PRODUCTION OF READY-TO-DRINK GREEN TEA BEVERAGE

“JOY TEA” IN PLASTIC BOTTLE AT PT SINAR SOSRO CAKUNG

By: Ivan Jeremy Yuwono

Supervisor: Jeremia Manuel Halim, MP

Field Supervisor: Rochmat Budi Nuryanto

Introduction

1. Background

2. Objectives

3. Methods

Background

1. Tea:

1. Soothing and thirst-quenching drink

2. Good functional effect on the body

2. Internship: Academic knowledge Experience on working field Practical work

3. PT Sinar Sosro:

1. The 1st packaged ready-to-drink tea product manufacturer

Objectives

1. General Objectives:

1. Preparation for future employment

2. Knowledge broadening (practical exp)

3. Academic knowledge implementation

2. Specific Objectives:

1. Practical understanding of the production process and related food technology things (e.g. warehousing and sanitation)

Methods

1. Descriptive Type

2. Primary and Secondary Data Collection:

1. Primary Data:

1. Direct self-observation

2. Interview with Field Supervisor and Employees

2. Secondary Data:

1. Literature-based information

2. Information obtained from the factory

General Company Profile

1. Company History and Development

2. Company Layout

3. Company Organizational Structure

4. Laborship

5. Company Products

History and Development 1. 1940: Started from home industry of aromatic tea

(“Poci”) in Tegal, Central Java

2. 1945: Product introduction to Jakarta citizens

3. 1974: Establishment of 1st PT Sinar Sosro factory in Cakung

4. 1975: Line 1; 1978: Line 2; 1982: Line 3; 1984: Medan Factory & Sosro Group

5. 1996: Halal certificate and ISO 9002 certificate

6. 2004: Rekso Group (PT Sinar Sosro and PT Gunung Slamat)

7. 2007: Launching of “Joy Tea” products

Company Layout 1. Three closed building

2. First building: factory department (admin), warehouse (PB/PI & document samples), utility room (boiler, compressor, and genset room), employees’ toilet, and reservoir room

3. Second building:

1. 1st floor: recycling room, kitchen unit, bottling line, water treatment unit, analyst division QC room, incoming material division QC room, and supervisor room

2. 2nd floor: microbiology division QC room, production manager room, archive room, and meeting room

4. Third building: R&D room, workshop, promotional goods storage, warehouse (raw materials and supporting chemicals), and supervisor room

Company Organizational Structure

Vision and Mission 1. Vision: becoming a beverage company that can soothe

consumer’s thirst whenever-and-wherever, and giving added value(s) to the related parties (The Indonesian World Class Beverage Company)

2. Mission:

1. Building “Sosro” brand

2. Giving birth to new leading products in the market

3. Building and leading distribution network

4. Creating and nurturing commitments for long-term growth

5. Giving satisfaction to the consumers

6. Taking part in giving foreign exchange to the country

Laborship

1. Labors: 487 workers

2. Working Time:

1. Office: 08.00–16.00 (Mon-Fri), 08.00-13.00 (Sat); rest time: 12.00–13.00 (Mon-Thu), 12.00–13.30 (Fri)

2. Production:

1. 3-shift: 08.00-16.00, 16.00-00.00, 00.00-08.00

2. 2-shift: 08.00-16.00, 16.00-00.00

3. Some departments (2-shift)

1. 3-shift: 09.00-15.00, 17.00-23.00, 01.00-07.00

2. 2-shift: 09.00-18.00, 00.00-09.00

Company Products 1. Products:

1. Teh Botol Sosro

2. Fruit Tea

3. Joy Tea

4. S-Tee

5. TEBS

6. Happy Jus

7. Creso

8. Prim-A

2. Marketing Area:

1. Domestic

2. International: ASEAN countries, Australia, Saudi Arabia, USA

3. Factory Location: Medan, Pandeglang, Jakarta, Tambun, Ungaran, Surabaya, Gianyar, and Cibitung

Production Process of “Joy Tea”

