Feka Pepsi Gonder

BAHIR DAR INSTITUTE OF TECHNOLOGY
FACULTY OF CHEMICAL & FOOD ENGINEERING
4TH YEAR CHEMICAL ENGINEERING
HOSTING COMPANY: GONDER PEPSI-COLA FACTORY
Internship Report and Project By:
1. Fekadu Mazengia……………………………….0701693
2. Tadilo Belete ……………………………….0702316
Submitted to: Mr. Bassazin A.
June 2018
Bahir Dar- Ethiopia

Internship report and project on MOHA soft drinks/Gondar 2010 E.C
Declaration
We would like to declare that we have successfully completed a four month internship
program at Gondar Pepsi-Cola factory. We have stayed from February 05/2018 to June 2018.
This paper includes all requirements of an internship program. We want to assured that this
report exactly belongs to us. We have done a project during the internship program and is
included as part of this report. We were fully engaged to write this report and also to perform
our project. Except we have taken from reference materials all the descriptions,
recommendations are our own. Finally, we are intended to tell you this document is a good
indicator of how much effort we made to go steps forward in the practical world by
integrating it with the theoretical knowledge.
Intern name: Signature: Date:
Fekadu Mazengiaw ----------------- --------------
Tadilo Belete ---------------- -------------
Mentor Signature: Date:
Bassazin Ayalew ------------------ ----------------
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Acknowledgment
First of all thanks to God for keeping all things to be happened in good manner. We would
like thanks to Bahir Dar University for giving this chance to get practical skills & Gondar
Pepsi Cola plant for accepting us to get costless knowledge. There are many people around
that have supported us all the way through and to make things easier. We tank our advisor
Mr.Bassazin Ayalew for visiting and advising us in doing of our project and report. We
thanks for managers and employees of Gondar Pepsi cola company specially the company
supervisor Mr. Nuredin who is supervisor of production for his incredible level of advice,
many suggestions and constant support at every step of this report. This report could not
finalize without his regular valuable suggestion and encouragement. And, we have a great
honor for other employees for their genuine intention to teach us under great motivation.
II
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Executive summary
MOHA soft drink industry S.C is one of the leading competitive companies in Ethiopia
which is found in most Ethiopian region. It has many branches. Among them Gondar Pepsi
Cola plant the one, which is found in Amhara region. Currently Gondar Pepsi cola plant
manufactures Pepsi and Mirinda only. It uses oldest technology, different machines,
materials, human skills and methods to manufacture its products qualitatively and
quantitatively. This report consists of the brief history and profile of our hosting company
including the main raw material used to produce its main products and also the main
customers that use its main products and supplier, consequently its organizational structure
and detail work flow of beverages production activities in each section and the overall
systems of the organization. The report also describes the current practice and activities that
take place in the production Department and other main supportive departments. Project work
on wastewater characterization is done and the document is included in this report. The main
benefits of internship are also included on this report.
The wastewater effluent has different concentration for various samples. During production
period the wastewater has temperature of 280c, PH of 10.93, TDS of 1100 ppm, turbidity of
45.05 NTU and TSS of 60mg/l this is mostly generated from bottle washer. During sanitation
wastewater effluent has average temperature of 330c, PH of 10.87 and TDS of 900, turbidity
of 54.65 NTU and TSS of 75 mg/l.
This document consists of the characterization of wastewater effluent in Gondar Pepsi Cola
Company. The nature of wastewater effluent in GPCP includes physical (temperature, color,
odor, turbidity), chemical (PH, TSS, TDS, COD and BOD), and biological characteristics
which depend on the wastewater discharge section. All those parameters are measured to
characterize the effluent wastewater in GPCP. Caustic soda consumption for washing process
has highest contribution to this wastewater characteristic. These values are compared with
standard and except PH other effluent parameters are acceptable. We recommended for the
company to apply a simple treatment process before discharging the wastewater.
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Table of Contents
Declaration................................................................................................................................................................I
Acknowledgment.....................................................................................................................................................II
Executive summary.................................................................................................................................................III
Table of Contents....................................................................................................................................................IV
List of figures...........................................................................................................................................................VI
List of tables...........................................................................................................................................................VII
List of acronyms....................................................................................................................................................VIII
CHAPTER ONE...........................................................................................................................................................1
1. INFORMATION ON GONDAR PEPSI COLA PLANT.................................................................................................1
1.1 Background of the Hosting Company................................................................................................................1
1.2 Objective of the Company..............................................................................................................................2
1.3 Mission and Vision of the Company...............................................................................................................2
1.3.1 Vision of the Company............................................................................................................................2
1.3.2 Mission of Company................................................................................................................................2
1.3.3 Future Program of the Company............................................................................................................3
1.4 Main Products of Gondar Pepsi-Cola Company.............................................................................................3
1.4.1 The Main Customers/End Users of Its Products.....................................................................................3
1.7 Organization structure...................................................................................................................................4
1.7.1 Responsibilities of the department.........................................................................................................5
CHAPTER TWO..........................................................................................................................................................8
2. PRODUCTION PROCESS OF GONDAR PEPSI COLA PLANT....................................................................................8
2.1 Main Raw Materials and Their Properties.....................................................................................................8
2.2 General Process Flow Sheet of Gondar Pepsi-Cola........................................................................................8
2.3 Main Rooms of Gondar Pepsi Cola Plant.....................................................................................................10
2.3.1 Water Treatment Section......................................................................................................................10
2.3.2 Boiler Room...........................................................................................................................................15
2.3.3 Air Compressor Room...........................................................................................................................17
2.3.4 Syrup Room...........................................................................................................................................18
2.3.5 Bottle Washer........................................................................................................................................21
2.2.6 Filling room............................................................................................................................................23
2.3.7 CIP Method............................................................................................................................................27
2.3.8 Quality Control Section.........................................................................................................................27
CHAPTER THREE.....................................................................................................................................................32
PROJECT WORK......................................................................................................................................................32
3. 1 Introduction.................................................................................................................................................32
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3.2 Statement of the Problem............................................................................................................................36

3.3 Objective......................................................................................................................................................36
3.3.1 General Objective:.................................................................................................................................36
3.3.2 Specific Objective..................................................................................................................................36
CHAPTER FOUR.......................................................................................................................................................37
4. MATERIAL AND METHOD...................................................................................................................................37
4.1 Material and Equipment Used.....................................................................................................................37
4.2 Methodology................................................................................................................................................37
CHAPTER FIVE.........................................................................................................................................................40
5. RESULTS AND DISCUSSION.................................................................................................................................40
CHAPTER SIX...........................................................................................................................................................45
6. CONCLUSION AND RECOMMENDATION...........................................................................................................45
6.1. Conclusion...................................................................................................................................................45
6.2. Recommendation........................................................................................................................................45
CHAPTER SEVEN.....................................................................................................................................................47
7. OVERALL BENEFITS OF INTERNSHIP...................................................................................................................47
7.1 Background of Internship.............................................................................................................................47
7.1.1 How We Get Into the Gondar Pepsi Cola Company.............................................................................47
7.2 Main benefits of internship..........................................................................................................................47
7.2.1 Practical Skills........................................................................................................................................48
7.2.2 Theoretical Knowledge..........................................................................................................................48
7.2.3 Improving Communication Skills...........................................................................................................48
7.2.4 In terms of improving team playing skills.............................................................................................49
7.2.5 Improving Leadership Skills...................................................................................................................49
7.2.6 In terms of understanding work ethics.................................................................................................49
7.2.7 In terms of Entrepreneurship skills.......................................................................................................50
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List of figures
Figure 1 organization structure of the company.......................................................................................................4
Figure 2 general production flow sheet of Gondar Pepsi cola plant........................................................................9
Figure 3 sand filter tank.........................................................................................................................................12
Figure 4 Cartridge Filter.........................................................................................................................................13
Figure 5 polishers...................................................................................................................................................14
Figure 6 block diagram in water treatment room...................................................................................................15
Figure 7 fire tube boiler..........................................................................................................................................16
Figure 8 Air compressor.........................................................................................................................................18
Figure 9 finished syrup reservoir...........................................................................................................................19
Figure 10 solid ingredient of Mirinda....................................................................................................................20
Figure 11 bottle washer..........................................................................................................................................22
Figure 12 water and syrup reservoir for mixing.....................................................................................................24
Figure 13 carbon cooler.........................................................................................................................................24
Figure 14 date coder...............................................................................................................................................26
Figure 15 Drainage System of Gondar Pepsi Cola Plant Wastewater Effluent.....................................................44
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List of tables
Table 1 standard for finished syrup........................................................................................................................21
Table 2 faults on filler and possible causes............................................................................................................25
Table 3 CIP steps for production change...............................................................................................................27
Table 4 Food safety and quality department..........................................................................................................29
Table 5 Summary of Typical Characteristics of Untreated Wastewater................................................................35
Table 6 Wastewater discharges to land or water regulation..................................................................................35
Table 7 values of wastewater characterizations parameters.................................................................................39
Table 8 measurements conducted for TSS determination......................................................................................41
Table 9 comparison of measurements with the standard.......................................................................................43
VII
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List of acronyms
AC Activated Carbon
BOD Biological Oxygen Demand
Bph Bottle per hour
CEO Central Executive Office
COD Chemical Oxygen Demand
CIP Cleaning In Place
CLTS Conventional Lime Treatment Systems
DS Dissolved Solids
DE Diatomaceous Earth
EBI Empty Bottle Inspection
EMS Environmental Management System
GMP Good Manufacturing Practice
GPCP Gondar Pepsi Cola Plant
HACCP Hazard Analysis and Critical Control Point
IT Information Technology
LAB Laboratory
M reading Methyl Purple
Mgr Manager
MOS Micro-Organisms
NEA National Environmental Act
P reading Phenolphthalein
PLC Programmable Logic Controller
Ppm Part per million
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QAS Quality Auditing System
S.C Share Company
Sup Supervisor
TDS Total dissolved solids
TSS Total suspended solids
TS Total solids
TN Total Nitrogen
UV Ultra Violet
WWTP Wastewater Treatment Plant
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CHAPTER ONE
1. INFORMATION ON GONDAR PEPSI COLA PLANT
1.1 Background of the Hosting Company
Pepsi cola traces its origins to 1898 by Caleb Brad ham, a pharmacist in New Bern, North
caroling, created a curative drink for dyspepsia called Pepsi cola – Pepsi cola later referred to
simply as Pepsi was a mixture of carbonated water, cane sugar syrup and an extract from
tropical Kola nuts. To sell this product, Brad ham formed the Pepsi cola company in 1903.in
addition to selling the drink at drug store counters brad ham bottled Pepsi for sale on store
shelved. At this time bottling was a new innovation in food packaging.
Nefas Silk Pepsi Cola is the first Pepsi Cola plant in Ethiopia and was established in 1966 as
a share company with an initial capital of 1 million Birr. The capacity of the bottling line at
that time was 20,000 bottles per hour (BPH). In 1986, the plant was renovated and expanded
to a capacity of 50,000 bph with twin fillers. Total renovation and expansion investment cost
was Birr 6,647,944.00.
Dessie Plant, Dessie soda industry was established in 1952 by and individual owner In1979.
The plant discontinued other soda products and started producing Pepsi Cola, Miranda brand
and carbonated Tosa Water.
Gondar Plant was established in 1961 as ‘Saba Tej’ Share Company, but nationalized in 1975
replacing the old line as stated predicating Pepsi cola, Miranda and Team brands in January
1978. Gondar Pepsi Cola Plant, before nationalization was owned by private individual
produced wilk-fite water. The Ethiopian beverage corporation made a new feasibility study
on Pepsi cola product which got the blessing of the government to erect the currently
operating plant in 1986.
The current Gondar Pepsi-Cola Plant was established in 1986 by the Government owned
Ethiopian Beverages Corporation under license from Pepsi Cola Company. The capacity of
the bottling line at that time was 5000 per hour (bph). The sales area of the plant is north and
south Gondar and west and central Tigray. GPCP’s activity is being managed by General
Manager and under him there four department managers and one supervisor. In all these
departments there are 10 supervisors, who are management team members. The plant
executes its production and sales activities with a total number of 230 permanent and 61
contract employees. The plant is striving for the development and implementation of food
safety management system based on HACCP, to improve its overall food safety performance
and achieve certification to the standard. To achieve this goal, the HACCP study team.
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Which consist of seven members from different departments with different disciplines and
skills, has developed this HACCP plan for best food safety achievements.
1.2 OBJECTIVE OF THE COMPANY

