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PRODUCTION SETUP

1. Purpose

To outline the steps required to move from approved beverage formulation to commercial-scale production while ensuring quality, compliance, and efficiency.

2. Confirmation & Documentation

  • Final Recipe Lock-In

    • Freeze formulation (no further changes without formal approval)

    • Record ingredient percentages, sourcing details, and processing notes

  • Approval Sign-Off

    • Obtain customer’s signed recipe approval form

    • Archive lab samples for reference

  • Product Specifications

    • Finalize product specification sheet (Brix, pH, color, taste notes, shelf life)

3. Pre-Production Planning

  • Ingredient Procurement

    • Confirm suppliers, lead times, and minimum order quantities

    • Order raw materials with enough buffer stock

  • Packaging Procurement

    • Secure bottles, cans, closures, labels, cartons

    • Confirm artwork approvals and printing schedules

  • Production Scheduling

    • Book production line slots

    • Allocate staff and equipment

    • Align with customer delivery timelines

4. Equipment & Facility Preparation

  • Cleaning & Sanitization

    • Perform CIP (Clean-In-Place) for tanks, lines, fillers

  • Calibration

    • Ensure pH meters, refractometers, and scales are calibrated

  • Line Setup

    • Configure machines for bottle/can size, carbonation level, fill volume

  • Trial Run

    • Conduct small pre-production test batch to verify scaling and taste consistency

5. Quality Control Setup

  • Incoming Material Inspection

    • Check raw ingredients for compliance (appearance, odor, lab results)

  • In-Process QC

    • Monitor pH, Brix, temperature, carbonation, viscosity

  • Finished Product Testing

    • Microbiological tests

    • Shelf-life stability checks (if needed)

6. Production Execution

  • Batch Mixing

    • Follow Standard Operating Procedures (SOPs) for ingredient addition sequence and mixing times

  • Filling & Packaging

    • Maintain correct fill levels, closures, labeling

  • Coding

    • Apply batch/lot codes and expiry dates

  • Palletizing & Storage

    • Store under specified conditions before dispatch

7. Post-Production Steps

  • Customer Notification

    • Send production completion report and QC test results

  • Retention Samples

    • Keep samples for reference throughout shelf life

  • Logistics Coordination

    • Arrange transport per agreed schedule

  • Production Records

    • Document batch records, raw material lot numbers, QC data

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