新厂投产要求及程序.精品文档

1、中国区受控技术文件 China Division T-Document要求 Requirement新厂投产要求及程序New Plant Start-up Requirement and Procedure颁布日期 Issue Date：97-08-04T-11共 12 页第 1页 Page 1 of 12Purpose:目的：To ensure that every new bottling/canning plant, and line expansion is capable to produce Company products. 阐明新可口可乐装瓶厂和新生产线投产的要求，以确保生产出的

2、产品符合可 口可乐公司的要求。Requirement: 要求：1. MINIMUM REQUIREMENT FOR BOTTLING PLANT START UP 装瓶厂投产的最低要求1) At least one permanent concrete road to main entrance and warehouse is completed.至少已建成一条从大门至仓库的水泥路。2) All construction material and rubbish around building must remove. 必须清除掉建筑物周围所有的建筑材料及垃圾。3) All construc

3、tion in water treatment room, syrup room, filling room, packaging area, raw materials warehouse, package material warehouse, Concentrate/Beverage Base warehouse and final products warehouse must be completely finished. 水处理车间、糖浆间、注入间、包装区域、原材料仓库、包装物料仓库、 浓缩液/主剂库和成品库内的所有工程必须全部完成。4) All above area have b

4、een cleaned and sanitized as following section 2 in this document.必须按照本文件以下第 2 节的要求对以上区域进行清洁和消毒。5) Whole production area must be completely enclosed. 整个生产区域必须完全封闭。6) All personnel in production area are required to wear uniforms and head covers 生产区域内所有人员必须穿戴工作服和工作帽。7) At least one set toilets availa

5、ble for plant staff daily use. 至少有一套厕所可供工厂员工日常使用。8) Plant has specified persons to be responsible for whole plant cleaning and hygiene.有专门的人员负责整个厂区的清洁与卫生。9) All personnel in plant are required to wear I.D. badges. And specified color can allow to key area such as syrup room, water treatment room and

6、 filling room etc.中国区受控技术文件 China Division T-Document要求 Requirement新厂投产要求及程序New Plant Start-up Requirement and Procedure颁布日期 Issue Date：97-08-04T-11共 12 页第 2页 Page 2 of 12厂内所有人员都必须佩带身份识别卡，并且只有佩戴特定颜色的卡才 能进入关键区域如糖浆间、水处理车间和注入间等。10) All visitors (including installation engineer) are required to wear bad

7、ges. 厂内所有人员都必须佩带身份识别卡，并且只有佩戴特定颜色的卡才 能进入关键区域如糖浆间、水处理车间和注入间等。11) Restricted areas (e.g. syrup room) are clearly identified and securely controlled.明确标明限制进入区域(如：糖浆间)并采取安全控制措施。* BEFORE CONSIDERING START UP, ABOVE MINIMUM REQUIREMENT MUST MEET.*在计划投产前必须达到以上最低要求。2. Plant on-site and Building Cleaning and

8、Sanitizing Procedure 厂内场地和建筑清洗和消毒程序When finishing works of construction is completed, then sanitation of building will be begun soon. Before starting sanitation, restricted access to the process area must be informed to all employees and outside visitors including workers involved in the installatio

9、n works.建筑施工完成后，应尽快进行厂房消毒，开始消毒前，必须通知所有员工和 外来人员(包括安装施工的工人) 。2.1General instruction 一般要求a) Cleaning of whole area in the plant building is simultaneously carried out in one day.整个厂房建筑的清扫必须在一天之内集中进行。b) Entrance to the plant building must be limited, and water should be prepared to wash shoes at the ent

10、rance.必须限制进入厂房建筑的入口通道，并在入口处备有用于清洗鞋子的 水。c) The air blower of the air conditioner or the ventilator should be turned on prior to cleaning of floor, wall and process facilities because dust in the duct would be scattered in the process area at the first time.在清洁地面、 墙壁和生产设备前空调吹风或排风机必须启动， 因为管道内 的灰尘会在第一次使

11、用后散落在生产区域内。d) Machinery and equipment must be cleaned up after the walls and floors be cleaned properly. 墙壁和地面清洁完成后必须进行机械和设备的清洁工作。e) Following tools and chemicals must be prepared at sanitation: 必须准备以下用于消毒的工具和化学品：中国区受控技术文件 China Division T-Document要求 Requirement新厂投产要求及程序New Plant Start-up Requiremen

