Carbonated Soft Drinks (CSD)

Carbonated Soft Drinks (CSD)

• CSD are light, sweet, non-alcoholic, water-based effervescent drinks
that have carbon dioxide added to make them bubbly or fizzy.
• CSD often contains added acid, mostly phosphoric acid, which can
cause the pH to fall as low as 3.
• CSD are beverages with added carbon dioxide to give them an
effervescent taste. CSD is further classified as colas, non-colas, diet
soft drinks, and regular soft drinks.
• Some of the most well-known examples of CSD are Coca-Cola,
Mountain Dew, Sprite, etc.
The popularity of CSD?

o These fizzy drinks have an acidic bite and

produce a pleasant tingling, cooling sensation
with every sip.
o The bubbles also carry the aroma of the
beverage to engage your sense of smell as well
as taste.
 HISTORY of CSD
o Soft drinks can trace their history back to the mineral water
found in natural springs. Bathing in natural springs has
long been considered a healthy thing to do, mineral water
was said to have curative powers. Scientists soon discovered
that gas carbonium or carbon dioxide was behind the
bubbles in natural mineral water.
o In 1767, the first drinkable, man-made glass of carbonated
water was created by Englishmen, Dr. Joseph Priestley.
Three years later, the Swedish chemist, Torbern Bergman,
invented a generating apparatus that made carbonated
water from chalk using sulfuric acid. Bergman's apparatus
allowed imitation mineral water to be produced in large
amounts.
History of soda water
• The roots of soft drinks extend to ancient times. Two thousand years ago Greeks and Romans
recognized the medicinal value of mineral water and bathed in it for relaxation, a practice that
continues to the present.
• In the late 1700s Europeans and Americans began drinking the sparkling mineral water for its reputed
therapeutic benefits. The first imitation mineral water in the U.S. was patented in 1809. It was called
"soda water" and consisted of water and sodium bicarbonate mixed with acid to add effervescence.
Pharmacists in America and Europe experimented with myriad ingredients in the hope of finding new
remedies for various ailments. Already the flavored soda waters were hailed as brain tonics for curing
headaches, hangovers, and nervous afflictions.Pharmacies equipped with "soda fountains" featuring
the medicinal soda water soon developed into regular meeting places for local populations. Flavored
soda water gained popularity not only for medicinal benefits but for the refreshing taste as well.
• The market expanded in the 1830s when soda water was first sold in glass bottles.
• Filling and capping the gaseous liquid in containers was a difficult process until 1850, when a manual
filling and corking machine was successfully designed. The term "soda pop" originated in the 1860s
from the popping sound of escaping gas as a soda bottle was opened.
Invention of Coca-cola and Pepsi-cola
• New soda flavors constantly appeared on the market. Some of the more popular flavors were
ginger ale, sarsaparilla, root beer, lemon, and other fruit flavors.
• In the early 1880s pharmacists experimented with powerful stimulants to add to soda water,
including cola nuts and coca leaves. They were inspired by Bolivian Indian workers who
chewed coca leaves to ward off fatigue and by West African workers who chewed cola nuts as a
stimulant. In 1886 an Atlanta pharmacist, John Pemberton, took the fateful step of combining
coca with cola, thus creating what would become the world's most famous drink, "Coca-Cola".
The beverage was advertised as refreshing as well as therapeutic: "French Wine Cola—Ideal
Nerve and Tonic Stimulant."
• A few years later another pharmacist, Caleb Bradham, created "Pepsi-Cola" in North Carolina.
Although the name was a derivation of pepsin, an acid that aids digestion, Pepsi did not
advertise the beverage as having therapeutic benefits. By the early 20th century, most cola
companies focused their advertising on the refreshing aspects of their drinks.
• As flavored carbonated beverages gained popularity, manufacturers struggled to find an
appropriate name for the drinks. Some suggested "marble water," "syrup water," and "aerated
water." The most appealing name, however, was "soft drink," adapted in the hopes that soft
drinks would ultimately supplant the "hard liquor" market. Although the idea never stuck, the
term soft drink did.
Ingredients for CSD
1. Carbonated Water
2. Sugar or HFCS
3. Carbon dioxide
4. Acid
5. Flavorings
6. Colors
7. Caffeine
8. Preservatives
Formulation of CSD
Carbonated water : Carbonated water constitutes up to 94% of a soft drink. Carbon dioxide adds that
special sparkle and bite to the beverage and also acts as a mild preservative. Carbon dioxide is an uniquely
suitable gas for soft drinks because it is inert, non-toxic, and relatively inexpensive and easy to liquefy.

