BISLERI WATER INDUSTRY

Project report
Submitted by:
Moideen afreed h
Ibrahim shairish

St Aloysius collage
Autonomous,Mangalore

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 DECLARATION

We do hereby declare that project report of overall study of

packaged drinking water/ carbonated water / carbonated fruit drin-
ks submitted to st Aloysius collage autonomus mangalur is a bona-
fide record of project study done by us under the supervision of
[Link] gowda head department of food processing and
engineering.

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 ACKNOLEDGEMENT

First we express our thanks to god almighty in guiding and blessing

us for making these project a great success. we are heartly thankfull
to each and everyone for the guidance and support for completing
our great effort.
We express our profound to the banglore bisleri industry HR
Manager for granting us the permission for the project in company.
We also owe thanks to, Mr SIDDESH (Quality Executive) and each
and every department staffs for their guidance and whole hearted
co-operation during the period of training.
It is our privilege to extend our sincere thanks to, [Link] (Quality
manger) and Miss. Kurath (laboratory assistant) and [Link]
(laboratory assistant) for theire co- operation and quidence.
We convey our sincere gratitude to our respected teachers
[Link] gowda (Head of the Department), miss. jenissa cinora
(class guider ) in Department of Food processing and engineering for
allowing us to undergo the training and for the valuable guidance.
Finally, we thank our parents and friends, who sparked the spirit of
enthusiasm and sculptured us in to the present position. They were
always supporting and encouraging us with our welfare in mind.

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 INDEX

[Link] TITLE PAGE NO.

1 COMPANY PROFILE 5
2 INTRODUCTION 6
3 BISLERI CERTIFICATION 7

4 WATER PRODUCTION FLOWCHART 8

5 20L JAR PRODUCTION FLOW CHART 11
6 WATER PROCESSING 13
7 GOOD MANUFACTURING PRACTICES 27
8 PACKAGE MATERIAL STORAGE AND 34
HANDLING
9 PEST CONTROL PROGRAM 31
10 COVID19 PRECAUTION 37
11 PET WATER BOTTLES 46
12 COUSTMER COMPLIENTS RESPOND 49
SYSTEM
13 CHEMICAL TEST 52
14 MICROBILOGY TEST 53
15 CONCULUSION 54

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COMPANY PROFILE

In 1967, Bisleri an Italian company, started by Singer Felicebisleri, first brought

the idea of selling bottled water in India. It started a company called Bisleri
India. In 1969, Ramesh Chauhan, the Chairman of Parle Exports, bought over
the brand. In those days, Bisleri packaged drinking water was available in glass
bottles. Being a returnable package owing to various other problems such as
breakage and weight, in 1972-73, Bisleri was made available in PVC (Poly Vinyl
Chloride) bottles. After this plastic packaging was introduced, things started to
change, and sales increased rapidly. The upsurge in the sales of Bisleri started
in 1993 as Ramesh Chauhan sold off the Parle stable of brands, including
Thums up, Limca and Gold Spot. Recognizing the potential of the drinking
water market, he then went on to concern trade on marketing Bisleri a top
selling brand in India.

VISION
Our vision is to be the dominant player in the branded water
business. We must expand and be a leader in the premium
beverage category.
MISSION
We must have world class quality, at the lowest production and distribution
cost. This will make us an unbeatable leader, and we will have satisfied
loyal customers.

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 INTRODUCTION

Bisleri is a brand of bottled water in India. Bisleri has 60%

market share in packaged drinking water in India. Product
range comprises of variants : Bisleri with added minerals &
Bisleri Mountain Water. It is available in 6 pack sizes: 250ml
bottles, 500ml, 1 litre, 2 litre, 5 litre, and 20 litre. Its operations
run throughout the subcontinent of India and is one of the
leading bottled water supplying companies in India. Bisleri has
13 plants & 200 co-packers all over India. Over 20,100 workers
in company role. Company produce MINERAL WATER Bisleri
mineral water contains minerals such as magnesium sulphate
and potassium bicarbonate which are essential for healthy
living.
FIZZY SODA It is the most recent product of bisleri. Fizzy soda
carbonated water and comes under Soft water
segment. BISLERI VEDICA Mountain water from the natural
Himalayas. The Bisleri bottled water range comprises of:- 500
ml 1 litre, 1.2 litre 2 litre 5 litre and 10 litre jar. here are 200
workers working in devanahalli plant. The water rescore here
is collected from 5 bore well, The production process adopted
by Bisleri is batch production.  The workers work in 3 shifts
which comprises of 55- 66 workers per shift.

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 BISLERI CERTIFICATION

BIS

 The Bureau of Indian Standards (BIS), successor to the erstwhile Indian

Standards Institution, is the national standards body responsible for
formulating National Standards established under the Bureau of Indian
Standards Act, 1986.
 To protect the interest of the Consumers, BIS operates a Certification
Mark Scheme.
 Under the scheme, BIS grants license to such manufacturers who are
capable of producing goods on continuous basis as per relevant Indian
standards

FSSAI
 Food Safety and Standards (Prohibition and Restriction on Sales)
Regulations 2011 state that no person should manufacture, sell or
exhibit for sale, packaged drinking water and mineral water except
under the Bureau of Indian Standards (BIS) certification mark, the
regulator added.

