Dire Dawa University

Institute of Technology

Externship Report on:

East Africa Bottling Share Company (EABSC)

(Dire Dawa Plant)

Name of Extern Department Tell. No

1. Solomon kerealme……………………………………………….. SMIE ……………………… 0972272220

2. Amdail Shefaw……………………………………………………. Electrical Eng………….0912047623
3. Getnet Awoke……………………………………………………… Chemical Eng………… 0929397438

August, 2017

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CONTENTS
CHAPTER ONE ............................................................................................................................. 4

1.1 Company Background ...................................................................................................... 5

1.2 Main products or services ................................................................................................ 7

1.3 Main customers or end users ............................................................................................ 7

1.4 Organizational Structure .................................................................................................. 8

1.5 Work Flow........................................................................................................................ 9

CHAPTER TWO .......................................................................................................................... 10

2. OCCOPUTIONAL HEALTH SAFETY .................................................................................. 10

2.1 EOSH Principles ................................................................................................................. 10

2.2 Site Tour Rules .................................................................................................................... 11

2.3 Emergency Preparedness..................................................................................................... 12

2.4 First Aid Measures .............................................................................................................. 12

CHAPTER THREE ...................................................................................................................... 13

3. PLANT UTILITIES .............................................................................................................. 13

3.1 Water Treatment .................................................................................................................. 13

3.1.1 Rapid Mixing ................................................................................................................ 13

3.1.2 Sedimentation ............................................................................................................... 13

3.1.3 Sand Filter..................................................................................................................... 13

3.1.4 Granular Activated Carbon Filter (GAC) ..................................................................... 14

3.1.5 Polishing Filter ............................................................................................................. 14

3.1.6 Reverse Osmosis........................................................................................................... 14

3.1.7 Ultra Violet Light ......................................................................................................... 15

3.1.8 Process Flow Path ......................................................................................................... 16

3.2 BOILER .............................................................................................................................. 18

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3.3 COOLING SYSTEM .......................................................................................................... 21

3.3.1 Cooling Tower .............................................................................................................. 23

3.4 SYRUP ROOM ................................................................................................................... 24

3.4.1 Soft Drink Manufacture - Preparation of Sugar Syrups ............................................... 24

3.5 BLENDER .......................................................................................................................... 29

3.5.1 GENERAL DESCRIPTION OF THE MACHINE ...................................................... 29

3.5.2 MACRO OPERATION ................................................................................................ 29

3.6 WASHER ............................................................................................................................ 33

3.6.1 GENERAL DESCRIPTION OF THE MACHINE ...................................................... 33

3.6.2 OVERALL OPERATING DESCRIPTION ................................................................. 34

3.7 FILLER ............................................................................................................................... 36

3.7.1 GENERAL DESCRIPTION OF THE MACHINE ...................................................... 36

3.7.2 MACRO OPERATION ................................................................................................ 37

3.8 BOTTLE CLOSING MACHINE (CROWNER) ................................................................ 40

3.8.1 BASIC PRINCIPLE OF BOTTLE CLOSING ............................................................ 40

3.8.2 Closing Process............................................................................................................. 41

3.9 PACKER AND UNPACKER ............................................................................................. 42

3.10 WASTE WATER TREATMENT ..................................................................................... 43

3.10.1 Grit Channel ............................................................................................................... 44

3.10.2 Oil Trap Channel ........................................................................................................ 44

3.10.3 Pump Pit ..................................................................................................................... 44

3.10.4 Dozing Station ............................................................................................................ 44

3.10.5 Equalizer ..................................................................................................................... 44

3.10.6 SBR1 (Sequential Batch Reactor 1) ........................................................................... 45

3.10.7 SBR2 (Sequential Batch Reactor 2) ........................................................................... 45

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 3.10.8 SBR2 DATA............................................................................................................... 45

3.10.9 Sludge Tanker ............................................................................................................. 46

CHAPTER FOUR ......................................................................................................................... 47

4. BENIFTS OF EXTERNSHIP EXPERIENCE .................................................................. 47

4.2 In terms of Upgrading Theoretical Knowledge................................................................... 47

4.3 In terms of Inter Personal Communication ......................................................................... 47

4.4 Improving Team Playing Skills .......................................................................................... 48

4.5 In terms of Improving Leadership Skills............................................................................. 48

4.6 In terms of Improving Work Ethics .................................................................................... 49

4.7 In terms of Improving Externship Skills ............................................................................. 49

4.8 In terms of Identifying Company problems and Possible Research Areas ......................... 49

List of Figures

Figure 1: Organizational structure of EABSC DD Plant ................................................................ 9

Figure 2: Work flow diagram of EABSC DD plant ....................................................................... 9
Figure 3: Flow Diagram of Water Treatment ............................................................................... 17
Figure 4: THERMAX Boiler ........................................................................................................ 20
Figure 5: 3D View of Boiler ......................................................................................................... 21
Figure 6: Chillier Unit ................................................................................................................... 22
Figure 7: Schematic Diagram of Cooling Tower .......................................................................... 23
Figure 8: 2D Drawing of Blender Machine .................................................................................. 30
Figure 9: Sidel Washing Machine................................................................................................. 33
Figure 10: 2D Drawing of Filler Machine .................................................................................... 38
Figure 11: Crowner Machine ........................................................................................................ 40
Figure 12: Treatment Flow Chart ................................................................................................. 43

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CHAPTER ONE

1.1 Company Background

The first Coca-Cola bottler in Ethiopia was established in 1959 G.C by five Ethiopians with its
initial capital 750,000 Birr as the Ethiopian Bottling Share Company. As the business expanded a
branch was established in DIRE DAWA in 1965 G.C again with the capital of 750,000 Birr. In
February 1975 G.C the two factories were nationalized, re-named as Addis Ababa Soft Drinks
and DIRE DAWA Soft Drinks and operated under separate management. In March 22, 1996 G.C
the two plants were re privatized again by five young local entrepreneurs with a registered
capital of Birr 67 million and who formed Ethiopian Bottling Share Company. In May 1999 G.C,
a joint venture agreement was signed between Ethiopian Bottling Share Company & Coca-Cola
SABCO to bring the professionalism, knowledge and experience that was lacking in the
operation. The name of the company was changed to East Africa Bottling Share Company
(EABSC). The shareholding proportion was 51% and 49% by EABSC and CCS respectively.

