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
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
Laborship
1. Labors: 487 workers 2. Working Time: 1. Office: 08.0016.00 (Mon-Fri), 08.00-13.00 (Sat); rest time: 12.0013.00 (Mon-Thu), 12.0013.30 (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
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. 2. 3. 4. 5. 6. 7. 8. Water: extracting solvent Tea Leaves: Main ingredients to be extracted Sugar: Imparting sweetness PET Bottle: Products primary packaging Screw Cap: Closure of the packaging Carton Box: Products secondary packaging Bottle Label: Labelling info of the product Cap Seal: Requirement for specific customer (e.g. Cineplex 21 Group) 9. Food Additives: Imparting desired flavor (Jasmine / Honey Lemon Flavor) and keeping products 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: Nonstandard products 5. Spare Part Warehouse: Spare Part of the Machinery 6. FIFO system
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
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.