tin can

1. Purpose
Guide the production staff to make the production operations of fruit juice beverages standardized, standardized and programmed.

2. Scope of application
Applicable to the production operation of the company’s juice beverages

3. Responsibilities
3.1 The production workshop is responsible for the production and operation of fruit juice beverages, and is responsible for recording.
3.2 The Quality Control Department is responsible for the quality inspection of in-process products and the disposal of substandard products

4. Working process
4.1 Process flow
See the document “Production Process Flow Diagram”
4.2 Workflow
4.2.1 Process water production
4.2.1.1 Before production every day, carry out “reverse, positive” flushing on the sand filter tank and carbon filter tank for 5 to 10 minutes until the discharged water is free of impurities.
4.2.1.2 Pre-filtered water is prepared by sand filtration and carbon filtration and put into a water tank for use.
4.2.1.3 During production, open the bottom valve of the primary filtration water tank, and turn on the ultraviolet sterilizer. The pump is sterilized by 5u and 1u fine filtration and ultraviolet sterilizer to prepare fine filtration process water for production standby.
4.2.2 Purchase acceptance of raw and auxiliary materials
4.2.2.1 Select all kinds of food raw and auxiliary materials that meet the product standards. Concentrated fruit juice, fructose syrup, white sugar and food additives that have been subject to production license management must be purchased with food production licenses and have passed the third-party inspection and passed the inspection. Products with a certificate of conformity shall be checked and accepted according to the “Inspection and Recording Specifications for Purchases”, and non-conforming products are strictly prohibited from being put into production.
4.2.2.2 Raw and auxiliary materials shall be put into production according to the principle of first-in, first-out, and ensure that there is no deterioration within the shelf life. Do not use raw materials of unknown origin for production. The scope of use and the amount of food additives should be strictly in accordance with the provisions of GB2760.
4.2.2.3 Concentrated juice must be stored in cold storage at 5°C, take it as needed, and return it after use to prevent deterioration.

4.2.3 Dissolving sugar
According to the requirements of the formula, accurately weigh the corresponding amount of high fructose syrup (or white sugar) that has been verified correctly, add about 300kg of RO water to the sugar dissolving tank at the same time, and boil the RO water to about 80 ℃ by stirring with steam. Weigh the syrup or white sugar to dissolve it completely, and continue to heat it to 90±2℃. Keep warm for 20 minutes.

4.2.4 Ingredients deployment
Pump the melted syrup into the batching tank through the filter, then fully dissolve the concentrated juice with process water, add it to the batching tank, and then weigh and check the food additives to be added according to the requirements of the formula, and press ① Raw syrup ②Juice ③Potassium sorbate or sodium benzoate ④Sweetener ⑤Antioxidant ⑥Sour agent ⑦Fragrance ⑧ Pigment and other ingredients are added in the batching tank while stirring, and finally add water to the mark of 1.8 tons, and continue to stir for 15 minutes , and then the sugar, acidity and appearance are checked by the quality control department. If the requirements are met, the pump will be pumped through the filter to the temporary storage tank.

4.2.5 UHT sterilization and cooling
4.2.5.1 Check whether the UHT equipment, pipelines and valves are unblocked, and whether the temperature gauge, steam and pressure gauge are normal.
4.2.5.2 Open the bottom valve of the temporary storage tank, start the feeding pump, open the steam valve, and observe the temperature change. When the coil discharges the material, rotate the coil to make the material enter the storage tank, and control the sterilization temperature ≥121℃. When the discharge three-way cock is opened, the discharge can be started.
4.2.5.3 When it is necessary to increase or decrease the discharge temperature in the process, the steam valve or the cooling water valve of the tube cooler can be opened to control the beverage with a discharge temperature of 42℃~67℃ into the temporary storage tank before filling.
4.2.5.4 In case of temporary shortage of material supply or sudden power failure, the steam valve should be quickly closed, the steam discharge valve should be opened, and then the water inlet valve should be opened to prevent coking and fouling of materials.
4.2.5.5 After the material is produced, turn on the process water and pour it into the UHT. When the discharged material is clean water, transfer the three-way cock to the storage tank, and control the temperature to 85°C, recirculate and clean it for more than 20 minutes, and finally wash it with clean water. Wash for about 5 minutes.
4.2.5.6 When the production capacity is significantly reduced, the CIP washing procedure shall be adopted:
a. Water washing: when the water flowing out of the equipment becomes clear, it can be stopped.
b. Alkaline washing: Prepare 2% sodium hydroxide solution, heat it to 80℃, and cycle for cleaning for about 20 minutes.
c Water washing: After removing the lye, circulate the water for about 10 minutes until the pH value is about 7.0.
d Pickling: prepare hydrochloric acid with a concentration of 1%~2%, heat it to 40~60℃, and cycle for cleaning for about 20 minutes.
e Washing: After removing the acid, clean the pipes and containers with RO water until the pH value is around 7.0.

