COMPANY STUDY - Spring Drops (GRP 3)
COMPANY STUDY - Spring Drops (GRP 3)
COMPANY STUDY - Spring Drops (GRP 3)
School of Engineering
Industrial Engineering Department
Submitted by:
Submitted to:
CHAPTER 1 3
INTRODUCTION 3
About the Company 3
Company Location 4
Products or Service Description 5
Target Market Description 7
CHAPTER 2 9
CHAPTER 3 29
CHAPTER 4 31
Pictures of the Working Group 31
REFERENCES 34
BIBLIOGRAPHY 37
1
GLOSSARY OF TERMS
Backwashing - The process of reversing and increasing the flow of water through a filter to
agitate the filter media and dislodge any trapped particles.
Filter media - the portion of a filtering system that separates unwanted particles from the
substance being filtered.
Ion Exchange - A reversible chemical reaction wherein an atom from a wastewater solution is
exchanged for a similarly charged ion attached to a static solid particle.
Metropolitan Cebu Water District (MCWD) - A government owned and controlled corporation
that supplies water for the four cities and four towns in Metropolitan Cebu.
Microns - Short for micrometers; a length of measurement equal to one millionth of a meter.
Often used to measure the size of particulates that are filtered from water.
Osmosis - The movement of water molecules from a region of low concentration (dilute) to a
region of high concentration (concentrated) through a semipermeable membrane.
Reverse Osmosis - The opposite of osmosis; the movement of water molecules from a region of
high concentration (concentrated) to a region of low concentration (dilute) after application of
pressure through a semipermeable membrane
TDS (Total Dissolved Solids) - These consist of inorganic salts, principally calcium, magnesium,
potassium, sodium, bicarbonates, chlorides, and sulfates and some small amounts of organic
matter that are dissolved in water.
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CHAPTER 1
INTRODUCTION
Since the company’s debts, losses, and liabilities along with all its profits belong
to Albert, he is the sole proprietor of Springdrops. Albert, along with his two other
employees, are legally registered in the City Health department. Currently, Albert
recently opened a purified ice and ice cream shop right beside his refilling station about
four months ago, expanding his business.
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B. Company Location
4
Figure 8 - Springdrops and the newly opened Springdrops Purified Ice.
1. Purified Water
Springdrops water refilling station provides high quality purified water that
undergoes a thorough filtration process to remove impurities and contaminants.
This ensures that the product is safe and clean for the consumers.
2. Dispensing Equipment
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Figure 10 & 11 - Branded water dispensers offered by Springdrops.
Customers are asked to provide their own container upon picking up their
water container as per order. If not, customers have the option to buy a new
water container from them.
4. Bagged Ice
5. Ice cream
Next to the ice storage cooler is the ice cream refrigerator which they
franchised from another company; also an additional sideline product.
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Figure 16 - The business’s ice cream freezer.
6. Delivery Service
Their target market consists of individuals and families residing in the Nasipit,
Talamban area. Their primary target includes:
2. Active Individuals: The busy individuals residing the area, who may be working
8-10 hours a day that value convenience as Sprindrop refilling stations offer door
to door delivery to their product, considering their busy work schedule.
3. Residential Homes: They also make a delivery to some area in Dona Rita Village,
beside the Rosedale Commercial Space, providing a constant source for each
household.
5. Students of University of San Carlos: Students aging from 17-30 who studies in
university of San Carlos are their main target market individuals. Students living
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near the area, may it be dormitories, apartments, or their own household.
Springdrops Refilling Station also has a contract to the inside campus of USC
Dormitory making them the main provider of purified water to 392 individuals
living in the said dormitory.
Competitors are everywhere, in nearby areas, and even in distant areas. JMC
Refilling Station acts as their biggest competitor - known to have been the previous
owners of the lot and building Springdrops reside in. The said brand has been in the
industry for a long time already which makes it difficult for Springdrops refilling stations to
stay on top of the line. Considering the long ties the company has adhered to, the strong
brand recognition, as well as loyal customer base. There are also competitors acting
upon despite the distance it exhibits from the area. Refilling stations from the
Cabancalan area to the nearby areas of Nasipit Talamban, as refilling stations in the
Cabancalan area pose delivery distribution of their products to their selling spots.
