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
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Inplant Training at Coca-Cola
College of Food Technology, Parbhani.
INPLANT TRAINING REPORT (01 JAN 2009 to 31 MARCH 2009)
Shashank Joshi QA Manager HCCBL Sanjay Uppadye Team Leader (QA)
Bankim Naik (Factory Manager) HCCBL Baba Shetty Team leader (QA)
Inplant Training at Coca-Cola
College of Food Technology, Parbhani.
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
,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
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
Inplant Training at Coca-Cola
College of Food Technology, Parbhani.
Contents….. 1. Introduction
2. Certificate 3. Acknowledgment 4. About COKE 5. Products of COKE 6. Plant layout 7. Organizational setup
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
Inplant Training at Coca-Cola
College of Food Technology, Parbhani.
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
Inplant Training at Coca-Cola
College of Food Technology, Parbhani.
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.
Inplant Training at Coca-Cola
College of Food Technology, Parbhani.
Raw Water From Well
Pressurized Sand Filter
Raw Water Storage Tank
Solid Contact Clarifier(165 m3)
Clear Well
Pressurized Sand Filter
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
Inplant Training at Coca-Cola
College of Food Technology, Parbhani.
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
Inplant Training at Coca-Cola
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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
Inplant Training at Coca-Cola
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Pressurized Sand Filter
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
Inplant Training at Coca-Cola
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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.
Inplant Training at Coca-Cola
College of Food Technology, Parbhani.
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
Inplant Training at Coca-Cola
College of Food Technology, Parbhani.
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
Inplant Training at Coca-Cola
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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.
Inplant Training at Coca-Cola
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� 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.
Inplant Training at Coca-Cola
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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
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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
Inplant Training at Coca-Cola
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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.
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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
+
Inplant Training at Coca-Cola
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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.
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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
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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,
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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
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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.
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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
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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
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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.
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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
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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
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RGB Line
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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
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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
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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
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• 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
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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
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• 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
o At product changeover
• 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
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o After 30 minutes
o At product changeover
o At package changeover
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• Crown Crimp (Glass)
o At start up
o Every 4 hours
o At product changeover
o At package changeover
• Date Coding (all types of containers)
o At start up
o After 30 minutes
o At product changeover
o At package changeover
• Closure Torque (Glass and PET)
o At start up
o Every hour
o At product changeover
o At package changeover
• Proper Application Test (Glass and PET)
o At start up
o Once per shift
o At product changeover
o At package changeover
• Can Seam Evaluation (Cans)
o At start up
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o Every 4 hours
o At product changeover
o At package changeover
• Air Content (Cans)
o At start up
o Every 30 minutes
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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.
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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
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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.
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Feed water should have following specifications-
• pH should be > 4.5
• Hardness should be less than 5ppm
• TDS should be less than 500 ppm
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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.
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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.
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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.
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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
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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.
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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
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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