COLLEGE OF AGRICULTURE

SCHOOL OF NUTRITION, FOOD SCIENCE AND TECHNOLOGY

BY: DANIEL GASHE………FS/0011/10

ADVISOR; TADESSE F. (PhD)

SUBMITTED TO THE DEPARTMENT OF FOOD SCIENCE AND POST HARVEST TECHNOLOGY

IN THE PARTIAL FULLFILLMENT OF THE REQUIRMENT OF THE COMMUNITY ORIENTED
PRACTICAL EDUCATION (INTERNSHIP) COURSE

PLACE OF THE WORK HAWASSA MILLENNIUM PEPSI COLA PLANT

DURATION OF STAY; MARCH TO MAY

JUNE, 2021

HAWASSA, ETHIOPIA

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Table of Contents
List of tables...............................................................................................................................................iv
List of figures..............................................................................................................................................iv
ABBREVIATIONS.....................................................................................................................................v
Student Declaration and Approval of Mentor & Supervisor................................................................vi
ACKNOWLEDGEMENT..........................................................................................................................vi
1. INTRODUCTION...................................................................................................................................1
1.1 BACKGROUND...............................................................................................................................1
1.2 Objectives.....................................................................................................................................2
1.2.1 Objective of MOHA soft drink factory.......................................................................................2
1.2.1 Objective of the internship..........................................................................................................2
1.3. ORGANIZATIONAL STRUCTURE OF THE COMPANY...........................................................2
2. Process description of Hawassa Millennium Company...........................................................................4
2.1. Raw materials of Hawassa millennium plant....................................................................................4
2.1 Raw material reception......................................................................................................................4
2.3 Raw material handling and storage....................................................................................................4
2.3.1 Concentrated handling and storage.............................................................................................4
2.3.2 Sugar storage and handling.........................................................................................................5
3. Main sections of Hawassa millennium plant Soft Drink Company..........................................................5
3.1 Syrup preparation..............................................................................................................................6
3.1.1Parameters to be controlled in syrup room...................................................................................7
3.1.1 Main unit operations in syrup preparation section......................................................................8
3.1.2 Syrup preparation and procedure..............................................................................................11
3.1.3. CIP for syrup room..................................................................................................................14
3.2. Water treatment room.....................................................................................................................15
3.2.1. Chemicals and filtering media.................................................................................................16
3.2.2. Water treatment process...........................................................................................................16

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 3.2.3. Cleaning in place (CIP)............................................................................................................20
3.3. Laboratory room.............................................................................................................................20
3.3.1. Laboratory instruments and their functions..............................................................................23
3.4 Bottle washer and packaging room..................................................................................................24
3.4.1Process of bottle washing...........................................................................................................25
3.5 Filling room.....................................................................................................................................27
3.5.1. Empty bottle inspection (EBI).................................................................................................27
3.5.2 Mixer machine..........................................................................................................................28
3.5.3 Bottle Filling.............................................................................................................................29
3.5.4 Crown and capper.....................................................................................................................30
3.5.5. Full bottle inspection (FBI)......................................................................................................30
3.5.6. Date coding..............................................................................................................................30
3.5.7 Light inspection........................................................................................................................31
...............................................................................................................................................................31
Figure. Process flow diagram of production room.................................................................................31
3.6. Carbon dioxide production room....................................................................................................31
3.6.1.Process of co2 production.........................................................................................................32
3.7. Boiler room.....................................................................................................................................36
3.7.1Process of boiler plant................................................................................................................36
3.8Chiller and compressor room............................................................................................................37
3.8.1Chiller room...............................................................................................................................37
3.8.2 Compressor...............................................................................................................................38
3.9 Waste water treatment plant............................................................................................................39
3.9.1 Process of waste water treatment..............................................................................................39
4. Challenges during internship.................................................................................................................41
5. Overall benefits gained from internship.................................................................................................41
6. Conclusion and recommendation...........................................................................................................42
6.1Conclusion........................................................................................................................................42
6.2. Recommendation of the company...................................................................................................43
6.3 Recommendations for the department.............................................................................................43
7. Reference...............................................................................................................................................44

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List of tables

Table 3.1: standard to prepare simple and finished syrups……………………………………………….11

Table 3.2: CIP in syrup preparation section (mixer tank)

…………………………………………….........15

Table 3.3: procedure to bottle washer…………………………………………………………………....24

Table3. 4 Mixing Ratio for Water and Finished Syrup…………………………………………….........28

List of figures

Figure 1.organizational structure of company……………………………………………………………..3

Flow chart 1: syrup preparation…………………………………………………………………………...10

Flow chart 2: water treatment ……………………………………………………………………….........19

Flow chart 3:bottle washer....................................................................................21

Flow chart 4:production process..........................................................................29

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Flow chart 5: co2 productions……………………………………………………………………………..34

Flow chart 6: steam production……………………………………………………………………………36

Flow chart 7: chart of chiller………………………………………………………………………………37

Flow chart 8: air compressor………………………………………………………………………………38

ABBREVIATIONS

CIP Clean in place

EBI Empty bottle inspection

FBI Full bottle inspection

FS Final Syrup

MEA Mono Ethylene Amine

MOHA Mohamed Hussein Alamudin

PLC Program Logic Control

PPM potassium per manganese

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RO Reverse osmosis

SC Share Company

SS simple syrup

UV Ultra Violate

UAS United Arab state

Student Declaration and Approval of Mentor & Supervisor

I am 4th year food science and post-harvest technology student in Hawassa University, college of
agriculture and I have been undertaken by my internship experience in hawassa millnium pepsi
cola plant. for a period of three months from march 2013 to May 2013 under the guidance of
Tadesse F.(phD) Academic advisor and Mr. Habtamu production manager.

ACKNOWLEDGEMENT

First of all I would like to express heartfelt thanks for God for providing me healthy time and letting me
to run this work enabling to reach for this time. I also have great inexpressible thanks to my advisor
Tadesse F. (PhD) great role to inter and work Hawassa millennium Pepsicola company and also for
checking what I have done and giving me help full advice. Special thanks are due to HU, FSPT
department for offering opportunity and facilitating necessary conditions required for the activities.

Thanks also go to members of MOHA, staffs mainly Mr.Mekuriya technical support and assistance
during internship work and thanks Mr.Habtamu to help me during internship report submission.I would
like to appreciate all workers of Hawassa millennium Pepsi cola company are willing to help me during
practical work.

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1. INTRODUCTION
1.1 BACKGROUND

MOHA (Mohamed HusenAl-Amoudi) soft drinks industry was formed and registered under the
commercial code of Ethiopia on the 15th of may1996, this company was formed after the acquisition of
four Pepsi cola plants located at AddisAbaba (nifas silk and tecklehaimanot), Gonder, and Dessie which
have been opened by sheik Mohamed Husen Al –Amoudi on the 18 th of January 1996.The hand –over of
the factory was finished on the 4 th of April 1996.later MOHA added summit beverage and plant to
optimize system functionality and operating efficiency to provide outstanding customers service.

