A TECHNICAL REPORT

ON

STUDENT INDUSTRIAL WORK SCHEME

(SIWES)

UNDERTAKEN AT

SEVEN UP BOTTLING COMPANY ILORIN PLANT KWARA STATE,

OLD ASA DAM ROAD.

BY

ZAINAB OMOBOLANLE ADEOTI

MATRIC NO: 20/57MB/01419

SUBMITTED TO THE DEPARTMENT OF MICROBIOLOGY, FACULTY

OF LIFE SCIENCES, UNIVERSITY OF ILORIN. KWARA STATE.

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE

AWARD OF BACHELOR OF SCIENCE IN MICROBIOLOGY.

SEPTEMBER 2023

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 DEDICATION

This report is dedicated to Almighty God.

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 ACKNOWLEDGEMENT

Appreciation goes to the creator of the universe for His protection, wisdom and grace throughout

my life.

I’m grateful to the entire staff of 7up bottling company Ilorin plant kwara state for making my

SIWES program educative, interesting and memorable.

Special gratitude goes to my industry based supervisor Mr. Misiko Monu for his effort during my

training, and also my H.O.D Prof. S. Awe and all lecturers of Microbiology department.

I can never forget to appreciate Mrs. Fola Ajimati for her relentless effort in imparting

knowledge towards this program, God bless you.

My uttermost regards goes to my parents Mr & Mrs Adeoti for their financial support towards

my educational pursuit, Remain blessed by God Almighty.

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 TABLE OF CONTENTS
Title of page Pages
Dedication ii
Acknowledgement iii
Table of content iv
Abstract v
chapter One

1.0 Introduction

1.1 Brief History of SIWES

1.2 Scope of SIWES

1.3 Aims and Objectives of SIWES

Chapter Two

2.1 Brief History and Background of 7up Bottling Company

2.1.1 Seven Up Branches and Locations in Nigeria

2.2.1 Mission of Establishment

2.2.2 Vision of Establishment

2.2.3 Core Values of Establishment

2.3 Organization Chart of Establishment

2.4 Departments and Functions of Seven Up Bottling Company

Chapter Three

3.0 The Quality Control

3.0.1 Introduction to the Quality Control

3.0.1.1 Projects Carried Out in the Establishment

3.0.2 Safety Precautions in Quality Control

3.0.3 Rules and Regulations in Quality Control

3.0.4 Laboratory Equipment and their Uses

The Quality Control Sections and Various Test Carried Out (ACTUAL WORKDONE)
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3.1 The Microbiology Laboratory

3.1.1 Microbial Analysis on Water

3.1.2 Microbial Analysis on Finished Beverages

3.1.3 Microbial Analysis on Washed Bottles

3.1.4 Microbial Analysis on Crown Corks

3.1.5 Microbial Test on Syrup Tanks

3.1.6 Microbial Analysis on Strainers

3.1.7 Microbial Test on Environment

3.1.8 Sanitation in The Establishments

3.1.8.1 Factors to Consider While Taking Sanitation in Microbiology

3.1.8.2 Common Micro Organisms Found In Bottling Company

3.1.8.3 Sterilization in the Microbiology Laboratory

3.2 The Chemical Laboratory

3.2.1 Brix Determination of a Carbonated Drink or Syrup

3.2.2 Methylene Blue Test

3.2.3 Titrate-Able Acidity

3.2.4 Caustic Strength Analysis

3.2.5 Caustic Carry over Analysis

3.3 Production Lines

3.4 Water Treatment Plant

3.4.1 Softening of Water

3.4.2 Water Alkalinity Test

3.4.3 Test for Hardness of Water

3.4.4 Test For Free Chlorine

3.5 Traceability Section

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Chapter Four

4.0 Summary, Challenges Encountered, Recommendations and Conclusions.

4.1 Summary and Conclusions

4.2 Challenges Encountered

4.3 Recommendation

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 ABSTRACT

The objective of student industrial work experience scheme (SIWES) was exposing students of
higher institutions to acquire practical experience in their various courses of study and to prepare
them for industrial work situation which they are likely going to encounter after graduation. This
technical report is solely based on the experiences gained during my six month of industrial
training in 7up bottling company Ilorin plant, kwara state. This report portrays how the
carbonated soft drinks (beverages) owned by this company are produced, raw materials used in
the production and diverse analysis carried out to guarantee the safety consumption of the
beverages to the health of their customers and in conformance to the establishment standards.
Different analysis such as microbial analysis on water, beverages, washed bottles, syrup tank,
crown corks, environment and sanitation of the production lines. Brix test in beverages,
methylene blue test, titrate-able acid test, caustic strength and caustic carry over test. Hardness,
softner, alkalinity and chlorine test of water. Traceability of beverages batch numbers. I was
privileged to work in five sections of quality control which are: microbiology section, chemical
section, production line section, water plant section and traceability section. This various
department have exposed me to customers satisfaction, mission and vision of the company,
safety precautions in a bottling factory, rules and regulations of a bottling factory and different
test analysis. This report also states the problems encountered and gave recommendation to
improve the scheme.

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 CHAPTER ONE

1.0 Introduction

SIWES (student industrial work experience scheme) is a scheme designed by the federal ministry

of education, the industrial training fund is the National board for technical education and

institution of high students in Nigeria.

SIWES (student industrial work experience scheme) is aimed at granting or exposing students to

experience the nature of work they are to encounter when they finish their program in school

depending on one discipline

The scheme also gives students opportunity to gain experience practically what was not taught in

school during their program.

It also helps students to practice the theory aspect of their lecture in school. It also gives the

students the opportunity to be versatile .it makes the students popular, it also act as a medium of

job opportunity when they finish their program in school.

It gives a detailed account of all work carried out during SIWES and as well as the problems

faced.

1.1 Brief History of SIWES

The student Industrial Work Experience Scheme (SIWES) was established in 1973/1974 session

by the Industrial Training Fund (ITF). Prior to the establishment of this scheme, there was a

growing concern among our industrialists that graduates of our institutions of higher learning

lacked adequate practices background studies preparatory to employment in the industries. It is

against this background that the aim of initiating and designing the scheme was hinged.