12、t and Procedure颁布日期 Issue Date：97-08-04T-11共 12 页第 3页 Page 3 of 12- Detergent.Floor cleaner, detergent safe to use for food process.清洗剂.地面清洗剂 , 清洗剂必须满足食品生产的安全性。- Chlorine. Calcium hypochlorite, sodium hypochlorite.氯 . 次氯酸钙，次氯酸钠。- Brush. Floor brush, pot clean, scrubbing brush, pipe brush, tooth brus

13、h. 刷子.地板刷、 pot clean, 钢丝板刷、管道刷、牙刷。- Hose, Bucket, ladder软管、水桶、梯子。2.2 Filling, packaging and syrup rooms注入间、包装区域和糖浆间a) Take away construction tools.拿走施工用具。b) Clean off dust on machinery and equipment, trashes of cement and sand, and drop of paint. 清除掉机械和设备上的灰尘、水泥污迹和沙子和沾上的油漆痕迹。c) Brush with detergent

14、solution.用清洗剂溶液擦洗。d) Rinse with clean water and squeeze out water. 用清水冲洗并将水排掉。e) Spray 200ppm chlorine solution and keep it overnight( Dont spray on the surface of machine).洒上 200ppm 氯水并保留过夜 (不要洒在设备表面 ).f) Repeat the above procedure at least 3 days. 至少三天重复上述程序。2.3 Water treatment room and CO2 purifi

15、cation room 水处理车间和二氧化碳净化间a) Take away construction tools.拿走施工用具。b) Clean off dust on machinery and equipment, trashes of cement and sand, and drop of paint. 清除掉机械和设备上的灰尘、水泥污迹和沙子和沾上的油漆痕迹。c) Brush with detergent solution.用清洗剂溶液擦洗。d) Rinse out thoroughly with clean water and squeeze out water. 用清水冲洗并将水

16、排掉。e) Spray 200ppm chlorine solution and keep it overnight.洒上 200ppm 氯水并保留过夜。中国区受控技术文件 China Division T-Document要求 Requirement新厂投产要求及程序New Plant Start-up Requirement and Procedure颁布日期 Issue Date：97-08-04T-11共 12 页第 4页 Page 4 of 122.4 Storage rooms of sugar, crown/closure and Concentrate/Beverage Bas

17、e 糖、皇冠盖 /旋盖和浓缩液 /主剂仓库a) Take away construction tools. 拿走施工用具。b) Clean off dust on machinery and equipment, trashes of cement and sand, and drop of paint. 清除掉机械和设备上的灰尘、水泥污迹和沙子和沾上的油漆痕迹。c) Brush with detergent solution. 用清洗剂溶液擦洗。d) Rinse with clean water and squeeze out water. 用清水冲洗并将水排掉。e) Spray 200pp

18、m chlorine solution and keep it overnight. 数天内重复上述程序。f) Repeat the above procedure for few days. 数天内重复上述程序。2.5 Plant warehouse 厂内仓库a) Take away construction tools. 拿走施工用具。b) Clean off dust on machinery and equipment, trashes of cement and sand, and drop of paint. 清除掉机械和设备上的灰尘、水泥污迹和沙子和沾上的油漆痕迹。c) Brus

19、h with detergent solution. 用清洗剂溶液擦洗。d) Enough persons and tools are required due to large space to be cleaned up simultaneously. 因较大场地须同时清扫，必须有足够的人员和工具。e) Rinse out thoroughly with clean water and squeeze out water. 用清水彻底冲洗并将水排掉。f) Spray 200ppm chlorine solution and keep it overnight. 洒上 200ppm 氯水并保

20、留过夜。2.6 Boiler room, air compressor room, parts stock room, break room and shower room.锅炉房、空压机房、零部件库、休息室和浴室a) Take away construction tools. 拿走施工用具。中国区受控技术文件 China Division T-Document要求 Requirement新厂投产要求及程序New Plant Start-up Requirement and Procedure颁布日期 Issue Date：97-08-04T-11共 12 页第 5页 Page 5 of 12