Sugars: Contribute sweetness to the body to drink, acting as synergists and giving balance to the flavor. It
is used 7–12% m/v when it is the only source of sweetener. The second main ingredient is sugar, which
makes up 7-12% of a soft drink. Used in either dry or liquid form, sugar adds sweetness and body to the
beverage, enhancing the "mouth-feel," an important component for consumer enjoyment of a soft drink.
Sugar also balances flavors and acids.

Carbon dioxide: It is used 0.3–0.6% m/v. Provides mouth feel and sparkle to drink (carbonates only)
Acids: The overall flavor of a soft drink depends on an intricate balance of sweetness,
tartness, and acidity (pH). Acids add a sharpness to the background taste and enhance
the thirst-quenching experience by stimulating saliva flow. The most common acid in
soft drinks is citric acid, which has a lemony flavor. Acids also reduce pH levels, mildly
preserving the beverage. Dosage: 0.05–0.03% m/v. Contributes in sharpness, sourness,
and background to flavor; increases thirst-quenching effects.
Flavors Nature identical and artificial: CSD uses cola nuts from the African trees,
Cola nitida, and Cola acuminata as flavoring agents. Used 0.1–0.28% m/m Provide
flavor, character, and identity to natural: up to 0.5% m/m the drink.
High-intensity sweeteners: Are used based on sucrose equivalence (e.g., aspartame
might be employed at 0.4–0.6% m/v as a sole sweetener). Provide sweetness, calorific
reduction, and synergist action; often used in combination, e.g., aspartame with
Acesulfame- K.
Colors: (natural or synthetic). Dosage: 0–70 ppm. Standardize and identify the color
tone of the drink
Preservatives: Statutory limits apply (e.g. sorbic acid up to 250 ppm in the EU).
Restrict microbial attack and prevent destabilization of the drink
TYPES OF CONTAINERS used for CSD

1. RGB (Returnable Glass bottle)

2. PET (Polyethylene terephthalate) bottle
3. Metal Cans

There will be a separate production line for each type of CSD

RGB
Traditionally, glass bottles were the preferred form of
packaging for carbonated beverages. They are still preferred
today in many applications:
o Provided effective closures are correctly applied, gas
retention is excellent.
o To enhance a brand image.
o To provide longer shelf life.
There are disadvantages of weight and brittleness (breakable
without significant deformation). Unless appropriately tinted
or covered with a large label, glass allows ingress of light which
may damage the product and affect the shelf life.
 Why RGBs bottle washed?
o The used RGBs need to be cleaned before
beverage filling and packaging is carried out
since used bottles may contain dust, sand,
beverage residues, rainwater, mineral stains,
coins, wrappers, insects, and microbes.
o Therefore, only rinsing of the bottles is not
sufficient in the case of used RGB but the
bottle needs to be cleaned using an alkali
solution at a certain temperature for the
sanitation of the bottle, which is ensured by
the bottle washer machine.
Washer or Bottle Cleaner
The RGB are passed through different treatment zones:
o Pre-cleaning
o Pre-heating
o Cleaning
o Rinsing and freshwater spraying operation
A specific concentration of caustic soda is used at a certain
temperature. To neutralize the effect of caustic soda, a small
concentration of phosphoric acid is used.
 Bottle washing machines

