TUAF-ELEARNING ONLINE TRAINING PROGRAMME

COURSE
TECHNOLOGY OF BEVERAGES

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TABLE OF CONTENTS
LESSON 12 - PRACTICE 2: PRODUCTION OF CARBONATED SOFT DRINKS ...... 3
STUDY GUIDE ........................................................................................................................ 3
LESSON CONTENT ............................................................................................................... 3
LESSON OBJECTIVES .......................................................................................................... 3
INTRODUCTORY SITUATION ........................................................................................... 3
1. INTRODUCTION TO CARBONATED SOFT DRINKS ................................................ 4
2. GENERAL PROCESS OF PRODUCING CARBONATED SOFT DRINKS ............... 4
2.1. General process .......................................................................................................... 4
2.2. Step descriptions ........................................................................................................ 5
3. PRACTICAL INSTRUCTIONS: PRODUCTION OF A LEMON-FLAVORED
CARBONATED SOFT DRINK .............................................................................................. 5
3.1. Objective .................................................................................................................... 5
3.2. Equipment .................................................................................................................. 5
3.3. Ingredients (for 2 l batch) .......................................................................................... 6
3.4. Procedure ................................................................................................................... 7
3.5. Safety notes ................................................................................................................ 8
3.6. Expected outcomes .................................................................................................... 8
LESSON SUMMARY .............................................................................................................. 8
REVIEW QUESTIONS ........................................................................................................... 8
ANSWER GUIDE .................................................................................................................... 9
REFERENCES ......................................................................................................................... 9

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LESSON 12 - PRACTICE 2: PRODUCTION OF

CARBONATED SOFT DRINKS
STUDY GUIDE
To study the lessons, students should:
- Follow the weekly course schedule, complete practice exercises and participate in
forum discussions.
- Discuss with other classmates and instructor (s) through the forum or text messages
and questions.
- Follow the online course materials.
LESSON CONTENT
Lesson 12 on Practice 2: Production of carbonated soft drinks is one of 12 lessons in
the beverage technology course.
1. Introduction to Carbonated Soft Drinks
2. Ingredients and Their Functions
3. Water Treatment and Purification
4. Syrup Preparation and Mixing
5. Carbonation Process
6. Filling and Packaging
7. Quality Control and Testing
8. Safety and Hygiene Standards
9. Common Issues and Troubleshooting
10. Practical Demonstration: Soft Drink Production
LESSON OBJECTIVES
The objectives of this lesson are to:
1. Understand the principles and processes of carbonated soft drink production.
2. Identify key ingredients and their roles in formulation.
3. Demonstrate mixing, carbonation, and bottling steps.
4. Apply quality control measures to ensure product safety and consistency.
5. Evaluate processing parameters’ impact on final product quality.
INTRODUCTORY SITUATION

Imagine you’re a food technologist tasked with developing a new carbonated soft
drink for a beverage company. Your goal is to create a refreshing, safe, and
consistent product that meets consumer demands. In this lesson, you’ll explore the
production process, from selecting key ingredients to mastering mixing, carbonation,
and bottling, while ensuring quality control to deliver a high-quality drink.

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1. INTRODUCTION TO CARBONATED SOFT DRINKS

Carbonated soft drinks, commonly known as sodas or fizzy drinks, are among the most
popular beverages globally, with an estimated market value of $392 billion in 2023 (Statista,
2023). These beverages are characterized by their effervescence, achieved through the
dissolution of carbon dioxide (CO₂) under pressure, which creates bubbles and a distinctive
mouthfeel. The production of carbonated soft drinks involves precise control of ingredients,
equipment, and processes to ensure consistent quality, safety, and shelf stability. Key
components typically include water (85–95% of the formulation), sweeteners (e.g., sucrose or
high-fructose corn syrup), acidulants (e.g., citric acid), flavorings, preservatives, and colorants.
The carbonation process not only enhances sensory appeal but also contributes to microbial
stability by lowering pH and creating an anaerobic environment.
This practical lesson focuses on the small-scale production of a lemon-flavored
carbonated soft drink, emphasizing critical steps such as water treatment, syrup preparation,
carbonation, and bottling. Students will gain hands-on experience with formulation
calculations, equipment handling, and quality control measures, such as pH and Brix testing.
The process mirrors industrial practices but is adapted for a laboratory setting, ensuring safety
and educational clarity. Understanding these principles is essential for food technologists, as
carbonated beverages require meticulous attention to ingredient interactions, gas solubility, and
packaging integrity to meet consumer expectations and regulatory standards (FDA, 2021;
Codex Alimentarius, 2020).
2. GENERAL PROCESS OF PRODUCING CARBONATED SOFT DRINKS
2.1. General process