Hawassa millennium Pepsi cola plant is one of the seven soft drink plant under MOHA itself a member of
Ethiopian group. The plant was found in the capital of southern region (Hawassa). It islocated at the
southeast edge of Hawassa town on 2500 square meter adjacent to textile and Hawassa cheap wood
factory. It was in 1999 the foundation was laid and the whole process of construction and machine
assembly was complete by 2007. It was in that same year the company begin its licensed official
production. Because of the high technology appliances used .The company’s production capacity is
36,000 bottles per hour. The total project cost was180, 000,000 birr. It is the latest plant which uses  the
new state of art technology such as reverse osmosis water treatment, electronic bottle inspection and best
fillers which totally satisfy the southern region demand. Currently the overall cosmetic of the plant is
impressive, well designed, aimed to produce safe and wholesome beverages and uses its own waste water
treatment plant. Releasing filtered and neutral water to the collecting pond for farm use contributing a
major share for environmental protection. The plant is producing the major brands of their franchised
industry called Pepsi cola international beverage industry. Its main products include; Pepsi Cola, seven
up, mirinda orange, mirinda apple, and mirinda tonic.

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1.2 Objectives
1.2.1 Objective of MOHA soft drink factory

MOHA soft drink factory has its own objectives.

 To satisfy the need and interest of the customer by producing safe and quality product.
 To produce and distribute the product to the local and outside customer.
 To make Pepsi cola soft drink industries competent and dominant in the market.

1.2.1 Objective of the internship

 To develop practical knowledge and professional skill.

 To gain work experience in a professional environment.
 To practice theoretical knowledge acquired during stay in university .

1.3. ORGANIZATIONAL STRUCTURE OF THE COMPANY

Hawassa millennium Pepsi cola plant is a well-organized factory and it fulfills the necessary
organizational structure required to beverage plants.

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Figure 1.organizational structure of company

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2. Process description of Hawassa Millennium Company
2.1. Raw materials of Hawassa millennium plant

Most of the raw materials used in soft drink industries are;

 Sugar; The industry imports sugar from both local and abroad countries; Meteharaand Wenji
is local supplier and countries such as some countries from Far East (Germany
&Russia)are abroad suppliers. White (carbonated) sugar is mostly used because the obtained
from it is clear, soft drinks like 7up are clear because of this property.
 Water; Treated ground water used.
 Carbon dioxide; the company has own carbon dioxide production plant.
 Flavors; for each products it has their own flavor. Two forms of flavor is available; powder
and liquid form and which is imported from Ireland.
 Dry components like sodium benzoate, potassium sulfate, citric acid anhydrous, sodium
chloride, sunset yellow and, etc.

2.1 Raw material reception

The company receives raw material from different sources .concentrates are received from republic of
Ireland, sugars are received from local sugar factories such as metehara,wenji,fincha and also from
countries of republic of Ireland. The company also receives packaging materials such as corks/crown
from Adiss Ababa (kaliti) and bottles come from UAS (united Arab state) which is an approved supplier.
The company receives such raw materials including packaging materials only if they fulfill the general
quality parameters settled by Pepsi cola international .also water which is treated by rivers osmosis co 2 is
produced in its own plant.

2.3 Raw material handling and storage

2.3.1 Concentrated handling and storage

Concentrates handling and storage must be properly managed to ensure quality product. Excessive heat
age or exposed to UV can cause breakdown of flavor components. Concentrates are stored and handled
carefully with storage location >15 cm above floor,>50 cm flow walls in clean and dry

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areas.Concentratesin jericans are not double stacked,also it is stored at temperature between 4-20 0c at cold
room. Concentrate are stored in clean free rodent and other contaminant to maintain good sensory.

2.3.2 Sugar storage and handling

Sugar storage and handling should be properly managed to ensure good quality product. so that sugar
stored in accordance in appropriate temperature and humidity,i.e. at temperature of 30 0c and humidity
level between 40-60 %. Fluctuation in temperature and humidity leads to colure formation and also
increases microbial activity. Also if sugar is stored for extended period of time at higher temperature and
humid condition, the flow ability of materials cannot be guaranteed. Sugar is a hygroscopic and
susceptible to odor pickup, so that to protect these problems it is stored in tightly sealed and away from
odor active substance .MOHA soft drink industry stores its sugar in dry and cool place, odorless area,
sanitary condition and insect and rodent free area and other contaminants free area to maintain good
quality

3. Main sections of Hawassa millennium plant Soft Drink Company

1) Quality control section

 Water Treatment Room

 Syrup Room
 Laboratory Room
 Waste water treatment

2) Production section

 Bottle Washer Room

 Unpackermachine
 Filling Room
 EBI machine
 Mixer machine
 FBI machine
 Date coder machine
 Packer machine

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3) Utility section

 Carbon dioxide Room

 Boiler Room
 Compressor and chiller room

3.1 Syrup preparation

Objective ;to prepare a finished syrup with a desired brix’s and volume (different for different flavor), of
it for those flavor which is initially determined as target value and with all component contribution of the
beverage as it consists of all of ingredient ,flavor, treated water and sugar.

 Ingredients which used for preparation of syrups for different soft drink are:-
 Sugar
 Treated water
 Dry components
 flavors(pepsi,seven up,mirinda orange,mirinda apple,mirinda tonic).

Syrups preparation is one of the step of soft drinks processing technology, which is prepare in 2 phase

1. Simple syrup; is a mixture of the treated water and raw sugar in the dissolved tanker dissolves at the
800C. First the treated water added in to the dissolving tank which is jacketed vessel and the water will be
boiled up to 800C.

2. Finished syrup; is adding the flavor and the dry components to the simple syrup. When all the simple
0syrup is in the syrup storage tank and the brix and amount of simple syrup are confirmed the next step is
to prepare the finished syrup. Where hot sugarprocessing is used, the simplesyrup should be at ambient
temperature (250C is maximum) prior to the addition of concentrate. Otherwise, theflavor oil can be
destroyed. The additions of dry components and flavors are different in different beverage products in
different purposes such as for preservation, for flavor, and for odor of the beverage products.

NB:-General rule is that no more than four hours should elapse between the times of the sugar is added to
the mix tank and time concentrates are added. Because simple syrups is highly susceptible to fermentation
organism.

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3.1.1Parameters to be controlled in syrup room

1,Controlled variables

These are the independent variables of a process and can be defined as parameters of the
process indicating product quality or the operating conditions of the process .It also called
output, factor (variable) that is caused by a system and which is used as a measure of
performance for a given system.

 Volume of syrup in mixing tank

 Degree brix of syrup
 Color of soft drinks
 Ph. of finished syrup
 temperature of final syrup

2, Disturbance variable

A signal that tends to adversely affect the state of the systems that value of the system’s output
and can be classified by internal or external disturbances. Examples of disturbance variables

 Quality of raw sugar

 Environmental temperature
 Quality of concentrates (dry components and flavors)
 Accuracy the equipment
 Quality of reagents
 Accuracy heat exchanger
 Raw materials variability etc.

3, Manipulated variables

These input variables are adjusted dynamically to keep the controlled variables at their set-
points. Therefore inputs are variables that cause or simulate a change in system behavior.

 Control valve buffer tank

 Human and automatic operator

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  Dissolving temperature of sugar in dissolving tank
 Conveying (feed flow rate of sugar)
 Steam temperature on dissolving tank

3.1.1 Main unit operations in syrup preparation section

1. Sugar Conveyor

The first step in syrup preparation is conveying the sugar to sugar dissolving tank through screw
conveyor.

