The document discusses the manufacturing process for packaged drinking water. It begins by defining packaged drinking water and outlining acceptable sources and treatments, including filtration, disinfection, and remineralization. It then describes the types of containers used for packaging, including jars, bottles, cups, and glass bottles. The remainder of the document details the typical manufacturing process, which involves collection of raw water, filtration to remove impurities, reverse osmosis to remove dissolved solids, disinfection through methods like ozonization and UV treatment, filling and packaging, and quality testing. Process steps like CIP cleaning and sterilization are also summarized.
The document discusses the manufacturing process for packaged drinking water. It begins by defining packaged drinking water and outlining acceptable sources and treatments, including filtration, disinfection, and remineralization. It then describes the types of containers used for packaging, including jars, bottles, cups, and glass bottles. The remainder of the document details the typical manufacturing process, which involves collection of raw water, filtration to remove impurities, reverse osmosis to remove dissolved solids, disinfection through methods like ozonization and UV treatment, filling and packaging, and quality testing. Process steps like CIP cleaning and sterilization are also summarized.
The document discusses the manufacturing process for packaged drinking water. It begins by defining packaged drinking water and outlining acceptable sources and treatments, including filtration, disinfection, and remineralization. It then describes the types of containers used for packaging, including jars, bottles, cups, and glass bottles. The remainder of the document details the typical manufacturing process, which involves collection of raw water, filtration to remove impurities, reverse osmosis to remove dissolved solids, disinfection through methods like ozonization and UV treatment, filling and packaging, and quality testing. Process steps like CIP cleaning and sterilization are also summarized.
The document discusses the manufacturing process for packaged drinking water. It begins by defining packaged drinking water and outlining acceptable sources and treatments, including filtration, disinfection, and remineralization. It then describes the types of containers used for packaging, including jars, bottles, cups, and glass bottles. The remainder of the document details the typical manufacturing process, which involves collection of raw water, filtration to remove impurities, reverse osmosis to remove dissolved solids, disinfection through methods like ozonization and UV treatment, filling and packaging, and quality testing. Process steps like CIP cleaning and sterilization are also summarized.
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Packaged drinking water means water derived from any source of potable water
which may be subjected to treatments such as, decantation, filtration,
combination of filtrations, aeration, filtration with membrane filter, depth filter, cartridge filter, activated carbon filtration, demineralization, remineralization, reverse osmosis or any other method to meet the prescribed standard and packed. It may be disinfected to a level that will not lead to harmful contamination in the drinking water.
The potable water used for production of packaged drinking water is water derived from any source (such as ground water like Borewell, public drinking water systems such as Municipality Supply or Supplies from other sources) received on regular basis. Supplies of such water through pipelines or tankers would be acceptable provided the source remains the same.
As indicated above, the packaged drinking water can be produced by way
remineralization. This process involves addition of ingredients. In case remineralization is carried out by any manufacturer, ingredients used for the purpose shall be of food grade quality conforming to the requirements of the PFA Act, 1954 and the Rules framed there under.
Processed water may be disinfected by means of chemical agents and/or
physical methods to control the micro-organisms to a level that does not compromise food safety or suitability for consumption. Various means adopted for disinfection include ozonization, ultraviolet treatment, silver ionization, etc. and/or combination thereof.
The processed water shall be filled in sealed containers of various
types/sizes/shapes made from the plastic materials permitted under ISS, suitable for direct consumption without further treatment. The filling & packing of the processed water shall be in containers which are tamperproof, tight and impervious. The containers with features like Cool Jugs, Jugs with built-in taps, Jars with threaded (reusable) caps etc. Which are not tamperproof and leak proof shall not be permitted.
There are many terminologies presently adopted by the industry & consumer for describing the processed water as packed in different packaging. For the purpose of uniformity in describing the various types of containers, the following definitions are suggested: TYPE OF DESCRIPTION CONTAINER
Jars Reusable plastic containers
Bottles One time use plastic containers, to be crushed after use
Cup One time use plastic container in the shape of cup or
glass/tumbler, to be crushed after use.
Glass Bottle Containers made of glass material (to be used after
sterilization)
MANUFACTURING PROCESS & CONTROLS
IS 14543 does not prescribe any specific process for manufacturing of the processed water. However, the definitions given under the standard provide information regarding steps that may be involved in the acual practice. In fact, the manufacturing process of the processed water is essentially a purification process of raw water through different treatments, for conformance to the requirements of IS 14543.