4.2.6 Filling
4.2.6.1 Bottle/cap cleaning and disinfection
1) Before filling, the bottles of different specifications are sent to the filling room from the upper bottle room through the conveyor belt. The bottle-filling personnel conduct preliminary inspection of the empty bottles by sight, hand, etc. After passing the qualification, the bottles are placed in the row and blown into the air duct with the conveyor belt and blown into the filling room.
2) After the production, in principle, the remaining bottles in the empty bottle warehouse should be cleaned (dustproof), and the number of bottles should be counted for statistical use.
3) The bottle is automatically cleaned and disinfected after entering the three-in-one automatic cleaning, filling, capping and filling machine.
4) The bottle cap must be sterilized and sterilized by an ultraviolet disinfection cabinet for more than 30 minutes before it can be used.
4.2.6.2 Automatic filling and capping
1) Before and after production in the filling room every day, the production personnel must turn on the ultraviolet germicidal lamp and air purifier to sterilize the filling workshop, and the sterilization time should be maintained for more than 30 minutes. Clean all containers, utensils, conveyor belts, machinery and equipment with clean water before production. And use 75% alcohol to sterilize the operating platform, adjust the perfusion volume to ensure accurate net content.
2) Before the filling personnel enter the machine room, they should change into work clothes, work caps, and water shoes. After washing and disinfecting their hands, the water shoes should be disinfected in the foot bath, and then the air shower should be used behind the whole body to air shower. Can enter the filling room.
3) Check whether each valve, especially the drain valve of the return tank is closed, check the air source, power supply, and flushing water source, and focus on checking whether the ozone in the bottle cap ozone cabinet is normal, and whether the bottle cap is consistent with the produced variety, and confirm and add the cover. After that, you can start the test run.
4) After the trial operation is normal, notify the batching room to supply materials, enter the empty bottle, reflow, measure and control the filling temperature of 50-60 °C, and start production after normal operation. The first 64 bottles are not capped, and the subsequent caps can be officially produced.
6) At the beginning of filling, the production personnel should control and stabilize the speed of the conveyor belt, control the flow by adjusting the valve, ensure that the injection volume meets the specified requirements, and make “original records of filling production”.
7) During the filling process, it should be avoided that the filling flow is too large to splash the beverage, resulting in waste. The beverage should not be overfilled, generally about 5-10mm away from the mouth of the can. If the injection volume is insufficient, the production personnel should take it out for rework in time. The inspector should regularly check whether the net content after filling meets the specified requirements.
8) When the machine has been shut down for more than half an hour due to equipment failure, it should be reflowed, and production can only be performed after the temperature is normal.
9) When changing the variety, the residual material of the original variety should be drained, and the valves and pipes should be rinsed with hot water above 85 ℃, and then the variety should be changed. Before resuming production, return to production.
10) After the production is over, rinse it once with cold water, and then rinse it with hot water at 85°C. If necessary, use the CIP five-step cleaning method to clean: ①Wash with water. ② Wash with 2.0% sodium hydroxide at 80℃ ③ Wash with water ④ Wash with 1%~2% hydrochloric acid at 40~60℃ ⑤ Wash with hot water at 85℃.
11) After the cleaning is over, clean the equipment and pipes in the filling room, drain the remaining water in the valves and tanks, and remove the bottle caps, turn on the ultraviolet light and leave.
12) During the rainy season, it is not only required to spray alcohol indoors when repairing the machine, but also to spray alcohol indoors every two hours. After production, spray the room with peracetic acid or fumigate with chlorine dioxide.

4.2.7 Light inspection
Filled beverages should be carefully inspected by light, and those with high caps, partial caps, crooked caps, impurities or leaks in the bottle should be picked out and discarded, and the good bottles should be washed and disinfected for reuse.

4.2.8 Set of labels
First check whether the label is consistent with the product, turn on the shrinking machine and the sleeve labeling machine after confirmation, and test a few bottles to see the shrinkage effect. After confirmation, the sleeve labeling machine can be placed in the automatic place for sleeve labeling. To the standard label position, to ensure that the sleeve label is beautiful.

4.2.9 Coding
First turn on the coding machine, check whether the coding position and date meet the requirements, and try to print a few bottles after confirmation. In the production process, if there are missing codes, incomplete codes, crooked codes and incorrect codes, they should be picked out, washed with code washing water to remove the bad codes, and then re-printed.

4.2.10 Packing and sealing
Before packing, check whether the box is consistent with the variety of beverages. After confirming, put the box into the beverage. After the box is full, push it to the machine sealing place through the slideway. Sealing requires proper sealing, tight sealing, and firm sealing, and the length of sealing glue is moderate to avoid waste. It is especially important to check whether there are any leaking bottles, poor label shrinkage, and no code bottles when packing. If it is found, pick it out in time and do not put it in the box.

4.2.11 Typesetting
The typesetting personnel should carefully check the quality of the sealed boxes, and the unsealed boxes should be taken back and re-sealed in time. The sealed boxes should be selected with suitable floor boards, and the typesetting should be done according to the palletizing requirements of various varieties, and the layout should be carefully recorded. After a certain variety is produced, the remainder of the beverage should be recorded so that the output can be calculated.

4.2.12 Warehousing
The warehousing personnel should check whether the quantity of each plate meets the requirements, and arrange appropriate locations to store the beverages. After production, the plate should be marked.

4.2.13 Sanitary requirements
4.2.13.1 Before production, each sugar dissolving tank, batching tank, temporary storage tank and pipeline should be cleaned and disinfected. The workshop should turn on the ultraviolet light for 30 minutes for disinfection. The air purification system should be turned on in the filling room in advance, and the filling room should be opened before each filling. Apply ultraviolet sterilization, and the sterilization time is 30min.
4.2.13.2 Sanitary and disinfection operations must be strictly implemented when entering and leaving the filling room. When leaving the filling room, work clothes, shoes, caps and masks must be removed. Before re-entering, work clothes and caps must be replaced. After sterilization and disinfection in the foot bath, Ran can enter the filling room only after passing through the air shower room, and it is required to change the washing liquid and disinfectant in time, and wash the work clothes frequently.
4.2.13.3 After the daily production is over, the relevant containers, equipment, pipes and sites shall be rinsed and cleaned to ensure that there is no breeding of mosquitoes, flies and insect pests.

