CHAPTER 1

INTRODUCTION
1.1 Industrial Training
Industrial training provided real world experiences to explore the relevant knowledge
and skills which are required to enter into a particular career field and preprofessional work experience with specific assignments and responsibilities. An
Industrial Training is very important to attain good working experience in an
organization by applying theoretical knowledge into practical situations. Because
theoretical knowledge along is not enough to do a professional career in future
industrial world.
Internship is an excellent way of building communication skills and decision making
abilities in a working environment and it is more helpful to develop work ethics of
the organizational culture and behavior.

1.2 Objectives of the training

1.2.1 Main objectives
1. To gain knowledge about the way of applying theoretical knowledge into
practical situations.
2. To experience and understand real life situations in industrial organizations
and related environments.
1.2.1 Specific objectives

To improve communication skills and decision making abilities in a working

environment.

To understand about the formal, informal relationships in an industrial

organization and ethics and behavior of the organizational culture.

To gain knowledge on pre-professional work experience with specific

assignments and responsibilities.

To gain knowledge about way of promoting favorable human resources in

teamwork to achieved targets.

1.3 Organization of the report

The information about industrial training placement of Country style food (PVT) Ltd
was collected before entering training. And the information about product processes
was studied during the training period. Working with managers, supervisors of the
factory and labours were gave great experience. Training was done according to the
time table under supervision.
The introduction and objectives of industrial training is included in the chapter one
according to my point of view. The second chapter contained overall idea of the
company is given with the description, as the business process and organizational
hierarchy. Describe about the training experience and training activities are included
in the third chapter. Chapter four explains limitations, issues experienced while
working in the organization and the suggestions that can be offered in the point of
view of the student. And conclusion of whole program technologies, learning and
experience include throughout the industrial training period with the flow diagrams.

CHAPTER 2
COMPANY BACKGROUND
2.1 Overview of Company
Country style food (PVT) Ltd is the pioneer in fruit based ready to serve beverage
industry in Sri Lanka which is located in Kadawatha. It started in 1981 to
manufacture and market a range of food products under the brand name SMAK to
meet the needs of the Sri Lankan and Export Markets. With the growing demand for
its products in international markets, currently the products are exported to Australia,
New Zealand, Italy, United Kingdom, Germany, Canada and Middle East since 1990.
The SMAK products are manufactured under strict hygienic conditions and quality
control in order to maintain its highest quality. The whole fruit based beverage range
of SMAK is SLS certified for its quality. Country Style Foods (Pvt) Ltd. was
awarded with three prestigious International standardization certificates; ISO 22000,
HACCP (Hazard Analysis and Critical Control Points) and GMP (Good
Manufacturing Practices) by the Sri Lanka Standards Institution (SLSI) in 2013.
However it is the zero waste company pioneers in Sri Lanka. SMAK is enjoying the
market leadership for last two decades in the local fruit base beverage market
segment. Today, SMAK has become one of the market leaders in the fruit drinks
industry in Sri Lanka living up to its slogan Full of Natural Goodness.
2.1.1 Vision of the Company
To be among the corporate leaders in the natural based food and beverage industry,
and cater to a wide range of markets with a wide range of products.
2.1.2. Mission of the Company
To achieve total productivity in the natural based food and beverage industry,
manufacturing under strict hygienic conditions, being mindful of health and wealth
of the entire society.

2.2 Nature of business

Country Style Foods (Pvt) Ltd manufactures fruit drinks, herbal drinks and milk
added drinks from the specially selected ripe fruits, best quality herbs and fresh milk
respectively. They packed their products in 190ml glass bottles, PET bottles and tetra
pack. Apart from that Country Style Foods (Pvt) Ltd market trading items with the
brand name of SMAK such as drinking water, Choco bubbles, wafer sticks and
SMAK bites (Snaks) under the strict quality supervision.
2.2.1 Fruit Drinks