Indian Standards on Packaged Drinking Water

 IS 10500:2012 Indian Standard -Drinking water –Specification

 IS 14543:2006 Indian Standard -Packaged drinking water (other than
packaged natural mineral water) –Specification
 IS 13428:2005 Indian Standard -Packaged Natural Mineral water –
Specification
 IS 15410:2003 Indian Standard –Testing for Plastic Bottles/Containers for
PDW

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 WATER PRODUCTION FLOW CHART

RAW WATER TANK PRESSURE SAND ACTIVATED

(OZONATION:0.4- FILTER (PSF) CARBON FILLTER
0.6 PPM )

ANTIDCSLRNT DOSING

1 MICRON PRE RO
FILLTER

R.O SYSTEM

Magnesium sulphate

Potassium bicarbonate

Product water
tank

Ozonation:

0.2-0.3 ppm

Two-way
One way
filling
filling

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 ONE WAY PROCESS

Water treatment
Collecting preforms from
process
store

Preform hopper Product water ozonated air (pressure

should be 0.3-0.5) or
ozonated water
elevator
Bottle rinsing

+
Blowing machine Air
conveyor Filling
Collecting closures from
(ozonized water 0.2-0.3 store
ppm)

cap hopper

Capping

(cap rinsing with ozonized air/water)

Light inspection

Labelling

Primary coding (laser coding)

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 Shrink film

Secondary coding

Shrink wrapping

Storage & dispatching

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 20Litre Jar production flow chart

Physical inpection of market retrun empty jar

Segreation of quality non conformance jars

Jars are subjected to premanual washing

Jars are rinsed Bottom jar Neck Jar pre

with ozanated brushing brushing inspection
water with 2.5% with 2.5% station to
DBG solution DBG solution ensure high
product quality

Jars are then subjected 9stages of robust washing system without any human intervention

External brushing and Hot water dtergent Pre rins station 3

post rins station with wash station -4 stages final fresh
ozone treated water stages water

Online validation of jar cleaning by chemist and microbiologyist

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 Collection of final rinsed jar for microvalidation

Filling and capping

Codding

Inspection

Finshed goods were transferred to ware house through conveyor for

stocking

Storage and dispatch

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 MANUFACTURING OF PACKAGED DRINKING WATER

1. RAW WATER SOURCE

We should have stringent checks on the source water.
BOREWELL:
Area around bore well should be kept clean and free from any dirt. garbage,
rough surface, stagnant water and
pests. It should be covered from all sides and closed from top with lock & keys
to avoid any contamination.
Where sampling points are necessary, they should be designed and operated
to prevent any contamination.
The immediate surroundings of the extraction or collection area should be
protected by limited access to only authorized person.
Source water should be analysed twice in a year as per IS 10500: 2012 by
approved external lab (as per new FSSAI guidelines) and once a month in the
plant (as per BIS form 5) to monitor its quality.

2. WATER TREATMENT PLANT:

The treatment procedure has to be simple and effective to ensure right quality
of the product water. The treatment should ensure control of physical,
chemical and microbiological impurities.
Following process and equipment's have to be available for the treatment
plant.
1. Raw water tank:
100kl capacity tank 1- tank 2 ,it should be properly covered to prevent
exposure to direct sunlights
2. Ozonator for Raw water:
Raw water ozonation with adequate capacity ozonator should be done.

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(Residual ozone of 0.4 to 0.6 ppm should be always maintained).

[Link]:
It consists of 2 steps - Sand filtration, for removal of course particles up to 30-
micron size. Activated Carbon filters, for removal of ozone, colour, odour and
taste.
3.1 PRESSURE SAND FILTER:

Sand filtration is commonly used as a pre-treatment to remove suspended

particles from raw water. The filtration medium consists of a multiple layer of
sand and gravel.
Raw water is first filtered by filtration unit in series prior feeding R.O. Plant.
Pressure Sand Filter Unit is provided for removal of suspended matters &
turbidity from raw water. PSF Unit is a vertical Pressure Vessel. Internally, itis
fitted with bottom collecting system. Uniform grades silica quartz sand is
charged on the supporting media of pebble sand gravels. This unit is fitted with
PVC frontal pipe work and Multiport/Butterfly Valve externally. During service
cycle water is passed in downward direction through sand bed, thus
entrapping suspended matter &turbid particles. Over a period of time, sand
bed gets choked due to suspended matters resulting in higher pressure drop
and lesser flow At this stage filter bed need to be backwashed. When pressure
drop across the sand bed increases beyond the specified limit (0.5kg/cm2) or
quality of filtered water determinates, whichever is earlier; regeneration
should be processed regeneration in valve backwash & rinsing of Sand bed.
Sand and Activated Carbon filters for removal of coarse suspended material,
foul odour, pesticide residues and organic matter i.e. VOC.
1 micron spun type non-woven filter to be installed before RO, to prevent
entry of any sand-carbon particles in RO membranes.
Capacity of sand filter and carbon filter should match with total RO feed flow.
3.2 ACTIVATED CARBON FILTER:
Activated carbon filter is used for de-ozonation, colour and dour removal, VOC
removal, removal of heavy
metals, BOD/COD reduction, pesticide residue and a number of other
applications.
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3.3 DE-OZONISATION:
It is important to remove ozone from water since it is an oxidizing agent and
any oxidizing agent could damage the RO [Link] carbon will lose its
active sites due the adsorption of organics, oils and the physical blockage of
the poresdue to dirt particles. As a result, the effectiveness of the carbon bed
will progressively decrease and ozonecarryover will be observed in the out-
feed water and the carbon bed will have to be regenerated or replaced.
3.4 COLOUR AND ODOUR REDUCTION:
The colour and odour in water is due to the presence of organics. Activated
carbon is one of the best knownadsorbent for organics. When the water
containing organics is passed through the carbon bed, the organics are
adsorbed on the bed thus removing or reducing the colour and dour. In the
process of colour and odourremoval, carbon is acting as an [Link]
like type and quality of carbon, contact time between carbon and water as well
as bed depth play an important role. Carbon employed for colour and dour
removal will need frequent replacement as it will havelimited capacity to
adsorb the organic as the active sites get taken up by the organics.

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3.4 Reverse Osmosis:
This technique is used to reduce the total dissolved solids and make the water
palatable. This process removes the excess quantity of salts, minerals. Reverse
osmosis is capable of rejecting bacteria, sugars, salts, proteins and other
constituents that have a molecular weight greater than 150-250 Daltons. The
separation of ions with R.O, is aided by charged particles. This means that
dissolved ions that carry a charge are more likely to be rejected by the
membrane, than those that are not charged, such as organics. The larger the
charge, the larger the particle, the more likely it will be rejected.
PRINCIPLE OF OPERATION OF R.O.:
Reverse Osmosis (R. O.) is the process in which water is forced by high pressure
through a semi permeable membrane. When pressure is applied to the
concentrated solution, water is forced through the membrane from the
concentrated side to the dilute side. This is just the opposite of osmosis where
the water would flow from the less concentrated side to the high
concentration side. The membrane allows the water to flow through, but
restricts the impurities such as dissolved ionic material. The rejection of the
dissolved ionic material is function of both, molecular weight and ionic charge.
For example, we can expect a nominal 90% rejection of sodium chloride. The
rejection of calcium carbonate (hardness) will be near 95%, while most metallic
salts are rejected at the rate of 98 to 99%. The rejection of non-ionic and
organic material is mainly a function of the pre-treatment, which includes the
micron filters that precede the R.O plant.
Based on the characteristics of source water, a suitable RO system should be
installed.
Preferably RO system should contain online meters for pH, TDS and ORP. It
should also be provided with dump valve and auto flushing system.

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3.5 Mineralisation:
Minerals (Potassium bicarbonate and Magnesium sulphate) should be
prepared in SS 316 tank on daily basis
REQUIREMENTS:
0-6 lit/hrs. Capacity dosing pumps - 1 no. (Metering pump)
[Link] Grade Magnesium Sulphate
[Link] Grade Potassium Bicarbonate
4.S.S.-316 Tank - maximum 50 lit. Capacity - 1 no.

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3.6 Holding tank
Holding tank of suitable capacity for storage of product water should be
available.
A set of 0.45 Micron pleated absolute filter to be installed to ascertain the
effectiveness of the water

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3.7 MICRON FILTRATION
Product water ozonation with adequate capacity ozonator should be done.
(Residual ozone of 0.2 to 0.3 )
These are used mainly to ascertain the effectiveness of the System. The Micron
filters should be 5 micron
spun type (non-woven) for pre RO filtration and 0.45 Micron absolute
polypropylene pleated types for post RO section. Depending upon the pressure
drop and level of contamination filters need to be discarded and replaced with
new filters. The minimum frequency for replacement of pre RO filters is
monthly and post RO filters is quarterly.

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3.8 FINAL OZONISATION:
one way and 0.3 to 0.4 ppm for two way pack should be always maintained).
Ozone is a powerful disinfectant and used at final stage of treatment. It is used
mainly to disinfect empty containers, especially returnable jars. The ozone in
the sealed bottle ensures the bottle; cap as well as the head space (the air
above the water in the bottle) gets sterilized. Ozone also helps maintain the
sterility of the water during filling and the shelf life of the product.

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3.9 FILLING SECTION:
Filling section will have a bottle filling line and Jar filling line,Depending on the
requirement there may be two or any one or Iwo of the above filling lines.
There may bemore than one bottle filling line as per the need.
3.9.1MACHINS AND EQUIPMENT:
 Suitable automated filling machine with rinsing machine and conveyer.
 Machines and pipelines made up of stainless steel (SS 316)
 Suitable capping machine for the bottle filling line.
 Online labelling machine, if applicable.
 Online coding machine for automatic coding.
 Jar rinsing, disinfection and filling machine.
3.9.2 BLOWING OF THE CONTAINERS:
 Preforms are loaded first into preform hopper, and then preforms are
elevated to the blowing machine with preform elevator.
 The preforms are heated with the help of an IR lamp oven to the
required temperature.
 The heated preforms are feed into the water cooled moulds. At this
stage the preforms are first stretched using stretch rod/pin and blown
with air pressure and simultaneously cooled.
 Then blown bottles are conveyed to the filler with the help of air
conveyor.