2. Sugar Dissolving Tank

This tank is jacketed tank in order to pass the steam. It contains a hot water that is boiled about 80 0C in
order to dissolve the sugar. The heat that used to boil the water is in steam form which comes from boiler
room.

3. Filter Della Toffola

It is a tank consists of multiple plates in it. It used for filtration. Its principle is that; water and celatonwill
be mixed in it and after a while, the celaton(chemical used to filter the dissolved sugar or simple syrup)
will form a cake on the plate found in the tank.

4. Buffer Tank

The purpose of this tank is to control the level of simple syrup transferred into police filter aid or filter
bag. It is performed by the help of two sensors on the buffer tank; one at the bottom of the tank and the
other at the top. When the simple syrup reaches at the top sensor of buffertank it closes automatically.

5. Plate Type Heat Exchanger

The plate type heat exchanger (chiller) receives 80 0C hot syrup and cool to the suitable temperature for
the next process, which is to 250C by the cooling water. Decreasing the temperature is needed because of
the simple syrup gets into mix tank with high temperature it may damage the flavor in mix tank.

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7. Mixing Tank

There are five mixing tanks in syrup room with size of 11,000Lt each. The simple syrup, which has less
than 250C transferred into mixing tank from plate type heat exchanger .Then, flavors and dry components
from concentration tank mixed with simple syrup in order to give finished syrup. Except for Pepsi, dry
components and flavors mixed in concentration tank, where dry components mixed before they are added
to mixing tank.

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Flow chart 2: syrup preparation

Sugar conveyer

-treated

sugar dissolving tank(800c) -sugar(milled)

-Activated
strainer carbon(15kg)

Celaton
filter

buffer tank

filter bag

heat exchanger (<250c)

mix tank Concentrated treated

Concentrate water

dissolving tank

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 Pepsi cola Miranda 7-up Miranda tonic Miranda apple
orange

T.water for 700Lts 226Lt 230Lt 180Lt 260Lt

dissolving

D.E used for 15kg 15kg 15kg 15kg 15kg

pre-coat

S.S volume 1668.2Lt 516.4Lt 525.8Lt 460.5Lt 595.8Lt

S.S brix 54 62.7 57.1 55.4 57.8

F.S Brix 53.3-54.1 59.1 54.4 48 52.1

F.S Volume 1703.4Lt 567.81Lt 567.8Lt 567.8Lt 681.4Lt

Sugar used 112.8kg 421.4kg 380.6kg 321.3kg 436.2kg

Table 2: standard to prepare simple and finished syrups for 1 unit

3.1.2 Syrup preparation and procedure

MIRINDA ORANGE

 Simple syrup was prepare from treated water and sugar

 The simple syrup was transferred to mix tank and color ,brix,volume and turbidity were checked.

 Sodium benzoate (0.652kg) was dissolved in the small tank and added to the mix tank

 Potassium sulfate (0.34kg) was dissolved in the small tank and added to the mix tank

 Sodium chloride (0.680kg)was dissolved in the small tank and added to the mix tank

 Citric acid (5.783kg) was dissolved in the small tank and added to the mix tank

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  Miranda orange flavor (15.14Lt) was mixed in the small tank and added to the mix tank

 Ascorbic acid (0.133kg) was mixed to the mix tank after the finished syrup brix was tasted

 The mix syrup was agitated for 10 min and was stand for 10 min before bottling

 Brix ,color,volum and turbidity were chucked

 The syrup was transferred to mixer

PEPSI COLA

 Simple syrup was prepared and transferred to mix tank

 Brix ,color ,volume and turbidity were cheeked

 Pepsi cola acid was dissolve in small tank and added to mix tank

 Pepsi cola flavor was mixed in small tank and added to mix tank

 The syrup was agitated for 5min ever 12 hr.

 The syrup was kept for 24 hr.

 The mixed was agitated for 20min and stand for 10 min before bottling

 Brix ,color, volume and turbidity were checked

MIRINDA APPLE

 Simple syrup was prepared and transferred to mix tank

 Brix volume ,color and turbidity were checked

 Sodium benzoate (0.326kg )was dissolved in small tank and added to mix tank

 Sodium citrate (0.329kg)was dissolved in small tank and added to mix tank

 Citric acid (3.219kg) was dissolved in small tank and added to mix tank

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  Miranda brown apple flavor (3.185Lt) was mixed in small tank and added to mix tank

 The mixed was agitated for 10min and was stand for 10 min before bottling

 Final syrup brix ,volume , color and turbidity were checked

 The syrups was bottled in the same date of preparation

7-UP

 Simple syrup was prepared and transferred to mix tank

 Brix ,volume ,color and turbidity were checked

 Citric acid anhydrous (3.56kg) was dissolved in small tank and added to mix tank

 Malic acid (1.814kg)was dissolved in small tank and added to mix tank

 Sodium citrate (1.588kg) was dissolved in small tank added to mix tank

 7-up flavor (5.678kg) was dissolved in small and added to mix tank

 The mixed was agitated for mix 10 min and Stan for 10min before bottling

 The syrup was bottle in the same date of preparation

MIRINDA TONIC

 Simple syrup was prepared and transferred to mix tank

 Brix, volume ,color and turbidity were checked

 Sodium benzoate (0.652kg) was dissolved in small tank and added to mix tank

 Citric acid (9.979kg) was dissolved in small tank and added to mix tank

 Miranda tonic flavor (2.27Lt)was mixed in small tank and added to mix tank

 The mixed was agitated to mix for 10 min and stand for 10min before bottling

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  The syrup was bottled in the same date of preparation

3.1.3. CIP for syrup room

CIP is a process of cleaning in place. Therefore in the syrup room cleaning in place are different for
different products.

1. The Three Steps

a) First, rinse by 500C- 600C hot water for 10-15 minutes

b) Cleaning by 500C -600C using caustic soda for 20 minutes and the concentration of this soda should
be between concentrations of 0.5%-2%.

c) Rinse by 380C -400C water for 10-15 minutes then checking for the absence of chemicals.

2. The Five Steps

a) First, rinse by 500C- 600C water for 10-15 minutes

b) Cleaning by 500C -600C using caustic soda for 20 minutes and the concentration of this soda should be
between concentrations of 0.5%-2 %

.c) Rinse by 380C -400water for 10-15 minutes then checking for the absence of chemicals

d) Sanitize either by hot water at 800C for 15 minutes or chlorine at 100ppm PH concentration for
20minutes

e) Rinse by water for 10-15 minutes then checking the absence of chemicals

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 To Pepsi cola 7UP Miranda Miranda Miranda tonic
orange apple
From

Pepsi cola 5-steps Rinse 3-steps 3-steps

Rinse Rinse Rinse 3-steps

7UP X

3-steps 5-steps Rinse 3-steps

Miranda X
orange

3-steps 5-steps 3-steps 3-steps

Miranda X
apple

3-steps 5-steps 3-steps 3-steps

Miranda tonic X

Table 3.2: CIP in syrup preparation section (mix tank)

3.2. Water treatment room

Water comprises 89-95% of the Pepsi cola beverages. In MOHA soft drink company the purpose of
Water is for the preparation of beverage, washing the bottles, heat exchange or for other cleaning
purpose. The source of water supply is the underground water which is usually free from natural organic

15
matter, but can be high in minerals, alkaline compounds such as iron, calcium and magnesium. It is also
free from external pollution, but it is not pure water, there is growth of microorganisms and minerals
unless it is treated in the plant.

