TRAINING REPORT

8th Semester January – June2024

Quality analysis and Production Manufacturing

Submitted by

Neeraj

200080830008

Under Guidance of

University Advisor:- Industry Advisor:-

Dr. Navnidhi Chikkara R.P Chaurasia

(Professor) (General Manager – Quality )

Department of Food Technology

Guru Jambheshwar University of Science & Technology

Hisar

1
January to July, 2024

2
3
 CANDIDATE’S DECLARATION

I, Neeraj hereby declare that the Project “Observation of “Inspection & Sorting (INS)”
process” is an authentic report of my own work carried out at “Asianlak Health Food Ltd
(Bisleri)” as a requirement of 8th Semester for the award of degree of Bachelor of Technology
in Food Technology at Guru Jambheshwar University of Science And Technology, Hisar,
Under the guidance of Mr. R.P Chaurasia and Dr. Navnidhi Chikkara, during January to June,
2024

Signature

Student Name: Neeraj

Roll No. 200080830008

Date_

Certified that the above statement made by the student is correct to the best of my
knowledge and belief.

University Advisor:- Industry Advisor:-

Dr. Navnidhi Chikkara Mr. R.P Chaurasia

(Professor) (General Manager – Quality)

4
 Acknowledgement

I would like to express my special thanks of gratitude to my university guide Dr. Navnidhi
Chikkara Professor, Department of Food Technology, Guru Jambheshwar University of
Science and Technology, Hisar, who gave me invaluable guidance and support, enthusiasm
with knowledge to do this project report successfully. It is a golden opportunity to complete this
project report under her guidance and support.

I would like to thank Dr. Manish Kumar, Chairperson, Department of Food Technology,
Hisar, for his valuable suggestions and encouragement during completion of this project report.

I am grateful for all those with whom I have the pleasure to work during this project report and
other related matters. I would like to convey my immense thanks to Mr. Karun Katiyar , Mr.
Ravi Raj Yadav, special thank to Mrs. Reeta mam and Mr. RP Chaurasia sir for their
valuable advice and cooperation throughout the project. Also, I gave credit to our net source as
well as research papers related to this project report.

Signature
Neeraj
Roll. No. 200080830008
GJUS&T,Hisar
Haryana (125001)

5
 CONTENT

Serial no. Title Page no.

1. Industry profile 7-9

2. Brands 10

3. Introduction 11-15

4. Quality analysis of samples 15-17

 Raw water & Product Water

5. Instruments 17-26
 pH meter
 Conductivity meter
 Turbidity meter
 Spectrophotometer
 TDS meter
6. Packing materials 26-35
 CC box
 Labels
 Mono carton
 ROPP caps and closure
 Pet bottle
 Adhesive tape
7.  Role And Responsibility 36-38

8. Blending 38-39
 Flow chart of blending
 Role of blender
9. Bottling plant 39-41
 Flow chart of production line

6
 CONTENT

Serial no. Title Page no.

10. Machinery used in production line 41-47
 Blowing Bottle Machine
 Bottle Filling Machine(Filler)
 Air Conveyor
 Power conveyor
 Labeling machine
 CCP1
11. Project 48-50
12. Conclusion 51
13. Reference 52

7
INDUSTRY PROFILE

Company Profile
History and Background
Asianlak Health Foods Ltd. was established in [Year] and has since grown into a
leading name in the health food and beverage industry. The company’s
collaboration with Bisleri has bolstered its presence in the bottled water market,
contributing to the production of one of India’s most trusted water brands.
Vision and Mission
The company’s vision is to lead the market with innovative health food and
beverage products while maintaining the highest quality standards. Its mission is to
ensure consumer well-being by providing safe, nutritious, and sustainably
produced products.
Product Range and Market Position
Asianlak Health Foods Ltd. offers a diverse range of products, with Bisleri bottled
water being a flagship product in their portfolio. The company holds a competitive
market position, known for its rigorous quality control and commitment to
excellence.

MANUFACTURING UNIT

8
OUR VISION
ABOUT US

ASIANLAK HEALTH FOODS LTD BRANDS

INTRODUCTION

PRODUCT DISCRIPTION
Method Of Manufacture

PARAMETERS
1. Sensory
2. Ph
3. Conductivity
4. Turbidity
5. Hardness
6. Chloride

ENA

QUALITY ANALYSIS
Raw water & Product water
1. pH:-
Principle: It measures the voltage between the two electrodes, one is a glass
electrode, and the other is a reference electrode. Sometimes, if both electrons are
present, it is called the combination electrode, and they are inserted into the
solution in which pH is to be tested, after immersing these electrodes in a
solution, the H + ion in the test solution was exchanged for other positively
charged hydrogen ions present on the glass ball. So there is an action between
these H + ions of the solution and the H + ions or positively charged ions present in

9
 the glass bulb. The amplifier detects the difference in electric potential between
the two electrodes. The contrast of these potentials is called the ph unit.

Why Range of pH always lies between 1 to14

pH is always measured between (1 to14). The solution having the pH=1 is called
an acidic solution, or generally, it is highly acidic. The solution with the pH=14
is highly alkaline, or it is a more natural solution than the solutions having more
H + ion concentration. It is highly acidic, and the solutions with more OH – ions
are highly basic or highly alkaline.

Working of a pH meter

A pH meter measures the concentration of the hydrogen ions in a solution An

acidic solution has far more positively charged hydrogen ions in it than an
alkaline solution, so it has greater potential to produce an electric current under
certain conditions. It is like a battery that can produce a greater voltage. A pH
meter takes advantage of this and works like a typical voltmeter. It consists of a
pair of electrodes connected to a meter capable of measuring small voltages. It
measures the voltage (electrical potential) produced by the solution whose
acidity we are interested in, compares it with the voltage of a known standard
solution, and uses the difference in voltage (the potential difference) between
them to calculate the difference in pH.

