400 bpm dual filling sytem(completed)

A Team Work ………

Presented by.

Md.Amzad, Hossain , ACE, PFG.

DUAL FILLER BUILDING

PLANT LIST

1. BLOWING SYSTEM.

a) HP Compressor, 40 BAR

b) Chiller Plant

c) SIDEL PET Blowing Plant.

2. Central Syrup & Blending

a) Central Syrup , 4 nos

b) Central Blending System

c) CIP Unit

3. Power & Utility

a) 1.5 MW Gas Generator & Gas use Reconciliation.

b) 4000 Amp substation in CAN Building.

c) 100 TPH WTP

d) 80 TPH RO Plant

3. 400 BPM Dual Filler Plant.

Filler Name: DUAL FILLER Location: New CAN Building Capacity: 400 BPM Filling system : Soft & Hot Filling Control System : Flow meter controlling. Filling Valve : Electro-pneumatic Valve. Filler model : DQRS – 80 x 80 x 18. Type: Monoblock. Total No of Nozzle : 80 CO2 Consumption : 180 Kg/hr. Air Consumption : 24 M3/hr@6 Bar. Required Chilling water temp: a) Glycol water = -2 to -4 Deg C b) Chilled water = 7 Deg C.

CSD Hot Fill

Carbo mixer

Rinser Filler Capper

Warmer/

Cooling

tunnel

Conveyor Blow

Dryer

Band-R

Labeler

Wrapper

(Packaging)

Blowing

UHT

PET Bottle

Conveyor

Belt

Pre form

Syrup

Homo

Syrup Juice

Mixing

Closure

Hopper

Caper

Rinser

Over head conveyor

FIG : PROCESS FLOW DIAGRAM (CSD & HOT FILL.)

Date

Coding

Che ck

Cycle time : 35-40 Min

MACHINE NAME

UTILITY CO2, Kg/Hr.

LP AIR, CFM

Chilled water, M3/Hr

RO Water, M3/Hr

Fresh Water, M3/Hr

Steam, Kg/Hr.

Power, KW

CT water

DUAL FILLER 90 32 NA 7 4 NA 31 NA

CARBO MIXER 90 21 40

15 3 NA 34 NA

HOMO NA 25 NA NA 2 NA 132 NA

WARMER NA 32 50 NA 1 400 34.9 80

LABELLER NA 45 NA NA NA NA 15 NA

WRAPPING NA 50 NA NA NA NA 78.5 NA

Band –Roll inserter

NA 10 NA NA NA NA 27 NA

UHT NA 25 55 20 12 800 18 120

TOTAL 180 240 145 42 22 1000 363.4 200

1. Filler machine (Rainser + Filler + Capper), 80 x 80 x 18, Tech-long.

2. Carbo Mixer , 16 TPH Tech-Long, China.

3. Cooling Tunnel or Warmer , 4 Chambers, Tech-Long.

4. Air Blower / Dryer , Tech-Long

5. Date Coding Machine, Image Model: 9020.

6. Labeler, OPP, HF SSO-6000, Korean

7. Band-Roll Inserter, LEBAL TRADING CO, LTD.

8. Wrapping Machine: Automatic Shrink Film Wrapping system.

Capacity : 35 Boxes/Min, Model: WSD- LMB35T , China.

9. Homo : GEA, Max Pressure 25 MPa, Rated Flow : 1000 dm3/h,

VFD System, Italy.

10. UHT/Sterilizer : Type: Tabular, (Shell & Tube),

Heating Area = 88 M2 , Max temp = 1500 C

11. PHE : Total 5 nos.

12. Dosing Pump: Grundfos , 5 L/H, 6 Bar, 0.011 KW, 50 Hz.

13. Conveyor Lubrication system.

14. Cap Sterilization System: Cap: 32000 BPH, Pump = 4 Bar, 2 stage.

20-25 Min

Carbon -Di-Oxide Tank Installation date : 09:05:2014. C.Run :

Location : Beside CSD CO2 Tank.

