internship report on the beverage company,nepal

7/31/2019 Internship Report on the Beverage Company,Nepal

1/31


2/31

2

2. Objectives:

1. To know the overall processing of the natural mineral water to the sterilized puredrinking water.

2. To understand the fundamental parameters and procedures of quality control andquality assurance of thus processed drinking water.

3. To get the basic idea of the managerial structure and parameters of anindustry/factory for its successful running.


3/31

3

3. Brief Executive Summary of the Internship:

Yeti Beverage Private Limited, the factory where the internship was performed, is located in

Nasikasthan, Bhainsepati, Banepa. This is the processed bottled drinking water manufacturing

plant of the nation which is (International organization of standards) ISO 9001:2008 certified and

thus very popular among the consumers in a very short period of time.

Since the water is one of the greatest and inevitable basic requirements of the living beings,

humans want their drinking water to be completely hazardless and safe to drink. Knowing the

fact, the factory is especially conscious and well aware of the plant sanitation and general

hygiene either related to the workplace or with that of the workers personal hygiene. Good

Manufacturing practices (GMP) is well practiced to avoid all possible product hazards.

Having in the mind to experience such environment to work in as well as to learn, this factory

was chosen for an internship for which the great co-operation was shown by the staffs. I was

supervised well enough by the production in-charge, in one department at a time and various

queries and questions were properly answered. Since the production was carried out in the

factory using the automatic machineries (as discussed under further headings), not much manual

work and supervision was required thats why temperature, speed, pressure etc were set initially

then supervised periodically. However, sometimes the production was carried out semi-automatically i.e. along with the laborers help in each section.

Theoretical knowledge was compared to that of the practical knowledge gained during the

internship/in-plant training which made me confident on acquiring more of the practical

knowledge so as to learn more and clearer. So, it would not be wrong to summarize the whole in

plant training as one of the fruitful practical learning experience during the Bachelors program

of food science and technology.


4/31

4

4. Table of contents:

1.WEEKLY SCHEDULE1

2.OBJECTIVES: ................................................................................................................................................. .2

3. BRIEF EXECUTIVE SUMMARY OF THE INTERNSHIP: ......................................................................... 3

4.TABLE OF CONTENTS: ................................................................................................................................. 4

5. INTRODUCTION OF THE COMPANY: ....................................................................................................... 6

5.1. ORGANIZATIONAL CHART OF YETI BEVERAGES PVT LTD: ................................................................... 8

5.2. RAW MATERIALS REQUIRED FOR THE FACTORY: .................................................................................... 9

5.3. MACHINERIES AND EQUIPMENTS: .............................................................................................................. 10

5.4.FEW TERMINOLOGIES . .14

5.5. MANUFACTURING SYSTEM14

5.6. FLOW CHART OF MANUFACTURING PROCESSED BOTTLED WATER.15

5.7. PROCESSING DEPARTMENTS IN YETI BEVERAGES PVT LTD: .............................................................. 17

5.8.MARKETING CHAIN OF THE COMPANY17

6. INTERNSHIP ACTIVITIES: .................................................................................................................... 22

6.1.DEMONSTRATION AND INTRODUCTION TO THE MACHINE: ................................................................. 22

6.2.RAW MATERIALS QUALITY CONTROL AS WELL AS RESPONSIBILITY: .............................................. 22

6.3.IN PROCESS QUALITY CONTROL (IPQC)21

6.4.FINISHED PRODUCT CONTROL...................21

7. ASSESSMENT OF THE INTERNSHIP: ...................................................................................................... 25

8. PLANT SANITATION...23

9. WASTE AND BY-PRODUCT...............................................23

10. R&D23

11.CONCLUSION AND RECOMMENDATIONS: .......................................................................................... 27

12.APPENDICES: .............................................................................................................................................. 28


5/31

5

Table of figures:

Figure 1:organizational chart of the yeti beverages pvt ltd ..................................... 9

Figure 2:flow chart showing the manufacture of pure processed bottled drinking

water .................................................................................................................... 16

