inplant training report-coke2009

Inplant Training at Coca-Cola

College of Food Technology, Parbhani.

INPLANT TRAINING REPORT (01 JAN 2009 to 31 MARCH 2009)

A.P - Pirangut, Taluka-Mulshi Dist. - Pune- 411004

PATKI PRASHANT JANARDAN (05T47B)

In the partial fulfillment of the B.TECH (Food Science & Technology)

COLLEGE OF FOOD TECHNOLOGY, PARBHANI-431402 (MAHARASHTRA)

MARATHWADA AGRICULTURAL UNIVERSITY.PARBHANI



Certificate

To whom so ever it may concern

This is to certify that PATKI PRASHANT JANARDAN

(05T47B) from College of Food Technology, Parbhani

Has successfully completed the Inplant Training in “Hindustan Coca-Cola

Beverages Private Limited, Pune Unit”

From 1st JAN to 31h MARCH 2009, in the partial fulfillment of the

B.Tech (Food Sciences & Technology) curriculum as prescribed by College of

Food Technology, Marathwada Agricultural University, Parbhani.

Shashank Joshi QA Manager HCCBL Sanjay Uppadye Team Leader (QA)

Bankim Naik (Factory Manager) HCCBL Baba Shetty Team leader (QA)



ACKNOWLEDGEMENT

I have undergone Three Months In plant Training at HINDUSTAN COCOHINDUSTAN COCOHINDUSTAN COCOHINDUSTAN COCO----

COLA BEVARAGES PVT. LTD. PIRANGUT.,COLA BEVARAGES PVT. LTD. PIRANGUT.,COLA BEVARAGES PVT. LTD. PIRANGUT.,COLA BEVARAGES PVT. LTD. PIRANGUT., PUNEPUNEPUNEPUNE, to fulfill the requirements of

curriculum of my course B.Tech (Food Science & Technology).

I have immense pleasure in expressing my deep sense of gratitude,

indebtness and sincere thanks to Dr. P. R. Shivpuje Dr. P. R. Shivpuje Dr. P. R. Shivpuje Dr. P. R. Shivpuje ( Dean & Director of ( Dean & Director of ( Dean & Director of ( Dean & Director of

InstructionInstructionInstructionInstruction) and Prof. D. M. Shere (Associate Professor & I/C inplant training),

College of Food Technology, Parbhani faring me an opportunity to undergo

inplant training at, Hindustan Coca Hindustan Coca Hindustan Coca Hindustan Coca----Cola Beverages , Pvt. Ltd., PirangutCola Beverages , Pvt. Ltd., PirangutCola Beverages , Pvt. Ltd., PirangutCola Beverages , Pvt. Ltd., Pirangut, Pune.Pune.Pune.Pune.

I express my sincere thanks to Bankim Naik(Factory Manager), Shashank Bankim Naik(Factory Manager), Shashank Bankim Naik(Factory Manager), Shashank Bankim Naik(Factory Manager), Shashank

JoshiJoshiJoshiJoshi (QA Manager), Phanindar Jamula(Production & Maintenance manager), (QA Manager), Phanindar Jamula(Production & Maintenance manager), (QA Manager), Phanindar Jamula(Production & Maintenance manager), (QA Manager), Phanindar Jamula(Production & Maintenance manager),

Dhiraj Batoyhita (Area HR Manager)Dhiraj Batoyhita (Area HR Manager)Dhiraj Batoyhita (Area HR Manager)Dhiraj Batoyhita (Area HR Manager),Mr. Sanjay Upadhye(Mr. Sanjay Upadhye(Mr. Sanjay Upadhye(Mr. Sanjay Upadhye(Team Leader QA), Team Leader QA), Team Leader QA), Team Leader QA),

,Mr. Baba Shetty (Team Leader QA), ,Mr. Baba Shetty (Team Leader QA), ,Mr. Baba Shetty (Team Leader QA), ,Mr. Baba Shetty (Team Leader QA), for giving me chance to undergo in plant

training at Hindustan CocaHindustan CocaHindustan CocaHindustan Coca----Cola Beverages, Pvt. Ltd., Pirangut, PuneCola Beverages, Pvt. Ltd., Pirangut, PuneCola Beverages, Pvt. Ltd., Pirangut, PuneCola Beverages, Pvt. Ltd., Pirangut, Pune.

And also I express my sincere thanks to all lab personnel’s Mr. Manish Mr. Manish Mr. Manish Mr. Manish

Bhosle, Mr.shashikant Bhosle, Mr.shashikant Bhosle, Mr.shashikant Bhosle, Mr.shashikant Sawant, Mr. Mandlik Appasaheb, Mr.Deepak Diwe, Sawant, Mr. Mandlik Appasaheb, Mr.Deepak Diwe, Sawant, Mr. Mandlik Appasaheb, Mr.Deepak Diwe, Sawant, Mr. Mandlik Appasaheb, Mr.Deepak Diwe,

Mr.Yogesh Bhoi, Mr. Virendra Patil, Mr.Mahesh Wani, Mr.Sudhir Panase, and Mr.Yogesh Bhoi, Mr. Virendra Patil, Mr.Mahesh Wani, Mr.Sudhir Panase, and Mr.Yogesh Bhoi, Mr. Virendra Patil, Mr.Mahesh Wani, Mr.Sudhir Panase, and Mr.Yogesh Bhoi, Mr. Virendra Patil, Mr.Mahesh Wani, Mr.Sudhir Panase, and

Mrs. Vaishali, Ms Pranjal Mrs. Vaishali, Ms Pranjal Mrs. Vaishali, Ms Pranjal Mrs. Vaishali, Ms Pranjal and all QA Executives QA Executives QA Executives QA Executives for their valuable inspiration,

guidance & unforgettable co-operation during the training period.

I take this opportunity to thanks my family members, friends MaheshMaheshMaheshMahesh, , , ,

Vrushali, Darshan, Priyanka, Akhil, Ravi Vrushali, Darshan, Priyanka, Akhil, Ravi Vrushali, Darshan, Priyanka, Akhil, Ravi Vrushali, Darshan, Priyanka, Akhil, Ravi and all others helping me directly or

indirectly in plant training and stay at Pune only.

- Patki Prashant



Contents….. 1. Introduction

2. Certificate 3. Acknowledgment 4. About COKE 5. Products of COKE 6. Plant layout 7. Organizational setup

8. Instruments in lab

9. Details of products manufacture

10. RMPM & Microbiology

11. Process manufacture

• Water treatment Plant

• Syrup making

• Beverage manufacturing in PET/CAN

• Polyethylene Terephtalate-Advantages & limitations

• Carbonation-Basic Consideration

• Carbonation Measurement

• Feeling Principle

• Beverage manufacture in RGB

• Bottle washer

• Online quality checks

12. Cleaning in place

13. Boiler section

14. Refrigeration Section

15. Effluent Treatment Plant (ETP)



About Coke…. The manufacturing unit of Hindustan Coca-Cola Beverages (P) Ltd. Pune is

located at scenic and peaceful environs of village Pirangut, Taluka. Mulshi and

Dist. Pune, just 18-20 Km from Pune city. The plant commenced operation in

January 1996. Spread over 25 acres, the Pirangut plant is the only plant with

canning facility for Coca-Cola & production of Diet coke in India. The main

business of the company is to produce and distribute the products of the Coca-

Cola Company. The brands being currently produced are Coca-Cola, Thums Up,

Limca, Fanta Apple, Fanta Orangey Blast, Sprite, Diet Coke and Kinley Soda.

• First plant commissioned by TCCC in India- 1996

• PET LINE: - First Commissioned in Jan. 1996. (To Dec.1999)

• PET LINE:- Second Commissioned in March 2003

• CAN LINE:- Commissioned in Jan. 1996

• RGB LINE:- Commissioned in May 2000

The production facility of Pune plant is capable of producing

RGB: - 36000 cases/day,

PET: - 12000 cases/day,

CAN: - 66000 cases/day.

The sales territory of HCCBPL, location is at south Maharashtra state

extending from Raigrah to Nanded and Pune to Sindhudurg. The

manufacturing site is located on an area of around 1, 15,342 m2, and has two

number of filling lines for manufacture of RGB, PET and CAN. This

Quality System relates to the full range of company activities as determined

by the standards describe in TCCMS



Origin of Coke… John stitch pemberton started coca-cola drinks in Atlanta’s Jacobs

Pharmacy in 1986. John was borne in 1831 in tiny village Knoxville, Georgia, in

1831; Pemberson had trained in college of pharmacy from pharmacy school in

Philadelphia. He first practiced his trade in Oglethorpe before moving to Columbus

after relocating in Atlanta in 1869, pemberton begin to experiment extensively

with extract of coca leaf and cola nut, initially marketing a moderately successful

health drink called “French Wine Coca”, John Pemberton with his four partners

coined and trademark the term “coca-cola”

Pembertons new and small company grew rapidly after it acquired by

Asa griggs Candler between 1889 –91 outlined the company basic strategy-

manufacture and distribution of coca-cola syrup to be mixed with carbonated water

at the soda fountain.

In 1886, sales of Coca-Cola averaged 9 drinks per day. That first, Dr

Pemberton sold 25 gallons of syrup, shipped in bright red wooden kegs. Red has

been distinctive colors associated with the No.1 soft drinks brands ever since. For

his efforts, Dr Robinson Grossed $ 50 and spent $73.96 on advertising. By 1891,

Atlanta entrepreneur Asa G. Candler had acquire complete ownership of Coca-

Cola business. IN 1892 G Candler to core the business and incorporated the coca-

cola company in Atlanta- Georgia with an aggressive marketing cam. Within 4

years, his merchandising flair help expend consumption for $ 25 million. Robert

W. Woodruff became president of Coca-Cola Company 1923 and his more than 6

decades of leader ship took the business to unrivalled heights of commercials

success, making Coca-Cola an Institution the world over. This year E. Neville

Isdell has been appointed as the 12th global CEO and Chairman of the Coca-Cola

Company.



Arrival of COKE in India….

While the Coca-Cola Company is global company and has completed 119

years of consumer service with some of the world’s most widely recognized

brands. The Coca-Cola business in India, as in each country where they operate, is

a local business. Their beverages are produced locally, employing Indian citizens,

their product range and marketing reflects Indian tastes and lifestyles.