Calibration of pH meter

To calibrate the pH meter, turn on the pH meter and allow adequate time for it to
initialize. Remove the electrode from the storage solution gently. Clean the
electrode by rinsing it with deionized water under an empty waste beaker and
finally, dry it by using soft tissue paper. Do not rub the electrode as it can
damage the sensitive membrane around it before taking any sample
measurements.

First, Calibrate the pH meter by taking three color-coded standard buffer

solutions having pH 7.0, 4.01, and 9.21. The first buffer solution always used for
calibration is to be a neutral buffer with a pH of 7.0, because the value of the
electrode at 7.0 pH is zero so always zero point calibration is preferred first .
The second calibration should be near the expected sample pH, either 4.01 or
9.21. Bases should be measured with buffers with a pH of 9.21, while acidic
samples should be measured with a pH of 4.01.

Calibration of pH meter by using standard buffer solution pH 7.0: Place the

electrodes in the buffer solution with a pH of 7.0 and set the slop to pH 7.0 value,
which is the pH of our buffer solution if, the H + ion concentration determines the

10
needed pH. suppose the concentration of H + ions inside the glass membrane
electrode and solution of buffer solution present outside the electrode is the same. In
that case, the pH equals 7.0. Once the standard with pH 7.0 is calibrated, rinse the
electrode with distilled water and dry it by using soft tissue paper.

Calibration of pH meter by using standard buffer solution pH 4.01: In the

next step, if the sample’s expected pH is acidic, select the buffer solution of pH
4.01, place the electrodes in the buffer with a pH value of 4.01, and press the
calibrate button. Allows the pH reading to stabilize at 4.01. if the concentration
of H + ions inside the glass membrane electrode is lower than the buffer solution
present outside the electrode, pH will be less than 7.0. Once the standard with pH
4.01 is also calibrated, rinse the electrode with distilled water and dry it by using
soft tissue paper.

2. TURBIDITY METER

WORKING

Turbidity meter is also called turbidity meter, is a tool used to measure the level of turbidity of
analyzed water or solutions. A Turbidity meter is a tool that has optical properties due to the
dispersion of light, which can be expressed as a ratio of light reflected to the incident light. The
intensity of light reflected from a suspension is a function of the concentration if all other
conditions are constant.

Turbidity in liquids is usually caused by a variety of factors, including microscopic particles,

such as microorganisms present in the liquid, dissolved solids, etc.

There are two types of general-purpose turbidity meters in common use today, namely:

 Bench top and portable units for sample grabbing on top of the analytical unit Bench top
is usually used as a fixed laboratory instrument and is not suitable for portable use.
 In-line instruments are usually installed in the field and continuously analyze the sample
stream overflowing from the process sampling unit.

11
Turbidity instrument measuring principle
An infrared diode shines infrared light into the medium. The particles in the medium reflect the
irradiated light detected by the receiving diode (backscattering principle). The electronic device
calculates the relative turbidity of the medium based on the received signal.

Working principle of Nephelometric Turbidity meter

Generally most of the Portable and Bench type Turbidimeter operates on the nephelometric
principle of turbidity measurement.

The optical system (Ref Figure) includes a tungsten-filament lamp, a 90° detector to monitor
scattered light and a transmitted light detector. The instrument’s microprocessor calculates the
ratio of the signals from the 90° and transmitted light detectors. This ratio technique corrects for
interferences from color and/or light absorbing materials (such as activated carbon) and
compensates for fluctuations in lamp intensity, providing long-term calibration stability. The
optical design also minimizes stray light, increasing measurement accuracy.

3. SPECTROPHOTOMETER
Principle
The principle of a spectrophotometer is based on the measurement of light intensity as a
function of wavelength. It achieves this by utilizing a prism or grating to disperse the
incident beam into different wavelengths. The device then manipulates waves of specific
wavelengths to pass through the test solution. The range of wavelengths used can vary,
typically ranging from 1 to 2 nanometers.

Working
A spectrophotometer is an analytical instrument used to measure the absorption of light
by a sample at different wavelengths. Here is an explanation of how a spectrophotometer
works and its working mechanism:

a) Calibration: Before using a spectrophotometer, it needs to be

calibrated using standard solutions of known concentration. This

12
 ensures accurate measurements and establishes a baseline for
comparison.
b) Selection of Wavelength: Depending on the solution being analyzed,
a specific wavelength of light is selected for the test. The
spectrophotometer allows for the precise selection of the desired
wavelength.
c) Light Path: The light emitted from a source passes through a series of
components in the spectrophotometer. It first encounters a diffraction
grating, prism, and mirror, which help in manipulating and directing
the light.
d) Diffraction Grating and Prism: The diffraction grating splits the
incoming light into different wavelengths, while the prism further
disperses the light into its constituent wavelengths. This process allows
for the isolation of the desired wavelength for analysis.
e) Cuvette and Sample: The selected monochromatic light then passes
through a cuvette that contains the sample solution (either the test or
standard solution). When the light interacts with the solution, some of
it is absorbed, some is reflected, and the rest is transmitted.
f) Photo detector System: After passing through the cuvette, the
transmitted light is detected by a photodetector system. The system
measures the intensity of the transmitted light and converts it into
electrical signals.
g) Galvanometer and Absorbance: The electrical signals from the
photo detector system are sent to a galvanometer. The galvanometer
measures the received signal, which corresponds to the absorbance of
the solution. Absorbance is a logarithmic measure of the amount of
light absorbed by the sample.
h) Calculation of Concentration: The concentration of the solution is
determined based on the absorbance using the Beer-Lambert law: C =
A/(εL), where C is the concentration of the solution, A is the
absorbance, ε is the molar extinction coefficient (a constant specific to
the substance being analyzed), and L is the path length through which
the light passes in the cuvette.
i) Double Beam Spectrophotometer: In some spectrophotometers, such
as double beam spectrophotometers, the monochromatic light is split
into two beams. One beam passes through the standard solution, while
the other beam passes through the test solution. This allows for
simultaneous analysis and comparison between the two samples.
How does a spectrophotometer work?

