Cocacola- automization in production

A PRESENTATION ON...

• Submitted to: - Prof. T.H.Bhatt

• Submitted By: - Ami gajjar (07-0140-2013)

Hritvika Ghadiyali (07-0142-2013)

Pargi Jigisha (07-0148-2013)

Patel Hiral (07-0152-2013)

Patel Riya (07-0155-2013)

PROCESS FLOWCHART

• The dimensions of the liquid content of a

vessel and the dimensions and

arrangement of impellers, baffles and

other internals are factors that influence

the amount of energy required for

achieving a needed amount of agitation or

quality of mixing.

• The internal arrangements depend on the

objectives of the operation: whether it is to

maintain homogeneity of a reacting

mixture or to keep a solid suspended or a

gas dispersed or to enhance heat or mass

transfer.

• A basic range of design factors, however,

can be defined to cover the majority of

cases, for example as in Figure.

MIXING AND AGITATION TANK

BAFFLES

• baffles are needed to prevent vortexing and rotation of the liquid

mass as a whole.

• Four radial baffles at equal spacing are standard; six are only slightly

more effective, and three appreciably less so.

• When the mixer shaft is located off center the resulting flow pattern

has less swirl, and baffles may not be needed, particularly at low

viscosities.

DRAFT TUBES

• A draft tube is a cylindrical housing around and slightly larger in

diameter than the impeller.

• Usually draft tubes are used with axial impellers to direct suction and

discharge streams. An impeller-draft tube system behaves as an axial

flow pump of somewhat low efficiency.

.

IMPELLER SIZE

• This depends on the kind of impeller and operating conditions.

• For the popular turbine impeller, the ratio of diameters of

impeller and vessel falls in the range, d/D,=0.3-0.

IMPELLER SPEED

• With commercially available motors and speed reducers,

standard speeds are 37, 45, 56, 68, 84, 100, 125, 155, 190, and

320rpm.

• Two-speed drives may be required when starting torques are

high, as with a settled sluny.

IMPELLER LOCATION

• Expert opinions differ somewhat on this factor. As a first

approximation, the impeller can be placed at 1/6 the liquid level off the

bottom.

• In some cases there is provision for changing the position of the

impeller on the shaft. For off-bottom suspension of solids, an impeller

location of 1/3 the impeller diameter off the bottom may be

satisfactory.

• A second impeller is needed when the liquid must travel more than 4 ft

before deflection.

APPLICATION

Continuous degassing and

carbonation of Coca-Cola syrup.

PRINCIPLE OF OPERATION

• The Carbonator comprises a

degassing module and a

carbonating module.

DEGASSING

• The syrup is fed to the degassing

tank through a control valve and

an injector. Degassing takes

place by means of pressure.

Oxygen and nitrogen in the water

are expelled by the addition of

CO2.

CARBONATOR

CARBONATION

• CO2 is dissolved in accordance with the saturation carbonation principle.

• This result in the syrup being degassed a second time and carbonated

simultaneously.

• An integrated controller calculates the pressure required and adjusts it

continuously to the current temperature of the drink.

PERFORMANCE RANGE

• Three sizes with an output of 15, 30 and 45 m3/h

• Carbonation in the range of 3 – 10 g/l CO2 (up to 20 °C) with gas loss

minimised simultaneously

• Dosing accuracy for CO2 1 sigma = 0.08 g CO2/l (continuous production)

• Pressure degassing and carbonation are performed in a hermetically

divided two-chamber tank.

CHARACTERESTICS

• Degassing of the product water in accordance with the two-stage pressure

degassing principle, with the first stage in the degassing tank and the second

stage in the saturation carbonation.

• Robust and simple technology without extensive and expensive sensor

technology.

• Main characteristics of pressure degassing: Prevention of water

consumption and little maintenance.

• Continuous mode of operation in the range from 80 to 100 % of rated

capacity.

• Less stress for the operator thanks to the program-controlled performance of

all work steps (production including start-up, shut-down and CIP).

• All product-dependent parameters can be set on the touch-screen and be

saved in the integrated program for type management.

• Type parameters can be saved on a USB stick for use in verification and

documentation workflows.

BOTTLE WASHER

• Empty glass bottles arrived from the market are

loaded on a conveyer belt for washing purpose.

• This conveyer belt leads the bottles to the bottle

washer. Here the bottles are cleaned from inside

and outside surface.

• The whole process is fully automatic and

controlled by PLC system.

Washing Cycle

• The washing cycle consists of distinct phases, depending from the

configuration that best suits the need of the customer.

• Depending from the machine configuration, all along the path of the bottles,

many different stages are realized.

• In the most sophisticated machine version, all the following steps are

included.

1. PRE-WASH:

• Right after the infeed area the bottles are turned upside-down so that

the liquid residuals and loose dirty particles fall out of the bottles .

