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UNIVERSITY OF DAR ES SALAAM

COLLEGE OF ENGINEERING AND TECHNOLOGY

FACULTY OF CHEMICAL AND PROCESS ENGINEERING

DEPARTMENT OF CHEMICAL AND MINING ENGINEERING

PRACTICAL REPORT

PT 2

2015/2016

COCA-COLA BEVARAGE PROCESSING

DEGREE PROGRAMME: BACHELOR OF SCIENCE IN CHEMICAL AND

PROCESS ENGINEERING

NAME OF STUDENT: MARO, ROLLAND D.

STUDENT’S REGISTRATION NUMBER: 2013-04-01965

NAME OF PT COMPANY: COCA-COLA KWANZA COMPANY LTD.

NAME OF INDUSTRIAL TRAINING OFFICER: Mr. AMUR

NAME OF ACADEMIC TUTOR/SUPERVISOR: ABRAHAM TEMU

PT DURATION: EIGHT WEEKS

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Table of Contents AKNOWLEDGEMENT.................................................................................................... iii

GENERAL ABSTRACT .....................................................................................................iv

PART 1 ..........................................................................................................................v

WEEKLY REPORT............................................................................................................v

PART 2 .........................................................................................................................vi

MAIN REPORT ..............................................................................................................vi

1.0 COCA-COLA KWANZA COMPANY LTD ..................................................................1

1.1 HISTORICAL BACKGROUND OF COCA-COLA KWANZA. .......................................1

1.2 COMPANY VISION AND PURPOSE. ...................................................................2

1.2.1 Vision ............................................................................................................2

1.2.2 Purpose.........................................................................................................2

1.3 ORGANISATION STRUCTURE IN COCA-COLA KWANZA. ......................................2

2.0 SOFT DRINK MANUFACTURING. ..........................................................................3

2.1 RAW MATERIALS ..................................................................................................5

2.2 UTILITIES..............................................................................................................5

2.2.1 COMPRESSED AIR ..........................................................................................5

2.2.1 STEAM. .........................................................................................................6

2.2.3 WATER ..........................................................................................................8

2.3 SRYUP ROOM AND SYRUP PRODUCTION ............................................................. 11

2.3 BLENDING SYSTEMS (MIXER) .............................................................................. 13

2.4 PLASTIC BOTTLED BEVERAGE PRODUCTION LINE ................................................. 14

2.4.1 INJECTION PLANT......................................................................................... 14

2.4.2 BLOWING SECTION ...................................................................................... 15

2.5 FILLING SYSTEMS ............................................................................................... 17

2.5 GLASS BOTTLE BEVARAGE PRODUCTION LINES .................................................... 18

2.5.2 EMPTY BOTTLE INSPECTION (EBI).................................................................. 20

2.6 DATE CODING SYSTEMS...................................................................................... 20

2.7 PACKING SYSTEMS ............................................................................................. 20

Glass bottle beverage packing............................................................................... 20

Plastic bottle beverage packing ............................................................................. 20

CONCLUSION .............................................................................................................. 21

RECOMENDATION ....................................................................................................... 21

REFERENCE ....................................................................... Error! Bookmark not defined.

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AKNOWLEDGEMENT

I would like to express my deepest appreciation to all those who provided me the

possibility to complete this report. A special gratitude I give to our industry

training officer, Mr. Amur, whose contribution in stimulating suggestions and

encouragement, helped me to coordinate my practice process in the industry and in

writing this report.

Furthermore I would also like to acknowledge with much appreciation the crucial

role of the staff of COCA-COLA Kwanza Company LTD, who gave the permission

to use all required equipment and the necessary materials to complete the learning

task Mr. Proches. A special thanks goes to my fellow student during this practical

training, Miss Haule Pendo. Last but not least, many thanks go to the supervisor of

the training, Mr. Abraham Temu whose have invested his full effort in guiding us

on what we are supposed to do and learn during the training session and this report

writing. I have to appreciate the guidance given by other supervisors as well as the

Company specialists, technicians and operators especially in our training process

that has improved our skills thanks to their comments and advices.

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GENERAL ABSTRACT

The aim of this field work training was to expand our technical skills and

experience in real industrial production situation of beverages, practicing the

knowledge we acquired from course studies inside the university and from

industrial trainers.

