Yakult Danone India Pvt. Ltd.

INDUSTRIAL
VISIT TO YAKULT DANONE
INDIA PVT. LTD.

SUBMITTED TO
CCR
SUBMITTED BY
HIMANSHU(2K16GA010)

Yakult Danone India Pvt. Ltd.

SEPTEMBER 12,2016

Yakult Danone India Pvt. Ltd.

INDEX

1)Introduction
2)Introductory Presentation on Yakult
a) History
b)What is Yakult
c) What is Probiotic Drinks
d)Distribution Process
3)Factory Tour
a) Production Process
b)Conclusion
c) Recommendation

d)

Yakult Danone India Pvt. Ltd.

Report on
Industrial visit to Yakult Danone India Pvt. Ltd.

Introduction:
The students of Asia-pacific Institute of Management, PGDM section - A
were taken on an industrial visit to Yakult Danone India, Sonepat, Haryana
in India. The largest Probiotic Drink producer and distributor in India. We
reached the plant at about 12 PM on 22 august, 2016 and was greeted by
Mr. Abhishek, HR of Yakult.
The Industrial visit was divided into two phases:
An introductory presentation on Yakult.
The Factory Tour.

1. Introductory presentation on Yakult:

Students were given a bottle of the drink to taste and refreshments before presentation started.
Yakult Danone in India:
Yakult Danone India Pvt. Ltd. is a 50-50 joint venture between Yakult
Honsha, Japan and Group of Danone of France. The joint Venture was
formed in 2005 and It is carrying out its operations since 2007. Yakult is
presently available in Delhi/NCR, Nasik, Chandigarh, Punjab, Jaipur,
Mumbai, Pune, Ahmedabad, Hyderabad, Chennai, Bangalore, Kolkata and
Lucknow. Yakult is manufactured at an ISO 9001:2008, HACCP and OHSAS
18001:2007 certified.

History:
1930: Dr. Minoru Shirota succeeds in culturing and utilizing lactic acid
bacteria (Lactobacillus casei strain Shirota).
1935: Yakult is introduced in the Japanese market.
1938: Yakult is registered as a trademark.

Yakult Danone India Pvt. Ltd.

1940: Local offices of the Association for Promotion of Preventive Bacteria

Strain Shirota are established in various parts of Japan for the purpose of
marketing and distributing Yakult.
1963: Yakult launches its unique Yakult Ladies system of door-to-door
distribution in Japan.
1967: Yakult Central Institute for Microbiological Research is established in
Kunitachi, Tokyo.
1968: Yakult is introduced to the market in a new plastic container.
1972: Program of regular visits to senior citizens by Yakult Ladies begins.
1981: Company stock was listed on the first section of the Tokyo Stock
Exchange.
1998: Yakult is approved by the Ministry of Health and Welfare for labeling
as Foods for Specified Health Uses (FOSHU).
2005: Decision made to enter the Indian market in alliance with Group
Danone.
2007: Production facility of Yakult in Sonepat, Haryana, India completed
and product launched in India.

What is Yakult?
Yakult is a fermented milk drink containing over 6.5 billion Probiotic
bacteria (Lactobacillus casei strain Shirota). Unlike most bacteria found in
normal yoghurt, these Probiotic bacteria are able to survive the acidic
environment of the stomach and reach the intestines alive, helps to
restore the balance of the friendly bacteria in the gut. The friendly
bacteria in Yakult help to improve digestion, build immunity when
consumed everyday.

What is Probiotic Drink?

A probiotic drink is like a yoghurt drink designed to give the body some much needed good
bacteria.
According to WHO/FAO, Probiotics are live microorganism which when
administrated in adequate amounts confer a health benefit on the host.

Yakult Danone India Pvt. Ltd.

Nutritional Fact: Per Serving (65ml) bottle

Energy
= 50kcal
Protein
= 0.8 g
Carbohydrates = 12g
Fat
= 0.1g
Added sugars = 10g
Benefits of Drink:

Reach the intestines alive and transiently colonize the gut,

Improve the intestinal barrier function,

Stimulate systemic and mucosal host immunity,

Suppress growth of pathogenic bacteria and inhibit the production of

harmful substances,

Helps in building immunity,

Potentially help in reducing the risk of Breast Cancer.

Distribution Process:
Retail Shop
Yakult is available at selected supermarkets and high volume retailers,
bakeries, chemists, hospitals and small retailers in Delhi/NCR, Nasik,
Chandigarh, Punjab, Jaipur, Mumbai, Pune, Ahmedabad, Hyderabad,
Chennai, Bangalore, Kolkata and Lucknow who have an established cold
storage facility. It is their Endeavour to make Yakult available to
consumers at all times, anywhere. They Track the need of availability of
Yakult and act accordingly for supplying.
Home Delivery by Yakult Ladies
Ever since this system was introduced in 1963, Yakult has successfully
used it to deliver its products worldwide through a network of over 80,000
ladies. This system was created to help customers fully understand the
benefits of probiotics and bring Yakult products to them every day as
ladies are homemaker and they are easily available at home. In India too
there are 150 Yakult ladies involved in this unique distribution system.
They all are called as Ambassador of Yakult.

