Introduction
Soft drink is a refreshing, non alcoholic, thirst quenching
beverage that typically contains carbonated water, a
sweetener and a flavoring. Carbonated water (also
known as club soda, soda water, sparkling
water, seltzer water, or fizzy water) is water into which
carbon dioxide gas under pressure has been dissolved.
Most carbonated water is sold in ready to drink bottles
as mineral water and carbonated beverages such as
soft drinks.
Soft drink/ soda production
Ingredients in soft drinks
Soft drinks typically contain,
water (up to 98 vol-%)
sweeteners (812%, w/v),
fruit juice (usually up to 10%)
carbon dioxide (0.30.6% w/v),
acidulants (0.050.3%)
flavourings (0.10.5%)
colourings (070 ppm)
chemical preservatives (legal limits)
antioxidants (< 100 ppm)
foaming agents (e.g. saponins up to 200 mg/ml)
stabilizers (0.10.2% per GMP) .
Nowadays soft drinks may also contain added vitamins, minerals,
proteins, fibres and
other functional compounds.
Soft drink production process
There are several steps in the manufacturing process of
soft drinks.
1. Clarifying the water
2. Filtering, sterilizing, and dechlorinating the water
3. Mixing the ingredients
4. Carbonating the beverage
5. Filling and packaging
1. Clarifying the water
Removing impurities of the water through the process of a series of
coagulation, filtration, and chlorination. Coagulation involves mixing a
gelatinous precipitate, or floc (ferric sulphate or aluminum sulphate),
into the water. The floc absorbs suspended particles, making them
larger and more easily trapped by filters. During the clarification
process, alkalinity must be adjusted with an addition of lime to reach
the desired pH level.
2.Filtering, sterilizing, and dechlorinating the water
The clarified water is poured through a sand filter to remove fine
particles of floc. Sterilization is necessary to destroy bacteria and
organic compounds that might spoil the water's taste or color. The
water is pumped into a storage tank and is dosed with a small amount
of free chlorine. Next, an activated carbon filter dechlorinates the water
3. Mixing the ingredients
The dissolved sugar and flavor concentrates are pumped into the
dosing station in a predetermined sequence according to their
compatibility. The ingredients are conveyed into batch tanks where they
are carefully mixed; too much agitation can cause unwanted aeration.
The syrup may be sterilized while in the tanks, using ultraviolet
radiation or flash pasteurization, which involves quickly heating and
cooling the mixture. Fruit based syrups generally must be pasteurized.
The water and syrup are carefully combined by sophisticated
machines, called proportioners, which regulate the flow rates and ratios
of the liquids. The vessels are pressurized with carbon dioxide to
prevent aeration of the mixture.
4. Carbonating the beverage
Carbonation is generally added to the finished product, though it may
be mixed into the water at an earlier stage. The temperature of the
liquid must be carefully controlled since carbon dioxide solubility
increases as the liquid temperature decreases. Many carbonators are
equipped with their own cooling systems. The amount of carbon dioxide
pressure used depends on the type of soft drink.
For instance, fruit drinks require far less carbonation than mixer drinks,
such as tonics, which are meant to be diluted with other liquids. The
beverage is slightly over-pressured with carbon dioxide to facilitate the
movement into storage tanks and ultimately to the filler machine.
CO2 + H2O
H2CO3
H2CO3
H+ + HCO3-
5. Filling and packaging
The finished product is transferred into PET or glass bottles or
aluminium cans. at extremely high flow rates. The containers are
immediately sealed with pressure-resistant closures, either tinplate or
steel crowns with corrugated edges, twist offs, or pull tabs.
Because soft drinks are generally cooled during the manufacturing
process, they must be brought to room temperature before labeling to
prevent condensation from ruining the labels. This is usually achieved
by spraying the containers with warm water and drying them. Label
are then affixed to bottles to provide information about the brand,
ingredients, shelf life, and safe use of the product. Most labels are
made of paper though some are made of a plastic film. Cans are
generally pre-printed with product information before the filling stage.
Finally, containers are packed into cartons or trays which are then
shipped in larger pallets or crates to distributors.
Chemical Engineering Aspects
The production processes range from batch to continuous production
processes.
Major Brands - Continues for in-line blending and corbonation.
For smaller batch- Batch-continuous production to large vessels.
Blending/ Mixing Process
usually carried out in a continuous mixing method before the liquid
is chilled and carbonated in a carbonator
Carefully prescribed standard operating procedure ensure the
homogeneity of the batch.
Carbonation
Expressed as unit called volumes.
The ability of water to absorb CO 2 depend on,
Efficiency of the carbonating unit, product type, product
temperature, CO2 pressure, Time and contact surface area,
air content.
If the temperature of the water beverage drops, the CO 2
becomes more soluble, and the pressure must be decree to
keep the volume of carbonation within standards.
For 300mL volume of liquid , approximately 1200 cc of
carbon dioxide has been introduced. ( For gas volumes )
Advantages and Disadvantages
Advantages
Potentially greater
yields
A continuous mixing
and blending system
from with highly
accurate in-line
measurement and
very fast settling
times result in
a precise and
consistent product,
high performance
savings in raw
ingredient
Disadvantages
Higher initial costs
Energy consumption
is high.
Advance technology
request for
production and
quality controlling
Carbonated Soft Drink Manufacturing In
Sri Lanka
Macro scale industry in Sri Lanka.
Eg :- Elephant, Coca-Cola, Pepsi
Ceylon Cold Stores Limited (CCS),
also known as Elephant House, has established itself as the
leader in Sri Lankas carbonated soft drinks market.
Ceylon Cold Stores Limited (CCS) cont.
Raw Materials
From own plantations
Ginger Cultivation - Poojapitiya
Vanilla Farm -Halawathuwala
Treacle
- Agricultural communites in Deniyaya ,
Matale and Kegalla
Latest Technology
Consumer preferences
Continuous Research and Development
Innovation
Reference
Hui, Y.H; (ed.) .(2007).Handbook of Food products
manufacturing. New Jersey: John Wiley & Sons, Inc.
Steen, D.P; Ashurst. P.R; (ed) (2006). Carbonated soft
drinks. Oxford:Blackwell Publishing Ltd.
Elephant House. 2015.[online] available at:
http://www.elephanthouse.lk/our-company.html
[accesed 09 November 2015]
Mitchell, A.J; (ed). (1990). Formulation and Production
of Carbonated Soft Drinks. Glasgow : Blackie and Son
Ltd.
Thank you
Group members
R.W.M.M.K.K.Saumyamali
D.W.W.Sewwandi