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 3.9.3 WASHING AND DISINFECTION OF CONTAINERS AND CAPS:

 All one-way pack containers should be rinsed with ozone gas/ozonated

water before filling.
 Returnable containers should not be used for any purpose that may lead
to the contamination of the
 Product and should be individually inspected for suitability.
 All Returnable containers should come back from the market with the
caps on them 100 %.
 Returnable containers should be washed and disinfected in an
appropriate system with Johnson Diversely Solution SU 120 for external
Jar Cleaning at a concentration of 0.5%-1%, Divosan BG for internal Jar
 cleaning at a concentration of 0.8%-1.2 % and temperature Should be
53- 58°C, finally rinsed with ozonated water. Containers should be filled
immediately after rinsing to avoid contamination.
 One-way pack caps to be emptied directly into the cap hopper & before
capping disinfecting provision should be present in their place.
 Returnable pack caps should be rinsed with ozonated water prior to
capping.

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3.9.4 FILLING AND CAPPING OF CONTAINERS:

Bottling operations (i.e. filling and capping of containers) should be conducted

in a manner that protects against contamination. Control measures include the
use of an enclosed area and a containment enclosed system separate from
other operations of the processing plant to protect against contamination.
Dust, dirt, microorganisms (using environmental exposure test) in the air
should be controlled and monitored. An Air Sampler if available should be
used.
All lines should be flushed for 15 minutes with 0.4-0.6 ppm ozonated water
before starting Production. Lines should not be rinsed with sodium
hypochlorite solution.

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3.10 PACKING SECTION:
Packing area should be clearly separated from filling area. It should be
maintained in clean & hygienic condition. Cartons to be used should be neatly
stacked on Pallets. The cartons should be stacked properly for ease of counting
and kept in clean condition.
Adequate manpower to be provided to run the packing operation smoothly.
RAW MATERIALSTORES:
 Sufficient space is provided for Raw Material stores and the area should
be clean and pest free.
 Pallets or rust free metal racks to be provided for keeping material. A
space of 18 inches to be kept between rows of pallets or racks and walls
and the material stacks to facilitate cleaning.
 Each lot of material is properly labelled and kept in a marked space.
Provide separate space for rejected materials.
 Material is stored in clean and dust free condition.
 Goods Receipt Notes are made for each received lot mentioning lot no. ,
date of receipt, quantity received and other relevant information.
 Proper inventory control system and First in First out (FIFO) is should be
maintain in store & shipping Dept.
 A qualified, experienced person should handle the stores job.

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3.11 UTILITY SECTION:
A separate area away from production area should be provided for utility
section.
 All machines are to be properly identified. Operating procedures with
specifications should be available and displayed near each machine.
 The machines should be serviced as per the schedule and records
maintained. Required spares of right specifications to be available.
 A qualified, technically competent person should supervise the utility
section.
 Following machines, tools to be available in the utility section.
 Low pressure compressor, Pumps, Bench drilling machine, Portable
electrical handling machine, Pedestal
 grinder, Bench vice, welding machine, Toolbox containing spanner of
required size, screw driver, hammer,
 Hacksaw etc., Hand grinder, Drill and tap set of required size, Grease gun

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3.12 FINISHED GOODS WAREHOUSE AND DISPATCH SECTION:

Finished Goods warehouse should be clean and pest free. 18-inch gap is kept
between the rows of stacks and wall and the material.
Finished Goods should be stacked on plastic or wooden pallets. The stacks
should be labelled with batch numbers, pack size, and date of manufacturing.
Old lots should be arranged in front to facilitate compliance lo FIFO at the time
of dispatch.
Daily dispatch records to be maintained. It should have the Batch No.,
quantity, pack size, date of manufacturing and the name and address of
customer. Distributor for traceability purpose.
The transport vehicles should be in clean and pest free condition and with
smooth inside surfaces to avoid damage to the product.

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GOOD MANUFACTURING PRACTICES
PURPOSE:
To provide requirements for Good Manufacturing Practice for Packed Drinking
Water manufacturing facilities for compliance to Regulatory and company
requirements and also to ensure manufacturing facilities are periodically
assessed and are maintained in compliance With Good Manufacturing Practice
requirements
SCOPE
All Packaged Drinking Water manufacturing facilities are required to follow the
Good Manufacturing Practices
GMP GUIDELINES:
4.1 SITE SELECTION
Select a site that protects the plant from outside contamination and
Environmental influences.
4.2 PREMISES
 Design and construct the plant and ground to prevent contamination
from entering the plants from outside area.
 Design and construct the plant and grounds to eliminate standing water.
 Design and construct the plant and grounds to keep insects, vermin, and
other pests from entering the plant.
 Design the storage and handling area to prevent possible contamination.
4.3 PROCESSING AREA
 Protect processing area from contamination from other parts of the
plant.
 Prevent the contamination of finished products, raw materials,
ingredients, and packaging materials.
 Supply enough drainage to prevent standing water and odours.

