QA Glass Bottle - CIPL

Glass Bottle Line –
Packaging Standard Checks

Carlsberg India Pvt. Ltd.
Thank You
Glass Bottle Line Sampling Points
Introduction Process Flow Chart

Glass bottle packaging is critical process in beer packaging
with respect to quality, food safety and legality. There are
various sampling point in bottle packaging which need to
monitored during beer packaging. Bottle Loading Bottle Washer EBI Filler & Crowner Pasteurizer Labeler & Case Packer
Process Involve in Beer Packaging Chip Neck Caustic Temp. EBI Validation Packed DO PU Zone Temp. Label Artwork
Bottle Loading Broken Bottle Net Caustic EBI 2 Hourly Verification Packed TPO Interlock System Label Alignment
Level 3 Dirty Bottle Aluminates CO2 Total PU Label Coding
Bottle Washer
Oil / Grease Carbonates Fobbing Jet Pressure Lethal PU Mandatory
EBI Crowned Bottle Spray Pressure Jet Temp. Max Temp.
Other Brand Bottle Spray Alignment Filled Volume Run Time
Filler & Crowner Bottle Washer

Bottle Burst Validation Bottle Out Temp.
Interlocking
Label Carryover Bottle Burst Verification Spray Pressure

Pasteurizer
Visual Appearance Sealing Spray Alignment
Labeler
Caustic Carryover Leak Test
Hard Pad Test

Case Packer
Incoming Bottle Inspection – Recycled Glass Bottles
Sample Size 10 Bags per Consignment Acceptable Not Acceptable
When During Unloading of Vehicle
Who Contractual Worker
Tools needed Training & Awareness, Visual Inspection
Bottles are free from obvious damage,

What good breakage and impacts. Bottle packaging ins bags Torn bags in incoming vehicles.
looks like Bottle packaging condition is to be should be intact without tear Leading to breakage and health
verified. off. Number bottles are intact & safety risk.
without any obvious defect.
Acceptance Criteria
The bottle should be of correct brand.
The shape of the bottles should match with standard design.
The bottle should not be Excess dirty either from inside or outside.
The bottle should not be broken, chipped (Neck or base), cracked

or have objectionable excess scuffing. Poor Packaging Poor Packaging Poor Packaging Poor Packaging
Condition of incoming Condition of incoming Condition of incoming Condition of incoming
The bottle should be free from stains deposited as white recycle bottles. recycle bottles. recycle bottles. recycle bottles.
spots/layer inside, e.g. Oil, Soils, Paint, Cement and Sauce etc.
Sample Size 10 Bags per Consignment Acceptable Alert

What good breakage and impacts.
looks like
Bottle free of damage, excess Scuffed Bottles Crown Bottles
Bottle packaging condition is to be dirt, obvious Foreign Matter,
verified. Retained crown, Bottle is
correct style for SKU being run
Acceptance Criteria Stop & Correct Stop & Correct
The bottle should be of correct brand. Reject bottles

that cannot be
The shape of the bottles should match with standard design.
cleaned or are
Damaged Bottle Crack Bottle Other Bottle
The bottle should not be Excess dirty either from inside or outside.
damaged.
Reject bottles
The bottle should not be broken, chipped (Neck or base), cracked
or have objectionable excess scuffing.
showing excess
scuffing. Other
The bottle should be free from stains deposited as white
spots/layer inside, e.g. Oil, Soils, Paint, Cement and Sauce etc. brand bottles.
Dirty Bottle Chip Neck Bottle
Sample Size 10 Bags per Consignment Acceptable Not Acceptable

Chip Neck Crack Bottle Dirty Bottle
What good breakage and impacts. Smooth Finish Sealing Smooth Finish Sealing Bottle
looks like Bottle packaging condition is to be Surface Surface
verified.
Level 3 Bottle Cleaning Not Acceptable

Level 3 bottles are the highly dirty recycle glass bottle
accompanying high dirt & solid mud deposition.
It also includes bottle used for oil, sauce which are not
easily cleaned in bottle washer.
It shall be dipped with 3% power dip solution for 90

minutes.
Ensure that there is no air pocket formation in bottles

Bottles with obvious Bottles with obvious Bottles with obvious Bottles with obvious
damage, breakage and damage, breakage and damage, breakage and damage, breakage and
After 90 minutes by shaking inside solution and keep on impacts impacts impacts impacts
conveyor before washer.
Bottle Washing Operation
Introduction Specification
Bottle Washer is used for washing new and old bottles in Parameter Description Lower Target Target Upper Target Frequency
beer packaging operations in which bottles are washed
with caustic, other chemical components and predefined Net Caustic Strength Soak 1 & 2 (%) (For Old Bottles) 2.00 2.35 2.70 Once per Batch
temperatures.
Net Caustic Strength Soak 1 & 2 (%) (For New Bottles) 1.50 1.75 2.00 Once per Batch
Monitoring & Measurement Carbonate Strength Soak 1 & 2 (%) - - 0.70 Once per Batch
Aluminium Strength Soak 1 & 2 (%) - - 0.30 Once per Batch
Caustic Temp. Net Caustic Aluminates Carbonates
Additive Strength Soak 1 & 2 (%) 0.20 0.25 0.30 Once per Batch
Caustic Temperature °C (For Old Bottles) 78 80 82 Once per Batch
Spray Bottle Washer Label Caustic Temperature °C (For New Bottles) 65 70 75 Once per Batch
Spray Pressure
Alignment Interlocking Carryover
Caustic Residue Test – pH Value (with pH Paper) 6.00 7.00 8.00 Once per Batch
Visual Caustic Methylene Blue/Hard Pad Test Should be negative Once per Batch
Hard Pad Test
Appearance Carryover
Water Spray Alignment Perfect Centre Once per Batch
Final Rinse Water Pressure (Kg/Cm2) 1.20 - - Once per Batch
Acceptance Criteria
Final Rinse Interlocking System Should work perfectly Once per Batch
Bottle washer shall be equipped with pressure sensor and
flowmeter to ensure constant flow of spraying nozzles. Total Soaking Time in Caustic Zone - - 15 -
Pay Your Attention