3.2.1. Chemicals and filtering media

There are chemicals and filtering media used for treating water. Those are;

 Chlorine →to prevent microbial growth

 Quartz sand → to avoid physical hazards

 Hydro-anthracite→to avoid physical hazard

 Activated carbon →to DE chlorinate /avoid chlorine

 Polishing filter →to remove carbon fragment

 Softener resin/resin sand →to avoid water hardness

 Sodium chloride →to regenerate resin

 Ultrasil

 fumados used during rivers osmosis CIP

 citric acid

 Cousticsoda→to adjust PH from 7.5-8/neutralize acid

 Antiscalant →to prevent scale formation in membrane

3.2.2. Water treatment process

1. Concrete Tank

It is a tank used to receive the pumped water from the bore-hole and store before transferring tosand tank.
The reason required to store the water in concrete tank is to have a consistent supply of water and
moreover the water used to be treated with chlorine in this tank, though this treatment no longer
taking place at concrete tank.

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2. Sand Filter Tank

Sand filter is type of physical treatment, which provides to separate solid particle, sand and soil content,
to remove unwanted materials from the raw water like floating materials, algae’s present in the ground
water.

3. Intermediate (Raw Water Storage) Tank

In water treatment section there are three intermediate tanks used to receive water from sand
filter tank and store the raw water that passed through sand filter tanks .Then chlorine will be added in
these tanks for disinfection of microorganisms and water without chlorine by itself cannot stay any
longer it will smell and also will have an odor. The water will be stored for about two hours retention time
(time for effective disinfection process).

4. Carbon Filter Tank One

Carbon filter is used to treat (filter) water that stored in an intermediate tank. Its main purpose is DE
chlorinating the water that was chlorinated in product water tank by using the activated carbon in
it.

5. Cartridge Filter (Polisher, 1 micro sized)

It is an instrument to separate (filter) small precipitates, sands, sulfates, ferric salt from water to minimize
the load and avoid damage on the membrane. This polisher contains 10 bags of filtering material which
working together (they are 1 microns) and arranged parallel, where they are packed in one .It is used to
filter the DE chlorinated water by using a 1 micro sized polishing filter bag.

6. Reverse Osmosis (RO)

RO is used to treat the water using high pressure (maximum design pressure 20 bar) to remove almost all
contaminants (inorganic and organic compounds, microorganisms and toxic traces) This is done after
the water is free from chlorine

7. Product Water Tank

It is a tank used to store the water after treated in reverse osmosis. When water
storedmicroorganisms cause off test and color so disinfectant must be added. In this tank, chlorine will be
added for the removal of remaining microorganisms and disinfection. After chlorinating, the water will be
distributed in to two carbon filter tanks: which are carbon filter two and three.

17
8. Carbon Filter Tank Two

This tank task is similar to the previous carbon filter tank one, which is de chlorinating the water
by using the activated carbon. We check the chlorine amount, which must be zero in 1hr. After de
chlorinating, the water goes to five micro size cartridge filters.

9. Cartridge Filter (5 micro sized polisher)

This cartridge filters works in similar way and purpose with the previous one (1micro sized
polisher) but it is 6 parallel arranging straining tube. It used to remove solid impurity and fine suspended
particles, which may pass through carbon filer tank two before transferred to UV. The apparatus used for
filtration is called polishing bag with 5 micro size.

10. Ultra-Violet (UV) Radiation

Last treatment for the product water is used for destroying any present microorganisms is ultraviolet (UV)
radiation. 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 syruppreparation and filling room.

11. Softener Tank

It’s a mechanism of removing chemicals like calcium and magnesium, which could increase the hardness
of the water and also those minerals could have itching effect on boiler and bottle washer
machines by forming scales on the machines body. It is an application to change the hard water in to soft
one.

12. Carbon Filter Tank Three

It is obvious that after storing and treating the water in product tank, the next step was splitting the water
in to carbon filter tank two and three. Moreover, after the water was brought into carbon filter
tank three, it is DE chlorinated by using active carbon containing tank as it was done in carbon
filter tank one and two. Following DE chlorinating the water, 50% of water from softener tank and 50%
of DE chlorinated water from carbon filter tank three mixed together and transferred in to bottle washer,
boiler, chiller and CO2 as a soft water.

Flow chart 2: water treatment

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 Concrete tank
Chlorine

Sand filter

Storage tank Chlorine

(5mg/lit)

Carbon filter

cartridge

Softeners

rivers osmosis

Softner-1

Softner-2

product water tank

Carbon filter-3

Carbon filter-2

Cartridge filter -2

UV system 19
3.2.3. Cleaning in place (CIP)

The CIP system can be used to clean the reverse osmosis system. CIP should be carried out at least three
times per year at an interval of approximately four months. CIP, Backwash And Regeneration Steps
Of Sand Filter Tank; There are five steps to regenerate sand filter tank. Those are Back wash for 1-5
min, Lowering for 5 min, Back wash air for 5 min, Back wash 2 for 5 min, and Final rinse for 5 min. RO
CIP; it is required when the pressure in the membrane gets 12-14 bars. Which is done firstby circulating
the membrane using anthracite at PH>10 and then flush with water, next bycirculating the
membrane with citric acid at PH 2-3 and then flush with water and lastly circulating the
membrane with anti-scalant or in order to prevent scale formation and then flush with product water.
Carbon Filter Tank; CIPdone backwashing with hot water for about 5 min and Final rinse is done for
20min.

3.3. Laboratory room

Laboratory room is a room where the quality, nutrition, and compromising of product with
international Pepsi cola standard is checked and approved. All the way to production is under the control
of laboratory room.

0bjective;

 To check the quality and the acceptability of water, the chlorine content, hardness,
softener of the water from water treatment room and from concrete tanker, the caustic
amount in the bottle after bottle washer and also to know the final product and finished syrup
composition and to make it under the standard.
 To identify the chemicals in the wastewater, check the acidity and caustics of the
wastewater from wastewater treatment.

To check different parameters from different section.

1. Water Treatment;In water treatment room, three samples are taken from raw water, softener water
and treated water respectively.

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A) Raw Water

Parameters to be checked during testing raw water are;

 PH; most of the time raw waterPH be positioned between 6.5 and 8.5. However, it is required to
be seven that is neutral and this can be done by treating the water.
 Conductivity; is the primary measurement of mineral contamination in water. This
contamination is checked in laboratory and, depending on the results, 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 nonsucrose
substances, such as polysaccharides, high molecular weighting polyphenols and suspended
minerals (ash) that are generally invisible to the naked eyes. This parameter of 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.

B) Softener Water

This 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.

 Total Hardness; this also treated it change the hard water to soft as much as possible after
knowing it result from laboratory.
 Conductivity; Like to the raw water, the mechanism is also similar to softener water.

C) Treated Water

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. Note that treated water is safer and cleaner than raw and softener water.