The main objectives of the establishment of Pepsi cola plant in Gondar are:
o Producing good quality of soft drink to fulfill human needs
o Commitments for the production &supply of high quality and safe products that
satisfy the need of customers.
o Creating values to customers and to be owners by making their products the first
choice of the customers.
1.3 MISSION AND VISION OF THE COMPANY

1.3.1 Vision of the Company
The vision of the plant is
o to insure the competitiveness of the company through the sustained innovation of its
infrastructure and work towards information technology focused,
o well managed and led organization for achieving best quality, huge volume products
based on customer’s demand and be recognized as a profitable and growth oriented
company.
o To make each of the Pepsi products to be a drink of first choice amount consumers
and obtainable throughout the Ethiopian market
o To create superior value for its shareholders, its customers and employees
1.3.2 Mission of Company

The mission of the company is to reach, maintain, and expand our national market leadership
through optimal customer service and exceed the expectation of customer /stake holders for
our existing and new products both in quality and quantity. They believe they will
continuously improve their customers need, employees, partners and the communities in
which they serve. These will accomplished through the development of their employees, an
emphasis on cost, efficiency, market expansion and profitability. The company will expand
their marketing and improve their positions by placing emphasis on innovation and
technological to the competition.
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1.3.3 Future Program of the Company

Future program of the Gondar Pepsi-Cola company is to change the place of plant by installing new
machine the plant wants to change its original place from paisa to Azezo to expand the plant and to
satisfy the customer needs market share and fully satisfy Northern part of Gondar and all part of
Amhara region .The installation of machines have started and production will be started next year
1.4 MAIN PRODUCTS OF GONDAR PEPSI-COLA COMPANY

The international PepsiCo Company have more than hundreds of types of food and beverage
Products. But there are only few products of PepsiCo are producing in our country and these products
became well known brands of Pepsi in Ethiopia.
These products are:-
 Pepsi
 Miranda orange
 7UP
 Miranda Tonic
 Miranda Apple
Currently Gondar Pepsi cola plant produces only Miranda orange and Pepsi.
1.4.1 The Main Customers/End Users of Its Products

The plant distributes those beverages for many part of Gondar regime and to all part of north
Gondar and south Gondar. The company distributes its products only for domestic markets.
These are:
 For local customers mainly to the nearest Zone and Woreda towns
 For hotels and individual person.
 Café and restaurant
 Schools and universities
 Merchants
 Governmental and nongovernmental organizations
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1.7 ORGANIZATION STRUCTURE

The plant has their own organization structure to perform their task. And the plant manufactures
currently two types of soft drinks with standard of Pepsi Co international by the following flow
structure.
General Manager
Business unit
Finance Human Commercial Production &

QC &food safety
Mgrs. Resource mgrs. Mgr technical mgr
Sales sup Prod.sup Senior

Cost & budget
Personal sup chemist
sup.
G\account sup. G\Service sup. Procurement

Tech.sup
&store\supplies sup
Warehouse sup
Vehicles maintenance
sup
Fleet sup
Branch manager
Figure 1 organization structure of the company
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1.7.1 Responsibilities of the department

CEO/CHO
 Direct, plan, coordinate, organize, control, and administer the overall operation of the
company.
 Hire and fire personal directly through his delegated management team.
 Represent the company in all fields of activities.
 Approve annual budget justify to the board chairman.
 Keep and maintain proper booking of the company accounts.
General Manager
 Develops strategic plan by studying technological and financial opportunities.
 Presenting assumptions, recommending objective.
 Establishing plans, budgets, and result measurements, allocating resources, reviewing
progress, making mid-course correction.
 Coordinate efforts by establishing procurement, production, marketing, field, and
technical services policies and practices; coordinating actions with cooperate staff etc.
Vehicle maintenance supervisor
 Maintain records and reports as Beasley.
 Maintain tools and machinery used in the maintenance shops.
 Assist mechanics in the ordering and requisitioning of all parts and approve materials
required for the repair and maintenance of district vehicles.
 Maintain an accurate inventory of parts by insuring that issued parts are accounted for
accurately on each work order etc.
Executive secretary
 Provide office support services in order work shire efficiency and effectiveness within
the band office. Such as;
 Receive, direct and relay telephone messages.
 Provide administrator services for the workers
Human Resource manager
 Developing and implementing strategies and initiatives aligned with the overall
business strategy.
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 Bridging management and employee relations by addressing, or give other issues.

 Asses training needs to apply and monitor training programs etc.
Finance manager
 Managing budgets.
 Controlling income.
 Producing long term business plan.
 Collecting, preparing reports, budgets, accounts, and financial statements etc.
Technical manager
 Estimate, plan, scheduling, budgeting, leading technical teams.
 Provide annual spare part availabilities
 Must provide technical training to teams when required and serve as technical monitor
to team members.
Production manager
 Decide date, time
 Forming production team
 Minimizing' through put time's and work in process inventory
 Making most efficient utilization of the available sources for production
 Reducing material handling cost
Quality control manager
 Setting Custer service standards.
 Specifying quality requirements of raw materials with suppliers.
 Investigating and setting standards for quality and health and safety.
 Determining training needs.
 Insure products meet quality and efficiency standards set by the company.
Human Resource Manager
 Developing and implementing HR strategies and initiatives aligned with the overall
business strategy.
 Managing the requirement and selection process.
 Report to management and provide decision support through the HR metrics etc.
Electrical maintenance supervisor
 Plan and estimate electrical jobs.
 Maintain records on electrical jobs and assign to appropriate personnel.
 Examine electrical services for proper working procedures etc.
Mechanical maintenance supervisor
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 Review weekly maintenance schedule

 Review and assign work to maintain employees
 Maintain schedule compliance and priority
 Ensure prompt repairs by responding to emergency break downs
Sales manager
 Implement national sales programs by developing field sales action plan.
 Maintains sales volume, product mix, and selling price by keeping current with supply
and demand, changing trends, economic indicators and conspirators.
 Determines annual unit and gross profit plans by implementing marketing strategies,
analyzing trends and results etc.
Medical and safety & General Services supervisor
 Responsible for monitoring and assessing hazardous and unsafe situation and
developing measures to insure personal safety
 Correct unsafe cuts or conditions through the regular line of authority
 It may exercise emergency authority to prevent or stop unsafe acts when immediate
action is required
 Ensures the site safety and health plan is prepared and implemented
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CHAPTER TWO
2. PRODUCTION PROCESS OF GONDAR PEPSI COLA PLANT
2.1 MAIN RAW MATERIALS AND THEIR PROPERTIES
 Water: - as the main component of a soft drink, usually accounts for between 85−95%
of the product and acts as a carrier for the other ingredients. This water used should be
treated water.
 Sweeter - are a critical ingredient of Pepsi cola products and there use must be properly
controlled which greatly affect the sensory experience.
 Concentrate - receipt and handling must be properly managed ensure good quality
beverage.
 Carbon dioxide - imparts a pungent slightly acidic taste to the finished product as well
as creating greater eye appeal.CO2 to extent used as preservatives.
 Food grade raw materials- These raw materials have direct contact with the product
and they are not toxic for the product. From these: - Sugar, Water, Carbon dioxide,
Flavorant, Common salt, Acidulates and Colorant
 Non –Food raw materials- Those raw materials are not direct contact with the product
and they are toxic for the product mostly they are used for water treatment and bottle
washing purpose .From these:-Activated carbon, Coagulants like Aluminum sulfate
Caustic soda Lime, Lubricant ,Chlorine, Calcium hypo chlorate and Crown cork
2.2 GENERAL PROCESS FLOW SHEET OF GONDAR PEPSI-COLA

In Gondar MOHA soft drink plant there is different sections, these sections are very essential for the
manufacturing of soft drink and they have their own procedure and safety majors to be ready for the
final production .Those sections are:-
1. Raw material reception room
2. Water treatment room
3. Boiler room
4. Bottles washer room
5. Mixing and carbonation room
6. Syrup room
7. Filling room
8. Quality control room
9. Cooling compressor room
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10. Generator
11. Workshop
Sugar
Water treatment
Simple syrup
Boiler room (steam)
preparation
Concentrate
Finished syrup
preparation
Bottle washing
Carbonation and mixing Filling and crowning
Co2
reser
Bottle Inspection
voir
and date coding
Storage
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Figure 2 general production block diagram of Gondar Pepsi cola plant
2.3 MAIN ROOMS OF GONDAR PEPSI COLA PLANT