1. Purpose
Instruct the production staff to make the production operation standardized, standardized and programmed.

2. Scope of application
It is suitable for the production operation of the company’s protein drinks.

3. Responsibilities
3.1 The production workshop is responsible for the production operation of protein drinks and is responsible for recording.
3.2 The Quality Control Department is responsible for the quality inspection of in-process products and the disposal of substandard products

4. Working process
4.1 Production process flow
See the document “Production Process Flow Diagram”

4.2 Workflow
4.2.1 Water treatment
Before making RO water every day, the mechanical filter and activated carbon filter should be flushed in reverse and positive order in the order of “reverse” and “forward”, and the time of reverse and forward flushing should be adjusted appropriately according to the length of stop running, generally 3 to 6 minutes. After the reverse and forward flushing is completed, start the reverse osmosis device to start the production of RO water. The initial RO water has a high conductivity and can be drained. When the RO water conductivity is lower than 10us/cm, the RO water is injected into the RO water tank. Start the multi-stage centrifugal pump, and pump the RO water from the RO water tank in the water treatment room to the batching sterilization room for batching.
For the specific reverse osmosis water treatment process, please refer to the “Reverse Osmosis Water Treatment Operation Instructions”.

4.2.2 Purchase acceptance of raw and auxiliary materials
4.2.2.1 Purchasing raw and auxiliary materials such as peanut concentrate, white granulated sugar, milk powder, and food additives (non-dairy creamer, compound emulsified thickener, acesulfame potassium, sodium cyclamate, edible flavor, etc.) must be purchased with a food production license Products that have passed the third-party inspection and have a certificate of conformity shall be checked and accepted according to the “Inspection and Recording Specifications for Purchases”, and non-conforming products are strictly prohibited from being put into production. If peanuts, soybeans, etc. cannot pass the inspection report of the third party, they should send it to the third party for inspection by themselves, and the products that pass the inspection can be put into production and use.
4.2.2 Raw and auxiliary materials can be put into production according to the principle of first-in-first-out, and to ensure that there is no deterioration within the shelf life. Do not use raw materials of unknown origin for production. The scope of use and the amount of food additives should be strictly in accordance with the provisions of GB2760.

4.2.4 Dissolving sugar
4.2.4.1 According to the requirements of the formula, accurately weigh the corresponding amount of white granulated sugar that has been checked and verified. At the same time, add about 500 liters of RO water to the hot and cold cylinder of ingredients, and boil the drinking water to about 80 ℃ by stirring with steam. Weigh the white granulated sugar, continue stirring with steam, and heat to 90±2℃. Keep at this temperature for 20min to completely dissolve the white sugar.
4.2.4.2 Filter the completely dissolved syrup through a tubular filter, and store the cold syrup in an emulsifying tank through a pipeline for the next process.

4.2.5 Emulsification
4.2.5.1 According to the formula requirements, weigh and check the peanut butter, casein yogurt, stabilizer and milk powder to be added, put them into the emulsifying tank, start high-speed stirring, and stir for 15 minutes to fully dissolve them.
4.2.5.2 After the stirring, the temperature of the material in the cylinder is raised to 70℃±2℃ through the plate heat exchanger, and then pumped to the temporary storage tank A.

4.2.6 Homogenization and deployment
4.2.6.1 Pass the semi-finished slurry into the primary homogenizer, adjust the homogenization pressure to 25±1 Mpa, and put it into the mixing tank B.
4.2.6.2 Weigh and recheck the remaining unweighed raw materials and additives (except sodium bicarbonate) according to the formula requirements, and start stirring for 5 minutes to fully dissolve them, and then pump them to the C tank through the bag filter.
4.2.6.3 Weigh the sodium bicarbonate according to the formula and put it into the blending tank C, and add purified water to make up the volume to the 1000L mark, and start stirring for 10 minutes. After the quality controller detects the soluble solids, PH value, and sensory qualifications, the secondary homogenization is carried out.
4.2.6.4 Pass the semi-finished slurry into the secondary homogenizer, adjust the homogenization pressure to 45±1 Mpa, and put it into the high-level storage tank for filling and production.