Mixed Fruit Drink

Mixed Fruit with Lime Drink

Wood apple Drink

Lime Drink

Pineapple Drink

Mango Drink

Papaya Mandarin Drink

Passion Drink

Anoda Drink

Amberella Drink

2.2.2 Herbal Drinks

Ginger Drink

Eramusu Drink

Tamarind Drink

2.2.3 Milk added Drinks

Chocolate Drink

Sherbet Drink

Coffee Drink

Mango Blast Drink

2.3 Organizational Structure

Figure 2.1: Flow chart of Organizational Structure

CHAPTER 3
LEARNING OUTCOMES
3.1 Working Experience
These areas was covered successfully within three months of industrial training
period,

Main purchasing stores

Fruit stores
Fruits washing section
Glass bottles washing section
Glass bottle checking section
Fruit cutting & pulp production
190ml glass bottle retort section and labeling section (for milk drinks)
190ml glass bottle labeling section (for fruit drinks)
Fruit nectar filling section
Fruit nectar labeling section
Tetra pack division
Laboratory
Quality assurance department

I worked at each of the above sections as a labour to a gain the experience and
observed all the process which can apply theoretical knowledge in practical way. The
knowledge of Accounts and Economics was applied in the purchasing division.
However theoretical knowledge of the subjects which learned in the university were
more helpful to understudied the process of the company. The quality of raw
materials and final products were checked and that was wonderful when working in
the industry. Machine repairing, cleaning and machine operating were observed and it
is more important to gain knowledge as a student of specialized in food engineering.
Machine operating, cleaning and the process of production of Tetra pack was a great
experience. Some milk tests, brix test were done and other tests were observed.
Industrial training at Country Style Foods (Pvt) Ltd was very important to gain a
great experience and knowledge about way of applying theoretical knowledge into
6

practical situations and to understand real life situations in industrial organizations

within related environments. This was a great experience with nice people.

3.2 Training Activities

3.2.1 Main purchasing store
Raw materials, spears and other required services are acquired through purchasing
division. Materials which required mainly for the production process such as fruits,
additives, packing materials and milk are considered as the main purchasing items.
Purchasing division is followed company standards and ISO 22000 standard to
purchase goods.
3.2.1.1. Objective of Purchasing
Purchasing good quality raw material from the supplier, provide the good quality raw
material to the production and issuing good quality final product to the consumers.
3.2.1.2 Purchasing Procedure
Purchasing division is touched with stock levels and reorder levels of each material.
It is assisted to purchase materials before exceeding their minimum stock level.
When goods are purchased from new supplier, purchasing division should get the
product specification and quality certificate from supplier. This specification is varied
according to the material.
3.2.1.3 Supplier Evaluation
Supplier evaluation is done by a panel comprising of Managing Director, Quality
Assurance Manager and incase of raw materials in different divisions relevant
divisional managers through whole year.
Evaluation criteria are based on:

Product performance

Quality and Consistency of the product

Price

Delivery time

Supplier feedback

3.2.2. Fruit Stores

Fruit store is responsible for receiving well ripens quality fruits and store the fruits
until it released to the production. Staff members of the fruit store are paid special
attention towards quality management while sorting and storing of the received
fruits. Following procedure is practiced in the fruit storage;

Receiving of fruits

Selection of quality fruits

Weighting

Storing of fruits

Sorting and Washing

Issued production line

Figure 3.1: Flow chart of Fruit Store
Most probably fruits are stored for about three days. This is depended on fruit
ripening speed and production requirement. Before transferring of fruits in to the
production, fruits are cleaned manually by using three tanks.
3.2.3 Fruit Cutting and Pulping Section
3.2.3.1 Cutting Area
In cutting section fruit peel, seed and other contaminant are removed and chopped in
to small pieces by using stainless steel knifes. Sizes of fruit pieces are varied with the
type of fruit.
8

3.2.3.2 Pulping Area

Pulp machines are used to crush the fruit pieces and extract the fruit pulp. Pulp
machine is included rotating stainless steel bar which is fitted to few brushes. Metal
net is installed to cover the bar. Mainly three types of pulp machines are used in pulp
preparation area. These machines are varying according to the sieve size. Usages of
these machines depend on the type of fruit. There are two outlets, one for pulp, and
another for seeds, peels and wastage. Lime juice is extracted using the screw mill
machine.