Yakult Danone India Pvt. Ltd.

2. Factory Tour:
Production Process:
There we student observed various stages to produce a probiotic drink
Yakult, as follow:

Mixing of Raw Materials

Storage Tank/Dissolving Tank

Homogenization machine/Blending Tank

Injection Moulding Room (for making 65ml bottle)

Printing Machine

Filling Machine/Sealing machine

Packaging Machine

Refrigeration Room

SEED ROOM:
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Yakult Danone India Pvt. Ltd.

1. Mixing of Raw Ingredients

Live Lactobacillus casei Shirota strain is cultured in a 'seed tank' in there
laboratory.
Skim milk powder is mixed with sugar, glucose and filtered, sterilised
water to make a sweet milky solution.
2. Sterilisation
The sweet, milky solution is sterilised at a high temperature for a short
time, destroying any bacteria that may be present. The solution is then
transferred to a 6,500-litre culture tank via a closed system of pipes.
CULTURE & MIXING ROOM:
3. Culture Tank
The temperature of the tank is reduced to 37C and live Lactobacillus
casei Shirota strain is added. The solution is allowed to ferment for about one
week until the number of Lactobacillus casei bacteria reaches an ideal
concentration.
4. Mixing and Storage Tank
The concentrate is transferred to a 12,000-litre mixing and storage tank. The
tank is chilled to around 2 C. Sterilised flavours, syrup solution, vitamins and
calcium are added to the concentrate. Prior to bottling, the concentrate is diluted
with filtered, sterile water.

MOULDING ROOM:
5. Injection Blow Moulding Machine
The plastic bottles are produced on site. The bottles are made from polystyrene.
65ml bottle are moulding for Indian customers.

FILLING ROOM:
6. Bottling and Packaging
The bottles are wrapped with individual bottle labels. Then, they are filled with
Yakult, capped with a foil lid, sealed and transferred along the conveyor belt to
the packaging facility. Single bottles of Yakult are sorted into groups of five and
shrink-wrapped in polypropylene film. Ten "5-packs" are grouped together and
wrapped again in polyethylene film and then heat shrunk, forming a 'carton' of
50 Yakult bottles.

Yakult Danone India Pvt. Ltd.

PLACING ROOM:
7. Refrigeration Room
Finished products are kept refrigerated before delivery to stores.

QUALITY CONTROL ROOM:

8. Yakult Quality Assurance
Yakult maintains a comprehensive quality assurance program in order to ensure
that our product is of the highest quality. For this reason, samples are collected
for laboratory analysis throughout the production process to confirm that the
quality assurance measures in place have been effective. They pick Yakult
randomly from conveyor belt and test accordingly for quality purposes.

Quality measures they were taking:

Special care is taken to safeguard the viability of live Yakult bacteria,

Workers have to wear special protective clothes,
Bottling and filling area is controlled with germ-free air,
Frequent testing at our on-site quality control division makes sure
that each bottle of Yakult has 6.5billion beneficial bacteria i.e.
Lactobacillus casei strain shirota and the product is of the highest
standard, right up till the date of expiry,
Each room has separate colour carpet.

CONCLUSION:
MY EXPERIENCE ABOUT YAKULT DANONE INDIA Pvt. Ltd.
It was a great experience of the visit, student learned about the benefits
and importance of the probiotics in our life. Learned about the strategies
which we study in our PGDM course how they are practically implied, how
to do a proper plant layout and also the use of skilled labour with the new
advanced technology. Mr. Abhishek gave us a sound about the plant and
the production process. The concept of the YAKULT ladies is awesome like
this they are generating employment for ladies and also doing the
marketing and selling of their product efficiently and effectively. The
tracking system of Demand of Yakult to be Supplied is very much
sustainable. There Tag line Daily piyo, Healthy jiyo is much effective to

Yakult Danone India Pvt. Ltd.

generate awareness about the product and is very catchy. Over all the
entire trip was very beneficial to all of us.

RECOMMENDATION:
Student got limited time to discuss on some important matters, so
industrial visit should be for more time. Time is essential but
discussion needs time.
Indians are not much aware of this Yakult product. So they should
take measures accordingly.
Though their supply chain is very much sustainable but to expand
the supply with awareness they should open new factory in every
region like, we have Yakult Danone in Sonepat in northern region,
they should open factory in eastern, western and southern as well.
Which will eventually help them to expand business and make good
profits.
They need diversification. New product with new line of segment.
Selling only product cant help them as product itself is not that
much capable of beating other substitute products.

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