
5. Approved rinse agents shall be used to remove caustic residue after returnable
glass bottle washing.
6. EDTA testing required for returnable glass bottles on a daily frequency. The
EDTA level shall not exceed 5ppm.

Maintenance Controls
1. Thermally processed beverages shall be subjected to time/temperature
parameters that have been established using scientific criteria, and effectiveness
shall be verified by conducting commercial sterility testing as art of qualification
protocol. Records shall be maintained.
 2. Holding tubes shall be properly sized for adequate microbial kill.

3. To maintain sterility of the sterility of the systems, proper differential pressure

shall be maintained. A higher pressure on the media side on the heat exchanger
shall also be maintained.

4. The containers and closures for all thermally processed beverages shall be
adequately sterilized. A higher pressure on the media side on the heat exchanger
shall also be maintained.
5. The containers and closures for all thermally processed beverages shall be
adequately sterilized. Hot-filled packages are properly inverted to ensure
adequate sterilization of the closure.

6. The hot fill provides sterility to containers and shall be controlled between 79.4
-83.3 C (175-185 F) for pet bottles.

A formal preventive maintenance program and work order system shall be in use to
prioritize the elements of identified structural, equipment or utensils maintenance
problems that could cause food adulteration. Segregation of operation shall be
undertaken to the degree appropriate and reasonable and shall take into account the
flow of product, nature of materials, equipment, personnel, airflow, air quality and
services provision.
Such segregation can be accomplished through the use of air
curtains, partitions, door and/or other exclusionary systems. The process flow for
receiving to shipping shall be arranged to prevent product contamination and there
shall be an effective segregation between high and low risk and operation to minimize
the risk of cross-contamination. Facilities for tray and utensils washing and general
purpose cleaning should, where appropriate, be adequately segregated from
production activities.

All plant equipments and utensils shall be designed and of such material and
workmanship as to be adequately cleanable and shall be properly maintained. Food-
contact surfaces, including scoop, shall be corrosion-free and be made of a nontoxic
material. Seams on food-contact surfaces, when necessary shall be smoothly bonded.
Spot or tack welds are prohibited.
Continuous welds shall be used where metals allow
it. Temporary repair materials such as tape, wire, string, cardboard, plastic etc. shall
not be used in the product zone, production areas or production without a corrective
action plan and scheduled follow-up. Repair parts equipment shall be clean and stored
in an orderly fashion in the parts storage areas. All regulating and recording controls,
thermometers or other temperature measuring device shall be installed and routinely
celebrated on any equipment intended to sterilize, pasteurize or otherwise prevent the
growth of pathogenic microorganism. This calibration should be traceable to a national
standard.
In addition, thermometers should be present inside coolers, freezers and other
temperature-controlled storage rooms. Ongoing monitoring of temperature control
system shall be frequently under taken with proper documentation maintained and
readily available. Mechanical monitoring system shall also be utilized and shall be
trigger an alarm when temperature exceeds limits. The temperature recording device
shall be linked to suitable failure alarms. Adequate ventilation shall be provided in
storage and processing areas to minimize odors, fumes and vapors. Air makeup unit
shall be fitted with clean filters and maintain free of mold and algae.

Air returns ducts for heating and air conditioning systems or air makeup unit shall be
provided with cleaning and audit hatches, fans, bowers, filters, cabinets and plenums
shall be placed on a preventive maintenance schedule to prevent possible development
of mold or insects, or the collection of foreign materials.

1. Windows and skylights shall be non-opening. Where windows and doors must
be kept open for ventilation, they shall be screened to prevent access by pests.
2. Dust extraction equipment for dry powder handling equipment shall be installed.

 The maintenance department shall be responsible for the prevention of and the
systematic elimination of leakage excessive lubrication. Where drive motors are
mounted over product zones or where conveyors cross or run parallel to other at
different levels, catch pans shall also be fabricated and installed.
 Only approved lubricants shall be utilized on food processing machines. All such
lubricants shall be fully segregated and stored in a secured and designed area.
Excess lubricant shall be removed after equipment is serviced.
 Compressed air used in processing shall be properly filtered to remove particles
of 50 microns or larger and shall not contain dirt, oil or water. Traps and/or
filters shall be inspected and/or changed regularly. The filters for air used on
product contact surfaces should be located as close to the point of use as
practical.
 Beverage facilities shall filter compressed air to minimum of 0.3 microns in
product zone.
 Forklifts, hand jacks and other transporting equipment shall be maintained in
such a manner that prevents the adulteration of product being transported. Black
tires on forklifts mark floors and should be discouraged.

