Equipment Planning

Total Equipment Portfolio for a Water Treatment
Plant Factory
1. Bottle Production Process Flow

Plastic performances are made by injection molding, followed by a reheat stretch blow
molder which creates the final shape, followed by inspection and testing of the plastic
bottles to ensure application suitability.
⇒ Raw Materials: - the plastic bottles are made from a light but strong plastic
known as polyethylene terephthalate (PET). Caps are also made from LDPE, HDPE,
and coloring agents.
⇒ Bottle Injection Molding Machine: - the first stage of stretch blow molding is
to heat PET pellets and put them in a mold to form what is known as a "perform."
⇒ Stretch Blow Molding: - the preform is heated again, placed in a

bottle-shaped mold, and "blown" with high-pressure air that pushes or stretches the
plastic against the sides of the mold. A separate piece of plastic is added to the bottom
of the bottle so that it will stand up on its own. Once the plastic bottle has been blown
molded, it is cooled with water, moist air, or liquid
carbon dioxide (CO2) as quickly as possible to prevent it from losing its shape.
⇒ Cap Injection Molding machine: - in the cap injection molding machine the
LDPE and HDPE pellets are mixed with the coloring agent and heated to be put in a
mold to form caps, it has cooled them as quickly as possible to prevent from losing its
shape.
Conveyor belts will transport the bottles and caps from the bottle production room to
the bottling section.
PAGE 1
2. Bottling Process Flow

The first step for setting up the water purification plant is the chemical analysis of the
source of water. After the chemical analysis, the specifications of the purification plant
are set.
➡In the purification plant, the source water is stored in the feed water tank and then
passes through the sand filter for preliminary water filtration.
➡Water then passes through the dosing pump to the chlorination tank where primary
disinfection is brought about by bubbling chlorine gas. Here chlorine is added to kill the
microorganisms in the water.
➡After the chlorination, the water is passed through sand filters for trapping un-
dissolved impurities.
➡The water after sand filtration is passed through Carbon filters for removal of odor,
and color and for de-chlorination (removes chlorine from water). Carbon filters help in
the maintenance of the proper odor and taste of the water.
➡Water then passes through the reverse osmosis module. This stage of the process
makes the water clear of all the contaminations and minute particles.
➡Water is then passed through a series of micro filters comprising 5 microns, 1-
micron, and 0.4-micron filters followed by an ultraviolet disinfection system.
➡After this stage, water undergoes Ultraviolet treatment to avoid any contamination
from bacteria and other microorganisms using UV light
energy.
➡Water then passes through automatic washing, filling, and capping of plants fitted
with an Ozone generator. Here water is filled into bottles.
➡The bottles after capping are shrink-wrapped and packed in corrugated boxes of one
dozen each for 0.5-liter bottled water and half a dozen each for 1 and 1.5-liter bottled
water.
➡After packing, bottles are taken into the warehouse or shipped to the retailers. The
complete process flow is shown in the annexed process flow diagram.
PAGE 2
3. Production Sections
The plant has 5 interconnected subdivisions.
I. Purification Section
Water received from the external source is passed through the purification plant and
stored in a stainless-steel tank. Thereafter it is fed to the bottling section. The capacity
or flow rate is 1000 liter/hour.
The water is processed with multi-stage purification processes such as: -
Sand filter:
Eliminates a load of total suspended solids in the raw water.
Activated Carbon Filter:
removes most of the organic contamination and pesticide residuals from the water. It
also controls the taste and odor of water
⇒ Ultraviolet disinfection (UV): - water is exposed to UV light of wavelength 245

nanometers (nm). A dosage of 16000 microwatt/sq.cm at 40° C for effective
disinfection
Ultrafiltration:
low-pressure membrane process that removes
dissolved organic macromolecules, viruses, pyrogen enzymes, etc. ⇒ Reverse

Osmosis: - eliminates dissolved impurities like unwanted salts and retains minerals
that are essential to the human body
⇒ Ozonation: - is the strongest oxidizer and disinfection agent which acts on a broad
spectrum of microbiological organisms.
⇒ Filtration: - pumps water through a microscopic filter that is rated for a certain size
organism. The standard size rating is the micron
II. Bottle Manufacturing Section