The Coca-Cola Kwanza Company Ltd. is a bottling company that deals with

processing of soft carbonated drinks, drinking water and distributing them to the

market.

Coca-Cola Kwanza Company is composed of different utility plants used to

produce the production requirements which are steam, compressed air, treated

water, chilled water and carbon dioxide.

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PART 1

WEEKLY REPORT

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PART 2

MAIN REPORT

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1.0 COCA-COLA KWANZA COMPANY LTD

Coca-cola Kwanza Ltd is located in Msasani Dar Es Salaam offering services in

Dar Es Salaam. It deals with processing and bottling soft drinks and distributing

them to the local distributors.

1.1 HISTORICAL BACKGROUND OF COCA-COLA KWANZA.

The seeds of Coca-Cola Kwanza (CCK) were sown on a warm Christmas Eve in

1952, when the first Coca-Cola bottled in the east African country rolled off the

production lines.

Then called Tanganyika Bottlers, it was owned by Greek businessman Aris

Cassolis. The country gained independence in 1961 and changed its name to

Tanzania in 1964, following the union of Tanganyika and Zanzibar. Cassolis was

quick to follow suit, proudly changed his company’s name to Tanzania Bottlers.

In the decades that followed, growth was somewhat sluggish and the company

changed hands. In 1995, when Coca-Cola Sabco became the majority shareholder

in Tanzania Bottlers Ltd, the company’s name again evolved to become Kwanza

Bottlers, (meaning ‘first’ in Swahili), and later Coca-Cola Kwanza (CCK).

Exciting developments followed, including a new, ultra-modern facility in

Mikocheni in Dar-Es-Salaam. CCK also has a bottling plant in Mbeya.

CCK’s significant events and achievements include:

In 1997, its new Mikocheni plant was opened by the then Tanzanian president

Benjamin William Mkapa, who enjoyed the first bottle of Coca-Cola off the line.

In 1998, Zanzibar Bottlers won a Silver Quality Award. In 1999, Zanzibar Bottlers

received the Coca-Cola Northern Africa Division President’s Gold Award for

Quality.

In September 1999, CCK celebrated record sales, topping the list of Coca-Cola

Sabco companies. In 2002, Zanzibar received the Bronze Quality Award In 2004,

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the Zanzibar Plant received a Silver Quality Award. In 2013, Mbeya received the

Bronze Quality Award.

1.2 COMPANY VISION AND PURPOSE.

1.2.1 Vision

The company wants to be best In sales volume and in return on capital employed.

Coca-Cola Bottler: A consumer driven, customer oriented, manufacturer, sales &

Distribution Company that markets the products & brands of The Coca-Cola

Company. In the World: To measure the company against the best Coca-Cola

bottlers in the World.

1.2.2 Purpose

The purpose of the company is to create value for everyone touched by its business

by providing, with passion and focus, the right refreshment, at the right price, in the

right place.

1.3 ORGANISATION STRUCTURE IN COCA-COLA KWANZA.

COUNTRY MANAGER Tanzania

Kadir Gunduz

Country DF Manager

Pancras BabuCountry ME / DC Manager

Feisal Abdallah

Country P / F Manager

Murray Loggie

Country HR Manager

Caroline T. Kavishe

Country Auditor

Felix Maagi

DF-MNGR

DSM

Innocent Mushi

DF - MNGR

MBY

Pasaka Nyamusika

DF- MNGR

ZNZ

Ali Kassim

MBY Operations

Manager

Stephen Akyoo

ME Manager

DepotsJohn Mugakanaga

ME Manager DSM

Mapendo

Operations Manager

Zanzibar

Songoro Mnukwa

Operations ME

Manager

Abdallah Said

Finance Manager

DSM & ZNZ

Geoffrey Kiarie

Finance Manager

Mbeya

Vacant

HR Manager

Coastal

Vacant

Country Employee

Relations Manager

Mario Mahenge

External Affairs

Manager

Kippi Warioba

DC Territory

Manager

Francis Nanai

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2.0 SOFT DRINK MANUFACTURING.

In general during Beverage production processes precision monitoring system is

ensured to get accurate mixing and blending of ingredients. These ingredients

includes water, syrup and Air / N2 / CO2 to complete the blending process.