4.2.7 Filling and capping
4.2.7.1 Bottle/cap cleaning and disinfection
1) Before filling, the bottles of different specifications are sent from the upper bottle room to the bottle cap cleaning and disinfection room through the conveyor belt.
2) The bottle-filling personnel conduct initial inspection of the empty bottles by sight, hand, etc. After passing the test, the bottles are placed on the conveyor belt.
3) Bottles and caps can only be sent to the filling room after being cleaned and disinfected.
2) After the production, in principle, the remaining bottles in the empty bottle warehouse should be cleaned (dustproof), and the number of bottles should be counted for statistical use.
4.2.7.2 Automatic filling and capping
1) Check whether each valve, especially the drain valve of the return tank is closed, check the gas source, power supply, and flushing water source, and focus on checking whether the ozone in the bottle cap ozone cabinet is normal, and whether the bottle cap is consistent with the produced variety, and confirm and add the cover. After that, you can start the test run.
2) After the trial operation is normal, notify the batching room to supply materials, enter the empty bottle, pump back, measure and control the filling temperature of 70-80 °C, and start production after normal operation. The first 20 bottles are not capped, and the subsequent caps can be officially produced.
3) At the beginning of filling, the production personnel should control and stabilize the speed of the conveyor belt, control the flow by adjusting the valve, ensure that the injection volume meets the specified requirements, and make an “original record of filling production”.
4) During the filling process, it should be avoided that the filling flow is too large to splash the beverage, resulting in waste. The beverage should not be overfilled, generally about 5-10mm away from the mouth of the can. If the injection volume is insufficient, the production personnel should take it out for rework in time. The inspector should regularly check whether the net content after filling meets the specified requirements.
5) When the machine is shut down for more than half an hour due to equipment failure, it should be reflowed, and the production can only be performed after the temperature is normal.
6) When changing the variety, the residual material of the original variety should be drained, and the valves and pipes should be rinsed with hot water above 85°C, and then the variety should be changed. Before resuming production, return to production.
7) After the production is over, use cold water to rinse once, and then rinse with 85 ℃ hot water. If necessary, CIP five-step cleaning method can be used to clean: ① water washing. ② Wash with 2.0% sodium hydroxide at 80℃ ③ Wash with water ④ Wash with 1%~2% hydrochloric acid at 40~60℃ ⑤ Wash with hot water at 85℃.
8) After the cleaning is over, clean the equipment and pipes in the filling room, drain the remaining water in the valves and tanks, and remove the bottle caps, turn on the ultraviolet light and leave.
9) During the rainy season, it is not only required to spray alcohol indoors when repairing the machine, but also to spray alcohol indoors every two hours. After production, spray the room with peracetic acid or fumigate with chlorine dioxide.

4.2.8 Sterilization
4.2.8.1 The capped product must be sterilized in time to prevent the growth of microorganisms in the tank. Production personnel must operate the sterilization equipment in strict accordance with the relevant operating requirements of the equipment.
4.2.8.2 The production personnel should place the capped products in the designated area of ​​the sterilization workshop (the area to be sterilized) in a timely manner, and make the identification signs to be sterilized.
4.2.8.3 The production staff pushes the iron frame containing the products to be sterilized into the retort, removes the identification plate on the basket, closes the door of the retort, and closes the safety lock after checking that the door of the retort is well closed.
4.2.8.4 Check whether the automatic tubular sterilizer, pipes, valves, etc. are unblocked, and whether the temperature gauge, steam and pressure gauge are normal.
4.2.8.5 First, turn on the steam for evacuating for 5 minutes, then close the exhaust valve, and start the constant temperature sterilization when the sterilization temperature in the pot rises to the specified temperature value. During the sterilization process, the pressure of the sterilization pot was kept at 0.21MPa, the sterilization temperature was 121°C, and the post-sterilization process was carried out under the sterilization time of 20min.
4.2.8.6 The production personnel must regularly monitor the readings of the thermometer and pressure gauge of the sterilizer, and make production process monitoring records such as “monitoring records of key quality control points” to ensure compliance with the specified technological requirements. During the sterilization process, it is necessary to prevent the temperature, pressure, etc. from rising and falling, especially when the temperature is lower than the production process requirements, it is prone to the phenomenon of incomplete sterilization, and the production personnel must pay special attention. If abnormal readings or deviations are found, they should be recorded immediately and the relevant personnel should be notified.
4.2.8.7 After the sterilization is completed, when the temperature cools to 38-45℃, the production personnel open the pot door to take out the product, hang up the sterilized sign in time, and place it in the designated area (sterilized area) for natural cooling or Turn on the cooling fan for air cooling.
4.2.8.8 After sterilization, the can body of the product should be free of swelling, concave can, wrinkles and other phenomena. The inspector shall carry out sampling inspection in accordance with the requirements of “In-process Inspection and Recording Specifications”. If the inspection result fails to meet the specified requirements, it shall be dealt with in accordance with the requirements of the “Nonconforming Product Management Procedures”.

4.2.9 Sleeve label, heat shrink
First check whether the label is consistent with the product, turn on the shrinking machine and the sleeve labeling machine after confirmation, and test a few bottles to see the shrinkage effect. After confirmation, the sleeve labeling machine can be placed in the automatic place for sleeve labeling. To the standard label position, to ensure that the sleeve label is beautiful.

4.2.10 Code
First turn on the coding machine, check whether the coding position and date meet the requirements, and try to print a few bottles after confirmation. In the production process, if there are missing codes, incomplete codes, crooked codes and incorrect codes, they should be picked out, washed with code washing water to remove the bad codes, and then re-printed.

4.2.11 Packing and sealing
Before packing, check whether the box is consistent with the variety of beverages. After confirming, put the box into the beverage. After the box is full, push it to the machine sealing place through the slideway. Sealing requires proper sealing, tight sealing, and firm sealing, and the length of the sealing glue is moderate to avoid waste. It is particularly important to check whether there are any leaking bottles, poor label shrinkage, no code bottles, etc. when packing. If it is found, pick it out in time and not put it in the box.

4.2.12 Arrangement
The palletizing personnel should carefully check the quality of the sealed boxes, and the unsealed boxes should be taken back and resealed in time. The sealed boxes should be selected with suitable floor boards, and the pallets should be arranged according to the palletizing requirements of each variety. One board should be arranged carefully. Record the number of plates, and record the remainder of the beverage after a certain variety is produced, so that the output can be calculated.

4.2.13 Warehousing
The warehousing personnel should check whether the quantity of each plate meets the requirements, and arrange appropriate locations to store beverages. After production, they should be marked with signs. Warehouse stacking requires no upside down, no mixing, neat and vertical stacking, separation between stacks, and no wet marks on cartons. Make it 10~15cm away from the wall and the ground.