Conductivity meters have to be installed for each caustic
soak where chemicals are dosed. If Mix bottles in use at time, strength shall be maintained according to old bottle.
Automated additive dosing has to be monitored with a flow

Total Carbonate + Aluminate must be < 1.00%
meter, measuring flow and amount.
If Mix bottles in use at time, temp. shall be maintained according to old bottle.
Temperature must be checked continuously. If there is no Caustic residue test is to be performed with pH Paper.
automatic measurement system, manual check and
recording must be in place. Spraying nozzles must be checked visually (orientation, flow, function). Inspection windows must be in place.
Bottle Washing Operation
Introduction Action to be Taken

Bottle Washer is used for washing new and old bottles in
beer packaging operations in which bottles are washed Upper
with caustic, other chemical components and predefined Parameter Description Lower Target Target Action to be Taken
Target
temperatures.
< lower limit – add caustic
Net Caustic Strength Soak 1 & 2 (%) (For Old Bottles) 2.00 2.35 2.70
Monitoring & Measurement > Upper limit – add water
< lower limit – add caustic
Net Caustic Strength Soak 1 & 2 (%) (For New Bottles) 1.50 1.75 2.00
Caustic Temp. Net Caustic Aluminates Carbonates > Upper limit – add water
Carbonate Strength Soak 1 & 2 (%) - - 0.70 > Upper Limit – Change Caustic
Spray Bottle Washer Label
Spray Pressure
Alignment Interlocking Carryover Aluminium Strength Soak 1 & 2 (%) - - 0.30 > Upper Limit – Change Caustic
Visual Caustic < lower limit – add caustic

Hard Pad Test Additive Strength Soak 1 & 2 (%) 0.20 0.25 0.30
Appearance Carryover > Upper limit – add water
< lower limit – increase temp.

Caustic Temperature °C (For Old Bottles) 78 80 82
Pay Your Attention > Upper limit – reduce temp.
< lower limit – increase temp.
Inspect the Condition bottle of rinsing jets of bottle Caustic Temperature °C (For New Bottles) 65 70 75
> Upper limit – reduce temp.
washer. If not – check the spray pressure,
Caustic Residue Test – pH Value 6.00 7.00 8.00
alignment, spray nozzle blockage
It should be properly aligned, not chocked without If not – check the spray pressure,
sign of slime or mold. Methylene Blue/Hard Pad Test Should be negative
alignment, spray nozzle blockage
If any spray is chocked or mis aligned,

In case of low water pressure and/or water flow at Water Spray Alignment Perfect Centre
it should be on attend immediately.
final rinse, bottle washer must stop automatically.
If is below 1.20 Kg/Cm2, washer shall
Final Rinse Water Pressure (Kg/Cm2) 1.20 - -
Spray nozzles for internal AND external rinse in all be stopped automatically.
zones must be checked for proper function Final Rinse Interlocking System Should work perfectly
Verification of interlocking must be
done on daily basis.
Bottle Washer Discharge – Clean/Dirty Bottles
Sample Size Random 5 bottles Acceptable Alert
At start up, change overs – Bottle

When
source / SKU, Maintenance.
Who Associate / QA Executive
Free from labels or label traces. No

residues of chemicals. Only with a small Bottles are clean, free from Bottles are clean, free from
What good
amount of residual water without dirt/debris/label pulp & dirt/debris/label pulp & Minor label carryover at
looks like residual liquid residual liquid
crystalline precipitations inside or
washer outlet
outside the bottles. Clear and lucent.
Acceptance Criteria Not Acceptable

Free from labels or remaining parts of labels, No
residues of chemicals, residues of disinfectants.
Only with a small amount of residual water (3-

5drops with neutral pH-value)
Without crystalline precipitations inside or outside

the bottles.
Clear and lucent

Label Carryover Label Carryover Label Carryover
EBI Operation – As per Filtec
Introduction EBI Test Bottle Criteria – As per Filtec