The first step in the production process is to get and produce utilities like water,

steam, compressed air and electricity. Water goes through a two-step filtration

process and then deoxygenated process. Concentrate and sugar go into a reservoir

tank creating syrup which then goes through a clarification and filtration process.

Water purity is an important process in soft drink preparation along with

proprietary ingredient. Automated monitoring systems plays an important role in

the production process. The purified water and syrup concentrate merge into a filler

tank. CO2 is injected into the blend and bottled as it moves down a conveyer belt

prior to packaging.

In production of plastic bottled beverage the raw materials required are resins

which are imported. They are used to produce preforms which when blown

produces plastic bottles. The following flow chart shows the flow of production

process in the industry.

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Incoming raw materials

Refillable glass

bottle

Carbon

dioxide

Crowns Sugar & Concentrates

Chlorination

Container

preinspection

Underground

water storage

tank

Container washing

and rinsing Water

softener

Water

treatment Syrup

manufacturi

ng

General

cleanliness

Washed bottles

inspection

Date coding

Blending

Warehousing

Consumer

Filling & crowning

Full inspection

Packing

Palletizing

Resins

Preform

plant/inje

ction

Preform

Inspection

Preform Heating

Inspection

Preform blowing

Plastic bottle

Incoming raw

water

A

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2.1 RAW MATERIALS

The raw materials that were used in the industry are Sugar and other sweeteners,

Carbon dioxide, Preservatives, color, and acidulates delivered as Part I and II,

Returnable glass bottles, resins and preforms for manufacture of plastic bottles

The industry imports sugar from abroad, normally Egypt. White sugar is mostly

used because the syrup obtained from it is clear, soft drinks like Sprite are clear

because of this property. The sugar (sucrose) is extracted from sugar cane.

2.2 UTILITIES.

2.2.1 COMPRESSED AIR

Compressed air had many uses in various areas of the industry ranging from high

pressure of 40 bar to low pressures. The compressed air came from the HP(high

pressure) compressor plant and the low pressure compressors plant. Compressed

air was used in the following production process: preform (PET) blowing in blower

moulder , cleaning in place, valves in machines and many other areas of the

industry.

HP COMPRESSORS PLANT

This plant is composed of two High pressure compressors and cooling towers

which can produces compressed air up to 40 bar mainly to be used by PET blowing

process.

Description of HP compressors .

A HP compressor system was composed mainly of three parts which are: High

pressure PET compressor and air receiver, Electric cabinet and 40 bar air dryer and

other pneumatic tools.

The 40bar oil free compressor has a capacity of 225m3/H to 3200m3/H and is

equipped on anti vibration mountings. The air compressor contains electric motor –

from 55 to 550 kW and V-belt transmission, V-Belt drive system complete with

sheet steel guard and inspection door. The system allows the compressor speed to

be adapted to give precisely the required Free Air Delivery. Standard range design

for optimum efficiency.

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Process description. Compression is done in three stages in a “L” three stages compressor. There are

intercoolers between each stage and after-cooler. This utilizes a multistage

compression principle.

The following flow daigram shows how compression is done in three stages.

For multistage compression with minimum work and perfect inter-cooling and no

pressure drop that occurs in the inter-coolers between stages, the following

conditions apply: the work at each stage are equal the pressure ratio between stages

are equal the air temperature in the inter-coolers are cooled to the original

temperature T1 but in real situation there are loses of pressure in the intercooler

therefore the efficiency of the machine falls.

2.2.1 STEAM.

Steam is an important utility that is used in syrup making, washing of returnable

glass bottle and cleaning of various parts of the machines during CIP mostly inside

pipes.

1 2 3 4

Suction Discharge

5 6

LP Intercooler

1st

stage 2nd

stage 3rd stage

HP Intercooler

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BOILERS (STEAM PLANT)

The plant is composed of two boilers each of them has a capacity to evaporate

6000Kg/Hr. at and from 100 centigrade and a working pressure of 18.00Kg/cm2

both of them uses fire tubes and uses heavy oil as fuel but one can utilize gas as a

fuel. The key boiler components involved in this process are the burner,

combustion chamber, heat exchanger, and controls.

