PRODUCTION AND QUALITY MANAGEMENT

VISIT TO: BISLERI FACTORY(ANDHERI)

GROUP MEMBERS

ROSHAN CHELLANI 70

VEENA GOREGAONKAR 76

DIMPLE PANCHAL 91

RANJITHA KUTTAN 95

DEEPA CHANDIRAMANI 136

SNEHA GHOSH 137

JYOTI SINGH 138

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SR. NO TOPIC PAGE NO.

1 ABOUT BISLERI 3

2 PACKAGED DRINKING WATER INDUSTRY 4

3 PRODUCT RANGE 5

4 MATERIAL 6

5 SUPPLIER 6

6 QUALITY CONTROL AND QUALITY STANDARDS

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7 QUALITY POLICY 9

8 WATER PURIFICATION PROCESS 9

9 PRODUCTION PROCESS 10

10 MACHINES AND EQUIPMENTS 12

11 WORKERS 13

12 INSPECTION 13

13 DISTRIBUTION CHANNEL OF BISLERI 13

14 FUTURE OBJECTIVES 14

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ABOUT BISLERI:

Mineral Water under the name 'Bisleri' was first launched in Mumbai in glass bottles in two varieties - bubbly & still in 1965 by Bisleri Ltd., a company of Italian origin. This company was s t a r t e d b y S i g n o r F e l i c e B i s l e r i w h o f i r s t b r o u g h t t h e i d e a o f s e l l i n g b o t t l e d w a t e r i n I n d i a . Parle bought over Bisleri (India) Ltd. In 1969 & started bottling Mineral water in glass bottles under the brand name 'Bisleri'. Later Parle switched over to PVC non-returnable bottles & finally a d v a n c e d   t o   P E T   c o n t a i n e r s .   . Since 1995 Mr. Ramesh J. Chauhan has started expanding Bisleri operations substantially and the turnover has multiplied more than 20 times over a period of 10 years and the average growth rate has been around 40% over this period. Presently Bisleri has 8 plants & 11 franchisees allover India. Their presence covers the entire span of India. The company is planning to set up four more plants. Bisleri commands a 65% market share of the organized market. Overwhelming  p o p u l a r i t y o f ' B i s l e r i ' & t h e f a c t t h a t i t h a s p i o n e e r e d b o t t l e d w a t e r i n I n d i a , h a s m a d e i t synonymous to Mineral water and has made it a household name. When you think of bottled water, you think Bisleri.

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PACKAGED DRINKING WATER INDUSTRY

Water everywhere, not a CLEAN drop to drink! Who would have thought that there will be a day when sanitation of available water would be more of a concern than availability of water itself? Hygiene is of great concern to everyone today, and this is evident with the surging rise in the consumption of packaged/bottled water. India has 16 percent of the world's population, 2.5 percent of the land mass and 4 percent of the world's water resources. These limited water resources are depleting rapidly while the demands on them are increasing. Drinking water supplies in many parts of India are intermittent. Transmission and distribution networks for  water are generally old and badly maintained, and as a result, are deteriorating. India is one of the biggest and most attractive water markets in the world. The boom time for Indian bottled water industry is to continue- more so because the economics are sound, the bottom line is attractive and the Indian government hasn’t planned well for utilization of the nation's water resources. Corporate control over water and water distribution in India is growing rapidly: the packaged water business is worth $250 million. Around 1,200 bottling plants and 100 brands of packaged water across the country are battling over the market. Most multi-national (MNC) companies view India as the next big market with a lot of potential and growth possibility. Several MNCs are waiting in the wings to expand a $ 287 billion global water market into India. There is a huge market being exploited by the packaged water industry, and it's growing at 40% per annum. With over a thousand bottled water producers, the Indian bottled water industry is  big by even international standards. There are more than 200 brands, nearly 80 per cent of which are local. Most of the small-scale producers sell non-branded products and serve small markets. From being confined to the uppermost echelons of society, packaged water has now become a common place commodity and almost a necessity in metros. After witnessing historic growth in recent years, it has become a Rs 3,000-crore industry, one that is slated to only post healthy growth rates to become a Rs 10,000-crore business in just three years, The bulk water industry, or water in 12-, 20- and 25-litre packages, has also witnessed a parallel growth of Rs 700-1,000crore. Basically, the market can be divided into two segments — the retail consumer market where the pack

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sizes are 500 ml, one litre, 1.2/1.5/2-litre and five-liter, and the household and institutional market, where the pack size is usually are 20- or 25-litre.The Bureau of Indian Standards (BIS) is the governing authority on all quality introductions regulations related to natural mineral water as well as packaged drinking water.