2.3.1 Water Treatment Section
Water is the main component of a soft drink, usually accounts for between 85−95% of the
product and acts as a carrier for the other ingredients. So this water should be treated. Water
treatment is the process of removing undesirable chemicals, biological contaminant,
suspended solids and gases from raw water and that makes the water more clean and
acceptable for specific end use. The source of the water is ground water and sometimes uses
municipal water. When they have shortages of the ground water they use municipal water
because the municipal water is coasty than ground water and can NOT get sufficiently.
The water treatment selection is depends on the source of water. The raw water supplies are
contaminated by different pollutants when the water affected by pollutant the water may have
suspended solids, Bad odor, Taste and Smell.
In Gondar Pepsi cola plant the source of water supply is the ground water source which is
usually free from natural organic matter but can be high in minerals, alkalinity compounds
such as Ca+ & Mg2+ ,it is also free from external pollution, but it is not pure water there is
growth of microorganisms & minerals unless it can’t be treated. To treat this water MOHA
soft drink Gondar branch uses coagulation system.
The standard coagulation plant offers coagulation with alkalinity reduction, super
chlorination with two hours retention .followed by sand filtration, carbon purification and
final polishing. It is also now required that UV disinfection be the final step prior to filling.
This tank can handle most water treating problems with exception of water with high salts
and total dissolved solids. It also has difficulty removing small sized organic molecules such
as tri-halo methane.
Coagulation in beverage industry, coagulation water treatment technology also known as
convectional lime treatment systems (CLTS). This mechanism can also use to meet different
conditions therefore they remain a valuable treatment used in different manners to meet our
treatment needs. The chemicals used in the water treatment section are mentioned below:-
 Lime: - lime is used for alkalinity reduction. It is also used to increase the pH of the
water. The total alkalinity of the treated water should be below 50 ppm. Lime reduces
alkalinity by converting carbon dioxide to bicarbonate alkalinity, and bicarbonate
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alkalinity to the insoluble forms calcium carbonate and magnesium hydroxide, which
precipitate out of the water.
 Calcium chloride: - reacts with the lime to reduce the water alkalinity. Sodium
alkalinity is present when the total alkalinity is greater than the hardness of the water.
Calcium chloride which forms calcium carbonate from the sodium bicarbonate as the
calcium bicarbonate is formed. In some cases, water contains sodium alkalinity. If
sodium alkalinity is present, it will be necessary to add small amounts of calcium
chloride to get the treated water total alkalinity below the maximum limit of 50 ppm.
Na2CO3+CaCl2 → CaCO3 + 2NaCl
 Chlorine− used for sanitation and to kill microorganism

 Aluminum sulphate: - is the most widely used coagulant for water treatment. At
high alkaline (PH) prevalent in the water these salt produce insoluble aluminum
hydroxide.
Al2 (SO4)3 +6H2O→ 2Al (OH) 3 +3H2SO4
3H2SO4+3Ca (HCO3)2→3CaSO4 +6H2CO3
6H2CO3 → 6CO2 +6H2O
Al2 (SO4)3 + 3Ca (HCO3)2→2Al (OH)3 + 3Ca SO4 + 6 CO2
i. Coagulation Tank
Coagulation (Reaction) tank is the first tank in the water treatment room. The desired
chemical reaction takes place and water is sanitized. Coagulation is a chemically water
treatment process by changes smaller particles in to heavier that is they can quickly settle out.
The aluminum sulfate, lime and chlorine join the raw water as it flows in to the mixing zone
of the tank. The coagulant, usually Aluminum sulfate with the assistance of the chlorine and
lime, forms heavy flock which entraps particles of debris, dirty organic matter and other
undesirable material in the water, and settles slowly toward the bottom of the tank. The flock
forming the lime is causing the alkalinity components (calcium carbonate and magnesium
hydroxide) to precipitate out of the water. The precipitated alkalinity also settles slowly
toward the bottom of the tank. The treated water flows upward toward the treated water draw
off pipe, the flock because of its own weight, is left behind continuously trapping particles of
debris as it settles. The treated water flows toward the treated water draw off pipe and out of
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the tank (toward the sand filter and reminder of the system, while still reserving the benefits
of chlorine. The chlorine in the coagulation tank, in addition to oxidizing organics and in
organics and reacting with ferrous sulfate, is destroying microorganisms so that sanitary
water is assured. The treated water then flows through a sand filter for straining (and removal
of flock particles), a carbon filter to remove chlorine,(and color, odors, tastes and
organics)and final polishing. Terminal ultraviolet disinfection follows the polisher.
ii. Sand Filter Tank
The purpose of sand filter tank is to remove only physical matters and unwanted materials
from the raw water like floating materials present in the ground water. The sand removal
filter tank consists of three layers. At the bottom of the tank there are sands which also called
gravels and they are relatively larger in size. On the medium part of the tank there are also
sands which are lesser in size than gravels and also they cover a few heights above the gravel.
Finally the upper part of the tank is filled with fine sand filters followed by anthracite at top
up that enhances filtration of foreign matter or suspended particles coming with raw water
which may occur during storage at concrete tank. Then the raw water passed through the sand
filter will be stored in three different raw water storage tanks each sized 80m3.
Figure 3 sand filter tank
The treated water that comes from coagulation tank enters in to the sand filter. In this tank
there is small sand that is used to settle the lime. This used to remove the unwanted chemicals
except chlorine from water. In the sand filter we can checked the lime dosage in the treated
water, by using the formula: A= 2P-M
Where: A -is which tells us whether the lime treatment is correct or not
P-is phenolphthalein indicator
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M -is will tell us if all bicarbonate was removed whether we have free lime present.
• When A is positive, that is 2P is >M this implies that free lime is present in the
treated water.
• When A is negative, that is M is> P this implies that bicarbonate is present in the
treated water.
For proper lime treatment A value should be in between 2 and 7.
iii. Carbon filter tank
The treated water that comes from the intermediate tank is entered in to the carbon purifier.
This is used to remove chlorine by using activated carbon that present in the water. The
presence of chlorine can be changed the color and test of the final product (Pepsi, Miranda,
7up Miranda apple, Miranda orange and Miranda tonic). The chlorine dosage in the carbon
purifier must be in between 6and8.
If the color can be c hanged the water has chlorine, therefore the treated water can be
corrected by removed chlorine before enter in to the polisher. Because if the water that has
chorine is passed in to the process can be changed the color and test of the product.
Regeneration of activated carbon is takes place by the incoming steam from boiler room.
iv. Cartridge Filter (Polisher, 1micro Sized)
This is used to remove suspended activated carbon that comes from the carbon purifier and
other unwanted particle that may be passed through the carbon purifier before transferred to
UV. The filter bag used for filtration is called polisher
Figure 4 Cartridge Filter
The white colored polisher is the new/to be used by replacing the old one that used for one
month period inside the Cartridge filter. Cartridge filter contains five polishers inside it as in
the above arrangement for one month.
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Figure 5 polishers
v. Ultra Violet (UV) Radiation

It is the final treatment for the product water. It is used for destroying any microorganisms
present in water. It’s known as the critical control point for the quality of the water. After
passing through UV, now the water can be used for production purpose, such as syrup
preparation and filling room.
Water storage tanks → Water treatment by Coagulation tank → Sand filtration → Carbon
(Activated) purifier → Polishing → UV → Treated water (fot syrup preparation, filling…..)
vi. Softener Tank

In almost every raw water supply, hardness is present as calcium and magnesium
bicarbonate, often referred to as carbonate hardness.
From the storage tanker water is pumped in to the softeners in which hard water is converted
in to soft water. The main function of the softeners is to soften hard water by eliminating
Mg2+ and Ca2+ ions existing in their carbonate form. Two stage softener used in our factory.
When one works other regenerate it.
In the first softener:
MgCO3+ NaAlSi2O6: H2O → Na2CO3 + Mg (AlSi2O6: H2O) 2
CaCO3+ NaAlSi2O6: H2O → Na2CO3 + Ca (AlSi2O6: H2O) 2
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These reactions are continuous until the active site of sodium in zeolite complex compound is
all occupied by Mg and Ca. The structure contains a relatively large central open area which
allows large ions or other molecules to move through or reside within its frame. As a result,
sodium zeolite can function as a chemical sieve. During the reactions since alkali metals are
more active than alkaline earth metals; Mg and Ca are displaced from their carbonate
compound by Na to form Na2CO3. Na2CO3 does not have an effect on the hardness of water.
In the second softener: In this softener sodium zeolite is regenerated by adding brine solution
Mg (AlSi2O6: H2O) 2 +NaClNaAlSi2O6 → H2O + MgCl2
Ca (AlSi2O6: H2O) 2 + NaClNaAlSi2O6: → H2O + CaCl2
Softened water obtained from the softener is transferred in to different rooms; such as boiler
room, washer room and cooling room, chiller.
Lime
CaCl2
Al2 (So4)3
Coagulation tank
Raw water
Softener Softener tank 2

tank 1
Cl2
Brine solution
Soft water
Sand Filter
Treated
Cartridge filter
water UV
Carbon purifier
Figure 6 block diagram in water treatment room
2.3.2 Boiler Room

This room is one of the company’s essential units. It mainly produces steam for syrup room,
bottle washer and sanitation. The main parameters used to produce steam are:- Furnace
(Heavy oil), soft water and LVG gas. The reason behind for choosing furnace over fuel
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(Light oil) is that it is cheaper than fuel. A boiler or steam generator is a device which is used
to create steam by applying heat energy to water. This generated steam has different
functions in different sectors of the company.
Such as;
o for heating caustic soda in washing room
o To dissolve sugar in syrup room.
o Sanitation
There are three types of boilers namely, fire tube, water tube and electrical tube boiler. The
plant uses fire tube boiler to produce steam. Fire tube boiler flame is move inside the tube and
water is on the outside of the tube meaning on the shell side, while water tube boiler water
moves inside the tube and flame on the outside of tube.
Figure 7 fire tube boiler
A boiler machine requires different raw materials to produce steam. These raw materials
possess combustion process. During combustion the heat energy is produced. This heat
energy is applying to the water inside the boiler tanker, then the water heated more and more
it changes to steam which is required product.
The boiler machine requires sensor solenoids which controls the amount of water present
inside its tanker. This simply indicates that when the amount of water present in its tanker is
less, it opens the water valve from the reservoir water tanker, and when it is excess amount of
water, it closes the reservoir water tanker. These two values are sensitive materials.
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2.3.3 Air Compressor Room

An air compressor is a device that convert power (using an electric motor, diesel or gasoline
engine, etc.) in to potential energy stored in pressurized air, (compressed air) having the
following futures;
In take air filter: - prevent dust from entering a compressor, if the dust is gate in to the air
compressor machine, there will be un masked for sticking valves, scoured cylinders,
excessive wear etc.
Inter stage cooler : - reduce the temperature of the air before it enter the next stage to reduce
the work of compression and increase efficiency they are normally water cooled.
After cooler: - is used to remove the moisture in the air by reducing the temperature in a
water cold heat exchanger.
Air dryer: -the remaining trace of moisture after cooler are removed using air dryers. So by
using this machine (Air dryer) the moisture content will be removed.
Moisture drain trap: -is used for removal of moisture in the compressed air.
Air reservoir tank: - is serving as storage of compressed air
By one or several method an air compressor force more and more air in to a storage tank,
increasing the pressure. When tank pressure reaches its upper limit the air compressor shuts
off, the compressed air can be used for a variety of applications like: - utilizing the kinetic
energy of the air as it’s released and the tank depressurizes. When the tank pressure reaches
its lower limit, the air compressor turn on again and pressurizes the tank.
Due to adiabatic heating air compressor requires some method of disposing of waste heat.
This is some form of air or water cooling, although some compressor way is cooled by oil.
Generally in Gondar MOHA soft drink Company the air compressor is cooled by water, also
its have 2 compressors and it works with 3 phase motor.
In order to treat or clean the moisture content of the air is gate in to dryer machine. The oil is
used for the shafts or gear that drives by the motor so the oil is smoothest the shaft or the
gear.
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Figure 8 Air compressor
Use of Air Compressor in Gondar MOHA Soft Drink S .C

