Chapter-1 Purpose of the Study

Objective

There are certain sequentially laid down objectives stated as under:1. The objective of this project report is to do study of production process of Beverage in parle agro pvt. Ltd. Company. 2.To evaluate the major competitors of Parle Agro product in the market.

Scope
The ultimate scope of study this topic was to know about parle agro pvt. Ltd company and about the production process of parle agros products.

Chapter- 2 Introduction

2.1About the Industry

Parle products Pvt Ltd based in Mumbai, India has been Indias largest manufacture of biscuits and confectionery, for almost 80 years. Makers of the worlds largest selling biscuits parle-G, and the host of other very popular brands. Its reach even of the remotest villages of India. Many of the parle products biscuits or confectionery, are market leader in there category an have won acclaim at the monde Selection, since 1971. With a 40 share of the total biscuit market and a 15 share of the total confectionery market in India, Parle has grown to become a multi-million dollar company. Parle Agro is a food and beverage company based in Mumbai, India.

Parle Agro a trusted name in the beverage industry for agro based drinks. Parle Agro is a leading Indian Beverage Company, the only Indian transnational giant with the past experience of having successfully launched leading soft drink brands like Frooti, Appy Classic, Appy Fizz Bailley Packaged Drinking Water & Confectionery brands like Mintrox and Buttercup. Parle Agro strength is our people who have worked towards making our presence felt throughout the country and all over the world through a strong franchisee network and well developed strong infrastructure. Parle Agro has its

factories located in Silvassa, Patalganga, Bhopal, Chennai, Ghaziabad and Hyderabad. At Parle Agro, success is a habit, where greater heights are achieved through consumer insight, sound business practices, marketing and sales innovation, with the focus on the consumer. Thinking consumer, Tasting success, Always that is what Parle Agro is all about.

2.2Nature of business

Parle agro is a trusted name in the India beverage industry an has been refreshing India since more than two decades with leading brands like frooti, appy classic, Appyfizz, Balley saint juice, LMN & recently launched grappo fizz. Parle agro Pvt Ltd. Manufacture, distributes, sells, and export fruit drinks in India and internationally. The company offers fruits and milk drinks, packaged water. And apple and mango drinks in polyethylene terepthalate(PET) bottles and containers, and tetra packs. The company also operates a healthy and fitness studio for woman. The company distributes its products through franchisees. Parle Agro., Pvt LTd. Was founded in 1985 and is based in Mumbai, India

Parle Agro has been trusted name in the beverage industry providing wholesome and healthy agro-based drinks brands. It has successfully launched some of Indias leading beverage like Frooti, appy and N-joi,

And packaged drinking water, Bailley, over the last two decade. In a country were health consciousness is growing at a rapid pace, Parle Agro, with its numerous fruit-based drinks, has struck a chord with the masses. It brings to the consumer the magic of premium quality fresh fruits drinks conveniently packed and available all through the year. Fruit beverage are wholesome, easy to digest, highly refreshing with natural nutritional values as compared to synthetic and aerated drinks. Parle Argos Frooti is Indias first national mango drink. The mango segment is 95% of the India fruit drink market and Frooti has 855 market share in the tetra pack segment. Made from fresh and premium India mangoes, Frooti has gone to be one of Indias top 50 most trusted brands. When Parle Agro launch N-joi with real fruit and fresh milk, it not only launched a new healthy beverage, but also created a whole new category in India. The milk shake claims to contain no preservatives and its full of nutritional goodness. Its a delicious filler and an apt quick refreshing nourishment for todays hectic stressful life. 3

2.3Geographic area

Figure-2.1

Chapter-3 Company Profile

3.1Organisation Structure
An organizational structure is a mainly hierarchical concepts of subordinates of entities that collaborate and contribute serve one common aim.

Organization are a variant of clustered entities. An organization can be structured in many different ways and styles, depending on there objective and ambience. The structure of an organization will determine the mode in which it operate and performs. Organizational structure allows the expressed allocation of responsibilities for different function and processes to different entities such as branch, department, workgroup, and individual. Individual is an organizational structure are normally hired under time limited work contract or work order, or under permanent employment contract or program orders.

BUSINESS HEAD

BUSINESS MANAGER (GENERAL RETAIL)

BUSINESS MANAGE R (HoReCa

BUSINESS MANAGER (INSTITUTIO NAL)

Figure-3.1

BUSINESS MANAGER (MORDEN TRADE)

MARKETING TRADE

3.2Vision & Mission

Vision

To be the leaders in our business. We will stand apart from the competition by being the first in the market to innovate.

Mission

We will be the leader in our business by maintaining high quality, introducing new and innovative product, reaching every part of India, remaining customer-centric , constantly upgrading our knowledge and skill To provide consumers superior, wholesome agro based food and drink brands through which parle can build a profitable; growth oriented organization.

Parle is a leading Indian Food and Beverage Company, the only Indian Transnational gaint with the past experience of having successfully launched leading soft drinks like Frooti, Appy, Njoi and Bailley. Toady its brand portfolio consists of No. 1 brands like froti along with Appy, Njoi and Bailley.

3.3Products/Services offered
Parle agro Pvt. Ltd operate under three business verticals. Beverage fruit drinks, neetars, 100%juice, sparkling drinks, Water packed Drinking water, foodsconfectionery, snacks.