A spectrophotometer works by passing a beam of light through a sample and measuring the
intensity of light before and after it interacts with the sample. The instrument then calculates the
absorbance or transmittance of the sample, which can be correlated to the concentration of a
substance or used for qualitative analysis.

13
What is the purpose of calibration in a spectrophotometer?

Calibration is essential in a spectrophotometer to ensure accurate and reliable measurements. It

involves using standard solutions of known concentration or absorbance to establish a reference
point for the instrument. By calibrating the spectrophotometer, you can account for any
variations or deviations in the system and obtain accurate results.
Spectrophotometer calibration

Spectrophotometer calibration is a process by which users find out the light source’s accuracy
using a calibration standard. This is an important procedure to make sure that the device
functions accurately and the correct measurement is obtained.

4. Total Dissolve Solids:-

INSTRUMENTS

pH meter
pH Meter is used to measure the acidity and alkalinity of a solution by measuring
Hydrogen ion concentration in a solution. pH Meter Calibration is required at regular
intervals or as per the defined frequency to maintain its accuracy.

pH Meter Principle

pH Meter Principle: It measures the voltage between the two electrodes, one is a glass
electrode, and the other is a reference electrode. Sometimes, if both electrons are
present, it is called the combination electrode, and they are inserted into the solution in
which pH is to be tested, after immersing these electrodes in a solution, the H + ion in
the test solution was exchanged for other positively charged hydrogen ions present on
the glass ball. So there is an action between these H + ions of the solution and the H + ions
or positively charged ions present in the glass bulb. The amplifier detects the difference
in electric potential between the two electrodes. The contrast of these potentials is
called the ph unit.

Why Range of pH always lies between 1 to14

14
pH is always measured between (1 to14). The solution having the pH=1 is called an
acidic solution, or generally, it is highly acidic. The solution with the pH=14 is highly
alkaline, or it is a more natural solution than the solutions having more H + ion
concentration. It is highly acidic, and the solutions with more OH – ions are highly basic
or highly alkaline.

Working of a pH meter

A pH meter measures the concentration of the hydrogen ions in a solution An acidic

solution has far more positively charged hydrogen ions in it than an alkaline solution,
so it has greater potential to produce an electric current under certain conditions. It is
like a battery that can produce a greater voltage. A pH meter takes advantage of this and
works like a typical voltmeter. It consists of a pair of electrodes connected to a meter
capable of measuring small voltages. It measures the voltage (electrical potential)
produced by the solution whose acidity we are interested in, compares it with the
voltage of a known standard solution, and uses the difference in voltage (the potential
difference) between them to calculate the difference in pH.

Calibration of pH meter

To calibrate the pH meter, turn on the pH meter and allow adequate time for it to
initialize. Remove the electrode from the storage solution gently. Clean the electrode by
rinsing it with deionized water under an empty waste beaker and finally, dry it by using
soft tissue paper. Do not rub the electrode as it can damage the sensitive membrane
around it before taking any sample measurements.

First, Calibrate the pH meter by taking three color-coded standard buffer solutions
having pH 7.0, 4.01, and 9.21. The first buffer solution always used for calibration is to
be a neutral buffer with a pH of 7.0, because the value of the electrode at 7.0 pH is zero
so always zero point calibration is preferred first . The second calibration should be
near the expected sample pH, either 4.01 or 9.21. Bases should be measured with
buffers with a pH of 9.21, while acidic samples should be measured with a pH of 4.01.

Calibration of pH meter by using standard buffer solution pH 7.0: Place the

electrodes in the buffer solution with a pH of 7.0 and set the slop to pH 7.0 value,
which is the pH of our buffer solution if, the H + ion concentration determines the
needed pH. suppose the concentration of H + ions inside the glass membrane
electrode and solution of buffer solution present outside the electrode is the same. In
that case, the pH equals 7.0. Once the standard with pH 7.0 is calibrated, rinse the
electrode with distilled water and dry it by using soft tissue paper.

Calibration of pH meter by using standard buffer solution pH 4.01: In the next step,
if the sample’s expected pH is acidic, select the buffer solution of pH 4.01, place the
electrodes in the buffer with a pH value of 4.01, and press the calibrate button. Allows

15
the pH reading to stabilize at 4.01. if the concentration of H + ions inside the glass
membrane electrode is lower than the buffer solution present outside the electrode, pH
will be less than 7.0. Once the standard with pH 4.01 is also calibrated, rinse the
electrode with distilled water and dry it by using soft tissue paper.

CONDUCTIVITY METER
Conductivity is the ability of a material to pass or carry electricity or an electric current. It
means the existence of charged particles or ions from electrolytes dissolved in it that enable the
solution to be conductive. If the test solution contains an acceptable concentration of ions, then
the conductance of the solution is great.

Types of ions, the concentration of ions, and the solution’s temperature are the factors that
affect conductivity.

The conductivity meter measures conductivity. In this article, we will discuss what a
conductivity meter is and how such meters work.

The device determines the health status of the natural water body. It is beneficial for inspecting
the properties of solutions, such as total dissolved solids (TDS) for water quality investigation.

The meter also checks the correct temperature of the solution and expresses the results on the
monitor. The degree of ability to pass electric currents can vary. Substances with conductive
solutions are known as electrolytes.

How Is Conductivity Measured?

A conductivity meter has a probe that measures conductivity. A conductivity meter measures
conductivity by applying an alternating electrical current (I) to two or four electrodes. It
determines the electrical resistance of the solution. To do this, the current method or
potentiometric method is used.

After immersing electrodes in a solution the meter applies a voltage between two electrodes.
Electrical resistance from the solution creates a drop in voltage, which is read by the meter.

When the electrical current is applied to the solution, the cations or ions with a + charge transmit
to the negative electrode, and the anions or ions with a - charge transmit to the positive
electrode. This transition of the ions leads to the solution being conductive.

What Is The Conductivity Meter Basic Principle?

There are two technical approaches or principles to measure conductivity

- inductive and contracting.

