7/25/2019 Training 03

1/25

CHAPTER 1

INTRODUCTION

1.1 Industrial TrainingIndustrial training provided real world experiences to explore the relevant knowledge

and skills which are required to enter into a particular career field and pre-

professional work experience with specific assignments and responsibilities. An

Industrial Training is very important to attain good working experience in an

organization by applying theoretical knowledge into practical situations. ecause

theoretical knowledge along is not enough to do a professional career in future

industrial world.

Internship is an excellent way of building communication skills and decision making

abilities in a working environment and it is more helpful to develop work ethics of

the organizational culture and behavior.

1.2 Objectives ! t"e training

1.2.1 #ain bjectives

!. To gain knowledge about the way of applying theoretical knowledge into

practical situations.

". To experience and understand real life situations in industrial organizations

and related environments.

1.2.1 $%eci!ic bjectives

To improve communication skills and decision making abilities in a working

environment.

To understand about the formal# informal relationships in an industrial

organization and ethics and behavior of the organizational culture.

To gain knowledge on pre-professional work experience with specific

assignments and responsibilities.

To gain knowledge about way of promoting favorable human resources in

teamwork to achieved targets.

!

7/25/2019 Training 03

2/25

1.& Organi'atin ! t"e re%rt

The information about industrial training placement of $ountry style food %&'T( )td

was collected before entering training. And the information about product processes

was studied during the training period. *orking with managers# supervisors of the

factory and labours were gave great experience. Training was done according to the

time table under supervision.

The introduction and ob+ectives of industrial training is included in the chapter one

according to my point of view. The second chapter contained overall idea of the

company is given with the description# as the business process and organizational

hierarchy. ,escribe about the training experience and training activities are includedin the third chapter. $hapter four explains limitations# issues experienced while

working in the organization and the suggestions that can be offered in the point of

view of the student. And conclusion of whole program technologies# learning and

experience include throughout the industrial training period with the flow diagrams.

"

7/25/2019 Training 03

3/25

CHAPTER 2

CO#PAN( )AC*+ROUND

2.1 Overvie, ! C-%an$ountry style food %&'T( )td is the pioneer in fruit based ready to serve beverage

industry in ri )anka which is located in adawatha. It started in !/0! to

manufacture and market a range of food products under the brand name 12A3 to

meet the needs of the ri )ankan and 4xport 2arkets. *ith the growing demand for

its products in international markets# currently the products are exported to Australia#

5ew 6ealand# Italy# 7nited ingdom# 8ermany# $anada and 2iddle 4ast since !//9.

The 2A products are manufactured under strict hygienic conditions and quality

control in order to maintain its highest quality. The whole fruit based beverage range

of 2A is ) certified for its quality. $ountry tyle :oods %&vt( )td. was

awarded with three prestigious International standardization certificates; I< ""999#

=A$$& %=azard Analysis and $ritical $ontrol &oints( and 82& %8ood

2anufacturing &ractices( by the ri )anka tandards Institution %)I( in "9!>.

=owever it is the zero waste company pioneers in ri )anka. 2A is en+oying the

market leadership for last two decades in the local fruit base beverage market

segment. Today# 2A has become one of the market leaders in the fruit drinks

industry in ri )anka living up to its slogan 1:ull of 5atural 8oodness3.

2.1.1 /isin ! t"e C-%an

To be among the corporate leaders in the natural based food and beverage industry#

and cater to a wide range of markets with a wide range of products.

2.1.2. #issin ! t"e C-%an

To achieve total productivity in the natural based food and beverage industry#

manufacturing under strict hygienic conditions# being mindful of health and wealth

of the entire society.

>

7/25/2019 Training 03

4/25

2.2 Nature ! business

$ountry tyle :oods %&vt( )td manufactures fruit drinks# herbal drinks and milk

added drinks from the specially selected ripe fruits# best quality herbs and fresh milk

respectively. They packed their products in !/9ml glass bottles# &4T bottles and tetrapack. Apart from that $ountry tyle :oods %&vt( )td market trading items with the

brand name of 2A such as drinking water# $hoco bubbles# wafer sticks and

12A3 bites %naks( under the strict quality supervision.