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CHAPTER 2
The manufacturing process of Springdrops starts with the initial preparation steps
before the water treatment process. In the chart, the inputs required for the water
filtration and refilling process are first determined which are the raw materials, labor,
machines, and electricity. The process then continues into parts. The first part is the
preparation of the 5-gallon water container the company either receives from refills or
their brand-new water gallon products for sale. In this stage, the preparation includes
cleaning the gallons, but if the gallons have extremely stubborn dirt and residual
build-ups, then it is soaked in a chlorine and water mixture (with the chlorine making up
1⁄4 of the overall water mixture) for 2-3 minutes then washed with basic dish soap for 2-3
minutes. However, if the gallons have minimal dirt, then the next process of cleaning
them with dish soap will be implemented. The second part is the backwashing of the 3
pumping filters which would take an hour per filter making this process quite lengthy and
causing a delay in the overall manufacturing process. The third part is the pre-filtration of
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the raw water supplied by the Metropolitan Cebu Water District (MCWD). Once the
backwashing of the filters and the pre-carbon filtering of the raw water, the process then
proceeds to filtration.
The next stage of the process will be the water treatment. The pre-filtered
reserve water is pumped to the water filtration system using the centrifugal pump taking
into account the amount of sodium ions needed in the brine tank. If the sodium ions are
depleted, then the brine solution tank is regenerated with 4-5 kg of industrial salt then
proceeding to the next process. If the sodium ions are not depleted, then the next
process continues. The pre-filtered water will then enter the ion-exchange water
softener, the multimedia filtration, and through the carbon block filtration. Once it has
undergone the pumping filtrations, it proceeds to reverse osmosis where the wastewater
is separated from purified water and expelled from the process. The wastewater
comprises 60% of the output. After the reverse osmosis, the water will continue to the 4
filters – it undergoes through the 1st sediment filter (micron 1), to the 2nd sediment filter
(micron 5), to the 1st carbon block filtration, and to the 2nd carbon block filtration, and
then it enters the ultraviolet light purification or sterilization. The output which is the
purified water, consists of 40% of the overall water utilized in the process.
The last stage of the manufacturing process is the packaging and distribution
process. The purified water enters the two reserve product tanks with a capacity of 1,700
liters and 1,200 liters. The purified water is then dispensed from the faucets through
booster pumps. The purified water will then enter the clean 5-gallon container resulting
from the 1st stage of the manufacturing process which is the preparation. This purified
water enters the clean container for about 50 seconds to 1 minute. The filled 5-gallon
container is then sealed with Polyvinyl Chloride (PVC) cap seals by using heat guns
which takes less than 10 seconds. The packaged purified water is then set aside for
eventual pickup or shipment to customers that availed service and products from the
company.
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B. Raw Materials
Raw Water. The main source of the process in making the resulting product,
purified drinking water. It’s mainly tap water that’s usually sourced from groundwater,
which for the general part of Cebu, these waters are sourced from the Metropolitan Cebu
Water District (MCWD).
Slim Water Container with Faucet. Its capacity can usually store up to 5 gallons
of water. Another container choice that comes with a cover and a faucet that allows an
easier transfer of fluids compared to the typical water gallon, however comes in a more
expensive price.
Round Plastic Gallon Container (5 gallons). Used to store the product that is
then to be distributed to the customer, it is made of polycarbonate plastic for its
long-lasting, impact-resistant, and clear properties. Although it is said that polycarbonate
has quite the intrinsic qualities, the overall material is good for both humans and the
environment in a sense that it’s been proven that it does not leach enough bisphenol A
(a hazardous component of plastics) to cause any health concerns and is completely
recyclable at the end of its use. It also usually comes in the color blue, serving a purpose
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in minimizing the light exposure that helps limit biological growth (bacteria and algae)
(Emergency Essentials, 2013).
Round Gallon Container Cap. This is used to close and secure the water within
the container.
PVC (polyvinyl chloride) Heat Shrink Cap Seal. As these are exposed to
directed heated air they shrink into the shape it was placed on, entirely sealing off the
water container, preventing possible leakages and also serving as a safety measure, an
evidence of untampered water.
Hot Air Heat Gun. The heat gun is used to provide hot air to the PVC seal which
allows it to shrink tightly around the head of the container and the cap.
Figure 20 - PVC Heat Cap Seal being shrunk due to heat from the Hot Air Heat Gun.
Plastic Pipes. Usually comes in PVC as the material, and is used to deliver
water supply into the water refilling station.