Figure 3:showing semi-automatic bottle washing machine .................................. 17

Figure 4:showing bottle capping section and filling section respectively ............. 18

Figure 5:showing the label shrink packager ......................................................... 18

Figure 6:showing the preforms and the blow moulding machine ......................... 19

Figure 7:showing the jar filling and sealing section ............................................. 20Figure 8:showing the market chain of the factory ................................................ 21

Figure 9:showing the production chart for the water processing .......................... 28

Figure 10:showing carbon filters and storage tank............................................... 29

Figure 11:showing reverse osmosis RO machine and ozone generator................. 30

Figure 12:showing micron membrane filter and UV sterilizer.............................. 31

Figure 13:showing the ISO certification of the YETI BEVERAGES ................... 31
http://c/Documents%20and%20Settings/Administrator/My%20Documents/2.docx%23_Toc337583839http://c/Documents%20and%20Settings/Administrator/My%20Documents/2.docx%23_Toc337583839http://c/Documents%20and%20Settings/Administrator/My%20Documents/2.docx%23_Toc337583839


6/31

6

5. Introduction of the company:

Yeti beverages Pvt Ltd, is the factory manufacturing the processed, pure drinking water located

in Nasikasthan, Bhainsepati, Banepa covering 10 ropanis of area just linked to the Araniko

highway. The company is under the sole ownership and was solely established in 2007 A.D.

However, the same company owns the nations highly demanded pipe and plastics of various

sizes and types named under the Yeti plastics Pvt Ltd with the long history behind.

The factory started to manufacture bottled yeti pure and processed drinking water since 2007

A.D. i.e. 2064 B.S. after the neighbor Bisleri drinking water manufacturing company was shut

down. Since then the market has been just expanding. The company has been the member of

Nepal Bottle Water Industries Associations (NBWIA).

Today, the factory produces i)yeti drinking water

ii) Fresh n cool drinking water

Similarly, factory also produces i) various gauges of plastic pipes

According to the sana tatha gharelu udhyog praman patra, the company has registered to

produce 1 million liters of pure and processed drinking water each year in the beginning. Now

the production has increased by 3 times till the end of 2068 B.S. Of these products above, about

80% is consumed by the local market of Kavre district from the urban to the very rural areas ofwhich the market chain and consumer has been shown below. Remaining 20% is consumed by

the market of capital city and the some of the neighboring places of Bhaktapur district. In case of

the plastic pipes of various gauge /gsm, it is circulated throughout the nation.

Among these two main bottled water production, 25% of the total production volume is

contributed by Fresh n Cool whereas the remaining big 75% is contributed by the Yeti

drinking water. The production on the daily basis is variable, mainly depending upon the market

demand and slightly on the remaining stock. Roughly, during a production cycle in the semi

automatic machines, the production is about 6000 liters-7500 ltrs i.e. within one cycle of about 3

hours. At the same time, the filling and sealing of the jars (20 liters) take place in the automatic

machine in a higher speed thus producing about 150 jars per an hour. Similarly, the 500 liters

tanker is also filled with the pure filtered drinking water whenever demanded.


7/31


8/31

8

5.1. Organizational chart of Yeti Beverages Pvt Ltd:


9/31

9

5.2. Raw materials required for the factory:

Director

CEO

GM

FM

Accounts

Engineering

Quality

Production

Store

Sales/Purchase

Personnel

Figure 1:organizational chart of the yeti beverages pvt ltd


10/31

10

S.n Raw materials Manufacturer Description of manufacturer

1.

2.

3.

4.

5.

Raw water

Preform(PET)

Jar + jar cap+ bottle

cap

Label+ neck seal+

cartons

CaCO3, NaHCO3

Shallow and deep

wells.(3)+reservoir

TSN corporation Nepal

TSN corporation

Nepal.

Chandeshwori flex

print.

Just near the factory and sometimes from the

nearby village.

Multinational company importing, exporting,

and manufacturing PET and polymers related

materials.