Figure3.2

Beverage1.Frooti launched in 1985 as a mango drink, Frooti is the first beverage to be launched in tetra packed in Indias. Frooti is Indias favorite Mango drink and its ranked amongst the most trusted brands in numerous national surveys.. just like that Fresh and juicy! What a beauty! Mango Frooti! juice up your Life Accepting that Frooti would perhaps always be identified as Fresh and juicy, Frooti packs currently incorporate the decades-old tagline, with a minor change, saying, Fresh N Juicy Mango. Even the ad plays the jingle towards the end. But Frootis brand communication is based around the theme of Why grow up.

Figure-3.3

2.Appy Classic:Launched in 1986 as apple nectar and originally available in a white tetra pack with an applle and leaf graphic, today it comes in black tetra packaging. Apply remains the first apple neetar to be launched in India.

Figure-3.4

3.Appy Fizz: Launched in 2005, appy Fizz is Indias first sparkling apple drink available in a champagne shaped PET blttle. Considered the Champagne of Fruit drinks Apply Fizz jis a one of a kind product in the beverage market, Recently, Appy Fizz has been given a makeover in terms of a new packaging.

Figure-3.5

4.Grappo Fizz:

Launched in 2008, Grappo Fizz is a sparkling grape juice drink.

Credited with crfeating the sparkling fruit drinks category in India, Grappo Gizz is along the lines of existing product Appy Fizz. It is purple-red in color and has no close competition in the market.

Figure-3.6

5.Hippo: Hippo is a baked snack with the goodness of wheat. It is available in seven flavors from around the world-Italian Pizza, Chinese Manchurian, Hot-n-Sweet Tomato, Thai Chili, Yoghurt Mint Chutney, Indian Chatpatta and Arabian Salted. These baked wheat munchies have no added MSG, no GMO, and no cholesterol and zero trans-fat.

Figure-3.7

6.Saint Juices: Launched in 2008, Saint juice is available in four variants-Orange, Mixed fruit, Grape and Apple. Sanit Juice is 100% juice with no added color, sugar or preservatives. Saint Apple Juice comes with the natural benefits of green apples. Compared to other varietes of apples, Green Apples are richer in Vitamin C and are high on fiber

content.They are an excellent source of potassium and antioxdants. The concentrate for Saint Apple Juice is made from carefully selected green apples from the best orchards in Austria and imported to India.

Figure-3.8

Water
1.Bailley Aqua: It is a mineral water and was launched in the year 1993. It is one of the first brands to get an ISI certification. Bailley conforms to stringent BIS Norms. It undergoes 51 Quality control tests includes 32 chemical tests, 9 microbiological tests and 10 physical tests meets international standards laid down by WHO, USFDA, PFA.

Parle Bailley Aqua is unique because it has the same consistent taste across India. This is because of the unique purifying processing system, which removes all minerals and salts and puts back only exact premeasured quantities of salts and minerals necessaryfor the human body. Bailley Aqua is purified with chemical free natural U.V. Treatment.

Figure-3.9

10

Confectionary1.Mintrox: Mintrox is a hard mint candy. It is available in two flavors- Hard Cinnamon Mint and Hard Menthol Mint

Figure-3.10

2.Buttercup Softies: A Buttercup softie is a toffee which gi8ves a uniquely chewy & smooth eating experience with a rich after taste. It is available in 4 variants Strawberry, Coconut, Vanilla and Caramel

11

3.4 Distribution Network

Regions For all the trades, Delhi is divided into five regions North Region Central Region South Region West Region East Region

Genral retail Distribustion

DELHI

NORTH

CENTRAL

SOUTH

WEST

EAST

NORTH1

NORTH2

CENTRAL 1

CENTRAL 2

SOUTH1

SOUTH2

WEST1

WEST2

EAST1

EAST2

Figure-11

12

HoReCa, Institutions and modern trade

DELHI

NORTH

CENTRAL

SOUTH

WEST

EAST

Figure-3.12

Coverage plane followed by distributors

Figure-3.13 For Delhi Beverage Factory location-Ghaziabad Warehouse- Alipur,North Delhi Parle agro has a wide product line with frooti as theire flagship product. Frooti has such as an impact that almost every distributor is involve and the rest of the product are carried along with the dirstibution of frooti Penetration of frooti is to level of outlets such as small kiosks, telephone booths and even stationery shope now sall Frooti. For Delhi company has two approaches 13

(MODELS) MODEL-1 FACTORY

COMPANY (ALIPUR)

DISTRIBUTORS

GENRAL RETALER

WHOLESALER

Figure3.14

14

MODEL-2 FACTORY (GHAZIABAD)

COMPANY (ALIPUR)

MORDEN RETALIERS (FOOD BAZZAR,VISHAL etc)

Figure-3.15

These two models are Implemented through their sales team and Distributor. Company reaches out to 15000 retailers in Delhi directly.