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4.4GENERAL GUIDELINES TO BE FOLLOWED IN THE PROCESSING AREA

 Filling area should be separate from packing area. The Filling area should
be properly ventilated with sufficient exhaust fans.
 Exhaust fans should be checked that they are wired correctly and that
the fan is moving in the correct direction and the exhaust air is being
blown out. A simple method to check this would be to attach arib bon on
a stick and affix it on the exhaust fan in the front
 All equipment and utensils which is in direct contact with product water
should be made up of SS [Link] maintenance of equipment is
performed as per schedule and recorded. Machines are in proper
working condition.
 Ensure confect plugs for sockets are used and no tapping is done using
bare wires.
 Online defect monitoring system is followed. The on line Inspector check
the packs and removed achive packs. The defective packs are reviewed
by production and QA supervisors, The reason. For defects is found out
and appropriate corrective and preventive measures are taken to
remove-the defects.
 Each pack of finished product is properly coded to allow product
traceability, Coding should contain shift number; date, month, year of
manufacturing, time and Initials of shift supervisor and quality inspector
 Permanent, legible and dated records of processing and production
details for each batch / lot to be maintained. These records are retained
for a period up to the shelf life plus three years.
 Floors, walls, ceilings should be smooth, without cracks, crevices, paint
peelings, cobwebs and easy to clean. Angles between walls and floors
should be smooth, sealed and curved to facilitate cleaning. Doors should
have smooth surfaces and to be kept close when not in use. Windows
should be closed and with screens to avoid entry of insects.

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  All Returnable pack sizes should come back from the Market to the Plant
with the caps on them. This is to prevent foreign matter from entering
into the jars while they are being stored in various places before they
reach the Plant. Cleaning will thus be much easier if the foreign matter
has been prevented from entering in the first place. Neck of the jar will
also be protected from damage.
4.5 STORAGE AREA
Design storage areas (ambient temperature) to prevent contamination or
degradation of material and finished products.
Store ingredients in clean area to prevent degradation and contamination.
4.6 STORAGE AREA OF AUXILIARY MATERIALS
• Prevent contamination of product, ingredients, and other packaging
materials.
4.7 WATER TREATMENT AREA
Design and construct the water treatment area to prevent contamination.
Design and construct the water treatment area to provide sufficient drainage
to prevent standing water
and odours.
4.8 EQUIPMENTS, PIPING. AND UTENSILS
 Ensure that equipment, pipe work, and utensils in contact with finished
products are inert to the material handled, easily cleaned, and self-
draining
 Install equipment's and pipe work to prevent contamination of
ingredients, and finished product.
 Install equipment's and pipe work to avoid the possibility of cross-
contamination of products, cleaning or sanitizing agents.
 Install equipment's and pipe work to supply enough space for cleaning.

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 4.9 UTILITIES
 Install and equip lighting fixtures, skylights, or other utilities, to prevent
contamination.
 Install enough lighting throughout the plant to ease cleaning and
processing activities.
 Install, operate, and maintain ventilation systems to prevent
contamination of products, ingredients, or packaging from
condensation, dust, debris, or odours.
4.10 PERSONNEL FACILITIES
 Supply sanitary equipment and produces for plants workers.
 Provide toilets designed and located so they don't contaminate
ingredients, or finished product
 Post hand-wash signs requirement in all toilet facilities.
4.11 QUALITY CONTROL LABORATORY
Build a quality control laboratory that doesn't contaminate ingredients, raw
materials, and finished products during analysis.
Equip room used for microbiological testing with clean and filtered air/AC.
Provide utilities to support activities and keep test results accurate.

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PACKAGING MATERIAL, STORAGE AND HANDLING
PURPOSE: To provide storage and handling requirements for packaging
materials to protect the quality of packaging material during storage before
use in production for units manufacturing Packaged Drinking Water.
SCOPE: The storage, handling and transportation requirements for packaging
material applies to all Packaged Drinking Water manufacturing locations and
storage and handling requirements of PET applies to all PET jar
manufacturing and distributing locations.
5 REQUIREMENTS:
5.1 GENERAL:

1. All the receiving material should be purchased from authorised

suppliers.
2. All consignments of Incoming materials will carry a Certificate of Analysis
from the supplier.
3. Incoming matenial shall be visually inspected for tamper evidence,
damage and abnormal odours.
4. Storage of receiving material before testing and release shall be done at
the designated locations (Quarantine Area) and approved material only
transferred to appropriate storage conditions after QA
checks/acceptance.
5. Identification of Material status for Passes, On Hold and Rejected should
be implemented and stock & status updating should be done.
6. Plant should have demarcated covered controlled storage area for all
the raw materials primary and secondary packaging material. The
storage area must kept free from debris and spillage.
7. Records should be maintained for handling and storage of Packaging
materials.
8. All rejected materials will be marked REJECTED on each and every
carton/bag to avoid any accidental use.
9. Ensure that incoming materials are coded with the date of receipt and
date of manufacturing at the supplier end or supplier lot no.
[Link] management should be controlled by maintaining monthly
stock updates.
[Link] inventory rotation using First In First Out (FIFO) & First
Expired First out (FEFO) principle.