Storage Capacity : 10 Cubic meter. y

Storage Condition: Liquid.

Vessel weight : 6500 kg

Operating & test pressure :

Max = 22 Bar, Min: 10 Bar. Test Pr = 25 Bar

Dimension : Dia = 2020 mm , 3 Legs,(@ 70” & 120 deg)

Vaporizer capacity = 150 NM3/H.

Piping : 25 mm SS 40 schedule, with PRV, 8 Bar

Welding System : TIG with filler rod. Leak Test @ 12 Bar by water only pipe line.

CO2 Process Flow Diagram CO2 Tank Instruments:

1. Two pressure relief valve.

2. Operating pressure gauge.

3. Storage/capacity gauge.

4. High & Low level audible alarm.

Storage Pressure & Temp = 20.5 bar & -17 C.

CO2 Uses System:

1. During filling to storage tank use both hoses vapor and liquid to

displaced gas by liquid.

2. Use Non –return valve for Tanker & storage tank.

3. It is better to be safe than sorry , so use 0.01 micron polishing filter.

4. Use PRV after vaporizer. 15 Bar to 8 bar.

15% CO2 Losses in PET Bottle; 1. For 2 ltr = 12 weeks, 2. 500 ml = 9 weeks, 3. 250 ml = 7 weeks.

High Pressure Compressor. Installation date : 24:05:2014.

Commissioning Date : 07:12:2014

Location : HP Compressor area.

Machine Specification :Brand: ABC , Spain

Model: 4HA-6TER- LT, SL# 24472. 4 stage, 6 cylinder, 280 KW motor (Brazil) , 28 M3 / min. , 670 rpm, Wt : 13 tons. Main Base dimension (mm) = 6800 x 2060.

Working Pressure : 35 Bar to 38 Bar

Power status:

Total Connected Load : 291.85 KW

Current at Load : 153-155-156 amp

Current at unload: 17 amp

HP Comp#1

High Pressure Compressor.

HP Comp#2

Air drying system/Air Dryer: Brand: Airsec,Model:FD-300-WH,Flow rate: 1768 M3/H Type: Refrigeration, R-404A, (3.5 kg), DP = min 3 deg C. Air input Temp max = @40 Bar,40 deg C. Compressor Hermetic Type , 3.7 KW, 7A, Condenser water cooled. Cooling system/Cooling Tower: Model : RMA -101 D, TEVA Closed cycle , evaporative system with shell & tube .Its blower motor permanently lubricated by bush bearing (2Z) , Motor = 3 nos. @ 1.1 Kw Size : 680 x 1270 mm. Two parts wt = 800 + 1300 = 2100 Kgs. Piping System :

Total length : 345 ft.

Size : 80 mm , 40 schedule , 40 BAR Grade : 304 L

Welding: V- shaped, SS filler rod .

MS 18” header with Grid system (by pass with HP # 1)

Hydraulic test : 55 Bar , Holding Time : 4 hours, by water.

Points / Aspects. ABC HP COMPRESSOR IR HP COMPRESSOR

1. Space Less More

2. Starting load Less (Due to LP air connected) More

3. Cooling system Good (Closed cycle) Poor, open

4. Dryness of air Good , 3 deg C Up to 8 deg C

5. Power consumption Less than IR, due to VSD drive

6. Air Filter 16000 hrs 8000 Hrs

ABC main motor is 280 Kw, 10 Kw bigger than IR. Equipment setup on base are more complex.

Plant Safety

1. PPE ( safety shoe, tight dresses)

2. SOP

3. CO2 Fire Extinguisher

4. Proper earthling by two 90 RM copper cables.

Main Feature of ABC HP Compressor

Re-Engineering for HP Air Compressor.

HP Comp#3

Description: As per design schedule we had to made a header by SS 18 inch pipe (40 schedule). So as per design we tried to collect it locally ,

but it was not in local market.12 inch SS pipe is available and market price is 22,000 Tk per feet. Our demand was 20 feet , total price = 22000

x 20 = 44,0000 Tk. KAIZEN WORK : We decided to make header by MS alloy pipe which

will be same as SS 40 schedule pipe. MS pipe price is 4000 Tk per feet. Here total cost = 80000 Tk.

