I have visited Bisleri factory for my production and quality management project this data is primary data which help you to understand the process of production.
M.R RAMESH CHAUHAN is the vintage boss of the 250 crore PARLE BISLERI LIMITED. The brand has some 18 manufacturing locations spread across the country. The mainstream competition is in the form of coca-cola India’s Kinley, Acquafina from Pepsi foods and nestle India’s pure. Bisleri continues to lead in the Rs 700-1,000 crore organized, packaged water market with an estimated 40 per cent market share, followed by Kinley at 28 per cent and Aquafina with an 11 per cent share. In terms of volumes, the North and West remain Bisleri’s biggest performing markets, despite the brand’s sustained national-level presence.
OPERATION OF BISLERI: –
The Bisleri bottled water range comprises the conventional 500 ml, one litre, 1.2 litre and two litre bottles; five litre and 20 litre jars for the home segment, and smaller packs sizes of 250 ml cups and 330 ml bottles, though in very limited numbers for now. Among all pack sizes the brand straddles, it is the one-litre non-returnable bottles priced at Rs 10 each, and the 20-litre jars for Rs 40 aimed at the home segment that are Bisleri’s bestsellers at present. While the 20-litre jar comprises about 40 per cent of overall Bisleri sales, the one-litre bottles account for approximately 25 per cent brand sales. The main source of water is bore wells from where they get thee water. Then the raw materials required for the bottle is PET i.e. poly ethylene terephatalable. There are 250 workers working in mumbai and 3000 all over India. The production process adopted by bisleri is batch production. The time taken to fill one bottle is approximately 5 minutes. The workers work in 3 shifts which comprises of 60-70 workers per shift. The maintenance of the machines is done every month and every 45 days there is sanitation and cleaning of the machine.
Visit Analysis:
A)
1. Research & Development Dept:
The R & D Dept of this company starts planning 6 months in advance. The R & D Dept conducts market survey for 2-3 months for modification of the shape of the bottle.
2. Market Survey:
The different design is shown to a special group of customers & dealers and according to the demand, the design is chosen by the company.
B)
PRODUCTION CYCLE:
There are mainly three stages in the production cycle:
1. Disinfection: In this stage, water is collected from bore wells which are then disinfected using chemicals.
2. Filterization: In this stage, water is passed through different filters to kill the bacteria present in it. Then, the water is passed on to the next level for filling up.
3. Filling: In this stage, the bottles are ozonated and then the water is filled in the bottles.
C)
PRODUCTION PROCESS:
1. Quality Management of Water:
Raw water which is collected from the wells is stored in a tank which has a capacity to store 1 lakh liters of water. Then the water is chlorinated to kill the bacteria present in the water which is passed through 20 micro arcal filters. Then it is passed through carbon filter which is used for removing activated carbon and odor and also acts as chlorine remover. Then it is passed through 10-micron filter. Then it goes through REVERSE AUSMOSES PLANT, which contains semi-pomitable membrane which removes dissolved solids and bacteria of size 0.001 micron. It is passed through 1 micron and 0.5-micron filters. T hen the water gets ozonated and passed through SS 316 MACHINE. Water is stored in 10000 liter tanks.
2. Blowing of Bottles:
The bottles in this factory are given the desired shape by the use of blowing machines. These machines blow at a temperature of 300 degrees Celsius. The machine used for the blowing purpose is known as the AOKI MACHINE. This machine has a blowing capacity of 10 bottles per minute.
3. Filling of Bottles:
There are three types of filling machines, which are used for the filling purpose. The different sizes of bottles that are filed are of 500ml, 1liter, 1.2liters and 2liters respectively. First the bottle gets ozonized when it is passed through JET MACHINES. In this the bottle gets integrated and disintegrated, it gets rinsed, and then the water is filled into the bottles.
4. Filling of Jars:
The different sizes of jars are 5liters, 10liters and 20liters. The jars are cleaned manually by soap and water. Then it is cleaned with sodium hypo-chloride and virosin, which are disinfectors. When jars are passed through washing machine first it is rinsed with hot water, then disinfected and then it is ozonated. Then jars are passed on to jar fillers where it gets filled and the packing of sealed jars into boxes is done manually.
5. Laboratory Testing:
Every hour samples of water that are filled in to the bottles are taken and various testing is done. First it is checked for odor if any, presence of alkanity, chlorine and calcium. The water is also checked in machines like PH METER, TDS(TOTAL DISSLOVE SOLIDS) METER, NEPHLOMETER, SPECTROPHOTOMETER AND MEASURING OF TUBILITY. They also do aerobic microbial count and pathogen testing.
FURURE PLANS: –
Bisleri have been the market leaders in India as far as mineral waters are concerned. Every time their bottle and waters are checked and rechecked for its purity. Their main aim is to stay ahead of the main rivals i.e. Pepsi and Coca Cola. Their raw material comes from reliance industries limited who are their main suppliers of the raw material i.e. PET.
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