 Cleaning of the bottle
 Push the piston of the bottle on filling beverage
 Dry the moisture on the bottle by using video jet
 Cooling the beverage
2.3.4 Syrup Room
Syrup is a condiment that is thick, viscous liquid consisting primarily of a solution of sugar in water
containing large amount of dissolved sugar. Syrup preparation starts from simple sugar dissolving
tank and ends in final syrup tank.
i. Syrup Preparation Detail
The process of syrup preparation is started from sugar treatment. The sugar is comes from
India, Brazil, Dubai, Italy and Netherland in order to fulfill the quality of PepsiCo standard.
Then this sugar is stored in the sugar storage room. For the treatment process we have to use
hyflo or diatomite and activated carbon.
The process is started from adding of sugar in the sugar dissolving in tank the tank have 700L
of water with 600c of temperature, then 1,128 kg of sugar is added in to the tank, in addition 4
kg of activated carbon and 2 kg of Sylatom is added in the sugar dissolving tank, then agitate
in order to mix and weight until the temperature is rise in to 80 0c. The activated carbon is
important for the odor and removing un-wanted thing in the sugar. Sylatom or diatomite is
use full to catch the activated carbon. In the other tank hyflo will mix with water in the tank
in order to catch up or separate the activated carbon from sugar in the candle filter tank.
Through circulation the mixture of dissolved sugar and hyflo will be contact in this candle
filter then the activated carbon will be coached by this hyflo then the pure sugar will be pass
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through the heat exchanger in order to loss its hotness temperature and gating to the syrup
room. After all this process the simple syrup will be produced.
There are two types of syrup preparation in the production of soft drink plant, those are: -
o Simple syrup: - Is the mixture of water and granulated sugar
o Finished (final) syrup: - In this unit there are huge tankers and they used to store and
Convert the simple syrup in to the final syrup, but before these it should be cheek the brix
and the amount of simple syrup. The next step is adding of flavor and other ingredients in
to the tanker, but those ingredients are different for different soft drinks. Then agitate
until the components are mix and it’s have a manual or standard for this work, so the
chemists cheek the quantity and quality in every 4 hours, after all this final syrup will be
produced.
Figure 9 finished syrup reservoir
ii. Preparation of Pepsi

Pepsi which have Pepsi acidulate, Pepsi flavor, Sucrose granulated and treated water
ingredients are very essential, and the first step is adding of 700L of treated water at 60 0c in
to sugar dissolution tank, then we begin agitation by this time dissolve 1,128 kg of sucrose
granulated in to sugar dissolution tank and by using agitator we mix it and also the
temperature will be rise in to 800c .at this time the simple syrup will be produced so it should
have to cheek or test the color, turbidity and brix of the simple syrup, then transfer simple
syrup from the dissolution tank through filter to the syrup mix tank. After agitation the next
step is adding of 18.930L (24.730) kg of acidulates to the syrup mix tank, then rinse Pepsi
acidulates container with 4.000L (3.989) kg of treated water and transfer in to the syrup mix
tank. Next 3.785L (3.918)kg of Pepsi flavor will be added in to the syrup mix tank and rinse
Pepsi flavor container with 4.000 L of treated water and transfer in to syrup mix tank , and
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agitate until mixed.[from the workers] After this entire step stop agitation of syrup and test
the brix, total volume and specification of finished syrup. Then hold the syrup for 24 hrs.
iii. Preparation / processing instruction for Miranda
Syrup preparation for marinade orange and the Ingredients for Merida orange: -
Figure 10 solid ingredient of Mirinda
o Citric acid it’s organic acid that prepare acidic media and preventing from mold and
bacterial contamination
o Sunset yellow: it’s a chemical that bring the desired color for the final product
o Sodium chloride: it contribute for the better test of the product and also for long shelf
life
o Potassium sulfate: it’s a chemical that makes our product soft drink & makes it sharp
o Benzoate: it’s a preservative that use to prepare our product
o Liquid Flavor: that brings the desired orange flavor to our product.
Dissolve 0.940 kg of sodium benzoate in 4 L treated water, then add to the tank and agitate
until completely mixed. Then add 11.70kgs of citric acid anhydrous, 1.360kg sodium
chloride, 0.680kgs of potassium sulphate, and 0.345kgs of sunset yellow (color) and mix
them with the agitator and then add orange flavor (30.05kgs). This is for 2 unit finished syrup
preparation which is 1280L in volume. Finally, the brix of the syrup test by chemists and if it
fits to the standard; it will go to production line.
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Table 1 standard for finished syrup
Batch No Pepsi cola Miranda orange

Water for dissolving(L) 700 450
Water for pushing(L) 100 25
Sugar used(Kg) 1128 858
Simple syrup brix(%) 53.4-54.1 62.7
Finished syrup brix(%) 53.7 59.1
Flavor (unit) 1 2
Celatom or DE 16 16
Simple syrup volume(L) 1600 1180
Finished syrup volume(L) 1700 1200
2.3.5 Bottle Washer

The bottle washer clean and sanitize returnable bottles that have been brought back from the
trade. Returnable bottles are rinsed to remove beverage residues, straws and any liquids or
suspended material. High strength of caustic, caustic based detergent, or caustic with other
additives, at elevated temperatures are used to clean and sanitize the bottle. The bottle washer
takes dirty bottles from the trade and subjects them to:
o Water and caustic rinsing
o Soaking periods in hot caustic
o A number of inside and outside fresh water flushing’s with sanitary
Water to deliver a clean and sanitary bottle to the conveyer ensure route to the filler. For glass
bottle extending soak time can allow a slight reduction in the basic requirements. Washed
bottles that exist the washer should be checked for caustic carry over at start up and during
operation. Checking for caustic carryover should be performed at start up and twice per shift,
testing a complex row of pockets at the bottle discharge station of the bottle washer and
during production every two hours 3 additional bottles should be spot checked. Generally the
washer section is the major part of the company. In this section the process become started by
selecting the most defect bottles by using manual inspection then transfer in to the washer
machine by using bottle conveyor. The soap can be added in to the conveyor in order in to
reduce friction between the conveyor and the bottles. then the bottle is intend in to the washer
machine.
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Figure 11 bottle washer
This machine uses different chemicals for washing bottles. These are:-
o Steam: which comes from the boiler room
o Caustic soda: for washing bottle after dissolving in a dissolving area with water at 75
up to 82 degree centigrade.
o Water: comes from water treatment room.
o DIVOBRITE: - It is a chemical used to strengthen caustic soda during washing. It will

be added in each 5minute in caustic one and in each seven minute in caustic two for
15 seconds.
o DIVO LE: - This chemical is used to remove scale formed during the drainage and
also in addition it uses to dry the jolliness’ and the foam occurred because of the
caustic.
o DIVO NP: -It used to control the PH value of the water in the bath.
o Chlorine: - It used as disinfectant. It is added on warm water and it kills
microorganisms if any.
NB: - DIVO LE & DIVO NP are both added on the cold water.
These chemicals are the bottle washing elements that washes in their own steps. The washing
machine washes the bottles and gives to the drier machine which dries the bottles and transfer
to the conveyor. After this the conveyor feeds the bottles to the filler machine continuously.
The following steps show the procedure of the washing machine when it washes the bottles.
Returned Bottle (sales)→empty bottles stores/sales→ De palletizing→ Declassing→
Sorting→ Neck inspection→ Pre rinse clean→ Caustic soak→ Caustic spray jet→ Warm
Water spray→ Final rinse (Cold water) →Fresh water spray jet→ Clean bottles discharge
→Inspection
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This machine is very important and usable to be effective for bottle washing and it’s suitable
to wash that bottle with a little (minimum) amount of time and labor. The bottle is waiting for
30 minute in the washer machine until in late up to final out, and it pass different stages.
Pre-rinse: -This is the first stage for bottle washing and the bottle is wash internally and
externally with soft water by using spray jet.
Caustic 1: -After pre rinse the bottle is going to caustic 1, this is a kind of bath and in this
bath there is 7000 L of caustic soda solution, also the caustic strength is must be 2 – 2.5 in
scale and the chemists is cheek this scale in every 4 hour, and the amount of caustic is 100 kg
In this section the temperature of caustic soda is must be 65 0C. Caustic 1 is used for removing
of the bacteria and microorganisms inside and outside of the bottle.
Caustic 2: -The difference between caustic one and caustic two: -the strength of caustic in
caustic 2 is less than caustic 1(or it measure 1 - 1.5 in caustic 2) and also the temperature is
decrease by sum amount like 25 -280C from caustic 1.
Warm water: -The temperature of this warm water is 45 -48 0C and the bottle is washed
internally and externally by using spray jet hole, those spray jets have 15 holes. Cold water:
-Also wash the bottle with cold water.
Final rinse: -This is the final stage for bottle washing process and the water is comes from
water treatment room, so the water is clearly treated in order to protect the bottle from
microorganism and other un-desire things.
2.2.6 Filling room
Process takes place in the filling room:
 Empty bottle inspection
 Mixing
 Filling
 Crowning
 Full bottle inspection and
 Date coding
i. Empty Bottle Inspection
In this process the washed bottles are inspected manually by peoples and electrically through
light screening in order to check any untreated bottle. The inspection includes properly
unwashed bottles, rust and bottles that cannot be used for specific kind of product. The
purpose of inspection is to insure the safety of the work in the processes. People inspect
manually 150 bottles per minute and 18,000 bottles per hour
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vii. Mixing & cooling