After a 16-years absence, Coca-Cola the world’s favorite soft

drinks returned to Indian market in 1993 with its launch in Agra. The company’s

presence in India was cemented in November that year in a deal that gave Coca-

Cola ownership of the nation’s top soft-drinks brands and bottling network. Coca-

Cola India has made significant investments to build and continually improve its

business in India, including new production facilities, wastewater treatment plants,

and distribution systems and marketing equipment.

Coca-Cola business systems employ over 15,000 local people in

India. Virtually all the goods and services required to produce and market Coca-

Cola locally are made in India.

The Coca-Cola systems in India comprise 27 wholly owned

company-owned operations and another 17 franchise-owned bottling operations.

A network of 29 contract-packers also manufactures a range of products for the

company.



PRODUCTS OF COKE… COCA-COLA

The world’s favorite drinks and most valuable brand. Cola

has a truly remarkable heritage. From a humble beginning in 1886, it is now the

flagship brand of the largest manufacturer, marketer and distributor of non-

alcoholic, beverages in the world. It is positioned as a mind refresher. Coke is

available in 200ml&300ml in glass. 600ml, 1.25, 1.5, 2lit and lit in PET and 330

ml in CANS. The product can use for a period of two &half to six months from

date of packing. Thumps Up is a leading carbonated soft drink and most trusted

brand in India. Originally introduced in 1977 and later on was acquired by the

Coca-Cola Company in 1993. Thumps-Up is known for its strong, fizzy taste and

uniquely masculine attitude. This brand clearly seeks to separate the men from the

boys .Available in same size and pack as above.

FANTA

Fanta entered the Indian market in the year 1993. Over the years

Fanta has occupied a strong market place and is identified as “The Fun



Catalyst”Fanta stands for its vibrant color, tempting taste and tingling bubbles that

not just uplifts feeling but also helps free spirit thus encouraging one to indulge in

the moment. Fanta is available around the country in 200ml, 300ml, 600ml, 1.25

Lit, 1.5Lit, 2.25Lit and 330ml Cans

DIET COKE

Diet Coke was born in 1982 and quickly became the No.1 sugar-

free in diet –conscious America. As Diet Coke in the U.S, Canada, Australia and

Great Britain, And Coca-Cola lights in other countries, it’s now the No. 3 soft

drink in the world. It’s the drink for people who want no calories, but plenty of

taste.

KINLEY WATER

Water, a thirst quencher that refreshes a life giving Force that

washes all the toxins away. Water, the most basic need of life, the very sustenance

of life, a celebration of life itself. The importance of water can never be

understood. Kinley water understands the importance and value of this life giving

force. Kinley water thus promises water that is as pure as it is meant to be. Water

you can trust to be truly safe and pure. Kinley water comes with the assurance of

safety from the Coca-Cola Company. That is why company introduced Kinley with

reverse-osmosis along with the latest technology to ensure the purity of the

product. That’s why we go through rigorous testing procedures at each and every



location where Kinley is produced. Because we believe that right to pure, safe

drinking water is fundamental. A universal need that cannot be left to chance.

Available in 1lit and 2lit PET.

LIMCA-

The drink that can cast a tangy refreshing spell on anyone, anywhere.

Born in 1971, Limca has been the original thirst choice, of millions of consumers

for over 3 decades. The brand has been displaying healthy volume growth year on

year and Limca continues to be the leading flavor soft drinks in the country with a

market share of 12% The success formula of Limca lies in its sharp fizz and lemoni

bite combined with the single minded positioning of the brand as the ultimate

refresher has continuously strengthened the brand franchise. Available in same size

and pack as above expect CAN.

SPRITE

Worldwide Sprite is ranked as No.4 soft drinks and is sold in

more than 190 countries. In India, Sprite was launched in year 1999 and today it

has grown to be one of the fastest growing soft drinks, leading the Clear lime

Category. Today Sprite is perceived as a youth icon. Its clear crisp refreshing taste

encourages the today’s youth to trust their instincts, influence them to be true to

who they are and to obey their thirst. Sprite advertising has always been



memorable with very high recall value, especially amongst the youth. Sprite is

available around the country in 200ml, 300ml, 600ml, 1.25lit, 1.5lit, 2lit, 2.25lit,

and 330ml Cans

MAAZA

Maaza was launched in 1976. It was a drink that offered the same

real taste of fruit juice. In 1993, Maaza was acquired by Coca-cola India. Maaza

currently dominates the fruit drink category. Over the years, brand Maaza has

become synonymous with Mango. It is available in SKUs of 200ml RGB,

250mlRGB, 125ml Tetrapack, 200ml Tetrapack.

FANTA APPLIE

This is new product now ready to jump in the market having enchanting

taste of fresh apple. This thirst quenching drink has already started in some part

of India.



FLAVOURS MANUFACTURED AT PUNE UNIT

IN RGB (200ML & 300ML) � THUMS UP � COCA COLA � FANTA APPLE � FANTA ORANGY BLAST � LIMCA � SPRITE � KINLEY SODA

IN PET (600ML, 1.25LTR, 1.5LTR, 2 LTR) � THUMS UP � COCA COLA � FANTA APPLE � FANTA ORANGY BLAST � LIMCA � SPRITE � KINLEY SODA (600,1.5 LTR)

IN CAN (330ML) � DIETCOKE � THUMS UP � COCA COLA � FANTA APPLE � SPRITE

CANISTERS

POSTMIX (Each 18 liter) � FANTA � SPRITE � COCA-COLA � THUMS UP



Plant Layout

Main Gate Entry

Admin block / Utility area

Prodn Hall / WTP / Warehouse

ETP



Area General Manager

Finance Manager Factory Manager RTM ManagerSales Manager Area Capability Manager HR Manager

Quality assurance Manager

Production/Maintenance Manager

Techno-Commercial Manager

Team Leader

QA Executives Microbiologist Production Maintenance

Team Leader Team Leader

Production Executives

Maintenance Executives

Operation technologist

Operation technologist

PET/CAN line

RGB Line

Process

Effluent Treatment

Plant

Organizational Setup



Departments in Coke…

All the plant operations can be broadly classified into four main areas

namely

1. Warehouse

2. Production

3. Process/Quality

4. Utilities

Apart from these, the general functions such as HR, Finance, Sales, etc. exist

in coordination with them.

QUALITY DEPARMENT –

Quality is nothing but the “Degree of Excellence”. Quality Department is

responsible for all parameters related to quality from overall process staring from

raw materials to finished goods.

Quality Department ensures the operations of

1. Inspection of Raw Materials.

2. Water Treatment Plant.

3. Syrup Preparation

4. Online Quality of beverage manufacturing

5. Effluent Treatment Plant.

6. GMP & Housekeeping.



Instrumentation

Quality Assurance Lab Microbiology Lab Packaging Lab Effluent Treatment Plant Lab

�Digital pH meter

�Density meter

�Gas volume tester

�Turbidity meter

�Total dissolved solids meter

�Spectrophotometer meter

�Vacuum filtration assembly

�Flocculator for jar test

�Water bath

�Jar Test Apparatus

�Base clearance gauge

�Hamilton beach blender

�Go-no go gauge for crown crimping

�Conductivity meter

�Digital weighing balance

� Distillation assembly

�Torque tester

�Gas volume & air content tester in cans

�Lovibond comparator

�Lovibond iron tester

�Laminar air flow

�Digital colony counter

�Autoclave

�Incubator

�Sterile filtration assembly

�Digital weighing balance

�Bursting strength tester

�Magnamike for thickness

measurement

�Enamel rating tester

�Digital vernier caliper

�Mechanical can cutter

�Video seam monitor

�Secure seal tester

� top load tester

�Hot wire bottle cutter

�Digital pH meter with

combined electrode

�Cod apparatus

�BOD incubator

�Vacuum pump

�Hot air oven

�Stirrer set up

�Muffle furnace



DETAIL OF PRODUCT MANUFACTURE… GENERAL INFORMATION Soft drinks means sweetened carbonated beverage. In soft drink, there are

three main ingredients, which are as follows,

1. Water

2. Carbon dioxide;

3. Sugar

ABOUT SOFT DRINKS:-

Soft drinks have been part of the American lifestyle for more than 100 years;

many of today’s soft drinks are the same as the first ones enjoyed in the

1800’s.Soft drink production begins with creation of flavored syrup using a

closely-guarded company recipe; the syrup is mixed with purified water and then

carbonated by adding carbon dioxide gas under pressure. This carbonation creates

the “Tingly Fizz” that gives soft drinks a refreshing taste.

SOFT DRINK INGREDIENTS:-

Like other foods, the ingredients that are used in soft drinks are approved and

closely regulated by the U.S. Food & Drug Administration (FDA) .All of the

ingredients used in soft drinks are found in a variety of the foods.

WATER:-

Soft drink production starts with a pure source of water.

Regular soft drinks contain 90% water while diet coke soft drinks contain 99%

water. Drinking water often contains trace amount of various elements that



affects its taste. Ii is noticed that tap water tastes different in various regions of

the country. Bottlers use sophisticated filtering & other treatment equipments to

remove any residual impurities and to standardize the water used to make soft

drinks. That is why our soft drink tastes the same in all over the world.

CARBON DIOXIDE:-

A colorless & odorless gas, carbon dioxide is essential characterizing ingredient

in all carbonated beverages. It is given off when we breathe and is used by plants

to produce oxygen.

When dissolved in water carbon dioxide imparts a unique taste , for that reason

natural sources of carbonated or effervescent, mineral water were once highly

priced ,These rare mineral waters also believed to have beneficial medicinal

properties.

It was the innovative step of adding flavors to these popular soda water that

gave birth to the soft drink beverages we enjoyed today. In the early days of soft,

drink manufacturing, carbon dioxide was made from sodium salts .This is why

carbonated beverages were called as Sodas or Soda Water.

Today bottlers buy pure carbon dioxide as a compressed gas in high-pressure

cylinders, carbon dioxide gas is absorbed in to the flavored soft drinks in a

carbonator just before the container or bottle is sealed. While under pressure and

chilled the soft drink may absorb up to four times the beverage volume of carbon

dioxide.