15

Distributor requirements

1) General trade Distributer;

Fees: Initial fees of Rs 5 lakh through draft Space requirement: min. 100 sq metre Transportation required: commercial vehicles depending upon the area such as: Tata Ace, Vikram etc. I.T infrastructure: No requirement Inventory management capability: Done manually Manpower requirement: 1auto driver multi tasking and educated (12thpass)

2) Institutional Distributor: Fees: initial fees of Rs 15 lakh through draft. Space requirement : Min.300 sq. mt Transportation required: commercial vehicles depending upon the area such as: Tata Ace, Vikram etc Inventory management capability: computerized, centrally

monitored from Alipur warehouse. I.T infrastructure: 2-3 computers Manpower requirement: 1auto driver per vehicle multi tasking and educated (12thpass) and 1 computer operator

16

Company initiatives in distributors:

PARB:A lot of support is provided by the companys active recharge wing, Parle agro retail barometer (PARB)intelligence, the company support its franchisees with an array support system which include, Quality control, Periodic technology up gradation, Fresh distribution pattern Even the installation of new machinery.

3.5 SWOT Analysis

Strength 1.PARLE Agro effective growth strategy and strong distribution channel due to effective distribution model to reach interior of the untapped market. 2.A systematic, planned and quick action taken up which will lead to quick reactions by the HORECA Channels ultimately is providing a competitive edge to PARLE AGRO. 3.A dedicated Intellect; Marketing and Distribution team enhances the sales of the Fruit Juices and other fmcg products. Moreover, PARLE has monopoly in the market 4.For its fruits drink FROOTI. PARLE association with the rural and retail market making the fmcg products in reach of the common man.

Weakness: 1.The data collected cannot be considered as 100 accurate but it is only an estimated figures gathered by the various HORECA Channels in the M.P. region. 2.The analysis so done cannot be regarded as the final as change is the constant thing which happens. 17

Opportunities;

A huge rural and retail untapped market can be the new platform. Brand image of PARLE AGRO products and it is the time to increase to product line by introducing other fmcg products.

Threats;

Throat cut competition with Pepsi.co. And Coca-Cola and other Local products in Retail market with respect to sales margin. Non availability of stock for Rural and Retail market Carriage problem hinders the distribution, specifically in rural market.

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3.6Competitor information
Beverages

1.Frooti

There are over 100 mango based drinks in India. It is one of the largest selling Mango drinks in India. However, if faces stiff competition from Mango Slice which is a Pepsi product. It was launched in the Indian markets in 1993. Slices sensuous positioning is in complete contrast to the positioning of other mango drinks. Last year, Slice brought Katrina Kaif on board, making her the first star to endorse the brand. The brand was also revamped a new look, a new three-dimensional logo, reformulation of the taste, and a fresh concept Aamsutra the art of experiencing mango pleasure. Also, the target group for the brand, which was earlier between the ages of 18 - 24 years, shifted. The brand sought a new target audience people aged 22 years and above. It occupies a much larger shelf space and more facings as compared to Frooti in retail outlets. Another stiff competition which Frooti faces is in the form of Coca-Coals Mazaa. Mazaaisa fruit drink brand marketed in India and Bangladesh, the most popular drink being the mango variety, so much which over the years, the Maaza brand has become synonymous with Mango. Initially Coca-Cola had also launched Maaza in orange and pineapple variants, but these variants were subsequently dropped. Coca-Cola has recently re-launched these variants again in the Indian market. Maaza was launched in 1976 in India. The Union Beverages Factory, based in the United Arab Emirates, began selling Maaza as a franchisee in the Middle East and Africa in 1976.By 1995, it had acquired rights to the Maaza brand in these countries through Maaza International Co LLC Dubai. In India, Maaza was acquired by Coca-Cola India in 1993 from Parle-Bisleri along with other brands such as Limca, Citra, Thums Up and Gold Spot. As for North America, Maaza was acquired by House of Spices in 2005.Star Bazaar has come up with its own Mango drink. However, that is available only at Star Bazaar. But it is being offered at comparable prices and even discounts are given on it. Hence, it is posing as a competition, not just for Frooti but for Slice and Mazaa as well.

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2.Appy classic and appy fizz

Appy Classic and Appy Fizz are the undisputed leaders in the Apple drink category. Appy Classic is plain aerated apple drink whereas Appy Fizz is carbonated apple drink. Litchica International has brought out its Apple flavor product in the market. Litchica products are a hit in the states of Bihar and Madhya Pradesh. However, the apple juice from Litchica is in a very nascent stage and will take time to capture substantial market share (if consumers like the product).Star Bazaar has come up with its own Apple drink. However, that is available only at Star Bazaar. But it is being offered at comparable prices and even discounts are given on it. Hence, it is posing as a competitor to Appy at Star Bazaar.

3.grappo fizz
Grappo Fizz is the new sparkling grape drink in town. It is a first of its kind product with no close competition in the market. However, Appy Fizz faces competition from Grappo Fizz after it launch. People who were regular consumers of Appy Fizz might shift to Grappo Fizz now.

4. LMN
LMN is a natural lemon juice drink and the only brand in India with a taste closest to home made, fresh lime water, also known as nimbu pani. With no artificial flavours and real lemon juice, LMN will provide consumers a healthy, refreshing drink with the goodness of vitamin C. Every summer, the Indian beverage market has seen cola majors battle it out. This summer, the launch of LMN saw the cola wars taking a back seat and the battle spilled over to the non-cola segment, to be more precise in the nimbu paani category. Major competitors for LMN in this category are Nimbooz from Pepsi and Minute Maid Nimbu Fresh from Coca-Cola. Nimbooz was the first brand that was launched in market which was positioned as natural lemon refresher. It was positioned as asli Indian, asli nimbu(Real Indian, Real Lemon). Then came LMN, which also positioned it as lemon based refreshing drink. Now few months back, Coca-Cola too

20

entered the battle with the lemon flavor of its brand Minute Maid which was available in Pulpy Orange flavor. The positioning is similar. They claim it to be Ghar Jaisa(Home Like).The shelf space at all retail outlets is also directly proportional to the time they have been in market. Nimbooz occupies the maximum shelf space in this category followed by LMN and then Minute Maid Nimbu Fresh. However, Nimbooz and Minute Maid are rising real fast as brands.LMN is not that much visible in the market.