The burner mixes the fuel and oxygen together and, with the assistance of an

ignition device, provides a platform for combustion. This combustion takes place in

the combustion chamber, and the heat that it generates is transferred to the water through the

heat exchanger. Controls regulate the ignition, burner firing rate, fuel supply, air supply, exhaust

draft, water temperature, steam pressure, and boiler pressure. Hot water produced by

a boiler is pumped through pipes and delivered to equipment throughout the

building, which can include hot water coils in air handling units, service hot water

heating equipment, and terminal units. Steam boilers produce steam that flows through

pipes from areas of high

pressure to areas of low pressure, unaided by an external energysource such as a

pump.

The following diagram explains the process flow

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2.2.3 WATER

Water constitutes some 90% of a typical soft drink. Water used in production

process is ensured to reach the KORE requirements. The quality of water helped to

make drinks un distinguishable, test and quality and most importantly free from

disease causing agents.

The industry uses water that is supplied by DAWASCO. This water is received

soften and stored in an underground tank in which Chlorine is first dozed.

WATER TREATMENT PLANT.

The industry received water doesn’t meet KORE requirements therefore the

industry does further water treatment.

Reaction Tank

The reaction tank is designed in such a way that the mixture of water and chemicals

mix and react thoughly. There are three small dosage tanks which are used to dose

in the reaction tank. The following takes place in the reaction tanks.

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COAGULATION AND FLOCCULATION REACTION

This reaction aims to remove undissolved solid that do not settle. The chemical

aggregates them and thus they becomes heavier and settles down (sediments).

Normal chemical used in coagulation is iron sulphate or iron chloride.

2FeCl3 + 6H2O 2 Fe (OH)3 + 6HCl

ALKALINE REDUCTION

This is attained by adding the solution of slaked calcium hydroxide also called milk

of lime. The reaction is as follows.

Ca(HCO3)2 + Ca(OH)2 2CaCO3 + 2H2O

The removal of magnesium is done in two stages first magnesium carbonate and

calcium carbonate are formed. On addition of more of milk lime it combines with

magnesium to form magnesium hydroxide.

STERILIZATION BY SODIUM-HYPOCHLORATE SOLUTION.

Sterilization of water to remove organic species that are harmful is done by dosing

sodium hypochlorite.

NaOCl + H2O HOCl + NaOH

HOCl HCl + <O>

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DEGASEFYING TANK

This is a tank used to remove all dissolved gases and mostly it removes chloroform.

Chloroform is a bleaching agent and therefore if it is not removed it de colorize the

soft drink.

CARBON FILTERS

These filters consists of activated carbon and are responsible for removing

chemicals and impurities by the method of chemical absorption, therefore these

filters remove the rest of chlorine. In this plant there are four carbon filter tanks and

each time three are in use and one stand by.

SAND FILTERS

Sand filters are arranged to work after carbon filters and are composed of different

layers of sand varying in size which increases when to the top. The sand filters

removes pathogens, taste and odour.

REVERSE OSMOSIS PLANT (RO)

This water purification technology uses a semipermeable membrane to remove

larger particles from drinking water. Pressure is used to overcome osmotic pressure.

The plant consist of two UV treatments before and after the fibers to kill any

surviving microorganisms. There are 7 fibers and they work in set of 4-2-1.

These fibers are cleaned with citric acid.

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2.3 SRYUP ROOM AND SYRUP PRODUCTION

Syrup is consists of the following compositions: water, sugar or other sweetener,

acid, sometimes fruit juice, flavors and emulsions, colors, preservatives and

antioxidants. These constituents are grouped together to form simply two parts i.e.

part I and part II. These parts are imported as raw materials.

Process description.

The production of syrup is two stages

i. Production of simple syrup

ii. Standardization to get final syrup.

In Coca Cola Kwanza the formation of beverage syrup is done in the blending

machine which is not in the syrup room.

Simple syrup

Simple syrup is the form of syrup which is obtained by mixing sugar and treated

water. Sacks sugar are opened and fed up to pneumatic conveyor which feeds the

silo which mixes the sugar with hot water. The silo mixes the sugar in a circuit with

the sugar mixer until the mixture is homogenous and all sugar is dissolved. The silo

and sugar mixer holds 7000 liters of water. To this amount of water 15 tons of

sugar to obtain the brix of . After thorough mixing the mixture solution is

cooled and filtered to remove undissolved solids and then transferred to the storage

tank ready to be used for different beverages.