1. “Joy Tea”

2. Raw Materials

3. Water Treatment

4. Kitchen Unit

5. Bottling Line

6. Storage and Distribution

7. Supporting Power Procurement

8. Sanitation

9. Waste Treatment

10.Problems and Troubleshooting

“Joy Tea”

1. Green Tea Beverage

2. Production capacity: 5-7 batches (@ 9000 L)

3. Varieties (4): Jasmine Regular, Jasmine Less Sugar, Honey Lemon

4. Available in two sizes: 300 ml and 500 ml

5. Ingredients: Water, Sugar, Green tea extract, Ascorbic acid, and Flavoring(s)

6. Nutrition facts:

1. 300 ml: 21 grams of sugar w/ no fat and protein (85 kcal energy)

2. 500 ml: 36 grams of sugar w/ no fat and protein (140 kcal energy)

Raw Materials 1. Water: extracting solvent

2. Tea Leaves: Main ingredients to be extracted

3. Sugar: Imparting sweetness

4. PET Bottle: Product’s primary packaging

5. Screw Cap: Closure of the packaging

6. Carton Box: Product’s secondary packaging

7. Bottle Label: Labelling info of the product

8. Cap Seal: Requirement for specific customer (e.g. Cineplex 21 Group)

9. Food Additives: Imparting desired flavor (Jasmine / Honey Lemon Flavor) and keeping product’s color (Ascorbic acid), etc.

Water Treatment

1. Flowchart: Well Reservoir Sand Filter Carbon Filter Cation Exchanger Anion Exchanger Carbon Filter Demin Water Buffer

Kitchen Unit

1. Flowchart of Bitter Tea Liquid: Extraction (Tannin, Turbidity) Filtration 1 (Bag Filter) Filtration 2 (“Cosmos”/”Filtrox” Filter) (Turbidity) Mix Tank

2. Flowchart of Syrup: Dissolution (Brix) Filtration Syrup Buffer Mix Tank

3. Flowchart of Sweetened Tea Liquid: Syrup in Syrup Buffer + BTL in Mix Tank

Bottling Line

1. Flowchart of product bottling: Pasteurization (Temp., time) Filling (Temp.)

2. Flowchart of bottles: Loading Rinsing ([Cl], pressure) Filling Capping (Torque, seal secure test) Tilting (time) Cooling (Temp., time) Inspection 1 Drying Coding Labelling Label Shrinking Inspection 2 Packing into Carton Box Taping of Carton Box Warehousing

Warehouses

1. Logistic Warehouse: Raw and supportives

2. PB Warehouse: RGB

3. PI Warehouse: Final “Sosro” Products

4. Below Standard Warehouse: Non-standard products

5. Spare Part Warehouse: Spare Part of the Machinery

6. FIFO system

Storage and Distribution of Final Product

1. Carton boxes piled up in a pallet

2. Forklift is used

3. QC-supervised incubation

1. OK: marketed

2. Not OK: quarantined for further analysis

4. Quarantine also for: start-up & jammed

5. Distribution: Trucks & Boxes

Storage and Distribution of Raw Materials

1. Sugar, Tea Leaves, and Food Additives:

1. Logistic Warehouse

2. Controlled condition:

1. Sugar and Tea Leaves: T 28 C, RH 32%

2. Food Additives: T 20 C, RH 70%

3. No direct contact w/ floor

4. Vacuum cleaning

Supporting Power Procurement

1. Electricity

1. PLN

2. Genset

2. Steam

1. Solar-fueled Boilers

3. Air

Sanitation

1. Outsourcing: All areas, exclude HO

2. Production workers: Production Equipments and Logistic Warehouse

Waste Treatment

1. Flowchart until Clarifier: Drainages Pump Pit Cooling Tower Equalization Tank Aeration Tank Clarifier Tank

2. Flowchart of turbid water: Clarifier Tank Divider Aeration Tank

3. Flowchart of solid mud: Clarifier Tank Divider Filter Press

4. Flowchart of clear water: Clarifier Tank Cleaning Water Buffer Tank

Problems and Troubleshooting (I)

