Internship Report 2018
Internship Report 2018
Internship Report 2018
Submitted By:
Ali Haider
2013-ag-2416
Dedicated to
My Beloved
“Parents”
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Outline:
2 RO Plant 5-7
3 Chemicals Used In RO 7
4 Test Analysis in RO 8-11
Hardness 8
Alkalinity 9
pH 10
TDS 11
5 Standard Chart by PCI 12
6 Sugar Dissolving (Old) 13
7 Sugar Dissolving (New) 14
8 Syrup Room 16
Sanitation Processes For Syrup Tank 16
Required Syrup for different flavours 18
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Introduction of the Company:
Distribution:
In Pakistan, PCI was divided into five functional departments franchising,
marketing, soliciting companies (bottlers), sales operations, and finance.
According to PCI records, approximately 54,000 Pakistani retail outlets sold soft
drinks. Since large stores were practically non-existent in Pakistan, almost all of
these retail outlets were small stores with limited storage capacity.
Business goals
“The global food system is at an inflection point. The vast network of farmers,
traders, processors, suppliers, manufacturers and retailers that feed our world must
embrace change. This year, I have been inspired by the response to our new
Performance with Purpose goals. We understand that there is much more to be
done to achieve our objectives, but we also know that, by working together, we
will succeed in creating a healthier and more sustainable future for us all.”
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RO Plant.
Reverse osmosis is most commonly known for its use in drinking water
purification from water, removing the salt and other substances from the water
molecules. This is the reverse of the normal osmosis process, in which the solvent
naturally moves from an area of low solute concentration, through a membrane, to
an area of high solute concentration. The movement of a pure solvent to equalize
solute concentrations on each side of a membrane generates a pressure and this is
the “osmotic pressure”. Reverse osmosis applies an external pressure to reverse the
natural flow of pure solvent.
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3 . U l t r a - F i l t r at i o n V e s s e l s :
Ultrafiltration is a separation process using membranes with pore sizes in the range
of 0.1 to 0.001 micron. Typically, ultrafiltration will remove high molecular-
weight substances, colloidal materials, and organic and inorganic polymeric
molecules.
4. Ultra-filtration Tank:
From the Ultra-Filtration Vessels water comes in Ultra-Filtration Tank, from that
Tank it goes into the Activated Carbon Filtration Tank. Ultra-Filtration tank Temp.
Is 40C.
5. Activated Carbon Filtration Tank:
Activated Carbon Filter are designed and manufactured with dual filtering media
like sand and activated carbon. These filters can be used as initial unit for industrial
water treatment. It is also used as pretreatment and tertiary treatment of waste
water. Due to its highly developed porous structure and huge specific surface area,
activated carbon has very strong adsorption capacity. It removes bad odors and
Chlorine from water. It is used as a catalyst or catalyst carrier, to find wide
applications in industrial production, agriculture environmental protection.
ACF Inlet pressure= 2 Bar
ACF outlet pressure= 2.5 Bar
6. Micron Filter:
It is made up of Polypropylene fiber and Polypropylene core. Its pore size is 5
micron. It has excellent depth filtration due to micron porosity. Graded pore
structure increases dirt holding capacity and filtration efficiency. Provide a wide
range of filtration application from 1 micro meter to 100 micro meter.
7. Membrane vessels:
These membranes are made up of Polyamide. There are 12 Primary Membrane
Vessels and 10 secondary membrane vessels. Up to six membrane cartridges are
connected together within a pressure vessel. Pressurized feed water enters the
pressure vessel shell and flows through the channels between the spiral windings
of the first cartridge. Feed water pressure is 10 Bar. Some of the feed water
permeates through the membrane and travels a spiral path to the product water
collection tube at the center of the membrane cartridge. The remaining feed
continues through the spiral layers, the length of the cartridge. It then encounters
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the next membrane in the vessel and the process is repeated. The product from
each membrane cartridge exits from the common product tube in the pressure
vessel. The feed water becomes more concentrated as it passes through each
membrane cartridge and exits from the pressure vessel as brine. It Collected in the
Rejected Tank. From rejected tank there is a Recovery Membrane that take water
from rejected tank and try to remove the TDS, then the water contain more TDS
will drain and low TDS water will transfer to the raw water tank. Its pore size is
0.0005 micron. Reverse osmosis will allow the removal of particles as small as
individual ions. The pores in a reverse osmosis membrane are only approximately
0.0005 micron in size (bacteria are 0.2 to 1 micron & viruses are 0.02 to 0.4
microns).