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Final syrup

Final syrup is obtained by mixing of simple syrup, water, part I & II (flavor, color,

preservatives) of the beverage to be produced in order to obtain the required brix.

The following is the table of final brix and beverage brix.

Coca Cola Kwanza bottling Company.

S/N Brand Final Syrup (°Bx) Beverage (°Bx)

1 Stoney Tangawizi 52.10 11.48

2 Coke 54.85 10.37

3 Sprite 53.20 10.00

4 Fanta Orange 57.82 13.00

5 Fanta Black Currant 59.65 13.50

6 Fanta Passion 58.57 13.20

7 Fanta Pineapple 53.89 11.95

Cleaning in Place Systems (CIP)

Sanitation is principally undertaken to remove all undesirable matter from any surface in

contact with the product to a level at which the residues remaining present minimal risk

to the product during its shelf life.

The cleaning system starts at the syrup room in which there is cleaning solution tanks, hot

water and cold water. After every production and change of flavor or beverage CIP is done

from the syrup room to the production room and back to the syrup room.

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2.3 BLENDING SYSTEMS (MIXER)

The blending systems for the Coca Cola Kwanza Ltd are of very little difference.

The aim was to produce drinks which are indistinguishable in taste, odour and

appearance. Therefore I am going to report both RGB and PET blenders on the

same section.

1. Base frame, 2. Deaeration tank, 3. Vacuum pump, 4. Dosing pump for syrup, 5.

Buffer tank, 6. Carbonation, recirculation pumps, 7. Control panel, control cabinet,

8. Acoustic warning unit, signal beacon post, 9. Air service unit, 10.Connections

for CO2, N2, 11.Product water connection, 12.Connection for syrup, 13.Product

feed pipe to the filler

Blenders received final syrup from the syrup room, carbon dioxide and treated

water. They performs the following function.

Deaeration of water with a vacuum assisted system in which most of air is removed

in unit 2 and 3.

CO2 or N2 injection in the buffer tank. Also in the buffer tank the there is already a

homogenous mixture with constant concentration known as beverage brix. The

machine has valves which are controlled by flowmeters which ensures the correct

mixture ratios for the specific beverage.

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2.4 PLASTIC BOTTLED BEVERAGE PRODUCTION LINE

Line 5 & 6 of the manufacturing unit at Coca Cola Kwanza uses plastic bottle

containers for beverages. These plastic bottles are also used for production of

mineral water.

2.4.1 INJECTION PLANT

Injection plant produces preforms.

Polyethylene terephthalate (PET) a polyester polymer consisting of alternate units

of ethylene glycol and terephthalic acid is the monomer used to produce pellets of

resin, these resins in a close control state are melted and solidified to form

preforms. Resins are imported into the industry as raw materials.

Process description

In stage one a preform is produced by high-pressure injection molding in which the

pellets of resin which have initially been dried are melted at temperatures of about

275 ◦C. If color is required for the final design, it was added during the melting

process at the required dosage, just before being injected into the mould. When

melted the molten plastic is injected into a precision mould; the mould is cooled

with chilled water, which solidifies the PET. At this point in the process the bottle

neck finish, to which the closure will eventually be applied by the bottler, is

produced very accurately.

The machine used in this process is called an injector. Resins are fed to it by means

of neumatic conveyer, melting starts in a screw conveyer which also provides the

important force for injection, the machine constitutes of ovens which finishes the

melting process, the molten material is fed to the cavity which has an outer shape of

a preform, the inner core is also a part of a robotic machine that removes the

preform from the cavity and feeds a belt conveyer to the outlet.

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This is a 40g preform that will make 1500 ml bottle when blown.

2.4.2 BLOWING SECTION

Blowing section is done in a machine called Contiform (Container formation) and

can be divided into two sections:

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i. Heating section

ii. Blow moulder section

At the start of the bottle blowing process, the preform is heated to get a correct

temperature profile to a maximum of about 90 ◦C. The incorrect temperature profile

could result in distortion of the neck finish which in turn will affect the distribution

of mass and handling on any air conveyor system on route to the filling and closure

application after filling. The machine constitutes of five ovens each with nine

radiation lamps. The power fed to the lamp is different and depends on the

temperature profile to be attained. There are check mats to check for defective

preforms or preforms with incorrect temperature profile.