2. Syrup Room

A) Simple Syrup

21
A sample will be taken from simple syrup to check its 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.

B) Final Syrup

Under final syrup, brix also will be checked, and titrableacid is the other parameter to be
checked. The value of final syrup is different from simple syrup, because of the addition of dry
components and flavors to it. And the range differ across the type of the product. For example: -Pepsi
53.5 to54.00, Miranda 59.10, Tonic 48, 7-up 54.40.

3. Finished Product

Whenever finished productsare brought to laboratory, the first step is to observe the existenceof foreign
materials in it by using bottle inspection glass. Then its cork size and fill height will be measured by
using cork measurement and fill height gage respectively. After measuring temperature and
pressure of the products in order to read carbon dioxide, carbon dioxide is removed to measure
brix. If we measure the brix with carbon dioxide present in it, it will not give as the correct result
because the system works oscillating, when carbon dioxide present in it, it will start trapping. This all
checkup is done continuously in every 20 min.

4. Hot Water For Bottle Washer

The bottles are washed with hot after leaving caustic washing section. To approve the
perfectiveness of the bottles, the hot water alkalinity checked by treating it with H 2SO4 of 0.02N.

5. Caustic Concentration

The concentration of caustic required can be checked by using H 2SO4 of 2.5N.

6. Carbon Dioxide Preparation Section Test

The test done this section are water softness test, oxygen and carbon dioxide test, soda ash test, MEA
test, CO2 purity test, PPM test, test for toxic gases, oil and odor test

22
3.3.1. Laboratory instruments and their functions

There are different laboratory instruments and their functions are as follows;

 Absorbance; a measure by spectrometer of the amount of light lost after passing through the
sample solution.
 Absorbance unit; measures turbidity of a sugar solution calculated from absorbance difference
between unfiltered and filter solution.
 Hand shaker; to measure CO 2 volume in beverage by using pressure and temperature
correlation.
 DE carbonator; used to remove co2 from carbonated beverage in order to measure brix or
density of mixed ingredient and sugar in beverage using density meter or refractor meter.
 Carbon dioxide quality control; used to measure the volume CO 2 in carbonated beverage after
enough sample of beverage sucked to enter using CO 2 device.
 Density meter; used to measure brix of beverage that is total ingredient and sugar.
 Refract meter; used to measure brix of beverage that is total ingredients and sugar using refractive
index.
 UV-spectrophotometer; is used to know the Quality of raw and treated sugar interims of their
color and ash content and also it measures the amount of light at a given wave length
after it has passed through a solution in a cell.
 Conductivity meter; used to measure sugar quality in terms of its turbidity.
 PH meter; used to measure PH value of –beverage water and other solution.
 Magnetic stirrer; used to mix granular chemicals added with water and other chemicals with
water.
 Analytical balance; used to measure the mass of solid or liquid chemicals.

3.4 Bottle washing

The bottles collected from different areas are contaminated with different contaminants that affect the
final products. so that the contaminated bottle must be properly washed before filling.

Chemicals used for bottle washer are:-

23
  caustic soda :-used for washing the bottles for removing the contaminants in the inside and
outside of the bottle
 Chlorine:-used to kill microorganism
 Divo bright :-used for caustic strength during washing
 Divo LE(VB92):-used to remove the dirty and contaminant on the side of the bottle and prevent
the contamination
 DivoAI ;-used to calibrate the PH of the water.

Bottle washer procedure

Operation Pressure (bar) Temperature (0c)

High pressure jetting 2.7 40

Pre jetting 1.2 40

Caustic 2.1 65-70

Caustic 1.5 60-75

Post caustic 1.6 38

Warm water1 1.2 48

Warm water 2 1.0 40

Cold water 1.3 38

Fresh water 2.5 25

Table 3.3: procedure to bottle washer

3.4.1Process of bottle washing

1) High Pressure Pre Jetting

24
It is a section where more the dirty from the bottles are removes by injecting by high pressured
(i.e.2.7bar) hot water.

2) Pre Jetting

Pre-jetting follows remnant beverage emptying. This flushes out any impurities clinging to the bottoms of
bottles. Rough impurities such as drinking straws, cigarette butts, and crown corks, etc. are deposited in a
collection pan together with residue from rinsing bottles.

3) Caustic I

The long-drawn guides of the vertical bends in the caustic solution bath make a long submerged treatment
time of the bottles possible and permit at once a compact machine construction. The caustic solution is
drained via quick drain valves. Leaving the pre rinse section, bottles areinverted to drain pre rinse water
(avoid dilution of wash solution) and enter the wash caustic onetanks.

4) Caustic II

In this step, the mechanism is almost similar to caustic one. It is applied after caustic one just for further
cleaning. In these tanks, the bottles are subjected to a series of soak and/or detergent jetting. To
increase the efficiency of the cleaning solution, the bottle washer operates at high temperature
(65°C/149°F glass).

5) Post Caustic

It removes the amount of caustic remained in the bottle by the action of hot water at the
temperature of 600C.

6) Warm Water I

Zone one immersion bath is dimensioned in such a way as to ensure complete bottle filling. It guarantees
a very efficient rinsing of bottles and supporting units. On leaving the wash tanks, the bottles are drained
and then enter the pre-final rinse recirculating spray section. A series of sprays from dilute caustic to fresh
water remove the last traces of soil and residual detergent on the outside and inside of the bottle. The pre-
final rinse tank has two features; removing detergent, dissolved or suspended dirt from the inside
and outside of the bottle and lowering bottle temperature gradually to avoid thermal damage .

7) Warm Water II

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This water-spraying zone is a combination of flushing zone, lower and upper external flushing system and
rotating inner spraying with adapted filter system. The final rinse is one with clean water of good
bacteriological quality.

8) Cold Water

It is final cold fresh water rinsing the gradual decrease of temperature at which reaches colder than before
to cool the bottle to ambient without thermal damage. Rinse compartments of the bottle washer should be
hosed free of debris daily. If fresh water rinses do not contain chlorine, then water with chlorine level of
1.0 mg/l of free chlorine, should be circulated from the final rinse jets back to the pre-rinse jets and to
drain.

9) Fresh Water Spraying

Fresh water spraying is the final step before discharging the bottles into filler room and it is a rotating
inner spraying. The fresh water flow rate corresponds to the amount of discharged in the pre-heating
section. Its duty is only to rinse the bottle with 25 oc water. In this step, if the bottle fails; one of the
above inspections, it will be removed automatically or manually by visual inspectors.

10) Bottle Exit

After the final rinse, the bottles are drained, mechanically discharged from the bottle cells onto the
conveyor where they proceed to the empty bottle inspector station and eventually to the filler.

Caustic 2 Post caustic

High Pre jetting Caustic 1
pressure
jettinig

Warm water Warm water Cold water Fresh water

1 2

Figure. Steps of bottle washer machine

Packaging room

Packer machine is used to load the crates with bottles containing the soft drinks.

26
Unpacker machine is used to unload the empty bottles from their crates.the basic compotes are several
links motor,chain,grippers,pneumatic compontes and sensor.

3.5 Filling room

Among the other sections of production, filling room is most valuable one having the purpose of verifying
the container whether constantly filled to the correct level as established by correct volume or
weight for the brand and package type or not. Thefinished syrup from syrup preparation section
pumped to heat exchanger to form cold beverage by cooling fluid glycol and ready for the parameter
operation. The parameter blinds the syrup with distilled water and CO 2based on determined ratio. In the
filling room, the syrup and CO 2come from their respective side. From carbon cooler, syrup goes to the
filler and from other side empty bottles and then crown cork or cap corks are fixed on the bottles.