21、b) Clean off dust on machinery and equipment, trashes of cement and sand, and drop of paint. 清除掉机械和设备上的灰尘、水泥污迹和沙子和沾上的油漆痕迹。c) Brush with detergent solution. 用清洗剂溶液擦洗d) Rinse out thoroughly with clean water and squeeze out water. 用清水彻底冲洗并将水排掉。2.7 Toilet 厕所a) Take away construction tools and provide wi

22、th necessary fixtures. 拿走施工用具并提供必要的用具。b) Brush with detergent solution. 用清洗剂溶液擦洗c) Rinse out thoroughly with clean water and squeeze out water. 用清水彻底冲洗并将水排掉。d) Spray 200ppm chlorine solution and keep it overnight. 洒上 200ppm 氯水并保留过夜。e) Furnish is ready for use.( cleaning soap, paper tower, antiseptic

23、 solution and hand dryer etc.) 备有清洁用具可供使用。 ( 肥皂或皂液、纸巾、消毒液和烘手器等) 。f) Specify one person to be responsible for cleaning. 指定专人负责清洁工作。3. PEST CONTROL 虫鼠控制a) Install insect killer at all entrance of processing area and corridor. 在所有生产区域和走廊的入口安装灭蝇灯。b) Place baits in non-production area or outside the plan

24、t.(Please refer Beverage Quality Manual HK-R-164.1 & HK-G-164.2) 在非生产区域或厂区外放置灭鼠诱饵。(请参照饮料质量手册 HK-R-164.1 和 HK-G-164.2)4. EQUIPMENT CLEANING AND SANITATION 设备清洗和消毒4.1 Water Treatment System 水处理系统4.1.1 Water reservoir (if have)中国区受控技术文件 China Division T-Document要求 Requirement新厂投产要求及程序New Plant Start-up

25、 Requirement and Procedure颁布日期 Issue Date：97-08-04T-11共 12 页第 6页 Page 6 of 12储水槽 (若有 )a) Inspection 检查 To check if there are dead pocket, proper round corner, unnecessary hole and pipes, crack on floors, walls and ceiling, and contamination source around the reservoir.检查有无无法清洁的死角、 接缝圆角是否合适， 不必要的孔和管道

26、， 地面、 墙壁和天花板裂缝以及 储水槽 周围有无污染源、b) Cleaning in the reservoirBrush all the inner surface of reservoir with detergent, then rinse off thoroughly with clean water. Spray 200ppm chlorine solution and hold for 4 to 5 hours then rinse with clean water.储水槽的清洗 用清洗剂擦洗储水槽的整个内壁，然后用清水彻底冲洗，喷洒 200ppm 氯 水并保留 4 至 5 小时

27、然后用清水冲洗。4.1.2 Reaction tank, sand filter, activated carbon filter, store tank and polish filter 反应池、沙滤器、碳滤器、储槽和精滤器a) Inspection : 检查： To check cracks or defects on inside coated surface of reaction tank, filters (sand, carbon and polish) and store tank.检查反应池、 沙滤器、碳滤器和精滤器以及储槽的内表面涂层有无裂缝或 缺陷。b) Cleanin

28、g in the tanks/filters 清洗水槽和过滤器c) Brush (soft brush is recommended to prevent a injury on inside surface) all the inside surface of tanks/filters with detergent, then rinse off thoroughly with clean water. 用清洁剂刷洗水槽和过滤器的所有内表面(建议用软刷以免损伤内表面。d) Wash sand and gravel with clean water after charging and th

29、en must be sterilized with 100ppm chlorine solution for 4 hours. And then flush it with water from reaction tank with 6-7 ppm chlorine. 装完沙子和卵石后用清水冲洗然后必须用 100ppm氯水消毒 4 小时，然后 用反应池内 6-7 ppm 的氯水冲洗。e) Sand must be washed by 0.5% HCL before sterilization if sand with limestone. 如果沙子含石灰，消毒前必须用 0.5%盐酸清洗。f)

30、 Wash activated carbon with clean water after charging and then must be sterilized with steam. Keep the temperature of condensation not lesst han 85 for at least 2 hours. After cooling, backwash must be taken.中国区受控技术文件 China Division T-Document要求 Requirement新厂投产要求及程序New Plant Start-up Requirement an