2. WASHING :

• The bottles are then taken to the actual washing zone which consists of a

certain number of identical detergent soaks – the exact number depends on

the required treatment time.

• Bottle washing is in three essential stages

1. The bottle is immersed in the soak, where dirt is chemically attacked by the

caustic action of the soda, increased by high temperature

2. The bottle is emptied to remove the dissolved dirt and the used solution

3. The mechanical action of the internal jet removes the dirt, which had been

chemically attacked.

3. RINSING :

• The bottles then move on to the rinsing zone, that usually

includes an immersion zone and a set of spraying zones.

• In this zone the temperature is gradually lowered and the

detergent solution is removed, both from the bottles and from

the carrier beams, through dedicated sets of sprayers.

• All the rinsing water is then recovered to the pre-washing

zone. Every spraying zone consists of a set of high pressure

internal sprays and an external shower.

• The bottles enter the

machine on a conveyor

belt.

• At the transfer point, a so-

called “infeed finger” raises

them and pushes them

precisely into the bottle

pocket

LOADING SYSTEM

• Special discharge fingers

transport bottles of all

shapes and sizes without

allowing them to fall and

with little noise onto the

conveyor.

UNLOADING SYSTEM

BOTTLE TRANSPORT

• As the bottles are conveyed inside the machine, they are housed in mild

steel pockets specifically designed to facilitate label removal and enable

perfectly centered spraying on the bottle neck.

• Rotating spraying nozzles

clean the bottle from

different angles of

incidence. This guarantees

that the complete interior is

evenly cleaned.

• The bottle is cleaned from

different angles of

incidence

• Self-cleaning jetting units

INTERIOR CLEANING

• The exterior is cleaned from

above

• Special jetting units deluge the

bottles with water and rinse away

any dirt and caustic residues.

• Double spraying nozzles for the

targeted cleaning of the bottle

EXTERIOR CLEANING

• All machine functions are

controlled by a PLC.

• All componentry is housed in the

main panel, while the machine

operation controls are located in

the console near the operator’s

station, at the in feed side.

• The main operator panel is a PC

based operator.

ELECTRICS AND OPERATOR INTERFACE

• The main advantages of this solution

are:

• A friendly operator interface

• A data acquisition system integrated

in the interface

• The possibility of remote connection

for diagnostics or updating

purposes.

• All cables and electrical components

are properly codified to facilitate

identification.

• The main advantages of

this solution are:

• A friendly operator interface

• A data acquisition system

integrated in the interface

• The possibility of remote

connection for diagnostics

or updating purposes.

ELECTRICS AND OPERATOR INTERFACE

FILLING MACHINE

• The cleaned bottles are now conveyed to the filing machine.

• Different filling machines can have different technologies for

filling the coca cola into the bottles.

• These machines are capable to fill all type of bottles with

varying speed, volume and flow rate.

• For atomization of filling process the bottle fillers have excellent

other features and sensing devices which can be operated by a

PLC.

• Volumetric

• Pressure

• Rotary

• Pressure/Gravity

• Gear Pump

• Gravity

• Vacuum

Two or more methods in a single machine can be utilized for better accuracy.

• Piston

• Fill-To-A-Level

• Cosmetic Fill

• Electronically Controlled Fill

• In-Line

• Combination Fillers

• Automatic/Semi– Automatic

FILLING METHODS AVAILABLE:

FEATURES OF FILLERS

• Stainless steel level sensor for supply tank.

• Adjustable patented bottle gating system (count in, count out).

• NEMA 4 electrical enclosure.

• Main air supply filter/regulator and shut-off with lockout.

• Easy finger-tip controls permit operator easy access to all fill values and settings.

• Stainless steel conveyors with electronic variable speed controls.

• No bottle - no fill electronic controls.

• Easily adjustable nozzle height settings accommodate vials to gallons.

• All supply tanks are specially designed to accommodate fillers with minimum waste of product.

• Portable on swivel casters.

• Requires minimal floor space.

FEATURES OF FILLERS• Finger-tip nozzle positioning.

• Standard operator safety guards are provided with all automatic FILLS-ALL fillers.

• Bottle counter.

• Precision stainless steel nozzle rack.

• Stainless steel leveling screws with floor pads.

• Heavy duty one piece welded stainless steel frame.

• Fully adjustable patented stainless steel conveyor guide rails.

• Programmed electronic microprocessor ensures precision filling and repeatable fast

changeovers.

• Nozzles (and valves) available in several sizes, styles and materials for most

applications.

• Modular design - expandable from 1 to 24 nozzles. Electronic access module (Model

• ECF).Stainless steel screws and hardware are standard.

BOTTLE LOCATING SYSTEM

(NECK-CENTERING)

• A horizontal comb-type bottle

neck centering guide for bottles

with small or irregular neck

openings provides exact bottle

positioning for nozzle entry.