There are different machines to do the entire job under filling room.

3.5.1. Empty bottle inspection (EBI)

This machine is used to inspect the empty bottle that comes from the bottle washer. It has about eight
parameters to inspect the coming bottles continuously.

1) Neck Finish;by using camera system it detects the bottleneck, whether it is cracked or not.

2) Base; it checks the bottles base or bottom part. If it is too thick or too thin or if it has no gear on it, the
machine let the bottle leave the canal.

3) Inside Wall; it checks whether the inside wall is cracked or not.

4) HF Caustic; using antenna system it detects whether there is any caustic in the bottle that comes from
bottle washer or not.

5) IR Residual Liquid; using infrared ray it checks whether a residual liquid is present in thebottle or
not.

6) Too Tall; there is a sensor to detect the length of the bottle, it checks the bottle whether it is too tall or
not.

27
7) Too Short; there is a sensor to detect the height using adjustment sensors whether the bottle is too
short.

8) Cork; it detected by the adjustment sensor.

3.5.2 Mixer machine

The mixing processor combines different sub processes such as de-aeration, proportioning and blending,
carbonating and cooling. Ingredients such as water, finished syrup and carbon dioxide are mixed, and
filled into closed and packed sanitarycontainers.

1) De Aeration

The benefits of de-aeration of the incoming water supply are important, particularly, for canning, high
speed bottling lines and ambient filling. This is because of reduced air is necessary to meet standards for
canned product and less air equals more accurate proportioning and CO 2 control. Additionally, less air
means greater product stability in filling and less foaming, less air equals less product oxidation and less
risk of contamination, less air is important in achieving maximum filling speeds and becomes critical
when utilizing "ambient" filling processes.

2) Product Cooling

The use of the cold filling process minimizes foaming at the filler, allows the systems to run at lower
carbonating pressures, can give a faster rated speed, and offers advantages from a microbiologic
standpoint.

Cooling of product is done by heat exchanging through a chiller by ammonia where ammonia is cooled
by outer air cooling system..

3) Carbonation

Carbonation is the process of combining the finished syrup, treated water, and CO 2. It is the
processes utilities physical characteristics such as temperature, pressure, surface area and contact time to
facilitate the absorption of carbonation in the beverage. As the beverage is chilled, itabsorbs
carbonation. If the product temperature is raises, the CO2becomes less soluble. The gas pressure must
be increased to maintain the same absorption of CO 2. If the temperature of the product is decrease,
the CO2 becomes more soluble. The pressure must be decreased to keep the volume of carbonation within
standard.

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4) Proportioning

The primary function of the proportioning equipment is to blend accurately finished syrup with water at
the correct ratios or proportions

Product Water Syrup

Miranda orange 4 1

Pepsi cola 5 1

7-up 5 1

Miranda tonic 5 1

Miranda apple 4 1

Table3. 4Mixing Ratio for Water and Finished Syrup

3.5.3 Bottle Filling

In the filling room, the syrup and CO2 come from their respective side. From carbon cooler, syrup
goes to the filler and from other side empty bottles and then crown cock or cap cocks are fixed on the
bottles. Filler machine is a machine used to fill the product into empty bottle. The machine that sucks the
bottles and fills the product is called a bowl.

Purpose of the filler machine is:-

 Minimizing foaming

 To fill returnable and non-returnable bottle to a predetermined level

 Deliver the bottle to a crowner

The filler machine has six sequences from receiving the empty bottles to filling the product. These
sequences;

1-evacuation:-it is a process of evacuation unnecessary gases from the bottle

29
2-rising /flushing:-it is a process using to arrange purity /to risingby removing microorganism and other
contaminants from the bottle by using pure co2.

3-preservation:-it is a process of removing co2 used during rising /flushing

4-filling:-it is a process of fill the mixed products with desire volume after co 2

5-fill level correction:-it is a process of correct volume /to correct filling performance .i.e, if over filling
control via sucking

6. Sniffing:-it is a final step of filling process using to reject the corrected product

3.5.4 Crown and capper

The crown and capper apply the closure to the filling bottle .the function of the crowner is to
mechanically apple and seal crowns to bottles. This procedure uses a crimping technique that applies
pressure causes the top and side of the crown. This pressure causes the crown to adapt to neck of the
bottle.

The important of the crown closure are;-

 To prevent the entity of air and microorganism in to the product

 To protect the releasing of co2 from the product

 To ensure the confidence of the of the customers

 To keeps the loss of the product

3.5.5. Full bottle inspection (FBI)

Full bottle inspection machine is using after the bottle is filled to inspection and reject under fill, over fill,
uncrowned and daddy crowned bottles.

3.5.6. Date coding

There is a legal requirement to mark products with a ‘Best before End’ date. Date coder is a
machine used to label the best before date and the factory’s abbreviation name with the time of

30
production. This is typically done by a series of dots, and this can be done with ink. it is a written type on
the neck of the bottle to express the products for the customers.

It include;-

 The name of the company that is the products is produced.

 The date and the year of the product are produced
 The time which is the product is produced.

3.5.7 Light inspection

Using to inspection and reject over filling and contaminated produced by light inspection machine

Filler machine Capper FBI machine

EBI machine Mixer
machine
machine

distribution Full bottle Palletizing Packer Date coder

storage machine

Figure. Process flow diagram of production room

3.6. Carbon dioxide production room

Carbon dioxide is one of the essential components in beverage production process. It is prepared from
fuel oil by burning the fuel oil in the burner due to combustion. During the combustion of fuel oil CO 2 is a
gas. It is a colorless, odorless and tasteless and hard to detect.

Since the fuel oil contains ammonia, Nitrogen, sulfur, oxygen and other different gases it must have to
pass different necessary steps to remove these undesirable gases.It has critical temperature and critical
pressure, critical temperature of CO2 is 87.9oc above it is impossible to liquidity the gas by increasing the
pressure and the critical pressure of CO 2 is 7281kpa and above, it is impossible to liquidity the gas by
increasing the temperature.

Some function of carbon dioxide in Pepsi cola plant:-

 increases preserve

31
  increase acidity product
 act as antimicrobial agent
 Contribute to sensorial characteristics of the product.

The raw materials to produce carbon dioxide are;-

 Fuel oil; used for gas generation.

 Sodium Carbonate (soda ash); used to remove SO 2 and SO3 from flue gas or
neutralization purpose to regulate the PH of around 6 – 7.
 MEA( Mono ethanolamine); used as carbon dioxide absorbent, boiler temperature control,
steam generation. Its temperature is 1100C.
 PPM (Potassium per Manganese); removes impurities from CO 2.
 Activated Carbon; additive used as filtering aid)
 Water; for cooling purpose.

3.6.1.Process of co2 production

1) Fuel Oil Tanker

Fuel Oil Tanker is a tanker that used to store the basic source for the production of carbon
dioxide, which is fuel oil. The fuel oil is burned in order to give 160 kg/h of CO 2 gas. It holds 63 l/h of its
maximum.