2.2.1 0ruit Drins

2ixed :ruit ,rink

2ixed :ruit with )ime ,rink

*ood apple ,rink

)ime ,rink

&ineapple ,rink

2ango ,rink

&apaya 2andarin ,rink

&assion ,rink

Anoda ,rink

Amberella ,rink

2.2.2 Herbal Drins

8inger ,rink

4ramusu ,rink

Tamarind ,rink

2.2.& #il added Drins

$hocolate ,rink

herbet ,rink

$offee ,rink

2ango last ,rink

7/25/2019 Training 03

5/25

?

7/25/2019 Training 03

6/25

2.& Organi'atinal $tructure

:igure ".!@ :low chart of

7/25/2019 Training 03

7/25

CHAPTER &

EARNIN+ OUTCO#E$

&.1 3ring E4%erienceThese areas was covered successfully within three months of industrial training

period#

2ain purchasing stores

:ruit stores

:ruits washing section

8lass bottles washing section

8lass bottle checking section

:ruit cutting B pulp production

!/9ml glass bottle retort section and labeling section %for milk drinks(

!/9ml glass bottle labeling section %for fruit drinks(

:ruit nectar filling section

:ruit nectar labeling section

Tetra pack division

)aboratory

Cuality assurance department

I worked at each of the above sections as a labour to a gain the experience and

observed all the process which can apply theoretical knowledge in practical way. The

knowledge of Accounts and 4conomics was applied in the purchasing division.

=owever theoretical knowledge of the sub+ects which learned in the university were

more helpful to understudied the process of the company. The quality of raw

materials and final products were checked and that was wonderful when working in

the industry. 2achine repairing# cleaning and machine operating were observed and it

is more important to gain knowledge as a student of specialized in food engineering.

2achine operating# cleaning and the process of production of Tetra pack was a great

experience. ome milk tests# brix test were done and other tests were observed.

Industrial training at $ountry tyle :oods %&vt( )td was very important to gain a

great experience and knowledge about way of applying theoretical knowledge into

D

7/25/2019 Training 03

8/25

practical situations and to understand real life situations in industrial organizations

within related environments. This was a great experience with nice people.

&.2 Training Activities&.2.1 #ain %urc"asing stre

Eaw materials# spears and other required services are acquired through purchasing

division. 2aterials which required mainly for the production process such as fruits#

additives# packing materials and milk are considered as the main purchasing items.

&urchasing division is followed company standards and I< ""999 standard to

purchase goods.

&.2.1.1. Objective ! Purc"asing

&urchasing good quality raw material from the supplier# provide the good quality raw

material to the production and issuing good quality final product to the consumers.

&.2.1.2 Purc"asing Prcedure

&urchasing division is touched with stock levels and reorder levels of each material.

It is assisted to purchase materials before exceeding their minimum stock level.

*hen goods are purchased from new supplier# purchasing division should get the

product specification and quality certificate from supplier. This specification is varied

according to the material.

&.2.1.& $u%%lier Evaluatin

upplier evaluation is done by a panel comprising of 2anaging ,irector# Cuality

Assurance 2anager and incase of raw materials in different divisions relevant

divisional managers through whole year.

4valuation criteria are based on@

&roduct performance

Cuality and $onsistency of the product

&rice

,elivery time

upplier feedback

F

7/25/2019 Training 03

9/25

&.2.2. 0ruit $tres

:ruit store is responsible for receiving well ripens quality fruits and store the fruits

until it released to the production. taff members of the fruit store are paid special

attention towards quality management while sorting and storing of the receivedfruits. :ollowing procedure is practiced in the fruit storage;

Eeceiving of fruits

election of quality fruits

*eighting

toring of fruits

orting and *ashing

Issued production line

:igure >.!@ :low chart of :ruit tore

2ost probably fruits are stored for about three days. This is depended on fruit

ripening speed and production requirement. efore transferring of fruits in to the

production# fruits are cleaned manually by using three tanks.