Figure 3.2: Pulping machine

3.2.3.2.1 Pulp preservation
Prepared fruit pulp can be preserved according to two methods.
1. Boiling for freeze

Weighted fruit pulp is transferred in to the open steam jacketed pan and
cooked, after reaching boil.

Pulp is poured in to the clean can and transferred in to the freezer.

2. Adding preservatives

Weighted fruit pulp is transferred in to the open steam jacketed pan and
cooked, after reaching boiled.

Preservatives and acids are added in to the pulp and poured in to the
clean, sanitized plastic cans.

Cans are weighted and date, batch coded on the can. Filled cans are stored
in ambient temperature ware house.
9

Receiving of
washing fruits

Peeling Cutting

Store in a plastic
crates
Issuing to pulping
section

Pulp from pulp

machine
Issuing to production
area
Figure 3.3: Fruit Cutting and Pulping Section
3.2.3.2.2 Cleaning procedure of pulp machines
Before use pulping machine, used two types of water to clean.

Chlorinated water

Warm water

After use pulping machine, used this tree types of water to clean.

Pure water

Chlorinated water

Warm water

3.2.4 190ml Glass Bottle Washing and Inspection Section

3.2.4.1. Washing Section
Glass bottles are checked before sent the washing to ensure bottles are free from;
Straw
Heavy worms and eggs
10

 Damage bottles
Unclear and different shaped bottles
There are mainly two types of washing
Manual washing
Machinery washing
3.2.4.1.1 Machinery washing
Then 190ml empty glass bottles issued to machine through the conveyer system to
washing. Following methods can observed inside machinery and Bottles labels
removed of automatically brush system.
Hot Water bath
Hot Caustic Soda bath
Spraying hot Caustic Soda mixed water
Spraying warm water
Spraying cold water
Draining

Figure 3.4: Glass bottle washing machine

Washed bottles were checked after washing whether bottles are washed properly,
properly removed debris and any particles of bottles and labels.
11

Every 01 hour checked quality of washed bottles quality using

phenoptheline. Few drops of phenoptheline were put into properly washed
bottles and checked colour of it.

3.2.4.1.2 Manual washing

If bottles contain corrosion and un-removable debrides from the machinery washing
that were sent for the manual washing. Manual washing contained three washing
tanks.
st

1 tank washing with Teepol

nd

tank clean water

rd

3 tank clean water

3.2.4.2 190 ml Inspection Section

Washed bottles again washing by manually used Johnston taps and high pressure
chlorinated water and checking quality of bottles used frozen light and white
background. Then bottles issued to filling area by conveyer belt.

Removed white and dirty bottles, ten issued again bottle washing section.

Bottle Washing

Wa
pr

Figure 3.5: 190ml Glass Bottle Washing and Checking Section

12
3.2.5 Filling Area
3.2.5.1 Filling of 190 ml glass bottle fruit drinks

Fill using filing machine.

When fill bottle immediately sealed by crown caps.
Then passed through steam chamber.
Issued to 190ml labeling section.

Receiving of filled
glass bottle

Quality checking

Labeling of
machine

Checking of
properly
labeling of

Figure 3.6: 190 ml fruit drinks filling

3.2.5.2 Filling of 190 ml glass bottle with milk added drinks

Using filing machine fill.

When fill bottle immediately sealed by crown caps.

After that bottles passed through steam chamber and finally send to
retorting section for pasteurization.

Receiving of
filled milk
glass bottle

Quarantine
period

Labeling

Issued to stores

Figure 3.7: 190 ml milk added drinks filling

13

3.2.5.3 Fruit nectar filling section

Nectar filling section fills drink into different sizes such as 200 ml, 500 ml and 1L.
When receiving the drink from production area its stock in stock tank and then fill
into PET bottle using filling and sealing machine.
Drink
preparation

Cooling

Tunnel

Stock tank

Checking filled
drink bottles

Drink filling

Drying

Place in
crates

Figure 3.8: Fruit nectar drink filling

3.2.5.4 Checking Quality of drink bottles

The quality of drinks bottles were checked after filling fruit and milk added drinks

Checking this qualities

Properly fixed lids

Lids damages

Particle dirty or debris on bottle

After checking reject this bottles.

dirty bottles

half bottles

sample bottles and other bottles

3.2.6 Laboratory
Laboratory is playing important role in the factory by conducting testings and
maintaining natural taste of the drink. Mainly raw material and product testing are
conducted by laboratory. Mainly milk and fruit pulp is tested to check the quality and
the suitability of the material for production.
14

3.2.6.1 Testing in laboratory

Check pH, acidity, sulphur dioxide level and brix value of every batch of drink
prepared. There are three types of pulps;

Fresh pulp
Boiled Pulp
Cold room pulp

Check acidity, pH, sulphur dioxide level, brix value and sensory characters of
above mentioned pulps.