• https://youtu.be/hyyposVuRdM
CSD Glass Line

See on website with animation

https://www.sidel.com/en/csd-lines-cl-4#map0
PET Bottle
Most carbonated products are packed in PET bottles.
Typical sizes range from 250 ml to 2.0 L PET bottles are
manufactured in a two-stage process.
‘Preforms’ are made by an injection molding operation
with the required amount of plastic.
The preform also incorporates the neck finish with
screw thread Preforms, which may be stored for future
use, are then fed into heated molds of the required
design in the stretch-blowing operation. This produces
the final bottle shape and size.
o Shelf-life of carbonated drinks in PET is shorter than for
products packaged in glass or cans. This is due to the loss
of CO2 through container walls.
o For a typical 2 L PET bottle weighing 43 g, a loss of some
15–16% of gas may be expected to occur within 8 weeks of
bottling. For a 250 ml bottle, this loss may be expected to
occur within 6 weeks.
o CO2 loss may be further minimized by incorporating into
the PET, other polymers with better gas retention
characteristics.
o Closures for carbonated products may be either metal or
plastic. High-density polyethylene (HDPE) is normally
used for PET bottle closures.
 Bottle
PET Bottle BlowBlower and Bottle Washer
Moulding
The Technique
The PET bottle blow moulding process
works by reheating a pre-moulded PET
preform which is then automatically
positioned into a mould. High-pressure
food grade compressed air is then injected
into the preform which expands to form the
shape of the mould. Once the plastic has
cooled, the bottle is removed and the
process repeats. This process is suitable for
making a large range of bottles up to 1 litre
in capacity with a range of standard necks
available.
 CSD PET line

See on website with animation

https://www.sidel.com/en/csd-lines-cl-4#map0
High speed blow molding machine

https://youtu.be/qJRI18P6tk8

https://www.youtube.com/watch?v=C3B9-8SC0J4
 Metal Cans CANS
o Cans are also widely used for carbonated beverages.
Most cans are now made from two pieces of
aluminum. The body is produced by the process of
“drawing and wall ironing”.
o Cans are now almost always pre-printed and only
the data relating to traceability and product
durability is applied immediately after filling, by an
ink-jet labeler.
o Provided can ends are correctly applied and steps
taken to minimize the risk of corrosion, can
provide arguably the best protection of a
carbonated product as they do not allow ingress of
light or oxygen.
 CSD can line

See on website with animation

https://www.sidel.com/en/csd-lines-cl-4#map0
Processing steps of CSD
1. Clarification of water
2. Sugar Syrup Clarification
3. Carbonation
4. PET Bottle Blower
5. RGB Bottle Washer
6. Bottle Filler
7. Bottle capping
8. Bottle labelling
9. Filled bottle inspection
10. Printing
11. Palletizing
Clarifying the water
• 1. The quality of water is crucial to the success of a soft drink. Impurities, such as suspended
particles, organic matter, and bacteria, may degrade taste and color. They are generally
removed through the traditional process of a series of coagulation, filtration, and
chlorination. Coagulation involves mixing a gelatinous precipitate, or floc (ferric sulphate or
aluminum sulphate), into the water. The floc absorbs suspended particles, making them
larger and more easily trapped by filters. During the clarification process, alkalinity must be
adjusted with an addition of lime to reach the desired pH level.
• Filtering, sterilizing, and dechlorinating the water
• 2. The clarified water is poured through a sand filter to remove fine particles of floc. The water
passes through a layer of sand and courser beds of gravel to capture the particles.
• 3.Sterilization is necessary to destroy bacteria and organic compounds that might spoil the
water's taste or color. The water is pumped into a storage tank and is dosed with a small
amount of free chlorine. The chlorinated water remains in the storage Soft Drink tank for
about two hours until the reaction is complete.
• 4. Next, an activated carbon filter dechlorinates the water and removes residual organic
matter, much like the sand filter. A vacuum pump de-aerates the water before it passes into a
dosing station.
 Sugar Syrup Clarification
PROCESSING STEPS
The mixture of sugar, flavorings, essences, and water is called
syrup. Syrup clarification will retain particles and crystals from
your syrup.
Sugar Syrup Preparation (67 degree Brix)

• One of the first stages in a typical manufacturing process is sugar syrup preparation. Sugar is
used in either granulated or liquid form. Liquid sugar simply requires blending with water,
however when granulated sugar is used, several processing factors must be considered:
• Small-scale production of syrups with a low sugar content can be carried out at ambient
temperature. However, with some concentrated products, sugar solutions at 60% or above are
not uncommon, requiring water heating to aid dissolving.
• In large-scale operations, heating to around 95℉ (35℃) may be carried out to speed up dissolving.
• Other powdered ingredients may be dry premixed with part of the sugar, which helps to prevent
them from agglomerating, and “weights” light powders tend to float.
• Syrup is usually prepared by mixing 1 part (volume) syrup with 3-6 parts (volume) water in
stainless steel tanks fitted with top-driven agitators.
• In sugar-based products, the syrup typically consists of sugar syrup of 67º Brix strength, citric
acid, flavoring, colorings, preservatives, and water.
• Sugar syrup is passed through a plate heat exchanger to decrease the microbial load.
• Syrup is pre-prepared, tested, and diverted to proportioner for mixing with water and
carbonation.
Dissolving granulated sugar by simple agitation is a slow process

• Liquid sugar can be considerably more expensive than granulated sugar.