• This adjustable system easily

accommodates a wide range of

container sizes and shapes.

• The bottle locating system is

available for all models ensuring

a trouble-free filling operation.

EXCLUSIVE SYNCHRONIZED DISPENSING SYSTEMS

• Fillers have an exclusive programmed microprocessor and numerous safety

features, ensuring that all functions of the filler are synchronized at all times.

As examples:

1. The filler cannot discharge product unless the proper number of bottles have

entered the filling stage area and until all the previously filled bottles have

left.

2. The conveyor speed can be varied at any time during the fill cycle without

further timer adjustments.

3. Filled bottles cannot leave until the nozzles are completely up and out of the

bottles.

4. Pistons cannot dispense product unless completely aspirated.

5. Filling cannot occur unless nozzles are in the bottles, etc.

• All automatic fillers have an improved

method for feeding and positioning

containers into and out of the filling

stage area.

• The microprocessor counts the correct

number of bottles to be filled, then

closes the gating stage.

• The conveyor automatically stops for a

more gentle fill before filling begins.

• After fill completion, downstream

gating opens and counts the bottles

leaving to ensure a complete cycle.

• Simple control settings allow operator to set the correct number of nozzles being used.

• This system also reduces costly set-up time between changeovers, and eliminates the need

for time consuming no bottle-no fill delay settings.

CONTAINER INDEXING SYSTEMS

DIFFERENT TYPES OF BOTTLE FILLERS

1. Pressure, Gravity and Pressure-Gravity Fillers (COSMETIC/FILL-TO-A-LEVEL)

2. Volumetric Fillers (PISTON FILLER)

3. Compact Volumetric Fillers

4. Gear Pump Fillers

5. Electronically Controlled, Timed-Volumetric Fillers

6. Versatile, High Speed Rotary Fillers

1. PRESSURE FILLERS (COSMETIC/FILL-TO-A-LEVEL)

2. GRAVITY FILLERS (COSMETIC/FILL-TO-A-LEVEL)

3. VOLUMETRIC FILLERS (PISTON FILLER)

4. ELETRONICALLY CONTROLLED, TIMED VOLUMETRIC FILLERS

5. GEAR PUMP FILLERS

6. VERSATILE, HIGH SPEED ROTARY FILLERS

• The crowns are conveyed through a flat

crown feeder into a guide chute, thus

ensuring very gentle treatment.

• The patented crown transfer unit

positioned within the machine offers a

high degree of reliability and crowning

precision.

• In addition, the open design of the

crowning head allows it to be optimally

cleaned, thus guaranteeing a high

standard of hygiene.

CROWNING MACHINE

CAPACITY

• The Crowner can fit crowns on between 1000 78,000 bottles per hour.

• Once the crown has been fed from the crown chute into the

transfer segment, a magnet is used for the further guidance

of the crown.

• A pushing notch is then used to position the crown on the

ejection plunger of the capping head. The crowning head is

lowered until the crown in the crowning throat is placed on

the bottle.

• The bottle then holds it in place. Afterward only the

crowning throat continues to be lowered. In the first phase,

only the force of the guiding springs has any effect on the

crown. In the second crowning phase, the ejection spring is

pressed and the bottle is subjected to an increased amount

of pressure.

• The crowning procedure is completed once the crown has

been introduced 7.7 mm into the crowning throat. In doing

so, the crown is located 1 mm inside the cylindrical area of

the crowning throat and the required crown diameter of

between 28.6 and 28.7 mm has been exactly obtained.

METHOD OF OPERATION

• This completes the crowning procedure. The crowning force

once again drops. The delayed activity of the ejection

• spring guarantees high crowning quality while applying a low

level of pressure on the bottle.

• The plunger is then blocked while the crowning throat is further

lowered over the crown. At this time, the bottle height is also

compensated.

• A bottle which is too tall presses the bottle plate downwards

until the lowest area of the crowning head has been reached.

Controlled by the lifting cam,

• the crowning head is raised again and the guiding spring

pushes the ejection plunger back to its initial position.

DESIGN FEATURES :

• All main parts made of stainless steel

Wst. AISI 304

• Flushing of cap transfer unit and capping

head

• Motorised height adjustment of the

crowner top part with bottle selection

feature

ADDITIONAL EQUIPMENT

• UV lamp for cap disinfection

• Dust blow-off with ionised air and suction

• Additional flushing equipment Your

benefits

PRECISION

• Crowns enter the line with a defined alignment and are precisely positioned on the transfer plate by a draw-in magnet.

DESIGNED FOR PRACTICAL APPLICATIONS

• A bottle-neck centring system ensures that even bottles with inaccurate dimensions are reliably sealed.

CAN BE OPTIMALLY CLEANED

• The capping heads can be cleaned