&.2.& 0ruit Cutting and Pul%ing $ectin

&.2.&.1 Cutting Area

In cutting section fruit peel# seed and other contaminant are removed and chopped in

to small pieces by using stainless steel knifes. izes of fruit pieces are varied with the

type of fruit.

0

7/25/2019 Training 03

10/25

&.2.&.2 Pul%ing Area

&ulp machines are used to crush the fruit pieces and extract the fruit pulp. &ulp

machine is included rotating stainless steel bar which is fitted to few brushes. 2etal

net is installed to cover the bar. 2ainly three types of pulp machines are used in pulp

preparation area. These machines are varying according to the sieve size. 7sages of

these machines depend on the type of fruit. There are two outlets# one for pulp# and

another for seeds# peels and wastage. )ime +uice is extracted using the screw mill

machine.

:igure >."@ &ulping machine

&.2.&.2.1 Pul% %reservatin

&repared fruit pulp can be preserved according to two methods.

!. oiling for freeze

*eighted fruit pulp is transferred in to the open steam +acketed pan and

cooked# after reaching boil.

&ulp is poured in to the clean can and transferred in to the freezer.

". Adding preservatives

*eighted fruit pulp is transferred in to the open steam +acketed pan and

cooked# after reaching boiled.

&reservatives and acids are added in to the pulp and poured in to the

clean# sanitized plastic cans.

$ans are weighted and date# batch coded on the can. :illed cans are stored

in ambient temperature ware house.

/

7/25/2019 Training 03

11/25

Eeceiving of

washing fruits

&eeling $utting

tore in a plastic

crates

Issuing to pulping

section

&ulp from pulp

machine

Issuing to production

area

:igure >.>@ :ruit $utting and &ulping ection

&.2.&.2.2 Cleaning %rcedure ! %ul% -ac"ines

efore use pulping machine# used two types of water to clean.

$hlorinated water

*arm water

After use pulping machine# used this tree types of water to clean.

&ure water

$hlorinated water

*arm water

&.2.5 167-l +lass )ttle 3as"ing and Ins%ectin $ectin

&.2.5.1. 3as"ing $ectin

8lass bottles are checked before sent the washing to ensure bottles are free from;

traw

=eavy worms and eggs

!9

7/25/2019 Training 03

12/25

,amage bottles

7nclear and different shaped bottles

There are mainly two types of washing 2anual washing

2achinery washing

&.2.5.1.1 #ac"iner ,as"ing

Then !/9ml empty glass bottles issued to machine through the conveyer system to

washing. :ollowing methods can observed inside machinery and ottles labels

removed of automatically brush system. =ot *ater bath

=ot $austic oda bath

praying hot $austic oda mixed water

praying warm water

praying cold water

,raining

:igure >.?@ 8lass bottle washing machine

*ashed bottles were checked after washing whether bottles are washed properly#properly removed debris and any particles of bottles and labels.

!!

7/25/2019 Training 03

13/25

4very 9! hour checked quality of washed bottles quality using

phenoptheline. :ew drops of phenoptheline were put into properly washed

bottles and checked colour of it.

&.2.5.1.2 #anual ,as"ing

If bottles contain corrosion and un-removable debrides from the machinery washing

that were sent for the manual washing. 2anual washing contained three washing

tanks.

!st

tank G washing with Teepol

"nd

tank G clean water

>rd

tank G clean water

&.2.5.2 167 -l Ins%ectin $ectin

*ashed bottles again washing by manually used Hohnston taps and high pressure

chlorinated water and checking quality of bottles used frozen light and white

background. Then bottles issued to filling area by conveyer belt.

Eemoved white and dirty bottles# ten issued again bottle washing section.

ottle *ashing

*p

:igure >.@ !/9ml 8lass ottle *ashing and $hecking ection

7/25/2019 Training 03

14/25

!"

&.2.8 0illing Area

&.2.8.1 0illing ! 167 -l glass bttle !ruit drins

:ill using filing machine.