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Drum Barrel. Drum barrels are used to store water, items, and other fluids. It’s
optional and can be replaced with any other safe storing materials.
Figure 21 - Regeneration Salt stored in a Drum Barrel used in the treatment stage (d).
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Figure 22 - Some of the cleaning supplies used in Springdrops.
Electrical System. These consist of all the elements used to provide electrical
power to keep the production operational.
Stainless Steel Tank. Stainless steel offers great resistance properties against
corrosion whether in pure or contaminated waters, thus, a great and popular choice to
store fluids as it is less likely to crack, rust or freeze. It stores about 1700 liters of raw tap
water and a total of 2,900 liters of the product (1,200 liter tank and 1,700 liter tank).
Figure 23 - (From L-R) Raw water tank, and the other two tanks used for the
product.
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Control System. These include all the switches, control panels, and other
equipment used to control and aid the equipment within the facility.
Figure 24 - The control system for some of the main filtering processes.
Water pump. The water pump is used to aid the transfer of water throughout the
production process.
Figure 25 - The water pump used to pump the water to aid the filtering process.
Piping System and faucets. The pipe system is a set of pipes arranged in a
way that connects consecutive or nonconsecutive processes together for water,
wastewater and other fluids to be transported from one location to another. Some may
lead to a part of the process that requires faucets, which helps control the flow of the
water.
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Figure 26 - (From L-R) Ion-exchange tank, Multimedia filter tank, & Carbon block tank
Multimedia Filter Tank. This filter consists of multiple layers that usually sift
larger sediments then the smaller ones as the water passes further down into the filter.
Carbon Block Filter Tank. The Carbon filters are ideally suited to filter taste,
odors, and contaminants in the water.
Micron 1 and Micron 5. Used to remove sand and large sediments from a water
supply, netting any physical blocks unwanted in the product.
Reverse Osmosis Filter. The reverse osmosis filter reduces a wide range of
contaminants that also removes the sodium used to soften the water.
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Figure 28 - The Reverse Osmosis Filter.
Ultraviolet Water Sterilizer. The sterilizer uses ultraviolet light to purify water by
combating and damaging the DNA of any living organisms, preventing any reproduction
or growth of diseases.
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C. Manufacturing Processes
The manufacturing process of Springdrops Water Refilling Station can be divided into
three stages – the preparation stage, the treatment stage, and the packaging and distribution
stage. The steps of each stage are outlined and explained as follows:
Preparation Stage
a) Backwashing
Backwashing refers to the process of reversing and increasing the flow of water
through a filter. It is a preventative maintenance method used so that the filter media can
be reused. It is applicable for water softening systems, carbon filters, and rapid sand
filters. As filters operate, they trap particles in the media bed. However, water can begin
to cut channels through the media bed and reduce the effectiveness of the filter media.
Backwashing is used to clear the media bed of clogged particles, resettle the media bed,
and eliminate channels that may have formed (Kawamura, 2000). Filters are offline
during the backwash process. Clean water is sent down into the filter tank at high force,
which tosses the filter medium and dislodges any debris. The water then leaves the filter
tank through the control valve and is routed through the drain line. The backwash
process is continued until the water runs clear (Satterfield, 2005). One of the first things
done during the water refilling station’s daily routine is the backwashing of their water
filters. Springdrops refilling station runs their backwash process for an hour, with their
three main water treatment filters requiring an hour each to complete the backwashing
process. According to the owner of the business, backwashing can be run
simultaneously with product distribution so long as there is purified water in the
stainless-steel reserve tanks.
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Figure 30 - A diagram of a normal filtration system’s water flow. The red lines
indicate the flow of water.
Water yet to be processed is taken from the MCWD distribution line and run into
a carbon-block filter before being flowed into a large 1,700 liter capacity stainless-steel
tank to be held until it is filtered for distribution. Carbon block filtration is utilized multiple
times throughout the entire treatment process. For ease of explanation, it is described in
detail in step (f). Springdrops does not manually refill their reserve tank - rather, their
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reserve tank is fitted with float pumps that automatically close their connection to the
MCWD line when the reserve tank is full.
c) Preparation of containers
Round plastic five-gallon capacity containers and slim water containers with
faucets are kept in stock at the business, but they mostly take customers’ existing
five-gallon capacity containers for refill orders. However, the process for their preparation
before use in the packaging of the purified water is the same. The containers are
examined for any dirt or grime. Depending on their level of uncleanliness, they are either
first soaked in chlorine for two-three minutes or washed directly with dish soap for one
minute. Once deemed clean, they are now ready for use in the packaging and
distribution stage.