8. UV Light:
It is a reliable means of disinfection which involves exposing contaminated water
to radiation from UV light. The treatment works because UV light penetrates an
organism’s cell walls and disrupts the cell’s genetic material, making reproduction
impossible. UV disinfection can remove the threat to health from water borne
Pathogens without the creation of disinfection by products that can be generated
from drinking water chlorination. From the common bacteria, E-Coli through the
Cryptosporidium Oocysts to Adenovirus, UV disinfection is capable of providing
effective treatment to ensure inactivation of these pathogens and ensure drinking
water is safe.
UV Light Temp= 25C
UV Light Pass= 98%
9. Product Tank:
In product tank treated water is stored. It has 80,000L capacity to store water. From
storage tank water goes into polisher.
10.Polisher Filter:
If any particle remaining in the water, polisher filter will remove it, and then
distribute the water to the Lines.
Chemicals used in RO Plant:
HCL 30-35% for lowering the pH.
NaOH 50% for cleaning.
Chlorine for killing the micro-organisms.
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Anti-scaling used to prevent from scaling in the membranes.
Test Analysis in RO:
1) Determination of Hardness in water:
Principle:
Hardness in water is due to the presence of dissolved salts of calcium and
magnesium. It is unfit for drinking, bathing, washing and it also forms scales in
boilers. Hence it is necessary to estimate the amount of hardness producing
substances present in the water sample.
Apparatus:
Burette
Conical Flask
Magnetic stirrer
Beaker
Pipet
Measuring cylinder
Procedure:
The burette is filled with standard EDTA solution.
Take 100 ml of the given water sample into a clean conical flask.
Add 2-3 Drops of buffer solution.
Add 2-3 drops of EBT (Eriochrome Black T) indicator and Shake well.
Then Titrated against EDTA (Ethylene Diamine Tetra Acetic Acid) from the
burette.
The end point is the change of colour from wine red to steel blue.
The titration is repeated to get concordant titer value.
Volume of Burette Reading Hardness (Final
water sample- value-Initial
Initial Final
(ml) value) ppm
Raw water 2 23 220
Product Water 42 44 20
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2) Determination of Alkalinity in water:
Principle:
Apparatus:
Burette
Conical Flask
Magnetic stirrer
Beaker
Pipet
Measuring cylinder
Procedure:
The burette is filled with 0.02% sulphuric acid
Take 100 ml of the given water sample into a conical flask.
Add 2-3 drops of methyl Purple indicator.
Titrated against the 0.02% sulphuric acid.
The end point is the change of Greenish colour to Dark Purple.
The titer value is noted.
The titration is repeated to get concordant value.
Volume of Burette Reading Alkalinity (Final
water sample- value-Initial
Initial Final
(ml) value) ppm
Raw water 8 31 290
Product Water 42.5 43.5 10
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3) Determination of the pH value of water using a pH meter:
Apparatus:
An electronic pH meter.
Laboratory glassware including volumetric flasks etc.
A wash bottle filled with distilled water.
Buffer tablets of pH 4, 7 and 9.
Procedure:
Make up buffer solutions according to instructions, being careful that the
tablets remain intact until use.
Place about 30 mL of each buffer solution and also of the sample in separate
50 mL beakers.
Place the electrode from the pH meter into each of the buffer solutions in
turn. If necessary adjust the instrument to the pH of the particular solution.
Place the electrode into the sample and record the pH shown on the meter.
Techniques:
Place the electrode into the solution being measured so that the bulb is
completely immersed.
After each use, wash the electrode with distilled water from a wash bottle.
Never leave the electrode standing out of a solution as it should not be
allowed to dry out.
Carry out readings with the pH meter as quickly as possible.
Leave the electrode to soak in distilled water whenever not in use and
change the water at least weekly.