Coca- Cola SABCO (South Africa Bottling Share Company) is the franchise bottler of Coca-
Cola, Fanta, Sprite, Stony, Tab, Sparletta and other brands of Coca-Cola Company and bottles
these products on behalf of the Coca-Cola Company, which is situated in Atlanta, USA. In this
respect they act as the Coca- Cola Company’s Bottling arm. Coca- Cola SABCO has the task of
selling Soft Drinks to dealers, who in turn sell them to their customers.

This integration has proven to be a perfect match which has brought about many positive
changes, such as people development, which is mandatory to grow the business. In line with this,
a fully equipped training center was established as soon as the joint venture was signed. In
September 2007 G.C, a third production line was installed in the Addis Plant, increasing the
installed capacity by 75% and after a waste water treatment plant was built a new PET line is
started to be built in 2011 G.G and started production in late 2013 G.C. East Africa Bottling
Share Company is committed to developing and maintaining an integrated Occupational Health
&Safety, Environment and Quality Management System based on ISO 9001:2000,
ISO14001:2004 and ISO 2008.

Vision

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"We will be the Best Coca-Cola bottler in the World."

The Best- In sales volume and in return on capital employed

Coca-Cola Bottler- A consumer driven, customer oriented, manufacturer, sales &Distribution

Company that markets the products & brands of The Coca-Cola Company.

In the World- They measure themselves against the best Coca-Cola bottlers in the World.

Purpose

To create value for everyone touched by our business by providing, with passion and focus, the
right refreshment, at the right price, in the right place.

Values

We will create an environment where our people are passionate about performance. This will be
based on:

 Integrity: Be honest, open & sincere

 Individual Initiative: Take pro-active steps to drive performance
 Customer Value: Exceed customer expectations & add value to Customer’s
businesses
 Teamwork: Work with & support colleagues to raise overall performance
 People Development: Realize employee potential through training & development
 Mutual Trust & Respect: Treat each other with respect, dignity and to earn trust
 Commitment: Be accountable & do as you say.

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1.2 Main products or services

EABSC DD plant produces most of the Coca-Cola Company Products such as:

 Coca-Cola
 Sprite
 Fanta orange
 Fanta pineapple

1.3 Main customers or end users

Major Distribution center (MDC)

Secondary users:-

Hotels
Restaurants
Supermarkets
Institutions
110 Agents in Addis Ababa, North Ethiopia, West Ethiopia and East Ethiopia.

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 1.4 Organizational Structure

Operational manager

Engineering Logistics Quality Sales

Manufacturing
manager
Manager Manager Manager
Manager

Quality Regional sales

controller manager (RSM)

Specialist Controller Planne Technical

r trainer
Ware house Distribution
Supervisor District sales
manager
Electrical Mechanical

Production Distribution Distributio Sales

team coordinator n analyst representative
leader

Store Forklift Ware house

keeper operator facility

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 Figure 1: Organizational structure of EABSC DD Plant

1.5 Work Flow

Market distribution Ware house (return

center (MDC) empty glass

Ware house Production

(product filled
glass)

Figure 2: Work flow diagram of EABSC DD plant

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CHAPTER TWO

2. OCCOPUTIONAL HEALTH SAFETY

Safety is the condition of being protected from or unlikely to cause danger, risk or injury. Safety
also can be defined as relative freedom from danger, risk or threat of harm, injury or loss to
personnel and / or property whether caused by deliberately or by accident. Some scientists’ states
safety as follows, (LEVENSON 2002) safety is considered.

2.1 EOSH Principles

Main Task Performed on this includes:

 Study EOSH Principles as required by and applied in the KO system

 Review safety systems
 Identifying non-conformances in the plant and proposed corrective actions

East Africa Bottling SC: Safety Briefing

Occupational Health and Safety Induction

 Preventing as far as possible accidents and work related ill health. Where:
 Health - the condition of body or mind and
 Safety -not being exposed to an unacceptable danger or risk

Hazards at the Workstations

1. Cuts – from broken bottles

2. Noise - Generated from operations

3. Trip – Due to objects out of place

4. Slip – Due to slippery floors and spillages

5. Falling objects- from work-in-progress

6. Moving Equipment – forklifts and motor vehicles

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 7. Odor - Minor From the Effluent

8. Fire – From short-circuits, gas leakage, electrostatic, and sparks. In case of fire shout fire
and raise the alarm.

9. Chemicals – caustic, chlorine, acids and etc.

1.1 Safety Measures & Precautions

2.2 Site Tour Rules

• Never walk alone

• Use designated pedestrian walk ways- Observe the pathways to avoid being hit by
moving equipment’s.

• Use designated smoking zones

• Use the provided PPEs all the time during the tour

• Do not pick bottlers from moving conveyors

• Do not use camera unless prior permission is granted.

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2.3 Emergency Preparedness

 Proceed to your nearest exit under the guidance of your host.

 Inform safety personnel of locations (If you know) of the fire/hazard.

 Proceed quietly and orderly

 Do not open door if heat or if smoke is present.

 Once outside, assemble at a designated area and Safety personnel will tally those present.

2.4 First Aid Measures

First Aid

There are trained First –Aiders and fully stocked first Aid kits. In case of an injury, they will
provide the service.

Medical Attention

We have a Clinical Nurse on site to provide medical services.