The basic purpose of this room is to mix the three main contents of the product, which are
water, finished syrup and carbon dioxide. This process is called Carbonation. The water
comes from water treatment room and it is well-treated water and the finished syrup comes
from syrup room whereas the carbon dioxide comes from CO2 reservoir. There are two tanks
under mixer machine; these are dosing tank and water tank used to receive the finished syrup
and the treated water respectively. Flowing out from their own tanks the syrup and the water
will mix in the pipe in 1 to 5 ratios for Pepsi and 1 to 4 ratios for Miranda. They mixed
depending on the standard ratio of Pepsico international.
Figure 12 water and syrup reservoir for mixing
After the syrup and water are mixed regarding to their ratio, CO 2 will be added on the
mixture. There is no material to receive carbon dioxide, it just comes online and mix with the
water and the syrup and will get into the carbonation tank. There is also a standard for carbon
dioxide added. Carbonation tank is used to dissolve the CO 2 thoroughly in the mixture. When
the CO2 completely mixed with the mixture then it is called a final product and will be ready
for filling. Before CO2 combined with treated water and syrup it should be cool by carbon
cooler in order to dissolve CO2 .because CO2 is a gas, it dissolves at low temperature and high
pressure .the objective of cooling CO2 is to preventing foaming during filing and also prevent
under filing. As the beverage is chilled, it absorbs carbonation. Most beverage operation use
cooling to 20oc for cold filling. The finished beverage is cooled by ammonia gas; the cooling
tower for ammonia compressor is available in the company.
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Figure 13 carbon cooler
viii. Filling
Filler is a machine which is used to fill the bottle with the drink that has been prepared in the
Para mix. It is connected with the Para mix and the crowner cork. This machine has bowl
pressure, bowl level, bowl liter, capacity, mode filler, bottle counter and temperature and
controlled by PLC system. These all things have their own purpose. The various filling
processes are selected at the operator panel. First the drink is stored in the bowl and above
this drink car bon dioxide gas will be placed and then when the empty bottle is transported by
the in feed conveyer through the in feed worm gear which pushes the bottles in sequenced
manner. Then the bottles are pressed against the filling valve by a lifting element called
piston. The piston will perceive the existence of the bottles during the lifting process. If the
bottle is present the processes is started and the bottle is filled. The corresponding filling
valve remains closed if the bottle is missing. The machine works by lubrication system
automatically .there are also 15 filling valves called vents and expanding tubes where these
tubes have small holes that are used to transport the gas as well as the drinks respectively. In
this section the co2 should be filled first in the bottles in order to balance the temperature and
pressure as well. When the fluid (drink) poured in to the bottle the gas occupying the
remaining space of the bottle goes up to the returned gas media through the vent tube.
Table 2 faults on filler and possible causes
Faults on filler Possible causes

Bottle not properly filled  Bottle mouth damage
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 Lifting cylinder pressure to low

 Filling speed to high
 Amount soft drink is low
Bottle fobbing over when with drawn  Dirty bottle
 Filling pressure to low
 Temperature of the beverage is to high
ix. Crowner
It is a device used to seal the bottle with crown corks. It has cork feeder on top part, the cork
drop by the action of gravity to seal the incoming full bottle.
x. Full bottle inspection

Filled bottles are also inspected manually and by EBI. First they are inspected by EBI for any
defect i.e. if the crowns are not placed at the right place or if the bottles are perfectly filled.
Manual inspection is done by people who check if the bottle is of the right fill height.
Products should not be under filled or over filled.
xi. Date coder
The date coder is a machine that can print codes at elevated line speeds on consumer and
industrial products. The printer delivers superior uptime, excellent quality and ease of use to
the users. Its use is to print manufactured date and expiration date on the bottles. And it has
no contact area with the bottle it only prints the date by spraying the ink through the print
head.
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Figure 14 date coder
xii. Packing
The purpose of packing is to arrange the full & empty bottles in a proper order for the safety
of the bottles. In Gondar Pepsi cola plant packaging is done manually. The full bottle in the case is
will put by human
2.3.7 CIP Method

CIP process is the basic activity conducted in beverage plants. In Gondar Pepsi cola plant CIP
(cleaning in place) is a two-type of cleaning method. Those are:
o First rinse by 50OC- 60OC water for 10-15 minutes
o Cleaning by 50OC -60OC using caustic soda for 20 minutes and the concentration of
this soda should be in between 0.5%-2%.
o Rinse by 38OC water for 10-15 minutes then checking for the absence of chemicals
o Sanitize either by hot water at 80OC for 15 minutes or chlorine at 100ppm
concentration for 20 minutes
o Rinse by fresh water for 10-15 minutes then checking the absence of chemicals.
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Table 3 CIP steps for production change
To Pepsi Miranda Mirinda 7-Up Tonic

From Orange Apple
Pepsi 3-Steps Rinse 5-Steps Rinse
Miranda 5-Steps 3-Steps 5-Steps 3-Steps
Orange
Miranda 5-Steps 3-Steps 5-Steps 3-Steps
Apple
7-Up 3-Steps Rinse Rinse 3-Steps
Tonic 3-Steps 3-Steps 3-Steps 3-Steps
2.3.8 Quality Control Section

As a Pepsi cola plant and food handling company Gondar Pepsi cola plant follows standards
which ensure to apply a good manufacturing practice so as to produce safe and quality
products. The standards have their own audit program regularly (weekly, monthly, quarterly,
by the plant committee, which are certified management members and annually by third
party). The standards applied are the following:-
GMS: - is a good safety system which layout, control and evaluate the implementation of the
Training, Personal hygiene and Company visits health checks programs
HACCP: - it is a safety management system with Food safety policy, HACCP team
description, Prerequisite programs description, Hazard analysis program:-
QAS: - this procedure applies to all Pepsi Co beverage plants, franchises, and co-packers.
EMS: - this is establish and implement a functional waste collection and disposal system for
solid wastes generated by households, factory and office operations,
The overall processes in the company can be checked in this section. According to the
laboratory test whether the processes continue or not can be decided in this section. One of
the main goal of the quality control is to present the consumer with a product that is not
consistently with in standards, but that has a long shelf life .the primary purpose of quality
control and plant testing program is
 The beverage meets prescribed standards.
 The production lines and processing systems are functioning properly.
 The syrup is prepared correctly.
 The all ingredients used in preparing syrup and final beverage and correctly treated,
handled, stored and within standards.
i. Laboratory Testing
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In this laboratory section different devices are used for different purposes. Such as;
Refractor meter
It is device in the laboratory section for the purpose of determination of brix after
decarbonate the beverage and also determine the brix from simple syrup and final syrup from
beverage decarbonate first because the brix we cannot determine before decarbonate because
carbon dioxide not visible the brix amount.
Decarbonator
It is a device for the laboratory section for the purpose of removing of carbon dioxide from
beverage to know the amount of brix on the device of refractor meter.
Conductivity meter
Is a device used to check the total dissolved solid in the water in the natural water is the
normalized measure of the water ability to conduct electric current? This is mostly influenced
by dissolved salts such as sodium chloride and potassium chloride the common unit for
electrical conduct is Siemens per meter most freshwater sources will range between 0.001
and 0.1 Semen per meter. The source of electrical conductivity may be an abundance of
dissolved salts due to poor irrigation management minerals from rain water runoff or other
discharges.
Turbidity meter:
It is a measure of the cloudiness of water. Cloudiness is caused by suspended (mainly soil
particle) and planktons (microscopic plants and animal) that are suspended in the water
column is the material in water that affects the transparency or light scattering of the water.
PH meter:
It is used to know basic, acidic or neutral the solution of in the laboratory section.
Chlorine tester:
It is a device used to determine the amount of chlorine in the production water and washing
water.
The objectives of laboratory testing are:-
• To check the quality and the acceptability of the final products or line products. Un-
packed area Bottle washer selecting of damaged Bottle Visual inspected Filling area
Capper /closure area labeling area Package area Full bottle area to the consumer
• To check the quality and acceptability of water, the chlorine content, hardness,
softener of the water from water treatment room and from concrete tanker and the
caustic amount in the bottle washer of the water.
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• To check the quality of the simple and finished syrup from syrup room to producing
good quality product
• To check the water, the syrup and the class rooms must be free from any MOS. In the
laboratory, there are many activities are done according to the standard manual
Table 4 Food safety and quality department
Product parameter Pepsi cola Miranda orange 7up

CO2 gas volume 3.55 – 3.75 2.05 – 2.25 3.65 – 3.8
Inverted brix 12.2 – 12.4 12.6 -12.8 11.4 -11.6
Simple syrup brix 54 62.7 57.6
Finished syrup brix 53.4 - 54.1 59.1 54.4
Net content 291.0 – 309.0 291.0 – 309 291.0 – 309
Parameters to be checked in the laboratory
Parameters to be checked during testing raw water are:-
PH: Most of the time raw waters PH lie between 6.5 and 8.5. But it is required to be 7 which
is neutral and this can be done by treating the water.
Conductivity: Is the primary measurement of mineral contamination in water. This
contamination will be checked in laboratory and depending on the result a correction will be
taken according to its range.
Turbidity: Is the coldness or haziness of the water and it is caused by the presence of non-
sucrose substances, such as poly saccharides, high molecular weight poly phenols and
suspended minerals (ash) that are generally invisible to the naked eye, similar to smoke in air.
This parameter quality also be checked and it must be a very low number for application. It is
measure by turbid meter.
Total Hardness: Hard water is water that has high mineral content (in contrast with soft
water).Hard water is formed when water percolates through deposits of calcium and
magnesium containing minerals such as lime stone, chalk and dolomite. Treating hard water
is used to keep the safety of machines such as boiler and bottle washer.
Alkalinity: Is a measure of the capacity of water to neutralize acid. It is parameter to be
checked and will take an action if the result exceeds the range.
Softener type of water is used for bottle washer, boiler and chiller purposes. As raw water,
softener water also will be checked it hardness, duty and conductivity.
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Total Hardness: As it is stated earlier hardness is the amount of minerals such as calcium
and magnesium present in water .This also treated it change the hard water in to soft as much
as possible after knowing it result from LAB.
Duty: Is the number of the tank which holds water at processing time during sample taking
Conductivity: Like to the raw water, the mechanism is also similar to softener water. There
only difference is that the value will be lesser than that was in the raw water. It is because of
filtration. Most of the parameters that where checked under raw and softener water also will
be checked under treated water. The only and different parameter is that UV ray, because it is
the final step before going to in to production.
A sample will be taken from simple syrup to check it brix, color, turbidity and percent of
ash.
Brix: It is a sugar content of simple syrup. This amount varies depending on the product like
if its Pepsi the brix standard will be 54.00 for Miranda=62.70,for apple=57.60,for tonic= 55.4
and for 7-up=57.10.
Color: It is also the other parameter to judge the quality of simple syrup. The color tells as
weather the simple syrup is filtered properly or not. If the color of the simple syrup became
like water color, then we can say that it’s clean, unless otherwise it not. The apparatus used to
check color is called spectrometer.
Percent of Ash: This parameter tells as the quality of the sugar. Percent of ash rises, then the
sugars quality can be said t is low and vice versal. Under final syrup brix also will be
checked and Titrable acid is the other parameter to be checked.
Brix: The value of final syrup is different from it simple syrup, because dray component and
flavors are added to it. And there range is differ across the type of the product. For example
Pepsi=53.5 to54.00, Miranda=59.10, apple=52.10, tonic=48, 7-up=54.40.
Titrable Acid: Is a very use full and essential parameter which tell whether the sample has
acidic property or not, or if it has another unwanted substance, or if the dray component
didn’t added correctly or if the ageing Time was not correct and so all. This result will tell as
the answer for those questions. The substance used for titration is called sodium hydroxide.
Finished Product: - Whenever a finished product brought to laboratory, the first step is to
view whether there is a foreign material present in it by using bottle inspection glass. Then it
cork size and fill height will be measured by using cork measurement and fill height gage
respectively. After measuring temperature and pressure of the product in order to read carbon
dioxide, bicarbonate, remove carbon dioxide for measuring brix. If we measure the brix with
BIT, FCFE Page 31