EBI is an electronic empty bottle inspector that inspect
empty washed bottles. It plays an important role to Sr. No. Defect Location Position Size
produce quality and safe product. It is equipped with high
1 Base A) Periphery – Opaque 3.0 × 3.0 mm
resolution cameras to remove chip neck, crack and bottle
with foreign matter. 2 Base B) Middle – Opaque 3.0 × 3.0 mm
Monitoring & Measurement 3 Base C) Centre – Opaque 3.0 × 3.0 mm
4 Base A) Periphery – Cellophane 5.0 × 5.0 mm

Camera
PLC Setting Rotary Glass Sonic Sensor 5 Base B) Middle – Cellophane 5.0 × 5.0 mm
Setting
6 Base C) Centre – Cellophane 5.0 × 5.0 mm
False
EBI Reference 6.0 × 6.0 mm
EBI Validation Rejection 7 Inner side wall A) Backup Base Inspection – Opaque
Verification Sample 2 mm Thick
Index
8 Inner side wall A) Backup Base Inspection – Cellophane 10.0 × 10.0 mm 2 mm Thick
Machine Operational 9 Inner side wall B) Backup Base Inspection – Opaque 6.0 × 6.0 mm 2 mm Thick
Capability Reliability
10 Inner side wall B) Backup Base Inspection – Cellophane 10.0 × 10.0 mm 2 mm Thick
11 Inner side wall C) Middle – Thick Opaque 5 × 5 × 5 mm

Sample Size 21 + 4 = 25 Test Bottles
12 Neck Finish Across Sealing Surface – Chip Neck 2 mm D × 3 mm W
At Start up, At 2 hours / 50000
When 13 Neck Finish Outer Sealing Surface – Chip Neck 3 × 2 × 3 mm (HDW)
bottles (whichever is earlier)
14 Residual Liquid Water 4 mm above from highest point of bottle base
Who Associate / QA Executive 15 Residual Liquid Residual Caustic 1% 5 ml Total Volume
Tools needed Training & Awareness, EBI Test Samples 16 Foreign Body Inside Bottle – Cigarette End -
17 Foreign Body Inside Bottle – White Drinking Straw -

Schedule verification of EBI shall passed 18 Foreign Body Inside Bottle – Cap Liner -
for all test samples for its intended use.
What good 19 Foreign Body Inside Bottle – Cigarette Foil Crumbled -
The EBI passed bottles used for filling
looks like Inside Bottle – Cellophane wrapping from
operation should be safe enough as a 20 Foreign Body
cigarette pack
-
food safety prevention protocol. 21 Foreign Body Inside Bottle – Glass Piece 6 × 6 × 3 (LWT)
EBI Operation – As per COM
Introduction EBI Test Bottle Criteria – As per COM 70.03.12 EBI Validation Protocol
empty washed bottles. It plays an important role to Sr. No. Defect Location Position Size
1 Base Periphery – Opaque 3.0 × 3.0 mm
with foreign matter. 2 Base Middle – Opaque 2.0 × 2.0 mm
Monitoring & Measurement 3 Base Centre – Opaque 2.0 × 2.0 mm
4 Base Centre – Cellophane 3.0 × 3.0 mm

Camera
PLC Setting Rotary Glass Sonic Sensor 5 Inner side wall – S1a 30 mm from top – Opaque 4.0 × 4.0 mm
Setting
6 Inner side wall – S2a 10 mm above any embossed area 4.0 × 4.0 mm
False
EBI Reference 7 Inner side wall – S3a 25 mm above base 4.0 x 4.0 mm
EBI Validation Rejection
Verification Sample
Index
8 Inner side wall – S1b 30 mm from top 10.0 x 10.0 mm
Machine Operational 9 Inner side wall – S2b 10 mm above any embossed area 10.0 x 10.0 mm
Capability Reliability EBI Acceptance 10 Inner side wall – S3b 25 mm above base 10.0 x 10.0 mm
Procedure
11 Finish sealing chip Sealing surface 3.0 x 3.0 x 2.0 mm
Sample Size 21 + 4 = 25 Test Bottles
12 Glass split Glass split 1x1x5 mm
At Start up, At 2 hours / 50000 13 Chewed threads Outside of the neck 10 mm long
When
bottles (whichever is earlier) 14 Blocked neck Sealing surface -
Who Associate / QA Executive 15 Air bubble Finish Within the finish of the bottle > 2 x 2 mm
16 Residual liquid R1 Clean water >3mm above bottom center -

Tools needed Training & Awareness, EBI Test Samples
17 Residual liquid R2 1,5% NaOH HF 1 ml -
Schedule verification of EBI shall passed 18 Foreign body 1 cigarette packed foil crumpled inside bottle
for all test samples for its intended use. 19 Foreign body 2 cellophane wrapping from cigarette packet inside bottle
What good
The EBI passed bottles used for filling
looks like 20 Foreign body 3 cigarette end inside bottle
operation should be safe enough as a
food safety prevention protocol. 21 Foreign body 4 white drinking straw (standing on the base)
22 Foreign body 5 safety ring for plastic screw closure inside bottle
EBI Operation
Introduction Action to be Taken

