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Bottling Line Process & Safety Guide

This document outlines the processes involved in a bottling line and determines critical control points (CCPs). The bottling line involves 21 steps from receiving glass bottles to palletizing finished goods. Key steps include bottle washing, filling, crowning, and packing. Raw materials like water and glass bottles are assessed for hazards like microbes and foreign matter. Process steps like bottle washing are evaluated for hazards like microbes. Control measures for bottle washing include maintaining specific caustic levels, temperatures, contact times and chlorine levels in the final rinse. Monitoring includes weekly microbiological analysis and methylene blue tests to check for microbes. Corrective actions involve stopping equipment, reassessing parameters, and checking detergent effectiveness.

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Gorack Shirsath
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1K views5 pages

Bottling Line Process & Safety Guide

This document outlines the processes involved in a bottling line and determines critical control points (CCPs). The bottling line involves 21 steps from receiving glass bottles to palletizing finished goods. Key steps include bottle washing, filling, crowning, and packing. Raw materials like water and glass bottles are assessed for hazards like microbes and foreign matter. Process steps like bottle washing are evaluated for hazards like microbes. Control measures for bottle washing include maintaining specific caustic levels, temperatures, contact times and chlorine levels in the final rinse. Monitoring includes weekly microbiological analysis and methylene blue tests to check for microbes. Corrective actions involve stopping equipment, reassessing parameters, and checking detergent effectiveness.

Uploaded by

Gorack Shirsath
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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ProcessesInvolvedinThisBottlingLine

1. Glass receiving from warehouse 2. Depalletizing 2A. Pallet sorting 3. Unpacking 3A. Crate washing 4. Auxiliary material receiving and storage 5. Bottle washing 5a. Clean Bottle Discharge 6. Empty bottle inspection 6A. Visual inspection 7. A. Treated water online filtration B. Treated water dearation (vacuum method) 8. Final syrup storage (buffer tank) 9. Proportioning 10. Chilling 11. Carbonation 12. Product storage (buffer tank) 13. On-line product filtration 14. Filling

15. A. Crown receiving and storage B. Crown buffer storage (Bin) C. Crown conveying 16. Crowning 17. Date coding 18. Full goods visual inspection 19. Packing 20. Palletizing
DETERMINATION of CCPs Raw Materials:

Raw Materials Chlorinated water(deosan)?

Hazard THMs.

Q1 Y

Q2 Y

Q3 N

CCP

HACCP team Trace amounts on rinsed container surfaces.

No

Glass bottles

Microbial contamination- yeasts, coliform, bacteria. Foreign matter sticks, roots, herbs, cement, tar, glue, paint, candle wax etc. Glass fragments from trade/handling

Y Y Y

Y Y Y

N N N

No
No

Controlled at bottle washing Controlled at bottle washing and inspection

No

Bird swings and spikes on new glass causing glass fragments Raw water

Sensitive raw material No No No

New glass is controlled through supplier management. The supplier is KO approved and provides a CoA with each delivery.

Microbes ColiformTHMs

Y Y Y

Y Y Y

N N N

Levels of THMs in Municipal water are very low. Monitored through potability and KO THMs

Aluminum

Water diluted by semi-treated water at final rinse section.

DETERMINATION of CCPs Process:

Process Step 1. Glass receiving

Hazard Microbes - yeasts, coliform, bacteria.

Q1 Y

Q2 Y

Q3 N

Q4 Y

Q5 Y

CCP No

HACCP team Controlled at bottle washing

Foreign matter e.g. sticks, roots, herbs, pests, sticks, roots, herbs, cement, tar, glue paint candle etc Glass fragments from trade/handling Foreign bottles (e.g.Diet Coke/Coke Light when producing Coke- sucrose)

No

Controlled at bottle washing and inspection

No

No

Foreign bottles (e.g.Coke when producing Coke Light Phenylalanine and saccharin)

No

Operational PRPs -

Material/Pr ocess Bottle washing

O.PRP FoodSafety No. 1 Hazard i.Microbes(yeast andmould)

Control Measure(s) Maintain I.Caustic2.5 3% ii.Temp60 70C iii.Contact time5mins iv.Finalrinse chlorine1 3ppm

Critical limit <25CFU/ bottle

Monitoring

Correction

CorrectiveAction

Weekly Micro analysisfor viable mould

Micro biologist

Micro analysi s report

N/A

N/A

Reassessmentof QC washerparameters Chemist anddetergenttocheck validityofthe effectivenessof containerpreparation

100%

Methylene bluetest fornon viable mould

4hourly

Line inspector

Quality Stopthe control washerand sheet correctoutof spec parameters

Wash er opera tor

Reassessmentof QC washerparameters Chemist anddetergenttocheck validityofthe effectivenessof containerpreparation

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