For info:

http://tsncorporation.com/manufacturing.html

The print is situated in Banepa and is popular

in Kavre district for the print solution, flex

prints, cartons, labels etc.

Table 1: showing the raw materials and their manufacturer

5.3. Machineries and equipments:
http://tsncorporation.com/manufacturing.htmlhttp://tsncorporation.com/manufacturing.htmlhttp://tsncorporation.com/manufacturing.html


11/31

11

S.n Machineries and equipment Number Capacity

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11

12

13.

14.

15.

16.

17.

18.

19.

20.

21.

22

23.

24.

25.

PVC tanks

Pump

Storage tank

Salt containing jar

Filters

Salt containing vessel

Membrane filter

RO machine

Prefilter

Reserve tank

HF4 ozone generator

Filter

UVC water sterilizer

Pump

Semi-automatic bottle washing machine

Bottle filling machine

Bottle capping machine

Bottle labeling and neck sealing

Shrink wrap machine

Case packaging machine

Cargo

Blow moulding machine

Jar filling machine

Jar sealing machine

Label stamping equipment

5

2

1

1

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

3

2000 liter

5 hp

1500 liter

40 liter

20 liter

2X micron

1000 l/min

2X micron

2000 liter

7.5 hp

1000 bottles/min

1000 bpm

1000 bpm

50 cases

100 bpm

20 jars/min

20 jars/min

Table 2: showing the machines and equipments with their capacity

Generator


12/31

12

Manufacturers name : Kohler Company

Number : 4

Oil : Diesel

Oil consumption : 3.2 units/ltr

Total amp : 2200 amp

Volt : 400 V

Rpm : 1500

5.4. Few terminologies:

1. BPR (Batch Production Record)It is the systematic process of keeping the records as per GMP norms so that the errors

can be eliminated. BPR provides instructions and procedures for in-process check, packing

line check and finished product check. It is filled and checked by the both production chemist

and QA chemist and finally gets audited by head of QA before dispatch.

2. BOM (Bill of Materials)It gives the amount of all the ingredients required for the production of a certain product.

It actually gives the composition of the batch or lot to be produced.

3. MIN (Material Issue Note)It is the list of RM and PM required for the production of certain batch. It is sent with

BPR by QA department to the store and it is forwarded to the production department before

the production of the batch along with the issue materials.


13/31

13

4. MRN (Material Return Note)After the production if the extra material is left then it is given back to the store with

MRN.

5. MAN (Material Arrival Note)It is the system of recording all the purchased materials.

5.5. MANUFACTURING SYSTEM:

1. Firstly raw materials and packaging materials arrive at the factory with MAN.

2. After being approved by Q.A. these are sent to the store.

3. For the production, the production department asks for the raw material from the store. It

sends MIN to the store and the amount of raw material required for the production according to

BOM is issued by the store.

4. At the start of the production, the CIP process is carried out.

5. The production department prepares a batch according to BPR.

6. After being approved by the QA chemist the batch is sent for the processing.

7. Analysis of the finished product is then done.

8. The finished product is now undergone microbiological test. The finished products are

dispatched from the warehouse only when the QA chemist assures microbiological safety.

9. All the lab results are recorded in the ISO report so that could be checked upon by the

authority.


14/31

14

5.6. Flow chart of manufacturing processed bottled water:

Figurative chart followed by the company has been shown in appendix 1. Flow chart for the

manufacture has been shown as below:

shallow+deep well water

pump to the roof

water pretreatment

aeration

chemical treatment(opt)

pump pretreated water

sand filter storage tank

storage tank

Tanker filling

Calcium carbonate (250gm/40 litre)in case of

CIP.

4 filters

2 sand filters 1 carbon filter 1 ion-exchange resin

Sodium bicarbonate(200

gm/20 ltr) in case of CIP


15/31

15

pumping

Bottles were introduced

through conveyor

Membrane filterReverse osmosis(RO)

Shows TDS, input andoutput

Filter i.e. prefilter

Reserve tank(2000 litre

capacity)

Ozonisation (HF4 ozone

generator)

Filter

UVC sterilization(water

sterilizer)

Bottle washing machine

Semi-automatic bottlewashing

PET preforms

Blowing and moulding

of bottles(Blow and

mould machine)

Packed in sacks

Damaged weresorted out.