SWEETENERS:-

For soft drinks, normally cane sugar is used, but now due to classification of

soft drinks there are types of sugars, which are use in soft drink manufacturing.



1. FOR NON-DIET SOFT DRINKS:-

Most regular (non-diet) soft drinks are sweetened with either SUCROSE or

HIGH FRUCTOSE CORN SYRUP (HFCS).A mixture of these sweeteners may

also be used. Sucrose, the familiar sweetener comes from sugar cane or sugar

beets. HFCS is a newer and more convenient liquid sweetener, similar to

sucrose but made from corn. It is now use in many prepared foods. With either,

the amount of sugar or sweetener in a soft drink ranges from 7 to 14 %.

Both sucrose and High Fructose Corn Syrup are easily digested

carbohydrates, and carbohydrates are an important part of the diet. They

provide calories, which are the source of energy for the body.

Sometimes thoughts to be more fattening than other foods, sugar actually

contains the same no. of calories by weight as protein (4 calories/gram) , and

less than half the calories of fat(9 calories/gram). Sugar also contains far fewer

calories than alcohol (7 calories/gram).

DIET SOFT DRINKS:-

The popular class of beverages known as Diet Soft Drinks, which are made by

the intensely sweet substances we refer to as “DIET ” or “LOW CALORIE”

sweeteners. Aspartame, Saccharin, Sucrose, and Acesulfame-k are approved

sweeteners for use in soft drinks.

ASPARTAME:-

The use of intense sweeteners has increased significantly over the past 20 years

owing to the appearance, and acceptance, of new types in the market.

Saccharin, the first intense sweetener to be used on a commercial scale, has a

difficult taste profile that can seldom be masked with any success in application.

During its long history (initially being employed as a substitute for sugar in the



case of diabetic patients around 1890), consumers have had to accept its often

bitter/metallic aftertaste. In 1983 aspartame and acesulfame K were approved for

use under the European Sweeteners Directive/Amendment 96/83/EC and

immediately found favor in the soft drinks industry (aspartame in particular) as a

replacement for saccharin. Although aspartame provides a clean, lasting sweetness,

it has the disadvantage of undergoing hydrolysis and loss of potency during

storage. Below pH 3 and above pH 5, hydrolysis will occur relatively swiftly;

hence conditions in the range pH 4.2–4.3 are required, where maximum stability is

achieved. Aspartame and saccharin have been successfully used in combination,

and also with acesulfame K, where a more sugar-like taste may be achieved.

Because of the phenylalanine content in aspartame, a warning statement is required

on the label of products containing the sweetener. In the UK the words ‘contains a

source of phenylalanine’ must appear on the label to enable those who suffer from

phenylketonuria (an inherited disorder in which the enzyme that converts

phenylalanine into another amino acid, tyrosine, is defective) to factor the

consumption of aspartame into their daily intake calculations. After many years of

scientific testing aspartame was first approved for use in some foods in1981 and

for soft drinks in 1983.It has been reviewed and approved, not only by the U.S.

Food and Drug Administration (FDA), but also by the Governments of more than

60 countries, and the World Health Organization (WHO). Aspartame is a

“Nutritive” sweetener meaning it is easily digested and provides calories. However

it’s sweetening power is greater than sucrose.

FLAVOR:-

One of the major & important ingredients in soft drink is flavoring. Most soft

drink bottlers mix many individual flavors to create distinctive taste.



Natural flavors in soft drinks come from spices, natural extracts & oils, fruit

flavored soft drinks such as orange & lemon –lime often contains natural extract.

There are also some artificial or manmade flavoring used in soft drinks,

nature does not produce enough of some flavors to satisfy worlds demand , Also

some natural flavors are limited geographically & seasonally.

COLORS:-

Many people do not realize how important color is to taste

perception, color affects our physiologically impression of food. If we don’t

believe it, try eating food in the dark, the colors used in food and beverages

come from both natural and synthetic sources.



RAW MATERIAL SAMPLING PLAN & TESTING PROCEDURES

(RMPM)

Following are the raw materials, which are used in carbonated soft drink

industry: -

SUGAR –

Sugar is one of the major ingredient uses in soft drink industry, for

production of soft drinks special grade sugar is used from selected sugar factories.

SUGAR ANALYSIS -

Coca Cola Company has its own standards for quality of sugar,

-Frequency: - Each delivery

The sugar sample is drawn from at least 10 bags from different sites/layers from

the truck or from the stores.

1. The sample is mixed thoroughly in a container to produce a composite sample.

2. Consignment data collected with the sugar sample includes:

- Supplier’s name and location

- Date and time of delivery

- Quantity delivered

- Transportation vehicle number

3. The sugar is then tested as per the frequency for the following parameters:

• Appearance

• Taste

• Odor

• ICUMSA Color

• Odor after acidification

• Turbidity

• Ash by Conductivity



• Microbiological Analysis

4. If the sugar is from a new supplier, all parameters are tested according to the

Granulated Sucrose Specification for India (The sugar is then analyzed for each

of the above parameters. Sugar lots not meeting the specification are rejected

CARBON DIOXIDE –

Carbon dioxide was one of the first gases to be described as a substance distinct

From air. The Flemish chemist Jan Baptist van Helmont in the early seventeenth

Century noted that when he burned charcoal in a closed vessel, the mass of the

Resulting ash was much less than that of the original charcoal. He interpreted that

The rest of the charcoal must have been transmuted into an invisible substance he

Termed a ‘gas silvestre’, which we now know as carbon dioxide. Carbon dioxide

was studied more thoroughly by a Scottish professor of medicine, Joseph Black.

He found that limestone (calcium carbonate) could be heated or treated with acids

to yield a gas that he called ‘fixed air’. He observed that this fixed air was denser

than air and did not support either flame or animal life. He also found that this gas

would, when bubbled through an aqueous solution of lime (calcium hydroxide),

precipitate calcium carbonate. He used this phenomenon to demonstrate that

carbon dioxide is produced by animal respiration and microbial fermentation.

Carbon dioxide is a colorless, non-toxic, inert gas that is virtually tasteless

And is readily available at a reasonable cost. It is soluble in liquids, the degree of

Solubility increasing as the liquid temperature decreases and can exist as a gas,

Liquid or a solid. When dissolved in water it forms carbonic acid. It is carbonic

acid. That produces the acidic and biting taste found in carbonated waters and soft

drinks. Above a certain level of carbonation carbon dioxide has a preserving

property, Having an effective antimicrobial effect against moulds and yeasts. It



achieves this With moulds by depriving the moulds of oxygen required for growth

whilst with Yeasts it tends to stop the production of more carbon dioxide as a by-

product of the Fermentation of sucrose to ethanol. Carbon dioxide gas is heavier

than air, having a density of 1.98 kg/m3 at 298 K, some 1.5 times that of air. It has

a molecular weight of 44.01 and does not burn, though it will support the

combustion of magnesium. As it is fully oxidized, it is not very reactive. It is a

fairly stable compound that only decomposes at very high temperatures into carbon

and oxygen. It can cause death by suffocation if inhaled in large amounts. The gas

is easily liquefied by compression and cooling. When liquid carbon dioxide is

quickly decompressed it rapidly expands and some of it evaporates, removing

sufficient heat so that the rest of it cools into solid carbon dioxide. Carbon dioxide

is a waste product in organisms that obtain energy from breaking down sugars or

fats with oxygen as part of their metabolism. This process is known as cellular

respiration. This includes all animals, plants, many fungi and some bacteria. Plants

utilize carbon dioxide during photosynthesis thereby constructing carbohydrates. In

higher animals carbon dioxide is primarily held in solution in the blood which

transports it from the body’s tissues to the lungs to be exhaled. It makes up some

0.038% by volume of the earth’s atmosphere. In various parts of the world it is

formed underground and issues from fissures within the earth. This happens

notably in Italy, Java and Yellowstone National Park in the USA. Carbon dioxide

is a known contributor to the greenhouse effect, the balance in the atmosphere

increasing each year thus disrupting the natural carbon dioxide cycle. The initial

carbon dioxide in the earth’s atmosphere was produced by volcanic activity. This

was essential for a warm and stable climate conducive to life. Current volcanic

releases are some 1% of that released by human activities. The earth’s oceans

contain a large amount of carbon dioxide in the form of bicarbonate and carbonate

ions and much more than that found in the atmosphere. The carbon dioxide is in



the form of bicarbonate and carbonate ions, the bicarbonate being produced in

reactions between rock, water and carbon dioxide. An example is the dissolution of

calcium carbonate:

CaCO3 + CO2 + H2O _ Ca2+ + 2HCO-3

Such reactions tend to buffer atmospheric changes. Reactions between carbon

dioxide and non-carbonate rocks also add bicarbonate to the oceans. These

reactions can later be reversed to form carbonate rocks thereby releasing half of the

bicarbonate as carbon dioxide. This has produced large quantities of carbonate

rocks over the last few million years. So much now exists that if all these carbonate

rocks were converted back to carbon dioxide, the resulting level of carbon dioxide

would weigh 40 times as much as the rest of the atmosphere. Eventually most of

the carbon dioxide added to the atmosphere will be absorbed by the sea and

become bicarbonate ions, the process taking about one hundred years to achieve.

Carbon dioxide can exist as a solid, a liquid or a gas. The effect of temperature

And pressure on the state of carbon dioxide can be seen from the phase diagram of

carbon dioxide. At the triple point carbon dioxide can exist simultaneously

In the three states as a solid, a liquid or a gas by just a small perturbation. All

Phases are in a state of equilibrium at the triple point. This exists at 5.11 bar and

-56.4.C. above 31.C it is impossible to liquefy the gas by increased pressure. This

Is termed the critical point. At normal temperatures and pressures carbon dioxide

Is a colorless gas. At high concentrations it has a slightly pungent odor. Carbon

Dioxide cannot exist as a liquid at atmospheric pressure. Liquefying occurs by

Compression and cooling between the pressure and temperature limits at the triple

Point and the critical point. Above the critical point of 31.C it is impossible to

Liquefy the gas by increasing the pressure above the corresponding critical

pressure Of 73 bar. When liquid under pressure is released to the atmosphere it is



released as a gas and a solid only. This appears as a dense white cloud because of

the solid

Carbon dioxide phase diagram.