Figure 33. - A Springdrops employee washes a 5-gallon container with dish soap.
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Treatment Stage
Ion exchange filtration removes undesirable ions from raw water and exchanges
them for desirable ions. It is a process used to soften hard water by exchanging the
magnesium and calcium ions found in hard water with other ions, such as sodium.
Sodium ions are particularly used for the business’s purification process. Ion exchange is
carried out using an ion exchange resin which normally comes in the form of resin
beads. Water passes through a resin bed where contaminant ions in the water are
exchanged with ions on the resin surface, which removes the contaminant ions from the
water and concentrates them on the resin (Askenaizer, 2003). The sodium ions used in
this process need to be periodically recharged to keep the resin from becoming
ineffective. This is done by replenishing sodium brine, a mixture of industrial grade salt
and water, which is kept in a separate closed container close to the purification system.
This is referred to as “resin” filtering by the owner of the business. Ion exchange filtration
is the first part of the business’s main water filtration system.
Figure 34 - A sample of resin beads used in ion exchange filtration. (From Pure Aqua
Inc.)
Figure 35 - A listing of resin filter products from the Atlas Filtri company.
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e) Multimedia sediment filtration
In interviews with the owner of the establishment, he explained that while he was
aware of the filter medium’s properties, he could not accurately describe the specific
stages within the filtration system. Therefore, in the interest of honesty, the multimedia
sediment filtration system that the business uses cannot be accurately explained without
having to make assumptions, which would be unwise due to the diverse nature of
multimedia sediment filtration systems. A general overview of these filtration systems
can be given. Multimedia filters, as the name suggests, are filter vessels with three or
more different filter media. These filter media are ordered in decreasing porosity, weight,
and density. Multimedia filtration is preferred over single media filtration, which often
results in limited use of the media depth due to the distance that filterable particles can
travel. The layering of the filtration bed encourages larger contaminants to become
trapped in the first layer of the filter, while smaller particles continue to sift farther down
into the lower layers. Multimedia filtration is often used before the use of downstream
filtration equipment, such as reverse osmosis membranes. This allows for efficient
turbidity removal and for longer run times between backwash cycles. Multimedia filters
can remove particles down to 10-25 microns.
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f) Carbon block filtration
Carbon block filters (or simply carbon filters) are often used for the removal of
organic compounds that produce taste and odor, pesticides, and other synthetic organic
compounds. Carbon filters contain coal that is heated under anaerobic conditions, which
oxidizes the surface of the carbon, increases its porosity, and allows it to attract and hold
organic compounds. Carbon block filters are used multiple times throughout the process
used by Springdrops for their water purification process. It is used to pre-filter the water
that comes directly through the MCWD distribution line before it is run into their reserve
tank for water to be filtered for distribution. It also serves as the third step in their main
water filtration process, as well as their second to the last step in the process before the
water proceeds to the UV light filter.
Figure 37 - Examples of carbon block filters of differing sizes. (from Global Water
Solutions LTD)
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g) Reverse Osmosis filtration
Reverse osmosis is the first step after the business’s main water purification
system. Reverse osmosis filters are often used to reduce the levels of total dissolved
solids (TDS) and suspended particles in the water. Reverse osmosis is based on the
principle of osmosis, wherein a membrane separates two solutions containing a different
concentration of chemicals. The membrane is semipermeable, which means that it
allows some materials (like water) to pass through it, but not others. Pressure is applied
that causes pure water to pass through the membrane from the dilute to the more
concentrated solution. Reverse osmosis is the reverse of this process, where pressure is
applied to the contaminated or concentrated side so that pure water is forced from the
contaminated side to the dilute side. This process is where wastewater is expelled from
the business through a sewage line. Wastewater consists of 60% of the business’s water
output, with purified water comprising the other 40%.
Figure 39 - A diagram of the process of osmosis. (From “Water Treatment Notes: Reverse
Osmosis Treatment of Drinking Water,” Cornell Cooperative Extension, New York State College
of Human Ecology.)
Figure 40 - A diagram of the process of reverse osmosis in water filtration. (From “Water
Treatment Notes: Reverse Osmosis Treatment of Drinking Water,” Cornell Cooperative
Extension, New York State College of Human Ecology.)
