BIB PROCESS FLOW CHART

CIP of BIB Filler As Per CIP

Matrix

CIP Should not Exceed 4 Hrs If Exeed > 4 hr Then

Before Filling again CIP

Ready Syrup Stored in ambient

temperature

Empty Bags Recived

from Approved
Verify Brix & Density
Supplier with COA

Do Sensory For Release of Ready Empty Bags Received

Syrup to BIB Filling From Store

Syrup Released & Pumped QA Inspection Of

Through 100 Mesh Strainer Empty BIB Bags

BIB Empty Bags

BIB Filler
Released for Filling

Volumetric Filling of BIB Bags

of 10 OR 20 Liter

Manual Weighing Of Each Filled

No correct Weight
BIB Bags
Empty Bags Recived
from Approved
Supplier with COA Change The Setting As Given Discard The Bag &
BIB Manual Syrup

Empty Box Received

From Store YES
 cartoning & Strapping
BIB Empty Box
Released for Packing

Labelling & Batch Tagging Of

Each BIB Box

BIB Box Store In BIB Srorage

Room

Product release on the basis of

QA Check & Sensory result
 Superior Drinks Pvt. Ltd., Nagpur
FLOW CHART
Revision No. :01 FSMS-FLC-01 FLC

PACKAGED DRINKING WATER FLOW CHART

Source Water MIDC Supply (Raw
Water)
Chlorine dosing 3-5
ppm
Raw water sump tank (25 KL)

Raw water in modular tank 1&2 OPRP 1

3-5 ppm Chlorine
(500 KL each)

Clear zone Chemical dosing Chemical Preparation

Settling zone Lime -240 ppm Lime -10%
Coagulation Tank(60 m³/ hr)
Reaction zone Ferrous sulphate -40.51 ppm Ferrous sulphate - 6 %
Sludge zone Bleaching -19.73 ppm Bleaching - 6.25 %

Clear Water tank (82 KL)

Backwash line for PSF

1&2
Backwash recovery Pressure Sand filter (PSF)1&2 (40
line m³/hr each)
Chlorine Analyzer &
CO2 Dosing
Procee water tank (100 KL)
CCP 1
(Chlorine 3-5 ppm)
Backwash line for ACF
1,2&3
Backwash recovery Activated Carbon
line filter(ACF)1,2&3(40³/hr each)

Backwash Recovery Activated Carbon Preform & Closure Received

tank filter(ACF)LEAD(40³/hr each) From Approved Supplier with
Certificate Of Analysis
.
PSF 4 Activated Carbon
Internal QA Inspection
filter(ACF)LAG(40³/hr each)

Modular tank 1&2

QA Approval And Release
(500 kl each) UV Treatment (Intensity >75
w/m²& working hrs<9000

Closure Issue From Store for Preform Issue From Store for
5 micron filter (Volume 120 L&
Production Production
pressure 1-10 bar)

RO Reject Water
5 micron Filter Two Stage RO Unit
Holding Tank Closure Precoditioning & Loading Preform Precoditioning & Loading

Permeate water to Permeat water to 30 KL RO

Two Stage RO Unit Online Closure Inspection Online Preform Inspection
modular tank 1&2 Holding Tank in PDW Line
(500 kl Each) UV Light For
Recirculation

Prepared by FSMS TEAM

Approved by FSMS TEAM LEADER
Revision Date :10/05/2016 Issue :01/04/2015
 Superior Drinks Pvt. Ltd., Nagpur
FLOW CHART
Revision No. :01 FSMS-FLC-01 FLC
UV Light For
Recirculation
Mineral Dosing (TDS 18.4 TO 28.2 Closure Sanitation By Hot Air & Heating in Oven Of Blowing
Reject Water to Drain ) UV Light Machine At 110°to120°C

To ETP For Further

Ttreatment
1.2 Micron Filter Blowing At 30 Bar Pressure
Nitrogen Received From
Approved Supplier with
Certificate Of Analysis
0.2 Micron Filter Transfer For Filling
Internal QA Inspection

Ozone Generator
Ozonation in Product tank (0.1 to
QA Approval & Release From OZONETEK
0.4 ppm )

Nitrogen Dosing in Bottle After

Filling and before capping Ozone Level 0.1 to 0.4 Ionisation Unit for
Filling Volumetric Filler
ppm in bottle before Closure
CCP 3 60 sec
Recovery Tank (If Ozone < 0.15
From Filler Bowl) UV Light
Capping