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 [Link] protection from damage, deterioration, and contamination from
foreign matters, insects, dust and rodents and follow good
manufacturing practices.
[Link] in compliance with GMP requirements.
[Link] the storage area to authorized persons.
[Link] packaging material only for its intended purpose.
[Link] and after unloading shipping containers, inspect the vehicles foe
cleanliness, off-odours, that may have contaminated the packaging
materials.
[Link] packaging material indoors in a sanitary manner.
[Link] area must be well ventilated, free from dust, and free of truck
and forklift exhaust fumes. Poor storage condition cause excess rejects.
[Link] area must be protected from direct sunlight and from
temperatures exceeding 40°C.
[Link] for products for human consumption, and containers for
ingredients for these products, should never be used to contain non-
food substances be clearly marked and at least 18 inches should be
atlest a tall between paella stacks and walls

5.2 STORAGE AND HANDLING OF PET PREFORMS:

1. Shoe preforns in a covered / encased area (roofed) to prevent entry of
dust
2. keep fee passage for proper air ventilation between the stored pallets.
3. Avoid contact with water to prevent contamination and molsture
absorption by the preforms.
4. Keep the preforms in hygienic conditions to prevent contamination
5. Stack pallets in such a way to prevent any damage to the boxes or the
preforms
6. Align tine pallets properly so that the corners of upper pallet rest on the
corner of the lower box.
7. Use pallets which are free from any materials that could transfer an off-
taste or odour to bottles.

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8. Store the bose/ partly used preforms in the box with polythene liner and
seal the box perfectly.
9. Keep the material in the original packaging as far as possible. Consume
these materials at the next immediate production.
[Link] case of damage to the original packaging, transfer the preforms
hygienically to another undamaged box having polyethene liner and seal
the box openings.
5.3 CLOSURES, CARTONS, AND SLEEVES
1. Ensure that the closers, sleeves and labels are in sealed plastic or paper
bags inside a suitable container to protect the material against
contamination or deterioration.
2. Store closers in a dedicated storage area with restricted access that is
clean, well-ventilated and insect and rodent-proof.
3. Cartons and sleeves should be stacked on pallets or racks, and sufficient
spaces should be left between stacks and walls to allow adequate air
circulation.
5.4 LABELS
 Protects labels from extreme temperature conditions and high humidity.
Labels are sensitive to changes in temperature and humidity and hence
should be packed in protective moisture resistant containers and stored
in separate, dedicated areas.
 Racks or pallets should be provided to keep containers of the labels off
the floor and to avoid distortion from stacking.
5.5 Plant Warehouse
 Returnable Jars should be stored in a separate part of the plant to avoid
contamination of non-returnable containers and finished product.
 Keep the empty jars in a cool, dry place away from sunlight and in such a
way to prevent contamination from foreign matters, insects, dust, and
rodents.

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 PEST CONTROL PROGRAM

To provide standards on Pest Management Program for plants by Use of

at approved licensed professional pest from use of least toxic pest
control techniques and products at also provide guidelines to prevent
cross determination of products with pesticides while application, for
pest control activity.

SCOPE

Must be followed by all Packaged Drinking water manufacturing

facilities.

5.1 POLICY

1. General
Good hygiene practices are being employed to avoid creating an
environment conductive to pests. Good sanitation, inspection of
incoming materials and effective monitoring can minimize the likelihood
of infestation and thereby limit the need for pesticides.

[Link] control treatment should be done to control flies / insects,

rodents, birds and other pests. Insecticides are used carefully to avoid
any chance contamination with product water, source water or contact
equipment.

[Link] production area should be free from any pests such as rodents,
insects, flies, cockroaches, birds, etc. Adequate numbers of Fly catchers
are present in the plant. Fumigation of plant to be done as per schedule
to avoid microbial contamination.

[Link] pest control activities should be done by expert pest control

contractor. Details of chemicals being used along with MSDS are
available.

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 5. Plant interiors if using a trap or bait devices will use only glue traps or
non-toxic physical methods. The dead destroyed pests will be captured
and removed from site by Pest Control Contractor after recording
the relevant data in the log sheets.
6. No pesticides shall be applied on to the pallets.

7. No pesticides shall be applied to finished products.

8. The pest control activity shall be carried out only during non-
production hours.

9. Records duly signed by applicator and QA person must be maintained

every time an application of pesticide is carried out.

Preventing Access:

 Buildings should be kept in good repair and condition to prevent pest

access and to eliminate potential breeding sites.

 Holes, drains and other places where pests are likely to gain access
should be kept sealed. Where sealing Is not possible (e.g. open windows,
doors and ventilators) measures like wire mesh screens are be in place
to reduce the problem of pest entry.

