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SUBMITTED BY:
NISHANT GUPTA
Applied Electronics and Instrumentation
B.Tech. 2011-2012
CERTIFICATE
This is to certify that project work in NESTLE INDIA LIMITED, PANTNAGAR is a bonafide record of work done by Mr. Nishant Gupta under my Guidance in partial fulfillment of the requirements for the training program in 45 days in-plant training as required in 4 years course of B.Tech(Applied Electronics and Instrumentation).
CERTIFICATE
This is to certify that project work in NESTLE INDIA LIMITED, PANTNAGAR is a bonafide record of work done by Mr. Nishant Gupta under my Guidance in partial fulfillment of the requirements for the training program in 1 month.
DECLARATION
I, Nishant Gupta, Student of B.Tech(Applied Electronics and Instrumentation) hereby declare that the project report submitted here is a original piece of work done by me and has not been submitted to any other organization in any means possible. The work was done under the guidance and instruction of mentors in different departments. The projects are the result of my summer training at NESTLE INDIA LIMITED, PANTNAGAR Factory.
NishantGupta
ACKNOWLEDGEMENT
A work is never a work of an individual. It is more a combination of ideas, suggestions, reviews & contribution that cannot be completed without the help of guidance & demonstration. I want to take this opportunity to convey heartfelt gratitude towards all those whose contribution made this training report a reality. Firstly, I would like to thank THE ALMIGHTY GOD for giving me such good luck to get trained in as esteemed plant of NESTLE. Mr. ., The Factory Manager lend me the permission to undergo 6 months training in the prestigious & dignified plant like Nestle, Pantnagar. Thank you Sir. This is to express my gratitude to Mr. Pankaj Kapoor, Factory Engg., who gave me this opportunity, interacted with me from time to time and guided me ahead. I would like to take the privilege to express my gratitude to Mr. Sumant Tyagi (Electrical & Automation Engg.) who shared his tremendous knowledge & experience and guided me at every stage of my training. It gives me immense pleasure in stating that a man of his stature, knowledge and experience is humble enough in making my experience as a fresher full of learning and knowledge at every step. Lastly my special thanks to all my NESTLE INDIA LIMITED, PANTNAGAR team members who have extended their cooperation in making my training at Pantnagar Factory a significant success. I am indebted to many of my friends Apoorv, Sapna, Gaurav, Garima, Tarun, Champa, Nishta, Naina, Sujata, Amita to support me and always being their when I need their help and company.
Nishant Gupta
CONTENTS:
Acknowledgement Introduction Components of Noodle Line Projects Done -: PLC Working of Motors and Process. Study of Transformers & Techniques to remove losses Study in DG(Diesel Generators).
INTRODUCTION OF NESTLE -:
The company dates to 1867, when two separate Swiss enterprises were found that would later form the core of Nestle. In August of that year, Charles A and George Page, brothers from Lee Country II, in the United States, established the Anglo-Swiss condensed Milk Company in Cham. In September, in Vevey, Henri Nestle developed a milk-based baby food and soon began marketing it. In the succeeding decades both enterprises aggressively expanded their business throughout Europe and the United States. Henry Nestle retired in 1875, but the company, under new ownership, retained his name as Farina Lactee Henry Nestle. In 1877, Anglo-Swiss added milk-based baby foods to its products, and in the following year the Nestle Company added condensed milk, so that the firms became direct and fierce rivals.
HISTORY OF NESTLE -:
Nestle is the worlds leading Nutrition, Health and Wellness Company. We are committed to increasing the nutritional value of our products while improving the taste. Since Henri Nestle developed the first milk food for infants in 1867, and saved the life of a neighbors child, the Nestle Company has aimed to build a business as the worlds leading nutrition, health & Wellness Company based on sound human values and principles. Nestle SA, Switzerland is amongst the worlds largest food and beverages companies. The Company is progressively evolving from a respected, trustworthy food and beverage company to a
respected, trustworthy food, beverage, nutrition, health and wellness company. This objective is encapsulated in Good Food Good Life. The Principle activities of the group encompass: beverages, milk products, nutrition and ice cream; prepared dishes and cooking aids; chocolate, confectionery and biscuit; water; and pet care. It has 511 factories in 86 countries around the world. While our Nestle Corporate Business Principles will continue to evolve and adapt to a changing world, our basic foundation is unchanged from this time of the origins of our company, and reflects the basic ideas of fairness, honesty, and a general concern for people.