Filled Bottle closure Quality

Inspection

Rejection For Low

Filled Bottle Inspection
Filled Bottle

Convey Through Chain conveyor

Warmer

Air Blower

Labelling & Date Coding

Rejection For Without

Label & Date Code Inspection Label/ Date code

Shrink Wrapping

Secondary Date Coding

Prepared by FSMS TEAM

Approved by FSMS TEAM LEADER
Revision Date :10/05/2016 Issue :01/04/2015
 Superior Drinks Pvt. Ltd., Nagpur
FLOW CHART
Revision No. :01 FSMS-FLC-01 FLC

Secondary Date Coding

Palatizing

Stretch Wrapping

Storage In Warehouse

QA Inspection & Release After 24

Hrs

Dispatch Of Finished Goods

Prepared by FSMS TEAM

Approved by FSMS TEAM LEADER
Revision Date :10/05/2016 Issue :01/04/2015
 CONTAINER PREPARATION FLOW CHART
Worker Follow GMP
Market Return Empty
& GHK Practices

Sorting Of Breakage & Other

Brand , etc. Other Brand Removal

New Glass Empty Palatizing Of Empty & Storage In

After QA Release Empty Yard

Issue Empty For Production &

Shifting To Loading Area

Manual Depalletizing & On

Conveyor

Uncaser ( Remove Empty bottles

From Carates & Placed On
Conveyor)

Pre-Inspection

Removal Durty
Chipped Neck
,Foreign Matter No
& Rusty Empty
bottles

To Shiiping For
Manual Washing

Chopped Neck Empty

YES, Loading To Bottle Washer
Discard

Issue Caustic From Pre-Rinse Compartment Jet Dirty Washed Water

Store Pressure > 2.0 Kg/Cm² To ETP For Further
Treatment
Caustic Dissolving Soak 1 Compartment Temp.50 to
Tank 55 Deg. C
OP Steam From Boiler
RP6
Hot Lye/Caustic Soak 2(Main Soak) Temp 74±2 ° C
Dosing Caustic Conc. 2.8 ±0.2% DIVO Ultra Dosing
Min. 0.25%

Hydro Wash Temp. 50°-55° C Jet

Pressure > 2.0 Kg/ Cm²
Rinsing Water
Reusing Divo LE Dosing>25 ppm
Pre-Final Rinse Jet Pressure > 2.0
Kg/ Cm²
Divo AI Dosing: PH 7-8
Chlorinated Soft
Final Rinse Jet Pressure > 2.0 Kg/
Water After 5µ
Cm²
Filter (Chlorine 1-3
ppm & TH <10

Check Caustic Carry Over & MB

Test in Every Bottle ( 32
Compartment)

Post Light Inspection

Removal Durty
Chipped Neck
,Foreign Matter &
Rusty Empty
bottles
No EBI No Run
OPRP
7
EBI Test Run After Reject Bottle To Chipped
Every 2 Hrs EBI (Electronic Bottle Inspection) Sorting Neck

Washed & Sanitized Empty Bottle Bottle Washer Discad

For Filling
 PROPORTIONING & FILLING RGB FLOW CHART
CIP & Sanitation Of Filler As Per
Treated Water From CIP Matrix
WTP After 1 µ

Paramix (Propotioning Of Treated

Syrup From Syrup Room Transfer
Dereation Tank Water Syrup & co2)
Through 100 Mesh Strainer

Beverage with Desired Conc Cool

Glyco From Utility For PHE
In PHE (As Per OEM)

Paramix ( Propotioning Beverage

CO₂ From Bullet Through Domnic
with CO₂)
Hunter Filter -6 stage filter

Buffer Tank

Online Co-Brix Analizer

60 & 100 Mesh Stainner

Crown Issue From Clean & Sanitized

Counter Pressure Filler
Store Empty From EBI

Glass Fragment-PFD
Crown Transfer In Working In Auto CCP-2
Filling Of Bottle At 4°To 10° C
Hopper From Box Mode During Bottle
Burst

OPRP- 8
Check GO
Crown Elevator Crowning Of Filled Bottles
NOGO

Date, Batch No. & Time Coding

On Filled Bottle

Remove Uncrown bottle, half

Final Inspection
filled, over filled, smashed date
code
 Casing At Case Packer

Manual Palatization

Storage Of Finished Goods In

Warehouse

QA Release

Dispatch Of Finished Good

 Sanitation of Sugar Dissolving
Tank 1,2(SDT)

Taking Treated water in SDT

As per Batch size & Flavour

Weighing of Sugar As per

Batch size & Flavour

Water temp.> 65 C Dumping

Start

Dissolving of Sugar in tank &

heating up to 85 deg. C Temp.