16
Inductive Conductivity
Inductive conductivity meters or electrodeless conductivity meters use two electromagnetic coils
inside a corrosion-resistant casing to measure the conductivity of a solution.

When the device submerges into the solution, it applies an alternating voltage to the drive coil,
which causes a voltage in the receiving coil. The voltage makes an ionic current move
proportional to the conductance of the solution.

Contacting Conductivity
Contacting meters have conducting electrodes made of metal that are in direct contact with the
solution. The meter applies an alternating voltage to the electrodes, and the electric field created
in the solution causes the ions to move back and forth.

This creates a current between the two conductivity meter electrodes.

Conductivity Meter Units

Conductivity is usually expressed in micro- or millisiemens per centimeter (uS/cm or

mS/cm).

17
Another conductivity meter principle that must be taken into account when using a conductivity
meter is the temperature of the solution.

Conductivity is highly dependent on the temperature, therefore you must choose a temperature-
compensated device. you should calibrate the device to be the same temperature as the solution
under testing.

CALIBERATION

The most common solution for the calibration of conductivity meters is potassium chloride (KCl)
because it is soluble and stable. The composition of conductivity standard solutions is a ratio of
KCl: Water. The required ion concentration level of the standard solution determines the mix
ratio.

A simple method of conductivity meter calibration involves measuring conductivity of a standard

solution and adjusting the reading to match the known value.

TURBIDITY METER

WORKING

Turbidity meter is also called turbidity meter, is a tool used to measure the level of turbidity of
analyzed water or solutions. A Turbidity meter is a tool that has optical properties due to the
dispersion of light, which can be expressed as a ratio of light reflected to the incident light. The
intensity of light reflected from a suspension is a function of the concentration if all other
conditions are constant.

18
Turbidity in liquids is usually caused by a variety of factors, including microscopic particles,
such as microorganisms present in the liquid, dissolved solids, etc.

There are two types of general-purpose turbidity meters in common use today, namely:

 Bench top and portable units for sample grabbing on top of the analytical unit Bench top
is usually used as a fixed laboratory instrument and is not suitable for portable use.
 In-line instruments are usually installed in the field and continuously analyze the sample
stream overflowing from the process sampling unit.

Turbidity instrument measuring principle

An infrared diode shines infrared light into the medium. The particles in the medium reflect the
irradiated light detected by the receiving diode (backscattering principle). The electronic device
calculates the relative turbidity of the medium based on the received signal.

Working principle of Nephelometric Turbidity meter

Generally most of the Portable and Bench type Turbidimeter operates on the nephelometric
principle of turbidity measurement.

The optical system (Ref Figure) includes a tungsten-filament lamp, a 90° detector to monitor
scattered light and a transmitted light detector. The instrument’s microprocessor calculates the

19
ratio of the signals from the 90° and transmitted light detectors. This ratio technique corrects for
interferences from color and/or light absorbing materials (such as activated carbon) and
compensates for fluctuations in lamp intensity, providing long-term calibration stability. The
optical design also minimizes stray light, increasing measurement accuracy.

SPECTROPHOTOMETER

How does a spectrophotometer work?

A spectrophotometer works by passing a beam of light through a sample and measuring the
intensity of light before and after it interacts with the sample. The instrument then calculates the
absorbance or transmittance of the sample, which can be correlated to the concentration of a
substance or used for qualitative analysis.
What is the purpose of calibration in a spectrophotometer?

Calibration is essential in a spectrophotometer to ensure accurate and reliable measurements. It

involves using standard solutions of known concentration or absorbance to establish a reference
point for the instrument. By calibrating the spectrophotometer, you can account for any
variations or deviations in the system and obtain accurate results.
Spectrophotometer calibration

Spectrophotometer calibration is a process by which users find out the light source’s accuracy
using a calibration standard. This is an important procedure to make sure that the device
functions accurately and the correct measurement is obtained.

Working

A spectrophotometer is an analytical instrument used to measure the absorption of light by a

sample at different wavelengths. Here is an explanation of how a spectrophotometer works and
its working mechanism:

2) Calibration: Before using a spectrophotometer, it needs to be calibrated using standard

solutions of known concentration. This ensures accurate measurements and establishes a
baseline for comparison.
3) Selection of Wavelength: Depending on the solution being analyzed, a specific wavelength
of light is selected for the test. The spectrophotometer allows for the precise selection of the
desired wavelength.
4) Light Path: The light emitted from a source passes through a series of components in the
spectrophotometer. It first encounters a diffraction grating, prism, and mirror, which help in
manipulating and directing the light.
5) Diffraction Grating and Prism: The diffraction grating splits the incoming light into
different wavelengths, while the prism further disperses the light into its constituent
wavelengths. This process allows for the isolation of the desired wavelength for analysis.

20
6) Cuvette and Sample: The selected monochromatic light then passes through a cuvette that
contains the sample solution (either the test or standard solution). When the light interacts
with the solution, some of it is absorbed, some is reflected, and the rest is transmitted.
7) Photodetector System: After passing through the cuvette, the transmitted light is detected
by a photodetector system. The system measures the intensity of the transmitted light and
converts it into electrical signals.
8) Galvanometer and Absorbance: The electrical signals from the photodetector system are
sent to a galvanometer. The galvanometer measures the received signal, which corresponds
to the absorbance of the solution. Absorbance is a logarithmic measure of the amount of light
absorbed by the sample.
9) Calculation of Concentration: The concentration of the solution is determined based on the
absorbance using the Beer-Lambert law: C = A/(εL), where C is the concentration of the
solution, A is the absorbance, ε is the molar extinction coefficient (a constant specific to the
substance being analyzed), and L is the path length through which the light passes in the
cuvette.
10) Double Beam Spectrophotometer: In some spectrophotometers, such as double beam
spectrophotometers, the monochromatic light is split into two beams. One beam passes
through the standard solution, while the other beam passes through the test solution. This
allows for simultaneous analysis and comparison between the two samples.