The plastic typically used in most clear pop bottles and water bottles is Polyethylene
Terephthalate (PET or PETE). The PET bottle preforms are blown into bottles and
enough bottles, say 1000 pieces, are kept ready while the machine continues to
produce more during the shift.
High-Density Polyethylene (HDPE) and Low-Density Polyethylene (LDPE) with coloring

agents are also used in this section to produce the caps. The capacity of this bottle
manufacturing section is 1100 pieces of bottles and caps per hour of production using
two bottle blow molding and one bottle perform and cap injection molding machine.
III. Rinsing - Filling and Capping Section

This section receives the empty bottles, rinses them, and fills and caps them. Machine
speed is dependent on the volume to be filled. Bottles are rinsed by means of spraying
pressurized water inside the bottle.
After rinsing, the bottles are loaded into the filling and capping machine one by one.
This section has a capacity of filling and capping 24 bottles per minute for 1-liter bottles
(1440 bottles per day) and is capable of filling 0.5, 1, 1.5, and 2-liter bottles.
IV. Labeling Section

Expiry date and the batch number could be printed on labels prior to their being put on
the bottles. The label will include information such as the name of the product,
ingredients and the chemical composition of the bottled water, name and address of
the manufacturer. The label and the neck sleeve are to be manually put on the bottles
which will then pass through the shrink tunnels so that the label and neck sleeve shrink
and stick to the bottles.
V. Packing Section
This is the final section where a dozen 0.5-liter bottles and half a dozen 1, 1.5, and 2-
liter bottles are packed into a corrugated plastic package. The bottles bound in the
plastic bag are allowed to pass through a heating tunnel which shrinks and packs the
bottles. The packages are then transported to the warehouse to be distributed.
VI. Quality Control Section

It is important to maintain product consistency. Batches of products must contain the
same ingredients in the same quantities and the finished products must taste the same
and have the same chemical composition. Products must be completely free of
contaminants and the bottled product must be clean and ready to be stocked on the
shelves of sellers.
Laboratory technicians (the chemist) test products from each batch produced to ensure
consistency of quality and carry out operations related to the development and
implementation of quality-assurance programs. The chemist designs and administers
programs for health and safety, chemical hygiene, hazard communication,
environmental compliance, medical surveillance, indoor air-quality monitoring,
hazardous waste management, emergency response, and training.
Laboratory
A standardized laboratory should be arranged to assure the constant quality of
cleansing of the drinking water production with a team of experts. The setup would
comprise general laboratory materials and equipment including deionized and distilled
water, analytical balances, refrigerators, ovens, glassware specifications, and filters for
processing samples for organic determinations.
Sampling
⇒ In any consignment all the bottles of the same size and belonging to one batch of
the manufacturer or supply would constitute a LOT.
⇒ Each bottle of the sample would be marked with the necessary details of sampling
and the bottles for bacteriological testing will be marked
separately.
⇒The bottles of the sample should be stored in such a manner that there will be no
deterioration of the quality of the water.
⇒ The bottles for bacteriological testing should be brought to the testing laboratory
within one hour, of sampling. If this is not possible the bottles should be stored at 10 °C
or below and transported to the testing laboratory within 24 hours. In the case of small
units, the original packing would be treated as a sample.
⇒ Sample shall be tested from each lot for ascertaining its conformity to the
requirements of the specification. The number of bottles to be selected from a lot
should be in accordance with the QSAE and ESA
standards.
The production processes for purified bottled water have three major processes these
are summarized as follows:
PAGE 3
EQUIPMENTS NAME:
* Raw water tank
* Water pump
* Sandy Filter
* Activated Carbon filter
* Softener
* Regeneration tank
*.10 mm - 5 Mm filter
* Pressure Pump
* RO filter
*Preform molding Machine
*Blowing Machine
*Filling Machine
* Label Machine
* Xtreme heating machine
*Warping Machine
PAGE 4

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Total Equipment Portfolio for a Water Treatment

1. Bottle Production Process Flow

⇒ Stretch Blow Molding: - the preform is heated again, placed in a

2. Bottling Process Flow

The plant has 5 interconnected subdivisions.

The water is processed with multi-stage purification processes such as: -

Activated Carbon Filter:

⇒ Ultraviolet disinfection (UV): - water is exposed to UV light of wavelength 245

low-pressure membrane process that removes

dissolved organic macromolecules, viruses, pyrogen enzymes, etc. ⇒ Reverse

II. Bottle Manufacturing Section

High-Density Polyethylene (HDPE) and Low-Density Polyethylene (LDPE) with coloring

III. Rinsing - Filling and Capping Section

IV. Labeling Section

VI. Quality Control Section

* Raw water tank

* Activated Carbon filter

*Preform molding Machine

* Xtreme heating machine

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