Total save = 440000-80000 = 360,000 Tk.

So it is re-engineering to select metal.

Ammonia Plant Installation Date: 27:12:2014

Commissioning Date: 05.01.15

Plant Origin : DCE Refrigeration Pvt Ltd, India.

Capacity: 676000 + 220000 = 896000 Kcal/Hr(296Ton)

As chilled water = 223.4 Ton, Glycol water = 72.7 Ton.

Chilled water temp = 7 deg C.

Glycol water temp = -4 to -2 deg C.

Total Connected Load:

Space Required : 25’-0” x 45’-0” x 22’ -0”.(LWH)

Type of Plant : Vapor Compression type.

NH3 # 1

Machinery & Equipment List of NH3 Plant

NH3 # 2

1. Refrigerant Compressor 2. Discharge valve 3. Non –return valve 4. Oil separator 5. Discharge header. 6. Condenser 7. Liquid receiver 8. Surge Drum 9. Evaporator 10. Suction header 11. Cooling Tower 12. Tanks 13. Pumps 14. Controlling devices 15. Fittings 16. Panel board

FLOW DIAGRAM OF NH3 PLANT

NH3 # 2 NH3 3

Machinery & Equipment List of NH3 Plant

NH3 # 2

Refrigerant Compressor: Brand: KIRLOSKER, Type: Reciprocating, Model: KC-4, Single stage, 4 cylinder,

Operating system: Belt drive, Motor 90 KW, 1, 2 No cylinder direct loading & 3 for 75% and 4 no cylinder 100% on load. Cylinder head water cooling. Suction = 80 mm, Discharge = 65 mm.

Working pressure status: a). Low oil pressure alarm = 1.5 Kg/cm2

b). Low suction pressure = 0.5 Kg/cm2

c). High Discharge Pressure = 15 Kg/cm2

Power Status: a) Amp at Load = 65 Amp @ 50 % Load. b) Amp at unload = it is running always at 50% load. It start at unloading condition, after oil pressure raise (2 Bar) , goes to

loading with 2 cylinder i.e. 50%. Then after load condition rest of cylinder will open @ of load 75%(3 Cyl) and 100%.(4 cyl).

NH3 # 4

Machinery & Equipment List of NH3 Plant

NH3 # 5

Condenser: Brand: LAVA, Type: PHE, Model: MK15-144 PLTS, Capacity = 887770 Kcal / Hr Qty = 1 No Medium = Vapor NH3 and CT water. Brand: LAVA, Type: PHE, Model: MK10-82 PLTS, Capacity = 307274 Kcal / Hr Qty = 1 No Medium = Vapor NH3 and CT water. NH3 Liquid Receiver: Metallic cylindrical , Design code: ASME SECT VIII DIV 1, ED 2007,ADD Fluid : Ammonia, Design Pressure: 21 Bar, Working Pressure = 15 Bar, Wt

= 610 Kg, Wr. Wt = 750 kg. Fitting pipe = 40 Sch, Plate Thickness = 8 mm, Painting: a) Primer = 2 coats of red oxide, primer. 30 -40 micron

b) Intermediate = 2 coats c) Final = 2 coats

Machinery & Equipment List of NH3 Plant

NH3 # 2

Evaporator: Brand: LAVA, Type: PHE, Model: MK15-136 PLTS, Capacity = 676000 Kcal / Hr Qty = 1 No Medium = Brand: LAVA, Type: PHE, Model: MK10-124 PLTS, Capacity = 222000 Kcal / Hr Qty = 1 No Medium = Liquid NH3 and Hot Chilled water. Surge Drum:

Machinery & Equipment List of NH3 Plant

NH3 #7

Cooling Tower Type: Evaporative , Counter Flow. Sprinkler speed = 3-5 RPM. Capacity : 200 RT + 200 RT = 400 RT IN/OUT Let : 6” CT Fan motor = 4 Kw, Drive = Layer of fins = 2 , Fins Height , Dia = CT Pump Motor Specification = 4 Nos Pump ( Stand by 2 Nos) Power = 3 phase, 380 VAC, 15 KW. Flow rate = 120 M3/Hr. Head = 30 M Inlet / Outlet = 5” Type : Reciprocating, inline vertical. Pipe line connection : GI Pipe, Grade B Total No of CT = 2 Nos , Purpose: For NH3 Condenser.