An Ambulance will be called if the need requires one.

SANITARY FACILITIES

 Administrative building

 Next to receptionist -both ladies and Gents

 Next to Clinic - both ladies and Gents

 Above line 3 offices – both ladies and Gents

 Production changing room – Gents and ladies

 Good house-keeping and Hygiene to be maintained as part of our Food Safety

Requirement.

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CHAPTER THREE
3. PLANT UTILITIES

3.1 Water Treatment

The objectives of water treatment are the removal or inactivation of pathogenic microorganisms,
to minimize TDS, to remove dissolved impurities, to minimize alkalinity and to prevent the
spread of water borne diseases.

To remove such things, they use different process such as:

 Rapid mixing
 Sedimentation
 Sand filter
 Activated Carbon filter
 Polishing filter
 Reverse osmosis(RO) and
 Ultra violet light(UV)

3.1.1 Rapid Mixing

Once it arrives at the plant, the pH is adjusted and water is rapidly mixed with ferrous sulfate, a
coagulant that helps the impurities stick together to form bigger particles called floc. In this
mixing (reaction) tank in addition to ferrous sulfate, we also add the following chemicals,
chlorine for disinfecting purpose, Cao (Lime) for the purpose of softening water.

3.1.2 Sedimentation

At this process the heavy floc particles sink to the bottom and are removed from reaction tank in
the form of sludge.

3.1.3 Sand Filter

Sand filters work through the formation of a gelatinous layer or bio film called hypogeal layer in
the top of sand filter. The surface biofilm of sand is the layer that provides the effective

13
purification in potable water treatment. The underlying sand providing as support medium for
biological treatment layer.

As water passes through the hypogeal layer, foreign matters are trapped in the mucilaginous
matrix and soluble organic material is adsorbed.

The contaminants are metabolized by the bacteria, fungi and protozoa.

3.1.4 Granular Activated Carbon Filter (GAC)

Activated carbon is a crude form of graphite, with random or amorphous structure. It is highly
porous over a broad range of pore sizes and from visible cracks. Chemicals or materials reduced
or removed by granular-activated carbon include:

 Organic materials
 Off-taste and odor-causing materials
 Chlorine

3.1.5 Polishing Filter

Polishing filter is used to remove fine carbon and remains residual.

3.1.6 Reverse Osmosis

Reverse osmosis: Involves addition of external pressure to solution of higher concentration. This
makes the solvent, in our case water, flow through the membrane.

 Operates at 0.001 - 0.0001 micron range

 Can reject small ions like sodium, chloride etc…
 Higher the TDS in the feed water, higher will be the osmotic pressure exerted,
hence requirement of higher feed pressure.
 Membrane pores are fine and operation of the membranes involves careful
control of colloidal and suspended solids.

Reverse Osmosis-Some Basic Definitions:

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Reverse osmosis is the process that separates a solute from a solution by forcing the solvent to
flow through a membrane by applying a pressure greater than the normal osmotic pressure. RO
works at high pressure, to do so we have a high pressure pump. RO works at pressure of 6 bars.
We have also two micro filters with a capacity of 5 and 1(um). Then it is radiated with a UV ray
by the disinfection unit to eliminate any bacteria developed in the path. The disinfection unit has
a UV lamp and the water flows over the unit by cooling the unit and in the other way it is also
treated. The water that is rejected by the membrane is stored in small tanker and used for
cleaning purpose these reduces WUR (water usage ratio). Antiscalent is used for prevention of
scaling of particles in the membrane.

 Recovery % = (Product flow/Feed flow) x 100

 Salt passage % = (Product TDS/Feed TDS) x 100
 Concentration factor = 1/ (1 – Recovery)

3.1.7 Ultra Violet Light

UV light with wavelengths of 210-370 nm (nanometers) can inactivate:

 Microorganisms
 Algae
 Yeasts and molds.

They directly destroy cell proteins or penetrate their nucleic acids and rearrange their genetic
code.

Altering a cell’s code destroys its normal ability to reproduce, which makes it harmless because
it can't multiply to infectious numbers within a host body.
Flow chart of water treatment

15
 3.1.8 Process Flow Path

Under ground
water reservoir

Water house Buffer tanker

Reaction Sand Filter Sand Filter Carbon Carbon Lime

Tanker Tanker 1 Tanker 2 Filter Filter Preparation
Tanker 1 Tanker 2 Tanker

UV 1
Dozing Station

Micro
filter
Chlorine Sulphuric Ferrous
(CL) Acid (SO4) Sulphate
UV 2

Back Wash
Tanker
Rejected
Reverse
Water
Osmosis
Control Panel

Treated Water UV 3
Tanker
treatment

16
 Legend

 Brown line- main process

 Yellow line-dosing line
 Blue line –cleaning line

Figure 3: Flow Diagram of Water Treatment

When the water treated by using the above methods, the following parameters is checked:

1. Amount of chlorine
2. Iron
3. PH value
4. TDS
5. Sulphate
6. Conductivity
7. Total hardness
8. Turbidity
9. M-alkalinity
10. Sensory taste

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3.2 BOILER

Main tasks that we were tried to cover on this include:

 THERMAX Boiler Supervision/ Inspection

 Chemical Treatment/ Lab analysis/ Troubleshooting
 Steam and product knowledge Spirax Sarco
 Use of steam in Beverage Plants

THERMAX Boiler Supervision/ Inspection

The SHELLMAX is a smoke tube, three flue pass, fully wet back, packaged boiler. Its unique
design makes it the most efficient & rugged smoke tube boiler in its class. The technical
expertise that goes in designing this excellent piece of equipment is backed by several years of
boiler manufacturing experience by THERMAX Ltd.