5.Saint juice
Saint Juice is the new entrant to the fast growing fruit juice market. The brand is making a foray into a market which is highly segmented and often highly confusing (to the consumer).Indian beverages industry which is worth Rs 7000crore is divided broadly into carbonated and non-carbonated categories.

The fruit based drinks market is highly confusing for a customer. Frooti, Tropicana, Maaza, Real etc are all fruit based beverages. If you look at the products, there are different types of fruit beverages: Fruit Drinks: These are those drinks where there is a less than 20% fruit pulp. Frooti, Maaza etc belong to this category. Fruit drinks is the dominant category which is worth around 250-300 crores. Fruit Nectar: These contain less around 25- 85% fruit pulp. Brands like Godrej Xs and Real Nectar belongs to this category. This is a small category worth around Rs 35 crore. Fruit Juice: These are fruit beverages that contain 85% and more fruit pulp. Tropicana and Real belongs to this category. This category is worth Rs 150crore.With in the Fruit Juices segment, a new category is emerging which is the 100% juice category. Most consumers are not aware of this micro segmentation. Those who drink Frooti or Maaza do not know or is not bothered about the fruit pulp content. The reason is that, they drink these beverages for the taste (and quenching thirst).Unlike the fruit drinks, customers of fruit juices are health conscious. One of the reasons for them taking this product category is that they want a healthy drink. The product is more of a health supplement than a beverage. The fact that these products are less tasty compared to fruit drink is a proof that only the health conscious ones will take it. The category of fruit juices are dominated by Dabur's Real and Pepsi's Tropicana. Real is the market leader with around 55 - 60% share and 21

Tropicana takes the rest. Saint Juice is a 100% fruit juice. The brand is positioned as a 100 % juice. This positioning is relevant because consumers are confused about the category. The 100 % juice positioning of Saint is a real threat to Real and Tropicana. Real and Tropicana had extended itself into fruit drinks and fruit nectar categories. Real have Real Twist and Tropicana have Twirl in the fruit drinks category. Both these brands have their nectar variants. Recently Real and Tropicana launched their 100 % juice variant. This is atypical case where a brand is trying to be everything to everybody.

6. Packaged drinking water

Bailley is Parle Agros contribution towards the packaged drinking water segment.The Indian packaged water business is estimated at around Rs 2,500crore with a growth rate of close to 35 per cent. While India ranks in the top 10 largest bottled water consumers in the world, its per capita per annum consumption of bottled water is estimated to be five liters which is comparatively lower than the global average of 24 liters. Today it is one of India's fastest growing industrial sectors. Between 1999 and 2004, the Indian bottled water market grew at a compound annual growth rate (CAGR) of 25 per cent - the highest in the world. With over a thousand bottled water producers, the Indian bottled water industry is big by even international standards. There are more than 200 brands, nearly 80 per cent of which are local. Most of the small-scale producers sell non-branded products and serve small markets. In fact, making bottled water is today a cottage industry in the country. Leave alone the metros, where a bottled-water manufacturer can be found even in a one-room shop, in every medium and small city and even some prosperous rural areas there are bottled water manufacturers. Despite the large number of small producers, this industry is dominated by the big players -Parle Bisleri, Coca-Cola, PepsiCo, Parle Agro, Mohan Meakins, SKN Breweries and so on. Parle was the first major Indian company to enter the bottled water market in the country when it introduced Bisleri in India 25 years ago. Bailley faces stiff competition from Parle Products Bisleri, Pepsis Aquafina, TatasHimalayan, United Spirits Kingfisher Drinking Water, Aqua, Sumeru, etc. Now even the International brands like Evian and Schweppes are entering the Indian market screating further competition. 22

7. Snacks
Following the recent launches of LMN and Grappo Fizz, Parle Agro has extended its presence into the snack food category, by the launch of a new baked wheat snack brand'Hippo'. Hippo is a baked product which has minimum levels of cholesterol and fat. It falls into the baked product category. However, it has to compete with the products present in the fried chips category like Ruffles Lays, Kurkure, Bingo, Musst Chipps and Pringles. In all the retail outlets, Hippo is kept along with the fried wafers and potato chips category. Ideally it should fall into the baked products category. Also, these kinds of products give better margins to the company, in addition to the fact that companies want to capitalize on the growing health consciousness of Indian consumers. Parle Agro has positioned 'Hippo' as a healthy-baked snack with the goodness of wheat. Ideally it should be competing with Frito Lays Aliva which is also newly launched.

8.Confectionery
Parle Agro has forayed into the confectionery category also by launching Butter Cup candies. These are hard boiled candies made with caramel. Post that PAPL launched Butter Cup Softease which is easy chew toffee available in different flavours.Both these are directly in competition with Alpenliebe, Eclairs, Mentos, Coffee Bite, Parle Poppins and many more.