And the condensation of atmospheric moisture at the low temperatures obtained.

The solid falls to the ground as snow. The compression of this snow forms a

translucent white solid known as dry ice. As carbon dioxide regulates the breathing

function, an increase in concentration causes an increased breathing rate. The

Occupational Exposure Standard (OES), from EH40, which is updated annually, is

0.5%. However, changes in the breathing rate may not be noticed until the

concentration reaches 2%. At this concentration the breathing rate increases to

about 50% above the normal level. Prolonged exposure at this level for several

hours may cause a feeling of exhaustion and a headache. At higher concentrations

carbon dioxide may cause asphyxiation and can temporarily paralyze the



respiratory system. Breathing in a rich carbon dioxide atmosphere can cause

immediate rapid breath and loss of consciousness. Symptoms of asphyxiation

Can include rapid and gasping respiration, nausea, vomiting, cyanosis and rapid

Fatigue. This may lead to loss of consciousness or death from anoxia. Hence the

Hazards associated with the use of carbon dioxide need to be explained to any

Personnel who may be exposed to it. Carbon dioxide is most important ingredient

in carbonated beverages. For carbon dioxide some standards are there to which the

incoming carbon dioxide has to match.

1. Purity-Must be pure above 99.9%

2. Taste & Odour – Should be normal not pungent or like rotten egg.

3. Snow Test

4. Appearance

Sample is collected from the liquid line of the carbon dioxide tanker as soon as it

is received. The sample is then analyzed as per the authorized testing procedures

provided by the Division in the Carbonated Beverage Quality Control Manual (The

consignment is then either accepted or rejected as per the analysis results.)

TREATED WATER -

Water main & most important ingredient have also some standards

according to Coca-Cola standards. For this regular analysis of water has been done

to check all the quality related parameters.

Treated water used for syrup/beverage production is checked for

• Appearance

• Taste

• Odor

• Turbidity



• P-Alkalinity

• M-Alkalinity

• Total Hardness

• Residual Chlorine at every four hours.

• Iron content is checked once in a day.

OTHER RAW MATERIALS –

• Bleaching Powder & Sodium Hypo chlorite are checked for available

chlorine at each delivery.

• Lime, Ferrous Sulphate, Sodium Chloride, Caustic Soda are checked for %

assay.

• Activated Carbon is checked for moisture content, total ash at each delivery.

• Filter Aid is checked for 10% slurry in distilled water at each delivery.

• Filter Sheets are checked for dimension, GSM at each delivery.

All materials mentioned above are relatively important because they are

used to treat water, for making syrup, CIP purposes.

All parameters are tested according to the Authorized Testing Methods,

Frequencies & Specification for India.

Raw Materials lots not meeting the specification are rejected.

CONCENTRATE AND BEVERAGE BASES:-

Only visual checks for presence of tamper proof seals/damages and

labels are done in case of Concentrate and Beverage Bases.



PACKAGING MATERILS (PRIMARY & SECONDARY): -

NRPET PREFORMS – 50 performs from each lot

Performs are nothing but the incoming PET () Bottles. Perform has been

checked at every lot so meet standards such as

• Weight

• Appearance

• Dimensions

• Height

• Thread go no go gauge

• Neck go no go gauge

• Wall thickness

• Visual checks under sodium vapor & high intensity lamp

CROWN CLOSURE – 50 crowns randomly from each lot

• Weight

• Height

• Go no go trough gauge

• Curve angle trough gauge

• Printing quality

• Out diameter

• Flange angle

• Metal thickness

• Metal hardness

• Line quality



PLASTIC CLOUSER – 50 closures randomly from each lot

• Weight

• Height

• Tamper & evident diameter


• Visual

CANS & CAN END– 50 cans & can ends randomly from each lot from each lot

• Average weight

• Average Height

• Brimful capacity

• Flange width

• Flange thickness

• Wall thickness

• Stand diameter

• Appearance

• Enamel rating

• Body diameter

GLASS BOTTLES – 50 bottles randomly from each lot

• Weight

• Height

• Fill point capacity

• Perpendicularity

• Brimful capacity



CORROGATED CARTONS – 5 cartons randomly from each lot

• Internal dimension (length, width, height)

• Total GSM

• Delamination


• Color

• Wrap page

• Moisture

• Flute count

• Bursting strength

WRAP AROUND LABELS – 5 labels randomly from each lot

• Total GSM

• Dimension

• Joints


• Ink adhesion

• Color

• Winding



MICROBIOLOGY

Microbiological analysis is carried out for assurance of safety of ingredients,

finished product. For microbiological analysis the different types of media used are

as follows

Cc-1 (TGYE i.e. Trypton Glucose Yeast extract): -

For bacterial count by membrane filtration technique.

Cc2 (M green agar): -

For counting yeast and molds in samples by membrane filtration technique.

Cc3 (Endo agar): -

For coli form bacteria in water for one step membrane filtration technique.

Cc4: -

For conformation of presence of E. coli.

General procedure: -

• Sampling

• Preparation of required agar media as per direction

• Sterilization of media.

• Membrane filtration of sample

• Inoculation of media contained in Petri plates

• Incubation at 37ºc in incubator gives total plate count (colony count) after

48, 72 hrs & coli form count after 24 hrs, whereas incubation at 25ºc gives

yeast & mold count.

COMPOSITION OF MEDIAS: -

Cc1: Casein enzymic hydrolyzate 10 gms/lit Beef extract 6 gms/lit Dextrose A 20 gms/lit Agar 15 gms/lit Final pH 7 +/- 0.2



Cc2: Yeast extracts 9 gms/lit Cerelose 50 gms/lit Biopeptone 10 gms/lit Magnesium Sulphate 2.10 gms/lit Potassium phosphate 2 gms/ lit Diastase 0.05 gms/lit Thiamine 0.05 gms/lit Bromo cresol green 0.026 gms/lit Agar 15 gms/lit Final pH 4.6+/- 0.2 Cc3 : Yeast extracts 1.50 gms/lit Casein enzymic hydrolyzate 5 gms/lit Special peptone 5 gms/lit Tryptose 10 gms/lit Lactose 12.50 gms/lit Sodium deoxycholate 0.10gms/lit Dipotassium phosphate 4.375 gms/lit Monopotassium phosphate 1.375 gms/lit Sodium chloride 5 gms/lit Sodium laurate sulphite 2.10 gms/lit Basic fuchsine 1.05 gms/lit Agar 15 gms/lit Final pH 7.2+/- 0.2 Cc4 : Peptic digest of animal tissue 10 gms/lit Yeast extracts 5 gms/lit Sodium chloride 3 gms/lit Lactose 12 gms/lit Bile salts 1.5 gms/lit Aniline blue 0.1 gms/lit Agar 15 gms/lit Final pH 7.4+/-0.2



Standards Sample

Sampling point

TPC Y & M Coli

a) Water

1) Well & external well Well water <500/ml <0/100ml

2) Raw water Well water inlet <500/ml <0/100ml

3) Storage tank water Storage tank water <500/ml <0/100ml

4) Treated water ACF outlet <25/ml <0/100ml

Lead ACF <25/ml <0/100ml

Lag ACF <25/ml <0/100ml

5) Treated water After micron filter <25/ml <0/100ml

6) Treated water After UV <25/ml <0/100ml

7) Treated water Raw syrup room <25/ml <0/100ml

8)Treated water Ready syrup room <25/ml <0/100ml

9) Treated water PET/ CAN/ RGB <25/ml <0/100ml

10) Final rinse water PET/ CAN/ RGB <25/ml <0/100ml

11) Warmer solution PET/ CAN <25/ml <0/100ml

12) Tertiary plant water Tertiary outlet <25/ml <0/100ml

13) Decausticiser water After micron filter <25/ml <0/100ml

b) Filling system Filler valves <10/valve <10/valve

Snift valves <10/valve <10/valve

c) Sugar _ 200/10gm 10/10gm



d)Syrup Simple syrup after filtration <5/5ml

Final syrup_ propotioner <5/5ml

e) Washed container RGB <50/ml 10/20ml

PET <50/ml 10/20ml

CAN <50/ml 10/20ml

f)CIP rinse Raw syrup tank <25/ml <10/100ml

Ready syrup tank <25/ml <10/100ml

RGB/ PET/ CAN <25/ml <10/100ml

g) Equipment Hopper of RGB, PET, CAN <50/ml <25/20ml

Seamer <50/ml <25/20ml

h) Finished product RGB <50/ml 10/20ml <0/20ml

PET <50/ml 10/20ml <0/20ml

CAN <50/ml 10/20ml <0/20ml



PROCESS MANUFACTURE:-

WATER TREATMENT PLANT Water is the main ingredient of carbonated beverages, so it is very important to check the quality of water for the better quality of final product. The Multiple Barrier Water Treatment System can continuously produce treated water and the Softener can produce soft water within Company stated specifications. The Multiple Barrier Water Treatment System used to produce treated water for syrup and beverage preparation. Soft water produced in softener is used for boiler for steam generation and in washer for container rinsing.



Raw Water From Well

Pressurized Sand Filter

Raw Water Storage Tank

Solid Contact Clarifier(165 m3)

Clear Well


Treated Water Storage Tank

Activated Carbon Filter

Lead ACF

Lag ACF

05 µ Filter

10 µ Filter

01 µ Filter

Ultra Violet Unit(254 nm)

Process

Cl2 Dosing

Ca(OH)2+Fe SO4+CaOCl2

Online CO2 Injection



PROCESS DESCRIPTION - Raw water is received from the wells through underground pipelines. Chlorination of water is done at the well site. 3-5 ppm Chlorinated well water is pumped to the Plant. This water is then filtered through a Pressure Sand Filter and stored in a raw water storage tank. The raw water from the storage tank is then used for making soft water or treated water using the respective treatment procedures. CLARIFIER – Clarifier is main and most important device in water treatment plant which clarifies water or in other words it is able to separate all the suspended as well as dissolved matters from the water.