1. Water Treatment: Non-standard treated water quality replacement/adjustment/sanitation

2. Kitchen Unit

1. Broken pump water supply decrease

2. Non-standard tannin content addition

3. Non-standard sugar content longer mixing

4. Non-standard water temperature inefficient heat transfer check PHE plates

Problems and Troubleshooting (II) 3. Bottling Line

1. Phlegm-covered Filler Tank higher washing freq.

2. Plugged Bag Filter proper / higher freq washing

3. Non-standard torque settings of the Capper

4. Blackout all production stops, need re-start proc.

5. Deformed and/or dropped bottles in Filler mach. A.

6. Unstable PHE temperature at Pasteurization Unit

7. Improper labelling system error restart needed

8. Non-standard steam pressure at Label Shrink Tunnel

9. Unclear and incorrect code on the cap

10. Tendency of Packer mach.’s T to rise restart needed

Conclusion 1. PT Sinar Sosro: good tea beverage producing company, esp.

“Joy Tea” products (Production quality, environment safety, food safety management, product hygiene)

2. Produced carefully using well-controlled raw materials

3. Standardized materials consistent product quality preservatives and colorings not needed

4. QC Analysis:

1. Water & Raw Materials Quality Parameters

2. Extraction Process

3. Sugar Production & Addition

4. Food Additives Addition

5. Pasteurization

6. Cooling

7. Packaging

8. Final Product (i.e. “Joy Tea”)

Suggestion

1. Separate route for forklift accident risk decrease

2. Proper use of working tools accident risk (due to carelessness) decrease

3. Good keeping of personal hygiene and environmental cleanliness product contamination risk decrease

Bibliography (I) 1. Belitz, Hanz-Dieter, et al. Food Chemistry. 4th Revised and Extended ed.

Heidelberg: Springer-Verlag, 2009.

  Brown, Amy. Understanding Food: Principles and Preparation. 3rd ed. Belmont:

Thomson Wadsworth, 2008.

Coles, Richard and Mark J. Kirwan. Food and Beverage Packaging Technology. New York: Blackwell Publishing, 2011.

  Fennema, Owen R. Food Chemistry. 3rd ed. Madison: Marcel Dekker, Inc.,

1996.

  Hara, Yukihiko. Green Tea: Health Benefits and Applications. New York: Marcel

Dekker, Inc., 2001.

  Kurian, Alice and K. V. Peter. Commercial Crops Technology: Vol. 08,

Horticulture Science Series. New Delhi: New India Publishing Agency, 2007.

Kuroda, Yukiaki and Yukihiko Hara. Health Effects of Tea and Its Catechins. New York: Kluwer Academic / Plenum Publishers, 2004.

Bibliography (II) McKinley, Helen and Mark Jamieson. Handbook of Green Tea and

Health Research. New York: Nova Science Publishers, 2009.

Nip, Wai-Kit et al. Handbook of Food and Beverage Fermentation Technology. New York: Marcel Dekker, Inc., 2004.

  Setyamidjaja, Djoehana. Teh: Budi Daya dan Pengolahan

Pascapanen. Yogyakarta: Kanisius, 2000.

  Singhal, Rekha S., et al. Handbook of Indices of Food Quality and

Authenticity. 1st ed. Cambridge: Woodhead Publishing Limited, 1997.

  Sivasankar, B. Food Processing and Preservation. New Delhi:

Prentice-Hall of India Private Limited, 2002.

  Varnam, Alan H. and Jane P. Sutherland. Beverages: Technology,

Chemistry, and Microbiology, Volume 2. Maryland: Aspen Publishers, Inc., 1999.