The blowing process is done in parts called sections. Sections have cavity which is

in shape of the container to be blown. Also the sections has chilled water systems

for cooling during the blowing process.

The sequence of operation in the blowing section: The section opens and preform

inserted between the cavities then the section closes. The preform is initially

stretched with a metal rod to elongate the preform lengthwise so the tip of the

preform is located into the center of the base section of the mould. Low pressure air

at ca. 7–8 bar is applied at the same time in order to form a balloon inside the

mould and then finally high pressure air of up to 40 bar is applied to stretch the

material sideways into the final shape of the bottle mould. The section opens and

the bottle is removed.

The following picture shows the blowing process

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2.5 FILLING SYSTEMS

There are two types of filling systems that are employed in the industry

i. Counter pressure fillers

ii. Level fillers

Counter pressure fillers

These types are used in the PET lines in which filling volume is considered. These

uses electro-pneumatic control systems. This procedure is carried out on a counter-

pressure filler. The complete filling process on a counter-pressure filler can be split

into the following phases:

1. Evacuation

The vacuum valve opens and produces a connection to the vacuum channel. The

bottle is subjected to vacuum and the air content in the bottle is reduced to

approximately 10% of atmosphere.

2. Pressurizing with gas

Almost pure CO2 flows out of the ring bowl into the bottle, equalizing pressure

between bottle and ring bowl.

3. Filling

Product flows into the bottle, the air tube returns the pressurized gas, there is a

small deflector that deflects the liquid to the inside bottle wall to ensure a gentle

product flow. When the gas reaches the return tubes the air flow is interrupted and

the flow stops.

4. Fill level correction

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The correction valve opens and pressurized carbon dioxide flows into the tube

forcing exceeded liquid to flow back to the valve.

5. Settling and snifting.

Pressure present in the bottle neck escapes until atmospheric pressure is reached

again.

Level fillers

This types of fillers utilizes mechanical filling valves with pneumatic control in line

1 and 4. It is called a mechanical valve because it controlled by external cams and

therefore the filler moves at a uniform speed so as to make the filling uniform. This

type of filler is utilized in RGB (returnable glass bottle) in which a uniform level is

important.

2.5 GLASS BOTTLE BEVARAGE PRODUCTION LINES

Washer

EBI

Blender

Filler

Caser

Palletizer

Uncaser

Depalletizer

Case turner

Case turner

Case washer

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Glass bottles are received from the market and stored in the warehouse. The crates

are first loaded to the conveyer to the unpacker (Uncaser). The unpacked bottles are

conveyed to the washer.

2.5.1 BOTTLE WASHER

The bottle washing process is done in the following manner: pre-soak tank, the loop

guide, and the post-treatment are combined to form an individual bottle washing

system. Additional components such as high-pressure pre-jetting, heat recovery and

label removal are included in the presoak tank.

Pre-soak tank post-treatment tank

The bottle washer washes the interior and exterior of the bottle.

Interior cleaning: Rotating spraying nozzles clean the insides of the bottles from

different angles of incidence. Exterior cleaning: External cleaning is effected from

above by patented jetting units.

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Interior cleaning exterior cleaning

2.5.2 EMPTY BOTTLE INSPECTION (EBI)

This is a process of visual inspection done to glass bottles to omit the defective

ones. This inspection is done using a machine called empty bottle inspection

machine. This machine constitutes cameras and light sensors that receives incident

light through the bottle. Due the shape and curvature of the bottle the received light

will have a characteristics property that describes the shape of the bottle, how the

received profile agree with prerecorded one, then the machine decides to reject or

accept the bottle. The functioning of this machine solely depend on fundamental

laws of light energy.

After the being inspected the bottle goes to the filler that uses level filling

mechanism.

2.6 DATE CODING SYSTEMS

The industry uses two types of date coding systems: Laser printing coding system,

and inkjet printing. The laser coding is used in plastic bottled beverage production

line 5 & 6 while inkjet printing is used in the glass bottle production so that it can

be removed during washing by caustic.