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Figure 41 - A diagram describing the things that can be removed using reverse osmosis. (From
ESP Water Products)
Like carbon block filtration, sediment filtration is used multiple times throughout
the business’s water purification process. Sediment filters are used as the final step of
the main water purification process as well as after the reverse osmosis filtration step
and before the UV purification system. Sediment filters are designed to remove large
particles, such as solid debris and particulates, from the water through mechanical
filtration. Sediment filters act as a net that physically blocks unwanted matter from
entering the water supply. A sediment filter’s capacity for particulate removal is
measured in microns, short for micrometer, which indicates what size particles the filter
will be able to eliminate. Springdrops use micron sediment filters with a rating of 1 and 5
respectively before the UV light purification process, which means that they remove
particles as small as 1 and 5 microns.
Figure 42 - the sediment filtration process. From Wagenet, L., K. Mancl, and M. Sailus, 1995. “Home Water
Treatment”
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i) Carbon block filtration (2 stages)
This serves as the second to the last process of the water treatment stage.
Processed water is flowed through two additional carbon blocks to remove any extra
odor or taste that may affect the drinking experience.
j) UV Light Disinfection
Figure 43. A diagram of how a UV light sanitizer works. (From Aquastream Water
Solutions, image courtesy of Gavin Kingon)
Once purified water has been stored in the reserve tanks, a single stage
centrifugal booster pump serves to flow it towards the faucet system by the front of
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the business used for customer distribution. It takes approximately fifty seconds to a
minute to refill two round plastic five-gallon capacity containers simultaneously with
the two faucets.
Figure 44 - A Springdrops employee watches over two round 5-gallon containers being
refilled simultaneously.
l) Sealing of containers
After the containers have been filled with purified water, they are capped with a
plastic lid and sealed with heat-shrinking PVC plastic and a heat gun for
approximately five seconds to create a breakable seal. This breakable seal indicates
that the product has indeed been sealed and can indicate to customers that it should
not be accepted should the seal be broken.
Figure 45 - A worker from Springdrops sealing a round plastic 5-gallon capacity container with
the heat gun and heat-shrinking PVC plastic.
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m) Distribution of product
Springdrops Water Refilling Station offers two options for product distribution,
either through pick-up or delivery. A window at the front of the business provides
customers with a place to drop off and claim containers to be refilled. A truck with the
business logos delivers purified water to customers who live in farther areas, or bulk
orders of purified water such as dorms or hotels.
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CHAPTER 3
A. Group Reflections
Our experience on this company study has been a very interesting learning
experience. Springdrops' availability in terms of distance has been very advantageous to
us when conducting our initial and follow up interviews. The owner of the refilling station
was also very accommodating to our group and happily answered our inquiries with
precision and detail which is helpful in writing our company study.
We noticed that although Springdrops has little space, the owner, Albert T. Rubio,
maximized the given amount of space with an effective floor layout. He stated in our
interview that the previous owners had pipes and equipment all over the place in an
unorganized manner. But he stated that he invested in remodeling and installing a new
piping to replace the dirty ones. We commend his initiative in doing so because this
decision has led to better overall product quality.
Our group has faced many different experiences in our company study.
Considering this is our first time conducting a company study, we believe there is still
room for so much improvement in the next one. We have to learn to be very attentive to
the entire process of the filtration system of Springdrops. Considering that the entire
distilling system is very long and complex, we had to pay attention to detail so that we
may be able to relay that information into our company study. We will take note of our
shortcomings as a group and hopefully avoid them in our next company study in the
future.
B. Conclusion
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The entire manufacturing process of Springdrops is similar to that of most water
distilling companies. They gather raw materials such as the plastic gallon and raw water
from MCWD and filter through a carbon block filter. Then the water gets treated into
numerous treatment equipments such as the ion exchange softener, multimedia filtration,
carbon block filtration, reverse osmosis, sediment filter (1 micron and 5 micron), carbon
block filtration (1st and 2nd), uv light purification in this specific order. Then the
aforementioned gallons get filled up with the purified water, ready to be sold and
delivered to customers.
Our group is thankful for the opportunities that this company study has allowed
us to experience. Springdrops Although the company is in good hands under Sir Albert
Rubio, our group would still like to discuss some areas in the manufacturing process that
can be improved through our recommendations.
C. Recommendations
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CHAPTER 4
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