Technical Assessment: Soft Drink Manufacturing - Essay Example

Technical Assessment: Soft Drink Manufacturing Introduction The basic concepts of soft drink manufacturing are the issues of primary concern for the majority of manufacturers. This fact can be explained by a rapid growth of ‘sensitive products’ development and a desire of manufacturers to provide the most perfect product quality. In case, there is a lack of efficient assets, as in the case considered further on, there is a need to increase optimum line efficiency. Flexibility of the production process is of the utmost importance. The newest recipes are currently performed via the lowest cost involvement and with regard to the shortage of production time. Under conditions of world’s economic crisis, soft-drink manufacturing industry has suffered serious challenges and unexpected upheavals. Thus, “during 2008-09, sales of higher value fruit juices fell off sharply, with a tight retail environment leading consumers to trade down to carbonated soft drinks and private label fruit juice” (Solutions for the fruit juice industry). With this regard, it is relevant to consider possible plant process and pasteurization options in order to increase output of soft drinks, reduce costs and price for the product. Process plant and pasteurization options Perfection of a management system of soft drink manufacturing as well as increase of the productivity is the main point to be included into the further technical assessment. Currently, it is relevant to decrease the number of employees and transfer to a uniform automation of soft drink manufacturing. Nevertheless, there is another option of manual, semi-automated or automated manufacturing. Concerning pasteurizing systems it is necessary to choose the short types. Thus individual solutions for any product can be performed. Current researches conducted in this field are focused on a high-temperature, short-time pasteurizer. The process of pasteurization can be controlled via computer. “The equipment is modified by computer-linked sensors that placed at critical points of the process” (GEA Process Engineering). Thus to modernize control over pasteurization process is convenient for manufacturers. A proper pasteurization guarantees that potential health risks are decreased. In accordance with the report of Carol Harper, Ph.D., a scientists participating in such kind of research, “this will result in cost savings, she explained, by generating data more quickly and accurately” (Swamidass 2002, p. 36). ACF system as alternative approach Another problem to be solved by soft-drink manufacturing company is polyethylene terephthalate (PET) for 2-liter soft drink bottles recycling. It is very important for the company to be considered further on, because it uses this type of packaging. The major challenge of the current project is producers’ intention to fill in PET containers. Aseptic filling of such kind of containers is rather new. There are two possible options for the company: ‘dry’ and ‘wet’ sterilization. ‘Wet’ aseptic process implies sterilization of containers with the help of peracetic acid (C2H4O3) and steam. The main function of the steam from the peracetic acid is to distribute and activate the disinfectant. This sterilization process guarantees that the whole surface is moistened and atmosphere is disinfected as well. The fasteners are disinfected with the help of peracetic acid as well (Concepts for Soft Drink Manufacture). In the process of dry sterilization H2O2 (hydrogen peroxide) is used. For example, milk industry chose this kind of sterilization many years ago. This process has a wide scope of application: manufacturers dealing with of carton packaging and aseptic PET filling chose it as the most optimum one. In order to prove the efficiency of the suggested method, it is relevant to refer to the issue of microbiological safety of the aseptic filling process. Concerning cold-aseptic filling it is relevant to note that this method is economically efficient. Thus clean rooms designed for this process may be smaller thus reducing energy costs; they save money and time spent on the aseptic process. Equipment arrangement of ACF system The arrangement of equipment in a cold-aseptic process should be fully integrated. As it is mentioned in the recently conducted research: “this applies to the process technology for the flash pasteurizer or ultra-high temperature system, to the mixer with sterile buffer tank, the aseptic fittings and to the media preparation of disinfectant solution, sterile water, sterile air, steam and inert gas” (Concepts for Soft Drink Manufacture). There is a perfect option to replace hot-filling processes by a cold-aseptic filling system. Thus, it can replace tunnel pasteurizers (Muris, 1993). We tend to claim that cold-filling aseptic process is relevant due to the following reasons: it meets the requirements of filling safety, provides with a possibility to save operating costs and increase operating safety. Aseptic filling is now considered as a new wave of production. The usage of preservatives and refrigeration