This high efficiency unit can be fired on liquid and or gaseous fuels. The configuration of this
boiler is such that it makes it suitable for burning liquid fuels & gases together, when fitted with
a special burner. However, the standard supply includes arrangement for firing one fuel at one
time. Shellmax Boilers consist of a combustion chamber where heat is generated by oxidising a
fuel and necessary heating surfaces to absorb this heat into water. The water so heated converts
into steam. The steam is separated out of the water by providing steam separation area on the
surface of the water. In order to ensure high efficiency of operation both the combustion
efficiency as well as heat absorption efficiency is to be maximised. Proper mixing of fuel and air
is engineered into a mutually supportive combination of burner and combustion chamber to give
the highest possible combustion efficiency. Sufficient heat transfer surface is provided to obtain
high absorption efficiency.

Combustion is the process of oxidation of fuel. Proper combustion of the fuel will be obtained if
all the components of the fuel get oxidised. Three basic conditions need to prevail in the
combustion chamber for proper oxidation i.e. TIME, TEMPERATURE AND TURBULENCE.
In SHELLMAX these three are achieved by a furnace of low volumetric heat release rate and
highly engineered burner design.

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THREE FLUE PASS DESIGN

The pressure part consists of a main shell. This has a combustion chamber fitted eccentrically on
the lower side of the shell. The rear end of the combustion chambers is connected to an internal
reversal chamber. The entire furnace assembly is held in position between the front and rear tube
plate. Stay bars are used to support rear end of internal reversal chamber.

The flue gases make three flue passes in the boiler for efficient transfer of heat to the water. 1 st
pass is in the furnace itself where heat transfer is mainly by radiation.

INTERNAL REVERSAL CHAMBER

The last part of furnace is having larger diameter than the main furnace and forms the beginning
of the second pass. The flue gases reverse direction of travel to enter the tubes. The chamber is
surrounded by water to keep it cool. The second flue pass is in the tubes between the reversal
chamber and the front end plate. The 3rd flue pass is in the tubes between the front and the rear
tube plate. In the second and third pass the heat transfer is mainly by convective heat transfer

Water level is maintained sufficiently above the reversal chamber top and third passes tubes to
ensure safe operation. Adequate disengaging surface, free board height and a moisture separator
is provided to ensure very good quality of steam.

19
 Figure 4: THERMAX Boiler

WET BACK:
Cooling of rear side of the furnace (reversal chamber) takes place by the water itself. No
refractory is installed, hence maintenance and heat loss associated with the refractory are
eliminated.

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 Figure 5: 3D View of Boiler

SINGLE OR DOUBLE FLUE

Single or double flue means single or double furnace. Two furnaces are used for large boilers.

INDIAN BOILER ACT (IBR)

All boilers have to be designed, manufactured and inspected during manufacturing as well as
prior to installation. This is a government’s compulsory (mandatory) requirement. The steam
boilers have to be operated by qualified and certified boiler operators and offered for annual
inspection to the IBR authorities.

3.3 COOLING SYSTEM

We all know that heat flows in the direction of decreasing temperature, that is, from high
temperature regions to low temperature. This heat transfer process occurs in nature without
requiring any devices. The reverse process, however, cannot occur by itself. The transfer of heat
from a low-temperature region to a high temperature requires special devices called refrigerators.

Refrigerators are cyclic devices, and the working fluids used in the refrigeration cycles are called
refrigerants. EABSC DD plant chooses to use R143a as a refrigerant.

21
The most frequently used refrigeration cycle is the vapor-compression refrigeration cycle, which
involves four main components: a compressor, a condenser, an expansion valve, and an
evaporator.

Figure 6: Chillier Unit

The specific task of each part is:

Compressor –compresses the refrigerant

Condenser – liberates the heat generated due to compression

Expansion valve – a narrow tube that drastically drop the pressure and temperature of the
refrigerant

Evaporator – is the area where we get the cooling effect

We have a compressor which is screw type and it compresses the refrigerant and sends the
compressed gas to the condenser

Compressor needs to be waited to 2 hour and 30 minute before starting the motor the oil must
be heated so that the lubrication is good enough and prevent damage to the motor and coupling
system.

There is heater, motor and coupling system inside the compressor chamber.

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3.3.1 Cooling Tower

Cooling towers are used to conserve or recover water. The hot water from the condenser is
pumped to the tower. There, it is sprayed into the tower basin. The temperature of the water
decreases as it gives up heat to the air circulating through the tower. In the cooling tower, the
water mixes and evaporates in the introduced airflow by a fan. Airflow escapes the top of the
tower at a more humid condition than when it entered. By evaporating the water, the remaining
water is cooled, and then mixed with a smaller flow of make-up water to maintain the mass flow
rate.

The cooled water by the cooling tower is pumped back to the condenser by two pumps. The
water that is lost to that evaporation and also to mist carry-over will be replaced with fresh water.

Figure 7: Schematic Diagram of Cooling Tower

Condenser is used for cooling the refrigerant by using chilled water from the cooling tower by
the action of the fun. And then the chilled water is pumped to the water inlet to the condenser
and by taking heat from the refrigerant through convection it returns by water outlet to the
cooling tower and by the action of the fun which is forced by the motor chills the water back to
its temperature and it recycles again the same rotation.

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3.4 SYRUP ROOM

Main tasks that we were tried to cover on this include:

 Study of syrup making process from raw material to final product including about
its raw material storage and handling.
 Auto and Manual C.I.P process and equipment
 Equations for manufacturing of syrup
 Laboratory practical assessment/ Beverage Quality Manual Requirement.

3.4.1 Soft Drink Manufacture - Preparation of Sugar Syrups

The sugar content of carbonated and still soft drinks varies considerably according to whether the
product is to be supplied, ready to drink, or as a concentrate (often referred to as “syrup”).
A typical formulation would also contain flavoring or concentrated fruit juice, acidity regulators,
preservatives, stabilizers, antioxidants and coloring. With “Diet” and other “sugar free” drinks
the sugar content is replaced with artificial sweeteners such as Aspartame.