2.7 PACKING SYSTEMS

Glass bottle beverage packing

After being filled and caped the glass bottled beverage are packed using a machine

called caser. The machine uses a vacuum system to hold up the bottles and insert

them into crates. The crates are conveyed and placed physically onto pallets.

Plastic bottle beverage packing

The packing is done in two stages: variopac and palletizing

Variopac

The variopac wraps a plastic nylon around grouped bottles and tightened by heat

treatment. After being tightened the pack is cooled at the exit fans.

Palletizer

The industry uses a robotic machine which provides automatic means for stacking

cases of goods or products onto a pallet.

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CONCLUSION

During my practical training I learnt a lot of thing concerning my course of study. I

learnt also how to work with different people in an organization by cooperation.

Apart from that I enjoyed a lot both practical works assigned to me because they

made me become confident and familiar mostly to processes in the industry.

RECOMENDATION

The industry should support creativity of the workers by implementing the work

rotation. Rotation of jobs will add skills and knowledge to the workers and also

motivates them to work hard.

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PROJECT: BOILERS EFFICIENCY

Introduction

The industry has two boilers Forbes Marshall boiler and Thompson Africa Redipac

boiler.

The Forbes marshal boiler has the following specifications: Sr no. FVPL-1931,

evaporation capacity 6000 Kg/hr. (from and at 100 oC ) working pressure of 10.55

Kg/cm2 and burner model INDFR100-44 M3L 340. The boiler uses heavy oil as

fuel.

The Thompson boiler has the following specifications: evaporation capacity 5000

Kg/hr from and at 100oC working pressure of 8 Kg/cm2 the boiler uses heavy oil as

fuel.

Problem Summary

The steam plant has been operating in a very low efficiency in both of its two

constituent boilers. In this mini project these problems will be analyzed and counter

measures will be recommended.

Purpose of improving boiler efficiency

The aim of the project is to improve the efficiency of both boilers to be able to

improve the ratio of steam to fuel ratio and therefore reduce the costs of running the

boiler and maximizing the output.

Efficiency terms and definition

Boiler efficiency.

Boiler efficiency, η=(Heat output)/(Heat input) x 100%

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Effi Max.

Effimax with latest communication technology, boiler house solutions (Effi Max) helps the

plant to enhance the safety and efficiency of boilers. This house is installed in one of two

boilers made by Forbes Marshall.

TEST AND MEASUREMENT

FORBES MARSHALL BOILER

boiler operating data.

Effluent

temp

oC

Fuel oil

temp

oC

Fuel in

pressure

Kg/cm2

Inlet air in

pressure

bar

Steam

pressure

Efficiency

(Effi

max)

200 50 8.5 21 450 67%

Break down

Break down

There is no need of calculating the efficiency of this boiler since it is read directly

from the Effi Max digital screenand was equal to 67%.

JJ THOMSON AFRICA BOILER

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Effluent

temp

oC

Fuel oil

temp

oC

Fuel in

pressure

Kg/cm2

Inlet air in

pressure

bar

Steam

pressure

KPa

190 50 8.5 21 450

190 53 8.5 25 450

200 55 8.4 21 450

190 50 8.5 21 450

Boiler Efficiency by Direct Method in the J Thompson Africa boiler

Heat output data

Quantity of steam generated (output) quantity (Q) : 4 TPH

pressure / temperature :8 kg/cm2

Enthalpy of steam (g)/ 180 0C (dry & Saturated) : 2815.57 KJ/kg

at 8 kg/cm2(g) pressure (H)

Feed water temperature : 330C

Enthalpy of feed water at 1atm (h) : 138.37 KJ/Kg

Heat input data

Quantity of coal consumed (Input) : 0.309 TPH

GCV of HFO (heavy fuel oil) : 44782.6 KJ/Kg

Efficiency Calculation

Boiler efficiency(η)= (Q*(H-h)) /(q*GCV)

η= 77%

The efficiency of J Thompson boiler is 77%

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TECHNICAL DEVELOPMENT

FACTORS CAUSING LOW EFFICIENCY

Water treatment

Water softener by chemical dosing: In this method the hard salts viz. Calcium &

Magnesium is replaced by soft salt sodium. By this scaling on tubes is

avoided. However TDS doesn’t decreases, in fact it increases slightly. The blow-

down requirement goes up slightly. For a boiler like J Thomson the blow down is

controlled manually and therefore lack of fall up on the boiler causes loss of energy

to heat up the solid particles.