• Dissolving granulated sugar by simple agitation is a slow process.
• Conventional agitators cannot dissolve high concentrations of sugar at
ambient temperatures.
• Heating the water to aid solution adds to costs and is energy inefficient.
• The cooling process further adds to costs and process time.
• Crystallization of the syrup can occur during heating/cooling.
• Incomplete solubilization can lead to sedimentation or even blocking of
vessel outlets.
Replacing conventional agitato with a high Shear Mixer
• A Silverson High Shear Mixer can substantially reduce mixing times and eliminate the
need for heating the water.
• This can be achieved with in-tank Batch Mixers or by adding a Silverson In-Line Mixer to
the existing process. This operates as follows
• The combination of granule size reduction and vigorous mixing dramatically reduces
mixing times.
• A 66% sugar syrup can be produced at ambient temperature.
• Increased versatility allows the manufacturer to use sugar in granulated or syrup form.
• A Silverson mixer can also disperse and hydrate thickening and stabilizing agents such as
CMCs and Xanthan gum in a fraction of the time taken by other means.
How the Silverson Batch Mixer Works

https://www.youtube.com/watch?v=cep81yJlgDk
Carbonation
Carbonation is the step of adding carbon
dioxide to a drink. The CO2 injected into your
beverage must be free of particles and
microorganisms.
The process of carbonation involves;
o Injecting the gas into a stream of water or
product or Adding it to the static liquid in a
pressurized vessel.
o Product is usually filled at a cool temperature
to minimize the loss of CO2 during the process.
CARBON DIOXIDE (CO2)

Carbon dioxide is a natural gas. It is present in the air at a very low level
of about 0.03% by volume. It is a vital substance to the plant kingdom for
the process of photosynthesis, in which it is converted, using water and
sunlight energy, into carbohydrates. These, in turn, serve as nutrients for
the growing plant and help to build its main cellular structural
component, cellulose. Carbon dioxide can exist in three forms: gas, solid
(dry ice), and liquid (under certain pressure levels).
Specifications for CO2
Soft drink companies have strict specifications regarding the purity and
general quality of liquid CO2. It is recommended to only deal with
suppliers that can meet these specifications. A bottler does not normally
have the equipment or the expertise for testing for specification details.
However, some basic routine testing of CO2 for taste, odor, and
appearance can be performed. This is done by gently bubbling some
CO2 gas that is drawn from an online sampling source through a
sweetened and acidified water solution simulating an average beverage
product. After a specified time of dispersing the CO2 in the solution, it is
tested for taste, odor, and appearance against a control solution. There
should be no off-tastes or off-odors in the test sample, which should also
be clear of any turbidity or foreign matter
Gas volumes
Water at 15.6°C (60°F) and 1 Atm of pressure will dissolve a quantity of
CO2 equal to its volume. In other words, 1 liter of water at this
temperature and pressure can absorb 1 liter of CO2. At 15.6°C (60°F) and
1 Atm of pressure, CO2 has a density of 1.86 (air = 1.00). This means that
at these conditions, 1 liter of water would contain 1.86 g of dissolved
CO2. At different temperatures and pressures, the volume of CO2
capable of being dissolved in 1 liter of water will change. At temperatures
below 15.6°C and at pressures above 1 Atm, there could be more than 1
liter of CO2 dissolved in the water.
It has, therefore, become a practice to speak of the amount of
CO2 dissolved in a CSD in terms of how many CO2 volumes it
contains. These are called gas volumes, and they are the unit
of measurement for the level of carbonation in a CSD
• Advanced intermix carbonator ensures an accurate
proportional mixture of water, syrup, and carbon dioxide
duly controlled by the screen. This ensures consistency in
various batch mixes, tastes & accurate mixture of Co2 gas. It
can be interconnected within the water/syrup chiller.
Many carbonators are equipped with their own
cooling systems. The amount of carbon dioxide
pressure used depends on the type of soft drink.
Caffeine
• Caffeine is an ingredient found in many beverages and foods,
such as coffee, tea, colas and chocolate. It is one of the
ingredients that helps give Coca-Cola its unique great taste.
• Coke's caffeine content is 34mg for a 12-oz can (354
mL), and Diet Coke caffeine content is 46mg. That's three
to four times less than coffee! The same-sized coffee, in
this case a 12-oz cup, has 140mg or more.
How much caffeine is too much?