Raw water from the storage tank is pumped at a constant flow rate of 30 m3/hr into the centre of the clarifier draft tube of a Solid Contact Clarifier, with the addition of water treatment chemicals like lime, ferrous sulphate and bleaching powder in required quantities through dosing pumps. The raw water entering the central section is distributed over the whole of the area. The raw water

Solid Contact

Clarifier

Water+Ca(OH)2+FeSO4

Sludge Outlet

Clear Water Tank

Mixing Zone

Reaction Zone

Mother Floc

Impeller

Water Movement



then descends to the bottom of the tank and rises up through the clarifying zone at a rising rate slow enough to allow the maximum deposition of flocks before reaching top water level, where the clarified water is decanted through slots in collecting launder. The collecting launder spans the top surface, thus ensuring an even rate of draw off from the entire surface of this relatively large area. The clarified water is then discharged from the collecting trough into the peripheral launder before gravitational discharge.The clear water is gravitationally discharged into the Clear Water Tank, and then filtered through Pressure Sand Filters and stored in the Treated Water Storage Tank. As per the requirement, the water from the Treated Water Storage Tank is filtered through Activated Carbon Filter to remove organics and residual chlorine. The water filtered through Dechlorination ACF is filtered through LLACF and then passed through Polishing Filters of 10 micron, 5 micron & 1 micron in that order, to remove any sand or carbon carried over and finally passed through an UV Disinfection System for Syrup and Beverage Preparation, and manufacture of beverage.

� PREPARATION OF SOFT WATER : Raw water from the Raw Water Storage Tank is pumped to a Pressure Sand Filter in order to filter the sediments. It is then pumped through an Activated Carbon Filter to remove the residual chlorine. This water is then directed to the top of the softener vessel. It passes downwards through the Ion Exchanger, the softening action takes place and the softened water flows from the vessel to the Soft Water Storage Tank.

Activated Carbon Filter

Drain

Outlet

Inlet Water

Air Bleed

Steam Inlet

Coarse Sand

Activated Carbon

Gravel Layer




Drain

Outlet

Inlet Water

Air Bleed

Steam Inlet

Gravel Layer

Coarse Sand

Fine Sand

Gravel Layer

QUALITY CHECKS OF WATER- Color- Indicates generally the presence of undesirable dissolved, colloidal and suspended impurities in the water

Examples: • Iron turns water to brown/red • Manganese makes it black • Organics make it yellow

Taste &Odor – • Indicates generally the presence of undesirable dissolved, such as hydrogen

sulphide or sewage contamination. • Important parameter for water quality control in the food and beverage

industry. Suspended Solids • Includes all matter suspended in water that is large enough to be retained on

a filter with a given porosity



Turbidity • Indicates level of colloidal matter of organic or inorganic origin • Suspended solids & colloidal matter make water turbid • No quantifiable relationship between turbidity & suspended Solids

pH:- • pH = - log [ H+ ] • [ H+ ] is concentration of hydrogen ion mole/l • pH of pure water is 7 • pH scale ranges between 0 and 14, 7 is neutral point • pH below 7 makes water acidic • pH above 7 makes water alkaline

Alkalinity • Indicates the quantifiable quantities of bicarbonates, carbonate and

hydroxide in water • Determined using Phenolphthalein & screened Methyl orange indicators • Phenolphthalein gives the P. alkalinity, P.Alk or P value • Methyl orange gives the M. Alkalinity, M. Alk or M value • Bicarbonates, carbonate and hydroxide in water are determined from P value

and M value by alkalinity relationships Total Hardness • Indicates the quantifiable quantities of calcium and magnesium • A part of total hardness is associated with alkalinity in water and is known

as alkaline hardness, carbonate hardness or temporary hardness • The balance of total hardness is associated with no alkaline ions such as

chlorides, sulphates etc. and is known as non-alkaline hardness or permanent hardness

Total Dissolved Solids • Indicates total content of dissolved solids in water • Represents all charged ions – cat ions, anions as well as uncharged and

molecular species • Summation of cat ions i.e. calcium, magnesium, sodium and anions i.e.

chlorides, sulphates, nitrates and uncharged ions as silica.



Daily Checks of Water: - • Taste

• Color

• Odor

• pH

• Turbidity

• P- alkalinity

• M-alkalinity

• 2P-M

• Total hardness

• Calcium hardness

• Total dissolved solids

• Iron

• Chlorine

• Micro-organisms- Coli forms



Raw Syrup Tank

FilterPress

PlateHeat

ExchangerUp to 200C

ReadySyrupTankProduction

Concentrate Addition

Water addition &

final 0Bx adjustment

Sugar+ Activated carbon+ Filtering Aid

1 Hr Contact time at 850C

Clear

Syrup

PrecoatingTank

Syrup Making

Recirculation Loop 45 Min.

Raw Syrup Room

Ready Syrup Room

Quality Checks



SYRUP PREPARATION –

GENERAL INFORMATION- Manufacturing of syrup involves preparation of simple syrup, its filtration &

its conversion in to final syrup by adding concentrate or Beverage Base. Following are the some basic terms which are generally used in preparation

of syrup. � BRIX –

The term was developed by ADOLPH BRIX, a German scientist. Normally Brix is nothing but “Total amount of soluble solids” I t is generally use to indicate the specific gravity of sugar solutions � ACTIVATED CARBON –

Activated carbon is a carbon in which adsorptive power has been increased by giving special treatments, Activated carbon is widely used to remove colour, off taste, & odour producing compounds from simple syrup. � CONCENTRATE OR BEVERAGE BASE-

Concentrate or beverage base is nothing but mixture of flavours acidulates& colouring materials produced by the coca-cola company. Concentrate parts are added to simple syrup to make final syrup.

� Raw / Simple Syrup Preparation: As per the syrup batch size the required

quantity of water is taken in the Raw Syrup Tank and heated to 85oC with continuous agitation.

� The required quantity of sugar is weighed and added into the tank and heated to 85oC. Activated Carbon is then added to the syrup along with filter aid for sugar clarification. A contact time of one hour is maintained. Meanwhile the filter press is precoated with filter aid. The syrup solution is then recirculated through the filter press and checked for clarity. Once the syrup is clear it is transferred to a Sanitized Ready Syrup Tank through a Plate Heat Exchanger where the syrup is cooled to a temperature below 30oC with the help of water and glycol. The syrup remaining in the pipelines are pushed to the Ready Syrup Tank with a minimum quantity of treated water. The syrup in the Ready Syrup Tank is then thoroughly mixed.

Ready / Final Syrup Preparation: As per the required Flavor and Batch size Concentrate and Beverage Base in the cold store are brought to ambient conditions four hours before their addition. Concentrate and Beverage Base are dosed in the required sequence as per the Master Mixing Instructions. The brix adjustment and final volume is then made. After proper brix adjustment and deaeration, the syrup is then ready for production.



� Preparation Manufacturing: In case of Preparations, there is no syrup

preparation, due to the absence of sugar in them. Preparations like Kinley Soda and Diet Coke are made by adding the Beverage Base to the required quantity of water directly to the final syrup tank, as per their respective Master Mixing Instructions.

� Simple syrup storage- Simple syrup storage is restricted if there is any major

failures in operation, so that concentrate addition is not possible immediately after the simple syrup preparation. Simple syrup (60 Degree Brix and above) can be stored up to 24 hours.



Sugar + Filtering aid + activated Carbon@850C for 1 hr.

Raw Water

Coagulation System

Sand And Carbon Filters

10µ ,5µ ,1 µ Filters

UV Treatment

Treated Water

Raw Syrup

addition of concentrate

Ready Syrup

Paramix Operations

Dearation and mixing of water with ready syrup

Chilling in PHECarbonation

Chilled carbonated beverage buffer tank

Rinse CAN/PET with water (1-3 ppm Cl2)

Beverage Filling

Capping with Closure (PET) / lid (CAN)

Date Code Application

PET/CAN warming

Labeling (PET)

Casing

palletizing

Warehouse

Beverage Manufacturing in PET & CAN



PLASTIC BOTTLES

Advantages And Limitations

Consider these differences with glass bottles.

Advantages

1. Plastics are lighter in weight when compared with glass; for example a

typical 1 l PET bottle weighs 38 g, against a 1 l glass bottle of 600 g.

2. No corrosion problems when compared to cans.

3. Versatility in design terms.

4. 4. The offer of a larger pack format, for example a typical PET bottle is 2 l

in size, the largest glass bottle offered for soft drinks is 1.1 l, and

dimensionally they would appear similar in size.

5. Impact strengths can be greater than glass and where breakages do occur

there are no splinters.

6. Quietness in use in the bottling plant.

Limitations

1. Plastics are not complete barriers to either gases or water vapor, this means

Carbonation can escape and oxygen ingress can occur over time.

2. Some chemicals attack plastics; for example silicone sprays, often used to

lubricate conveyors, can induce stress cracking in PET bottle bases.

3. Resistance to abrasion can mean a poor bottle surface appearance,

particularly if returnable plastic bottles are being considered.

4. There is a potential liability for the build up of static electricity, which can

give rise to two key issues in terms of soft drinks bottling. First, if a bottler

blows their own bottles on site then bottles may stick together on the air

conveyor system on route to the filler causing intermittent supply. Second,

if the bottles are pre blown or preforms used for bottling on site are not

100% clean then static can attract minute particles of dust which may coat



the internal surface of a bottle causing product to fob during filling.

5. When comparing plastic and glass bottles of the same volume then visually

the plastic bottle will look smaller giving a consumer the perception of

getting less.

Polyethylene terephthalate

Polyethylene terephthalate (PET) is a polyester polymer consisting of

alternate units of ethylene glycol and terephthalic acid. The chain length is about

30,000 double units, depending on application. PET used for carbonated soft

drinks has a different requirement to that used for still drinks.

History

PET was developed as a textile fibre in the 1940s and is still used as such for

carpets and clothing. Its use in packaging was initially in the mid-to-late 1960s for

packaging films. The use of PET for carbonated soft bottles started in the early part

of the 1970s, when it was first introduced as a bottle that comprised of two parts.

The main body section, which contained the product, had a cylindrical body

section with rounded shoulders and a hemispherical base. In order that the bottle

could stand up, a base cup, usually black and made from high density polyethylene

(HDPE) was stuck to the hemispherical bottle base with hot melt adhesive. The

main disadvantage of the two-piece bottle was the fact that gluing of the bottle and

base was a critical aspect of the process which was often its weakest link in terms

of final pack quality. Those first bottles weighed about 65 g excluding the base,

which compares with today’s modern five foot petaloid 2 l bottle which weighs

only 43 g.