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Consequently, the scheme affords students the opportunity of familiarizing and exposing

themselves, to the needed experience in handling equipment and machinery that are usually not

available in the institutions.

The ITF solely funded the scheme during its formative years. It withdraws from the scheme in

1978 due to the financial problem. The federal government handed the scheme in 1979 to both

the National University Commission (NUC) and the National Board of Technical Education

(NBTE). Later, in November 1984, the federal government changed the management and

implementation of the scheme to ITF and it was effectively taken over by the Industrial Training

Fund (ITF) in July 1985 with the funding being solely borne by the federal government.

1.2 Scope of SIWES

1. The student industrial work experience scheme (SIWES), a skill training program was

designed to afford students the opportunity of familiarizing and exposing themselves to

proper handling of equipment and machineries that are usually not available in their

institutions.

2. The program gives students the strength and ability to apply the given knowledge after

graduation. The program which is a successful attempt was to help students understand

the underlying principles of their future work.

3. In the bid to make it (SIWES) a successful program, federal government of Nigeria made

it mandatory for registered companies, ministries and parastatals in Nigeria to offer

places for attachment for the concerned students.

1.3 Aims and Objectives of SIWES

The aims and objectives of SIWES includes:

A. Enlisting and strengthening employers involvement in the entire educational process,

preparing them for employment after graduation.

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B. Exposing students to work methods and techniques in handling equipment and

machineries that may not be available in their institutions.

C. SIWES gives students an opportunity to apply their knowledge in real work situation

thereby bridging the gap between theoretical and practical aspect.

D. Prepares the students for the industrial work practices they are likely to encounter after

graduation.

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 CHAPTER TWO

2.1 Brief History and Background of 7up Bottling Company

7up bottling company plc is one of the largest manufacturer and distributor of the widely

consumed brands of soft drinks in Nigeria. It became a privately owned company after which the

investment arm of the founder’s family bought the outstanding public shares previously quoted

on the Nigeria stock exchange. The production of its first product, 7up started on October 1,

1960. Late Mohammed El khalil was the father of the company, Faysal El khalil the managing

director. The company amorphosed into a successful transport business (El khalil transport) in a

bid to diversify the then largest transport company in the entire west of Africa.

7up bottling company operates in some african countries such as Nigeria, Tanzania,

Ghana etc. The first factory of the company was located at Ijora in lagos state, Nigeria. Over the

years, the company grew from the then one factory to nine factories across Nigeria. Ilorin plant

was commissioned on the 1st of October, 2001.

Seven up has a history of sport sponsorship and promo involving limited prices drawn

under the crown cork of bottles in Nigeria. The firm introduced 35cl and 50cl of their soft drinks

for easy accessibility and affordability.

2.1.1 Seven Up Branches and Locations in Nigeria

The headquarter of 7up bottling company plc is located in Nigeria at 247 Moshood

Abiola way, Ijora apapa, lagos, Nigeria. Other factories are located at:

 Glass industry road ogbor hill, aba, abia state.

 New Nsukka road amaeke ngwo, 9th mile, enugu east, Enugu state.

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  Km14, zaria road kano municipal, Kano state.

 Benin-lagos express way benin city, Edo state.

 302-304 idu industrial estate, Abuja, FCT.

 17A Imuwa abdulkadir road Kaduna, Kaduna state.

 Oluyole industrial estate Ibadan, Oyo state.

 Old asa-dam road, Ilorin, Kwara state.

Ilorin plant, kwara state is the smallest plant among the factories across Nigeria.

2.1.2 The Company Products

7up bottling company plc deals squarely with distribution and bottling of carbonated soft

drinks such as Pepsi, Mirinda orange, Mirinda pineapple, Teem bitter lemon, Teem lemonade,

Teem tonic, Teem soda water, H 2Oh!, Mountain dew, 7up and aquafina table water (bottled only

at ikeja factory). Majority of the company’s products are packaged in 35cl, 50cl and 75cl to

allow easy affordability and accessibility to the products by consumers.

2.2 Scope and Objectives of 7up Bottling Company

2.2.1 Mission of Establishment

7up bottling company is regarded as one of the best soft drink bottling producing

company in Nigeria. Their mission is to inspire and refresh a youthful life style. They work

towards accomplishing this by producing high quality flavours to meet the demands of their

customers.

2.2.2 Vision of Establishment

Their vision is to become the most admired and innovative company in Nigeria.

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2.2.3 Core Values of Establishment

 Team work: Each employee recognize and understand the skill, abilities and cooperation

between relevant person and the units.

 Integrity: Highly reputed for uprightness and ethical standards.

 Trust: A clear inter relationship between management and employee, with the former

believing the employees will act in the best interest of the company and the latter

confident of no harm against their own interest

 Commitment.

2.3 Organization Chart of Establishment

Organizational chart of 7up Bottling Company Plc. Ilorin plant

List of abbreviations:
QCM: Quality Control Manager ASST. CMO: Assistant Chief Medical Officer
HRM: Human Resource Manager CSO: Chief Security Officer
PMM: Plant Marketing Manager HRO: Human Resource Officer

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PAO: Plant Accounting Officer HR INTERNS: Human Resource Interns
PCS: Process Control Superintendent QCS: Quality Control Superintendents
QCI: Quality Control Inspectors QC INTERNS: Quality Control Interns
TO: Transportation Officer CSO: Chief Security Officer

2.4 Departments and Functions of Seven Up Bottling Company

In order to fulfill the missions and the visions of 7up bottling company, the company in Ilorin

plant is sub-divided into four different sections which are:

 Manufacturing section

 Inventory section (sales, marketing and distribution)

 Administration section

 Fleet section

These four sections are further sub divided into units/departments which are tasked everyday

to enhance distribution and production of products.

Manufacturing Section

A. Production department: This department is headed by the factory manager. The unit is

responsible for producing and crowning of bottles containing beverages. They also

operate the production machineries used on the production lines.