4.2.14 Cleaning and disinfection of production equipment
4.2.14.1 After the production is over, the production equipment, pipes and containers should be cleaned and disinfected. For details, please refer to the corresponding regulations in DHZZ/JS-07 “CIP Cleaning and Disinfection Operation Regulations”. After cleaning and disinfection, drain all production equipment, pipes, valves, and residual water in storage tanks, and after cleaning out the bottle caps, turn on the ultraviolet light and leave.
4.2.14.2 Before the production starts, the production equipment, pipelines and containers shall be cleaned and disinfected. For details, please refer to DHZZ/JS-07 “CIP Cleaning and Disinfection Operation Regulations”. If the production is daily, the three-step hot water CIP procedure is adopted. If the production is stopped for more than three days, the four-step alkaline washing CIP procedure is adopted. If the production is stopped for more than two weeks, the five-step acid-base washing CIP procedure is adopted.

4.2.15 Sanitary requirements
4.2.15.1 Before production, all production equipment, pipelines and containers should be cleaned and disinfected. The workshop should turn on the ultraviolet lamp for 30 minutes for disinfection, and the air purification system should be turned on in advance in the filling room.
4.2.15.2 Sanitation and disinfection operations must be strictly implemented when entering and leaving the filling room. When leaving the filling room, work clothes, shoes, caps and masks must be removed. Disinfect the pair and disinfect them in the foot soaking pool, and then enter the filling room after passing through the air shower room. It is required to change the washing liquid and disinfectant in time, and wash the work clothes frequently.
4.2.15.3 After the daily production is over, the relevant production equipment, pipes, containers and sites shall be cleaned and disinfected to ensure that no mosquitoes, flies and insects breed.

5 Related records
5.1 “Original Production Records of Key Processes”

1. The principle of reverse osmosis
Pressurize the raw water side of RO, so that part of the raw water permeates the membrane in the direction perpendicular to the membrane, the salts and colloidal substances in the water are concentrated on the membrane surface, and the remaining raw water takes away the concentrated substances in the direction parallel to the membrane. Only a small amount of salt remains in the permeated water to achieve the purpose of desalination.
The reverse osmosis unit is designed with a reverse osmosis production rate of 10T/h. 6 reverse osmosis membrane shells are equipped with 12 reverse osmosis membrane elements. The main equipment includes high pressure pumps, high and low pressure alarms, matching valves and their instruments, reverse osmosis supports, reverse osmosis electrical automation equipment, etc.
The start and stop of RO is automatically controlled. The RO high pressure pump enters the water low pressure switch. When the pressure is lower than 0.05MPa, it will alarm and stop the high pressure pump; the outlet is equipped with a high pressure switch, and if it is higher than 2MPa, it will alarm and stop the high pressure pump. The pumps and valves on the RO device can be operated on the local control panel of the RO device, and the flow rate of the produced water and concentrated water in the system, as well as the pressure value of each measuring point can be observed.

2. Start and stop operation of reverse osmosis
(1) Preparations before starting the machine:
1. The liquid level of the raw water tank is at a high level
2. On-site control cabinets are powered on
3. Various instruments have been calibrated accurately and put into use
4. All production drugs are sufficient, and the liquid in the dosing box has been prepared adequately
5. The oil level of each water pump is normal, and the cranking of the water pump is normal
6. Each water pump should be tested for qualified insulation and has been powered
7. The pretreatment equipment has been rinsed to ensure that the effluent meets the design requirements.
8. Check that all valves in the system are properly open and closed
9. Open all exhaust valves on pipes and equipment, and fill with water and exhaust in advance. Close the exhaust valve after the equipment is running normally and the water is flowing out of the exhaust valve smoothly.

(2) Automatic operation
1. Start: Switch the automatic/manual knobs on all PLC control cabinets to automatic gear. Click the reverse osmosis start button to start the equipment automatically put into operation. Before the high-pressure pump is started, the system performs low-pressure flushing. After 2-5 minutes of low-pressure flushing, the high-pressure pump is turned on, and the concentrated water discharge and product water discharge valves are closed to enter the normal operation stage.
2. Shutdown: Click the reverse osmosis stop button, the equipment will be automatically shut down. Stop the high pressure pump first, and then the system is flushed with low pressure for 2-5 minutes. Close the manual valve in the system that needs to be closed.
3. Forced automatic shutdown: The reverse osmosis is in automatic operation state. If you need to stop the operation in case of emergency, you can click the emergency button on the control cabinet. After the emergency stop, the valves of all interlocking equipment are in the open pressure relief state. After the emergency stop is completed, check the fault point. Therefore, after the emergency stop is completed, operate the relevant valves to restore the equipment to the state before automatic operation.

(3) Manual operation
The RO device can be manually operated under special circumstances such as debugging, failure, and maintenance, and it should be automatically operated at ordinary times.
1. Driving: Turn the manual/automatic knob on the control cabinet and pump to manual. Open the product water discharge valve, concentrated water discharge valve and water inlet valve of the RO unit. Open the water inlet valve, exhaust valve and outlet door of the precision filter. Start the raw water pump, slowly open the outlet door of the raw water pump, close the exhaust valve after all the exhaust valves flow smoothly, and perform low-pressure flushing on the RO for 2-5 minutes. After RO low-pressure flushing, turn on the high-pressure pump, close the concentrated water discharge valve, and close the permeate water discharge valve after 30 seconds to start normal water production. Under normal circumstances, it is not allowed to adjust the opening of the manually adjusted valve, otherwise it will easily cause damage to the reverse osmosis membrane, including RO water inlet control valve, concentrated water control valve, and product water control valve.
2. Stop: Stop the high pressure pump, open the product water discharge valve and the concentrated water discharge valve, and rinse at low pressure for 2-5 minutes. Close the product water discharge valve, concentrated water discharge valve, and RO water inlet valve. Turn off the raw water pump.