However, the presence and visibility of Butter Cup and Butter Cup Softease is very poor in modern trade as compared to its competitors. Also, no promotion activities and advertisements can be seen in this regards.

23

3.7 Market share & Growth rate

Frooti has 85% market share in the tetra pack segment and a 15% share of the total confectionery market in India.

Figure-3.17

24

Parle agro has been a trusted name in the beverage industry providing wholesome and
healthy agro-based drink brands. It successfully launched some of Indias leading beverage like frooti, appy and N-joy, and packed drinking water, bailey, over the last two decades. In a country where the health consciousness is growing at a rapid pace, Parle agro, with its numerous fruit- based drinks, has struck a chord with the masses. It brings to the consumer the magic of premium quality fresh fruits drinks conveniently packed and available all through the year. Fruit beverage are wholesome, easy to digest highly refreshing with natural nutrition value as compare to synthetic and aerated drinks. Parle agros frooti is Indias first national mango drink. The mango segment is 95% of Indian fruit drink market & frooti has 85% market share in the tetra pack segment. Made from fresh & premium Indian Mangoes, frooti has grown to be one of Indias top 50 most trusted brands. When parle agro launched N-joi with real fruits & fresh milk, it not only launched a new healthy beverage, but also created a whole new category in India. The milk shake claim to contain preservatives & its full of nutritional goodness. Its delicious filler and apt quick refreshing nourishment for todays hectic stressful life.

Appy, another premium drink from the Parle portfolio, is a deliciously light and refreshing apple drink made from orehard fresh apple from himachal pradesh. Its a favourit with the young generation as a tasty, healthy, nourishing drink.Parle agro has also diversified into the fitness industery and has setup fitness center in juhu & malad in mumbai with aggressive plans to expend nationally .says Ms Nadia Chauhan,director, marketing,parle agro remains committed refreshing india and contantly caters to the health and quality conscious consumer through newer and varied initiatives parle agro is the first to introduce fruit drink in a tetra packed in indias the first to introduce fruit drinks in PET bottles in india the first to develop a real fruit and dairy fresh milk brands.

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Chapter-4: Relate with organisation

4.1 Production
There has been a considerable increase in the consumption of fruit & vegetable juices in the world during last few years and there are possibilities of further increase. The export of fruit juices from developing countries has been increases steadily. The total production of fruits and vegetables in the world is around 370 MT. India ranks first in the world with an annual output of 32 MT. While there are almost 180 families of fruits that are grown all over the world, citrus fruits constitute around 20% of worlds total fruit production. Major Indian fruits consist of mango, banana, citrus fruits, apple, guava, papaya, pineapple and grapes. The fruits are processed into various products such as fruit juices & concentrates, canned fruit, dehydrated fruit, jams & jellies etc, but it constitutes only 3-4% of total production. India with its current production of around 32 MT of fruit, accounts for about 8% of the worlds fruit production. The diverse agro-climatic zones the country makes it possible to grow almost all varieties of fresh fruits and vegetables in India. The fruit production in India has recorded a growth rate of 3.9%, whereas the fruit processing sector has grown at about 20% per annum. However, the growth rates have been extensively higher for frozen fruits & vegetables (121%) and dehydrated fruits & vegetables (24%). There exist over 4000 fruit processing units in India with an aggregate capacity of more than 12 lakh MT (less than 4% of total fruits produced). It is estimated that around 20% of the production of processed fruits is meant for exports, the rest caters to the defense, institutional sectors and household consumption, Mango and mango-based products constitute 50% of exports.

Fruit Beverages:

The beverage industries are by far largest outlet for fruit juice and concentrate absorbing over 80% of production. Much different type of beverages such as fruit juices, fruit

26

drinks, squashes, cordials and fruit punches are available. They are broadly defined as follows: Fruit juice: This is a natural juice pressed out of a fruit. This is unaltered in its composition during preparation and preservation. Fruit drink: This is made by liquefying the whole fruit and at least 10% of the volume of undiluted drink must be whole fruit. It may be diluted before being served. Fruit squash: this consists essentially of strained juice containing moderate qualities of fruit pulp to which sugar is added for sweetening, e.g., orange squash, mango squash, etc. Fruit cordial: This is fruit squash from which all suspended material is completely eliminated and is perfectly cleared. e.g., lime juice cordial. Fruit punches: These are made by mixing of desired fruit juices at the time of serving. Fruit juice concentrate: This is fruit juice which has been concentrated by the removal of water either by heating or freezing.

4.2 Raw material

Apple concentrate Apple concentrate used for the production of Appy classic or Appy Fizz is purchased from different fruit processing units situated in Jammu & Kashmir and some part of Shimla where the production of Apple is in abundant. The concentrate received at the unit is tested before use whether satisfying the under listed criteria or not. Description : Seven fold brownish red colored, free from any visible Impurities.

Storage condition

: In a cool, clean place shielded from direct sunlight.

Packaging details

: 85 liters HDPE containers. 27

General appearance

: Brownish red.

Brix

: 70 (min).

Acidity

: 0.14% (min.).

Aroma

: Good, free from fermentative smell.

Flavour

: Sweet and slightly acidic, free from fermentative taste.