Bottle filling (bottle filler

machine)

Adjust the rate.


16/31

16

Cartons

Figure 2: flow chart showing the manufacture of pure processed bottled drinking

water

Bottle capping (semi-

automatic)

Labeling (manually)

Neck sealing

Shrink wrapping(shrink

wrap machine)

Adjust the temperature

Bottle caps in hot water

Labels stamped date and batch

number.

neck seals, cartons at the place

o manu acture.

Packing in casesCount and record the

product.

Stacking

Storage in a suitable room


17/31

17

5.7. Processing departments in Yeti Beverages Pvt Ltd:

Yeti Beverages Pvt Ltd manufactures and sells pure and processed bottled drinking water and

the processing plant includes following various departments:

i)Bottle washing department:This is the plant in which the manufactured PET( polyethylene terephthallate) bottles are lined

up in the conveyer so as to wash the bottles prior to the filling. The speed adjustment is done

and monitored manually.(machine information is as mentioned above).

Figure 3:showing semi-automatic bottle washing machine

ii)Bottle filling department:After the proper washing of the bottles, these are filled in the filling department, generally 1 liter

processed water is filled at the adjusted rate under strict hygiene and safety practices.


18/31

18

iii) Bottle capping and labeling department:

This is the department where filled bottles are capped with the caps immersed in the warm water

to avoid contamination and the stamped labels are manually inserted around the body of the

bottles.

Figure 4:showing bottle capping section and filling section respectively

iv)Neck sealing and shrink wrapping department:

This is the plant where at first the neck sealing is manually done then afterwards the shrink

wrapping is done with proper adjustment.

Figure 5:showing the label shrink packager


19/31

19

v)Plastic preforms blow moulding department:

This is the department where usually 30 grams size performs are blown to the bottles using the

following machine. The preforms size varies according to the required size of the bottle i.e. 250

ml, 500 ml, 1 l, 1.5l, 2 l, 5 l, 20 l etc.

Figure 6:showing the preforms and the blow moulding machine

Bottle caps are usually made from the mixture of High Density Polyethylene(HDPE) and the

LLDPE using 4 cincinnati Milacron and 2 winds or injection moulding machines.

vi)Water pretreatment plant:

This is the plant where the raw water from the bore wells is treated differently before pumping it

to the processing plant thus making it very suitable for human use already.

vii)Quality assurance and control laboratory:

Water testing lab is very important department of the factory when it is world recognized ISO

9001:2008 certified and thus it is made sure that the water is of the ISO standards and completely

suitable for the consumption. ENPHO water test kit has been provided along with the operational

manual for the safety purposes.(details under the activities heading).


20/31

20

vii)Storage:

The stock of the finished, semi-finished goods are stored in a cold room and dispatched as perthe

orders.

viii)Jar filling and sealing department:

The jar filling and sealing needs to be done carefully so as to maintain hygiene and ensure the

product quality.(detailed processing has been described under activities heading)

Figure 7:showing the jar filling and sealing section

5.8. Marketing chain of the company:

The marketing chain of the company over the years has been changing frequently from the

middle person or retailer involved to the present one without any retailers i.e. directly from the

producer to the end consumers. Some cases include following market chain:

Stock point being at the factory location itself and the distributor located at the capital city

Kathmandu, Nepal. The retailers were at various locations at most of the popular cities of the

country. Thus the products are accessible to the consumers in two ways. Major consumers being

the hotels and restaurants of the capital as well as some major cities of Nepal, they could get the

product through the companys distributors as well as retailers, or directly from the factory itself.