Principle

The principle of a spectrophotometer is based on the measurement of light intensity as a function

of wavelength. It achieves this by utilizing a prism or grating to disperse the incident beam into
different wavelengths. The device then manipulates waves of specific wavelengths to pass
through the test solution. The range of wavelengths used can vary, typically ranging from 1 to 2
nanometers.

PACKING MATERIALS

Corrugated cartoon box

when a flute paper which is made by compressing the Kraft containerboard in the shape of S arch
and then sandwiched between the linear board with the help of the adhesive. This sheet is called
a corrugated sheet and the box made out of it are called corrugated box.

A corrugated box is a disposable container whose sides are made up of an inside layer, outer
layer, and middle layer of material. As with all manufacturing and shipping equipment,
corrugated boxes are designed and engineered to determine what they can hold, how much they
can hold, and their strength.

21
The corrugated box usually consists of 3 or more than 3 layers of linear board with a flute
sandwiched between them which increases the overall durability of the box.

3 ply corrugated box is also refered as Single Wall Corrugated Box & 5 ply corrugated boxes
referred as Double Wall Corrugated Box.

TESTING OF CC BOXES

General quality parameters of corrugated boxes are bursting strength of the board, compression
strength of a board, ring crush test, edge crush test, weight of the box, GSM of the paper used,
moisture measurement & moisture resistance, also known as cobb value.

1. Length , width and height of the boxes

2. Bursting strength testers – High-quality of bursting strength testers with the
superior quality of diaphragm is used. During the test, the sample is pressurised with
uniform pressure until the seal or weakest point of the box or paper burst. Bursting
strength defines the amount of pressure the paper can tolerate before it raptures. In a
corrugated box, the no of ply and flute paper increases the durability of the carton and
thus it increases the bursting strength.
3. GSM- GSM in corrugated box means Gram per square meter which means the
amount of ply used in building the corrugated box. The higher GSM Shows that the
more durability of the corrugated box and higher bursting strength.

Procedure

a. cut the 10*10 piece of carboard

b. took the weight of each cardboard.

c. Now soak the cardboard pieces in hot water for 1-2 hours so that each layercan separate with
each other.

d. Dry each layer of acardboard in oven for 3-4 hours.

22
e. Took weight of each layer and find the average weight then apply formula of GSM.

Calculation

GSM=average weight of each layer of cardboard/cut off length/1000*1000

4.Moisture Percentage-

Procedure

a. cut the 10*10 piece of cardboard.

b. took the weight of each cardboard.

c. Separate layer of cardboards by manually so that complete moisture%can befound out.

d. Keep the cardboard pieces in oven for 24 hours.

e. Remove it from oven and took the weight.

Calculation

Initial wt of cardboard-final wt. of cardboard*100

LABELS

MAJOR DEFECTS- These are defects where the cases don’t conform to specifications and
cause major production difficulties to non-functional or unmarketable.

1. Ink colour variations

2. Offensive order
3. Dirt or grease

When applicable limit sample may be established for defects listed above. They may also be
reclassified depending on the severity.

MINOR DEFECTS- These are cases considered to be defective primarily due to non-functional
aesthetic characterstics.

1. Blurred or smeared print

2. Poor ink coverage
3. Offsetting
4. Substrate shade variation
5. Spot or marks
6. Scuffing

23
 7. Tears/ scratches

QUALITY PARAMETERS FOR LABLES

1. GSM (Gram per square metre)

2. GD(Grain direction)
3. LSD Shade (Light Standard Dark)
4. Literature matching
5. Dimension of the labels (length,width)

Method of testing of GSM of paper:

Make perfect rectangle or Square of paper. Sample to be tested and note down its dimensions in
meters, weigh. the Sample paper on available electronic or mono per balance in grams.

Calculation

GSM of paper = weight of paper sample (in gm) / Paper Size (length x width) in meter

Method of testing of Grain direction -

Procedure

Moist the Sample label with water and observe the direction of Curling of paper.

Acceptable grain direction

- If the paper ends, to bring top and bottom close to each other

Reverse grain direction

- If the paper Curls, to bring two sides close to each other.

MONO CARTONS

24
Critical Defects: These are Consumer or defects which could harm the Consumer or cause the
Case to be illegal or otherwise unusable.

1. Mandatory Identification information-either inaccurate or Missing

2. Format - wording and /or design arrangement not according to approval artwork
3. Dimensional and Construction Requirement
4. Variation from requirement listed in the mono cartons specification list.
5. Ink coating stability- inks and coating used to print cartons shall dry hard

Major defects - These are defects where the cases do not conforms to Specifications and / or
cause major production difficulties or deemed to be. non-functional or unmarketable.

1. Dimensions ± 1.0 mm.

2. Print to print Registration ±0.5mm.
3. Ink/ Conting Scuffing
4. Glue joint Separation - Glue joint should not separate.
5. Tuck flap performance - Tuck flaps should not fully engage
6. Automatic bottom performance - Bottom should support the weight of contents
7. Board Stock- Cartons should be made to the Specified board stock
8. Color fade.
9. offensive odor.
10. Dirt or Grease
11. Improper pasting

Minor defects

Visual defects- spots, Smudgy print , scratches etc.

Die –cutting – cartons must be free or ragged edges.

QUALITY PARAMETER FOR MONO CARTONS

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 1. GSM (Gram per square meter)
2. LSD Shade (Light Standard Dark)
3. Literature matching
4. Dimension of the mono carton box (length, width, height )
5. Embossing
6. Mandatory identification information
7. Wording should be clear

CAPS and CLOSURE

Roll-on Pilfer Proof caps or ROPP caps are a type of bottle closure made out of aluminum that
has found widespread use in the pharmaceuticals, chemicals, and food & beverage industry. It is
not just a closure or cap but also acts as an effective seal for bottles that ensures the purity of the
packaged drug by safeguarding it from adulteration and illegal tampering. The seal can be
broken with a simple twist making it rather consumer friendly.