There are various established processes commercially available and being
practicesed by different manufacturers. The sector is supported by a core “supplier” group which supplies technologies as well as readymade plant machinery for water treatment. The manufacturing of the processed water mainly involves the following process;
a) Collection of Raw Water
b) Removal of suspended & colloidal impurities by filtration such as sand,
carbon, micron filter etc
c) Removal of dissolved solids by Reverse Osmosis, Ion Exchange etc
d) Disinfection by different means such as ozonization, U.V., Silver Ionization
etc
e) Filling & Packing
A TYPICAL MANUFACTURING PROCESS
Following treatment steps are involved in the manufacturing process:
Raw Water _Raw Water Storage Tank_ Raw Water Feed Pump_ dosing system 1 & 2_ Pressure Sand Filter_ Activated Carbon Filter _ Micron Cartridge Filter High Pressure Pump_ Reverse Osmosis_ Ozone generator and re circulation _ Finished Water Storage _ U.V System _ Filling and Packing _ Visual Examination _Storage for testing _ Forwarding.
1) DOSING SYSTEM 1 & 2
The water is drawn from Bore Well line. The water is then collected to storage tank. It then goes to dosing system through raw water feed pump. In the dosing system, antiscalent is used for the softening of the water.
2) PRESSURE SAND FILTER
From dosing system water goes to pressure sand filter, where the impurities of raw water are removed.
3) ACTIVATED CARBON FILTER
From pressure sand filter water goes to activated carbon filter where organic impurities are removed.
4) MICRON CARTRIDGE FILTER (MCF)
Water is then passed through micron filter. This filter removes the micron particles from the water.
5) DEMINERALISATION BY REVERSE OSMOSIS SYSTEM (R.O.)
Water from MCF goes to R.O. System through High Pressure Pump. R.O. removes 90-95% of dissolved solids. The finished water is passed into Storage Tank.
6) OZONE GENERATOR WITH RE-CIRCUALTION
Finished water from R.O. system is stored in S.S made storage tank. The tank is provided with the Man Hole so that the tank can be cleaned. This tank is used as ozone circulation tank. The ozone is passed to this tank for disinfections.
7) U.V. SYSTEM
Water from S.S. tank is passed through MCF to U.V. disinfection system, where the bacteria are inactivated. 8) FILLING AND PACKING
Water is then filled in cleaned and rinsed containers.
9) VISUAL EXAMINATION
Containers are visually inspected for any leakage and suspended matter against illuminated screen.
10) TESTING
The raw water is tested two times in a month. Finished water is tested as per scheme of testing prescribed by BIS.
A TYPICAL CIP PROCESS
Sanitization and Sterilization is done daily before resuming
production
SANITIZATION:
1. Take sufficient quantity of soft water in CIP tank.
2. Add required quantity sod. Hypo Chloride solution in CIP tank containing soft water. 3. Now start CIP pump. 4. Let the chlorine solution go into both tank through CIP line. 5. Solution will go from top through CIP volume which distributes solution in entire tank. 6. Check the available chlorine. 7. Chlorine (free) should be 10-15 PPM. 8. If %age of chlorine is less then add more hypo chloride solution till required strength of chlorine is achieved in water. 9. Start feed pump and pass solution through sand filter, all micron filters, Ozone contact column etc. and then filling machine. 10. Hold this solution at least for 30 minutes and can be extended to overnight. 11. Drain out the solution from the whole system. 12. Take fresh water and remove the chlorine of storage tank. 13. After removing chlorine traces from storage tank, fill with fresh bore well water. 14. Remove the chlorine traces from each points upto filling machine by flushing with fresh water. 15. To check the residual chlorine use chlorotex reagent.
STERLIZATION:
1. Steam is generated by boiler.
2. Soft water which is produced by softner is used in boiler to generate steam. 3. This, steam is supplied in both storage tank, break tank, bore well line and pipe lines upto filling machine. 4. Continue the steam supply in tanks till attains required temp. (un- bearable when touched). 5. Continue the steam supply to filling machine till steam comes out from all rinsing and filling nozzle of machine. 6. Stop steam supply and disconnect the hose pipe. 7. Rinse the whole system with fresh water.
TYPICAL CLEANING AND WASHING SYSTEM OF RE
USABLE JARS
The process of cleaning and washing of re-usable jars is as
follows:-
1. The jars are checked for crack, contamination and foul odors. The jars not fit for re-use are rejected.
2. The Jars are capped with cap and washing of outside surface is done thoroughly with Detergent solution and normal water. 3. After outer cleaning, jars are internally washed with food grade detergents (like iodine based) and then thoroughly washed till free from the last traces of detergent. 4. Then clean jars are sent to filling station. 5. At filling station, jars are rinsed internally with product water.