Standard plate count

: Less than 20 colonies per gram sample.

Totapuri mango pulp:

Description

: Single strength golden yellow colored with soft texture.

Storage condition

: In a cool, clean place shielded from direct sunlight.

Packaging details

: 3.1kg, 5.2kg Tin cans.

General appearance : Golden Yellow.

Brix

: 14 (min.).

Acidity

: 0.5% to 0.65%

Aroma

: Fresh mango flavour free from off smell.

Taste

: No fermentative taste.

Standard Plate Count : less than 5 colonies per gram sample. 28

Crystalline sugar
(C6H22O11; Molecular Weight: 342)

The most commonly used traditional sweetener is sucrose. It not only contributes to the sweet taste but also maintains the overall balance of the beverage with the other components. It should be available as hard, white, dry crystals, odour less, sweet taste and must be soluble in water.

PARAMETER Grade Grain size Sucrose content Moisture content Solubility (at 20C) Packaging

STANDARD M30/S30. Pass through IS sieve 10.70mm. not less than 98.5% < 0.5% 2 parts in part of water. 100 kg Jute bag.

Activated Carbon Powder

Activated carbon is carbon that has been treated with oxygen to open up hundreds of thousands of pores inside of it. Opening up these tiny pores between atoms expands the surface area of the carbon enormously. In fact, in terms of raw surface area, one gram of activated charcoal would be able to cover several football fields if it were rolled flat. The surface are of activated charcoal is only one of the reasons why it is so useful. Carbon is a naturally absorbent element, and it is able to absorb a wide variety of harmful chemicals. The large surface area of activated charcoal allows it to absorb and trap millions of chemicals at its countless bonding sites. Activated carbon is used in the purification process of sugar syrup. It is derived from hard wood charcoal or pinewood. 29

PARAMETER Moisture content pH Bulk density (ml/gm) Particle size

STANDARD <5 25 3.5 4.5 0.05 mm

Raw material Specification: Raw Material Apple concentrate Physical Appearance, taste, aroma, Chemical Brix, acidity Microbiological Frequency TPC, mold yeas, All drum in the given lot to be tested

foreign object, colour Totapuri Mango pulp Citric acid Colour, flavor, Acidity, consistency Colour, lumpiness Malic acid Colour, lumpiness Sugar Colour, lumpiness Purity, test floc TPC, Purity NA TSS Purity NA pH, NA

Each receipt

Each receipt

Each receipt

Yeast, Once in lots

on

10

Mold(once week)

CO2

Odour, taste

Purity, traces

H2s, NA

Each recipt

Water

Appearance. Odour, turbidity

Alkalinity,

TPC,E.

coli As

per

BIS

taste, hardness

(once in week)

standards

Table-4.1

30

4.3 Production process

Process involved in fruit beverage production

Juice concentrate / Pulp:Pulp is collected from the cans by using can cutting machine. This pulp is pumped

through pipelines to blender.

Sugar syrup:Sugar and sugar substitutes contributes the sweetness necessary to balance the

various ingredients and also act as a carriers to distribute the flavor components uniformly throughout the drink. Crystalline sugar is used here as sweetening agent. Some other sweetening agents are sucrose, fructose syrup (processed from corn starch) and cyclamates (which is banned due to its harmful effects). Sugar syrup is prepared by mixing dry sugar with hot water at 80C in 8200 liter tank.

Filtration:After preparing sugar syrup it passes through filtration unit. Activated carbon is used as filtration medium as it absorbs all the off flavours, colour making the syrup suitable for further use.

Blending / Mixing:Sugar syrup and pulp are transferred in a tank where proper mixing is carried out for several hours. Proper mixing is facilitated by impellors. At the same time formulation (flavours, colours, etc.) is also added.

Homogenization:Blended mixture is then transferred to homogenizer for homogenization. The process of homogenization takes place at 2700 psi. During this process ascorbic acid is used to prevent the flavour loss.

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Pasteurization:When homogenization completes, product is then send to the pasteurizing unit

which is fully automated. Here heating takes place through hot steam in counter current manner. Pasteurization takes place at 95C for 30 45 seconds.

Cooling:Before filling the temperature of pasteurized product is lowered by ~25C.

Bottling:Cooled product is then filled in PET bottles. Since the temperature during filling

is nearly 72C therefore the process is called as Hot Fill. These bottles are then cooled by the help of showers before there storage. For the preparation of carbonated beverages CO2 is mixed with the product before filling. In order to facilitate proper mixing of CO2 in the product, the temperature of product is lowered up to 0 1C. This is done by the help of any cooling agent, which in this case is glycol.

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PROCESS FLOW DIAGRAM OF PRODUCTION

Figure-4.1Schematic representation of fruit beverage production.

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4.4 Quality control

Microbiological analysis of raw material A complete microbiological program involves testing of three separate groups of microorganisms. These includes following: Yeast Mold Bacteria

Yeast:Yeast is spherical, oval or rod shaped unicellular fungi. The most common yeast is 3-20 in diameter. Some of the yeasts are capable of growth in acidic, carbonated and chemically preserved beverages. Yeasts enter in the production process through raw material, atmosphere, etc and spoils the beverages. Sacchromyces, Zygosacchromyces, Torulopsis, Cadida and Rhodotorula are some common yeast that causes spoilage in beverages.