empty washed bottles. It plays an important role to
Parameter Description Acceptance condition Action to be taken in case of deviation
with foreign matter.
Monitoring & Measurement Bottom / Top Camera Should detect test samples at any 1. Hold the entire production between last
given time good and present check.
Camera
PLC Setting Rotary Glass Sonic Sensor
Setting
2. Stop the line, check the condition of
EBI Reference
False 21/21 + 4 test sample should be camera, get it cleaned by smooth (Tissue)
EBI Validation
Verification Sample
Rejection PLC setting paper, check the PLC settings, if any
Index detected by EBI
setting found deviating, get it corrected,
Machine Operational re-pass the sample, if detected, allow line
Capability Reliability to run. If not detected, take the approval
Physical condition should be neat, from plant head / Quality Head / OD for
Pay Your Attention Rotary Glass / Cleaning brush way forward
clean and tidy
Empty bottles must be checked by an EBI before entering the filler. 3. Do the random sampling of hold lot to
max possible, if any suspected
Specification of every rejection parameter must be according to observation, do 100% sorting.
70.03.12 EBI validation protocol.
Should be in operation during
Sonic Sensory
running process
All functions of an EBI must be checked with test-bottles. 4. Visual inspection can be allowed in
special cases by approval from Group QA.
For all critical defects a complete set test bottles must be available.
5. In this case, max 250 bpm per inspector
After 50.000 bottles that have passed the EBI, a request for test- Physical Condition of EBI Defects All EBI defects sample as per COM and max 20 minutes per hour per person
bottles must automatically appear. If the test-bottle-program was Sample standard can be allowed.
not started after 2 hours and after every changeover the machine
has to stop.
EBI Operation – Test Bottle Preparation
Requirement Test Bottle Preparation
Requirement
Base Defects (nr 1 -4)
• Test bottles must be made using new
bottles which have successfully
passed through the EBI during • With a washable pen, mark each location where to place
normal running conditions. the contaminant on 4 different test bottles (these can be
• Each test bottle must be marked with the same bottles as used for sidewall defects).
a reflex strip on the neck, to prevent
mixed-up with commercial bottles. • Contaminants to be applied:
• Periphery: impermeable to light, with a defect size of 3.0
Do’s & Don’ts
x 3.0 mm
• Do ensure the test bottles are clean • Middle: impermeable to light, with a defect size of 2.0 x
and not damaged
• Do keep two (2) sets of test bottles
2.0 mm
for each format, in case one bottle • Centre: transparent cellophane (or scotch tape), with a
gets damaged or broken defect size of 3.0 x 3.0 mm
• Don’t keep the test bottles by the
line when line not running • Centre: impermeable to light, with a defect size of 2.0 x
• Do keep the test bottles in a secure 2.0 mm
and clean place
Requirement Side Wall Defects (nr 5-10)

bottles which have successfully • Use a standard template (e.g. plastic cup) so that the
passed through the EBI during contaminants are always placed at the same height.
normal running conditions. • You will need a standard cup for each bottle format used.
• Each test bottle must be marked with • With a washable pen, mark each location where to place the
mixed-up with commercial bottles. contaminant on six (6) different test bottles (four (4) of these can
be the same bottles as used for bottom defects).
Do’s & Don’ts • Contaminants to be applied:
• Impermeable to light, defect size of 4.0 x 4.0 mm
• Do ensure the test bottles are clean
and not damaged
• Transparent scotch tape, defect size of 10.0 x 10.0 mm
• Do keep two (2) sets of test bottles • Where to be applied:
for each format, in case one bottle • Neck: 30mm from top of bottle
gets damaged or broken
• Shoulder: not to be located in embossed or inscribed areas.
• Don’t keep the test bottles by the
line when line not running
Should the container have embossing, the mark should be
• Do keep the test bottles in a secure applied 10 mm above or below the described area
and clean place • Heel: 25mm above base of container
Requirement
• Test bottles must be made using new Neck Finish Defects (11-15)
bottles which have successfully
passed through the EBI during
normal running conditions. • With a small set of pliers or using a pointe pick hammer,
• Each test bottle must be marked with make a chip on the finish sealing surface of the bottle. If
a reflex strip on the neck, to prevent possible, the chip should be as small as 3*3*2 mm
mixed-up with commercial bottles.
• Using temperature gradients such as heating the bottle
Do’s & Don’ts and sipping in cool water, try to create a neck split
• With a file, create a chewed thread, no longer than
• Do ensure the test bottles are clean
and not damaged 10mm length (optional)
• Do keep two (2) sets of test bottles • Lay a crown on top of the bottle to create the defect nr
for each format, in case one bottle
gets damaged or broken 16
• Don’t keep the test bottles by the • Find a bottle from the supplier or request an example of
line when line not running
the defect nr 15 Air bubble inside finish
• Do keep the test bottles in a secure
and clean place
Requirement Residual liquid Defects (15 &17)

