Dasani Commissioning Run Checklist
Please Note that 3 consecutive commissions runs must be successfully
completed for a line to be commissioned.
YES NO SUBJECT RESOURCE
TRAINING
Are plant personnel trained in batching procedures (e.g., DG / RTM
mineral injection solution)?
Are plant personnel trained in the use of manufacturing Plant QA
equipment specific to Dasani, e.g., RO, ozone generator,
ozone monitoring, ozone permitting issues, and the use of
in-line probes to monitor processes.
Are the plant personnel trained on the use of the ozone RTM
destruct unit for product taste testing? Plant QA
QUALITY STANDARDS
Does the beverage conductivity reading correlate to total Plant QA
dissolved solids (TDS) of 23 ppm ±5 percent?
Is the final beverage turbidity reading less than 0.5 NTU? Plant QA
Is the plant UV system operational? Plant QA
Does the plant UV system have a minimum of 40,000 Plant QA
µW/cm2 strength?
Is a UV by pass in place so that some of the ozonated water Plant QA
can by pass the UV system?
Is the residual ozone level of the final beverage between RTM
0.1 – 0.4 ppm in bottle immediately after capping?
Is the product held for 48 hours to ensure ozone dissipation RTM
or released to market with ozone, taste, odor and
appearance testing after 24 hours?
Have finished beverage comparison samples been supplied David Gass
to the plant?
Have packaging graphic standards been supplied to the Mike Gage
plant?
Is the plant in compliance with CCNA line qualification RTM
requirements for bottled water?
Is the plant in compliance with the storage conditions for RTM
beverage base and finished beverage?
Does the plant have the ozone destruct unit for taste testing RTM
on hand and operational? Bryan
Does the plant have the water bath on hand and operational RTM
for conductivity testing? Bryan
Is Cpk > 1 for torque? Must use at least 30 samples. Plant QA
Is Cpk > 1 for Net Content? Two turns of capper.. Plant QA
YES NO SUBJECT RESOURCE
MIXING INSTRUCTIONS
Are the appropriate mixing instructions available for the David Gass
product? (Conventional batch system or mineral injection
system)
PRODUCTION EQUIPMENT AND MATERIALS
Is the filler sanitized using the standard 5 step cold RTM
cleaning and sanitizing necessary for sensitive
products?
Are proprietary (with the swirl) closures on hand? Plant QA
Does the lab have the Beverage Standard on hand? Brian
Plant QA
Is the UV system on the RO water storage tank operational Brian
and the pump designed for 2 turn / day?
Have beverage base part numbers and item numbers been Plant QA
verified using the mixing instructions?
Is the RO system capable of continuously supplying water RTM
with a TDS less than 9 ppm?
Are seals and gaskets ozone resistant, e.g., Viton or Plant QA
equivalent?
Are the RO membranes sanitized according to Plant QA
manufacturers’ recommended procedures?
Is the product water ozonation system designed for a Bryan
minimum 4-5 minute contact time for water and ozone?
Does ozonation system design provide a recirculation loop RTM
prior to filler to ensure proper ozone levels in the water?
Is the bottle rinser supplied with > 0.3 ppm ozonated water ? Plant QA
Is an in-line conductivity meter used in the final beverage RTM
stream? Existing systems if in place will be used.
Otherwise manual testing
Has the plant made the necessary line changes to handle Mike Gage.
the proprietary water bottles and to apply label and closures
properly?
Has the plant evaluated the proprietary bottle handling at the Mike Gage
case packer and do the bottles fit in available case shells?
Does the plant have the required date coding format Plant QA
programmed into the date coder.? RTM
Does the lab have the media and equipment to perform the Plant QA
coliform and total count and PSA membrane filtration
technique?