Machinery & Equipment List of NH3 Plant

NH3 # 8

TANKS: CHW = 1, Glycol = 1 Dimension : 1.5 x 3.0 x 1.0 (M), Metal: SS 304, Insulation :Rubber foam

75 mm thick with alu covering. PUMPS:

Sensors & Instrument of NH3 Plant.

NH3 # 9

Name : PET Bottle Blowing Plant.

Capacity: 450 BPM.

Model : SBO 14, Sl # 11779.

System : SBO

Using Medium : High Air Pressure ,35 to 38 BAR1527 M3/Hr(1 Ltr)

LP Air Pressure : @7 Bar 190 M3/Hr

Features : Dual system , CSD & Hotfill

Purpose : For New Dual filler room.

Location : Ground Floor ,CAN Building.

Power Consumption : 324 KW+ 30 KW

Total Power = 480 KW

Chilled water = 12 deg C, 30 M3/Hr

4 Bar pressure

Origin : Sidel, France

At the start of the bottle blowing process, the perform is heated to about

90°C. At this stage it is critical that the neck finish is protected in the oven, as

the incorrect positioning of heat shields could result in distortion of the neck

finish which in turn will affect handling on any air conveyer system on route

to the filling and closure application affect filling. Once heated the perform is

transferred by the neck to the bottle mould. The perform is then initially

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

is located into the centre 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 40bar is applied to stretch

the material sideways into the final shape of the bottle mould. These two

operations must be done sequentially in order to get maximum biaxial

orientation of the polymer chains.

Orientation is the process of aligning the polymer chains in an orderly fashion

by stretching, in biaxial orientation the amorphous polymer (the random

arrangement chains) is stretched in both longitudinal and transverse directions

simultaneously. Biaxial orientation improves both the tensile strength and the

stiffness of the PET bottle.

Preform specification

RESIN

CSD STILL PRODUCT PREFORM

I.V. (dl/g)intrensic viscosity

0.80 – 0.85 0.72 to 0.75 Maxi IV drop = 0.02dl/g

A.A.Acidaldihide < 2ppm < 1ppm CSD / 5 to 6ppm Mineral Water / 3 to 4ppm

MOISTURE PICK-UP After drying < 100ppm Just before blowing

2000 ppm recommended 2500ppm maxi

Preform : injection system at 275o C.

for blowing it hates 90 o C in oven,

PET Bottle Specification 1. Bottle height : a) Mitutoyo height gauge (or equivalent)

b) Roch marble surface standard.

2. Bottle Diameter

a) Pi Tape

b) Caliper Gauge

3. Bottle metarials Distribution by Cutting & Weighting.

a) Hot wire bottle cutter (3 or 4 wires) supplied by SIDEL.

b) Digital laboratory scales (Mettler PR 8100 or équivalent).

4. Volume Mesurement

5. Vertical Compression Strenght.

6. Drop Test

7. Creeping test

8. Burst Test

9. Weight

Sidel blowing

NH3 # 2

Sidel blowing Cycle

Preblow

Nozzle

raising

Difference Between RIP Sidel & AMCL Sidel (SBO -14).

Points / Subject RIP SBO -14 AMCL SBO -14 Remarks

Model SBO Universal SBO Universal HR( Heat Resistance)

PET Bottle Production Type

1. CSD 2. Warm Filling PET. (Filler Temp < 80 o C)

1. CSD 2. Hot Filling PET. (Filler Temp > 80 o C)

HP air Cooling System during blowing in mould.