bottles which have successfully • One (1) bottle with clean water: height > 3 mm above
passed through the EBI during
normal running conditions.
the bottom Centre
• Each test bottle must be marked with • One (1) bottle with 1 ml of 1.5% Caustic (NaOH)
mixed-up with commercial bottles.
Foreign body Defects (18-22)
Do’s & Don’ts
• Do ensure the test bottles are clean • cigarette packed foil crumpled inside bottle
and not damaged
• Do keep two (2) sets of test bottles • cellophane wrapping from cigarette packet inside
for each format, in case one bottle bottle
gets damaged or broken
• Don’t keep the test bottles by the • cigarette end inside bottle
line when line not running • white drinking straw (standing on the base)
• Do keep the test bottles in a secure
and clean place • safety ring for plastic screw closure inside bottle
Beer Filling Operation
Introduction Specifications
The beer filling is a high-speed machine that fills the beer
in the bottle. It is equipped with state-of-the-art facilities Parameter Description Lower Target Target Upper Target Frequency
for quality production. Fobbing is related to critical factors
- jet pressure, jet temperature and total package oxygen.
Beer Temperature (°C) - - < 7.00 Once per Batch
Monitoring & Measurement High Pressure Hot Water Fobbing Jet Pressure (Kg/Cm2) 1.5 2 2.5 Once per Batch
Bottle Beer Dissolved Jet
Burst Temp. Oxygen Pressure High Pressure Hot Water Fobbing Jet Temp (°C) 80 82.5 85 Once per Batch
Vaccum Fill Online DO Before Filler (ppb) - - < 75 Once per Batch
Jet Temp. TPO
Pressure Volume
Bottle DO (ppb) - - < 75 Once per Batch
CO2 Total Oxygen (ppb) - - < 120 Once per Batch
Acceptance Criteria Package Co2 (Gms/Ltr) 5.00 5.20 5.40 Once per Batch
Filler parts - internal & external should be free from Packaged Volume As per Legal Metrology Once per Batch
any kind of slime / Mold
Pay Your Attention
CIP & COP shal be performed at per standard cleaning Beer temp. shall measureed manually and filler HMI screen.
protocol at scheduled frequencies.
High pressure hot water jet (fobbing) must be auto mode.
Start up and shutdown protocol shall be followed
religiously. High pressure hot water jet (fobbing) temp. must be check manually and on filler HMI
All monitoring and measurement paramter shall be Bottle burst operation protocol must be validated at scheduled frequencies.
maintained according to specifications.
Filler vent tube must be checked for potentional microbial contamination.
Beer Filling Operation
Introduction Action To be Taken

The beer filling is a high-speed machine that fills the beer
in the bottle. It is equipped with state-of-the-art facilities
Parameter Description Acceptance Criteria Action to be Taken
for quality production. Fobbing is related to critical factors
- jet pressure, jet temperature and total package oxygen. Machine should be free from any
Beer Temperature (°C) Stop filling operation and COP / CIP as per standard protocol
kind of slime / Mold
Monitoring & Measurement
> 10 ppb of BBT DO, Check leakages – Beer Line
Bottle Beer Dissolved Jet DO Before filling ± 10 ppb of BBT DO
All bottles filled with high DO shall be taken for recovery
Burst Temp. Oxygen Pressure
Vent Tube Cleaning & Filling tubes must be disinfected Stop & correct filling vent tube. Check way of disinfection
Vaccum Fill Hygiene before use. Free from Slime / mold storage of tubes.
Jet Temp. TPO
Pressure Volume
TPO > 120, check head space DO, if high – stop line, check
CO2 Head space DO should be as evacuation settings / vacuum pump pressure against standard
Vacuum & Pre-evacuation minimum as possible to get TPO < (< -0.8 bar or > 550 mmHG), get it corrected in case deviating,
120 ppb Check valve by valve TPO results, if it is specific valve number,
Pay Your Attention check filling valve condition.
An alarm system for low Control of under-filling No glass fragments in any filled
Bottle burst operation Follow the Standard procedure
CO2 and compressed air must be in place after bottles
pressure and flow must the filler and after tunnel
be installed. pasteurizer.
Crimping operation No leakage Bottles If any head found unsatisfactory, stop line & do correction
Control of over-filling Local legal regulations Hot water fobbing Head space DO should be as
If not, check temperature, pressure, alignment
must be in place must be followed and operation minimum as possible
immediately after the measured according to
filler if tunnel approved methods for fill < Lower Limit – Stop Line
Dissolved CO2 It Should Be > 5.0 & < 5.40
pasteurizers are used. height and net volumes > Upper Limit – Stop Line
Beer Filler – Bottle Burst Protocol
Sample Size Not Applicable Bottle Shall Rejected as Illustrated Below
When Continuous – Automated

Filler Valve -3 Valve -2 Valve -1 Valve -0 Valve +1 Valve +2 Valve +3
Who Associate

Round-0 0 V1 X Bottle Burst X V1 0
Bottle plates, centering tulips and the

Round-01 0 0 U-X U-X U-X 0 0
What good filling tubes are flushed with water to
looks like remove glass splinters. Bottles are
rejected as illustrated in COM document Round-02 0 0 V2 U-X V2 0 0
Pay Your Attention Bottle Burst Protocol Stop & Correct