Activated Carbon powder Sg 50 grade

(0.2% by sugar weight)
Hot carbon treatment (as
temp. Reaches to 85 deg.C
Contact time 30 min.
Hyflo (0.25% by sugar weight

60 X 60 Size Filter paper

Filter press dress with filter

Hyflo 0.15% by
paper
sugar weight

Precoating tank 1 Dressed filter press precoating

or 2 with Hyflo

Precoating ( Hyflow carry over

) Check by Black 0.45 micron
filter paper

Hot syrup at 85 deg. C

circulation for 30 min

Check Carbon carryover test If carbon carryover then recirculate

No carbon carryover then

transfer

Transfer through [Link]. Cooling Tower Water, Glycol From

in between 10-30 deg. C Utility & Treated water from WTP
 Transfer through [Link]. Cooling Tower Water, Glycol From
in between 10-30 deg. C Utility & Treated water from WTP

Issue the required Flavour & No. of

CIP of FST done before Transfer but
unit of Conc. Acording to FEFO
not Exceed more than 4 Hours

Simple Syrup transfer in one

Transfer Conc. From conc. Room to of FST tank(1,2,3,4,5)
Ready syrup room

Washing & cleaning of Conc. Can

Check Brix, Volume & No currect volume then flush SDT &
from outside
calculate the sugar Filter press & Transfer to FST

CIP Of Conc. Tank Before mixing

Flushing of filter press with
treated water

Dissolving of the dry parts /pouring

liquid part in conc. Mixing tank as
per MMI After Flushing Down the pressure of
filter press
Concentrate Mixing as per
Transfer Concentrate From conc. MMI
Mixing tank through 100 mesh Remove filter paper with carbon cake
strainer

Make up standerd Brix &

volume as per MMI by adding Place in bags & trasnfer to ETP
treated water

Place this bags in Spent carbon Bed

Ready Syrup stored at 10-30

deg.C

100 Mesh Strainer 100 Mesh Strainer 100 Mesh Strainer

PET Line RGB line BIB Line

 Superior Drinks Pvt. Ltd., Nagpur
FLOW CHART
Revision No. :01 FSMS-FLC-01 FLC

TREATED WATER STREAM

Source Water MIDC Supply (Raw
Water)
Chlorine dosing 3-5
ppm
Raw water sump tank (25 KL)
SOFT WATER STREAM
OPRP
Raw water in modular tank 1&2 1
3 to 5 ppm Chlorine
(500 KL each)

Clear zone Chemical dosing Chemical Preparation

Settling zone Lime -240 ppm Lime -10%
Coagulation Tank(60 m³/ hr)
Reaction zone Ferrous sulphate -40.51 ppm Ferrous sulphate - 6 %
Sludge zone Bleaching -19.73 ppm Bleaching - 6.25 %

Pressure Sand filter 3

Clear Water tank (82 KL)
(25 m³/hr)
Backwash line for PSF
1&2
Backwash recovery Pressure Sand filter (PSF)1&2 (40
line m³/hr each)
Chlorine Analyzer &
CO2 Dosing CCP
Procee water tank (100 KL) Chlorine 3-5 ppm 1

Backwash line for ACF

Activated carbon filter 1,2&3
25m³/hr Backwash recovery Activated Carbon
line filter(ACF)1,2&3(40³/hr each)

Backwash Recovery Activated Carbon

tank filter(ACF)LEAD(40³/hr each)

PSF 4 Activated Carbon

filter(ACF)LAG(40³/hr each)
Softner (25 m³/ hr)
UV Treatment (Intensity >75
Modular tank 1&2 w/m²& working hrs<9000
(500 kl each) 5 micron filter (Volume 120 L&
pressure 1-10 bar)
5 micron filter (Volume 120 L&
pressure 1-10 bar)
UV Treatment (Intensity >75 OPRP
Chlorine Dosing 1-3 w/m²& working hrs<9000 2
ppm RO Reject Water
RO Unit 1 & 2
Unchlorinated Soft Chlorinated Soft Holding Tank
Water Tank (30KL)& Water Tank 1-3 ppm OPRP 3 micron filter (Volume 120 L&
hardness <10 &Hardness < 10 3 pressure 1-10 bar)
Permeat water to 30 KL Tank
5 micron Filter
Placed in PDW Line
1 micron filter (Volume 120 L&
pressure 1-10 bar)
Permeate water to
Utility
PDW modular tank 1&2
5 Micron Filter

Prepared by FSMS TEAM

Approved by FSMS TEAM LEADER
Revision Date :10/05/2016 Issue :01/04/2015
 Superior Drinks Pvt. Ltd., Nagpur
FLOW CHART
Revision No. :01 FSMS-FLC-01 FLC

PET LINE CIP

Boiler , Chiller , RGB &
Reject water draain to
Canteen Syrup
Bottle Washer ETP

Warmer & Chain

Lubrication

Cooling Tower

Prepared by FSMS TEAM

Approved by FSMS TEAM LEADER
Revision Date :10/05/2016 Issue :01/04/2015