Nil. No system Available After blowing high pressure air are released by nozzle to cold bottle and mould.

Oven Lamp Infra Red ECO Lamp ECO is good.

Best For CSD CSD & Hot Fill

Difference Between Sidel &RJM

Aspects Sidel RJM(Tech-Long) Remarks

Oven Lamp ECO Lamp IR (Infra-red) Lamp ECO lamp takes low current consumption.

No. of spindle 180 206

Maintenance costs high for RJM

HP Air consumption Less High Sidel has HP air recovery system.

Extra LP Air No need Need More utility need.

Efficiency 95% 75% 18000 BPH RJM machine could not give 18000 BPH. Its maximum output 15000 BHP(incase of RJM-10)

NB: Tech-Long have 5th Generation Blowing machine including Sidel system.

POWER (ELECTRICITY)

SL # Machine Name ELECTRICAL CONSUMPTION, KW

RUNNING LOAD, KW

1 DUAL FILLER PLANT 363.5 285

2 WTP 52 42

3 RO 125 125

4 Ammonia Plant 517.5 365

5 Blowing 480 420

6 HP Air Compressor 300 300

7 All CTs (Process) 80 50

8 All Chillers 40 40

9 Blending 190 175

10 CIP Unit 20 15

TOTAL (CONNECTED) = 2168 KW 1815 KW

GAS RUN

BOILER RUN GENERATOR RUN

PRESENT , CFH BEFORE , CFH PRESENT , CFH BEFORE, CFH

36240 45440 69555 60360

We have increased gas run for 1.5 MW Gas Generator by re-conciliation

of gas using machinery.

Sub-Station

• To face the increasing demand we have installed a 1.5MW gas

generator.

Fig: New 1.5 MW Gas Generator .

Sub-Station

• The LT panel has to modified to 7000Amp.

• Create provision for synchronous run for all generators.

Power Transmission • For the first time we are going to transmit 2.2MW power for

distribution to a separate building named canning building.

Cable Specification:

1 X 500 RM, 53 Nos Run.

Total = 12 Kilometer Cable.

It’s is the biggest cable laying in our group by own employee.

Control room

• The transmitted power will be distributed from the control

room located near to the lift on Ground Floor.

Fig : Verming Proof. Fig : New LT Panel, 4000 A.

Distribution Board

• The power is distributed through the distribution board of

630A to the plant.

Cable Information SL # Machine Name Power Cable Grounding Cable

1 DUAL FILLER PLANT Cable 3x70sm/35rm Cable 1x25rm BYA

2 WTP Cable 3x35sm/16rm NYY Cable 1x16rm BYA

3 RO Cable 3x95sm/50rm NYY Cable 1x120rm BYA

4 Ammonia Plant Cable 1x300rm XLPE, 3x95sm/50rm

Cable 1x120rm BYA

5 Blowing Cable 1x300rm XLPE Cable 1x120rm BYA

6 HP Air Compressor Cable 1x150rm XLPE (D) Cable 1x120rm BYA

7 All CTs (Process) Cable 4x4rm NYY Cable 1x4rm BYA

8 All Chillers Cable 3x50sm/25rm XLPE Cable 1x16rm BYA

9 Blending Cable 3x70sm/35rm

Cable 1x25rm BYA

10 CIP Unit Cable 3x25sm/16rm Cable 1x16rm BYA

Technical info for New Substation.

• LT panel 7000A for Synchronizing Generator

Sp. Incoming 6000A, ACB; outgoing 5000A, ACB one, two 2000A ACB

• LT Panel 6000A for distribution

Sp. Incoming 5000A, ACB; outgoing one 2000A, ACB; twelve 630A

MCCB

• For transmission Cable used 15 run/phase & 10 run for Neutral;

sp. Aluminium Cable 1x500rm XLPE & Al Cable 1x400rm XLPE

• For Distribution cable used 2 run/phase & 1 run for Neutral;

Sp. Al Cable 1x300rm XLPE

Name : Water Treatment Plant.