 Birds/ animals should be excluded from the grounds of factories and

processing plants.
Harbourage and Infestation:
 Potential product sources should be stacked above the ground and away
from walls.
 Areas both inside and outside product premises should be clean.
Monitoring and Documentation:
 Records should be available to demonstrate the pest control activities and
bait replacements.
Eradication:

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 Pest infestations should be dealt with immediately and carried out
without posing a threat to the safety or suitability of product.

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 COVID19 PRECAUTUION TAKEN BY BISLERI

IMPACT OF COVID-19
Funding sources. Water utilities’ operations are typically funded by customer
receipts (comprising water tariffs and one-off connection charges), grants, and
taxes. Tariffs are often set to achieve socio-political objectives at levels that are
insufficient to recover operating costs. Therefore, the water utilities require
support from other sources, usually the government budget. Additional
revenue pressures come from inefficient operations such as high non-revenue
water (leakages, water theft, uncollected revenues), which exceeds 40 percent
in several emerging market economies. Capital expenditures are mostly funded
through borrowing and public financing, with private capital covering a small
share of capital expenditure.
With a few exceptions, the outbreak of COVID-19 is projected to slow down
investments in the water sector worldwide. It has also increased the
importance of operational reliability due to the cost of disruption. These
operational needs derive from shifts in demand patterns, supply disruptions,
and the various emergency measures employed by governments to cope with
the pandemic.
The world’s poorest received the COVID-19 shock on top of existing major
urban water and sanitation services deficits, all pointing towards a potentially
overwhelming burden to contain the virus. Low access, reliability, and the
quality of water, sanitation, and hygiene (WASH) present risks in developing
countries. Large cities also face risks stemming from population density and
informal settlements. A recent World Bank tool for identifying pandemic
“hotspots” pointed to the cramped living conditions of cities and inadequate
public services, especially inadequate waste management and sanitation, as
significant sources of risk for contagions in large developing market cities, such
as Cairo and Mumbai.

Page | 37
 Plant Entrance – Security Gate

Body temperature monitoring for every Pulse rate monitoring for every indusial
individual before entering plant premises before entering plant premises

Page | 38
 Plant Entrance – Security Gate
Ozone treated Sanitization Chamber

Ozone tunnel Ozone tunnel

Page | 39
 Plant Entrance – Security Gate

Ozone tunnel Hand sanitation station – Foot

operated/ Contact less
operation

Page | 40
 Main Entrance – Production Area

Hand sanitation station fix at Potassium permanganate in a point

production main entrance of entry treatment to oxidizes
several compounds

Page | 41
 Plant Premises

Hand sanitation station fixed near Hand sanitation station at the

CSD packing area entry of production site

 Vehicle sanitation
 Sanitation – Office Section
 Fumigation – Accounts & WTP Section
 Fumigation – Processing Area
 Sanitation For Market Return Jars

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 GUIDELINES FOR PERSONS WORKING IN PLANT PREMISES

1. Restrict use of biometric attendance system and instead use manual

attendance register operated by fixed security person and not by
individuals.
2. Thermal screening of every person entering plant premises is to be done
at security gate. A calibrated thermal gun should be used. Any person
showing body temperature above 100.4 deg F or 38.0 deg C should be
considered as having fever due to illness and should not be allowed to
enter the plant premises.
3. Main gate security will ensure that every person entering the premises
should be provided with face masks. Normal three layer mask used by
the crew on production line shall be discarded after every 6 hours of
use.
4. Proper hand wash needs to be done-
 Before starting work
 After using washrooms
 After handling waste
 After blowing nose, sneezing or coughing
 After eating and drinking
5. Ensure availability of alcohol based (minimum 70% alcohol) hand
sanitizer dispensers at all entry points including main gate, washrooms,
hand washing stations, cafeteria, process areas and offices.
6. Avoid handshakes or any other type of physical contacts with anyone in
the premises.
7. Avoid touching nose, mouth and eyes with unwashed hands.
8. If any individual is found suspected with symptoms of running nose,
frequent coughing or sneezing, red eyes, fever, diarrhea etc. need to be
immediately inform superiors and visit doctor.

Page | 43
GUIDELINES FOR VEHICLE SANITATION

1. Unloading vehicle must be parked away from processing area and in an

open isolated area where abundant sunlight is available.
2. Unloading person has to be protected by providing proper PPE’s like
mask and glove and should be provided with sanitizer.
3. Unloading person has to discard their used PPE’s in trash bin provided
with airtight lid.
4. After discarding used PPE’s, persons must sanitize themselves with
suitable alcohol based sanitizer and use another fresh PPE’s.