The Process

One of the first stages in a typical manufacturing process is preparation of sugar syrup. Sugar is
used in either granulated or liquid form. Liquid sugar simply requires blending with water,
however when granulated sugar is used, a number of processing factors must be considered:

 Small scale production of syrups with low sugar content can be carried out at
ambient temperature. However with some concentrated products, sugar solutions at
60% or above are not uncommon, requiring heating of the water to aid dissolving.
 In large scale operations, heating to around 35˚C (95˚F) may be carried out to speed
up dissolving.
 Other powdered ingredients may be dry premixed with part of the sugar, which helps
to prevent them from agglomerating and “weights” light powders which tend to float.

The problem that probably happens when we make syrup includes:

 Liquid sugar can be considerably more expensive than granulated sugar.

 Dissolving of granulated sugar by simple agitation is a slow process.
24
  Conventional agitators cannot dissolve high concentrations of sugars at ambient
temperatures.
 Heating the water to aid solution adds to costs and is energy inefficient.
 The cooling process further adds to costs and process time.
 Crystallization of the syrup can occur during heating/cooling.
 Incomplete solubilization can lead to sedimentation or even blocking of vessel
outlets.

Hence, to reduce such a problem an appropriate Mixer can substantially reduce mixing times
and eliminate the need for heating the water. This can be achieved with in-tank Batch Mixers
or by adding a Mixer to the existing process. This operates as follows:

The high speed rotation of
the rotor blades creates a
powerful suction which
draws the water and sugar
granules from the vessel
into the work head
Centrifugal force drives
the materials to the
periphery of the work head
where they are subjected to
a milling action in the gap
between the rotor and the
stator wall.
The product is forced out
through the stator as fresh
materials enter the work
head. In a short mixing
cycle all the material passes
through the work head,
progressively reducing
particle size and exposing
an increasing surface area
of sugar to the surrounding
liquid, accelerating the

25 dissolving process.
The Advantages

The combination of granule size reduction and vigorous mixing dramatically reduces mixing
times.
 66 % sucrose syrup can be produced at ambient temperature.
 Increased versatility allows the manufacturer to use sugar in granulated or syrup form
 A mixer can also disperse and hydrate thickening and stabilizing agents such
as CMCs and Xanthan gum in a fraction of the time taken by other means.

Batch mixers operating in the vessel or In-Line mixers for larger volumes are generally used for
this application:

High Shear Batch Mixers

 Suitable for batch sizes up to 500 Gallons.

 Smaller units can be used on mobile floor stands.
 Small units available for R&D and pilot production

26
High Shear In-Line mixers

 Ideal for larger batches up to 10,000 Gallons and continuous processes

 Easily retro fitted to existing plant
 Aeration-free
 Self-pumping
 Can be used to discharge vessel

27
From condenser it enters to the expansion valve, here the pressure and temperature of the
refrigerant drops drastically so that the refrigerant can take heat and reaches its boiling point
easily by the heat from the cooling space or from the cooling load.

From expansion valve it enters to the evaporator which is the main component of chiller
because here the cooling is done by simply taking heat from the cooling space, the refrigerant
vaporizes to start the cycle again and the cooling space lose its heat energy and gets cooled and
that is why we need the cycle of refrigeration again and again to have this effect, so that our
cooling load in the case of chiller is water and by heat exchanger it chills syrup.

Cooling of water is needed due to the following reasons

 Foam prevention during packaging the product

 Carbon di oxide stabilization
 Carbon di oxide is stable under 13c˚
 Syrup room cooling purpose

28
3.5 BLENDER

3.5.1 GENERAL DESCRIPTION OF THE MACHINE

Sidel Blender Machine is designed for continuous production of clear or pulp−based beverages
by mixing base ingredients (water, syrup and carbon dioxide) in variable user − determined
proportions. Operation is completely automatic.

3.5.2 MACRO OPERATION

The blender machine have a system for the preparation of drinks in which the correct quantity of
basic ingredients (water, syrup and ) is measured and dosed in a continuous electronically
controlled process which leads to very high product quality (high precision Brix and Volume
values) in all operating conditions (steady−state and during transitory phases). Due to this
characteristic the yield of bottling lines has been increased by reducing product changeover time
(the initial product is immediately within specifications) and reducing wastage of syrup at
production end. The blending and carbonation precision is assured by flow metering of the fill
components and a control, performed by a dedicated microprocessor, based on the recipes of
each beverage which are stored on the interface PC.

The system consists of a deaerator, a carbonizer, a blender and a finished product storage tank,
all installed in a single frame. For temperature control of the beverage we can supply a plate type
heat exchanger of adequate cooling capacity, installed externally to the system (optional).
The blender can also be supplied with an integral CIP system utilized also for sanitization of the
filler. The sanitization and rinse programs are stored in the interface PC (optional).

In addition, the blender can be equipped with a brix and analyzer and recorder (optional).

There are various possible configurations of the machine:

 Without water deaeration;

 Without injection;

 Without syrup tank.

The machine is composed of the following components

29
 Figure 8: 2D Drawing of Blender Machine

30
Legend
[1] Base
The structure which supports the machine, constructed in welded stainless steel.
[2] Deaeration column
Extracts the dissolved air content of the water by means of an air/CO2 molecular exchange,
thus resulting in pre−saturation (The water can optionally be deaerated using a high vacuum
pump; this method is used in machines which are required to produce one or more still
products.)
[3] Syrup tank
Maintains a small stock of syrup upstream the dosing system.
[4] Flow exchange panel
The fluids control panel.
The production, machine and tubing sanitization cycles require control over the various
fluids involved. This can be obtained by correctly adjusting the flow adapting curves on the
flow exchange panel.