X: Bottle to be rejected, and if possible, without any crown
Oxygen Control system including alarm system
U: Bottle to be under filled
that stops the filler if the DO is above the limits
for more than 5 sec must be in place.
V1: If filler is equipped with plates on the bowl for separation of
If the filler stops for more than 60 min, a new each valve and with detection system for Round 0 and validation
check for TPO (Total Packaged Oxygen) must be process and daily check are done, then these bottles do not need
done. to be rejected. If the condition is not met, bottle must be rejected.
V2: If validation process and daily check are done, then these
Bottles remaining between filler and crowner, bottles do not need to be rejected. If the condition is not met,
must be rejected in case of a stop & packages bottle must be rejected.
are open for more than 30 seconds.
Beer Filler – Oxygen Management
Sample Size 10 Bags per Consignment Acceptable Acceptable
When Changeover for SKU / Brand

Filler vacuum Individual
Who Associate
is more than bottle DO is less
75% than 40 PPB
All previous SKU / Brand bottles & crown

What good removed & returned to store.
looks like Crown hopper is free of previous run SKU
/ Brand crowns.
Alert Alert Stop & Correct
Oxygen Control system including alarm system

that stops the filler if the DO is above the limits
for more than 5 sec must be in place. Individual DO > 100ppb in
bottle DO is line.
If the filler stops for more than 60 min, a new more than 40 > 10% difference
check for TPO (Total Packaged Oxygen) must be PPB and less between in-line
than 100 PPB and portable DO
done. meter.
Vacuum gauge <
Bottles remaining between filler and crowner, 75%
must be rejected in case of a stop & packages
are open for more than 30 seconds.
Bottle Filler – Fobbing Jet Pressure
Sample Size Not Applicable Acceptable Acceptable
When At Start up / Every 4 Hours

Fobbing device is adjusted so jet is
straight into center of bottle
Water is hot >80°C
Tools needed Calibrated Thermometer, Visual
Fobbing peaks at point of cap application

Fobbing device is correctly adjusted to
What good
provide jet of water into open bottle so
looks like
beer fobs immediately before capper. Jetting stops when filler stops
Pay your Attention Alert Stop & Correct
• Jetting water must be sterilized &

softened water Incorrectly set – sniffing No or incorrect foaming
• Nozzle must be periodically cleaned to too vigorous Fobbing set up causing
Foam collapses when foam collapse before
avoid choking of nozzles. jetted crowner
• Jetting water must be free of beer-
spoiling microorganisms
• Jetting water must be heated to min.
80°C - max. 85°C.
Fobbing Jet Fobbing Pressure
• Injection pressure must be enough just
to create foam cap.
Bottle Filler – Filled Volume (Net Content)
Table I
Sample Size 80
Sr. No. Declared Quantity Maximum Permissible Error in Excess or in Deficiency
As percentage of Declared
g or ml g or ml
When At Start up / Once per Batch Quantity
(j) Up to 50 9 -
Who Associate / QA Executive (ii) 50 to 100 - 4.5
(iii) 100 to 200 4.5 -

Tools needed Calibrated Weighing Balance
(iv) 200 to 300 - 9
(v) 300 to 500 3 -
As per Legal Metrology (Packaged (vi) 500 to 1000 - 15

Commodities) Rule, 2011 First Schedule
What good [Rule 2 e] Table –I the beer volume
(vii) 1000 to 10000 1.5 -
looks like packed in bottles is within maximum
permissible errors on net content
quantities declared by volume. (viii) 10000 to 15000 - 150
(xi) More then 15000 1.0 -

Crowner – Pull Off Crown
Sample Size 10 Bags per Consignment Acceptable Alert
At Start up, every 2 hours,

When
changeovers, material change
Cap is evenly applied Marks on
Who Associate / QA Executive Cap cannot be
twisted crown.
Tools needed Go-No Go Gauge, Visual Inspection No bubbles seen
when inverting
Marks on Cap
bottle
Correct cap applied - crimping is smooth Uneven skirt.
and even. No damage caused by Tab in wrong
What good crimping.
looks like Acceptable Sealing
position
Closure should sit evenly on the bottle
sealing surface. No leakages
Alert Not Acceptable
Ensure artwork before putting caps in

hopper.
Pull of ring must be in correct position

and not deformed or damaged.
Torn Pull Off Cap Missing Pull Off Ring Damage Pull Off Cap Damage Pull Off Cap
There should be no visual signs of
leakage (i.e. no bubble formation from
seal when inverted)
Change Over Of SKU – Line Clearance at Filler
Sample Size 10 Bags per Consignment Acceptance Criteria
Who Associate
All previous SKU / Brand bottles & crown

looks like Crown hopper is free of previous run SKU
/ Brand crowns.
Pay Your Attention
• All changeover of brands / SKU

shall be executed according to During brand changeover, all previous Clear visual standards shall be available as
standard changeover protocol. production material shall be removed from per current SKU. Check for no other SKU
This must be included working line – including cap, labels, carton, etc. material available. Watch out - other brand
shutdown procedure for end of according to brand changeover protocol. bottles, crowns in hopper, conveyor dead
production, major stoppages - plates, within Pasteurizer, labels.
malfunctions, change-overs, when
lasting over 30 minutes and small
stoppages on packaging line.
Change Over Of SKU – Line Clearance at Labeler
Sample Size 10 Bags per Consignment Acceptance Criteria
Who Associate
All previous SKU / Brand bottles & label

looks like Labeler area is free of previous run SKU /
Brand label.
Pay Your Attention
• All changeover of brands / SKU