Check the pH, colour, taste, brix, acidity and sulphur dioxide level of final
products.

Organoleptic test, Gerber test, lacto meter reading, curdle test and pH testing
were done when receiving fresh milk.

Check caustic soda concentration of bath in bottle washing machine using

phenolphthalein and check pH by Bench top type pH meter.

Weigh natural identifiable colors and flavors for productions.

3.2.7 Tetra Pack Division

3.2.7.1 Objective: - To heat treat the product sufficiently to eliminate spoilage
micro-organisms and subsequently package the product in a manner that prevents
recontamination.
3.2.7.2 Aseptic processing steps

Process hygienically safe product by using of following machineries:

CIP (Clean in Place) plant

Pasteurizer with Plate Heat Exchanger (PHE)

Aseptic filling machine (form fill seal machine)

3.2.7.2.1 CIP process

Water was used to CIP of machinery between two drinks. The CIP process was done
before start and after finished production using following steps;

15

Water

Caustic soda

Nitric acid

Water

3.2.7.2.2 Process of Pasteurizer

Prior to supply of drink circulate hot water.

Middle of circulation step done back wash.

Aim of pre-rinsing is to remove soils from backwash separate all soil particles
from surface.

After water circulation drink was supply and it heated.

3.2.7.2.3 Process of filling machine

Before starting of filling there are several steps up to filling stage.

Pre heating

Temperature increasing

Tube sealing (Forming of packaging material as tube)

Sterilization

Hydrogen peroxide spraying (Container is sterilized using chemical sterility as HO sufficient for reduction of some target micro-organisms.)

Drying & etc.

3.2.7.2.4 Tetra Bricks Aseptic (T.B.A) package layers

There are seven layers that are shown in below from out to inside;

Outer polyethylene layer

Printed design paper
Paper board
Polyethylene layer
Aluminum foil layer
Low Density Poly Ethylene (L.D.P.E.)

16
Food Raw Material

Incoming Packaging

Continuous
Thermal Processing

Continuous
Sterilization

Aseptic
Continuous

Zone

Aseptically Form Fill

Seal

Shelf Stable
Product
Figure 3.9: Aseptic Processing and Packaging
3.2.8 Waste Water Treatment Plant
3

Factory consumes 90 m of water per day for processing, boiling floor washing,
equipment cleaning and domestic purposes. All the waste water is accumulated in to
the waste water plant trough trench system. Treated water is released in to the natural
water source.
3.2.8.1 Procedure
1. Equalization tank
Effluents from all sources are directed in to the equalization tank to equalize the
water by adjusting pH. Caustic soda and hydrochloric acid are used to adjust the
water pH up to required level. Equalized water is pumped in to the anaerobic tank for
further treatments.
2. Anaerobic tank
Effluent is pumped at a constant flow rate from the equalization tank to anaerobic
tank. BOD and COD reduction is taken place inside this tank. This tank is covered 17

and divided in to several compartments to avoid the short circuiting of the effluent
flow through the tank.
3. Aerobic tank
The over flow from the anaerobic tank is directed to an aerobic tank for further
treatment. Aerators installed inside the tank to provide sufficient aeration for
reducing the BOD and COD.
4. Sand filtration
The over flow from the aerobic tank is directed through a sand filter to remove any
remaining suspended solids. This filter is packed with layer of gravel and sand. A
pump is installed to back wash the filter whenever required. The over flow from the
filter is directed to the treated water tank.
5. Sludge treatment
Waste sludge which is accumulated in the tank was removed and dried. Dried sludge
mix with the compost and use as a fertilizer.