Temperature of in feed Water

Every 6 0C rise in feed-water temperature will result in 1% fuel savings. Normally

an operator mixes condensate plus make up water to meet boiler load. In most

plants the make up water is added till feed-water tank is filled not paying any

attention to feed-water temperature.

Radiation and convection losses

This is a function of temperature gradient between the boiler water and the ambient,

quality of insulation and surface area of the boiler. This insulation should be able

resist heat transfer by radiation, and conduction by the boiler wall. It is typically

specified by the boiler manufacturer at full load conditions (say 1% for a packaged

boiler). However, since it is a constant loss, at half load it will be double as a

percentage.

Losses due to steam leaks in pipes.

Due to warn out pipes and un followed maintenance schedule.

WHAT IS ALREADY DONE TO IMPROVE EFFICIENCY.

FORBES MASHALL

Dismantling and reinstalling parts and components of the boiler and redusing losses

due to radiation by installing silvery surface on the boiler.

The forbes marshall boiler is installed with a package called Effi Max from the

manufacture. This digital evaluates the efficiency of the boiler by measuring

individual losses and changes the boiler settings to obtain minimum losses.

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The EffiMax package includes:

i. Oxygen analyzer for excess air measurement in flue gas.

ii. Stack temperature measurement

iii. Feed-water temperature measurement for enthalpy calculation

iv. High accuracy ,Low pressure drop vortex type steam flow meter

v. Steam temperature measurement for enthalpy calculation

vi. Automatic Blow-down control System .

vii. Computation & display unit

viii. Data acquisition & diagnostic software package.

The EffiMax Package provides online recording and trend analysis for the

following parameters: Boiler efficiency %, Stack loss %, Enthalpy loss %,

Combustion loss %, Radiation loss %, Total blow-down loss , % blow-down loss

& Average blow-down loss, Steam to fuel ratio

J THOMSON AFRICA BOILER

Repair of leaking steam pipes on this boiler was done.

EFFICIENCY IMPROVEMENT

FORBES MARSHALL BOILER & J THOMPSON AFRICA

Since Forbes Marshall boiler has Effi Max package for maximizing efficiency

already installed the following can be done that is not covered by Effi Max.

Blow down losses

Installing a Boiler Blow down Heat Recovery System line allows this waste heat to

be used in preheating makeup and feed water. Heat recovery is most suitable for

continuous blow down operations which in turn provides the best water treatment

program. This system can be used by both boilers to recover the heat during blow

down session.

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This will increase boiler efficiency up to 2%

Exhaust heat recovery System

A device like the one shown below can be attached to the flue to recover a portion

of the exhausted heat. This heat can be used to preheat boiler make-up water.

Extraction of so much heat causesthe flue gases condensation (causing corrosion).

This will raise the efficiency up to 1%.

The use of fuel efficiency tarbulators.

The use of fuel efficiency tarbulators can help to make the heat transfer in the fire

tubes more efficient and hence improve the fuel efficiency.

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The use of tabulators can raise the efficiency up to 2%

FOR J THOMSON AFRICA

This boiler does not consist of the Effi Max package therefore the monitoring of

efficiency factor is hard and not efficient. Therefore installing the package will help

raise and ensure the efficiency is at maximum.

CONCLUSION & RECOMENDATIONS

The use of the above methods and use of Effi Max package the effiency will be able

to rise up to 5% and therefore the boilers will offer a more reliable service of

producing steam.

The use of manual operation always lowers the efficiency of the boiler, therefore I

recommend the use of automatic systems in boiler operating and not switching to

manual operation due to any cause.

REFERENCE

1. Energy Hand book, Second edition, Von Nostrand Reinhold Company -

Robert L.Loftness

2. Industrial boilers, Longman Scientific Technical 1999

3. http://www.em-ea.org/Guide%20Books/book-4/4.1%20Boiler.pdf

4. http://www.energydepot.com/RPUcom/library/HVAC017.asp