21/31

21

Figure 8:showing the market chain of the factory

Mother warehouse

CNFA(clearing and forwarding agent)

Stock point

Retailer

End consumer

Distributor

Market Chain at Yeti Beverages


22/31

22

6.Internship activities:The internship activities on daily basis have been listed out in the weekly schedule above. The

tasks can be described based on the factory manufacturing system and processing cycle as below:

6.1.Demonstration and introduction to the machine:

At first, each and every department the intern was introduced to for their daily activities, the

operation was demonstrated properly by the department head or supervisor most of the times.

Then intern was allowed to take over partially under strict supervision to maintain the In process

Quality control(IPQC).

Then the activities were performed as per the production process at first then to the Quality lab

section and finally to the marketing which has been listed as:

6.2.Raw materials quality control as well as responsibility:

This is very important step and should be careful for that reason. Firstly, the amount of raw

materials those needed to be purchased is calculated and then the order is placed. The preforms,

jars, jar caps and bottle caps are weighed, graded then damaged are also recorded.

6.3.In Process quality control (IPQC):

All the processes of production are carried forward according to the BPR. After the preparation

of any batch, it is checked by the QA chemist. Only after the QA approval, the batch is

forwarded for processing. A precise control was maintained during the process with the regular

checks of batch code, volume, packaging and filling. IPQC parameters were checked as per

BPRs as per the frequency by both QA and production personnel.

Packaging checks:

i) Non-destructive checks: shape and top creases, printing, weight, tab positionii) Destructive checks, were done.


23/31

23

During the production cycle, after the performs were blown to bottles, the damaged were counted

as in bottles and in preforms itself. They were noted to calculate total production per batch and

thus damaged bottles and preforms were sold back to recycling or grinding department.

These produced bottles were carried to the washing department through the moving conveyor

belts, the machine was turned on. The rate of washing was set and machine was monitored

afterwards in case if the irregular bottles create problem in the machine performance.

Main steps as an intern, learnt were:

a)Routing: the route of the production process is designed in such a way that the transportation of

the materials is the minimum which is extremely taken care of.

b)Estimating: It can be called as a special type of the forecasting. To decide or preplan or guess

what the new things, tools, components of the part will cost and what will be its effect on the

production and demand of the product.

c)Loading and scheduling: Both of them helps in the production planning. Loading refers to the

time gap for various work loads booked in advance. Scheduling(preparing time tables from the

start to the end) ensures the delivery of the product whereas the other ensures the maximum

utilization.

d)Dispatching: It refers to the actual issuing of the orders for performing different actions in

various units for which above mentioned activities are done. Various paper works as well as

graphs and charts, records are studied well and finally decision is made.

Distribution afterwards is done using big or small vehicles as per the need and route of the

transportation.


24/31

24

e)Follow up: Regarding the actual performance, the production cycle and efficiency of the

factory can be judged so dispatcher keeps the record, feedback and counterchecks the production

system considering the seniors view.

f)Inspection: Its very important job underquality control and is detailed below. To inspect to

know the acceptable and unacceptable product and let know the QA officer may in future decline

the defects and produce better quality products.

g)Evaluation: It is a link between the control and future planning. The products of the Yeti

Beverages has been evaluated by the ISO 9001:2008 and also by the DFTQC(department of food

technology and quality control).

6.4.Finished product control:

The very important internship activity performed was as the quality control officer which was to

assure the quality of the processed water. The task was performed following the

ENPHO(environment and public health organization) water test kit which is especially designed

to test the drinking water[http://www.enpho.org/research-and-development/field-test-kits.html ]

10 parameters to check according to the kit and ISO requirements are:

i) pHii) Temperatureiii)Chlorideiv)Hardnessv) Ironvi)Ammoniavii)Phosphateviii) Nitrateix)Free residual chlorinex) Coliform test.(P/A)
http://www.enpho.org/research-and-development/field-test-kits.htmlhttp://www.enpho.org/research-and-development/field-test-kits.htmlhttp://www.enpho.org/research-and-development/field-test-kits.htmlhttp://www.enpho.org/research-and-development/field-test-kits.html


25/31

25

These tests were carried out in the lab daily and entered into the reports for the evaluation and

future reference. In case if the results were out of standards then the batch was rejected and the

plant was suggested washing.