(4) Water quality monitoring after water treatment
The quality inspector shall monitor the water quality of the effluent after the reverse osmosis water treatment, and fill in the “Water Quality Monitoring Record after Water Treatment”.
See the following table for water quality monitoring regulations:

1. Purpose
Instruct employees in production operations to standardize, standardize and program the mixing and carbonation operations of soda.

2. Scope of application
It is suitable for the production operation of the company’s bottled carbonated soft drinks mixed carbonation.

3. Responsibilities
3.1 The production workshop is responsible for the mixed carbonated production operations of bottled carbonated soft drinks and records.
3.2 The Quality Control Department is responsible for supervising the implementation of this operation and making relevant records.

4. Working process
4.1 Before production, the equipment, pipelines and containers should be inspected, whether they are disinfected, whether the cleaning meets the hygienic requirements, whether all the pipelines are leaking or running out of gas, and whether each valve handle is in the correct position.
4.2 Adjust the electrical contact pressure gauge of the degassing tank, pump the RO water to the degassing tank through the water pump for degassing treatment, and then pump the de-climate RO water to the pre-carbonation tank through the water pump; in this way, the prepared syrup is passed through the material. The liquid pump is pumped to the syrup tank for standby.
4.3 Adjust the power-on contact pressure gauge of the storage tank according to the product requirements. Generally, the lower limit can be adjusted to 0.3Mpa, and the upper limit pointer can be adjusted to 0.4Mpa.
4.4 Turn on the power of the soda-water mixer, and the power indicator light is on. Open the carbon dioxide bottle, adjust the output pressure to 0.7-0.8 MPa, and keep the pressure stable; slowly open the carbon dioxide inlet valve on the gas supply cabinet, adjust the back pressure filter and pressure reducing valve to 0.40-0.42 Mpa, press the back pressure button, and wait until There is the sound of carbon dioxide in the storage tank, then turn on the carbonization flow switch, and adjust it appropriately according to the detection of the gas content.
4.5 Click the water pump button on the touch screen in the manual state, the water pump will run, and the corresponding indicator button will flash. When the water level rises to the set high level, the water pump stops automatically and the corresponding indicator light stops flashing.
4.6 Click the syrup pump button on the touch screen in the manual state, the syrup pump runs, and the corresponding indication button flashes. When the syrup rises to the set high level, the syrup pump stops automatically and the corresponding indication button stops flashing.
4.7 When the pressure gauge on the storage tank shows about 0.20 Mpa, click the carbonization pump button on the touch screen, the carbonization pump runs, and the corresponding indicator light flashes. When the liquid level rises to the set high level, the carbonization pump stops automatically, and the corresponding indicator light stops flashing.
4.7.1 When the carbonation pump is running, it should be checked and adjusted:
a. Check the pressure of the back pressure filter pressure reducing valve, it should be 0.4-0.5 Mpa;
b. Adjust the carbonation flowmeter to 0.2-15 (m3/h);
c. Check the carbon dioxide reflux flowmeter, the indication value is about 0.2-12 (m3/h);
d. Adjust the ratio of syrup and water according to the different requirements of the product, not only adjust the adjusting valve of syrup and water, and test the sugar content to make it meet the ratio requirements.
4.8 When the above steps are performed correctly, and the filling machine is under the condition of back pressure, it can enter the production operation. Click the automatic button in the automatic state, and the machine will enter the filling machine for filling.
4.9 After about two rounds of filling by the filling machine, check the gas content of the beverage in the bottle. If it is qualified, it will be tested again every 10 minutes. If it is still qualified, the production can be continued.
4.10 In the production process, if the supply of RO water, syrup, carbon dioxide gas, etc. is in a stable state, the sugar content and gas content of the product can be tested at certain intervals in the future to ensure product quality. If the bottled beverage test does not meet the product requirements, it should be adjusted according to the specific situation until the product is qualified.
4.11 End of production. When the production is over, you can press the automatic button once to stop the automatic operation, switch to the manual state and press the carbonation button to start the carbonation pump, press the back pressure button to start the back pressure, when the beverage is observed from the storage tank level indicator After all the products are fed into the filling machine, close the carbon dioxide gas cylinder, close the carbon dioxide gas inlet valve on the gas supply cabinet, and press the stop button, the whole machine will stop running and the production will end.
4.12 Cleaning after production. Cleaning and disinfection are carried out in accordance with DHZZ/JS-07 “CIP Cleaning and Disinfection Operation Regulations”.

1. Purpose
1.1 Clarify the cleaning and disinfection of equipment, pipelines and containers in each production process of beverages in the production workshop to reduce microbial contamination and ensure product quality.

2. Scope
2.1 Equipment, pipes and containers suitable for each production process of beverages in the production workshop.

3. duty
3.1 The operators of each production process of beverage in the production workshop shall implement the operating procedures.
3.2 The Quality Control Department is responsible for monitoring, directing and maintaining the validity of the documents.

4. content
4.1 Dissolving and filtering process of white granulated sugar
4.1.1 Scope of cleaning and disinfection
1. Sugar-dissolving tank (cold and hot cylinder for ingredients) → sugar-dissolving pump
2. Diatomite filter and its pipeline → bag filter (install the filter bag during hot water disinfection, remove the filter bag during acid-base cleaning) → plate heat exchanger (close the cooling water) → enter the No. 1 mixing tank for reflux to the CIP tank.