[5] Storage tank

Stores the product for supply to the filler.

[6] Control panel

This consists of the PC and the conventional controls.

[7] Electrical cabinet

Contains all the electrical and electronic equipment required for machine operation.

[8] Water pump

Supplies water to the dosing system.

[9] Syrup pump

Supplies syrup to the dosing system.

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[10] Booster pump
Pumps the product from the storage tank to the filler
[11] Vacuum pump (optional)
Used for deaeration of still products
[12] Glycol heat exchangr (option)
Device which transfers thermal energy from a fluid to the glycol.
[13] Automatic C.I.P. (option)
Device used for local sanitization.
[14] CO2 /Brix monitoring system (option)
Complete system for on−linemeasurement of Brix and beverage carbonation
[15] Ammonia heat exchanger (option)
Device which transfers thermal energy from a fluid to the ammonia.

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3.6 WASHER

3.6.1 GENERAL DESCRIPTION OF THE MACHINE

A bottle washing machine is used to wash empty glass or plastic bottles. The width and length
depend on the washing cycle and the output required.

The machine is made of steel structure inside which two chains travel, carrying beams containing
the bottles to be washed. There are tanks that contain the washing fluids inside the structure of
the machine: each tank has inspection hatches for maintenance and manual or automatic valves
for emptying and filling. The system which feeds the bottles onto the transporter beams and the
system which removes them from the beams are on the short side of the machine. These systems
are connected to the other machines in the bottling line by means of bottle conveyor belts of
suitable size. All the systems required for the machine's operation are installed along its long
sides.

Figure 9: Sidel Washing Machine

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The machine is divided into a pump side and a gearbox side. On the pump side there are the
pumps that feed the spraying stations, pumps for label extraction and all the manual and
automatic filtering systems. The gearbox side carries the system that drives beam travel and the
loading and unloading systems. On both sides of the machine there are also the systems for
water, caustic soda, steam and air and the electrical cabling raceways. Each of these systems has
manual or automatic adjustment and control systems. The electrical components are grouped
together in a panel with a master switch. There are one or more operator panels on the machine
itself for monitoring and operation of the machine. The spraying stations for washing the inside
and outside of the bottles are located in the upper part of the machine. There are inspection and
maintenance doors. The roof consists of movable covers that rest on the fixed structure.
The whole machine stands on adjustable feet.

3.6.2 OVERALL OPERATING DESCRIPTION

The Sidel bottle washer has state-of-the-art technological solutions and a high degree of
automation. It is built with materials chosen for quality and durability.

The machine washes the bottles in fully automatic mode. The bottles are fed to the loading deck
by the conveyor belt, from where they pass into the conveyor system to perform the washing
cycle, consisting of three stages: i.e. prewash and gradual heating with internal and external
sprays, washing in a high-temperature caustic detergent solution, removal of labels and
alternation of immersion and internal sprays, rinsing and gradual cooling with internal and
external sprays until the microbiological characteristics are the same as the mains water used for
the final rinse.

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 Figure: Washer Stages/ Zones

Once they reach the end of the system, the bottles are transferred to the unloading deck and
passed to the conveyor belt where they are sent to be filled.

The machine consists of the following main parts:

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3.7 FILLER

Main tasks that we were tried to cover on this include:

 Basic principles of operation and C.I.P

 Principle of filling valve
 Maintenance of filling valve/ Troubleshooting

3.7.1 GENERAL DESCRIPTION OF THE MACHINE

The rotary filler is capable of high speed filling and capping. Each machine is made by Sidel
S.P.A., PARMA (ITALY) and incorporates cutting edge technological criteria for high speed
bottling and capping. The free−standing units are available in two configurations:

 Clockwise free−standing units (with bottle leftward infeed and carousel clockwise
rotation);

 Counterclockwise free−standing units (with bottle rightward infeed and carousel

counterclockwise rotation).

The rotation direction of this machine is clockwise.

The high productive potential development capacity, together with good resistance in corrosive
environments, reduced maintenance, high reliability and easy size changing adjustment
operations, make the machine safe, versatile and trustworthy for all types of applications. All
movements are carried out by means of electro−mechanical drive, electronically controlled by a
PLC. The electrical system is produced in appropriately dimensioned cables and contained in
special, easily inspectionable cable channels; the electrical panel is fitted with low tension
circuits for the control and programming phases and with remote control switches for the power
units. Inter−relation between the operator and the machine is provided by a push button panel
which, as well as providing full indications in real time, allows all of the machine operations to
be performed manually.

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3.7.2 MACRO OPERATION

Inside the machine the containers are filled and then closed. Fig. below provides a view of the
macro operation of the machine process.

The containers are fed to the machine by suitably sized conveyor belts. The containers are then
filled in the filler unit in accordance with the specified technological filling criteria.

The crowner / capper unit is supplied with closures. When the above operations have been
completed the filled and closed bottles are forwarded to the next process phase on conveyor
belts.

The machine is composed of the following components:

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 Figure 10: 2D Drawing of Filler Machine

38
Legend

[1] Center infeed column.

[2] Carousel.

[3] Filler bowl, piping and relief valves.

[4] Drive base.

[5] Bottle handling system.

[6] Jack.

[7] Filling valve.

[8] Operator interface.

[9] Vacuum pump (if present).

[10] Crowner / capsule unit.

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3.8 BOTTLE CLOSING MACHINE (CROWNER)

3.8.1 BASIC PRINCIPLE OF BOTTLE CLOSING

After filling the bottles are closed as soon as possible. For this, the closing machine (crowner) is
built into the same block as the filler and they are equipped with a common drive to ensure
synchronous operation.