POLY ETHYLENE TEREPTHALATE

It is a product of petrochemical industry. • 1941 Discovery by British Petroleum • 1952 First commercial application (textile fibres) • 1954 FDA acceptation for food contact • 1955 Dupont R&D on PET bottles • 1973 Dupont license for PET bottle • 1975 First test market in USA • 1976 FDA acceptation for PET bottle • 1987 First hot fill application • 1988 First Refill bottle production • 1989 Multilayer PET preform • 1997 Coated bottles

For PET Bottles performs are used which have their own specifications for different package size. � 600ML : 27 gm � 1.5/2 liter : 48gm � 1. 25 liter : 39 & 44 gm

Catalyst Antimony or

Germanium

Crude oil Refinery

Ethylene Glycol (EG)

Liquid +

PPaacckkaaggiinngg

Terephthalic Acid

(PTA) or Dimethyl

Terephthalate

(DMT)

White Powder

PET Raw Material

+



Desired preform size according to the SKU size is blown in a SBO-8 machine using compressed air.

• The preforms are unloaded in the preform hopper. • Then preforms are elevated to the blowing machine with preform

elevator • The preforms are heated with help of an IR oven to the required

temperature as per the recipe selected. • The heated preforms are fed into the water-cooled mold with rotating

arms. • In an operating cycle the preform is first stretched using a stretch rod,

preblown as per recipe desired and finally blown with 40 bar air pressure and simultaneously cooled

• The blown bottles are carried out to the filler (rinser) with the help of air conveyer.

PET FILLER

• The bottles are firstly rinsed with chlorinated treated water. • There after the bottles are filled with the beverage supplied by the Para

mix • The filled bottle is transferred to the capper and sealed with the closure • After filling and capping, the bottles are coded.

WARMER & LEBELLER

• The filled bottles are passed through the warmer to bring the temperature to room temperature for proper packaging

• The bottle is passed through the labeling machine for application of the desired label.

• The labeled bottle is packed in a carton using a caser machine and packed with top sealer.

• Sealed cartons are then carried out through a case conveyer coded with a box coder machine and finally go to the palletizer where it is stacked on pallets in desired sequence.

• The pallet is then transferred to the Warehouse for storage, by means of a forklift.

1. The shrink-wrap on the empty can pallet is removed and any dented can bodies found are rejected. 2. The pallet is then loaded on to the platform of the Depalletiser. 3. Each layer of cans is transferred onto a conveyor, wherein they form a single file onto a rope conveyor.



4. The cans then pass through a Can Rinser where they are rinsed on the inside with chlorinated treated water containing a chlorine residual of 1 – 3 ppm. 5. The cans then enter the Can Filler where beverage is filled into the cans. 6. Carbonated beverage is prepared as per the specified syrup and water ratio in the Propotioner. 7. The prepared beverage is then chilled and carbonated as per the product carbonation specifications. 8. The beverage is then filled in the cans at a maximum speed of 1100 cans per minute. 9. The filled cans then enter the Seamer where the exposed beverage in the can is subjected to CO2 cover gassing before the lid/end is placed on the can and sealed/seamed. 10.The seamed cans then pass through a Can Warmer where they are exposed to a hot water spray at about 40oC. This is to avoid condensation on the can surface and thus help in proper can coding and prevent cartons getting wet after packing. 11. An air blower at the Warmer exit blows off water on the base of the cans. 12. The cans then pass through an air jet to remove moisture on its base. They are then coded on the base using a high speed ink jet coding machine. 13. They then pass through a Fill Height Rejecter where cans with fill volume less than the set standard are knocked off the conveyor into a Fill Height Rejects bin. 14. Only cans with fill volume within specifications are conveyed to the packing machine. 15. The packing machine, Meypack, is fed with cartons on one side and cans on the other side. 16. The cases are then coded on the side flap with the Manufacturing Week Number and the Price. 17. These cases are then conveyed to a Palletizer where they are systematically stacked on to a wooden pallet (110 cases per pallet). 18. The pallet is then transferred to the Warehouse for storage, by means of a forklift. ON LINE CHECKS OF CAN:-

1. Brix by densitometer (DMA) 2. Gas Volume 3. Net Content 4. Seaming Parameters 5. Air Content 6. Appearance, Taste and odor



CARBONATION Basic considerations

If we consider a liquid–gas mixture in a sealed container, the state of

equilibrium is said to exist when the rate of gas leaving the liquid solution equals

that entering it. If you take any PET bottle of carbonated soft drink and shake it,

the liquid gas interface will initially fob. However, after a short while, the

equilibrium condition will have been reached and the liquid will be quiescent. If

the cap is then opened and some of the contents poured out, the cap replaced and

the procedure repeated again, it will be noted that before shaking the bottle is limp

but after shaking it becomes hard. In this process gas has come out of the solution

to attain the equilibrium condition. This state is just stable. Any decrease in

pressure, or increase in temperature, will render the mixture metastable, that is,

supersaturated, such that the temperature/pressure combination is insufficient to

keep the carbon dioxide in solution. If this occurs then the gas is spontaneously

released giving rise to fobbing. If the mixtures were agitated or some irritant, such

as small particulates added to the mix, then the rate of gas release will be even

more pronounced. This is due to nucleation sites being generated by the presence

of these particulates or other gases, such as air. Any carbonated product that is held

in a container that is open to the atmosphere will gradually lose carbonation. This

is due to the gas being liberated to the atmosphere as the liquid/gas interface

continually strives to achieve the equilibrium condition. In a closed container the

gas fills the container headspace, thus increasing the headspace pressure. This

happens quickly at first and then slowly as equilibrium is approached. The rate of

transfer of gas from the product to the headspace depends on the proximity of the

headspace pressure to the equilibrium pressure, the temperature of the liquid, the

nature of the beverage, the extent of any agitation and the presence of any irritants.

A quiescent, stable product will take many hours to reach equilibrium when not

subjected to any external forces such as agitation, movement,



temperature or pressure change. However, the same product roughly shaken will

only take seconds to achieve the equilibrium condition. The faster the rate of

change towards the equilibrium condition the sooner this condition will be reached.

For a given volume, the amount of carbon dioxide which a solution can maintain

depends on the temperature and pressure. The higher the temperature the greater

the pressure required to maintain the carbon dioxide in solution. Conversely, the

lower the temperature the greater the amount of carbon dioxide that is retained in

solution. Henry’s law was postulated by William Henry (1774–1836) and states,

‘The amount of gas dissolved in a given volume of solvent is proportional to

the pressure of the gas with which the solvent is in equilibrium’, whilst Charles’

law (1746–1823) states, ‘The volume of an ideal gas at constant pressure is directly

proportional to the absolute temperature’. These two laws can be combined to form

the universal ideal gas law:

where p is the absolute pressure, V is the volume, m is the number of moles

of gas, R is the gas constant (for that particular ideal gas) and T is absolute

temperature. A mole is that quantity of a substance which has a mass numerically

equal to the molecular weight of the substance. For carbon dioxide the molecular

weight is 44.01 and R is 0.18892 J/mol K. From this



relationship the carbonation chart shown in Figure can be deduced. Here the

concept of carbonation volumes is introduced. Volumes ‘Bunsen’ is where the gas

volume is measured at atmospheric pressure (760 mmHg) and the freezing point of

water (0.C). It is defined as the number of times the total volume of dissolved gas

can be divided by the volume of liquid in the container. As an example, a product

with four volumes carbonation will contain carbon dioxide to the extent of four

times the volume of the beverage. A 1 l container carbonated to 2.5 volumes would

contain 2.5 l of carbon dioxide, and likewise a 3 l container carbonated to 4

volumes carbonation would contain 12 l of carbon dioxide. One volume ‘Bunsen’

is equivalent to 1.96 g carbon dioxide per litre. This is often simplified to 2 g/l. For

PET bottles normally, the smaller the container the higher the carbonation

volumes. As the rate of loss of carbon dioxide by permeation due to a high surface

to volume ratio is large. Shelf life is normally defined as 15% carbonation loss in

12 weeks, which a 2 l bottle can easily meet. This will reduce to ca. 9 weeks for a

500 ml bottle and some 7 weeks for a 250 ml bottle. The light weighting of PET

bottles gives rise to thinner wall thicknesses and hence greater permeation and a

shorter product shelf life. Cans have carbonation levels up to 3.5 volumes. Any

higher internal pressures that can be generated during expected use would cause

can rupture to occur. Glass bottles can be designed to accommodate higher

pressures, such as tonic water which is traditionally a high volume carbonation

product, dependent on design and wall thickness.



CARBONATION MEASUREMENT

This is measured using a device similar to that shown in above figure. It

consists of a jig in which the container can be restrained and a piercer which,

when used to pierce the container, allows the gas pressure to be read. The container

is placed in the jig and is first of all pierced, then shaken, before the pressure is

measured. The release valve is then opened until the pressure gauge reads zero and

all the gas has been exhausted from the container headspace. The release valve is

then closed and the container shaken again. The pressure is retaken. The container

is released from the jig and the temperature of the contents taken. The carbonation

chart is then used to determine the volumes of carbonation. Why do we need to go

to the extent of releasing the pressure from the container before we take the

pressure reading? The problem is air inclusion in the beverage. This gives a twin-

gas system of air and carbon dioxide. It is necessary to first release the air to

determine how much carbon dioxide is present. Air is approximately one-fiftieth

the solubility of carbon dioxide in a liquid. Hence any air contained within the

beverage will exclude some 50 times its own volume of carbon dioxide. The Law

of Partial Pressures was postulated by Jon Dalton (1766–1844) as ‘the pressure P

of a mixture of gases that do not chemically react is equal to



the sum of the pressures of the individual constituents when each occupies a

volume equal to that of the mixture at the temperature of the mixture’. This can be

written for a mixture of N number of gases as

The partial pressure of a constituent gas in a mixture is equal to the product

of the total pressure and the mole fraction (X) of that gas in the mixture, that is,

where i corresponds to an individual component. the mole fraction X being

a method of expressing the composition of a mixture

Air is primarily made up of 79% nitrogen and 21% oxygen, ignoring for

simplicity the presence of the inert gases. In any carbonated mixture we will have

carbon dioxide, nitrogen and oxygen present. Due to the differing solubility and

proportions of oxygen and nitrogen, the dissolved air actually contains 35%

oxygen and 65% nitrogen as the solubility of nitrogen is low. It is this enrichment

of oxygen that can give rise to spoilage problems with the product if care is not

taken to minimize the amount present. The presence of air will also give rise to a

higher pressure and hence a false reading of the volumes carbonation from the

carbonation chart. The amount of air present clearly has to be minimised when

taking carbonation measurements. If we consider a bottle with a gas headspace of

5% of the bottle volume, on the first snift the gas loss would be 5% of the bottle

volume. On the second snift we would lose a further 5%. If only carbon dioxide

were present in the headspace we would expect to lose 5% pressure on the first

shake and some 7% by the second shake. If other gases were present we would

lose more pressure. Thus the amount of air present in the product can also be

estimated during carbonation measurement. If excess air is



found then actions need to be taken to minimise its presence. The problem is often

caused by air entrainment or poor sealing with the filler bowl. This can be seen

from an example where by volumetric analysis it has been found that the

headspace of a carbonated drink container contains 90% carbon dioxide, 3.5%

oxygen and 6.5% nitrogen.