co2 present in it, it went give as the correct result because the system works oscillating, but
when co2 is present in it, it will start trapping. This all checkup it continuously performs in
every 20 min.
Hot Water from Bottle Washer: -
After washing the bottle with caustic, we wash them with hot water to remove the caustic.
But the hot water alkalinity is checked by titrating it with H2SO4 of 0.02N.
CHAPTER THREE
PROJECT WORK
3. CHARACTERIZATION OF WASTEWATER EFFLUENT IN GPCP
3. 1 INTRODUCTION
Now a day the main concern of this world is environmental pollutions. So many wastes
released from the industries can affect the global status of nature. Specifically the waste water
emitted from the factories causes a serious of problems in large portion of water (seas, leak
and rivers) and on human’s well beings. The water that released from the industries may be
solid, liquid and gas; all of the three wastes have no effect on the same way that other do but,
all of them potentially and ultimately polluting the water in different ways.
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Soft drink industry forms a large part of the food and beverage industry. Thus it is important
to study the nature and amount of wastewater generated from the soft drink plants. Water is
an essential raw material in the soft drink production with a consumption of 2.5 to 3.5 litter of
water per liter of soft drink. The wastewater generated in this industry is mainly from bottle
washing, filler backwashing, washing of bottle machine, equipment’s, floors and pipe work
during flavor changing. The major contaminants in this effluent are caustic soda and sucrose.
Wastewater from bottle washing is almost 50% of the total waste water generated, which is
about 1.25 litter of wastewater per 1 litter of soft drink, bottle washing is performed by
washing machines that operate in different cycles.
Wastewater reuse is an essential factor in water resources management in industrial activities

and development .The high water consumption and demand exceed the local resources,
resulting sub regional deficit. The soft drink industry produces constitute of different
effluents, therefore reuse or internal recycle should be seriously considered when planning
water supply and resource managements
In order to reduce water consumption and volume of wastewater in soft drink plants, the
sources of wastewater uses should be identified then, measuring and monitoring the various
pollutants in the wastewater are to be performed. Process for soft drinks typically pollutes the
process water with sugar and other easily biodegradable substances. Pollutants in wastewater
generated from soft drink industries are also due to the fact that they are mainly composed of
washing water from production lines which is derived from the ingredients used in the final
production.
Much of GPCP wastewater is generated from bottle washer continuously during production
of Pepsi and Mirinda. There is a generation of wastewater from syrup room during simple
syrup & filter washing. Washing process takes 10-15 minutes. Wastewater is also generated
from water treatment room during backwashing of sand filter & carbon purifier. 3 step & 5
step sanitation generates much of wastewater within 1 hour to 2 hour time interval
The physical quality of municipal wastewater is generally reported in terms of temperature,

color, odor, and turbidity. These physical parameters are shown below:
 Temperature: the temperature of wastewater is slightly higher than that of water supply.
Temperature has effect upon microbial activity, solubility of gases and the viscosity.
 Color: fresh wastewater is light grey. Stale or septic wastewater is dark grey or black.
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 Odor: fresh wastewater may have a soapy or oily odor, which is somewhat disagreeable.
Stale wastewater has putrid odors due to hydrogen sulphide, and other products of
decomposition.
 Turbidity: turbidity in wastewater is caused by a wide variety of suspended solids- in
general, stronger wastewater has higher turbidity.
The chemical quality of wastewater is expressed in terms of organic and inorganic
constituents-domestic wastewater generally contains 50 percent organic and 50 percent
inorganic matter. A general discussion on organic components, total suspended solids, and
inorganic slat of wastewater is given below.
 Total solids (TS): organic and inorganic, settle able, suspended and dissolved matter.
 Total suspended solid (TSS): portion of organic and inorganic solid that are not
dissolved. These solids are removed by coagulation or filtration.
 Total Dissolved solid (TDS): portion organic and smaller than one mill micron (m μ) fall
in this category.
 BOD5: Biochemical oxygen demand (5-d, 20˚C) it represents the biodegradable portion
of organic component. It is a measure of dissolved oxygen required by microorganisms
to stabilize the organic matter in 5 day.
 COD: chemical oxygen demand, it is measure of organic matter and represents the
amount of oxygen required to oxidize the organic matter by strong oxidizing chemical
(potassium dichromate) under acidic condition.
 Total nitrogen (TN: total nitrogen include organic nitrogen, ammonia, nitrite, and nitrate.
 PH: is indication of acidic or basic nature of wastewater. A solution is neutral at PH 7.
The municipal wastewater contains microorganisms that play an important role in biological
waste treatment the principal groups of micro-organisms include bacteria, fungi, protozoa,
and algae.
Characterization of plant influent, effluent, and internal process streams provides plant
operations personnel with the information they need to properly control treatment processes.
As most water treatment processes are chemical reactions in nature the fundamentals of
wastewater chemistry are then necessary in understanding the wastewater characteristics and
hence in selecting, appropriate treatment technology to promote this understanding.
Wastewater characterization studies are conducted to determine the physical, chemical and
biological characteristics and the concentration of constituents in wastewater, and the best
means of reducing the pollutant concentrations.
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Wastewater from the soft drink industry may include wasted soft drinks and syrup, water
from bottles and cans washing, detergents and caustics, and traces of lubricants used in the
production process machinery.
These pollutants contain organic and inorganic substances described by the 5-day
biochemical oxygen demand (BOD5), and chemical oxygen demand (COD). Since
wastewater from the soft drinks industry generally contains organic substances that are
readily biodegradable, biological processes are mainly used for its treatment. The
effectiveness/efficiency of the treatment depends on many factors, as described by Anielak in
a review of solutions and technologies for the treatment of food industry wastewater
It is estimated that almost 50% of waste water produced during the beverage production
comes from the process of bottle washing.
Caustic soda and sugar are also released along with water as major pollutants. Beverages
industries require large quantities of fresh water for cleansing and rinsing operations. Wasting
such a huge quantity of fresh water in the beverage industry has been a debate since many
decades. One basic cause of fresh water wastage is the reuse of glass bottles which requires a
huge expense of water as a rinsing and cleansing agent before they are refilled.
Table 5 Summary of Typical Characteristics of Untreated Wastewater
Constituent Units of Low Medium High Strength

Expression Strength Strength
(BOD5) mg/L 110 190 350
COD mg/L 250 430 800
Total Solids (TS) mg/L 390 720 1230
Volatile Solids (VS) mg/L 270 500 860
Total Suspended Solids mg/L 120 210 400
(TSS)
Volatile Suspended Solids mg/L 95 160 315
Total Nitrogen, as N mg/L 20 40 70
Organic mg/L 8 15 25
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Ammonia mg/L 12 25 45
Nitrite mg/L 0 0 0
Nitrate mg/L 0 0 0
Total Phosphorus, as P mg/L 4 7 12
Organic mg/L 1 2 4
Inorganic mg/L 3 5 8
Faecal Coliform Col/100 mL 103 - 105 104 - 106 105 - 108
Source: Wastewater Engineering, Treatment and Reuse, Metcalf & Eddy, Inc., 4th Ed.,
McGraw-Hill Publishers, Boston MA, USA, 2003, p 186.
Table 6 Wastewater discharges to land or water regulation
Parameters NEA max. permissible limit

Temperature (0c) 20-35
PH 6-8
TDS (mg/l) 1200
TSS (mg/l) 100
COD(mg/l) 50
BOD (mg/l) 100
Color (TCU) 300
Turbidity (NTU) 300
Source: National Environmental Act, cap 153 .section 26 and 107 (Standards for Discharge
of Effluent into Water or on Land).
3.2 STATEMENT OF THE PROBLEM

In Gondar Pepsi Cola Company there is no wastewater treatment plant and hence there is no
characterization of the waste water effluent from each section. Much of waste water is
generated from bottle washer, syrup room, sanitation (CIP), back washing of sand filter and
carbon purifier and wall washing. This waste affects the community and environment in
different ways for example aquatic lives, because it contains caustic, chlorine, and other
residue. An understanding of these physical, chemical, and biological characteristics of
wastewater is very important in design, operation, and management of collection, treatment,
and disposal of wastewater. The measurement of flow rate, temperature, PH, turbidity, COD,
BOD, TSS, TDS, and conductivity is mandatory to know the characteristics of wastewater
generated from each section. This project focuses on measuring all those parameters of
wastewater effluent and comparing the value with standards prior to designing WWTP.
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3.3 OBJECTIVE
3.3.1 General Objective:
The main objective of this project is to characterize the wastewater generated in Gondar Pepsi
Cola Company before discharge to the environment.
3.3.2 Specific Objective

 To determine the physical characteristics (temperature, turbidity) of waste water
discharge from GPCP.
 To determine the chemical characteristics (PH, TSS,TDS) of wastewater effluent from
GPCP.
 To check whether the effluent has adverse effect on the environment or not by
comparing with the standards.
CHAPTER FOUR
4. MATERIAL AND METHOD
4.1 MATERIAL AND EQUIPMENT USED
The following equipment and chemicals are used for conducting our project.
Equipment used
 Thermometer: - an instrument that used to measure temperature of wastewater
sample.
 DS meter: - an instrument, used to measure the Total Dissolved Solid (TDS)
present in the wastewater.
 PH meter: - a device, used to measure the acidity or basicity of wastewater.
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 Turbid meter: - used to measure the turbidity of wastewater sample