Made Out Of Plain Aluminum Sheets Of Different Thickness & Fitted With EPE Liners, These
Caps Find Its Use In Sealing Glass/Plastic Bottles For Prevention Of Pilferage. This Ensures
Non-Tampering Of A Product. The Caps Can Also Be Customized With Your Logo.

Closures
Glass bottles have a variety of closures to seal up the bottle and prevent the contents escape.
Early bottles were sealed with wax, and later stoppered with a cork. More common today are
screw caps and stoppers. A closure is a device used to close or seal a container such as
a bottle, jug, jar, tube, or can. A closure may be a cap, cover, lid, plug, liner.

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TYPES OF DEFECTS
CRITICAL

1. Foreign maker like insects, hair, metal Shreds , paint shreds, liner facing shred etc.
2. Mix-up
3. Liner defects like-n no liner, cult liner etc.

MAJOR

1. Improperly fitted liner.

2. Deformed caps.
3. Crossly off- center.
4. loose liner (falling out).
5. Wrinkled caps
6. Burst caps
7. Gross Colour variation

MINOR

1. Dents on top
2. Shade variation
3. Smudgy prints.
4. slightly off

Accepting quality levels.

Critical – 0.65 %

Major – 2.50 %

Minor – 4.00 %

PARAMETER OF CAPS
1. Total Height of caps
2. Perforated height of the cap
3. Thickness of the cap
4. Inner diameter of the cap
5. Outer diameter of the cap
6. Wad thickness
7. Logo / print
8. Shades

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 9. Size of the cap ( 27mm,28mm.etc)

BOTTLES
There is types of bottle use in our beverage industry

1. Pet bottles

Pet bottles
This resin is commonly used for carbonated beverages, water bottles, and food packaging.
PET provides very good for carbonated beverage and water properties, generally good
chemical resistance, and a high degree of impact resistance and tensile strength. The
orienting process serves to improve gas and moisture barrier properties and impact strength.
This material is not resistant at high temperature. Its maximum temperature is 200 °F
(93 °C).

Types of defects (inspection)

Critical defect
1. Top seam /over press
2. Out press
3. De-shaped
4. Stick together
5. Holes in the body
6. Leakage from bottom or side joint

Major defect

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M1- functional defects

1. Shade shine
2. Offset finish
3. Bulging
4. Sagging
5. Bottom press
6. Shoulder not blown
7. Bend
8. Forgien particle
9. Loading mark

M2- dimensional defects

1. Lock gauge
2. Collar gauge
3. Thread gauge
4. Height gauge
5. Bore gauge
6. Body diameter gauge

Minor defects
1. Wavy finish
2. Lap mark
3. Pitting mark
4. Stone /black mark
5. Blister
6. Vent hole mark
7. Dirty /rough finish , air bubble

Quality Parameter of bottles

1. Weight of the bottle (g)
2. Height of the bottle (mm)
3. Brimful capacity (ml)
4. Fill point capacity (ml)
5. Major axis (mm)
6. Minor axis (mm)
7. Inner diameter
8. Outer diameter
9. Annealing grade
10. ph value

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 11. Neck dimension with the help of various types of gauges
12. Strength of the bottle

Accepting quality levels.

1. Critical – 0.65 %
2. Major – 2.50 %
3. Minor – 4.00 %

ADHESIVE TAPE-
The tape which is used to stick the cardboards opening are called adhesive tapes.

Parameters of tapes
1. length per roll meter

length per roll meter =net weight/wt. per meter gram.

2. weight of big and small roll

3. printed quality
4. Thickness
5. Width
6. GSM
net wt.= gross wt- core wt(50gms)

GSM= length per roll metre/1000*width of tape/1000*1000

DEFECTS
1. Error to text
2. Missed print operations
3. Damaged / crushed rolls
4. Spots, air gaps
5. Uneven spooling
6. Defective / damaged core
7. Telescopic winding
8. Spots and smudges
9. Wrinkled tape/ air bubbles
10. Shade variation
11. Excess ink / ink starvation

EQUIPMENT USED FOR PACKING MATERIAL

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VERNIER CALLIPER
Purpose - For measurement of bottles and caps .
(i.e. height , inner dia , outer dia, length , breadth etc.
Range – (0-15 cm) with least count 0.05mm

SCREW GAUGE
Purpose- For measurement of sheck thickness of ropp seals, tape thickness etc.

Range – (0-25mm) with least count of 0.01mm

STEEL SCALE
Purpose- for measurement of small item likes labels, mono cartons etc.

Range- (0-0cm) with least count of 1mm

FLEXIBLE STEEL MEASURING TAPE

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Purpose- for measuring of large packaging dimension like carton , mono carton and CC box

Range–(0-5m) with least count 1mm

STANDARD SQUARE
Purpose- for cutting paper to standard size to check the GSM of label and mono carton
laminates

Range -10cm x 10cm of stainless steel

Go or No Go
Purpose- for testing neck dimension of all types and sizes of bottles

Range – complete set to cover neck dimension

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BURSTING STRENGTH TESTER
Purpose – for testing bursting strength of cartons

Range – 0-7kg/cm2 and 0-30 kg/cm2

For CC boxes – for 3 ply the bursting strength is 5.5 and for 5 ply the B.S is 7.5.

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BLENDING
Blending is a process of mixing of the Various Components in a proper proportion to get desired
product.Depending on the type of products following Components are mixed in a Specified
proportion

1) Extra Neutral Alcohol

2) Matured Malt Spirit (MMS)
3) Vated Malt Sprit (VMS)
4) Flavour (Natural or synthetic)
5) Caramel as a colouring agents
6) DM Water

BLENDING FLOW SHEET

ENA + DM WATER + MMS + VMS + ADDITIVES

BLENDING TANK

CIRCULATION AND FILTERATION

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 STRENGTH AND COLOUR ADJUSTMENT

TO BOTTLING

Role of Blender/unit executives.

Preparation of Blends with Consistency in quality h and quantity of per marketing requirement.