PRODUCT RANGE

 Bisleri is packaged in:

 Non-Returnable Packs--

•250ml cups

•250ml bottles

•500ml

•1L

•1.5L

•2L

Returnable Packs— 

•5L

•20L

Recently  Bisleri  Natural  Mountain  Water  was  introduced  water  from the foothi l ls  of   themountains situated in Himachal Pradesh & Uttarakhand. Hence the product range now comprises of two variants: Bisleri with added minerals & Bisleri Mountain Water. Bisleri also has a marginal share in the Soda segment.

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MATERIAL:-

There is no output possible without the basic Raw Materials. Materials can account for almost 80% of the output. Hence Materials are very important in planning for any production. The Materials which are required by Bisleri are:-

Untreated Water 

HDPE

LLDPE

PET

Recycled PET Granules

Cartons

Stickers

SUPPLIERS

The main raw material for any bottling plant is water. The location that has been selected has 8 bore wells on site which is enough to supply water for the whole year. Hence the company does not rely much on BMC for its water.

The other raw material it requires is HDPE, LLDPE for the production of caps

And PET for the production of bottles. The granules of these are easily available. The polymer manufacturing companies i.e. CHEMCO and SNJ HYDERABAD have distributors in Mumbai.

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QUALITY CONTROL AND QUALITY STANDARDS

Bisleri International Pvt. Ltd. follows and conforms to the standards set by the Bureau of Indian Standards (BIS). Tests prescribed by the BIS are conducted daily and weekly on the Bisleri premises while quarterly, half-yearly and even yearly tests are conducted in a separatelaboratory.

REQUIREMENTS TO BE COMPLIED WITH BY THE APPLICANT OF PACKAGED DRINKING WATER FOR GRANT OF BIS LICENCE ACCORDING TO IS 14543:2004. General requirements for grant of BIS License. PRODUCT SPECIFIC REQUIREMENTS

(FOR PACKAGED DRINKING WATER)

1. List of Test Equipments, Glass wares & Chemicals

2. List of BIS approved outside lab for the Product Water, Containers (including lids/caps)

3. Details of samples of the product/containers to be drawn during BIS visits.

4. Acceptance of Marking Fee.

5. Acceptance of Scheme of Testing and Inspection (STI)

6. Guidelines for assessment of Hygienic conditions with Explanatory notes for guidance

7. List of Indian Standards which a Packaged Drinking Water Industry must have in original

8. Undertaking for getting the samples tested as per STI frequency from BIS approved/NABLaccredited outside lab.

9. Consent letter from concerned outside lab for testing of sample (Ref. Sr. No. 8).

10. Copy of the appointment letter, qualification certificates for Chemist and Microbiologist

11. No Objection Certificate (NOC) from the concerned office of Central Ground Water Authority (if applicable in the state).

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OTHER METHODS :

•The packed cartons are not placed directly on the floor of the plant, lest they get damaged and consequently degrade the quality of the product. Also trolleys and carts are used to transfer the cartons within the plant.

•Workers in the plant are required to wear head masks to avoid contamination of the  product.

•Daily pest control is undertaken to maintain a clean environment for manufacturing.

•There are at least two people appointed to remove defective or damaged pieces from the assembly line

•Water wasted during the bottling process is recycled and put to use.

•Bisleri maintains a regular sanitation and maintenance record.

Minimal human intervention is involved during the production process. If a bott le is unnecessarily touched by human hand, the product is discarded to maintain adequate quality.

•The mineral water is ozone treated before packaging.

•An expiry date is decided for the product so that the desired quality can be maintained.

•Overall productivity for a day is maintained at 80% to 85%. (For the day prior to the plant visit it was 82% productivity)Bisleri International Pvt. Ltd. has the following Quality Policy

 

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QUALITY POLICY

Bisleri commits itself to produce and market a world class product to satisfy the present and future needs. We will strive to train all our people and develop an obsession for quality in all aspects of work in an organization. We are committed to implement good manufacturing practices and to achieve continuous improvement in the plant, process and distribution chain. We ensure full compliance to all government regulatory norms and strictly adhere to the internal standards of quality and hygiene. Each and everyone in the organization are responsible for quality. The head is accountable for implementation of the quality policy and guidance. The quality policy is implemented uniformly across all manufacturing units. The “corporate quality Assurance” will provide necessary support and guidance for up gradation of the procedures and standards.