Figure 11: Crowner Machine

The main components of the crowner are:

 Magnetic conveyer
 Crown cork sorting device
 Sorting device drive
 Crown cork channel with turning tube
 Closing unit
 Bottle carrier
 Drive
The crown cork passes on a magnetic conveyor band into the storage hopper of the
bottle closer and is therefore brought into the correct orientation by a sorting device. This is done
by turning incorrectly positioned crown corks in a turning tube with fixed inserts, the
40
crown corks which may be turned 1800from the correct position can thereby be brought into
the correct position by a simple guide device. The closures finally slip downwards and to the
closing element in a delivery groove. The crown corks are supplied to the closer cone by
compressed air.

The closing elements are moved on a circular path and can move vertically. For this the closing
elements have two rollers at their upper ends which are guided on curved tracks. The elements
comprise a ball catch which ensures that no further force can exerted on the bottle after it is
closed.

3.8.2 Closing Process

Crown cork closing elements are:

 Closing ring
 Closing head
 Magnet
 Compensation spring
 Ejection spring
The closing element is lowered by the curved track onto the bottle until the crown cork rests on
the bottle mouth. Then the spring forces the closure onto the bottle and the closing cone forces it
down. There by the 21 teeth of the crown cork are bent down whilst the curved portion
between them push against the upper edge of the bottle mouth and thus seal the latter gas tight.
The closing cone is then raised again, whilst the bottle is still held by the magnet of the ejector
plunger. The closing cone is made of several parts to make removal of the bottle easier.

After filling and closing the bottles are inspected by full bottle inspection (FBI) machine to make
sure they are correctly filled to the filling height and properly closed. Unsatisfactory bottles are
rejected out by the FBI machine.

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3.9 PACKER AND UNPACKER

Then it will be filled with soft drinks and sealed then it goes to the packer where it will be loaded
back into their crates. In the due processes, manually bottles that are over filled and under filled
are removed from normally filled products. The packer is similar in every way with the unpacker
except for the fact that it loads bottles back on their crate while the unpacker performs the
opposite.

Main part of packer and unpacker:

 Gripper head with gripper head operating mechanism

 Create conveyor system
 Pneumatic and hydraulic system
 Sensor system
 Solenoid system

Packer and unpacker in EABSC DD plant is a pneumatic machine. The bottle contained crates
come through pack conveyance, when there is no any pack on unpacking section in feed side
stopper open the pack/crate gate line, after 4 crates passed the stopper locks the line, then no
excess packs are allowed to enter. After unpacking section is filled with enough crates, the
gripper head comes down and pick up the bottles up and slide horizontally then put on the
discharge table (bottle conveyor). Finally, the bottles are prepared for next process and also the
crates are goes to crate washer. The process is same for packer.

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3.10 WASTE WATER TREATMENT

Waste water gathered all around the plant through underground drainage system is stored to a
temporary storage known as EP then it is pumped to a grit channel with two submerged pumps.

The flow of the treatment is shown below

Figure 12: Treatment Flow Chart

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3.10.1 Grit Channel

EP has two submerged pump which pumps the waste water to the grit channel. These pumps
work in shift which have selector at the surface. In the grit channel we have rectangular metal
gauze called coarse screen which filters some fine materials and also a separator concrete in the
channel, so the sand can settle down and the water is passed to the next channel called oil trap
channel by gravity action without any pump action. This is the beauty of nature and engineering
as we use no power.

3.10.2 Oil Trap Channel

Oil trap channel has a mechanical device called oil skimmer which skims the oil that floats over
the channel. We know that the density difference between the oil and the water forces the oil to
float over the surface; since it is the lighter one. So easily it can be skimmed with the oil
skimmer which has a belt driven vertically through a motoring action. From here, it is again
passed to the next channel through a T shaped pipe, only gravity action is there. This is the
beauty of nature and engineering as we use no power.

3.10.3 Pump Pit

The pre neutralization (pump pit) is used to neutralize the waste water which is base due to
chemicals like caustic soda (NaOH), which is used for cleaning purpose in different parts of the
plant as a major drain cleaning agent like washer, CIP in syrup room etc. In pump pit we have a
PH and a LEVEL sensors and agitator. The PLC actuates the solenoid valve so it doze the proper
amount of sulphuric acid (SO4) needed to the pump pit so it neutralizes the waste water. Here the
PH is expected to be in the range (6.5 -8.5).

3.10.4 Dozing Station

Dozing station is a containment which the three tankers kept. These are Sulphuric acid tanker,
ferric chloride tanker and urea tanker.

3.10.5 Equalizer

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The pump pumps the waste water to the equalizer where we use both a biological and chemical
process to treat the water. The bacteria developed here is aerobic which uses oxygen for its
growth and the air is supplied by an electromechanical device called BLOWER, which it sucks
air from environment and pumps it to the equalizer from the bottom aiming to agitate the water
and simultaneously to provide the necessary oxygen supply for the bacteria developed.

We have a PH and LEVEL sensors and PLC controls the PH and if it is necessary it actuates the
valve and from dozing station it doze the sulphuric acid. From equalizer it is passed to the next
tanker SBR1 and SBR2 only bacterial action is there in the last two tankers the principle of
treatment is the same with that of equalizer except that equalizer has some chemical treatment
process.

3.10.6 SBR1 (Sequential Batch Reactor 1)

The process we do have here is only biological. The PH and level sensor send feedback to the
PLC so it actuates the system to doze proper amount and appropriate type of chemical.

3.10.7 SBR2 (Sequential Batch Reactor 2)

SBR2 also has only biological process and it has PH and level sensor. From here the water is
treated and discharged to the environment safely. We have two exit pump and returning pump
which pumps the sludge back to the sludge tanker.

For neutralizing the base, sulphuric acid is dozed and for neutralizing phosphate, ferric chloride
is used. The values expected here are

1. PH of (6.5 – 8.00)

2. PO4 in the range <2mg/L

3.10.8 SBR2 DATA

The end water treated after SBR2 is tested with a laboratory and by checking it is neutral and
safe for the environment it is then released to the environment.