In the event of a bubble being detected in the measuring electrode, it should
be removed by a gentle sweeping movement of the arm. Jerking should be
avoided.
Volume of pH Meter
water sample- Readings
(ml)
Raw water 7.60
Product Water 5.83
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4) TDS (Total Dissolved solids):
Apparatus:
An electronic TDS meter.
Beaker
A wash bottle filled with distilled water.
Standard Solution.
Procedure:
Take water sample in a beaker
Calibrate the TDS probe if not use for a long time of not show the perfect
readings.
Dip probe in the water sample and meter show the TDS Value
Note the readings and repeat this process 3 times for correct value
Clean the probe by distilled water and dip into the standard solution until
next use.
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Standard Chart by PCI:
TDS:
Feed Water <500 ppm 248
Product Water <100 mg/L 27
Rejected Water <1500 ppm 886
pH:
Feed Water <6.8 6.58
Product Water >5 5.44
Chemical Dosage:
Anti-scaling 10-16 ppm 13
Biocide 3-5 ppm 4
Recovery= 78%
Treated Water Analysis:
Taste Ok/Not Ok Ok
Odour Ok/Not Ok Ok
Appearance Ok/Not Ok Ok
Feed water Temp. 25-30C 26C
Hardness Product water <25 mg/L 10
Chlorine 00 ppm Zero
Alkalinity Product Water <50 mg/L 11
UV Transmission >70% 98%
Iron <0.1 mg/L 0
Manganese <0.05 mg/L 0
Raw water Analysis:
Total Chlorine 1.2-8.8 1.38
pH 7.5
TDS 237
Alkalinity 256
Hardness 202
Iron <0.1 mg/L 0
Manganese <0.05 mg/L 0
Silt Density Index <3 1.3
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Sugar Dissolving (Old)
Sugar bunker:
Sugar bunker is the sugar feed unit where sugar is added to the bunker or hopper.
It has 5000 kg capacity.
Bucket conveyor:
It conveys sugar through conveyor with the help of pump from sugar bunker to
contimol tank for mixing with water.
Contimol tank:
Its capacity is 450L. First of all water store in recup tank, water comes from RO
plant store in recup tank. From recup tank water moves through pump at 32°C and
goes into the heat exchangers where it transfer heat with hot syrup and water
becomes hot at 43°C and syrup becomes cool at 46°C from 85°C. This hot water
then moves toward steamer where it becomes hotter at 85°C and enters into the
contimol tank with high pressure. In contimol tank from the upper side sugar enters
and from the side hot water enters with high pressure and dissolves sugar in the
tank. Now our simple syrup is ready.
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Course Filter:
There are 2 course filters of 5mm size. It filters part of plastic bags if coming from
contimol tank.
Fine Filter:
There are 4 fine filters of 1mm size. It filters small particles that ranging in that
size.
Pasteurizer:
Sugar pasteurizer after the sugar has been completely dissolved, pasteurization of
the sugar syrup can take place in a flash pasteurizer for microbiological
stabilization. It increase the syrup temperature at 79°C.
Reaction Tank:
In reaction tank dozing of activated carbon (0.02%) for the removal of unnecessary
odour, flavour and taste.
Filter Press:
There are 2 filter press of 30 micron size. In filter press dozing of Hyflo (14%) for
the absorption of activated carbon. Hyflo makes layer in the filter and absorbs
carbon particles.
Bag Filter:
There are 2 bag filters of 10 micron size. They are effective in removing solid
particulate from liquids where large volumes of contamination are present or for
filtering high viscosity fluids. They are manufactured using high dirt holding
media that provides consistent particle retention. It filters the particles upto size 10
microns.
Heat exchanger systems:
Heat treatment of the sugar syrup through heating to the required pasteurization
temperature (e.g. 85 °C) and recuperative cooling. Syrup enters into the exchanger
at 85°C from upper side and from lower side water moves to cool down syrup.
Adjustment of the temperature profile to the local temperature level and to the
temperature of the available hot and cold water. Constant temperature in the
dissolving tank.