is unnecessary. It is even more appropriate to integrate air cold technology on all stages of manufacturing process: “Along with this development, the trend toward aseptic cold filling of beverage containers, which preserves a product's properties, continues unabated; this is why one of the most important challenges facing many drink manufacturers today is the technical updating and conversion of their plants to aseptic production” (Traditional and new aseptic cold filling technology). Moreover, in order to incorporate integrate designing mixing and pasteurization in one process; the majority of manufacturers imply heat transfer plates. For juices manufacturing the company uses the following method: “a concentrate is heated with steam to the required pasteurization temperature and is sustained hot” (Traditional and new aseptic cold filling technology). Further on, there is a process of mixture of concentrate with high-quality sterile water under chilled temperature conditions. A pasteurized product is then filled into sterile tank. Figure 1. ACF system arrangement. External conditions for ACF system Aseptic cold filling technology is rather effective but it is necessary to provide a sterile environment of the process. Hot sterilization technology is less safe as aseptic cold filling process. At this point the advantage of aseptic cold filling technology is material sterilization with the help of ultra high temperature UHT sterilization (Traditional and new aseptic cold filling technology). Another advantage is reduced time, a decreased nutrient loss with the stable quality and taste. A crucial stage is packaging sterilization. A preference of aseptic cold filling technology is in non-heat-resistant PET material. The sterilization process of the latter is mediated by chemical reagents (Traditional and new aseptic cold filling technology). Thus the main advantage of aseptic cold filling is a compliance with the health-level design (Traditional and new aseptic cold filling technology). Therefore out of two options of manufacturing, ACF is especially relevant to manufacturing of sensitive products (soft drinks). The microbiological sensitivity of a product to be manufactured is provided by the protection of the bottling process. The level of product’s sensitivity is measured by the pH value where the CO² content and nutrients for microorganisms play a role of identification criteria of a product’s sensitivity. Another issue to be solved by the manufacturers is to differentiate between ultra-clean filling (UCF) and the flexible ACF process (Traditional and new aseptic cold filling technology). From a practical perspective, UCF may serve a practical decision for aseptic process. With this regard, it is possible to underline that clean room may be smaller: “Filling machines used in the cold aseptic process are also getting smaller as the clean rooms that are needed for this procedure have shrunk in size, and are now no larger than the housings of the production units. Insulator technology has allowed companies to reduce by 80 per cent the clean room volume of two-lane rotary machines used in the filling lines” (Traditional and new aseptic cold filling technology). In the research conducted by Swamidass (2002) it is underlined that ACF installation is preferential for manufacturing of juices or drinks containing juice. This technology may be efficient in price decrease for soft drinks and satisfy coming levels of a great demand for this kind of production. It is better to look for a more flexible process implemented in the manufacturing process. Thus as another option such kind of filling systems which enable the non-contact filling of non-carbonated beverages and provide with automatic CIP caps (Traditional and new aseptic cold filling technology). A wide scope of bottles to be processed (e.g. bottles with different diameter mouths) may be filled in at different stages. Figure 2. A relative correlation between hygienic requirements and product sensitivity As it is shown on the above figure, ACF is a conventional system working in compliance with microbiological factors at the same time it guarantees products with longer shelf life. From environmental and health concerns, ACF provides with 100% hygienic filling and packaging of the company’s (The Manufacturing Process of Beverage Production). Another challenge is the absence of expensive product disinfection agents or damaging preservatives. Hot filling requires more costs because of plastic bottles usage. Therefore air-cold filling is a perfect cost-saving alternative for the company. Figure 3. Complete ACF system from KHS Quality Control With regard to the main features of soft-drink manufacturing process, it is very important to comply with environmental standards. Prior to these, it is necessary to keep all machines clean. In accordance with international regulations, water quality should be sustained at appropriate level (Traditional and new aseptic cold filling technology). If to be more exact, “the inter beverage production line manufacturers adhere to strict water quality standards