FILLING PRINCIPLE

The first criterion that needs satisfying is to seal the container, whether it is a

glass bottle, plastic bottle or can, to the filler bowl such that no leakage can exist

via the seal. The filler bowl is filled to a given level, which by means of float

valves is maintained within close tolerances. This ensures a near constant pressure

head during the filling process, an important factor if constant flow conditions and

repeatability are to apply. As shown above figure, once the container is sealed to

the filler bowl we can open valve to allow filling to commence. The gas within the

container, which for carbonated products is normally carbon dioxide though

nitrogen can be used, needs to exhaust somewhere as the liquid filling the

container displaces the gas. This is achieved by means of a vent tube, the rate of

flow of liquid into the container being proportional to the rate of flow of gas

displaced. When the liquid reaches the vent tube it will start to fill this until such

time as the pressure within the vent tube equates to the filling tube pressure. When

this equilibrium condition is achieved the liquid flow will stop. Then the filling

valve is closed. Following this the container can be lowered



from the filler bowl. During this process the liquid within the vent tube will drain

out that left in the vent tube due to surface tension effects dependent on the

characteristics of the liquid being filled. The process cycle is shown in below

figure .A bottle have a standardized neck finish to allow it to seal effectively at all

times with the filler bowl and this finish must be produced to a minimum standard.

It also have sufficient top load to withstand the forces involved during the filling

process. Bottle filler lifts PET bottles by the neck to overcome deformation

problems during the process. This also allows light weighting of the bottle, which

is advantageous for both environmental and commercial reasons. To achieve

commercially acceptable filling speeds fillers are rotary (RGB & PET).

Bottles are fed into the filler by conveyor to an in-feed worm and star-wheel

in single file. This star-wheel incorporates a air pressure-operated bottle stop which

stopped the bottle stop in emergency will engage automatically. From the star-

wheel the bottles are fed to a bottle-lift stirrup, sited below an individual filling

valve, and lifted by the neck to the seal with the filler bowl. RGB filler use bottle

lift on which the bottle rests, and then lifted to seal with the filler bowl. The filling

valves are sited at equal intervals around the base of the filling.

SCHEMATIC DIAGRAM OF BOTTLE FILLING

FILLER

Bottle infeed

Value Opening Lever

Value Closing Lever

COUNTER PRESSURE

FILLING PROCESS

Spray Jets

Value Closing Lever

Snifting

Bottles to Crowner



RGB Line



BEVERAGE MANUFACTURE IN RGB Empty Refillable Glass Bottles in crates are manually transferred onto a conveyor,

leading to the De-crater/Uncaser.

. The Uncaser empties the crates by lifting the bottles and transferring them

onto another conveyor.

. The empty crates are conveyed to a Crate Washer where the crates are

washed with hot water recycled from the Warmer/Hydro wash compartment of

the Bottle washer.

The empty bottles then pass through an Inspection station known as the

Prewash Inspection Station. Here very dirty bottles that are difficult to clean in the

bottle washer, foreign bottles and broken bottles are rejected.

These bottles then enter the Bottle washer where they are washed using hot

caustic solution and rinsed with water using stationary and rotary jets. The bottles

are finally rinsed with chlorinated soft water (1 – 3 ppm residual. chlorine) before

they exit the Bottle washer.

BOTTLE WASHER

Recent years, consumer awareness and regulatory demands have

emphasized the need for soft drinks to be packaged in clean, commercially sterile

containers .The purpose of container washing and rinsing is to provide clean and

commercially sterile containers that are ready to be filled. The bottle washing

operation must remove all dirt and foreign matter from the inside and out side of

returnable bottles, and bottle washing conditions (caustic concentration,

temperature, and contact time) must kill yeast, molds, and pathogenic bacteria, thus

producing commercially sterile bottles free from residual detergents. Before in feed

to the bottle washer, the prewash inspector removes all unacceptable bottles, such



as those that are chipped or cracked. Broken bottles can cause machine stoppages,

and glass shards can accumulate at the bottom of the washer’s soak tanks,

interfering with bottle flow.

The inspector also rejects foreign bottles as well as unclean able bottles,

such as those covered with paint, concrete, or grease.

Bottle washing equipment design

Bottle washing equipment needs to produce commercially sterile bottles.

Specifically, effective equipment will: Remove all dirt and foreign material from

the inside and outside of refillable bottles. Maintain washing conditions( caustic

concentration ,temperature, and contact time).Completely rinse all traces of

residual detergents from the bottles

Bottle washer Cycle

Usually bottle washer consists of following cycles

1. Pre-wash

2. Soake

3. Hydro

4. Pre- final rinse

Bottle Washer Structure

Pre-

Rins

e

Bottles In

Soak

-1

Soak

-2

Hydr

o Se

ctio

n

PreF

inal

-2

PreF

inal

-1

Fina

l Rin

se

Bottles out



5. Final rinse

Hot caustic Treatment in Soak Compartment

The bottles are subjected to undergo the process of hot caustic Treatment in

soak compartment. The material needed are

• Water

• Steam

• Caustic Flakes /Lye

• Additives

Water

• Caustic solution in Soak Tank should be prepared in soft water only. The

soft water used to avoid

• Improper Washing

• Scaling

• Damage to the Heating Coil

• Loss of Heat

• Corrosion

Steam

• Steam is supplied in to the soak tank through heating coil

• The steam should be regulated to raise the caustic solution temperature to

the standard range .As a result chemicals are activated to clean the bottle

effectively.

Caustic

Caustic is used as a Washing agent & it acts as follows

• Soluble in both hot & cold water

• Emulsifies the fat content

• Swells & Hydrolyses the protein



• Dissolves the Carbohydrates

• Disperses in soluble matters

• No trouble for bottle washer lubrication

• Non -Abrasive in nature

• Low foaming

• Better fluidity.

Additives

o The additives contains following

o A sequestering Agent

o An wetting Agent

o Defaming agent

o Corrosion Inhibitors

Sequestering is defined as the suppressing the property or reaction of a metal

without removing that metal from the system or phase by the process of

precipitation.

These are Non -ionic surface-active agents having detergent nature.

• By lowering down the surface tension of the bottle washer solution.

• It penetrates the soiling materials

• It acts as a catalyst for reactivity of caustic solution

Defoaming agents are added to the caustic solution to

• To increase the effectiveness of the cleaning

• To avoid the loss of the detergent solution-For operational safety

Corrosion takes place by

• Scale Formation

• Removal of the Metal ions



So to avoid this type of corrosion, Corrosion inhibitors like Phosphate salts of

Methylene Phosphoric Acids is added.

PARAMIX

It is the Proportioning Equipment wherein the Ready Syrup and the Treated

Water mix, in a definite ratio, along with CO2 as per the Gas Volume requirement,

by setting (temp. & pressure) for a particular flavor.

FILLER –

• Here empty bottles are filled by using isobaric gravity flow with a regular

speed of 600 bottles per min.

• Crowning done after filling process.

DATE CODING

• The crowned bottles are then coded on the bottle neck with the

manufacturing date, time and price.

• These bottles then pass through a Final Inspection Station where bottles

without proper fill level, date code, or crowns are rejected.

• These bottles are then transferred into crates with the help of Caser/Crater.

• The filled crates are then manually palletized and transferred to the

Warehouse for storage.

ON-LINE QUALITY CHECKS

Sampling and Testing Frequency of final product-

The finished product (carbonated beverage) sampling and testing frequency,

as a minimum requirement is as stated below:

Taste Test (all types of containers)

• At start up



• First product

• After 30 minutes

• End of run/batch

• At product changeover

• Appearance (all types of containers)

o At start up

o First product

o After 30 minutes

o End of run/batch

o At product changeover

• Brix/ratio adjustment (all types of containers)

o At start up

o First product

o After 30 minutes

o End of run/batch


• Carbonation (all types of containers)

o At start up

o First product

o After 30 minutes

o End of run/batch

• Net Content (all types of containers)

o At start up



o After 30 minutes


o At package changeover



• Crown Crimp (Glass)

o At start up

o Every 4 hours



• Date Coding (all types of containers)

o At start up

o After 30 minutes



• Closure Torque (Glass and PET)

o At start up

o Every hour



• Proper Application Test (Glass and PET)

o At start up

o Once per shift



• Can Seam Evaluation (Cans)

o At start up



o Every 4 hours



• Air Content (Cans)

o At start up

o Every 30 minutes



CLEANING IN PLACE

Cleaning and Sanitation –

Cleaning is nothing but the washing of the equipment to remove all

unwanted material, where as Sanitation is the treatment of cleaning surfaces and

equipments by a process that destroys pathogenic bacteria and substantially reduce

the population of all other micro-organisms. Cleaning solutions used in food

industries are most commonly aq.solution of biodegradable alkaline detergents.

The cleaning agent should be based on caustic soda or tri sodium phosphate.