B. Quality control department: This department is headed by the quality control manager.

The department is responsible for maintaining food and quality of the products i.e

products in accordance to the establishment standards.

C. Engineering department: The department is managed jointly by the factory manager and

maintenance manager. The unit is sub-divided into mechanical and electrical sections.

They are responsible for installation, repairs and maintenance of factory machineries.

Inventory Section

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 A. Warehouse and stores: The inventory manager work hand in hand with the warehouse

manager, tasked with documentation of inflow and distribution of products for day to day

operation of the plant.

B. Marketing department: The department is headed by the marketing manager. The unit is

responsible for selling company’s products to their various customers, maintaining an

healthy relationship between the customers and company.

Administration Section

A. General manager’s office: The general manager coordinates the activities of each

departmental managers towards achieving the objectives of the factory.

B. Human resources department: Headed by the human resources manager. The unit is

responsible for recruitment of workers and also look after the employees and company’s

welfare.

C. Accounts: This unit is headed by the account manager, they are tasked with precise

record keeping of the company’s financial expenses, loan taken by workers, payment of

tax and disbursement of employee’s salary.

D. Security: The unit is controlled by the plant security manager, chief security officer

together with a private security firm (Asco security company). They are tasked with tight

security of the factory.

Fleet Section

A. Transport department: The department is headed by the fleet manager alongside the

transport officer. This unit is responsible for transportation of the establishment’s

products.

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 B. Vehicle’s workshop department: This department is controlled by the maintenance

manager, it repairs the company’s vehicles such as products delivery trucks and forklifts.

CHAPTER THREE

3.0 The Quality Control

3.0.1 Introduction to the Quality Control

Quality control in 7up bottling company Ilorin plant is a sub-unit under the

manufacturing section. The department headed by the QCM (quality control manager) is where

tests and analysis are carried out to monitor production processes in order to ensure that they

conform to standards and quality products been produced.

There are units attached to the quality control to certify products conformance to the

establishment standards. These units are: chemical laboratory, microbiology laboratory, water

treatment plant, production lines (quality control inspectors inspect orderliness and smooth

running of the production lines) and traceability.

The following are some of the main functions of the quality laboratory:

 Testing and release or rejection of all incoming raw materials, packaging materials and

finished products as per specified specifications.

 Maintaining records of production lines workers (sorters, sighters etc)

 Regular analysis of caustic strength and caustic carryover.

 Calibration of laboratory instruments/equipment.

 Consistent microbial analysis.

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  Maintaining labeling Procedures at all the stages.

 Maintaining standard reference records of products.

 Analysis of complaint samples as at when required.

 Regular analysis in close intervals on water for production.

 Maintaining general cleanliness (sanitation) at all times.

 Consistent auditing of chemical stores.

 Ensure safety rules and precautions are carried out by workers.

 Checking of incoming and out-going products records.

Quality control can be regarded as the factory’s heart beat and a significant department

driving the establishment towards an achievable mission, visions and objectives in sight.

3.0.1.1 Projects Carried Out in the Establishment

Series of test were carried out to ascertain the product’s conformance to the company’s

standard. The following are the analysis carried out:

 Brix, methylene blue test and sanitation (CIP) in the plant.

 Titrate-able acidity test.

 Caustic strength and caustic carry over analysis.

 Hardness, softening, alkalinity and chlorine test in water.

 Microbial analysis on water and beverages.

 Microbial analysis on washed bottles and crown corks.

 Microbial analysis on syrup tank and strainers.

 Microbial analysis on environment.

 Record keeping of batch numbers (expiring and production dates of beverages)

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3.0.2 Safety Precautions in Quality Control

This unit operate sophisticated machineries in every day to day operations in the factory.

Therefore to prevent accident accompanied with serious injuries or death, the followings are the

safety precautions to follow:

i. Always put on protective foot wears to prevent injuries to the leg as a result of bottle

burst.

ii. Production line operators should always use ear-moff to reduce loud sound of bottle

burst.

iii. No use of lab coat breast pocket.

iv. Always use the safety valve on the autoclave.

v. Put on protective gloves when taking samples of caustic solution from the washer.

vi. No use of ear-piece or hand set when waking around the plant to prevent accidents with

forklifts.

vii. Wash your hand or affected areas immediately after chemical spillage.

3.0.3 Rules and Regulations in Quality Control

Every units/departments, sections and the establishment at large always have set down

rules and regulations that guides behaviors of her workers so as to achieve a common goal. The

followings are the rules and regulations in the quality control:

i. Always put on hair net whenever you are in the unit.

ii. No use of jewelries on the body, to prevent contamination of beverages.

iii. No use of ear-piece in the unit.

iv. No eating of food in the quality control (laboratories, production lines and water

treatment plant).

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 v. Sleeping on duty is highly prohibited.

vi. Use disposable gloves and nose cover when carrying out a microbial analysis to prevent

cross contamination.

vii. No use of mobile phones when working.

viii. Zero tolerance to lateness.

ix. Always wash your hands with soap before and after operation in each unit.

x. Always keep the laboratory clean at all times.

3.0.4 Laboratory Equipment and their Uses

 Autoclave: used in sterilizing microbial equipment to eliminate micro organism.

 Satorious manifold and cups: used in carrying out microbial analysis especially test on

water and beverages.

 Oven and incubator: used for sterilization and incubation respectively.

 Lamina flow: A sterile environment used in carrying out microbial analysis

 Densitometer: used to check amount of dissolved solutes in a solution. It is used to check

the sugar content in a beverage.

 Piercing food drink and carbo QC: used in piercing the filled bottle crown cork of

products, where this equipment suck out some of the beverage, analyze it and gives the

reading of the CO2 , air pressure and temperature of the beverage.

 Distiller: used to purify water for analysis in the laboratory.

 Micron polisher: used in proper filtration of water in the water treatment plant.

 Burette and burette stand: used for titration of chemical analysis.