• Caffeine is known to be safe when consumed in moderation.

Scientists and health authorities generally say that moderate
caffeine intake is about 400 mg/day for most healthy adults.
They advise a lower intake for pregnant women. This is much
more than is found in a 12oz can of Coca-Cola.
caffeine-free drinks examples

• Caffeine-Free Coca-Cola,
• Caffeine-Free Diet Coke and Caffeine-Free Coca-Cola Zero Sugar
• Seagram’s Ginger Ale, Diet Ginger Ale, Tonic and Seltzer
• Sprite and Sprite Zero
• Fanta, Fanta Grape and Fanta Zero Orange
• Juices like Simply and Minute Maid
 CAPPING
o Caps without a screw thread are applied to
bottle tops and by use of a rotating chuck on
the capping machine, are formed to fit the
exact profile of the screw thread on each
bottle.

o PET bottle moulds give bottles tighter

manufacturing tolerances, plastic caps are
usually molded to the exact thread profile
required.
FILLED BOTTLES INSPECTION
Light inspection is done to remove the empty bottles and bottles having
less volume of liquid or bottles containing any foreign particles in them.
PRINTING
Bottles are then passed through the printer, where manufacturing and expiry
date, production time, batch number, and other information are imprinted on
bottles.
Quality Control
• Soft drink manufacturers adhere to strict water quality standards for allowable
dissolved solids, alkalinity, chlorides, sulfates, iron, and aluminum. Not only is it in
the interest of public health, but clean water also facilitates the production process
and maintains consistency in flavor, color, and body. Microbiological and other
testing occur regularly. The National Soft Drink Association and other agencies
set standards for regulating the quality of sugar and other ingredients. If soft
drinks are produced with low-quality sugar, particles in the beverage will spoil it,
creating floc. To prevent such spoilage, sugar must be carefully handled in dry,
sanitized environments.
• It is crucial for soft drink manufacturers to inspect raw materials before they are
mixed with other ingredients, because preservatives may not kill all bacteria. All
tanks, pumps, and containers are thoroughly sterilized and continuously
monitored. Cans, made of aluminum alloy or tin-coated low-carbon steel, are
lacquered internally to seal the metal and prevent corrosion from contact with the
beverage. Soft drink manufacturers also recommend specific storage conditions
to retailers to insure that the beverages do not spoil. The shelf life of soft drinks is
generally at least one year
Health hazards of CSD
• There are various health hazards associated with consuming soft drinks like weight gain and
diabetes. The main ingredients in soft drinks which are hazardous to health include high sugar
content, phosphoric acid, and caffeine

• Refined sugars have adverse effects on health. WHO recommends that the daily sugar intake is not
more than 6 teaspoons or 25 g per day, while a soft drink (330mL) can contain 9 teaspoons of sugar,
which makes almost 35 g.

• The consumption of soft drinks is generally linked with an increased risk of anxiety and depression.
There are several risk factors associated with mental health. It is also associated with increased rates
of morbidity and mortality. Evidence has shown the negative effects of sugar on mental health.
There is an inverse relationship between sugar consumption from soft drinks and mental health
issues among adolescents
Sugar substitutes and their toxicity
Sugar substitutes such as aspartame and Acesulfame-K are used in CSD.
Sugar substitutes break down into toxins. For example, aspartame breaks
down into the toxin formaldehyde. Formaldehyde is linked to breast
cancer, damage to memory proteins in the brain, and multiple sclerosis.
Spindrift – a healthy type of CSD

Today, soft drink manufacturers are adapting to consumers’

demands for more novel flavor profiles and healthier choices.
Soft drinks such as Spindrift, carbonated water mixed with fruit
juice and a small amount of natural sweetener, appeal to a more
health-conscious crowd. The industry is ripe for innovation,
with customers looking for more premium soft drink beverages
with exciting flavor combinations.
Spindrift
• Spindrift is America's first sparkling water made with just real
squeezed fruit.
 How coke is manufactured
https://www.youtube.com/watch?v=8zqD-m2URA4

https://www.youtube.com/watch?v=LOsQap-P4kA&t=307s

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