for allowable dissolved solids, alkalinity, chlorides, sulfates, iron, and aluminum” (Concepts for Soft Drink Manufacture). There is a direct relationship between a facilitated manufacturing process and clean water. Water of high quality is a guarantee of consistency in flavor, color, and body. In order to control over this process, it is relevant to provide regular testing. In order to avoid severe punishment from the Environmental Agency, it is relevant to adhere to regulations developed by the National Soft Drink Association and related agencies. The quality of sugar and other components should be also taken account by manufacturers. Sugar quality should be also sustained at an efficient level. In case low-quality sugar is used, residue in the beverage will be destructing for it. Sanitized environment guarantees a careful sugar handling. Therefore a careful inspection of raw materials before manufacturing process is crucial point for soft drink manufacturers. A careful sterilization of all tanks and containers, constant monitoring is a guarantee of careful compliance with regulations (Solutions for Aseptic COLD Filling KHS Filling and Packaging). Sanitation principles should be of primary concern for manufacturers. Under well-regulated conditions processes of “transporting, packing, segregating, preparing, processing and storing should be conducted” (Solutions for Aseptic COLD Filling KHS Filling and Packaging). Plant sanitation should be supervised by individuals responsible for this function. Different safety measure should be taken into consideration to guarantee that manufacturing processes “do not contribute contamination such as filth, harmful chemicals, undesirable microorganisms or any other objectionable material to the processed product” (Market news service, Fruit Juices). Main violations of sanitary conditions are poor bottle washing, a scarce provision of sanitizing equipment and inefficient employee sanitary practices etc (The Manufacturing Process of Beverage Production). A proper interval for sanitization of all pipe lines, machines and containers is 4-hour interval. Conclusion The main concepts of soft drink manufacturing represent the problems of primary concern for the majority of manufacturers. This fact can be explained by a rapid growth of ‘sensitive products’ development and a desire of manufacturers to provide the best product quality. In case, there is a lack of efficient assets, as in the case considered further on, there is a need to increase optimum line efficiency. Consequently, it was essential to consider possible plant process and pasteurization options in order to increase output of soft drinks, reduce costs and price for the product. Therefore in order to satisfy the needs of the companies’ managers, who are striving for the increase of production volume in the future there are basic principles to be followed by the company. A new strategic development focused on implementation of air-cold filling system facilitates manufacturing process. This strategic decision is economically and environmentally safe; it requires individual responsibilities from employees and managers; relevant control options. Moreover, the manufacturing process of soft drinks is also facilitated because of experienced engineers’ involvement propagating ‘gentle product handling’. Air-cold filling system was suggested for the manufacturer as a ‘new wave of soft-drink manufacturing’. The basic concepts of the manufacturer are covered in case all the required steps are made. Works cited 1. Concepts for Soft Drink Manufacture. KRONES. [online]. Available from: http://www.krones.com/downloads/prozesstechnik_softdrink_e.pdf [Accessed February 25 2011]. 2. GEA Process Engineering. [online]. Available from: http://www.niroinc.com/gea_liquid_processing/pasteurization.asp [Accessed February 25 2011]. 3. Market news service (MNS) (December 2009). Fruit Juices. Quarterly Edition Bulletin. [online]. Available from: http://eacexport.com/includes/downloadmanager.asp?id=doc45&name...pdf [Accessed February 25 2011]. 4. Muris, T. et al., 1993. Strategy, Structure, and Antitrust in the Carbonated Soft-Drink Industry. Quorum Books. 5. Solutions for Aseptic COLD Filling KHS Filling and Packaging. [online]. Available from: http://www.khs.com/uploads/tx.../KHS_A_6_46_ACF_en.pdf [Accessed February 25 2011]. 6. Solutions for the fruit juice industry. [online]. Available from: http://www.khs.com/uploads/.../KHS_A_7_26_Fruchtsaft_en_RZ_01.pdf [Accessed February 25 2011]. 7. Swamidass, P. M., 2002. Innovations in Competitive Manufacturing. AMACOM. 8. The Manufacturing Process of Beverage Production. [online]. Available from: http://www.articlesnatch.com/Article/The-Manufacturing-Process-Of-Beverage-Production/1161637#ixzz1Ex36ZlOv [Accessed February 25 2011]. 9. Traditional and new aseptic cold filling technology. [online]. Available from: http://business.ezinemark.com/traditional-and-new-aseptic-cold-filling-pet-filling-technology-comparison-filling-aseptic-packaging-food-industry-16972955ef2.html#ixzz1EserNXb3 [Accessed February 25 2011]. Read More