Figure 1: Flowchart: Production of Carbonated Soft Drinks

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2.2. Step Descriptions

1. Water Treatment: Filter and purify water to remove chlorine, minerals, and
impurities.
2. Syrup Preparation: Dissolve sugar in hot water; add acid, preservative, flavoring,
and coloring.
3. Syrup Quality Control: Measure °Brix and pH to ensure the syrup meets
formulation targets.
4. Dilution & Mixing: Mix syrup with chilled purified water to reach the final beverage
concentration.
5. Carbonation: Cool the mixture and inject CO₂ at high pressure for proper fizziness.
6. Bottling: Fill sterilized bottles under pressure, seal with minimal CO₂ loss.
7. Final Quality Check: Randomly test for pH, Brix, carbonation level, and sensory
quality.
8. Labeling & Storage: Label bottles and store in a cool, dark place for product
stability.
3. PRACTICAL INSTRUCTIONS: PRODUCTION OF A LEMON-FLAVORED
CARBONATED SOFT DRINK
3.1. Objective
This practical session guides students in producing 2 liters of lemon-flavored
carbonated soft drink. The final product should have a Brix value between 10–12°, a pH of
3.0–3.5, and a carbonation level of 3.5 volumes of CO₂.
3.2. Equipment
Students will use basic food-grade lab tools including:
• a 2–3 liter mixing container,
• a CO₂ soda charger or benchtop carbonator,
• a refractometer,
• a pH meter, filtered water, precision scale, thermometer, sanitized 500 mL PET
bottles, and personal safety gear such as gloves and goggles.

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Before starting the practical session, students must prepare and check the following
equipment and tools:

• Mixing container (2–3 liters): for preparing syrup and mixing with water.
• Water filtration system (e.g., RO filter or activated carbon): to remove impurities.
• Digital precision scale (0.01 g accuracy): for measuring sugar, acid, preservative,
and colorant.
• Thermometer: to monitor temperature during syrup preparation and carbonation.
• pH meter (calibrated): ensure it's adjusted with standard buffer solutions (pH 4.0
and 7.0).
• Refractometer: to measure sweetness in degrees Brix.
• Carbonation device (soda charger or mini carbonator).
• Sterilized PET bottles (500 mL) and caps.
• Safety gear: gloves, face mask, and safety
goggles for hygiene and protection.
3.3. Ingredients (for 2 L batch)
• Filtered water: 1.7 liters
• Granulated sugar: 200 g
• Citric acid (anhydrous): 3 g
• Lemon flavoring (emulsion): 4 mL
• Sodium benzoate: 0.5 g
• Yellow food coloring (optional): 0.2 mL
• Food-grade CO₂ gas: as needed for 3.5
volumes carbonation.

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Table 1: Sample Formulation Table for Various Carbonated Soft Drinks (for 2 liters)

Sodium
Beverage Sugar Citric Acid Flavoring Food Color Target Target
Benzoate
Type (g) (g) (mL) (mL or g) pH Brix
(g)
Lemon 0.2 mL
200 3 4 0.5 3.0–3.5 10–12°
Soda (yellow)
Orange 0.2 mL
210 2.8 5 0.5 3.0–3.4 11–12°
Soda (orange)
Cola-Type 2.5 0.2 mL
190 6 0.5 2.8–3.2 9–11°
Drink (phosphoric) (caramel)
Strawberry
220 2.5 5 0.5 0.2 mL (red) 3.0–3.4 10–12°
Soda

Note: All formulations are for 2 liters of finished product. Carbonation: 3.5 volumes of CO₂.

3.4. Procedure
3.4.1. Water Treatment
o Start by passing the water through a household carbon filter or reverse osmosis
system to eliminate chlorine and impurities. From the treated batch, measure 1.7 liters and cool
to around 20°C for effective CO₂ absorption. It's recommended to check the pH of the water
(ideally 6.5–7.5) and TDS (<50 ppm) if tools are available.
3.4.2. Syrup Preparation
o In a clean container, heat about 0.3 liters of the filtered water to 40°C, then add the
200 g sugar and stir until fully dissolved. Add the 3 g citric acid, followed by 0.5 g sodium
benzoate and the 4 mL lemon flavoring. If used, add 0.2 mL food coloring. Stir well, then
cool the syrup to about 10°C before dilution.
3.4.3. Quality Control of Syrup
o Use a refractometer to test the syrup’s Brix, aiming for 50–55° Brix. Then use a
calibrated pH meter to confirm a pH between 2.8–3.2. If the syrup is too weak or strong,
adjust with additional citric acid or water as necessary.
o Quality Control Instructions: Brix & pH
1. Measuring Sweetness – Brix
o Tool: Handheld refractometer
o Procedure:
o Clean the prism and place 1–2 drops of the beverage sample.
o Look through the eyepiece toward a light source.
o Read the °Brix value at the boundary between light and dark zones.
o Clean the prism with distilled water and a soft cloth after measurement.
2. Measuring pH
o Tool: Calibrated digital pH meter
o Procedure:

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o Calibrate using buffer solutions at pH 4.0 and 7.0.

o Rinse the electrode with distilled water and blot gently.
o Immerse the electrode in a well-mixed sample of the beverage.
o Wait for the reading to stabilize and record the pH value.
3.4.4. Dilution and Mixing
o Combine the syrup (approx. 300 mL) with the remaining 1.7 liters of chilled filtered
water. Stir gently for a few minutes. Recheck final Brix (10–12°) and pH (3.0–3.5).
3.4.5. Carbonation
o Transfer the beverage into a carbonation bottle or soda maker. Cool the liquid to 4–
6°C, then inject CO₂ under 3.5 bar pressure. Shake or agitate for 5–7 minutes until well
carbonated (target: ~7 g/L of CO₂). If available, verify carbonation using a tester.
3.4.6. Bottling
o Sterilize PET bottles and caps using 1% sodium hypochlorite, rinse thoroughly with
clean water. Fill the bottles with the beverage, leaving about 2 cm headspace, and cap
immediately. Label each bottle with product details and date.
3.4.7. Final Quality Check
o Randomly select 1–2 bottles to check pH, Brix, and carbonation level. Also assess
the product’s color, clarity, fizz, and lemon aroma. Store bottles at 20°C for at least 48 hours to
observe stability and signs of sediment or flavor changes..
3.5. Safety Notes
• Wear gloves and goggles when handling CO₂ cylinders and acidulants.
• Ensure proper ventilation during carbonation to avoid CO₂ buildup.
• Follow equipment manuals for safe operation of the carbonator and filler.
3.6. Expected Outcomes
• A clear, lemon-flavored carbonated soft drink with stable effervescence.
• pH: 3.0–3.5; Brix: 10–12°; CO₂: 3.5 volumes.
• Shelf stability for at least 1 month under proper storage (cool, dark conditions).
LESSON SUMMARY
• This lesson covers the production of carbonated soft drinks, focusing on key
processes like formulation, mixing, carbonation, and bottling.
• Students learn to select ingredients, apply quality control, and optimize processing
parameters to ensure safety and consistency.
• By understanding these steps, you’ll be equipped to create a refreshing and high-
quality beverage that meets industry standards.
REVIEW QUESTIONS
Question 1: How does temperature affect CO₂ solubility and final carbonation?
Question 2: Why is pH control critical for both safety and sensory quality?
Question 3: What are the roles of sodium benzoate and citric acid in formulation?

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Practice Assignment (at-home)

Students are encouraged to independently perform the production of 2 liters of

carbonated soft drink at home using accessible tools and ingredients.
After completing the activity, each student should document and share their results
on the class discussion forum. This can include photos, videos, process notes, and reflections
on product quality.
The goal is to enhance peer-to-peer interaction, foster practical problem-solving, and
promote collaborative learning based on real practice experiences.
ANSWER GUIDE
Study the contents in sections 1, and 2 in the lecture.
REFERENCES
1. Statista. (2023). Global Soft Drink Market Value. Retrieved from [statista.com].
2. FDA. (2021). Code of Federal Regulations Title 21: Food and Drugs.
3. Codex Alimentarius. (2020). General Standard for Food Additives.
4. Ashurst, P. R. (2011). Chemistry and Technology of Soft Drinks and Fruit Juices.
Wiley-Blackwell.
5. FDA. (2021). Code of Federal Regulations Title 21: Food and Drugs.
6. Codex Alimentarius. (2020). General Standard for Food Additives.
7. Dewitt, J. J., & Johnson, R. R. (2021). Introduction to Beverage Production and
Process Optimization. Food Technology Press.
8. Thomas, A. M. (2020). Carbonation Techniques and Their Application in Soft
Drinks. Beverage Science Publishing.
9. World Health Organization (WHO). (2011). Guidelines for Drinking-Water
Quality, 4th ed.
10. Smith, L., & Chen, Y. (2019). Quality Control in the Food and Beverage Industry,
2nd ed. Academic Press.
11. Rahman, M. S. (2020). Handbook of Food Preservation, 3rd ed. CRC Press.
12. Ghidossi, R., Prucons, L., & López, A. (2018). Emerging Technologies in
Beverage Processing. Springer.
13. Paine, F. A., & Paine, H. Y. (2022). A Handbook of Food Packaging. Springer
Nature.
14. Silva, S. C., et al. (2021). “Consumer Perception of Carbonated Beverages: Flavor
vs. Functionality,” Beverages, 7(3), 47. https://doi.org/10.3390/beverages7030047
15. Coca-Cola R&D Center. (2023). Sustainability and Efficiency in Carbonated
Drink Production. Internal White Paper.
16. Codex Alimentarius. (2023). General Standard for Food Additives. Updated by
FAO & WHO.