*hen fill bottle immediately sealed by crown caps.

Then passed through steam chamber.

Issued to !/9ml labeling section.

Eeceiving of filled Cuality checking

glass bottle

:igure >.D@ !/9 ml fruit drinks filling

)abeling of

machine

$hecking of

properly

labeling of

&.2.8.2 0illing ! 167 -l glass bttle ,it" -il added drins

7sing filing machine fill.

*hen fill bottle immediately sealed by crown caps.

After that bottles passed through steam chamber and finally send toretorting section for pasteurization.

Eeceiving o

filled milk

glass bottle

Cuarantine

period

)abeling Issued to stores

:igure >.F@ !/9 ml milk added drinks filling

7/25/2019 Training 03

15/25

!>

7/25/2019 Training 03

16/25

&.2.8.& 0ruit nectar !illing sectin

5ectar filling section fills drink into different sizes such as "99 ml# 99 ml and !).

*hen receiving the drink from production area its stock in stock tank and then fill

into &4T bottle using filling and sealing machine.

,rink Tunnel tock tank

preparation

$ooling $hecking filled ,rink filling

drink bottles

,rying &lace in

crates

:igure >.0@ :ruit nectar drink filling

&.2.8.5 C"ecing 9ualit ! drin bttles

The quality of drinks bottles were checked after filling fruit and milk added drinks

$hecking this qualities

&roperly fixed lids

)ids damages

&article dirty or debris on bottle

After checking re+ect this bottles.

dirty bottles

half bottles

sample bottles and other bottles

&.2.: abratr

)aboratory is playing important role in the factory by conducting testings and

maintaining natural taste of the drink. 2ainly raw material and product testing are

conducted by laboratory. 2ainly milk and fruit pulp is tested to check the quality and

the suitability of the material for production.

!?

7/25/2019 Training 03

17/25

&.2.:.1 Testing in labratr

$heck p=# acidity# sulphur dioxide level and brix value of every batch of drink

prepared. There are three types of pulps;

:resh pulp

oiled &ulp

$old room pulp

$heck acidity# p=# sulphur dioxide level# brix value and sensory characters of

above mentioned pulps.

$heck the p=# colour# taste# brix# acidity and sulphur dioxide level of final

products.

7/25/2019 Training 03

18/25

*ater

$austic soda

5itric acid

*ater

&.2.;.2.2 Prcess ! Pasteuri'er

&rior to supply of drink circulate hot water.

2iddle of circulation step done back wash.

Aim of pre-rinsing is to remove soils from backwash separate all soil particles

from surface.

After water circulation drink was supply and it heated.

&.2.;.2.& Prcess ! !illing -ac"ine

efore starting of filling there are several steps up to filling stage.

&re heating

Temperature increasing

Tube sealing %:orming of packaging material as tube(

terilization

=ydrogen peroxide spraying %$ontainer is sterilized using chemical sterility as =T.).A? %acage laers

There are seven layers that are shown in below from out to inside;

7/25/2019 Training 03

19/25

$ontinuous

Thermal &rocessing

Incoming &ackaging

$ontinuous

terilization

Ase%tic

$ontinuous 6one

Aseptically :orm :ill

eal

helf G table

&roduct

:igure >./@ Aseptic &rocessing and &ackaging

&.2.@ 3aste 3ater Treat-ent Plant

:actory consumes /9 m> of water per day for processing# boiling floor washing#

equipment cleaning and domestic purposes. All the waste water is accumulated in to

the waste water plant trough trench system. Treated water is released in to the natural

water source.

&.2.@.1 Prcedure

!. 4qualization tank

4ffluents from all sources are directed in to the equalization tank to equalize the

water by ad+usting p=. $austic soda and hydrochloric acid are used to ad+ust the

water p= up to required level. 4qualized water is pumped in to the anaerobic tank for

further treatments.

". Anaerobic tank

4ffluent is pumped at a constant flow rate from the equalization tank to anaerobic

tank.