Indias Most Respected Companies and amongst the Top Wealth Creators of India. During the first half 2004, the company registered a total income of US$ 257.8 million and net profit of US$ 23.73 million. Nestle India is a 61.85 percent subsidiary of Nestle S.A Switzerland and was incorporated as a limited company in 1959. It produces a wide range of products including beverages, prepared dishes in 1959. It produces a wide range of products including beverages, prepared dishes and cooking aids, milk products and nutrition, chocolate and confectionary. Milk Products and nutrition account for around 45% of Nestle Indias total revenues. The Companys beverage products generate 22% of the companys total revenues, while prepared dishes and cooking aids generate 18%, and chocolates and confectionery 15%.
Pazzta Masala & Cheese and tomato, Masala-ae-Magic, Nestea Lemon & Peach, Lemonade, Orange, Frappe, Sunrise and NCVM.
conveyers are distributed to the wrappers and packing take place ultimately.
WRAPPER: There are wrappers in line and each wrapper contains metal detector, gap fill sensor, 1 metering sensor, 2 index sensor and their individual conveyers dispenser, horizontal flow wrap machine, sachet detector, check weigher and overhead conveyer which leads to the packing area. PACKING: Packing of packed packets in cartons is done manually. This is the last step or before storing and transportation. Automatic case packer (Pick, Place Robot) is also installed at Line 7 and there are further plans to have the same on other lines in the near future.
MANUFACTURING -:
Tipping:Tipping is the fast step in the Noodle manufacturing process. Here Flour from the begs is tipping or emptied into the hoper. After tipping, foreign body (FB) removal is done and flour free of any FB is conveyed to the mixers.
Mixing:In the step, thorough mixing and uniform dispersion of various Ingredients (Flour + kansui: solution of sales) is done to from a homogeneous mixture. This homogeneous mixture is essential for uniform Sheet formation at the rollers.
Sheet formation:The dough formed at the mixers is rolled into a sheet by a set of rollers. This Step is similar to a domestic kitchen operation, of rolling the dough into a Sheet for marking chapati/Indian bread. After the last roller, the continuous Sheet is passed through a kiriha/slitter, which slits the sheet into uniform Strands.
Cutting & folding:In this step, steamed noodle is cut and folded to form noodle Cake of prescribed weight and dimension.
Pre Drying:
In this step, noodle cakes are dried by application of heated air. The main purpose of the step is to reduce the moisture content of the noodle cakes which further helps in. Reduction in oil uptake in the noodle cake Reduction in frying time & temperature
Frying:During frying, noodle cakes are fried in an oil bath. In this step, oil penetrates into the product giving it a flavor and also adds Crispiness to the product.
Cooling:The cakes coming out of the fryer are at very high temperature. At this high temperature filling the cakes into packets is not advisable. So to bring back temperature of cakes to ambient temperature, a cooler is used.
Filling & Packing:In this step, filling machine is used to pack the cake and tastemaker sachet into a pouch. The main functions of packaging are: Protect the nutritional and sensory properties of the product. Contain to allow ease of handling, transport and distribution. Creating sales appeal and brand identity on the shelf. Provide convenience and added value to consumer.
WHAT IS CALIBRATION?
There are as many definitions of calibration as there are methods. According to ISAs The Automation, Systems, and Instrumentation the word calibration is defined as a test during which known values of measurand are applied to the transducer and corresponding output readings are recorded under specified conditions. The definition includes the capability to adjust the instrument to zero and to set the desired span. An interpretation of the definition would say that a calibration is a Comparison of measuring equipment against a standard instrument of higher accuracy to detect, correlate, adjust, rectify and document the accuracy of the instrument being compared. Typically, calibration of an instrument is checked at several points throughout the calibration range of the instrument. The calibration range is defined as the region between the limits within which a quantity is measured, received or transmitted, expressed by stating the lower and 2 Calibration Principles upper range values. The limits are defined by the zero and span values. The zero value is the lower end of the range. Span is defined as the algebraic difference between the upper and lower range values. The calibration range may differ from the instrument range, which refers to the capability of the instrument.
performed to a specified tolerance. The terms tolerance and accuracy are often used incorrectly. In ISAs The Automation, Systems, and Instrumentation, thedefinitions for each are as follows:
Accuracy:
ratio of the error to the output, expressed in percent span or percent reading, respectively.