 Potentiometer: used to check the total amount of acidic concentration in beverages.

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  Weighing machine: used in determining the weight of chemicals used for analysis.

 Microscope: This is used to view microscopic organism which cannot be seen with the

naked eyes.

 Purification tank (carbon & sand): used in the purification of water for production.

 Spectrophotometer: used in determining the colour, turbidity and ash conductivity of

liquid specimens.

 Nutrient pads: This pads are used to culture the growth of any possible microorganism in

the sample.

The Quality Control Sections and Various Test Carried Out (ACTUAL WORKDONE)

The quality control in 7up bottling company is regarded as a prominent department that

keep propelling the company to her mission and visions. It plays a crucial role in the assembly

process by eliminating inferior quality products. The unit is a process that ensures customers

receives products free from defects and meet their needs.

Quality control carry out various analysis/ test to ascertain product’s quality, zero

contamination of soft drinks and products in accordance with the company’s standards. This unit

has various sections (sub-units) to ensure the effectiveness and high productivity of zero risky

products ready for customer’s demand.

3.1 The Microbiology Laboratory

Microorganisms are microscopic organisms, meaning organisms not visible to the naked

eye. The microorganisms include bacteria, fungi, archea, protists and viruses.

The microbiology laboratory in 7up bottling company, Ilorin plant carry out microbic

analysis on everything in relation to the production of soft drinks (products) to inhibit the growth

or existence of microorganisms.

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3.1.1 Microbial Analysis on Water

Aim/Purpose: Microbial analysis on water is done to ascertain the effectiveness of water tanks

maintenance.

Materials Needed: Marker, whirl pace, forceps, 70% ethanol, nutrient pads, manifold cups,

sterile syringe & needle, incubator, filter paper, cotton wool, satorious filter pump, discharge

bucket and microscope.

Procedures

 The sample was collected from the water treatment plant.

 Opening of the water tank was disinfected with 70% ethanol.

 Sample was collected into the whirl pace.

 Lamina flow (where all microbial analysis take place) was disinfected with 70% ethanol.

 Well labeled nutrient pads (three) were moistened with 3.0 – 3.5ml of sterile water to

activate it using syringe and needle.

 The manifold cup was unmounted and the filter papers were fixed on the manholes of the

manifold.

 The manifold was then mounted back with the filter paper in contact.

 Sample was poured into the manifold cups, satorious filter pump was switched on till the

whole sample went through the filter papers into the discharge bucket.

 The pump was switched off, manifold cup was unmounted again and the filter papers

were carefully removed and placed into the activated nutrient pads using forceps.

 The nutrient pads were then placed in the incubator for the stipulated hours to allow the

growth of any present microbes in the sample.

 Result was viewed after incubation using the microscope.

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  Yeast and mold incubated at 250C for 120 hours, bacteria and coliforms incubated at 350C

for 24 hours and 48 hours respectively.

N/B: Manifold cups used in microbial analysis are three in number, nutrient pads used are three

and filter papers used as well are three with different colours (except for the multipurpose filter

paper). Each cup and filter paper represent each expected microorganisms (fungi, bacteria,

coliforms). The nutrient pads are labeled according to the three organisms that maybe present.

Plate 1: The manifold cups

3.1.2 Microbial Analysis on Finished Beverages

Aim/Purpose: Finished beverages are analyzed regularly in order to ascertain the presence or

absence of microbes in the products.

Materials Needed: Marker, glass beaker, bottle opener, weighing balance, forceps, 70% ethanol,

nutrient pads, manifold cups, sterile syringe & needle, incubator, filter paper, cotton wool,

satorious filter pump, discharge bucket and microscope.

Procedures

 Samples of filled bottle were removed directly from the production line or warehouse.

 The bottles were inverted to ensure contact with all internal surfaces.

 The lamina flow was disinfected with 70% ethanol.

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 The bottles crown corks were opened and the lip of the glass bottles were wiped with

moistened cotton wool of ethanol

 Well labeled nutrient pads were moistened with sterile water to activate it.

 The manifold cup was unmounted and the filter papers were fixed on the manholes of the

manifold.

 The manifold was then mounted back with the filter paper in contact.

 The sample was poured into the glass beaker and transferred into the manifold cup.

 The satorious filter pump was switched on till the whole sample were filtered through the

filter papers into the discharge bucket.

 The filter pump was switched off and the manifold cup was unmounted again.

 The filter papers were carefully removed with a forcep and placed in the activated

nutrient pads.

 The well labeled nutrient pads were then placed in the incubator for the incubating hours

to allow the growth of microbes in the sample.

 Result was then viewed after incubation using the microscope.

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Plate 2: The satorious filter pump.

3.1.3 Microbial Analysis on Washed Bottles

Aim/Purpose: To ensure that there is no presence of microbes (molds) in the washed bottles

coming out of the washer.

Materials Needed: Marker, forceps, 70% ethanol, nutrient pads, manifold cups, glass beaker,

sterile syringe & needle, incubator, filter paper, cotton wool, satorious filter pump, discharge

bucket and microscope.

Procedures

 Washed bottles just coming out from the washer were collected as samples from the

production line.

 Sterile water was poured into the bottles and then agitated properly.

 The lamina flow was disinfected with 70% ethanol.

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 Well labeled nutrient pads were activated with sterile water.

 The manifold cup was unmounted and the filter papers were fixed on the manholes of the

manifold.

 The manifold was then mounted back with the filter paper in contact.

 The sample (agitated water in the washed bottles) was poured into the glass beaker and

transferred into the manifold cups.

 The satorious filter pump was switched on till the whole sample were filtered through the

filter papers into the discharge bucket.

 The filter pump was switched off and the manifold cup was unmounted again.

 The filter papers in contact were carefully removed with a forcep and placed into the

activated nutrient pads.

 The well labeled nutrient pads were then placed in the incubator for the incubating hours

to allow the growth of microbes in the sample.

 Result was viewed using the microscope after incubation.

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 Plate 3: The lamina flow.