7/25/2019 Training 03

20/25

and divided in to several compartments to avoid the short circuiting of the effluent

flow through the tank.

>. Aerobic tank

The over flow from the anaerobic tank is directed to an aerobic tank for further

treatment. Aerators installed inside the tank to provide sufficient aeration for

reducing the

7/25/2019 Training 03

21/25

parameters to check before discharge the treated water to the inland. Table >.".0.! is

shown that parameters and limitation of that.

Table >.! Eequirements for discharge treated water

Para-eter

Total suspended solids %T(

&article size of the T

&=

7/25/2019 Training 03

22/25

&.2.6.1.2 Cleaning ! nce a ,ee

All machineries# equipment and places clean this washing procedure;

7sed normal water

rush with plastic brush pray sanitizer

*ash with high pressure water

pray chlorinated water

&.2.6.1.& Cleaning ! nce a -nt"

:ollow pest control procedure and fumigation process

&.2.17 Healt" and Hgiene %ractices !r ,rers

upervisors check workers health conditions every morning.

Any person who is shown illness or any other abnormal source of microbial

contamination# he or she does not involves in food handling.

Eemove all +ewelry and other ob+ects before entering the factory.

4ating food# chewing gum# drinking beverages or using tobacco is not allowed

within factory.

5ot allowed to touch nose# mouth or hair in the working time.

hort and clean nails to be maintained all ways# and not allowed use nail arts or

cutex.

All ways wear factory uniform# hair caps# masks# apron# gloves and boots before

involving in work.

Immersing your feet with and boots in the foot bath %chorine mixed water(.

Al ways carry out hand washing with sanitizer as a practice.

"9

7/25/2019 Training 03

23/25

&.& Prject ! Industrial training

uggestions were gave for fruit washing system# fruit storing house design# convey

system of processing line as the pro+ect of industrial training after searching

recommended processing lines of the factory. 2otivations of labours positivethinking were done as the part of pro+ect.

uggestion@

5ew washing system design

o nowledge of engineering workshop technology# and food equipment

design fabrication was more helpful to design new washing system

design.

5ew fruit storing house design

o nowledge of cereal science and technology and minimal processing

technology was more helpful to design new fruit storing house.

:or convey system of processing line

o Eepairing and maintaining the convey system in the !/9 ml fruit drink

steam tunnel line and !/9 ml milk added drink steam tunnel line

"!

7/25/2019 Training 03

24/25

CHAPTER 5

CONCUTION AND RECO##ENDATION$

5.1CnclusinIn the industrial training I upgraded my knowledge about following mentioned

categories which are related to the specialized in food engineering.

&reparation of food raw materials and ingredients

torage of raw materials and finish products

:ood process technology

Eesource planning

:ood manufacturing process control

:ood machinery and plant repairing# cleaning# operating

The company has a well-organized management structure which is a great strength

for the future progress of the company. =igh technology involve processing plant# so

it help to maintain the quality standard such as =A$$ ) and I< ""999. Also

there is high demand to produce value added products. It has a well-managed waste

water treatment plan which is another good management practice of the company.

5.2 Rec--endatins and $uggestins

There are several limitations in the organization which were observed during

industrial training period. 2ost of the limitations have very simple solutions and

some may come up with difficulties when executing.

)ack of skillful labor force and lack of positive attitudes labor force

Absence of microbiology and proximate analysis laboratory in the company

*astage of steam

$oncrete floor in the composting tent is damaged and has to repairing time to

time due to low p= in the waste

uggestions;

$onducting the training programs# workshops and team works to build up the

positive attitudes.

4stablishment of microbiology and proximate analysis laboratory.

4stablish the system to collect and condense the steam which are releasing as

waste

""

7/25/2019 Training 03

25/25

Re!erences

5ational 4nvironment Act 5o. ?F in !/09.

) tandard !"?D@"99>- pecification for $ompost from 2unicipal

solid waste and Agricultural waste.

) tandard for E.T.. %Eeady To erve drinks( G ) F"/.