Waste water
from factory

Settlement tank

Filter

Figure 3.10: Waste water treatment process

This waste water treated plant was established and maintained under the National
Environmental Act No 47 in 1980 of Central Environment Authority. There are some

18

parameters to check before discharge the treated water to the inland. Table 3.2.8.1 is
shown that parameters and limitation of that.
Table 3.1 Requirements for discharge treated water
Parameter
Total suspended solids (TSS)
Particle size of the TSS
PH
BOD (Biological Oxygen Demand)
Temperature of discharge
Oil & Grease
Phenolic compounds
COD (Chemical Oxygen Demand)

3.2.9 Cleaning and Sanitation of Factory

3.2.9.1Factory cleaning
3.2.9.1.1 Daily Cleaning

Clean floor, window glasses and door curtains with this washing procedure;

Spray high pressure water

Brush with plastic brush

Apply water and mop or removed water.

Clean fruit cutting area, pulping area, filling area and bottle washing area with
water at 03 times per day and filling document about cleaning.
Clean all machineries and all equipment end of the each working day.

19

3.2.9.1.2 Cleaning of once a week

All machineries, equipment and places clean this washing procedure;

Used normal water
Brush with plastic brush
Spray sanitizer
Wash with high pressure water
Spray chlorinated water

3.2.9.1.3 Cleaning of once a month

Follow pest control procedure and fumigation process

3.2.10 Health and Hygiene practices for workers

Supervisors check workers health conditions every morning.

Any person who is shown illness or any other abnormal source of microbial
contamination, he or she does not involves in food handling.

Remove all jewelry and other objects before entering the factory.

Eating food, chewing gum, drinking beverages or using tobacco is not allowed
within factory.

Not allowed to touch nose, mouth or hair in the working time.

Short and clean nails to be maintained all ways, and not allowed use nail arts or
cutex.

All ways wear factory uniform, hair caps, masks, apron, gloves and boots before
involving in work.

Immersing your feet with and boots in the foot bath (chorine mixed water).

Al ways carry out hand washing with sanitizer as a practice.

20

3.3 Project of Industrial training

Suggestions were gave for fruit washing system, fruit storing house design, convey
system of processing line as the project of industrial training after searching
recommended processing lines of the factory. Motivations of labours positive
thinking were done as the part of project.
Suggestion:

New washing system design

o Knowledge of engineering workshop technology, and food equipment
design fabrication was more helpful to design new washing system
design.

New fruit storing house design

o Knowledge of cereal science and technology and minimal processing
technology was more helpful to design new fruit storing house.

For convey system of processing line

o Repairing and maintaining the convey system in the 190 ml fruit drink
steam tunnel line and 190 ml milk added drink steam tunnel line

21

CHAPTER 4
CONCLUTION AND RECOMMENDATIONS
4.1Conclusion
In the industrial training I upgraded my knowledge about following mentioned
categories which are related to the specialized in food engineering.

Preparation of food raw materials and ingredients

Storage of raw materials and finish products

Food process technology

Resource planning

Food manufacturing process control

Food machinery and plant repairing, cleaning, operating

The company has a well-organized management structure which is a great strength

for the future progress of the company. High technology involve processing plant, so
it help to maintain the quality standard such as HACCP, SLS and ISO 22000. Also
there is high demand to produce value added products. It has a well-managed waste
water treatment plan which is another good management practice of the company.

4.2 Recommendations and Suggestions

There are several limitations in the organization which were observed during
industrial training period. Most of the limitations have very simple solutions and
some may come up with difficulties when executing.

Lack of skillful labor force and lack of positive attitudes labor force

Absence of microbiology and proximate analysis laboratory in the company

Wastage of steam

Concrete floor in the composting tent is damaged and has to repairing time to
time due to low pH in the waste

Suggestions;

Conducting the training programs, workshops and team works to build up the
positive attitudes.

Establishment of microbiology and proximate analysis laboratory.

Establish the system to collect and condense the steam which are releasing as
waste
22

References

National Environment Act No. 47 in 1980.

SLS Standard 1246:2003- Specification for Compost from Municipal

solid waste and Agricultural waste.

SLS Standard for R.T.S. (Ready To Serve drinks) SLS 729.

23