shall be executed according to There shall be no previous run material at line Rejected label bottle cleaning bath shall be
standard changeover protocol. the on same time. Immediately escalate the emptied during each batch and brand
This must be included working issue with concern to prevent accidental use of changeover.
shutdown procedure for end of previous material. OPL about the same is
production, major stoppages - recommended at point of use.
malfunctions, change-overs, when
lasting over 30 minutes and small
stoppages on packaging line.
Pasteurization
Introduction Specifications
Pasteurization is a process in which the biological
components of beverages are destroyed. The Parameter Description Lower Target Target Upper Target Frequency
pasteurization process is very important in beer
production to enhance the quality of beer and the
longevity of beer. Temperature of All Zones Should be as per setting Once per Batch
Monitoring & Measuring Pasteuriser Zones Set Point Should be 60 to 63°C Once per Batch
Pasteuriser Beer Temp. Interlock Systems Should work perfectly Once per Batch
Temperature Interlock
Zones Set Pasteuriser
of All Zones Systems
Point Exit Beer Temp. Pasteuriser Exit - - 35°C Once per Batch
Internal
PU Results PU Results (Total PU) 15 20 30 Once per Batch
Invertase Test Product
(Total PU)
Temperature
Invertase Test Should be - Ve Once per Batch
Acceptance Criteria Internal Product Temperature - - < 6 Bar Once per Batch
Pay Your Attention

R1H = 32 ±3 R2H = 42 ±3 R3H = 52 ±3
If there is no online PU control, the external control must be done minimum every 4 hours. Positioning of the PU Monitor must be cycled through all decks.
The pasteurization temperature must be measured at "cold spot" (10-20 mm above the center of the base of the container) the lowest temperature inside the
specific containers.
P1 = 60-63 P2 = 60-63 R1C = 52 ±3
Cut-off point at which temperature PU is recorded is defined as 58°C
A formalized routine to check and verify pressure and flow for flushing must be in place.
R2C = 42 ±3 R3C = 32 ±3 In case of longer downtimes of the line and product still inside the pasteurizer, a procedure must be in place to avoid over pasteurization above a critical limit.
Label Application
Sample Size Full round of labeler Acceptable Acceptable
Start up, change of SKU

and every 4th hour
When
Continuous vigilance
during production run
Tools needed Light & Standard sample

Label(s) are applied in correct
position and are free from Correct Label(S) Applied According To The
What good looks like No Misalignment Of Labels
wrinkles, damage or dirt. No SKU Being Run – Tuborg Strong Label
excess glue visible
Acceptance Criteria Not Acceptable Not Acceptable
Torn Label > 25 mm2
Wrinkled Label > 25 mm2
Spot on Bottle or Label ≥ 25 mm2
Misplaced or Skewed Label by > 4.5 mm - Neck
Misplaced or Skewed Label by > 4.5 mm - Front Incorrect Label(S) Applied

Tuborg Strong Neck Label Back Label is Missing
Misplaced or Skewed Label by > 4.5 mm- Back Applied to Tuborg Classic
Label Application

and every 4th hour
When

position and are free from Label(S) Are Applied at Correct
What good looks like Position. At Standard Label Position.
wrinkles, damage or dirt. No
excess glue visible No Torn or Scuffed label Labels
Torn Label > 25 mm2
Misplaced or Skewed Label by > 4.5 mm - Front Label(S) Are Not Applied at
Correct Position. Misaligned
Misplaced or Skewed Label by > 4.5 mm- Back Label. Scuffed Body Label Scuffed Neck Label
Label Application

Label(S) Are Applied Free From Label(S) Are Applied Free From
Start up, change of SKU Wrinkles. Wrinkles.
and every 4th hour
When

position and are free from
What good looks like
excess glue visible
Torn Label > 25 mm2 Label Applied with Full of Wrinkles. Label Applied with Full of Wrinkles.
Misplaced or Skewed Label by > 4.5 mm - Front
Misplaced or Skewed Label by > 4.5 mm- Back

Label Application

and every 4th hour
When

position and are free from Label(S) Are Applied Label(S) Are Applied
What good looks like Free From Wrinkles. Free From Wrinkles.
excess glue visible
Torn Label > 25 mm2
Misplaced or Skewed Label by > 4.5 mm - Front Label Applied with Label Applied with
Full of Wrinkles. Full of Wrinkles.
Label Application

and every 4th hour
When

position and are free from No Damage, Torn or No Damage, Torn or
wrinkles, damage or dirt. No Scuffed label Labels Scuffed label Labels
excess glue visible
Torn Label > 25 mm2
Misplaced or Skewed Label by > 4.5 mm - Front Torn Label, Damaged Torn Label, Damaged
Label Label
Label Application

and every 4th hour
When

No Damage, Torn or No Multiple Label
wrinkles, damage or dirt. No Scuffed label Labels Application to Bottle.
excess glue visible
Torn Label > 25 mm2
Misplaced or Skewed Label by > 4.5 mm - Front Torn Label, Damaged Multiple Label Application
Label to Bottle.
Label Application

and every 4th hour
When

No Damage, Torn or No Multiple Label
wrinkles, damage or dirt. No Scuffed label Labels Application to Bottle.
excess glue visible
Torn Label > 25 mm2
Misplaced or Skewed Label by > 4.5 mm - Front Torn Label, Damaged Multiple Label Application
Label to Bottle.
Label Application

and every 4th hour Correct Code Applied In Correct
When Missing Code
Continuous vigilance Position - Can Be Read Easily.