31、d Procedure颁布日期 Issue Date：97-08-04T-11共 12 页第 7页 Page 7 of 12装完活性炭后用清水冲洗然后用蒸汽消毒。保持蒸汽冷凝后 温度不低于 85至少 2 小时。冷却后必须反冲洗。4.1.3 Treated water pipes cleaning and sanitation 处理水管道清洗和消毒a) Inspection 检查 All pipes must be filled water to check leakage before take cleaning and sanitation.在清洗和消毒前所有管道必须注满水检查有无渗漏。b)

32、 Cleaning 清洗caustic soda solution must be filled up in the all pipes from the inlet to the outlet and hold for 1 hours. Then rinse with treated water. 所有管道从进口到出口必须浸泡苛性碱溶液并保持 1 小时，然后用处理水 冲洗。c) Sanitation消毒d) All pipes must be filled up with 100ppm chlorine solution and kept it for 4 hours. Then rinse

33、 with treated water.所有管道必须用 100 ppm氯水浸泡并保持 4小时，然后用处理水冲洗。4.1.4 Microbiological test 微生物测试Micro test must be run for treated water samples required by The Coca-Cola Company and result must be satisfactory after cleaning and sanitizing. 必须按可口可乐公司要求对处理水取样进行测试，清洗和消毒后的结果必须 合格。4.2 Syrup Tank, Syrup Pipes a

34、nd Equipment in Syrup Room 糖浆间内的糖浆缸、管道和设备。a) Adhesive oil on surface of syrup tank must be removed with detergent solution. 必须用清洗剂清除糖浆缸表面粘附的油垢。b) Inside surface of syrup tank must be cleaned by CIP system with circulation of 1% caustic solution at 60 for 30 minutes.糖浆缸内表面必须通过 CIP系统用 1%碱液在 60下循环 30 分

35、钟。c) Check with bottler and syrup tank supplier if the tanks were passivated, if not, follow Beverage Quality Manual CS-P-162.6 与装瓶厂和糖浆缸供应商一起检查糖浆缸有否钝化，如果没有，按照 饮料质量手册 CS-P-162.6进行。中国区受控技术文件 China Division T-Document要求 Requirement新厂投产要求及程序New Plant Start-up Requirement and Procedure颁布日期 Issue Date：97-

36、08-04T-11共 12 页第 8页 Page 8 of 12d) All the pumps, pipes, cam-valve, filter press in syrup room should be disassembled completely, and then clean with detergent solution. Sterilize with 50 ppm chlorine solution for 30 minutes, then assemble. 所有糖浆间内泵、管道、蝴蝶阀 ,过滤器必须完全拆开 然后用清洗剂清洗， 用 50 ppm氯水消毒 30 分钟，然后安装

37、。e) All tanks must be calibrated accurately with a repeatability of 0.125% flowmeter.必须用精确度达 0.125%的流量计对所有缸进行准确的标定。f) When machinery and equipment is assembled, Inside surface must be cleaned and sanitized with five steps CIP procedure before preparation of syrup. 机械和设备安装后，生产糖浆前其内表面必须进行五步 CIP 清洗和消毒程

38、 序。4.3 Carbonator and Filler 碳酸化器和注入机a) Carbonator (Mojornia) should be disassembled. 碳酸化器 ? (Mojonnier) 必须拆开。b) Filler must be disassembled. 注入机必须拆开。c) Inside surface must be brushed with detergent solution. 内表面必须用清洗剂刷洗。d) Sterilize with 50ppm chlorine solution for 30 minutes.用 50ppm 氯水消毒 30 分钟。e)

39、When Carbonator and filler is assembled, inside surface must be cleaned and sanitized with five steps CIP procedure before production. 碳酸化器和注入机安装完后， 必须在生产前内表面必须用五步 CIP 程序进 行清洗和消毒。4.4 Bottle Washer 洗瓶机a) All compartments must be charged with about 1% of caustic soda, and kept a temperature of normal

40、operation during wash test run without load until oil is removed.在清洗试运行时，先不进瓶，所有的槽用约 1%浓度的碱液浸泡并保持在 正常操作时的温度直至油污去除。b) Rinse compartment after cleaning. 清洗完后冲洗各槽。c) Disassemble jet nozzles and clean up the water pipe and nozzle. 拆下喷淋管并清理水管和喷嘴。d) Assemble jet nozzles and check water pressure. 装上喷淋管并检查水