 Bottle (sample taker): - used for collecting wastewater sample from deep well
drainage.
 Beaker: -used to hold samples for measuring temperature, PH, TDS.
 String: - it used us to tie a sample holder
 Oven: - used for heating wastewater sample to be evaporated
 Evaporating dish: - used to hold wastewater sample for heating
 Mass balance: - used for measuring the mass of petri dish and sample
 Volumetric cylinder: - used to measure the volume of wastewater sample
Chemicals used
 Distilled water: - used for rinsing the instrument before and after measurement.
 Tap water: - used for washing equipment and materials
 KCl solution: - used as neutral solution (calibration) in PH measurement.
4.2 METHODOLOGY
For characterization of wastewater effluent in any plant sampling technique must be
conducted before any activity. A sample of wastewater was taken from different section of
Gondar Pepsi Cola Plant (GPCP). The sample was collected from the final effluent of the
plant, bottle washing effluent, simple syrup preparation room and water treatment plant. The
amount of wastewater effluent from GPCP varies from time to time due to the working of
different task such as: sanitation (five step and three step), simple syrup tank and filter
washing, backwashing of carbon purifier and sand filter in water treatment room and floor
washing of all processing room. A different sampling point was used for taking wastewater
sample due to the variation of effluent. Besides the above sampling points, a sample of waste
was taken from the common final effluent of the company after different tasks conducted.
Sampling was done during normal period of operation (during production), five step and
three step CIP period, backwashing in WTP, and washing in syrup room.
Temperature, PH, turbidity, TDS and TSS measurement was done for GPCP wastewater
effluent. The measurement technique for that characterization of wastewater effluent is
written as follows.
Determination of Temperature
The temperature of waste samples was measured using mercury thermometer at room
Temperature. There was a time gap between temperature measurement and sample taking
process, so the resulted temperature might be lower than accurate measurement.
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Determination of PH
The PH of wastewater sample was measured using PH meter. The calibration was done by
using kcl solution, then a sample of waste was put to clean beaker and the probe was
immersed into the sample. Finally the displayed PH of wastewater was recorded.
Determination of total dissolved solids (TDS)
The total dissolved solid present in the wastewater sample was measured by DS meter which
is a product of Myron L Company. Wastewater sample was collected and added to the feeder
of DS meter, and then its bottom part was pressed to display TDS of sample.
Determination of Turbidity
The turbidity was determined photo electrically using turbidity meter. A sample of
wastewater was collected from the effluent line of GPCP. Turbidity of the waste was
measured and the results were expressed in term of turbidity units (NTU) for three different
sample.
Determination of TSS
A sample of wastewater was taken from GPCP wastewater effluent during production period
of Pepsi. TSS of this effluent was obtained by determining its TS firstly. A sample of
wastewater was measured and put in to evaporating dish. Sample contained evaporating dish
was subjected to evaporating using oven. Then the sample containing dish was removed from
oven and its mass was measured. Finally, total dissolved solid was calculated and total
suspended solid was obtained from TS and TDS. This method was repeated for a waste water
sample taken during sanitation and syrup and filter tank washing.
The measurement of all the above parameters is summarized in the table 7.
Table 7 values of wastewater characterizations parameters.
Sampling point
Parameters During normal During CIP During syrup tank

production and filter washing
normal production
0
Temperature( c) 28 29-36 25
Turbidity 45.05 54.65 345.89
PH 10.93 10.87 9.74
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TDS(ppm) 1100 900 1150
TSS(mg/l) 60 75 130
CHAPTER FIVE
5. RESULTS AND DISCUSSION
The temperature of wastewater effluent is different for different sampling. During production
period, the temperature of wastewater is 28 0c. This higher temperature comes from bottle
washing operation, which is processed at high temperature (steam temperature). In bottle
washer, there are steps that cause wastewater generation at higher temperature; those are hot
water rinse, caustic 1 and 2 rinses by heating using steam. During syrup tank and filter
washing, the temperature of the effluent has been 250c, which is measured at common
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drainage pipe of bottle washer and washing wastewater. During weakly and product change
sanitation the temperature of wastewater is variable, from our measurement the temperature
fluctuates between 29 and 360c. This is due to CIP method.
According to the National Environment act, S.I No 5/1999 (wastewater discharge regulation),
all above temperature measurements are acceptable. NEA States temperature of wastewater
effluent from industry should be between 20 and 350c. Therefore, temperature of GPCP
wastewater effluent has no series impact on the environment.
We have found that, the PH of wastewater effluent from GPCP is 10.93 during production
period of Pepsi and Miranda, 10.87 during five step sanitation, 9.74 during syrup tank
washing and production process.
From the result we justify that, the wastewater has basic behavior. This is due to the usage of
caustic soda for washing bottles in bottle washer and for sanitation. GPCP uses much amount
of caustic soda for above purpose, this results high PH content wastewater generation.
From the standard discharge regulation NEA, the PH of wastewater discharge from industry
should be within a range of 6-9. But our PH value is out of this range, as stated above this is
due to caustic soda usage. High PH content wastewater has impact on aquatic life and the
environment therefore appropriate PH reduction method should be practiced before
discharging the wastewater to the environment.
Using DS meter we have found that the total dissolved solid of wastewater effluent is 1100
ppm for production time sample, 900 ppm for five step CIP wastewater sample and 1150 ppm
for syrup tank & filter washing wastewater sample. These values are acceptable based on
NEA wastewater discharge to land or water standards.
TSS of GPCP wastewater effluent is calculated from: -

TSS= TS-TDS---------------------------------------- (Eq5.1)
TS = ((A – B)/VS)*1000ml ------------------------- (Eq 5.2)
Where: -TS is total solids
A is the sum of petri dish and sample of wastewater
B is mass of petri dish
VS is volume of sample
For TSS determination the following measurements are taken
Table 8 measurements conducted for TSS determination
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Measurements Mass of evaporating Mass of evaporating Volume of sample

dish, B (g) dish and sample, A Vs (ml)
(g)
During production 30.3757 30.3844 7.5
period
During sanitation 30.3757 30.3835 8.0
During syrup tank 30.3757 30.3854 7.5
and filter washing
For production period sample

From equation 2:
TS= ((A – B)/VS)*1000
1000 ml 1000 mg
TS= ((30.3844 – 30.3757)g/7.5ml* *
1l 1g
TS =1160 mg/l
The total solid of the wastewater is 1160 mg/l. Total Suspended solid of a given wastewater
is the difference between total solid and TDS. TDS is measured by DS meter and its value is
1100 mg/l.
From equation 1:
TSS= TS – TDS
TSS= 1160 – 1100= 60mg/l
For sanitation period sample
1000 ml 1000 mg
TS= ((30.3835 – 30.3757)g/8.0* *
1l 1g
TS = 975mg/l
TSS= TS – TDS
TSS= 975 – 900 = 75 mg/l
For syrup tank and filter tank washing sample
1000 ml 1000 mg
TS= ((30.3854 – 30.3757)g/7.5* *
1l 1g
TS = 1280 mg/l
TSS= 1280 – 1150
TSS= 130 mg/l
The TSS of GPCP wastewater effluent during production period is 60 mg/l. Based on NEA
Standards for Discharge of Effluent into Water or on Land, this value is acceptable. So the
total suspended solids of GPCP wastewater has no adverse effect on the aquatic life. During
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sanitation much of wastewater is generated for one up to two hours this may increase the TSS
to 75mg/l in wastewater but it is acceptable for discharging to the environment. The
wastewater effluent during syrup tank washing is 130 mg/l. This value is above NEA
regulation due to the residue of DE left during syrup and filter tank washing.
The turbidity of wastewater was measured by turbidity meter. A value of 45.05 NTU during
production period, 54.65 NTU during sanitation and 345.89 NTU during syrup tank and filter
washing were obtained. Except washing period sample the other wastewater samples are
acceptable based on NEA standards for discharging the wastewater to the environment . The
source of high turbid wastewater is filter tank washing that contains DE residue. The strength
and concentration of wastewater generated during filter tank washing is higher than that of
operation period wastewater.
Temperature, PH, TDS, TSS and turbidity of GPCP wastewater effluent is measured and the
values are described on table 7. From table 7 some parameters are not conforms to standard.
The temperature and TDS of wastewater conforms to standard, but its PH exceeds the
maximum permissible limit. So PH has adverse effect on the environment. It is summarized
on table 9.
Table 9 comparison of measurements with the standard
Parameters Our measurement Max permissible

limits(national
During Production During During syrup
environment act)
Period sanitation tank washing
Temp(0C) 28 29-36 25 20-35
PH 10.93 10.87 9.74 6-8
TDS(ppm) 1100 900 1150 1200
TSS(mg/l) 60 75 130 100
Turbidity(NTU) 45.05 54.65 345.89 300
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Limitations and challenges