3.1.4 Microbial Analysis on Crown Corks

Aim/Purpose: To ascertain zero presence of microbes in crown corks.

Materials Needed: Marker, 70% ethanol, swab kits, incubator, filter papers, cotton wool,

nutrient pads and microscope.

Procedures

 Few crown corks were selected randomly as samples.

 The lamina flow was disinfected with 70% ethanol.

 Well labeled nutrient pads were activated with sterile water but not flooded.

 The swab sticks (moistened in the solution in the swab tube) were used to swab the inside

of the crown corks.

 Then the swab sticks were streaked on the filter papers placed in the nutrient pads.

 The nutrient pads were then incubated at the stipulated hours.

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  Result was viewed using the microscope.

Plate 4: Swab tube and sticks (swab kit)

3.1.5 Microbial Test on Syrup Tanks

The syrup tank is where undiluted beverages are stored before being sent to the production lines

where it will be carbonated and diluted with water.

Aim/Purpose: This is to ascertain the sanitation level of the tanks, it must be microbes free at all

times

Materials Needed: Marker, 70% ethanol, swab kits, incubator, filter papers, cotton wool,

nutrient pads and microscope.

Procedures

 The syrup (undiluted beverages) is positioned in the syrup room.

 The lamina flow was disinfected with 70% ethanol.

 Well labeled nutrient pads were brought alive with sterile water but not flooded.

 The swab sticks were used to swab the tanks opening.

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  The filter papers were placed in the nutrient pads.

 Then the swab sticks (used in swabbing the syrup tanks) were streaked on the filter paper

placed in the nutrient pads.

 The nutrient pads were then incubated.

 After incubation, the result was viewed on the microscope.

3.1.6 Microbial Analysis on Strainers

The strainers used in 7up bottling company Ilorin plant is a barrier having punched holes

in it to prevent easy passage or flow of particles dangerous to health (i.e separate solid matter

from a liquid).

Aim/Purpose: Strainers are analyzed regularly in order to ensure absence or presence of

microbes and ascertaining the sanitation level of strainers.

Materials Needed: Marker, 70% ethanol, swab kit, incubator, filter papers, cotton wool, nutrient

pads and microscope.

Procedures

 The lamina flow was disinfected with 70% ethanol.

 Well labeled nutrient pads were activated with sterile water but not flooded

 The filter papers were placed gently in the nutrient pads.

 The strainers were swabbed inwardly with swab sticks.

 Then the swab sticks (used in swabbing the strainers) were streaked on the filter paper

placed in the nutrient pads.

 The nutrient pads were then incubated to allow any possible growth of microorganism.

 After incubation, result was viewed using the microscope.

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3.1.7 Microbial Test on Environment

Microbes are omnipresent in the biosphere, their presence invariably affect the

environment in which they grow, microbes are agents of spoilage and decomposition of food.

Microbial laboratory ensures these microbes are reduced to the minimal level through analysis to

extinct their presence.

Aim/Purpose: To ascertain the rate and level of development of microbes in the environment

and a way to reduce their activities.

Materials Needed: Marker, nutrient pads, cotton wool, 70% ethanol, filter papers, incubator.

Procedures

 The lamina flow was disinfected with 70% ethanol.

 The nutrient pads were brought back to life with 3.0-3.5ml of sterile water.

 The filter papers were placed in the activated nutrient pads.

 The nutrient pads were well labeled with the names of different working/operational units

where the pads are going to be exposed.

 The nutrient pads were then taken to those operational units in the factory and exposed to

the air for 3-5 minutes.

 After the stipulated time, the nutrient pads were then taken back into the micro

laboratory.

 They were then incubated to allow the growth of any possible micro organisms.

 Result was viewed on the microscope.

 Yeast and mold incubated at 25 0C for 120 hours, bacteria and coliform incubated at 35 0C

for 24 hours and 48 hours respectively.

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3.1.8 Sanitation in The Establishments

A comprehensive cleaning and sanitation program is necessary to prevent contamination

in a food producing factory. Sanitation maintains or restores a state of cleanliness and promotes

hygiene.

Micro laboratory unit controls the sanitation Procedures in the factory, but before

sanitation is conducted in 7up bottling company Ilorin plant, the following terminologies are

considered:

 Sanitation: This is a means of reducing microbes to the minimum level.

 Sterilization: This is the total removal of microbes.

 Sanitizers: These are the chemicals used in reducing microbes to the lowest level.

 Disinfectants: are the agents that kills the microbes effectively.

Sanitation in 7up bottling company is coded as CIP (clean in place). It is divided into

two major Procedures:

3 (three) steps sanitation

i. Rinsing with treated water.

ii. Clean with hot water at 850C.

iii. Rinse again with treated water.

NOTE: The 3 steps are carried out on every Monday morning before operation.

5 (five) steps sanitation

i. Rinsing with treated water.

ii. Clean with hot water at 850C.

iii. Rinse again with treated water.

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 iv. Sanitize for 20 minutes (chemicals used for sanitizing are phosphoric and Tri-sodium

phosphate (TSP) ).

v. Ascertaining zero presence of sanitizers using indicators (thymolpthalein and methyl

propyl).

NOTE: The five steps are performed on every other working days.

3.1.8.1 Factors to Consider While Taking Sanitation in Microbiology

i. Surface area must be clean.

ii. Concentration of chemicals must be in their right proportions.

iii. Contact time.

iv. pH of solution.

3.1.8.2 Common Micro Organisms Found In Bottling Company

The following are the microorganisms found in a bottling company:

Molds.

i. Aspergillus sp ( Aspegillus niger)

ii. Fusarium

iii. Rhysopus

Bacteria

i. Lacto bacillus

ii. Gluconobacter

iii. Leuconostoc

Coliform

i. Esherischia coli

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NOTE: molds can survive in a bottle containing beverages but cannot grow due to lack of

oxygen.

3.1.8.3 Sterilization in the Microbiology Laboratory

Microbial equipment for carrying out analysis must be sterilized regularly after each

analysis is carried out. This is done to obtain an effective result.

