Formulation and Production of Carbonated Soft Drinks

Soft drinks are enormously popular beverages consisting primarily of carbonated water,
sugar, and flavorings. Nearly 200 nations enjoy the sweet, sparkling soda with an annual
consumption of more than 34 billion gallons. Soft drinks rank as America's favorite
beverage segment, representing 25% of the total beverage market. In the early 1990s per
capita consumption of soft drinks in the U.S. was 49 gallons, 15 gallons more than the
next most popular beverage, 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.

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.
Until the 1890s soft drinks were produced manually, from blowing bottles individually to
filling and packaging. During the following two decades automated machinery greatly
increased the productivity of soft drink plants. Probably the most important development
in bottling technology occurred with the invention of the "crown cap" in 1892, which
successfully contained the carbon dioxide gas in glass bottles. The crown cap design
endured for 70 years.

The advent of motor vehicles spawned further growth in the soft drink industry. Vending
machines, serving soft drinks in cups, became regular fixtures at service stations across
the country. In the late 1950s aluminum beverage cans were introduced, equipped with
convenient pull-ring tabs and later with stay-on tabs. Light-weight and break-resistant
plastic bottles came into use in the 1970s, though it was not until 1991 that the soft drink
industry used plastic PET (polyethylene terephthalate) on a wide scale.

Soft drink manufacturers have been quick to respond to consumer preferences. In 1962
diet colas were introduced in response to the fashion of thinness for women. In the 1980s
the growing health consciousness of the country led to the creation of caffeine-free and
low-sodium soft drinks. The 1990s ushered in clear colas that were colorless, caffeine-
free, and preservative-free.
Raw Materials

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.

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.

Sugar-free soft drinks stemmed from a sugar scarcity during World War II. Soft drink
manufacturers turned to high-intensity sweeteners, mainly saccharin, which was phased
out in the 1970s when it was declared a potential carcinogen. Other sugar substitutes
were introduced more successfully, notably aspartame, or Nutra-Sweet, which was
widely used throughout the 1980s and 1990s for diet soft drinks. Because some high-
intensity sweeteners do not provide the desired mouth-feel and aftertaste of sugar, they
often are combined with sugar and other sweeteners and flavors to improve the beverage.

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.
Very small quantities of other additives enhance taste, mouth-feel, aroma, and appearance
of the beverage. There is an endless range of flavorings; they may be natural, natural
identical (chemically synthesized imitations), or artificial (chemically unrelated to natural
flavors). Emulsions are added to soft drinks primarily to enhance "eye appeal" by serving
as clouding agents. Emulsions are mixtures of liquids that are generally incompatible.
They consist of water-based elements, such as gums, pectins, and preservatives; and oil-
based liquids, such as flavors, colors, and weighing agents. Saponins enhance the foamy
head of certain soft drinks, like cream soda and ginger beer.

To impede the growth of microorganisms and prevent deterioration, preservatives are

added to soft drinks. Anti-oxidants, such as BHA and ascorbic acid, maintain color and
flavor. Beginning in the 1980s, soft drink manufacturers opted for natural additives in
response to increasing health concerns of the public.

Impurities in the water are removed through a process of coagulation, filtration, and
chlorination. Coagulation involves mixing floc into the water to absorb suspended
particles. The water is then poured through a sand filter to remove fine particles of Roc.
To sterilize the water, small amounts of chlorine are added to the water and filtered out.

The Manufacturing Process

Most soft drinks are made at local bottling and canning companies. Brand name franchise
companies grant licenses to bottlers to mix the soft drinks in strict accordance to their
secret formulas and their required manufacturing procedures.
• 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.
• 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.
• 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 tank for about two hours until the reaction is complete.
• 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.
• The dissolved sugar and flavor concentrates are pumped into the dosing station in
a predetermined sequence according to their compatibility. The ingredients are
conveyed into batch tanks where they are carefully mixed; too much agitation
can cause unwanted aeration. The syrup may be sterilized while in the tanks,
using ultraviolet radiation or flash pasteurization, which involves quickly heating
and cooling the mixture. Fruit based syrups generally must be pasteurized.
• The water and syrup are carefully combined by sophisticated machines, called
proportioners, which regulate the flow rates and ratios of the liquids. The vessels
are pressurized with carbon dioxide to prevent aeration of the mixture.
• Carbonation is generally added to the finished product, though it may be mixed
into the water at an earlier stage. The temperature of the liquid must be carefully
controlled since carbon dioxide solubility increases as the liquid temperature
decreases. Many carbonators are equipped with their own cooling systems. The
amount of carbon dioxide pressure used depends on the type of soft drink. For
instance, fruit drinks require far less carbonation than mixer drinks, such as
tonics, which are meant to be diluted with other liquids. The beverage is slightly
over-pressured with carbon dioxide to facilitate the movement into storage tanks
and ultimately to the filler machine.
• The finished product is transferred into bottles or cans at extremely high flow
rates. The containers are immediately sealed with pressure-resistant closures,
either tinplate or steel crowns with corrugated edges, twist offs, or pull tabs.
• Because soft drinks are generally cooled during the manufacturing process, they
must be brought to room temperature before labeling to prevent condensation
from ruining the labels. This is usually achieved by spraying the containers with
warm water and drying them. Labels are then affixed to bottles to provide
information about the brand, ingredients, shelf life, and safe use of the product.
Most labels are made of paper though some are made of a plastic film. Cans are
generally pre-printed with product information before the filling stage.
 • Finally, containers are packed into cartons or trays which are then shipped in
larger pallets or crates to distributors.
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.
Recycling
The $27 billion dollar soft drink industry generated about 110 billion containers each
year in the early 1990s. About half of soft drink containers were aluminum cans and the
other half, about 35 billion, were PET plastic bottles. Nearly 60% of all soft drink
containers were recycled, the highest rate for any packaging in the United States.
Environmental concerns continued to lead to improvements and innovations in packaging
technology, including the development of refillable and reusable containers.
The Future

In the 1990s there were more than 450 types of soft drinks on the market and new flavors
and sweeteners are developed all the time to meet market demands. In the future,
advanced technology will lead to greater efficiency of soft drink production at all stages.
New methods of water clarification, sterilization, and pasteurization will improve
production and minimize the need for preservatives in soft drinks. Concerns with
consumer health, safety, and the environment will continue to have a positive impact on
trends in the soft drink industry.