Storage tank:
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Store the simple syrup here for a while then transfer to other tanks to add flavour
and other ingredients to make beverages.
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Syrup Room
Sanitation Processes for Syrup Tank
4 Factors effecting the sanitation process.
1) Time.
2) Temperate.
3) Concentration.
4) Flow rate.
There are 2 types of CIP processes.
1) 3-Step
2) 5-Step
3-Step CIP:
3-Step CIP is done after CAT 1.
CAT1 is not sensitive to microbial growth that’s why we do 3-Step CIP.
CAT1 include:
Pepsi
Marinda
Mountain Dew
Procedure:
1) Pre-Rinsing:
Rinsing with the normal treated water for 5-10 minutes with the velocity of
1.5 m/s at ambient temperature.
2) Cleaning:
Cleaning with hot water at 85°C, Divoflo at 85°C, and 100 ppm chlorine.
Conductivity of Divoflo is 12-15 ms/cm.
Flow rate is 15m3/h and pressure is 3 bar.
Cleaning time is 15-20 minutes.
3) Final Rinsing:
Rinsing with Normal water for 10-15 minutes.
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5-Step CIP:
5-Step is done after CAT3 CAT4.
CAT3 CAT4 is very sensitive to microbial growth that’s why we do 5-Step CIP.
CAT3 include:
7up
CAT4 include:
Aquafina
Slice
String (Follow in CAT1 but due to its strong flavour we done 5-Step CIP)
Tetra pack Juice.
Procedure:
1. Pre-Rinsing:
Rinsing with Normal treated water for 5-10 minutes.
2. Cleaning:
Cleaning with Caustic for 5-10 minutes.
3. Intermediate Rinsing:
Rinsing with Normal treated water for 10 minutes
4. Sanitizer:
Rinsing with hot water at 85°C for 15 minutes.
5. Final Rinsing:
Rinsing with Normal water for 10-15 minutes.
Old Syrup Room:
Storage = 16,000L
Flavour Tank = 20,000L
New Syrup Room:
Storage = 20,000L
Flavour Tank = 30,000L
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Syrup Requirement for different flavours
Pepsi:
No. of units for Pepsi = 1 Unit
Amount of Syrup required = 1703.4L
Amount of sugar required for making required syrup = 1088kg
Final Brix = 52.20
Team:
No. of units for Team = 1 Unit
Amount of Syrup required = 567.8L
Amount of sugar required for making required syrup = 246.1kg
Final Brix = 38.20
Marinda:
No. of units for Marinda = 1 Unit
Amount of Syrup required = 681.33L
Amount of sugar required for making required syrup = 455.4kg
Final Brix = 54.30
7UP:
No. of units for 7UP = 1 Unit
Amount of Syrup required = 567.8L
Amount of sugar required for making required syrup = 369.7kg
Final Brix = 53.30
Mountain Dew:
No. of units for Dew = 1 Unit
Amount of Syrup required = 567.8L
Amount of sugar required for making required syrup = 413.65kg
Final Brix = 58.10
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Sting:
No. of units for sting = 1 Unit
Amount of Syrup required = 1135.8L
Amount of sugar required for making required syrup = 517.1kg
Final Brix = 40.50
Slice:
No. of units for Slice = 1 Unit
Amount of Syrup required = 34.07L
Amount of sugar required for making required syrup = 456.8kg
Final Brix = 13.90
Required Ingredients for different flavours
Pepsi:
Syrup Concentrate Flavour
Water
7UP:
Citric Acid Trisodium Citrate Flavour
Syrup & Water
Marinda:
Sodium Citrate Sodium Benzoate Sunset Yellow Colour
Citric Acid Flavour Syrup & Water
Mountain Dew:
Sodium Citrate Sodium Benzoate Caffeine
Citric Acid Ascorbic Acid Tartrazine
Dew Cloud Flavour Dew citrus Flavour Syrup & Water
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All Lines Processes
Line#1
Capacity: 22,500/h
Oven temperature: 95-105°C
Blow Moulds: 12 Mould
Pre Blowing Pressure: 12 Bar
Intermediate Blowing: 16 Bar
Final Blowing: 28-30Bar
Base Cooling By Air
Washing Valve: 120
Filler Valve: 110
Capper Valve: 15
Shrinking Tunnel Temp.:143°C
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Line#2
Capacity: 18,500/h
Oven temperature: 95-105°C
Blow Moulds: 12 Mould
Pre Blowing Pressure: 12 Bar
Intermediate Blowing: 16 Bar
Final Blowing: 28-30Bar
Base Cooling By Water
Washing Valve: 120
Filler Valve: 110
Capper Valve: 15
Shrinking Tunnel Temp.:143°C
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Line#3
Capacity: 16,500/h
Washing in 3 Steps:
Rinsing with hot water at 55-65°C
Rinsing with Caustic at 85°C
Rinsing with Soft water.