2) Combustion Chamber (Burner)

The fuel gas oil brought into burner and the burner generate flown gas that contain nitrogen, CO 2,sulfur
dioxide and carbon mono oxide by combustion of fuel oil with air.

3) Flown Gas Scrubber (Soda Ash Scrubber Tower)

Is the section flue gas is cooled down and sculpture is removedsoda ash solution is added in to soda
scrubber pump and by circulated in the system and remove the surplus which is present in the fuel gas,
sulfur and sulfur dioxide component are very harm full to the co 2 plant

4) Absorber

This compartment designed to separate CO 2 from the other flown gas by means of solvent
absorbent liquid MEA at moderate temperature (35-400C) and high pressure.

32
5) Stripper

Used to stripe/ separate the co 2 from mono ethanolamine (MEA) by evaporation of the co 2 from MEA by
application of temperature about 180 0c-2000c. The co2 separate from MEA is going to gas cooler and
MEA is circulated in the boiler.

6) Gas Cooler

Gas cooler Is heat exchanger using to cool down co 2 gas to 50% approximately by using cool water.

7) Water Separator

When CO2 passed through heat exchanger, it will be cooled and between the reactions of hot
CO2 and gas cooler it may absorb the moisture. As the temperature goes down (40 oC) separation of water
vapor and CO2 will be easy. Therefore, this water separator separates the moisture from CO 2.

8) PotassiumperManganese (PPM) Scrubber

After the water separator, the CO 2 gas enters the PPM scrubber, here the NOx, MEA particles and
acetaldehydes components are washed-out by with a 3% PPM solution circulating in the scrubber.
It oxidizes other gases except CO 2 and also it removes all organic materials and impurities and increases
contact and surface area reactions takes place.

9) Co2 Compressor

This unit is designed as piston type double stage compressor to develop high pressure of CO 2. The first
stage compressor compressed to a pressure of 3bars and a temperature of 150 oC then to shell and tube
heat exchanger to cool the temperature down after that the second stage compressor compressed
to 16bar and 30co this is due to the property of CO 2 to closer to liquefaction.

10) Dehydrator

Dehydrator isthe process of removing water from co 2 in the compressor. During this process final drying
of co2 take place.

11) Carbon Filter

As the CO2producing is for product carbonation it must be free from any odor, color and taste. So, active
carbon filters used to remove those odor and other impurities from the gas. Traces of different organic

33
and sulfuric compounds can be trapped and after successive work it regenerated by steam for biological
treatment.

12) Co2 Condenser and Refrigerator

The CO2 gas from the filter/purification system is going to the CO 2 condenser. The CO2condenser
is a shell and tube type where CO2is on one side, and refrigerant on the other.

Co2 condenser →at this stage co2 is condensed and then condensed co 2 is flowing by gravity to the
storage tank.

Between the carbon filter and co2 condenser the laboratory assistance take the sample to check purity of
co2 ,if the purity is greater than 98% it go to refrigerator where not rejected it.

Refrigerator →it is instrument which converting gas co 2 to liquid co2 by using Freon refrigerant at
temperature greater than 300c.

13) Co2 Storage

The CO2, which is in the liquid form stored at 27°C in the cylindrical storage tank before
evaporated into gas form again.

14) Evaporator

The liquid form CO2will be transferred into evaporator and will be heated until it changes its nature into
gas form. After it has changed into gas, finally the CO 2 can be goes to filler room in order to mix with
syrup and water for the final product.

Fuel oil tank Burner Fuel gas

Absorber stripper
1500 L 230 O
360 scrubber
C

CO2
dehydrator PPM Water Heat
compressor scrapper separator exchanger

Refrigerator
CO2 (L)
Carbon filter and evaporator Filler room
storage tank
condenser

34
Flow chart 1: co2 productions

3.7. Boiler room

It mainly engaged by generating steam that further used in washer room, carbon dioxide plant and syrup
preparation room.

The raw materials of boiler to produce steam are;

 Furnace (heavy oil)

 Soft water
 Air (oxygen)

The reason behind for choosing furnace over fuel (Light oil) is that it is cheaper than fuel oil but for
multipurpose boiler we only use high quality fuel oil.

3.7.1Process of boiler plant

1. Water Storage Tank; Softener treats soft water from the water treatment room again by adding
different chemical like NaCl and by using sand. Soft water heated by a temperature of about 100 0C. It can
store 3200lt of soft water.

2. Fuel Storage; the storage has the capacity of holding 500L of the furnace.

3. Boiler; Maximum set points of parameters in boiler machine are pressure at10bar, temperature at
1800C and steam capacity of 3200kg/hr. the boiler system comprises are three systems. Those are:

4. Steam Storage; here the steam produced at the boiler comes with line attached in the steam storage. It
distributed for different purpose. For instance for bottle and crate washer, syrup room, water treatment,
and for CIP purpose.

5. Condensate; is the storage of the condensate from different line and by using pump the
condensed water sent to the storage tank

35
 Flow chart 4: steam production

air
flame Boiler
burner gas
Fuel oil tank

Syrup room
Steam
steam
distribution
Bottle
washer
room

3.8.Chiller and compressor room

3.8.1Chiller room

Product cooling is done to reduce the product temperature from ambient to <15 0C. This
temperature is facilitating filling operation by reducing foam formation and increase the ability to accept
CO2 or facilitating also carbonation and it also vital role on preservation of product as cold product has
long shelf life than warm product. Working principle of product cooling is Cooling of product is done by
heat exchanging through a chiller by cooling fluid glycol. Glycol is cooled by ammonia where ammonia
is cooled by outer air cooling system. Product is better to cooled by glycol alcohol than ammonia base to
minimize contamination risk and side effect .the cooled product is then ready to mixing.

Flow chart 5: chart of chiller

36
 Soft water storage tank

Ammonia tank

Air cooler pump (<15oc) Syrups cooler pump(<15oc) Product cooler pump (<15oc)

3.8.2 Compressor

Digital automatic and modern and work max up to10bar. Air is compressed from environment but the air
contains dust, moisture and heat. For that case, the machine has filter to remove dust and air compressor
dry to remove moisture. The has also oil filter, the oil used for lubrication purpose. There is no direct
contact compressed airwith product. Compressed air usedfor pneumatic purpose such as at packing,
unpacking, bottle washing, water treatment, filling and so on.

Flow chart 6: air compressor

Moist air collection

37
 Dust collection
Water collection

Dry air collector

3.9 Waste water treatment plant

The main objective of wastewater treatment is to neutralize the wastewater comes from different sections
of the plant by physical, chemicals and biological means of treatment in order to reduce environmental
impact.

Main sources of wastes are filling area, bottle washer, water treatment, syrup room, cafeteria, CIP
and garage.

3.9.1 Process of waste water treatment

1. Screening; the raw wastewater contains physical impurity. This kind of impurities is separated by
strainer, which allow impurities under sized to pass and retains oversized contaminant.

2. Oil Skimmer; the raw wastewater also contains greases, oils and other water immiscible
substance from lubricant and other production assistant fluid. Since this kind of contaminant has greater
effect to the allowance of wastewater so it must be separated from the water and the instrument
to separate this mixture is oil skimmer pump. This works by the principle of rotating belt scrubbing. The
pump rotate at the upper surface of the water and it drive the soaked wider belt. When the belt rotates
from the water to outside it scrub and carry the oil. At the outer side of the belt, an oil line receives the oil
and stored to oil tank. Thus, the separated water goes to stage one.