The water released from SBR2 is safe as per the standard and is life supporting. The fish pond
makes sure of as our treated waste water is life supporting.

45
In addition to the PH test made there are parameters which are measured according to COCA
COLA standard, these includes phosphate (PO4), nitrate (NO3), nitrogen (N2) test, BOD, COD,
and etc.

3.10.9 Sludge Tanker

Sludge tanker is used to store the sludge that is returned from the three tankers by returning
pump. From here the sludge is used to make a fertilizer. Mono belt sludge compressor is used to
make the fertilizer through different mechanisms.

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CHAPTER FOUR
4. BENIFTS OF EXTERNSHIP EXPERIENCE

The externship program scales up our practical skills in deep knowledge as we get an
opportunity to deal with:

 Quality analysis/control
 Process control: bieng a process controller we are encountered with controlling the
process like the following:
 Raw material flow rate
 The gearing diagram and motion transmition in each of the machines.
 The operating principles of each machines
 Process parameters used at each machines
 The wastes produced and the ways/method the wastes are recycled,treated or ejected,
etc...
 Effective material handling at all parts of the production line
 Stages where inspection or testing is done and so no

4.2 In terms of Upgrading Theoretical Knowledge

 It improves our previous theoretical knowledge as we explore more than ever in

order to solve the existing problems of the manufacturing plant.

4.3 In terms of Inter Personal Communication

 It brings social interaction

 It helps to build up selfesteam/personal confidence
 It improves our speaking and listening skills
 It thoughts us to to behave in the proper manner
 It motivates us to see different problems and to find out solutions to them
 To exchange new ideas and knowledge,etc..
 Inter-personal communication may include one of the following
 Commmunication with the production line like
- With operators

47
 - Supervisor
- Production department head/clerks
- Plant Engineers
- Quality Inspectors

4.4 Improving Team Playing Skills

“Many eyes see much deeper than single!”

This proverb is to mean that a team of person come up with different ideas to find and to solve
the existing problems than an individual.

As a team member we contributes a lot in many ways there by this improves every individuals
commulative knowledge of solving the existing problem.

Being a team member we improve the following

 Ability of problem identification

 Selecting the most appropriate method to solve the existing problem.
 Generating or forwarding flexible premises to arrest the problem arised.
 A good decission maker, ability to persuade,others,etc.

4.5 In terms of Improving Leadership Skills

As a supervisory activity in the production line, one should be certian about having the
knowledge of the following:

 Process control
 All parameters
 Capacity
 Efficiency
 Quality

Each and every departments communicate with each other to excute their tasks and owes their
respective responsiblities. The out put of certain department may used as the input for the other

48
department and thereby the respective supervisor of each department have to concern about the
points listed out above for the quality and hygienity of the fina lproducts to be obtained.

4.6 In terms of Improving Work Ethics

It builts us with:

 Puntuality
 Reliability
 Honesty
 Independence in work responsibility in the task fulfilment
 Organization team participation quality as a team member
 Support of low level workers
 Cooperation with collageus
 Contribution to the company

4.7 In terms of Improving Externship Skills

The exprience obtained has a great importance upon our life to choose and plan each of our
future activity. Being an extern student we becomes knowledgable in:

 Selection of the effective processing with the least possible cost and maximum out put
 Reduce the production loss
 Increasing efficiency
 Prefering the easiest methods of producing a product
 Extend different projects upon existing proplem concerning certain company, etc.

4.8 In terms of Identifying Company problems and Possible Research Areas

The program is intended to create an industrial exposure for staffs and equipping them with
practical skills. And they are helping an industry by clearly identifying their real problems from
different perspective in such a way that research and community service areas would be derived
accordingly.

Hence, we are preparing a list of identified problems, research and community service areas as
shown in the table below.

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Table 1: Identified Problems and Possible Courses of Action

S.No Identified Problems Recommendation Remark

1 Manually operating fire alarm,

Absence of fire or smoke sensor

2 Absence of CCTV cameras in the

entire compound

3 Presence of old and broken pallets

causing misalignments in case
ordering

4 Absence of fixed place for breaking

and storing of recycling bottles

5 Incomplete waste water treatment such

as absence of BOD & COD treatment
check ups

6 Ware house design, and layout

problem preventing ordering of more
case by forklift

7 Inadequate layout of production area

for evacuation route indicator and
overall production visit tour

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8 Presence of malfunction devices in
waste water treatment plant… PH
meter, oil skimmer on the pump and
equalization tank

9 Rampantly happened burner HFO

valve leakage

10 Annual health check-ups syrup room

workers (special attention should be
given)

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Table 2: Research Areas

S.No Research Areas Remark

1 Study on Boiler Efficiency and Improving

its performance

2 Investigating an alternative mechanism for

replacing Boiler’s high HFO consumption

3 Investigating an economical feasibility

study on replacing a comparable alternative
for changing mechanically beverage filling
process by electronic mechanisms.

4 Study on the effect of discharged waste

water on the surrounding environment

5 Analyzing the chemical composition of

discharged treated waste water to
investigate their effect on the surrounding
environment.

6 Study on the effect of lime, Ca(OH)2

concentration on the formation of scale
during treating underground water

7 Study on the root causes of scale formation

and their subordinating effect on treating

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 underground water operation

Ergonomically analysis of equipment,

workplace, and operational safety

9 Assessment of maintenance scheduling and

Accidental budget analysis

10 Manufacturing system modeling and

performance analysis

11 Work measurement and setting appropriate

work standard

12 Improving water usage per bottle index of

the plant to meet the coca cola standard

13 Improving the energy usage per bottle

index of the plant to meet the coca cola
standard

14 Cost loss analysis due to sudden

breakdown of different machines in the
plant… like filler, crowner

15 Smart power system with renewable energy

sources for the plant

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