Maintenance cleaning
1. Maintenance debris created during repairs and alteration shall be promptly
removed. Control of nuts, washers, wire pieces, tape, welding rods and small
items that could contaminate the product should be a high priority.
 2. In the case of engineering or maintenance work being undertaken in either a
product zone or a product area, the facility shall follow an established Significant
Maintenance Activity program that gives due consideration to the protection of
the food product by the installation of effective protective screens. Such screens
shall be constructed to prevent any contamination of the product. If wood is used,
it should be plastic-covered on the side facing production.
3. Forklifts, hand jacks and similar equipment shall be scheduled for preventative
maintenance and cleaning. This cleaning shall be recorded on the MSS and kept
up-to-date.

Facility roof and grounds

The grounds around any food plant shall be maintained in a manner that will prevent
the possibility of food adulteration. This can be managed through a maintenance
department MSS. The method for adequate ground maintenance includes, but is not
limited to:

1. Proper storage of equipment away from walls and off the ground to prevent
harborage and allow for audit so the equipment is protected from contamination
and deterioration. Storage out of doors should not be permitted.
2. Removal of litter and waste, removal of weeds or tall grass from within the
immediate vicinity of the building, a minimum of 6 feet (2 meters).
3. Maintenance of roads, yards and parking areas to keep them free of dust,
standing water or other potential contaminants.
4. Provision of adequate drainage from grounds, roof or other areas.

Facility design
1. All structural beams, supports and other structural systems that are painted shall
be maintained in an appropriate manner to preclude or eliminate chipping,
flaking or peeling paint.
2. Sufficient space shall be provided for proper placement of equipment and
storage of equipment and storage of materials. Adequate aisles or a workspace
shall be maintained between equipment and structures to allow adequate
cleaning.
3. Bulk systems and unloading areas shall be installed and maintained to prevent
the adulteration of raw materials or finished product. Outside receiving lines
shall be identified and locked at all times.
4. Floors, walls and ceilings shall be of such construction to be adequately cleanable
and kept in good repair. The following are further guidelines to assist in this:
 a. Walls shall be designed, constructed, finished and maintained to prevent the
accumulation of dirt, reduce condensation and mold growth, and facilitate
cleaning.
b. Floor-wall junctures and corners should be coved to facilitate cleaning. Cavities
in the surface of walls and floors should be avoided to prevent debris from
lodging and to avoid pest harborage.
c. Floors shall be designed to meet the demands of the process and withstand
cleaning materials and methods. They should be impervious and maintained in
good repairs.
5. Adequate floor drains with grates shall be installed, maintained and operational
in all wet processing and wash areas. All floor drain grates shall be easily
removable for cleaning and audit. The drains should be easily accessible for
cleaning.
6. Consideration should be given to the location of machinery and drains so that
any discharge and overspill from processing goes directly into a drain rather
than on the floor.
7. Drainage shall not compromise product safety and shall flow away from high
risk areas. Drainage shall be design and maintain to minimize risk of product
contamination. Floors should have adequate sloping to direct the flow of any
water or effluent towards suitable drainage.
8. Where hollow or suspended ceiling are used, adequate access to the void shall be
provided to facilitate cleaning, maintenance of services and audit for pest
activity. Ceiling and overheads should be designed, constructed, finished and
maintained to prevent the accumulation of dirt, reduce condensation and mold
growth and facilitate cleaning.
9.
Production facilities, equipment and/or accessories shall be so designed or provided to
facilitate minimum hand contact with raw materials, work-in-progress or finished
product

1. Bottling operation shall be conducted in a manner that protects against

contamination. Control measure should include the use of an enclosed area
around the filling and sealing area. Dust, dirt, microorganism in the air and
condensation shall e controlled.
2. All ingredient, product-holding and packaging conveying and processing
systems, including bulk system, Include bulk systems, shall be so designed and
constructed in such a way that they can be adequately cleaned and inspected.