Molds:Molds grow in the form of tangled mass (mycelium) of cellular filament that spreads rapidly. Molds are aerobic and are capable of growth under acidic conditions. Under normal conditions they can grow on packaging materials, sugar, filling equipments, walls, floors, etc. Therefore whenever mold is found in the beverage then it indicates the improper hygiene and manufacturing practices in the plant. Peniflium, Physarum and Dictyostelium are a few of the most common molds found in the aseptic filling plants.

Bacteria:Bacteria grow in the form of spheres (cocci), straight rods (bacilli) or bent rods (spirila). The differences between these are very slight and can be determined by staining methods and with the aid of microscope. The number of bacteria present can be indicative of the sanitary condition of the material being tested. Juice or other nutrient

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containing ingredients can enhance bacterial growth, and thus present an increased spoilage problem. Bacteria most commonly found are more than 0.0005 mm in diameter. Acetobactor, Bacillus, Gluconobactor, Lactobacillus and Gluconostoc are a few acid tolerant bacteria foun commonly in carbonated beverages. Coliform bacteria are of special concern, as they are associated with fecal waste od humans and animals. Even though this bacterium may not be pathogenic, its presence is indicative of pollution problems, and therefore is particularly significant from a public health stand point.

4.5Methods of quantitative estimation of microorganisms

The quantitative estimation give san idea of how much extent of contamination takes place. This is done by mainly three methods:Pour Plate method:For estimation of environmental count as well as raw material and product count. Air sampler:For estimation of environmental and critical area count. Membrane filtration:Mainly used for water testing.

Pour Plate method:-

In Pour Plate method, a diluted sample is pipetted into a sterile petriplate, and then melted agar is poured in and mixed with sample.

Requirement:i. Laminar air flow. ii. Incubator (temperature 37C 1). iii. Petridish. iv. Pipettes

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v. Molten Parle Media and nutrient agar at 45C (pre sterilized at 15psi at 121C for 15 min).

Procedure:i. Dilute specimen to yield approximately 30- 300 CFU per aliquot to be plated. ii. Inoculate labeled empty petridish with the aliquot of diluted specimen. iii. Pour 15ml of melted plate count agar (45C) into the inoculated petridish. iv. Cover and mix thoroughly by gentle tilting and swirling the dish. Do not slope the agar over the edge of the petridish. v. Place on a flat surface undisturbed for about 10min to allow the agar to completely gel. vi. Invert and incubate at 37C for 24-48hrs. vii. Count, record and calculate: - Count all colonies, a magnifying colony counter can aid in counting small embedded colonies. Record the data. Calculate CFU/ml or CFU/g by the formula:CFU/ml = (CFU/plate Dilution Factor 1) per aliquot

Air sampler:-

It is a light weight portable system for testing the microbial quality of air in clean room, barrier environment and critical filling areas. The tester is small enough to be used in confined spaces, but powerful enough to sample up to 1000 liters in just 7 minutes.

Membrane filtration:-

The membrane filtration technique is the recommended method for microbiological testing in the plant. Membrane filters are thin pourous sheets of inert cellulose plastic containing capillary ploes of uniform size, small enough to prevent the passage of microorganisms. During filteration of a sample, the microorganisms can not pass through 36

the membrane, and therefore remain on the surfaces. Through selection of pore size, nutrient medium and incubation temperature, specific microorganism will grow to form visible colonies that can be counted.

Requirement:i. Laminar air flow. ii. Incubator (temperature 37C 1). iii. Petridish. iv. Pipettes v. Molten Parle Media and nutrient agar at 45C (pre sterilized at 15psi at 121C for 15 min).

Procedure:i. Wipe the sampling area with disinfectant. ii. Put sterile air blower on for 10 minutes at low-pressure position. iii. Close the shutter and keep UV lamp on for 45 minutes. iv. Keep sterile air blower on at medium pressure position.

Swab Test:-

Requirement:i. Presterilized hot molten Parle Media. ii. Nutrient agar and EMB Levine agar. iii. Sterile ready swabs. iv. Millipore unit. v. Cellulose titrate membrane filter paper. vi. Presterilized water. vii. Incubator. viii. Laminar flow unit.

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Procedure:i. Transfer approximately 10ml hot molten media into petri dish under laminar flow in three separate petri dishes. ii. Allow media to solidify in petri dish. iii. Take a bottle containing sterile distilled water to the required area of testing. Sanitize bottle mouth with acetone or disinfectant. iv. Remove the ready cotton swab and place it to the area and instantly dip the swab into the sterile bottle containing sterile distilled water. Carry the same for inoculation. Rub the swab on a 100 cm2 area of the equipment to be tested and immediately transfer to the sterile bottle.

4.6 Microbiological analysis of products

Microbiological analysis of product and raw material It allows us to monitor level of microorganism and permits us to take corrective actions before serious problem arise. OBJECTIVE: - Determination of TPC To determine total colony count in water, on enrichment agar, method is applicable to filter water of Sand Filter and Carbon Filter, DM Plant, Softener Plant, Frooti Plant, Norit Carbon Filter I and II.

Requirement:i. Filtration flask. ii. Vacuum pump. iii. Petri dish 5 tarn. iv. 0.45 filter paper. v. Sterile filter assembly. vi. Hot molten enrichment media. 38

Procedure:i. Collect 100 ml DM water in a sterile flask in aseptic condition. ii. Now filter 10 ml of sample water through 0.45 micron filter paper and place the filter paper over enrichment media.