WATER PURIFICATION PROCESS

1. Ozonization: The ground water is ozonized, by passing it through oxygen, which helps in destroying the prevalent bacteria and viruses in the water.

2. Prefiltration: It is done in 2 ways :

a. Sand filtration: Particles gets filtered through a sand filter thereby, removing coarse particles of up to 30 microns in size. Excess iodine/ salt also get filtered.

b. Activated carbon filter: The Carbon Filter is used to remove colour and odor from the sand filtered water. Particles left after sand filtration are also removed in this stage for better purification and to maintain the good quality of water.

3. Reverse Osmosis: It is the heart of this manufacturing plant which removes all harmful minerals and salts present in the water thereby converting ground water which is hard in nature into soft water making it edible for drinking purpose.

4. Micron Filter: This process further removes small particles of 0.2mm to 0.5 mm which are still present in the water thus adding to the purification process.

5. Mineral Injection: To bring back the taste and goodness of water, minerals such as magnesium sulphate, potassium bicarbonate, calcium and iron are added to the water. This enhances overall health and helps boost the immune system.

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Magnesium (Mg) is said to be good for the bones and Potassium (Na) reduces hypertension.

6. Ozonization: The water is ozonized once more to ensure zero contamination during filling, bottling and storage. It removes all the residues in the water after going through 5 stages thus making sure that the water is purified and is drinkable. It also increases the shelf life of water.

The purified water is then transferred to a tank after which the filling, bottling and labeling process commences. The bottles are also made from a preformed plastic which is in the shape of a test tube, which is passed through intense heat, to blow up in a mould, into a plastic bottle of a particular desired size.

PRODUCTION PROCESS

1. Blowing

In the blowing department the Performs, obtained from the performs department are Blown to form bottles. There are a total of 2 fully automatic blowing machines which are directly connected to the filler. Reforms are available in various sizes according to the size of bottle. 

2. Filling:

The filling department is situated in a closed and a controlled environment to maintain the Hygiene. Bottles are fed by an air conveyor from the blowing unit directly into the in-feed of the RFC. RFC equipment is neck run and it boasts of a mono block unit, which means that every bottle is held by the neck automatically while being inverted, rinsed and sprayed with ozonated water at 2 bar pressure. After draining, the bottles are re-inverted and transferred to the filler. At the filler these bottles are straightened up and gradually . Lifted to the filling valves which open only when a bottle is placed under them. Filling isthen done systematical ly   through gravity.  The bott les  are  direct ly  

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loaded onto  theconveyor belt, first the bottles are passed through UV light to kill the bacteria, then the Bottles are cleaned by pure water, then the bottles are filled to the desired quantity.The water dispenser fills the bottle till the desired level of water is filled which is checked by a sensor.

3. Capping:

The bottles are passed to the capper from the filler through the conveyer belt. The caps are produced in the cap department. HDPE and LLDPE which are in the form of granules are emptied into the hopper of the injection moulding machine with a colorant and toecaps are produced of the characteristic green colour of Bisleri. The caps that are produced are automatically packed into cartons. This semi finished product is transported, after quality testing has been done, to the filling department. The bottles are passed to the capper from the filler through the conveyer belt. Here Ozonated-water rinsed caps are screwed on the bottle with uniform torque. Since the water is ozonated al l product contact parts are of 316L grade stainless steel and the rubber parts are of EPDM.

4 Labelling:

From the capping section the bottles are directly sent to the labeling section. All Bisleri bottles are labeled on a hot melt reel feed BOPP labeling machine. This machine allows each individual bottle to be spaced out and fed to the labeling station where precisely cut labels with a strip of hot melt glue at the leading and trai l ing edge, get rolled around the bottle. These labels are fed into the machine in a roll form too.

5. Coding:

The labeled bottles are then passed to the coder. The sensor first senses the bottle and then the Price, manufacturing date, batch number are printed by spraying machine on the bottle itself, then the bottles pass through a screen of white light where workers manually check all the bottles for any defects. The code exactly contains Date, Time and Quality Checkers initials.

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6. Packaging:

Lastly they are packed in cartons and stored in the warehouse ready for transportation to its destination. All the waste bottles are separated send to the recycling department for recycling where they are cleaned, grinded to a coarse powder which is again used in the manufacturing process, thus reducing wastages and being environmentally friendly.