4.1.2 Table for Cleaning and disinfection methods

4.2 Food additive blending process, blending tank mixing and constant volume process
4.2.1 Scope of cleaning and disinfection
1. Batching mixing barrel, mixing tank → mixing tank CIP spray pipe → mixing tank discharge pipe → CIP return pipe → CIP tank
2. Auxiliary material tank → mobile pump
4.2.2 Cleaning and disinfection methods (refer to 4.1.2 Table for Cleaning and disinfection methods)

4.3 Beverage sterilization and soda mixed carbonation process
4.3.1 Scope of cleaning and disinfection
1. Feeding tube
2. Fully automatic tubular sterilization unit, filter, steam-water mixer, filling system
4.3.2 Cleaning and disinfection methods
a. Feeding pipe cleaning and disinfection method (refer to 4.1.2 Table for Cleaning and disinfection methods)

b. Cleaning and disinfection methods for automatic tubular sterilization units, filters, soda-water mixers, and filling systems

4.4 Can filling and capping process
4.4.1 Scope of cleaning and disinfection
3 in 1 automatic filling machine
4.4.2 Cleaning and disinfection methods (refer to 4.1.2 Table for Cleaning and disinfection methods)

1. Purpose
Standardize the incoming inspection and recording of food raw materials, food additives, and food-related products, ensure the stability of product quality from the source of production, and ensure that the materials meet the specified requirements.

2 Scope of application
It is suitable for the control of the incoming inspection process of food raw materials, food additives and food-related products used in the company’s production.

3 Responsibilities
3.1 The warehouse is responsible for the collection and storage of raw materials and packaging materials;
3.2 The inspector is responsible for extracting the specified quantity of purchased substances, conducting inspections, and judging whether the products are qualified or not. For unqualified products, they are responsible for timely isolation and disposal in accordance with the “Unqualified Management Procedures”.
3.3 The business department is responsible for contacting suppliers to solve quality problems in the procurement process, handling returns and exchanges, and requiring suppliers to take effective corrective and preventive measures to ensure the quality of purchased materials.

4 working procedures
4.1 Incoming material acceptance process

4.2 Receipt at the point of purchase and pending inspection
4.2.1 When the materials are purchased and returned to the factory, the warehouse clerk should collect the materials, varieties, specifications, and quantities listed in the “Purchase Plan and Arrival Registration Form”, and check them against the supplier’s delivery documents.
4.2.2 The warehouse keeper will place the collected materials in the raw material warehouse or area, and mark the product and inspection status (such as pending inspection, inspected qualified, inspected unqualified, etc.) with signs, storage cards or appropriate methods. The content of product identification includes: material name, specification, batch number, origin, quantity, date, etc.
4.2.3 The warehouse keeper shall promptly notify the quality inspector to conduct incoming inspection or verification of incoming materials.