Incubation: - Incubate the petri dish at 37C for 24 hrs.

Evaluation: - Max. Limit 20 colonies / ml.

OBJECTIVE: - Determination of Yeast and Mold for sugar samples.

Procedure:i. Prepare aseptically 20 % sugar solution with sterile distilled water.

ii. Deliver 1 ml of solution in triplicate into sterile petri dishes by means of sterile

1ml pipette.

Pour Plate:i. Melt the above medium in bacteriological tubes and keep at 44-46C. ii. Introduce medium aseptically into petri dishes. iii. Mix with swirling motion of hands and allow to set.

Incubation: - Invert petri dishes and incubate at 371C for 2 days, count the colonies and compute the total colonies per gram. Evaluation: - Max. limit 20 colonies / ml

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OBJECTIVE: - To determine TPC/ Yeast and Mold in sugar syrup.

Requirement: i. 100 ml sterile DW in a conical flask. ii. Petri dish (100mm). iii. Nutrient agar.

Procedure: i. Collect aseptically about 10 ml of sugar syrup in a sterile flask. ii. Add 50 ml sterile DW in it. iii. Pour 5 ml of the solution into each of the two sterile petri dishes. iv. Melt nutrient agar and Parle media separately and cool them up to 44 46C.

v. Introduce the media aseptically into the petri dishes respectively containing sugar syrup. vi. Mix by swirling motion of hands and allow to set. Incubation: Incubation time i. TPC ii. Yeast and Mold 24hrs 48hrs Incubation temperature 37C 37C

Evaluation: Maximum limit : Maximum limit : 5 colonies / plate for TPC. Nil (for Yeast). 1 colony / plate (for Mold).
OBJECTIVE: - To determine TPC/Yeast and Mold in intermediate product of mango pulp and apple concentrate

Requirement: -

i. 100 ml sterile DW in a conical flask. ii. Petri dish (100mm). iii. Hot molten nutrient agar media. 40

Procedure: A. For determination of TPC: i. Collect aseptically about 10 ml of sugar syrup in a sterile flask. ii. Add 50 ml sterile DW in it. iii. Pour 5 ml of the solution into each of the two sterile petri dishes. iv. Melt nutrient agar and Parle media separately and cool them up to 4446C.

v. Introduce the media aseptically into the petri dishes respectively containing sugar syrup. vi. Mix by swirling motion of hands and allow to set. B. For determination of Yeast and Mold: i. Melt Parle media and keep at 44-46C. ii. Introduce the media aseptically into the ready prepared petri dish containing sugar. iii. Mix by swirling action of hand and allow to set.

Incubation: Invert the petri dish and incubate at 37C for 48 hrs.

Microbiology of finished product

One sample per batch per machine should be analyzed every day for TPC and Yeast & Mold. Finished product should be free from microorganism as per standards specified by the parent company.

OBJECTIVE: - To determine TPC/ Yeast and Mold in finished product. Requirement: i. Petri dish (100mm). ii. Hot molten nutrient agar. iii. Sterile glass rod. 41

Procedure: For TPC: i. Take 5ml sample to be analyzed in a petri dish in a perfect aseptic condition. ii. Introduce 10 ml hot molten nutrient agar into petri dish. iii. Mix by swirling motion of hand and allow to set.

Incubation: Invert the petri dish and incubate at 37C for 24hrs. Evaluation: Maximum limit 1 colony/ml.

A. For Yeast and Mold: i. Take 2 ml sample to be analyzed in a petri dish in perfect aseptic condition. ii. Introduce 10 ml of molten nutrient agar into the petri dish. iii. Mix by swirling motion of hand and allow to set.

Incubation: Invert the petri dish and incubate at 37C for 48hrs.

Evaluation: Maximum limit: Yeast- Nil. Mold- 1 colony/ plate.

4.7 Physical & chemical parameters of product:

APPY CLASSIC

Appearance Acidity Brix pH Viscosity Specific gravity Microbial count

: Yellowish brown. : 0.36 0.37. : 14.8 15.2. : 3.5 4.0. : 5 10. : 1.065. : Nil. 42

APPY FIZZ

Acidity Brix Microbial count

: 0.25 0.27. : 12.8 13.2. : Nil.

FROOTI HOT FILL

Acidity Brix pH Viscosity Specific gravity

: 0.311 0.322. : 14.8 15.2. : 3.3 3.5. : 45 55. : 1.035.

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Chapter-5

CONCLUSION
This report is based on whole procedure involves in production & quality controls in fruit beverage production. During this study we have learnt all the processes (blending, pasteurization, filtration, etc.) which are required in fruit beverage production. In addition to this we have also observed different types of safety measures which are applied to ensure the manufacturing of good quality product.

All the products of Parle Agro Pvt. Ltd. are manufactured under the most hygienic conditions. Great care is exercised in the selection & quality control of raw materials, packaging materials. Rigid quality standards are ensured at every stage of the manufacturing process. Every batch of drink, are thoroughly checked by quality experts using the most modern equipment.

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BIBLIOGRAPHY

www. Parleproducts.com Www.Parle agro.com. www.google.com (for definition and products)

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