An autoclave is a device used for sterilizing equipment used for analysis in the aim of killing

microbes attached to it. The high temperature generated when the autoclave is being used limit

any survival chances of microbes.

Aluminium foils are used in wrapping micro lab equipment after sterilization and then

placed in the oven for an hour at 700C.

Every surfaces in the micro laboratory is disinfected with 70% ethanol before any analysis is

carried out for the day.

3.2 The Chemical Laboratory

This laboratory is where calibrations, tests and analysis are carried out to monitor the

production processes. In the laboratory, the quality control manager, supritendent, inspectors and

interns work closely to ensure the product conformance to standard and quality.

The following are the analysis carried out in the chemical laboratory:

3.2.1 Brix Determination of a Carbonated Drink or Syrup

Brix is defined as the amount of dissolved solutes in a solution. In the preparation of

carbonated drinks (beverages), it is essential to calibrate the amount of sugar dissolved in it.

Determination of the brix can be done using a refractometer or densitometer. When using a

refractometer, few drops of the solution to be analyzed is placed on the refractometer lens and

32
then the reading is taken. On the hand, when using densitometer the solution (finished beverage

or syrup) to be analyzed is injected into the densitometer using a syringe and the reading is taken.

The principle behind refractometer is the refractive index while the principle behind

densitometer is the Archimedes and oscillating u-tube. The densitometer is more accurate than

the refractometer.

Determination of Brix Using a Densitometer

i. Collect the sample of the beverage to be analyzed.

ii. De gas the beverage sample.

iii. Calibrate the densitometer using distilled water.

iv. The sample is then injected into the densitometer using a syringe.

v. The reading is then taken.

Plate 5: The densitometer

3.2.2 Methylene Blue Test

Common microorganisms found in bottles after consumption of the beverages is mold.

The methylene blue test is used to check for any presence of molds in the bottles coming out of

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the washer. The test is done is done to ensure effective working/maintenance of the bottle

washing machine.

Procedures

i. The methylene blue test is carried out manually in the chemical laboratory.

ii. Several bottles are chosen randomly as samples from washer after washing.

iii. Each washed bottle is then flushed with the methylene blue reagent.

iv. The bottles are then rinsed thoroughly with water.

v. The methylene blue reagent stains any presence of mold in the bottle making it visible

to the eyes.

Microorganisms are microscopic organisms not visible to the naked eye e,g molds, but

the methylene blue reagent stains those molds present in the bottles giving a clear conclusion of

presence of mold without using the microscope.

3.2.3 Titrate-Able Acidity

The titrate-able acidity of a solution is an approximation of the solutions total acidity. It is

measured by reacting the acids present with a base such as sodium hydroxide (NaOH) to a

chosen end-point, close neutrality, as indicator by an acid sensitive colour indicator or pH meter.

Equipment: pH meter, retort stand, burette, measuring cylinder (100ml), beaker (250ml),

magnetic stirrer.

Reagent: 0.1N NaOH, TPC if it is pepsi (tri-potassium citrate)

Procedures

i. 100ml of the sample is measured into a beaker.

ii. The beaker is placed on magnetic stirrer and a pH electrode is inserted.

iii. The beverage is then titrated against 0.1N NaOH till the pH meter reads 8.75.

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 iv. The amount of 0.1N NaOH consumed is used in the calculation of the titrate-able

acidity of the sample using this formula.

Calculation of the titrate-able acidity.

T.A= Vol. of NaOH consumed × corrective factor of NaOH

3.2.4 Caustic Strength Analysis

The glass bottles used in packaging the beverages are recycled (washed/treated to be

useful again). These bottles undergoes a thorough washing in the washing machine (washer).

Caustic soda (sodium hydroxide) is used to wash the company’s glass bottles in the washer. The

strength or concentration of the caustic soda in the washer determines how effective the washing

is (how clean the bottles are). The concentration of the caustic soda is therefore monitored

properly to prevent under washing of bottles, leading to the analysis done to ascertain the caustic

soda strength.

Apparatus/Reagent: Retort stand, burette, measuring cylinder (10ml), beaker (250ml), barium

chloride, 10% NaoH, phenolphthalein, distilled water.

Procedures

i. Samples of caustic soda solution are collected from the washer.

ii. 10ml of the sample is measured into a beaker using a measuring cylinder.

iii. 10ml of distilled water is measured into the same beaker.

iv. 5ml of bacl2 is measured into the beaker.

v. 3 drops of phenolphthalein is added into the mixture in the beaker as indicator.

vi. The mixture is titrated against 2.5N H2SO4 until a pink colour is attained.

vii. Then the reading is taken.

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NOTE: the washer has three compartment which are pre soak, soak I, soak II. The caustic

strength is done for each compartment at the same time.

When the concentration of caustic soda is low, there is a calculation to determine the

amount of caustic bags that was previously charged into the washer before the test was done and

how many bags will be discharge into the washer to raise the strength.

Standard – Actual × Tank capacity

Caustic bag (25kg) × 100%

3.2.5 Caustic Carry over Analysis

After complete washing of bottles is concluded they are passed through another

compartment of the washer where they are rinsed. The bottles are rinsed with chemicals called

rinsing agents (Divo Ai and Divo lee). Inadequate discharge of these rinsing agents into the

washing machine leaves the bottles not properly rinsed thereby causing residues of caustic soda

in the bottles.

Caustic carry over analysis is hereby carried on the 32 bottles coming out of the washer

before the commencement of production. Phenolphthalein is a reagent used to ascertain presence

or absence of caustic soda in the bottles. Bottles with residues of caustic soda turns pink on

addition of phenolphthalein.

All bottles tested are then returned back to the washer to be rewashed. Rinsing agents are

then properly charged into the washer if there is presence of caustic soda in the bottle when

analysis are carried out hourly.

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3.3 Production Lines

This is where the bottling process takes place. 7up bottling company Ilorin plant has two

production lines. Bottling can be described as an orderly sequence of steps in which beverages is

mechanically introduced into properly washed bottles. 7up Ilorin plant produces beverages in

returnable glass bottles (RGB) and the following is the orderly sequence in production conducted

in two production lines.