excess glue visible
Torn Label > 25 mm2

Condensed Coding. Coding is Not as
per Target Coding Requirement.
Misplaced or Skewed Label by > 4.5 mm - Front

Case Packing, Palletizing & Loading
Sample Size 10 Carton Palletizing
At Start, SKU changeover,

When Brand Changeover, Once
per Batch
Tools needed Visual Check

Is the pallet according SKU
standard?
No: stop line and correct
settings. Alert supervisor
• It is recommended that every round

include all stated parameter to be
checked visually.
• To be check – No. of missing bottles.
• No. of Carton bottle sealing
• No. of carton Missing code
• No. of carton Artwork / color not okay.
• BOPP tape to be pasted firm and
without any loose tape.
For each pallet For each pallet Cushioning is recommended
• FIFO shall be followed at time. belt is mandatory. belt is mandatory. while loading.
Carton Palletizing
Acceptable
Sample Size First pallet from batch

and every 4th hour
When
Proper Packing Coding Flap Alignment Palletizing

Not Acceptable
Tools needed Visual Check
Is the pallet according SKU

standard?
No: stop line and correct Mis-aligned Flap Improper Coding Mis-aligned Flap Improper Stacking
settings. Alert supervisor
Failure of Any Critical Check – Quality & Food Safety Risk – Block
Suspect Product
Introduction
Any finished product which is identified as a

nonconforming product is to be controlled, segregated
(where applicable) & evaluated to prevent accidental use.
Process Involve
Sample Size Not Applicable
Whenever a critical check

fails causing
When
a risk of food safety or
illegal product
Who
Operator
Hold all production back

Tools needed
to the last
good check
Hold all production back
What Good Look Like
to the last good check
Acceptable
Any failure in a critical check -
Stop production
Inform supervisor
Inform QA & Identify and block all production
between the critical check failure back to the last
good check
Thank You

QA Glass Bottle - CIPL

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Glass Bottle Line –

Packaging Standard Checks

Introduction Process Flow Chart

Level 3 Dirty Bottle Aluminates CO2 Total PU Label Coding

EBI Crowned Bottle Spray Pressure Jet Temp. Max Temp.

Other Brand Bottle Spray Alignment Filled Volume Run Time

Filler & Crowner Bottle Washer

Label Carryover Bottle Burst Verification Spray Pressure

Hard Pad Test

Sample Size 10 Bags per Consignment Acceptable Not Acceptable

When During Unloading of Vehicle

Who Contractual Worker

Tools needed Training & Awareness, Visual Inspection

Bottles are free from obvious damage,

The bottle should be of correct brand.

The shape of the bottles should match with standard design.

The bottle should not be broken, chipped (Neck or base), cracked

Sample Size 10 Bags per Consignment Acceptable Alert

When During Unloading of Vehicle

Who Contractual Worker

Tools needed Training & Awareness, Visual Inspection

Bottles are free from obvious damage,

Acceptance Criteria Stop & Correct Stop & Correct

The bottle should be of correct brand. Reject bottles

Sample Size 10 Bags per Consignment Acceptable Not Acceptable

When During Unloading of Vehicle

Who Contractual Worker

Tools needed Training & Awareness, Visual Inspection

Bottles are free from obvious damage,

Level 3 Bottle Cleaning Not Acceptable

It shall be dipped with 3% power dip solution for 90

Ensure that there is no air pocket formation in bottles

Pay Your Attention

Automated additive dosing has to be monitored with a flow

Introduction Action to be Taken

Visual Caustic < lower limit – add caustic

< lower limit – increase temp.

If any spray is chocked or mis aligned,

Sample Size Random 5 bottles Acceptable Alert

At start up, change overs – Bottle

Tools needed Training & Awareness, Visual Inspection

Free from labels or label traces. No

Acceptance Criteria Not Acceptable

Only with a small amount of residual water (3-

Without crystalline precipitations inside or outside

Clear and lucent

Introduction EBI Test Bottle Criteria – As per Filtec

Monitoring & Measurement 3 Base C) Centre – Opaque 3.0 × 3.0 mm

4 Base A) Periphery – Cellophane 5.0 × 5.0 mm

11 Inner side wall C) Middle – Thick Opaque 5 × 5 × 5 mm

17 Foreign Body Inside Bottle – White Drinking Straw -

Monitoring & Measurement 3 Base Centre – Opaque 2.0 × 2.0 mm

4 Base Centre – Cellophane 3.0 × 3.0 mm

16 Residual liquid R1 Clean water >3mm above bottom center -

Introduction Action to be Taken

Requirement Test Bottle Preparation

Requirement Test Bottle Preparation

Requirement Side Wall Defects (nr 5-10)

Requirement Test Bottle Preparation

Requirement Test Bottle Preparation