7. Assessment of the internship:

After the completion of 45 days of internship in the beverage company of Nepal, I, as an intern

feel to be more skilled, confident and capable of handling the responsibility provided in any

company. I found the working environment in the factory comfortable and easy to adapt. The

machine and the manual labor collaboration was shockingly balanced to provide such an

amazing output without much of an error.

As the departments have been clearly described above as well as the pattern of the internship, my

responsibility throughout the internship was differentiating as the week passed by. Each week I

was directed to the different departments and allowed gracefully to look after the respective units

under the very admirable supervision. Later on that respective week, I was fully relied upon to

take over the whole responsibility as mentioned above.

This internship will certainly be influencing my future plans. I will be planning my future careerswith a clear point of view now keeping on mind what might be the responsibilities and will I be

able to handle it or not, also the fact that will I be adapting to the working environment or not.

This activity has certainly developed my professional attics so that I can be more prepared and

enthusiastic to join the food and beverages industry in the nation.

When comparing the classroom knowledge I achieved when gaining the theoretical classes, the

internship has been more effective since I got opportunity to get involved practically whatever

was told by the supervisor. The same things I used to write has been clearer to me after the

internship as well as the mental conscience has increased leading to higher curiosity and thinking

behavior. However the strictness,precautions, dos/donts and the theory, in some cases have not

been followed in the company lab as used to be followed in the classes.


26/31

26

8. Plant sanitation:

GMP and ISO certified plant of drinking water processing unit is the most sophisticated

area. It operates at highly sanitized and hygienic condition. Each worker wears a cap, an apron,

hand glove and a mask. Aseptic condition is maintained here. Giving major attention to

cleanliness, CIP (cleaning in place) program is carried out here. It is done to ensure a sanitized

condition of the total process line. Further, the total area of the plant is also continuously cleaned

with water, detergent, combatan solution, etc. These include the cleaning of floor, glasses, tiles,

wash basin, etc.

9. Waste and by-product:

By product process utilization - no

Types of waste -solid, liquid and semi-solid

Solid and semisolid treatment- sent to the grinding section or sold to the recyclers.

Disposal of the liquid wasteincluding water rejected from RO is directly flown to

the reservoir which contains fish.

Waste water treatment -no

10. R&D:

There is no research and development carried out at Yeti Beverages. Only R&D on

process optimization and product stability is carried out.


27/31

27

11.Conclusion and recommendations:

The in-plant training at Yeti Beverages Pvt Ltd was aimed at studying the overall process of

manufacturing the pure and processed bottled drinking water along with its quality system. The

GMP and ISO 9001:2008 certified plant of the drinking water has fulfilled all the criteria of an

ideal plant from both sanitation and technical point of view. The chemical lab microbiological

lab, IPQC lab and packaging lab working under the QA department have a team of skilled and

well-trained employees, thus the quality system maintained here is dynamic. Quality is the main

goal and each department from Production, QC to Storage is doing its best to provide the highest

quality product to the consumers. The supportive and co-operative staffs have made a pleasant

working environment here.

The facilities of power, water, machineries and transport need not be exaggerated. The otherfacilities provided to the labors are good too. Some of the recommendations are as follows:

a)A major thing that is lacking at the factory is a proper waste water treatment and management

plant. It would have been better if the factory had a water utilization plant inside the factory

itself.

b) The time schedule could have been proper.

c) It could be beneficial if the company itself manufacture the jar, jar caps, bottle caps .

It was immense pleasure to perform the in-plant training at such a reputed private enterprise. The

knowledge and the experienced gained here will certainly be a great help in future.


28/31

28

12.Appendices:

1.

Figure 9:showing the production chart for the water processing


29/31

29

2.

Figure 10:showing carbon filters and storage tank


30/31

30

3.

Figure 11:showing reverse osmosis RO machine and ozone generator


31/31

4.

Figure 12:showing micron membrane filter and UV sterilizer

5.

Figure 13:showing the ISO certification of the YETI BEVERAGES