Depalletizing

There are 24 bottles in a case, and then 48 cases in a pallet. Pallets are flat wooden materials that

carries the cases of bottles having the soft drinks. The forklifts convey the empty bottles loaded

on the pallet to the conveyor train. The removal of cases from the pallet is called depalletizing.

Sorters

These are the workers responsible for removing abused bottle (chipped neck, foreign bottles,

faded logo on the bottle) from the conveyor train.

Uncasing

Bottles on the conveyor train passed fit by sorters passes through the uncasing machine, which

lift the bottles out from their cases. The uncasing machine removes 96 bottles at a go (4 cases).

Bottle Wetting

The sorted bottles are sprinkled with water to reduce adhesion of dirts before the bottles finally

goes into washer through the water-in-feed.

Bottle Washer

Bottle washing is done using the automated krones washer. The aim is to get rid of dirts in and

outside the bottles to make them fit for beverage bottling. Caustic soda and acu-booster are the

37
main elements in washing the bottles. It takes 18 minutes for the bottles to get washed with each

compartments (pre soak, soak I, soak II) taking six minutes in washing the bottles.

Empty Sight Seeing

The washed bottles are moved on the conveyor train to the empty sighting post where trained

inspectors inspect each bottle with the aid of an illuminating light. They removed bottles that are

not properly washed and those with foreign materials in them.

Electronic Bottle Inspector (EBI)

It is an electro mechanical machine that uses sensitive cameras to scan bottles for any presence

of foreign bodies. The EBI detects foreign objects, chips, cracks and other defects in the glass

returnable bottles. It rejects unfits bottles for production sending it back to the empty sighters.

Filling (Filler)

The filling of the beverages takes place in the filler. The beverages are prepared in the machine

called mojonnier. The mojonnier is made up of syrup reservoirs where syrup (undiluted

beverages) is stored and water reservoir where water is stored. The mixture ratio is 1:5 or 1:4 in

respect to syrup and water. Regulated volume of CO2 were injected into the beverages before

each bottle attached to the filling organ is filled with carbonated beverage. Effective filling (no

bottle burst) is achieved when the air displacement used in pressurizing the bottle is at

equilibrium with the strength of that bottle. Bottle burst occurs when the bottles are too weak to

handle the pressure inserted into it.

Crowning

The filled bottles passes from the filler into the crowner, which corks the bottles to prevent

contamination and loss of gas from the beverages. The crowner corks 15 bottles at a time.

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Coding

Each corked bottle moves along the conveyor train to the front of the coding machine which

electrically stamps the date of production, batch number and expiring date on it. The coder uses

ink jet technology to stamp the date codes.

Full Sight Seeing

Corked and coded bottles passes unto the full inspection area where trained inspector inspect the

bottle with the aid of an illuminating light .They are tasked on removing under or over filled

bottles, not properly corked bottles, contaminated bottles and chipped necks.

Bottle Caser (Casing)

Inspected and confirmed bottles moves to the casing machine, which lifts corked beverages at a

time into the plastic cases. The casing machine also lifts 96 bottles into their cases as well.

Palletizing

The cased bottles ready to be delivered at customers demands are arranged on pallets and carried

by forklifts to the conveying vehicles. Some of the finished beverages arranged on the pallets are

also stored in the warehouses

3.4 Water Treatment Plant

Water makes over 80% of soft drinks by volume. Water plays a very important role in the

taste and final quality of the beverage. Different measures or steps must be taken to ensure that

water used in soft drink manufacture must be free from contamination. A carbonated soft drink

contains about 87 to 92% of water showing the vital roles of water in appearance, physical,

chemical, micrological and taste of beverages. The water source before it is treated in the factory

is referred to as “raw water”.

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At 7up bottling company Ilorin, the source of water used for production is borehole. The

treatment system used is conventional lime system (CLTS); the system uses chemicals such as

chlorine, lime and ferrous sulphate in the treatment of water which aims at achieving a higher

purification degree that is free from microbial contaminants and others impurities.

The following are the analysis carried out in the ware treatment plant:

3.4.1 Softening of Water

Hard water can cause scale accumulation on water heating elements, pipes and tanks. It

can cause problems with the use of soaps and detergent department. Softening is undertaken as

part of the water treatment processes carried out to remove calcium and magnesium salts

(carbonates and bicarbonates) responsible for water hardness.

Sodium chloride (Nacl) was used in the water softener to regenerate the resin bed.

Sodium chloride eliminates the magnesium and calcium ions by binding its chlorine atoms with

them to produce magnesium chloride (Mgcl) and calcium chloride (Cacl) respectively.

Softening very hard water can lead to a high concentrations of sodium in water giving a

possible salty taste which is unlikely a health concern. Lime removes the component adding to

hardness of water as well.

3.4.2 Water Alkalinity Test

Alkalinity is the sum of the concentrations of carbonates, bicarbonates and hydroxides in a

given water sample. Analysis on water sample is done through titration. Raw and treated water

are taken as samples. Alkalinity of water used in beverages production should be at the range of

25-50PPM.

The effects of high or low alkalinity of water on the beverages are:

40
 i. Affects the titrate-able acidity (T.A) of the beverages (high alkalinity decrease the

T.A while low alkalinity increases it).

ii. High alkalinity imparts a bland taste to the beverage.

Apparatus/Materials and Reagents: 100ml measuring cylinder, 250ml beaker, burette, funnel,

retort stand, water sample, methyl purple, 0.02N H2SO4.

Procedures

i. 100ml of water sample is measured into a beaker.

ii. 3 drops of sodium thiosulfate is added to remove any presence of chlorine.

iii. 3 drops of phenolphthalein is added to give colour change to pink.

iv. Sample solution is titrated against 0.02M H2SO4 until colour changes from pink to

colourless. Reading is taken as P

v. 3 drops of methyl purple indicator turns the sample to green.

vi. Titration continues without refilling 0.02M H2SO4 until colour changes from green to

purple. Reading is taken as M.