4.3 Main raw and auxiliary materials and technical requirements
The purchased raw materials should have the characteristics of color, aroma, taste and tissue morphology that the variety should have, and should not contain toxic and harmful substances, and should not be polluted by them. Otherwise, it cannot be purchased.
1) Drinking water should meet the requirements of GB5749 “Drinking Water Hygiene Standard”;
2) White sugar should meet the requirements of GB317 “White Sugar”;
3) High fructose syrup should meet the requirements of GB/T20882 “Fructose Syrup”;
4) Concentrated fruit juice (pulp) should meet the requirements of GB17325 “Sanitary Standard for Concentrated Fruit and Vegetable Juice (Pulp) for Food Industry”;
5) Concentrated orange juice should meet the requirements of GB/T 21730-2008 “Concentrated Orange Juice”;
6) Mango juice should meet the requirements of NY/T 707-2003 “Mango Juice”;
7) Peanut paste
8) Tea powder
9) Milk powder should meet the requirements of GB 19644-2010 “National Food Safety Standard Milk Powder”;
10) Soybeans should meet the requirements of GB1352 “Soybeans”;
11) Peanuts should meet the requirements of GB1532 “Peanuts”;
12) Cocoa butter substitute should meet the requirements of the standard “Cocoa butter substitute chocolate and cocoa butter substitute chocolate products” SB/T 10402-2006;
13) Edible salt should meet the requirements of GB 5461 “Edible Salt”;
14) Sodium saccharin should meet the requirements of GB 4578 “Food Additives Sodium Saccharin”;
15) Citric acid should meet the requirements of GB1987 “Food Additives Citric Acid”;
16) Sodium citrate should meet the requirements of GB 6782 “Food Additive Sodium Citrate”;
17) Double Caramel
18) Sodium iso-VD
19) Edible flavors should meet the requirements of QB/T1505 “Edible Flavor”;
20) Potassium sorbate should meet the requirements of GB13736 “Food Additives Potassium Sorbate”;
21) Sodium benzoate should meet the requirements of GB1902 “Food Additives Sodium Benzoate”;
22) Acesulfame potassium (AK sugar) should meet the requirements of GB 25540 “National Food Safety Standard – Food Additive Acesulfame Potassium”;
23) Aspartame should meet the requirements of GB22367 “Food Additive Aspartame (Aspartame)”;
24) Lemon yellow should meet the requirements of GB4481.1 “Food Additives Lemon Yellow”;
25) Sunset yellow should meet the requirements of GB6227.1 “Food Additives Sunset Yellow”;
26) Brilliant blue should meet the requirements of GB 7655.1 “Food Additives Brilliant Blue”;
27) Allura Red should meet the requirements of GB 17511.1 “Food Additives Allura Red”;
28) Carmine should meet the requirements of GB 4480.1 “Food Additives – Carmine”;
29) Amaranth should meet the requirements of GB 4479.1 “National Food Safety Standard – Food Additive – Amaranth”;
30) Cyclamate should meet the requirements of GB 12488 “Food Additives Sodium Cyclamate (Sodium Cyclamate)”;
31) Carbon dioxide should meet the requirements of GB 10621 “Food Additives – Liquid Carbon Dioxide”;
32) Sodium bicarbonate should meet the requirements of GB 1887-2007 “Food Additives – Sodium Bicarbonate”;
33) Taurine should meet the requirements of GB14759 “Food Additive Taurine”;
34) Calcium chloride should meet the requirements of GB22214 “Food Additives Calcium Chloride”;
35) Potassium chloride should meet the requirements of QB2554 “Edible Potassium Chloride”;
36) Zinc sulfate should meet the requirements of Appendix A of Q/DHZZ0004S “Other Drinking Water (Mixed Water)”;
37) Sodium carboxymethyl cellulose should meet the requirements of GB1904 “Food Additives Sodium Carboxymethyl Cellulose”;
38) Agar (agar) should meet the requirements of GB1904 “National Food Safety Standard for Food Additives Agar (agar)”;
39) Sucrose fatty acid ester should comply with GB8272 “Food Additives – Sucrose Fatty Acid Ester”
40) Xanthan gum should meet the requirements of GB13886 “Food Additives – Xanthan Gum”;
41) Carrageenan should meet the requirements of GB13886 “Food Additives Carrageenan”;
42) Distilled glycerol monostearate should meet the requirements of GB15612 “Food Additive Distilled Glycerol Monostearate”;
43) Sodium alginate should meet the requirements of GB1976 “Food Additives Agar (Agar)”;
44) Sodium caseinate should meet the requirements of QB/T3800 “Food Additives Agar (Agar)”;
45) Sodium tripolyphosphate should meet the requirements of GB25566 “National Food Safety Standard – Food Additives Sodium Tripolyphosphate”;
46) The pop-top can should meet the requirements of GB/T 17590 “Aluminum Easy-Open Three-piece Can”;
47) PET plastic bottles should meet the requirements of QB2357 “Polyester (PET) Still Drink Bottles” and QB/T 1868 “Polyethylene Terephthalate (PET) Carbonated Drink Bottles”;
48) PET plastic drums should comply with GB13113 “Hygienic Standard for Polyethylene Terephthalate Molded Products for Food Containers and Packaging Materials” and QB/T 2665 “Polyethylene Terephthalate for Hot Filling” (PET) carbonated beverage bottles”;
49) The retort-resistant composite film should comply with GB/T18192 “Paper-based composite materials for aseptic packaging of liquid food”
50) The packaging carton should meet the requirements of GB/T6543 “Single corrugated carton and double corrugated carton for transportation and packaging”;
51) Suppliers should provide quality assurance documents such as product qualification certificates, inspection reports, and production licenses (if involved) of main raw materials.

4.4 Incoming goods inspection
4.4.1 When purchasing food raw materials, food additives, and food-related products, the supplier’s license and the product qualification certificates (such as product inspection reports, product qualification certificates, etc.) corresponding to the purchased batches of products shall be checked. Each batch of raw and auxiliary materials should be inspected, including appearance, sensory characteristics, specifications and dimensions.
4.4.2 Imported food raw materials, food additives, and food-related products shall comply with my country’s national food safety standards. Enterprises purchasing imported food raw materials, food additives, and food-related products that are subject to statutory inspection shall obtain valid inspection and quarantine certificates from suppliers;
4.4.3 For food raw materials, food additives, and food-related products that cannot provide certification documents, the enterprise shall conduct self-inspection or commission inspection in accordance with food safety standards, and keep inspection records; shall not purchase or use food raw materials that do not meet food safety standards , food additives, food-related products.
4.4.4 The food raw materials, food additives, food-related products and product labels used shall comply with the provisions of national laws, regulations and standards.

4.4.5 The incoming inspection of main raw and auxiliary materials is shown in the following table:

4.5 Processing of inspection results
a) The inspection situation is recorded in the “Inspection Report of Raw Materials” and “Inspection Ledger of Incoming Goods”, and the conclusion of whether it is qualified or not is indicated.
b) When unqualified products are found in purchase acceptance, they shall be disposed of according to the “Management Procedures for Unqualified Products”.
4.6 Raw material storage
According to the conclusion of the “Inspection Report of Raw Materials”, the warehouse keeper will go through formal warehousing procedures for qualified materials. non-conforming material
Identify, isolate and dispose of in accordance with the “Non-conformity Management Procedures”.
4.7 Regulations on incoming inspection records
a) Purchase inspection records (see “Inspection Report for Raw Materials”, “Inspection Ledger for Purchases”) should truthfully record the name, specification, quantity, supplier name and contact information, purchase date, etc. of food raw materials and food-related products, etc. And it corresponds to the original record certificate one by one.
b) The purchase inspection records shall be authentic, and the purchase or sales notes containing relevant information shall be retained, and the storage period of the records and notes shall not be less than 2 years.
5 Relevant documents and records
5.1 “Unqualified Management Procedures”
5.2 “Inspection Management Procedures”
5.3 “Purchase Plan and Arrival Registration Form”
5.4 “Inspection Report of Raw Materials”
5.5 “Acquisition Inspection Record Ledger”