DivoAI used for shiny appearance
Final rinsing in washing bottle at 65-70°C
Filling in bottle at 85-90°C
Crowner: 8 valve
Invertor Time 7 sec.
Cooling take place in 3 steps:
First at 50°C
Second at 35°C
Third at 25°C
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Line#4
Capacity: 20,000/h
Oven temperature: 95-105°C
Blow Moulds: 10 Mould
Pre Blowing Pressure: 10 Bar
Intermediate Blowing: 15 Bar
Final Blowing: 40Bar
Base Cooling Unit: 7.8°C
Filler Valve: 90
Capper Valve: 9
Shrinking Tunnel Temp.: 235°C
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Line#5
Capacity: 40,000/h
Oven temperature: 95-105°C
Blow Moulds: 22 Mould
Pre Blowing Pressure: 12.4 Bar
Intermediate Blowing: 16 Bar
Final Blowing: 30Bar
Base Cooling Unit: 7.8°C
Filler Valve: 160
Capper Valve: 30
Shrinking Tunnel Temp.: 235°C
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Process of all Lines is same.
Syrup Tank:
In this tank the water comes from the RO plant and the syrup comes from the syrup
room and heat it by heat exchanger and then water and syrup mix with each other
in pipes and moves to the syrup tank where from upper side of the syrup tank CO is
mixed in it. This mixture moved towards the filler.
Photoelectric Camera:
In this it check the quality of the preform if any scratch or it is not oval then it
rejected that preform. And the other moved towards the heater.
Heater:
In this there is 9 heater and there is 9 lamps in each heater. In this we have to
soften the preform so it can mold easily. Then it moved towards the blow molding.
Blow Molding:
In this section the soften preform is enter. Then it became long with the help of rod
and then the pressure apply and the preform becomes into required shape of bottle.
And then we cool it from the base. Because if we not cool it then at the filler it
deshape the bottle. And then it moved towards the filler.
Filler:
In this the bottle is filled by valves of filler. Then it moves toward the conveyer.
Conveyer:
In this the bottle moved from the filler to the coding machine and then it moves to
the other sections.
Labeller:
In this the bottle come from the molding section and it label it according to the
required product with the help of glue. The glue is showering at the labeling part of
the bottle and the bottle is rotating and the glue is easily attached. And the label
attached with it.
Coding Machine:
In this we enter the code in the machine. In this machine we place ink and a
solution. When the bottle is passed from it. It code it with the given code. Then it
moves towards the separator.
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Separator:
In this the bottle comes through the conveyer is arranged in that way so that the pet
can form. Then it moved towards the plastic section.
Plastic Film for Packing:
In this the plastic sheet covered the bottles and then it move toward the oven.
Shrinking Tunnel:
In this section the plastic sheet is heated at 135C so that the pet of bottles can form.
Then it moves toward the pet making.
Pet Making:
In this the pet comes from the oven is then arranged and then making a large tray
of pets and then packed it with plastic film and then it is good to go at the market.
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QA LAB
Top Load Test
Stress Crack test
Burst Test
Height Gauge
Hot Wire Cutter
Weighing Balance
Incubator
Thicken Gauge
Polarized light
STANDARDS OF SECTIONAL WEIGHT
PACKAGES SHOULDER LABEL BODY BASE
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QC LAB
Density Meter
Carbo QC
Water Bath
PH meter
TDS meter
Degassing
Torque tester
T.A Testing
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