Capacity : 100 Ton / Hr.

Treatment System : Softening system with ACF.(Activated Carbon

Filtering)

Vessel of Metal : SS 304 L

Purpose : For New 4 AMCL Lines.(Dual , Hot, PE & Alu CAN)

Features : It has sterilization system by LP steam to bacteria kill. Drive

regulated by Inverter.

Location : North – West of CAN Building.

Electrical Power : 40 KW

Steam Consumption : @ 1 Bar, 100kg

Origin : CHINA.

Output Water parameter: 1. Ph = around 6.5 to 7.5 2. Hardness = 0 to 3 ppm 3. Iron = 0.1 4. Free from Bacteria.

Accessories & Required Materials

• Row water pump

• Chemical dosing device

• Dosing tank

• Mechanical filter

• ACF

• Regenerator

• Salty water tank

• WTP valve

• Manual butterfly valve

• Cartridge

WTP pipe

• PLC

• Liquid level switch

• Conductivity meter

• VFD

• Control cabinet

• Sand

• Resin

• Activated carbon

Name : RO Plant.

Capacity : 80 Ton / Hr.

Treatment System : RO Filtration.

Vessel of Metal : FRP, & 13 Nos.

Purpose : For New 4 AMCL Lines.

Features : Drive regulated system.

Location : Ground Floor of CAN Building.

Power : 125 KW

Origin : CHINA.

MEMBRANE Size : 8” x 40” 2 Pass system. Brand: FILMTECH, USA Filter range: 0.0001 Micron. Total Number: 78

Water Network

Accessories Used for RO Plant

• RO unit

• High pressure pump

• VFD

• RO membrane

• Pressure meter

• Flow meter

• Resin valve

• Rising device

• Rising tank

• CIP pump

• Pure water tank

• Breath filter

• Pure water pump

• UV sterilizer

• Ozone pump

• Mixing tower

• Asepsis water tank

• Ozone generator

• RO pipe & fitting

• Flow rate adjusting valve

• Single direction valve

• Pure water tank

Name : Central Air-Conditioning System

Capacity: 50 TR

System : Vapor Compression system & AHU

Using Refrigerant: R-22

Total no of Chiller : 2

Purpose : For New Dual filler room.

Location : Roof of New Building.

Origin : TICA, China.

Pre-filter chamber Bag-Filter Chamber HEFA Filter Chamber

Cooling Coil Chamber

CT OF DUAL FILLER

NH3 # 2

Central Blending

1. 16 Ton per hour syrup process system for DUAL Filler.

2. 12 Ton per hour juice process system for HOTFILL.

3. 6 Ton per hour juice process system for ALU-CAN.

4. 5 Ton per hour Yogurt process system for PE-Lassi Line.

Blending Process

Proper Clean In Place (CIP) & Sanitation Ensure System Sterility

CIP Cycle Example: Hot water (>60°C) circulated for 10 minutes

Hot caustic, 80°C circulated for 20 minutes (with an active alkalinity of at least 2%)

Rinse 5 - 10 minutes with Hot water (>60°C) water

Hot Acid circulated for 20 minutes (with nitric acid of 0.6 - 0.8 % v/v)

Rinse 5 - 10 minutes with Hot water (>60°C) water Rinse 5 minutes with treated water

Hot sanitation step must be performed prior to production start-up

An chlorinated water or acid sanitizer solution must be left in the system during downtime

Merits & De-merits

1. A good team work. 2. Zero accident up to 5000 working hours. 3. Re-engineering. 4. 12 KM Cable laying by own-team.(Newly joint people)

1. GMP Space no consideration. 2. As per VUCA , need UV or Polishing filter for RO & CO2

delivery line. 3. Materials collection was not a good way.

Some Moments.

Fig: Support Fig: Unloading.

Fig: Set up

Fig: Meeting

Fig:Tank setup Fig: m/c setup Fig: Unloading Fig: Pipe welding

Fig: Positioning Fig: Lifting. Fig: Gen Set.

Fig: M/c Base