Services
 The quality of water, steam or ice that comes in contact with food shall be
regularly monitored and shall present no risk to product safety. Boiler chemicals
 shall be approved for food contact if the steam generated comes in direct contact
with food.
 All water installation and equipment shall be constructed and maintained to
prevent back siphon age or backflow.
 The sewage, effluent waste water disposal system shall be adequate and
appropriate for the process and shall be maintained to prevent either direct or
indirect contamination of food.
 All washrooms, had sinks and locker rooms shall have both hot and cold
running water readily available. Mix valves to adjust water temperature should
be provided. It would be desirable to provide automatic foot or knee or infrared
operated valves in production areas.
 Toilet rooms shall not open directly into production oe packing areas.

Environmental and waste management

 Outside wet or dry waste or scrap compactors, modules and dumpsters shall be
installed to minimize leakage, permitting the container to be easily removed and
the area cleaned. External waste collection containers compacters should be kept
closed or covered.
 Rubbish or inedible waste shall be covered in properly covered, labeled,
designated containers and emptied daily. When rubbish or inedible waste is
transported, it shall not come in contact with raw materials, work in progress
finished product. Waste disposal shall meet legislative requirements. When
required by region, waste shall be removed by licensed contractors.
 Processing and packaging waste containers shall be kept clean and well
maintained.
 Dock wells and leveler pits shall be kept free of standing waters, debris and other
pest attractants.

Audit of water treatment Plants

With above guidelines I have instructed to audit the water treatment plant of the
PepsiCo plant. The main focus points are as follows:

 Dust and dirt

 Cobwebs
 Drains
 Temporary repair- using of tape, carton, wire or make shift arrangement
 Loose items- bolt, gasket, box or any other loose item not belongs to that place.
As auditor can deduct points for each 15 loose items
 Labeling of containers- each container (to store chemicals, lubricants and other
chemicals) should be properly labeled.
 Place of GHK materials- place to be defined and this should not stored in
product zone.
 Use of pet bottles- using of product bottles to store any thing can result in
negative numbers.
 Strainers- strainers of syrup room and in product lines are critical and auditor
will ask to open them.
 Focus area- your focus should be maximum in product zone. Auditor may visit
wellhead, AHU, ETP, shipping yard apart from process and storage of raw and
packaging material storage.
 Post control-very critical as this covers almost 25-35% of the audit.
 Evidence for-eating, drinking and tobacco spitting.
 Leakages- if line is running then this to be taken care of.
 Live insect activity- critical in process area.
 Rust/Flaking paints- in product zone.

In the light of the guidelines given earlier I have audited/inspected the water
treatment plant. My observations/finding is as follows:

 Chemicals are leaking on the surface of coagulation tank.

 Rust is found on the bolts, nuts and pipes attached to coagulation tank.
 Flaking paints on ladder and pipes attached to different tanks.
 Leakages are found in the pipes where the line is running.
 Internal floor is not clean.
 Live and certain chemicals are lying on the floor, which makes the floor
slippery.
 Files are found in WTP.
 Caps and motors are not available, so they use of general plastic bags and
tapes.
 Conclusion

The supervision of cleanliness and sanitation of plant and premises includes not only
the maintainers of clean and well sanitized surface of all equipment touching the
beverage but also generally good house keeping in and about the plant, adequate
treatment and disposal of water. Duties affecting the health of the employees include
provisional of a portable water supply, supervision of matters of personal hygiene,
regulation of sanitary aspects of plant lighting, heating and ventilation.

The started chief

purposes of microbiological criteria for beverage are to give assurance that the beverage
will be acceptable from the public health stand point, e.g. will not be responsible for the
spread of infectious disease for food poisoning. The beverage will be of satisfactory
quality, i.e. it will consist of good original materials that have not deteriorated or
become unduly contaminated during processing, packaging, storage, handling or
marketing.

The beverage will be acceptable from aesthetic point of view. The beverage will have
keeping qualities that should be accepted of the product.