TREATMENT OF UNLOADED JARS-

5. Unloaded jars (with closures) needs to be sprayed with below chemicals-

a. Optional step-Depending on the severity of situation plant may opt for this
step.
Any alcohol (IPA /Ethanol) based sanitizer or specialty chemical (Quaternary
ammonium cations) based cleaners/ sanitizers.
This step is not compulsory, plant needs to preserve all validation documents
like food safety and compatibility certificate from manufacturer. Also should
take in writing that sanitizer will not impart any adverse effect on PET jar
appearance.
b. Mandatory step-
2% SU 120 solution with suitable equipment preferably with spray/ pressure
gun or manual brushing if such equipment is not available.
6. Provide contact time of min 5 minutes.
7. Loading person who is loading jars from isolated area to process area
have to be protected with proper PPE’s like mask and glove and should
be provided with sanitizer.

Page | 44
 8. Sniffing person on the jar line must be provided with N95 or equlent
mask which need to be changed as per the requirement.
9. Ensure all manpower involved in 20 ltr jar manufacturing are using
appropriate PPEs all the time.
[Link] distribution vehicles are washed with soap solution externally and
sprayed with IPA internally.
Depending on the severity of situation, plant may opt for external and internal
sanitization of vehicles by using chemicals.

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 BISLERI BOTTLES FOR A CHANGE

Bottles for change aims to create awareness that used plastic is

not waste. It has value , it is reyclable.
Plastic is a miraculous material that we invented from
petroleum derivatives. Recycled plastic can be converted into
polyester which is used to manufacture Shoes, T-shirts, bags,
chairs etc., thereby causing less strain on natural resources. The
only problem with plastic is its irresponsible human handling in
its disposing. We recognize how well plastic can work for us &
you if utilized properly. Keeping this in mind, we launched
‘Bottles for Change’.

India consumes 13 million tons of plastic every year, out of

which 60% is recycled. Rest 40% of plastic majorly contains
non-recyclable items like Wrappers, Plastic bags, Milk pouches,
Multilayer chips packets etc. These plastics can be recycled
several times but there are hardly any efforts made because of
their lightness & dirtiness. They are dumped in dump yards to
lie there forever and cause problems for the environment.
The plastic recycling process refers to the processing of plastic
and turning it into a new item altogether. It includes cleaning
the plastic, cutting it into flakes and then melting it at high
temperature for moulding it for desirable use.

Page | 46
On October 4th, 2015, Bisleri entered the Guinness World
Records and Limca Bookof Records for collecting highest
number of PET bottles for recycling, through a school contact
programme reaching out to over 2 lakh students

Page | 47
 COMPLIENTS RESPONDING SYSTEM

consumer can contacts trought

Bisleri International
Customer Service Contacts
Bisleri International Website

[Link]
Bisleri International Head Office Address

Western Express Highway, Andheri (East)

Mumbai
Mumbai City District
Maharashtra
India
400099

Bisleri International Social Media

Facebook- Bisleri International

Twitter- Bisleri International
Linkedin- Bisleri International
Toll free
1800 112 937

Page | 48
Bisleri is an independent website that was launched with the purpose to create
a platform for customers to voice their issues and concern publicly, without the
fear of being ignored. It is our core desire to make it easier for both customers
and companies to connect to each other.

Customer Grievance Redressal System

Page | 49
 BISLERI INTERNATIONAL [Link].
CAPA FORMAT

Plant name Region

Complaint Ticket No Complainant

Complaint from (City/State) Call log/Received date

Product type Nature of complaint

No of Packs involved Complaint closed Date

Complainant Name Complaint pack recovered

Complainant [Link]./ Email or not
Brief description of Consumer feedback

Product category Batch No.

Brand Mfg. date

Pack Size Mfg. Time

Age of product (Days) Package condition UNSEALED

Purchase Outlet Details (below)

Details of customer contact

Reference sample/Control
sample analysis

Market sample/ Complaint

Pack analysis ( If received)

CCP / OPRP Description

Raw water ozonation

Product water ozonation

Rinser jet pressure & alignment

Jar washer parameters (Divo BG strength &

Process parameters details temperature, jet pressure & alignment
Light inspection practice (Light intensity/inspector
training, rotation etc.)
Gas volume / Invert brix / Acidity
Syrup making parameters
Homogenization parameters
Pasteurization parameters
Physical/Micro parameters
preform Page | 50
Closure
Raw material Quality
Sugar
(Applicable for CFD products NA
Pulp
only)
Concentrate
 INTERNAL TEST FOR CHEMICAL TEST

1. PH TEST

2. TDS

3. ALKANLINETY

4. CHLORIDE

5. SULPHATE

6. RFC (RACIDAL FREE CHLORIDE)

7. TASTE

8. ODOUR

9. TURBIDTY

[Link]

[Link]

[Link]

[Link]

[Link]

[Link]

Page | 51
 INTERNAL TEST FOR MICROBIOLOGY

1. AMC AROBIC MICROBIAL COUNT

2. COLIFORMS

3. SULPHATE REDUCESING BACTRICA

4. DSEUDOMANS

5. YEST AND MOLDES

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 CONCLUSION

Through the 30 days’ project training program that we had the

opportunity to undergo in bisleri water industry we were able
to learn about various aspects of these company and
thoroughly understand the production process for the products
manufacture. We hope the exposer and experience that we
have received in this training would help us in the future and
contribute to shaping our careers

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