Key Role Areas:-

1. Selection of Raw materials like ENA, MMS etc.
2. To make blend as per market requirement.
3. To maintain consistency in quality to keep market Complaint minimum .
4. Bottling operation & Dispatch
5. Quality inspection of all inputs, on line and finished goods.
6. Waste Control

Thoroughly mixed blend is kept for Specified time for proper marrying. After that Sample to be
organolapticaly tested for it's quality. If the blend passing the quality specifications, it can be
released. for bottling after filtration.

BOTTLING AND PACKING

Bottling line operation comprises of Washing of bottles, filling, Sealing and packing of bottles
for dispatch. At every point of operation proper quality cheek and inspection are carried out.

FLOW CHART OF BOTTLING PLANT

WAREHOUSE (STORAGE VAT
FOR ENA) BLENDING SECTION (MIXING OF
ENA, DM WATER ,VMS,MMS and
ADDITIVES IN THE SILO)
DM PLANT (FOR DM WATER) FILTERATION
CHARGER

FILLING MACHINE RINSER

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 CAPPING/ SEALING

CHAIN CONVEYOR
CHECKING POINT 1

DRYER

LABELING MACHINE

BELT CONVEYOR

PACKING IN CC BOXES

TAPING

WAREHOUSE

DISPATCH

Machinery used in production line

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Bottle Washing Machines (Rinser)
Bottle Washers manufactured by Liquid Packaging Solutions are ideal for rinsing, washing and
sanitizing larger containers such as three, four and five gallon bottles. Depending on your
specific needs, these container cleaning machines may rinse, sanitize and wash the container or
the bottle washer can be coupled with a filling and capping machine to rinse, fill and cap with
one unique packaging machine.

Custom manufacturing of bottle rinsing machines and bottle washers is available to handle any
container type and size, including both plastic and glass containers.

Manual and Semi-Automatic bottle rinsers and bottle washing machines are manufactured for
stand alone or uniframe rinsing and washing operations for low to medium production facilities.
These container cleaning machines normally require an operator to place containers on the bottle
rinser or bottle washer prior to the cleaning process.

Filling Machinery
Liquid Packaging Solutions, Inc. manufactures a wide range of filling machinery to handle an
even wider range of products. Overflow filling machines for level fills on thin to medium
viscosity products and products that foam. Gravity Filling Machines for time based fills on low
to medium viscosity products like acids and solvents. Pump filling machines and piston fillers to
tackle thick viscosity products like honey or jelly.

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Piston Filling Machines
Piston Filling Machines from Liquid Packaging Solutions use a volumetric filling principle for a
wide range of different products. On both semi-automatic and automatic piston fillers, the piston
draws back to allow a specific volume of product from the supply system to enter the cylinder.
The product is then pushed out of the nozzle and into the waiting containers as the piston returns
to the cylinder.

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Though piston fillers can handle a wide range of viscosities, they are often the ideal choice for
the highest viscosity products as well as products with large particulates.

Capping Machines - ROPP Cappers

ROPP (Roll on Pilfer Proof) Capping Machines are available from Liquid Packaging Solutions
in both automatic and semi-automatic models. The ROPP Capping Head includes threading
knives manufactured for the individual needs of the customer container.

ROPP Cappers are a specialized capping machine ideal for wine bottles, distilled spirits, olive
oils, the pharmaceutical industry or any other application where evidence of no product
tampering is important. Semi-automatic ROPP cappers require manual placement of the closure
on the bottle, with the head descending to complete the seal once the cap and bottle are
positioned on the capper plate. Automatic ROPP Cappers can be integrated into existing
packaging lines or stand alone as a packaging station in a production facility, using a power
conveyor.

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The Semi-Automatic ROPP Capping Machine is manufactured specifically for aluminum roll on
pilfer proof caps. However, a capping head for the ROPP Capper is also available to seal
standard twist-off or screw-on plastic caps. The operator of the Semi-Automatic ROPP Capping
Equipment simply places a cap on the container and positions the container under the capping
head, then presses activation buttons to initiate the seal. The ROPP capping head will then
descend and thread the cap onto the container indexing system to provide higher speed capping.

Capping Machines - Snap Capper

Liquid Packaging Solutions manufactures Snap Capping Machines for both automatic and semi-
automatic production. The Snap Capper uses either a press on head or press belt to apply
pressure to snap on type caps as they move through the capping equipment. Automatic Snap

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Capping Machines will use a delivery system, such as an elevator and chute, to deliver the
closures to the containers just prior to the sealing process. Semi-automatic Snap Cappers will
typically require the operator of the machine to place each cap on the container prior to applying
the pressure necessary to complete the seal. Snap Cappers work with a wide variety of snap on
type caps, bottle types and bottle sizes.

Power Conveyors
Variable speed power conveyors from Liquid Packaging Solutions are manufactured using
stainless steel, aluminum or HDPE to allow the belt conveyor systems to be designed specifically
for each customer's individual needs. Conveyor line height and conveyor width, in addition to
construction material, will be customer specific.

Specialty conveyors for filing bottles onto a production conveyor, for indexing containers and
custom manufacturing of any power conveyor system, without the long lead times, are always
available for unique containers and/or projects.

Power Conveyors - Stainless Steel Sanitary Style

The stainless steel sanitary style power conveyor from Liquid Packaging Solutions is
manufactured with a raised belt and an upside down U-shaped design for protection against spills
and easy cleanup. Sanitary style power conveyors are ideal for food grade and dairy products
but will also convey almost any product

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Labeling Machinery
Labeling may be the single most important aspect of presenting your product to the consumer. In
most cases, your product label is, quite simply put, the way you communicate with your potential
customer! Liquid Packaging Solutions can recommend labeling machines with numerous
different applications, including wrap, front and back and panel, to name a few.

Automatic pressure sensitive front/back and wrap labelers are ideal for facilities labeling a wide
variety of containers in a different number of formats. This automatic bottle labeler can also be
custom manufactured to apply three panel labels and other unique labels. Quick and easy
centralized controls and adjustable label heads allow for fast container changeover.