Tolerance:
be expressed in measurement units, percent of span, or percent of reading. As you can see from the definitions, there are subtle differences between the terms. It is recommended that the tolerance, specified in measurement units, is used for the calibration requirements performed at your facility. By specifying an actual value, mistakes caused by calculating percentages of span or reading are eliminated. Also, tolerances should be specified in the units measured for the calibration.
the relationship between the accuracy of the test standard and the accuracy of the instrument under test .
Traceability: All
to a nationally or internationally recognized standard. For example, in the United States,the National Institute of Standards and Technology (NIST), formerly National Bureau of Standards (NBS), maintains the nationally recognized standards. Traceability is defined by ANSI/NCSL Z540-1-1994 (which replaced MIL-STD45662A) as the property of a result of a measurement whereby it can be related to appropriate standards, generally national or international comparisons. Note this does not mean a calibration shop needs to have its standards calibrated with a primary standard. It means that the calibrations performed are traceable to NIST through all the standards used to calibrate the standards. standards, through an unbroken chain of
Uncertainty:
measurement that characterizes the dispersion of the values that could reasonably be attributed to the measurand. Uncertainty analysis is required for calibration labs conforming to ISO 17025 requirements. Uncertainty analysis is performed to evaluate and identify factors associated with the calibration equipment and process instrument that affect the calibration accuracy.
Calibration technicians should be aware of basic uncertainty analysis factors, such as environmental effects and how to combine multiple calibration equipment accuracies to arrive at a single calibration equipment accuracy.
Calibration procedure of instrumentation 1. Pressure Guage Connect the guage to be calibrated on right side of the dead weight tester. Now add weight according to pressure to be appliked on the guage. Now roate the dead weight testers handle in clockwise till weight applied is lifted freely and weight equilant pressure is applied on the guage. Check the reading on the guage corresponding to the pressure applied.
Increase the pressure in steps of 1 kg/cm2 and check the zero and span error.
Attachguage to be calibrated to BSP hose fitting. Switch the indicator ON. Secure that the pressure system is pressureless by opening the valve and zero set the indicator. Turn needle Vent Valve of the pump clockwise until it is tight by hand only. Pump movable handle until the desired vacuum or pressure reading is obtained. Increase hand pressure on handle at the end of the stroke to obtain higher vacuum of item being tested. Turn vernier counter clockwise to decrease pressure reading and clockwise to increase pressure of item being tested. Turn vernier slowly for precise incremental pressure control. Upon completion of testing turn vent valve counter clockwise to release the vacuum or pressure to zero pressure or vacuum and remove the test device from the hose end. Increase the pressur in step of 1 kg/cm2 and check the zero and span errors. 3. By Pneumatic pressure pump
Take one calibrated pressure guage of desired range as refrence. For calibration purpose pressure/vacuum can be selected by change over switch. Generate pressure/vacuum by squeezing handles together and then releasing. Apply this pressure to guage to be calibrated and check for results. Take readings by applying pressure with different kg/cm2. 4. By multifunction calibrator Connect calibrator. Apply the known pressure from the MC%. Check the reading on the guage corresponding to the pressure applied. Increase the pressure in steps of 1 kg/cm2 and check the zero and span error. Tempratue sensor : Resistance temperature detector (RTD) and Thermocouple the guage under test to MC5
Remove the sensor from application are and clean it . Insert the sensor probe in oil bath and connect it with temperature indicator or resistance measure device. Set the oil bath temperature from 500c to 2500c or as per desired range. Compare the reading of oil bath and the temperature indicator or resistance measurement device. Resistance measurementdevice should variate resistance of RTD according to standard Resistance-Temprature chart.