During conducting this project the following limitations and challenges are faced.
 The amount of wastewater discharged from Gondar Pepsi cola plant varies from time
to time, even regardless of CIP period, backwashing of WTP’s equipment, and syrup
tank and filter washing. Due to this reason the measurement of wastewater property is
variable for different sampling.
 The drainage system in Gondar Pepsi cola plant is not suitable to take a sample of
wastewater effluent. The drainage pipe is constructed in deep well which is around
1.5m below the floor. It is difficult to measure the flow rate of wastewater, because of
construction of drainage system and the flowing of wastewater as storm. We didn’t
measure the flow rate of waste water due to drainage system.
Figure 15 Drainage System of Gondar Pepsi Cola Plant Wastewater Effluent
 We couldn’t find sampling point other than stated above
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 Absence of useful equipment in the plant and around sectors like COD meter, BOD
meter and the like.
 Lack of full data.
 We couldn’t measure all parameters of wastewater characterization due to availability
of equipment.
CHAPTER SIX
6. CONCLUSION AND RECOMMENDATION
6.1. CONCLUSION
From Gondar Pepsi Cola Plant, the characterization of wastewater is analyzed by determining
the physical and chemical property of wastewater effluent. Temperature, turbidity, PH, TSS
and TDS of wastewater effluent are measured and compared with NEA wastewater discharge
to water or land regulations. GPCP wastewater effluent has an average temperature of 27 0c,
average PH of 10.34, average TDS of 1025 ppm and TSS of 80 mg/l. From NEA regulation,
except PH the other parameters of GPCP wastewater effluent are acceptable for discharging
the wastewater to river. The main cause for high PH content of wastewater is caustic soda
usage for washing.
Generally by determining physical, chemical and biological parameters of wastewater
effluent, we can know the characteristics of wastewater, its degree of treatability and the
potential effect on the environment by comparing it with maximum permissible limit of
discharging wastewater to the environment.
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6.2. RECOMMENDATION
We have done a project on characterization of GPCP wastewater effluent with some
limitations. We recommend that, for measuring the flow rate of GPCP wastewater effluent,
the drainage system must be suitable for sampling. It is advantageous if the construction of
drainage system passes through pipes and tanks that are suitable for sampling and treatment
process. The plant and the community will be safe if these wastewater properties are applied.
Simple treatment process should be applied by improving the current installation area of the
plant. Non treatment of wastewater might not be a series problem for a community compared
to a community pollutes the environment by itself, but characterization and simple treatment
process of waste water should be conducted to save the environment.
BOD and COD are essential parameters to know the characteristics of wastewater in GPCP.
So a further characterization of wastewater effluent in GPCP should be done by determining
BOD, COD and biological parameters. Wastewater property measurements such as: - BOD,
COD bottles and conductivity measurement should be present for analyzing wastewater
generation.
When we were in the factory we have seen all the production process of soft drinks. And as a
chemical engineering student we want to recommend the following things.
The plant has not effective and suitable drainage and waste disposal system it release almost
basic water at PH above 10 and it has badly odor these condition affects the aquatic life and
has many environmental impact. So it is possible to apply simple wastewater treatment
method, especially PH reduction by characterizing of wastewater effluent.
In bottle washer bottles are charged to pre cleaning section without removing the liquid inside
it. The liquid inside the bottle may contain waste water, urine, remaining of soft drink, oil and
related dirty flowing matters. And these dirty liquids are directly mix with cleaning water in
the pre cleaning section of washer. This cleaning water is used for on full day of continuous
washing. So we are suggesting that to remove or drain those dirty liquids from bottles before
entering to the washer. So that it can eliminate the contamination of bottles by unwanted
matters and increases the quality of cleaning water of the pre cleaning section.
There is a heat loss in CIP and boiler rooms. In the boiler room the hot water and hot caustic
tanks are not insulated. So it is possible to insulate the shell of the tank using the principle of
critical wall insulation thickens. In boiler plant, the chimney has a temperature of above
150oc so we can install air pre heater or economize.
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Full bottles and empty bottles are dictated by human eye inspection this method is a very
back ward and it have lack of accuracy. If the bottle is detected improperly, broken bottle,
unfilled bottle or unpacked bottle and caustic carry bottle may pass. This lead to effect on
product quality. Also caustic is very dangers chemical so any residual of caustic that remain
in bottle may contact with the beverage and affect the customers of the products. So, it must
be replace human eye inspection by advanced technology electronics machine.
Because the plant uses old machines, it does not operate at its operation parameters that
shown on the manuals this affect the production process. For example it releases much
amount of waste gases to the environment and many bottles are broken during filling. As
much as possible use recently fabricated machinery and material to operate properly and
effectively.
Benefit and beneficiary
The benefit of this project is for management, knowing the amount and property of
wastewater generation in GPCP. The project provides a precondition for conducting
wastewater treatment process since there is no wastewater treatment process in GPCP.
CHAPTER SEVEN
7. OVERALL BENEFITS OF INTERNSHIP
7.1 BACKGROUND OF INTERNSHIP
Internships exist in a wide variety of industries and settings. An internship can be paid,
unpaid, or partially paid (in the form of a stipend). Internships may be part-time or full-time
and are usually flexible with student’s schedules. A typical internship lasts between one and
four months, but can be shorter or longer, depending on the organization involved. The act of
job shadowing may also constitute interning.
Internship is a great opportunity to practically prove the theoretical knowledge we got from
class into practice. Out of several departments that BIT is giving nowadays, chemical
engineering is one of those departments and also internship is one of great program that we
develop our theoretical and practical knowledge’s.
7.1.1 How We Get Into the Gondar Pepsi Cola Company

Bahir Dar University has an internship program for all engineering students, by the program
of the university that allows the students to get practical knowledge for a four month period.
We are try to find an appropriate internship by applied an internship request for many
companies but we couldn’t get the acceptance. Finally by the help of university industrial
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linkage coordinator we get the acceptance of MOHA soft drink S.C in Gondar Pepsi cola
plant.
During our time in the company, we observed almost all part of the company. We had a good
opportunity to deal with different sections of the company and each process in each section.
We were also capable of watching some processes from raw material feeding up to product
packaging.
The other experience we got is; how to control different machines when the production
process is still running, we worked with the laboratory assistant by while conducting different
tests
The challenging experience we got was finding solutions for existing problems, collecting
production data and specifying problems according to production quantity and quality.
7.2 MAIN BENEFITS OF INTERNSHIP
The experiences we gained during this internship program are categorized as;
o Practical skills
o Theoretical knowledge
o Inter-personal communication skills
o Team playing skills
o Leadership skills
o Work ethics & related issues, and finally
o Entrepreneurship skills
7.2.1 Practical Skills

During this internship period, we have advanced our practical skills regarding the production,
performance, process parameters and the machines that perform many works and gained new,
different, and interesting knowledge about soft drinks. Some of the practical skills are;
o Chemical preparation
o Solving machine problems
o Observing and controlling quality of the product
o The way of treating water, and
o How to check the pH variations in chemicals
7.2.2 Theoretical Knowledge

Theoretical knowledge is the base for all practical knowledge. It creates awareness and
understanding about the practical aspects. Thus, we tried to relate each practical observation
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and experiences we get form the internship with the theoretical knowledge we get from class.
This helped us in developing the theoretical knowledge and makes our previous knowledge
practically supported.
7.2.3 Improving Communication Skills
This one is the most common and important skill gained during our internship period. It helps
a person to interact with others in a better and pleasant manner. It is an art to present one’s
views, thoughts, and ideas to the listener.
It helped us in composing our project by asking question & info from the employees who
guided us in the best possible way. Our interactions and dealings with the workers made our
social interaction easy.
o It improves our speaking and listening skills

o We were motivated by the speech of the chemist that it led us to discover
different problems and come up with solutions to them
o It helps in building self-confidence by discussing ideas with section head &
other personnel
7.2.4 In terms of improving team playing skills
As a team member, someone contributes a lot in many ways. There by, this improves every
individual’s commutative knowledge of solving the existing problem. Being a team player,
everyone can improve the following
o Ability to identify problem(s)

o Choosing the most appropriate method to solve the existing problem(s)
o How to ask questions without hesitation
o Respecting other’s opinions, and
o Helping others
7.2.5 Improving Leadership Skills

Internship made us smart in managing our expenses regarding the project, how to become
better sales person or how to manage a team. Learning these skills can really help in creating
better individuals & better team. These items will help everyone developing their skills as a
leader;
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o Understanding group needs and characteristics

o Representing the group
o Knowing and understanding grouped resources
o Planning for the feature
7.2.6 In terms of understanding work ethics

Work ethics involve the following characteristics
o Honesty
o Reliability
o Cooperating with collogues
o Punctuality
o Working independently
o Taking responsibility
o Creating goals
o Effective Communication
o Managing time effectively
o Being prepared to do everything for the team
7.2.7 In terms of Entrepreneurship skills
Internship is an important tool for gaining experience and learning about one’s preferences
and interests. Perhaps most importantly, the experience obtained has a great importance up on
our life to choose and plan each of our future activity. Being an intern can build an individual
knowledgeable in;
o Moral & Ethics

o Selecting effective way of doing work
o Increasing work efficiency
o Creative mind; solving problems of the company
o Extend different projects up on existing problem concerning the company
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REFERENCE
1. PepsiCo, (2005). Quality manual PepsiCo international manufacturing processing

Vol-1 700 Anderson Hill Road, NY.
2. PepsiCo, (2005). Quality manual PepsiCo international Analytical methods Vol-2
700 Anderson Hill Road, NY.
3. PepsiCo, (2005). Quality manual PepsiCo international standards and specifications
and operational practice Vol-3 and Vol -4 700 Anderson Hill Road, NY.
4. Campers, E, R; Nacheva .P.M and Tapia, D 2004 "Treatment techniques for the
recycling of bottle washing water in the soft drinks industry” Wat. Sci. Tech
a. Vol.50 No. 2 pp107-112.
5. Visvanathan C. and Hufemia A.M. 1997 " Exploring zero discharge potentials for the
sustainability of a bottling plant " Wat. Sci. Tech. 35, No.9, pp181-190.
BIT, FCFE Page 51

6. Syed R. Qasim "Waste water treatment plant Planning, Design, and Operation ",
1985
7. Resources, Conservation and Recycling 16 (1996) 145-159 Environmental
Engineering Program, Asian Institute of Technology, Bangkok, Thailand
8. Anielak, Dairy industry and its water-sewage economics, Agro Przemysł 2, 57–59 (in
Polish), (2008)
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BIT, FCFE Page 52

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BAHIR DAR INSTITUTE OF TECHNOLOGY

FACULTY OF CHEMICAL & FOOD ENGINEERING

4TH YEAR CHEMICAL ENGINEERING

HOSTING COMPANY: GONDER PEPSI-COLA FACTORY

Internship Report and Project By:

Submitted to: Mr. Bassazin A.

Bahir Dar- Ethiopia

Intern name: Signature: Date:

Fekadu Mazengiaw ----------------- --------------

Tadilo Belete ---------------- -------------

Mentor Signature: Date:

Bassazin Ayalew ------------------ ----------------

3.2 Statement of the Problem............................................................................................................................36

BOD Biological Oxygen Demand

Bph Bottle per hour

CEO Central Executive Office

COD Chemical Oxygen Demand

CIP Cleaning In Place

CLTS Conventional Lime Treatment Systems

EBI Empty Bottle Inspection

EMS Environmental Management System

GMP Good Manufacturing Practice

GPCP Gondar Pepsi Cola Plant

HACCP Hazard Analysis and Critical Control Point

M reading Methyl Purple

NEA National Environmental Act

PLC Programmable Logic Controller

Ppm Part per million

QAS Quality Auditing System

S.C Share Company

TDS Total dissolved solids

TSS Total suspended solids

WWTP Wastewater Treatment Plant

BIT, FCFE Page 1

1.2 OBJECTIVE OF THE COMPANY

1.3 MISSION AND VISION OF THE COMPANY

1.3.2 Mission of Company

BIT, FCFE Page 2

1.3.3 Future Program of the Company

1.4 MAIN PRODUCTS OF GONDAR PEPSI-COLA COMPANY

1.4.1 The Main Customers/End Users of Its Products

BIT, FCFE Page 3

1.7 ORGANIZATION STRUCTURE

Finance Human Commercial Production &

Sales sup Prod.sup Senior

G\account sup. G\Service sup. Procurement

Figure 1 organization structure of the company

BIT, FCFE Page 4

1.7.1 Responsibilities of the department

BIT, FCFE Page 5

 Bridging management and employee relations by addressing, or give other issues.

BIT, FCFE Page 6

 Review weekly maintenance schedule

BIT, FCFE Page 7

2.2 GENERAL PROCESS FLOW SHEET OF GONDAR PEPSI-COLA

BIT, FCFE Page 8

Carbonation and mixing Filling and crowning

BIT, FCFE Page 9

Figure 2 general production block diagram of Gondar Pepsi cola plant

2.3 MAIN ROOMS OF GONDAR PEPSI COLA PLANT

BIT, FCFE Page 10

Na2CO3+CaCl2 → CaCO3 + 2NaCl

 Chlorine− used for sanitation and to kill microorganism

Al2 (SO4)3 +6H2O→ 2Al (OH) 3 +3H2SO4