MACHINES AND EQUIPMENT:-

The Machinery that is used for production has to be carefully selected as it can result in higher and more eff icient output at a lower cost . The fol lowing are the methods of  acquiring the machinery:-

1) Equipments can be purchased fresh or second hand

2) Equipment can be leased or rented

3) Equipment can be fabricated within the plant Machines used in Bisleri are as follows:-

Injection moulding machines for the production of pre-forms and caps.

Moulding machines for making the bottles according to the required size and shape.

Automatic fillers for the purpose cleaning and efficient filling of the bottles with least amount of rejection.

Bisleri has got 14 injection moulding machines, 2 automatic blow moulding machines and 4 semi automatic blow moulding machines. It has also got 2 plants located side by side for production purposes.

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W O R K E R S :

In the Bisleri factory, the workers have the following facilities:-

1) The plant is on the Western Express Highway and is also very close to the Andheri Station. This makes it very convenient for the workers to commune.

2) The Canteen for the workers is conveniently located and provides hygienic food.

3) The Washrooms for men and women workers are also conveniently located are kept in hygienic conditions.

There are 3000 direct employment and 5000 indirect employment.

INSPECTION: -Inspection is an integral aspect of quality control programme. It helps in maintaining and raising the quality of products. Inspection judges production against established standards. There is a very eff icient qual i ty control process fol lowed by Parle Bisleri Pvt . Ltd. i t inspects everything from the water to the bottles very regularly, in fact it is one the main issues in quality control of the company. The first thing the quality control head does is to check the previous day’s rejection and to finds its individual reasons of rejection and steps if required.

DISTRIBUTION NETWORK OF BISLERI

Our observation of the Andheri Plant What we found from our analysis of the Mumbai plant is that Out of the 3 shifts the factory has i.e. 7am-3pm, 3pm-11pm and 11pm-3am, the night shift 11pm-3am is used for loading of cartons Which carries approximately 40,000 litres of water? The distribution is done using 80vehicles and is sent to the 20 distributors in the city who then sells it to the retailers. Other plants across the country Bisleri has 52 bottling plants across India and uses state-of-the-art technology at all stages of its purification processes including double ozonisation. Bisleri’s portfolio includes Bisleri with Added Minerals and Bisleri Himalyan water.On a national level, there are 2,000 trucks on cal l for Bisleri , while the number of t rucks averages 300 and 250 in the Mumbai and Delhi market

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alone. Every day, nearly 5,000 delivery vans drive out of these 52 strategically located Bisleri bottling plants carrying over 1 million units of pure, sweet drinking water to replenish the stocks of 

2,500 distributors and nearly600,000 retail outlets

FUTURE OBJECTIVES

Bisleri is targeting a 40 per cent growth this year and has outlined an aggressive market penetration strategy which is a dual distribution plan– penetrating newer markets – including townships and rural India which includes smaller and interior markets and aggressively looking at entering newer territories and increasing shelf presence in the metros and existing markets. It also plans to penetrate every possible segment of the market by introducing more pack sizes and establishing the brand strongly with trendy new packaging.

Bisleri plans to overtake Himalayan, at the top end of the market (mountain water) with its premium variant Natural Mountain water in six months. Himalayan, which was acquired by Tata Tea last September, is the largest player in the natural mountain water category in India. For  which Bisleri began operations at its new mountain spring at Rudrapur in Uttaranchal. A bottle of Himalayan sells at Rs 25 and with Tata Tea taking charge, the company is expected to beef up its distribution significantly. Bisleri is confident that its one-litre bottle, priced at Rs20, will make an impact in an increasingly health-conscious market.

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Future projects

The company is setting up dedicated channels for its 20L jars to ensure that every household and corporate gets service at their door step. For which it is also investing heavily on vans, since distribution is a key factor in the business and focusing strongly on marketing to key accounts.

Bisleri plans to have six more plants in Mumbai. At present, the company has only one plant in Mumbai, with a capacity of more than 0.75 Million litres a day, which caters to the city and surrounding markets like Pune.

It is also planning to set up 25 new bottling plants across the country which will be located in states like Maharashtra, Kerala, Jammu & Kashmir, Himachal Pradesh, Tamil Nadu, Karnataka, UP, Orissa, Jharkhand and North Bengal states.

The company will start exports to the US, Europe, UK, UAE and Japan by the end of October 2009 for which the water will be bottled at the plant in Himachal Pradesh.

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