41、压。中国区受控技术文件 China Division T-Document要求 Requirement新厂投产要求及程序New Plant Start-up Requirement and Procedure颁布日期 Issue Date：97-08-04T-11共 12 页第 9页 Page 9 of 12e) Change caustic solution with warm water in final rinse compartment after cleaning of bottle carriers. 清洗完瓶子套袋后在最后冲洗槽注入洗瓶水。f) Charge 3 to 3.5 %

42、 of caustic solution in all caustic compartments. 所有碱槽用 3-3.5%浓度的碱液浸泡。 .4.5 Warmer 暖瓶机a) Clean all compartment with 0.5% NaOH.用 0.5%的碱液清洗各槽。b) Rinse compartment with water 用水冲洗各槽c) Charge 50ppm chlorine solution to recycle for 30minutes. 注入 50ppm 氯水循环 30 分钟。d) Rinse compartment with rinse water. 用洗瓶

43、水冲洗各槽。e) Fill up compartment with rinse water. 用洗瓶水注满各槽。4.6 Purifier and pipes of CO2 gas 二氧化碳净化器和管道a) Blow with compressed oilless air or CO2 and release it in use point. 用无油压缩空气或二氧化碳吹管道，并在使用点排放。b) Charge water, 3% KMnO4 and activated carbon in purifier 在各净化缸内分别装入水、 3%高锰酸钾溶液和活性炭。c) Regenerate activ

44、ated carbon with steam . 活性炭蒸汽再生。5. TEST RUN 调试5.1 Test Run of Each Individual Machine Without Loading 各单机不进瓶调试a) Necessary adjustment of machine 对设备进行必要的调整。b) Confirmation of operation condition of each machine 了解设备的运行状况。c) Be sure that all the automatic control mechanism and proofs equipped on eac

45、h machine work properly 确信所有设备上的自动控制机构和防护装置运转正常。签署 Signature：中国区受控技术文件 China Division T-Document要求 Requirement新厂投产要求及程序New Plant Start-up Requirement and Procedure颁布日期 Issue Date：97-08-04T-11共12页第10页 Page 10 of 125.2 Bottle Loading Test 进瓶调试A small amount of bottles should be loaded on the line to c

46、heck any major defect of the machinery, and adjust machinery and confrere operation. It may require several times.生产线进一小批瓶子以便检查设备有无主要缺陷，并调整设备，此过程可能 需要数次。5.3 One Small Batch of Syrup without Adding Concentrate and Beverage Base should be Prepared.准 备一小批不加浓缩液和主剂的糖浆 Following items must be checked duri

47、ng test trial: 调试时检查以下各项：a) Syrup manufacturing system work properly 糖浆制造系统运转正常。b) Syrup meet Coca-Cola Company specification 糖浆符合可口可乐公司指标。c) Operators and QC start to be familiar with syrup manufacturing process 操作工和品控开始了解糖浆制造过程。d) Start to learn how to complete production record 开始学习如何填写生产记录。5.4 F

48、illing Test of Carbonated Water 碳酸水试灌装a) Fill carbonated water with the highest gas volume that is planed to be produced at the line. 灌装碳酸水的含气量要达到生产线上生产的最高含气量产品的气量。b) Check each items (quality and operation condition) in the similar way as normal production 按正常生产时一样检查各项目(质量和操作状况) 。c) Check communica

49、tion between each department. 检查各部门之间协调。d) Operators and QC start to be familiar with filling process 操作工和品控开始了解注入过程。e) Start to learn how to complete production record. 开始学习如何填写生产记录。5.5 After first batch production 首批试生产后Micro test must be performed. During 2 days waiting time, plant can correct pr

50、oblem found in trial test or training. 必须完成微生物测试，等待结果的两天内，装瓶厂可以解决调试时发现的问 认可 Approval ：徐国民签署 Signature：中国区品质保证部经理中国区受控技术文件 China Division T-Document要求 Requirement新厂投产要求及程序New Plant Start-up Requirement and Procedure颁布日期 Issue Date：97-08-04T-11共 12页第11页 Page 11 of 12题或进行培训6 QUALITY CONTROL LABORATORY 品控实验室a) All required instrument are calibrated 所有必须的仪器校正完毕。b) Chemical reagent for quality control tests is ready for use. 已准备好品控测试用的化学试剂。c)