CIP-

It is the cleaning and sanitation system where detergents and sanitizing

agents with water are circulated through the equipment and lines by pumping or

spraying .In 3 step CIP first water is circulated through the lines after circulating

water all lines are sanitized with CIP chemical till all caustic residual is removed

from line

CIP means Clean-In-Place is used to describe the cleaning and

sanitizing system where detergents, sanitizing agents and water are circulated

through equipment and lines. Unlike the soaking or flooding system, circulation is

accomplished by pumping or spraying (using a spray ball) solutions from solution

holding tanks through equipment, and then in many cases returning it to holding

tanks. This allows equipment and lines to be cleaned and sanitized in place without

being dismantled. The system also allows for maximum economy when solutions

are reused.

3 Step is followed in plant contents pre-rinse, chemical circulation & final

rinse.



BOILER SECTION

Boilers are used for generating steam, which is used for various purposes in the

industry.

”A steam boiler is a closed vessel in which a steam or vapor is generated for

the external use by direct application of heat produced from the combustion of

fuel(solid, liquid, gases) or by the use of electrical energy.”

In our context the boiler is required for producing steam, which is used for

the following-

� Heating caustic/ water in the bottle washer

� Dissolving and pasteurization of raw syrup

� Heating of water for CIP system

� Degassing and sanitation of activated carbon filters.

� For evaporators in CO2 bulk storage tank

� Heating of water for floor washing

� For warmer of PET and CAN

A steam boiler is a closed vessel in which the steam or other vapors are

generated for the external use by the direct application heat produced from the

combustion of fuel. Boilers are two types “water tube” boiler in which water

passes through tubes and hot gases surround it, “Fire Tube” boilers the hot gases

passes through the tube and water surrounds it.

Heat is transferred through the hot gases to the water via the metallic tubes

in between them. After giving the heat to the heater the hot gases are exhausted

through the chimneys in to the atmosphere. In HCCBPL.Pune industry the heat is

utilized for the heating of incoming air. The steam formed from the water is taken



out through stem pipes to different required areas. The make up water is added as

per the requirement by multistage pump and the boiler is blown after Suitable

interval to remove the seals and other salts from it. (Above 2350 ppm) and the

other auxiliaries are also added to the boilers for its efficient use like stop valve,

pressure reducing valve, steam trap, steam separate etc components.

Components

• Steam Boiler

• Feed water pump

• Oil gear pump

• Feed Water Tank

• Oil tank

• Make-up tank

• Molding unit

• Pneumatic blown down valve

• Chimney

• Pressure reducing valve

• Steam separator

• Non-return valve

• Stop valve

• Steam trap

HCCBL has 3 pass fire tube boiler means the hot gases blown from the one of the

boiler to the other end three times. This is done due to increase the contact time

between water and flue gases. The bagass boiler consists of combustion of bagass

and hot gases produced are then circulated through boilers.

Plant steam requirement is 2 kg for Raw Syrup and 3 kg for bottle washer.

And plant boilers have capacity of 5 TPH each.



Feed water should have following specifications-

• pH should be > 4.5

• Hardness should be less than 5ppm

• TDS should be less than 500 ppm



REFRIGERATION SECTION

Refrigeration is a transfer of heat from a place, where it is not desired, to place,

where it is unobjectionable.

Use of refrigeration in plant-

Refrigeration system is required for the following purposes in plant. Such

as-

• Beverage cooling in the buffer before filling

• Raw syrup cooling

• Air conditioning of labs, micro-labs, offices.

• Maintaining low temperature in the concentrate storage room.

• Chilling of water mix with syrup in paramix before carbonation.

Flow of heat in plant-

1. from beverage/ raw syrup to propylene glycol-

Cold glycol is circulated through the heat exchangers by the

secondary pumps. In the beverage PHE the heat of the beverage absorbed by

propylene glycol flowing in opposite side to beverage. Similarly in the raw

syrup cooler heat is transferred from raw syrup to propylene glycol.

Hot propylene glycol goes to the hot well of the tank of the refrigeration

tank room.

2. from propylene glycol to ammonia

The glycol from the hot water well is circulating through the chillers

by the primary pumps. The glycol gets chilled in chillers by transferring heat

to the boiling ammonia on the other side of chiller.



The chilled glycol returns to the cold well of the tank.

3. from ammonia to the cooling water

Ammonia gas from the chiller is sucked by the compressor and

compressed to the high pressure. High pressure ammonia gas from

compressor goes to the condenser via oil separator. Heat input in the form of

electrical energy (power consumed) is added to ammonia in compressor,

where it get compressed.

In condenser the ammonia gas is condensed by cooling water and high

pressure ammonia liquid is drained ti ammonia receiver. The heat picked up

from the glycol as well as electrical input gets transferred to cooling water.

Ammonia liquid from the receiver goes to the glycol chiller. High pressure

liquid passes through expansion valve where it is expanded to low pressure

liquid before entering the chiller. The liquid ammonia is evaporated into the

heat exchanger there by cooling glycol.

3. From cooling water to atmosphere

The cooling water heated in the condenser is sprinkled in the cooling

tower where the heat from the water is transfer to air flowing in a reversed

direction. The transfer of the heat takes place by the evaporation of small

amount of water and saturation of the air.

The water gets cooled again circulated by pumps through condenser. thus

the heat from beverage/ raw syrup where it is undesirable is ultimately given

to the atmosphere by using refrigeration system.



Major components of refrigeration system -

• Compressor

• Condenser

• Expansion device

• Evaporator

For beverage application food grade propylene is used being non poisonous

also contamination by maintaining positive pressure of beverage in system.



Incoming Effluent

from PlantEqualization Tanks

Aeration Tanks

SecondaryClarifier Splitter

Chamber

Flash Mixer(FeSO4Dosing)

Clarifloculator

PS

F Pum

p

PSF

Softener UV Unit

Micron

FilterTertiaryWaterSump

ETP CollectionSump

HCl /NaOH & Urea, DAP

Gardening & Fish Tank

Sludge Holding Tank

Sludge Drying Bed

Effluent Treatment Plant

Cleaning

Dried Sludge

Cl2



EFFLUENT TREATMENT PLANT:-

Effluent treatment plant or in short ETP is one of the major and important

areas in the bottling plant. Its major function is treating of the effluent generated in

the plant operations. Effluent can be defined as anything that effects our

environment causing harm where environment is the surroundings where we live in

(air, water, nature etc.). The major characteristics of the effluent generated are as

follows:

� High pH

� High TDS

� High TSS

� High COD – Chemical Oxygen Demand

� High BOD – Biological Oxygen demand

� Oil and grease

This effluent if released in the atmosphere into a pond or lake) will cause

damage. The BOD in the effluent will result in the microorganisms to take

dissolved oxygen from water and grow. Thus the DO level in water decreases

causing danger to existing aquatic life. These die and cause a condition of septic in

water. This causes generation of many nutrients which result in growth of shrubs

and trees. All this results in the depletion of the water body, a condition called

Eutraffication. The plants so grown are rich in chemicals such as iron etc. which

were earlier dissolved in water and if consumed by animals will cause

accumulation of heavy metals in their body. This condition is called bio-

magnification. Thus the release of untreated effluents to water bodies destroys the

complete eco-cycle. To avoid all these unwanted results, it is necessary to treat the

effluent before releasing it into the environment.



Definitions:

Biological Oxygen Demand (BOD): It is the amount of oxygen consumed

by microorganisms in order to utilize the biodegradable matter present is the

sample when incubated for 5 days at 20oC, Oxygen demand for Microorganisms

Chemical Oxygen Demand (COD): It is the amount of oxygen consumed

by potassium dichromate in presence of Conc. Sulphuric acid heating at 140oC for

3 hours, Oxygen demand for Chemical Oxidation

The effluent basically undergoes primary, secondary and tertiary treatments.

Considering the importance of conservation of natural resources, the treatment

system is designed to treat the effluent up to the reuse standards of water for

secondary process applications. Primary treatment involves separation of floating

matter, oil and grease. The secondary treatment processes involved are

equalization, neutralization followed by two stage biological treatment consisting

of anaerobic-aerobic processes, in which importance is to conserve electrical

energy and recover non-conventional energy source, i.e., biogas. The tertiary

treatment involves sedimentation and filtration for suspended solids removal,

activated carbon filtration to control organic load and removal of contamination

using pre and post disinfection by chlorination and UV system. The waste water

generated from process, wash, utilities etc. is collected in a collection tank after

passing through a bar screen chamber and oil and grease trap where suspended

matter like straws etc. are removed in bar screen and floating oil and grease are

removed by skimming in oil and grease trap. Wastewater from the collection tank

is pumped alternatively into one of the two fill and draw type equalization cum

neutralization tanks. These tanks are used alternatively i.e. one tank is filled first

and then the flow is diverted in to the second. Waste water in the first tank is

equalized both quantitatively and qualitatively using neutralizing agents such as

lime or acid as per the requirements. Neutralizing agents are prepared in the dosing



tanks. Floating aerators are provided in the neutralization cum equalization tanks to

ensure thorough mixing.

This homogeneous mixture of wastewater is pumped into the anaerobic

tower where it is treated in the absence of air. Further the water is pumped to the

aeration tank where it is biologically treated in the presence of air. Aerators are

provided in the aeration tank to ensure necessary DO levels. The wastewater from

the aeration tank flows to the secondary clarifier where the MLSS settles down in

the form of sludge. The settled sludge is recycled to the required extent to maintain

MLS concentration in the aeration tank and the excess sludge is drained on to the

sludge drying beds for dewatering and drying.

The secondary treated effluent is collected in a collection/chlorination tank

where chlorine is dosed. The chlorinated effluent is then pumped to the chemical

treatment tank where coagulation/flocculation of suspended solids occurs. This

water is now sent to the lamellar clarifier for removal of suspended solids.

The clarified effluent is then collected in intermediate sump and pumped

through the PSF for further polishing. The effluent is then passed through the

activated carbon filter for removal of residual organics. The effluent is passed

through the UV disinfection system.

The new UF-RO system includes treating this water to higher levels of

purity. Here the water at the outlet of ACF is stored in a tank and sent to Ultra

filtration unit from where it passes through the RO unit where permeate is stored in

the permeate tank. This is further passed through the softener and water is then sent

to the soft water storage tank.

inplant training report-coke2009

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