3. Chemical Dosing;the raw waste from the plant are basic to de-alkalize it chemical dosing is necessary
beforethe buffer. The dosing chemical is sulfuric Acid (H 2SO4 98%) used to against the high PHwaste
water. For stage 1, chemicals are dosed in proportion of the flow and inlet PH, measured at the outlet the

38
sand trap. A correlation formula is then used to calculate thepulse-pause timer for the dosing valve. The
correlation uses the titration curveof typicalwastewater as it was analyzed by the laboratory and also the
same for stage 2.

4. Primary Settling Tank

Swimming pool like tank at which waste water is distributed by two equally working aerator to prevent
settling of impurity. Reaction tank and coagulation tank included under this tank. In reaction tank,
chemical that is poly aluminum chloride will be charged in order to adjust PH to7 and to breakdown
bonded bacteria from dissolved sugar waste and in coagulation chamber, polyelectrolyte will be
charged to get the better coagulation of the solids.

5. Bioreactor 1 and Bioreactor 2

Required to feed bacteria inside the filtered water by the action of other bacteria with in bacteria media
and also there is mixing in both reactors in order to eliminate odors.

6. Secondary Settling Tank

It is a matter of further filtration no more difference from primary rather than amount of treating
efficiency. The water from bioreactor two are pumped to the settling tank two by secondary centrifugal
pump which has a pumping capacity of 25m3/h and the settling tank filter the primary tank water. While
the impurity is retained by the settling tank as a coagulant and the filtrate goes to holding tanker for
further physical and chemical treatment and purification.

7. Holding Tank

In holding tanker, the chemical that is potassium hypochlorite will be charged in order to trap high flow
and to separate the sludge from the water.

8. Sand Filter

It is the final step to waste water treatment plant. Sand filter is turbidity reduction mechanism it retains
the remaining impurity by settling in sand containing pool and finally the water loss to the environment
by checking its purity to the environmental impact. The neutralized system is used to neutralize the
incoming wastewater to a PH range of 6.0 to 8.0. The coming wastewaterscontaining a physical
presence of floating and deposited materials which are removed by a screening method. The two

39
stages have the same principles but may different in the amount of dosing chemicals and treating
efficiency. In this tank, the chemical that is activated carbon will be also charged in order to remove odor,
taste and to DE chlorinate the charged chlorine.

9. Treated Water Tank

This tank is used to store the treated water before discharging to the available directions.

4. Challenges during internship

 Limitation of professional persons

 Program failures
 Scarcity of well documented material
 Some workers of the company are not volunteer to give experience
 Luck of safety shoes
 Transport Service Scarcity

5. Overall benefits gained from internship

During I stay three months I have gained the following benefits

 Up grading theoretical knowledge; my three-month stay in company, I really improved my

theoretical knowledge. This is by reading some essential books and searching for useful sites to
my internship. Since to get into practical knowledge theoretical knowledge is mandatory.
 Improving practical skill;in the period of stay four months internship, I improved mypractical
skill and also became familiar with equipment’s that had not seen. Before starting the practical
learning, I did not have sufficient practical skill. To improve mypractical skill, I used the
following tasks frequently while I was in the company:
 Creating smooth relationships with operators
 Spent more time on practice with operators
 Take enough time to understand and ask question
 Exchanging information
 Respecting others and keeping the rules and regulations of the company

40
  Improving team playing skill; learned a lot about works done together better than those done
individually.I courageously tried to work together with my internship friends. Ideas that are raised
in team work help to see one thing in different angles and to be a multi directional thinker for
elaborating our knowledge regarding the given issue.
 Understanding work ethics;essential work ethics that I have developed through the internship are:
punctuality, loyalty, dependability, self-discipline,leadership,accountability and transparency,
initiative, self-responsibility, trustworthiness, flexibility.

6. Conclusion and recommendation

6.1Conclusion

The internship program is very necessary for the students to apply the theoretical knowledge to the
practical skills and to ensure to develop our communication skill and the leader ship skills. So the
Hawassa University should be given the greater attention for the internship program for the students to
capture or collect the practical skills. In the time that I have spent in Hawassa Millennium Pepsi Cola
Plant I am getting acquainted with the process operation of how Pepsi cola products are produced, and I
am going to describe the following conclusion from my observations. Generally, Pepsi cola products are
nonalcoholic beverage (soft drink) which is mainly produced from sugar, water and flavoring acid. 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. So by changing the sugar content and the flavoring fruit juice the plant producing different
well organized and a good quality standard products like Pepsi cola, 7-up, Miranda apple, Miranda tonic,
Miranda orange, Miranda pine apple. Those products have strict quality control and standards of every
aspect either its carbonation level or the remaining concentrate as it is a soft drink and cannot preserve by
itself like that of alcoholic product rather than easily affected by biological contaminant. Products of
Pepsi cola Soft drink is not a zero impact drink as it has some sort of problem in our health if we
consumed much or addicted with it.

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6.2. Recommendation of the company

In our three months stay at Hawassa millennium Pepsi cola plant, we observed some problems and
mistakes made and we tried to give respective professional recommendations as follow;

 Since the condition is warm, it is difficult for workers to perform their activities; the air
ventilation should be installed especially in the syrup and laboratory room.
 In carbon dioxide production plant, as a source the company uses coal (fuel) which is
both expensive and hazardous to the environment. In case of cost and hazard, I
recommend to use other alternative (i.e. biogas)
 The company mainly uses imported sugar rather than locally produced sugar for the case
of relative clarity. But it is better to give constructive and corrective comment to local
sugar manufacturers to do more on sugar clarification section and with in international
standards

6.3 Recommendations for the department

 The university industry linkage must be follow day to day activities of the interns for
better activities of the students.
 The university not focused on the practical learning and not related with the industrial
application during learning the theory of the science which needs to be focused on the
practical learning
 At the beginning the internship was delayed due to finance therefore, for effective use of
time better to process finance on time.

7. Reference

Capobianco, D.J. And F.C. Blanc, 1990. Treatment of Soft drink Syrup and Bottling Wastewater using
Anaerobic Up flow Packed Bed Reactors, in Proceedings of the 44th Industrial Waste Conference May 9-
11, 1989 Purdue University. Michigan Lewis Publishers

David P. Steen and Philip R. Ashurst (2006), Carbonated soft drinks: formulation and manufacture, First
Edition, Published by Blackwell published Ltd, ISBN-13:978-14051- 3435-4, UK

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Nemerow, N.L., 1978. Industrial Water Pollution, Origin, Characteristics and Treatment. USA: Addison-
Wesley Publishing Co., Inc.

PepsiCo, (2005). Quality manual PepsiCo international standards and specifications and operational
practice Vol-3 and Vol -4 700 Anderson Hill Road, NY.

PepsiCo, (2005). Quality manual PepsiCo international Analytical methods Vol-2 700 Anderson Hill
Road, NY.

PepsiCo, (2005). Quality manual PepsiCo international standards and specifications and operational
practice Vol-3 and Vol-4 700 Anderson Hill Road, NY

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