Inspection of bottles/ Packed product (CCP-2)

In the production line, each sealed or capped bottle before labeling and packaging are checked
thoroughly at a point with a luminous screen in the background with minimum one thousand lux
of light to find out any hazardous material like dust particle, Low Fill, Damage on the bottle or
any other visible impurity. This point is considered as as per HACCP plan. The worker’s

42
involved in this point works six hours a day, their eye and health check-up is conducted by the
authority half-yearly basis and the records are kept properly. The finished product is stored at
appropriate conditions in clean and dry place away from direct sunlight.

TapingMachine

Manual and semi-automatic taping machines. They are capable to handle uniform, random, small
or large cartons. There are various accessories to improve the productivity. Also, we keep up
with high-quality components and good manufacturing practices. The machines are great to
package anything, effectively. They are engineered to meet your existing/new production lines.
Our taping machines are designed for high-speed and reliable tape applications. We design and
develop the machines in several configurations.

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 PROJECT
Title – Observation of “Inspection & Sorting (INS)” process.

Description – INS stands for “Inspection & Sorting ” process. Once the incoming bottles have
been washed from rinser, they pass through the INS conveyor belt. INS is a manual process with
at least 4 persons on duty who monitor and inspect the incoming lot of bottles before they can be
sent further for filling and if on close inspection, they notice any defect in the bottle, they either
sort-off the defective bottles.

Manual Sorting & Rejection Considerations

Installation of Pre filling Light Station in order to reduce the problems caused due to defective
Pet bottle i.e, Damage bottle, Neck Chip, Tilted cap etc. These Sort of defect may be the
prominent Contributors of Quality issues.

Therefore by applying the same issues are expected to get minimize.

The validation made on the ground of measuring end of line defect. The % of which gone down
up to an extent after applying the same ( Pre-filling inspection light)

Approach followed: On a daily basis, the INS section of L-4 production line was observed for
one hour. During the observation, the number of persons present at INS for inspection and
sorting of bottle is noted. Then the amount of incoming bottles s is noted. After the end of one
hour, the amount of bottles rejected by the workers is noted and put into the following formula
–

Formula used

% Rejected = no.ofrejected bottles /no. of incoming bottles × 100

Control point
Checking of empty bottles on hourly basis prior to use.

Types of defect
Functional defects

1. Crack shine
44
 2. Offset finish
3. Bulging
4. Stone
5. Sagging
6. Bottom press
7. Shoulder not blown
8. Bend , oval body
9. Air bubbles
10. Loading mark
11. Neck Chipped

Implementation Input put up by me.

Rinser

Inspections

Filling machine

OBSERVATION
Date Time of Time Duration No. of No. of No. of % of rejected
start of incoming person rejected
bottles
end bottle on duty bottles
12-06-2023 15:45 16:45 1 hr 1500 2 18 1.2

13-06-2023 15:00 16:00 1 hr 1500 3 11 0.73

14-06-2023 14:40 15:40 1 hr 1500 4 7 0.46
15-06-2023 15:30 16:30 1 hr 1500 2 14 0.93

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 16-06-2023 15:45 16:45 1 hr 1500 3 16 1.06
17-06-2023 14:40 15:40 1 hr 1500 4 14 0.93
19-06-2023 15:30 16:30 1 hr 1500 3 13 0.86
20-06-2023 15:00 16:00 1 hr 1500 4 10 0.66
21-06-2023 15:40 16:40 1 hr 1500 3 8 0.53
22-06-2023 15:30 16:30 1 hr 1500 3 14 0.93
23-06-2023 15:45 16:45 1 hr 1500 2 16 1.06
24-06-2023 15:40 16:40 1 hr 1500 2 9 0.60
26-06-2023 14:40 15:40 1 hr 1500 3 11 0.73
27-06-2023 15:40 16:40 1 hr 1500 4 8 0.53
28-06-2023 15:00 16:00 1 hr 1500 4 17 1.13

PREVENTATIVE MEASURE
1. Trained inspectors
2. Regular Eyesight checkup & rotation of inspectors.
3. Conveyer to have stopper to avoid passing uninspected.
4. Inspection stations to have adequate light intensity.
5. Preventive Maintenance.
6. No glass to metal contact.
7. Checking foreign objects

Hazard
Physical - Dust & Glass particles/ neck chipping

Conclusion –
Mode is defined as the value that has the highest frequency in a given set of values. So on
calculating the mode of the number of persons on duty at the INS section at L-4 production line,
it was found to be 3. This implies that on most days 3 persons were present on duty at the INS
section. However, as per the standards set by ADS spirits at least 4 persons must be present at the
INs section to monitor the incoming bottles after filling .

It can also be concluded, that more the number of people are at the INS section, better will be the
monitoring and the efficiency of the process.

46
The validation made on the ground of measuring end of line defect. The % of which gone down
up to an extent after applying the same ( Pre-filling inspection light)

REFERENCE

https://www.adsspirits.com/our-story.html

https://adsdistilleries.com/gallery.php

https://pharmaguddu.com/ph-meter-principle-calibration-working/

https://pharmaguddu.com/calibration-of-uv-visible-spectrophotometer/

https://www.dubai-sensor.com/blog/conductivity-meter-working-principle-types-
use/

https://hmhub.in/whiskey-history-production-process-scotch-brands/

https://www.envicaresystems.com/demineralization-water-treatment-plants-
pune.html

https://www.dubai-sensor.com/blog/conductivity-meter-working-principle-types-
use/#topOf

47
https://microbiologynote.com/spectrophotometer-principle/?expand_article=1

https://www.tridentpbi.in/products/corrugated-box-cardboard-cartons/

https://americanglassresearch.com/glass-analysis

https://rajatl.com/products/aluminium-ropp-caps

https://www.liquidpackagingsolution.com/category/labeling-machinery

www.kviconline.gov.in

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