Calculation of alkalinity

A=2P-M Where A= alkalinity

P= phenolphthalein

M= methyl purple

3.4.3 Test for Hardness of Water

Hardness refers to the total concentration of calcium and magnesium ions expressed as

calcium and magnesium carbonates. Effects of hardness on water are:

i. Hardness of water causes high levels of scaling in the washer, rinsers, boilers etc.

41
 ii. Hardness in water used for carbonated soft drinks will affect the titrate-able acidity of

the beverage (titrate-able acid is the amount of acid present in the beverage by

titration).

Apparatus/Materials and Reagents: 100ml measuring cylinder, 250ml beaker, 50ml burette,

funnel, retort stand, 5ml pipette, water sample, hardness buffer, Black T solution, 0.01N EDTA.

Procedures

i. 100ml of water sample is measured into a beaker.

ii. 1ml of hardness buffer is added.

iii. 3 drops of erichrome black T solution was added.

iv. The solution was then titrated against 0.01N EDTA until colour changes from purple

to deep green.

v. Reading is taken.

3.4.4 Test For Free Chlorine

Apparatus/Materials and Reagents: Sealable vial, DPD (N-N-Diethyl, P-Phenolene diamine)

NO. 1, DPD comparator.

Procedures

i. Water is taken from the sampling point into the sealable vial.

ii. DPD NO. 1 tablet is dropped into the vial and sealed.

iii. The tablet is allowed to stand in water for about 30 seconds.

iv. The sealed vial is turned over repeatedly for about 30 seconds.

v. The pink colouration is compared with the colour wheel of the DPD comparator to

determine value in ppm. The target is 6-8 ppm.

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 Chlorine is a disinfecting agent. It helps in coagulation and sedimentation of

treating water. Super chlorination is the excess addition of chlorine to water because of redox

reaction. Excess chlorine react with sodium, magnesium and calcium bicarbonate. The remaining

is used for disinfectation, justifying the excess charging of chlorine.

3.5 Traceability Section

Products to be delivered according to customer’s demands are loaded in the plant and

transported by the delivering trucks to various destinations. There are always in flow (in coming)

and out flow (out going) of products in the plant every day, the plant receives products produced

from other plants across the country (products not produced in the Ilorin plant e.g aquafina table

water, PETS (plastic soft drinks) etc).

Quality control is tasked in taking down the batch number, total number of products,

truck’s information and the driver’s name of incoming and outgoing trucks. One of the aim of

this process is to account and present records when issues regarding contamination or inadequate

supply of products to customers arises.

Raw materials utilized in the production are also well inspected and recorded with the

delivery truck’s detail not left out. Quality control department ascertain zero contamination of

product guarantee to customers whereby improving the company’s image and propelling it to

greater heights.

7up bottling company Ilorin plant only produces beverages packaged in returnable glass

bottles (RGB). They receive products from other bigger plants in the form of PETS (plastic

bottles) to satisfy their customer’s demands.

Below is the coding information inscribed on both RGBs and PETs by the coding machine

giving detail of the batch number (expiring date, production date and time , production line etc.)

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BB0321IL05X

170620B20:24

BB stands for best before

03 stands for the expiring month

21 stands for expiring year

IL stands for Ilorin plant (product producing plant)

05 stands for the batch number

X stands for the carbo QC (machine used in checking the amount of CO2 in the beverage

17 stands for the production date

06 stands for the production month

20 stands for the production year

B stands for the product producing line

20 stands for the hour of production

24 stands for the minutes of production

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 CHAPTER FOUR

4.0 Summary, Challenges Encountered, Recommendations and Conclusions.

4.1 Summary and Conclusions

7up bottling company, one of the largest manufacturer of soft drinks across the country

and globally produces diverse flavours of carbonated beverages which are mirinda, mountain

dew, pepsi, teem and 7up itself. The company operate in African countries such as Nigeria,

Ghana, Tanzania and Kenya.

I was privileged to carry out my student industrial work experience scheme (SIWES)

program at one of the nine branches of the Nigeria subsidiary, Ilorin branch to be precise.

My working experience in 7up bottling company Ilorin plant exposed me to practical based

knowledge and experience in the production of carbonated soft drinks, proper handling and

maintenance of sophisticated machineries, diverse analysis carried out in microbial, chemical

and water treatment plant.

I was assigned to the sub units under quality control such as micro laboratory, chemical

laboratory, production lines, water treatment plant and traceability of products. Microbial

laboratory carry out analysis in the aim of eliminating microbes activities and survival in

products and the factory.

The water treatment plant is where the main production of carbonated drinks begins. It is

where water used during production is treated to ensure a standard quality. The chemical

laboratory conduct test to monitor all processes going on in the production of products on

production lines, syrup room and incoming products. Production lines exhibit the bottling

processes from stage to stage, in terms of effective washing, uncontaminated filling and

crowning to the final stage of packaging of products to the final customers.

45
 The skills obtained from this industrial attachment is a fulfillment of the aims and

objectives of SIWES program. Practical experience and knowledge gained during this program

will no doubt be of great advantage after graduation in school.

4.2 Challenges Encountered

Punctuality as they say is the sole of business. I have to wake up very early consistently

every working days to meet up with the resumption deadline (7:30am) and then close from work

at 5:00pm.

The cost of transportation to the place of the establishment had a great negative effect on

daily expenses for transporting to the factory. 7up company frowns at hooky attitude towards

daily task in the plant and high cost of transportation played a challenge in this situation.

4.3 Recommendation

For the smooth, continual and effective functioning of the students industrial work

experience scheme, here are the few suggestions that can be considered for implementation:

i. Provision of more current and accessible data base for available I.T placement

companies which caused a major hassle towards some students.

ii. Industrial training fund (ITF) should consider early disbursement of students

allowances for participating in the SIWES program to eradicate the issue of cost of

transportation which played a major program during my 6 months of training.

46