YES NO SUBJECT RESOURCE
PRODUCTION EQUIPMENT AND MATERIALS Cont’d
Does the lab have a colormetric test kit for ozone testing? RTM
Plant QA
Is the lab equipped with a conductivity/TDS meter capable RTM/Plant
of measuring 0.1 ppm TDS? QA
Does the lab have an ozone/UV destruct device for Bryan/RTM
preparing samples for time of production taste testing?
Does the lab have a turbidity meter capable of measuring RTM/Plant
0.01 NTU? QA
YES NO SUBJECT RESOURCE
Phase 2 TESTING EQUIPMENT AND PROCEDURES
Does system design provide an in-line monitor with alarm Bryan
placed between the ozonator and the filler to detect low
ozone level or interruption of flow? Existing systems if in
place will be used. Otherwise manual testing.
Does the processing area have environmental monitors and RTM
alarms to detect excessive ozone levels? Worker exposure
cannot exceed 0.1 ppm on an 8 hour time weighted
average. See warnings in section X.5.0.
Not at this time. Manual testing required Hourly.
Is there a closure rinser supplied with ozonated water or RTM
deionized air; or a bottle twist after the filler to ensure the
sanitation of closure liner? Existing systems if in place will
be used.
YES NO SUBJECT RESOURCE
SAMPLING
Pull 14 full cases from (300 + bottles for damage) from the Plant QA
beginning, middle, and end of commissioning run # 1 and
ship them to Apopka for spot testing so that they arrive prior
to 7 days after production? See address below.
Pull 5 full cases from (96 + bottles for damage) from the Plant QA
beginning, middle, and end of commissioning run # 2 and
ship them to Apopka for spot testing so that they arrive prior
to 7 days after production? See address below.
Pull 5 full cases from (96 + bottles for damage) from the Plant QA
beginning, middle, and end of commissioning run # 3 and
ship them to Apopka for spot testing so that they arrive prior
to 7 days after production? See address below.
Pull 2 cases of packaged water from commissioning run #1 Plant QA
and ship overnight to NSF for testing. See address below.
YES NO SUBJECT RESOURCE
SAMPLING Cont’d
Have all routine tests as per Dasani Commissioning Run In- Plant QA
Plant Testing been completed and passed?
COMMISSIONING RUN
Have the 12,000 bottles for commissioning run #1 been Plant QA
placed on hold and isolated?
Have the 12,000 bottles for commissioning run #1 passed all Plant QA
inspections including Cpk for torque and Net Content ?
Have the 12,000 bottles for commissioning run #2 been Plant QA
placed on hold and isolated?
Have the 12,000 bottles for commissioning run #2 passed all Plant QA
inspections including Cpk for torque and Net Content ?
Have the 12,000 bottles for commissioning run #3 been Plant QA
placed on hold and isolated?
Have the 12,000 bottles for commissioning run #3 passed all Plant QA
inspections including Cpk for torque and Net Content ?
Has the line been commissioned? RTM
Ship Spot test samples to Apopka so that they arrive prior to 7 days after production.
Apopka Address
Sensitive Product Monitoring
Ingredient Sciences - CCNA
2631 Orange Avenue
Apopka, FL 32703
Attention: Susan Martin (407) 814-2880
Contact name and number for Apopka is Susan Martin 407-814-2880.
Ship NSF Samples Next Day Delivery
NSF Address
NSF International
789 N Dixboro Rd
Ann Arbor, MI 48105
Contact name and number for NSF is Patty Burns 734-769-5269.
Dasani Commissioning Run In-Plant Testing
Test Dasani Specification Frequency
Appearance/Color Normal visual & no color Collect 2 containers at
beginning, middle and
Taste No taste or odor end of each run for
routine
pH 5.0 to 8.0
Ozone residual 0.1 to 0.4
TDS 21.95 – 24.15 ppm
Turbidity 1 end of run.
Plus
Test 3 bottles per day for
14 days from each run.
Net Content 487.5 to 512.5 A complete turn of the
filler at the beginning and
Cpk >1 end of the run.