Final Intenship Report and Project: Acknowledgment

FINAL INTENSHIP REPORT AND PROJECT
Acknowledgment
First of all thanks to God for keeping all things to be happened in good manner. I would like
thanks to mekele university institute of technology for giving this chance to get practical
skills & to have some important and essential knowledge about soft-drink processing from
raw materials to finished product from company. Also deeply extending my sincere
appreciation to my advisor mr.Thedros, For his valuable advice, constant support,
commitment, dedication, encouragement and precious guidance, creative suggestions and
critical comments, and for his being everlasting enthusiastic from the beginning to the end of
the project. Without his urge, no doubt, this work would not have been possible at all
Secondly, a word of thanks must also go to all staffs’ of MOHA Soft Drinks Industry Dessie
plant for their valuable advice, constant support, commitment, dedication, encouragement and
precious guidance, creative suggestions and critical comments about the company.
MEU – CHEMICHAL ENGINEERING Page 1

Abstract
This paper concerns on the four month internship program on pepsi cola soft drink industry .I
have been working four months and in this time I have got practical skill more and I know the
aim of the internship. Pepsi cola soft drink industry is one of the huge companies that
contributing its effort for the world economy and Dessie Pepsi cola plant is the part of this.
Based on 1997 US Census Bureau The value of shipments for the soft drink industry is about
31.2 billion dollars. In Ethiopia MOHA has over seven soft drink manufacturing plantThe
international Pepsi Cola plant has more than hundred types of food and beverage products.
But there are only few products are producing in our country and these products became well
known brands of Pepsi in Ethiopia. These products are: Pepsi cola Miranda orange7-
upMiranda Tonic Miranda Apple. The raw material for the production those products are:
sugar, preservatives, water, carbon dioxide etc.

Symbol and abbreviations
Notetion stands
CO2 Carbon dioxide

MOHA Mohamed husen Al-Amoudi
S.C Share company
CIP Clean in place
DQ Dis charge
KG Kilo gram
KM Kilo meter
DPCP Dessie pepsi cola plant
MDCs Main distribute centers
MEA Mono ethanolamine
M.Apple Mirinda apple
MIDROC Mohamed international development research
And organization companies
M.ORENGE Mirinda orange

M.TONIC Mirinda tonic
PPM Potassium per manganite
Plc propertional levl control

Table of contents
DECLARATION................................................................................................................................................i
ACKNOWLEDGMENT....................................................................................................................................ii
ABSTRACT....................................................................................................................................................iii
ACRONYME..................................................................................................................................................ix
CHAPTER ONE...............................................................................................................................................1
INTRODUCTION............................................................................................................................................1
1.1Background of company..........................................................................................................................2
1.1.1 When and where did Pepsi cola start?................................................................................................2
1.1.2 What is the background of MOHA?.....................................................................................................2
1.2 Objectives of the company.....................................................................................................................3
1.3 vision of the company............................................................................................................................3
1.4 mission of the company..........................................................................................................................3
1.5 MOHA soft drink products......................................................................................................................4
1.5.1 Main products.....................................................................................................................................4
1.5.2 The main customers or end users of its products or service...............................................................4
1.6 Overall management organization and work flow..................................................................................5
CHAPTER TWO..............................................................................................................................................7
Chapter two …………………………………………………………………………………
2.1 process description ……………………………………………………………………
2.1.1 Water treatment process…………………………………………………………………
2.1.2 Washing machine operation…………………………………………………………….
2.1.2.1 Case washer………………………………………………………………………….
2.1.2.2 Bottle washer…………………………………………………………………………
2.1.3 Steam generation………………………………………………………………………….
2.1.3.1 Boiler plant……………………………………………………………………………..
2.1.4 Carbon dioxide production…………………………………...............................
2.1.5 Syrup preparation………………………………………………………………..
2.1.5.1 Main raw materials…………………………………………………………….
2.1.5.2 Preparation of simple syrup…………………………………………………

2.1.5.3 Preparation of finished syrup………………………………………………….
2.1.6 Mixing…………………………………………………………………………………….
2.1.6.1 Process mixing system………………………………………………………………….
2.1.7 Cooling system……………………………………………………………………………
2.1.7.1 Product cooling………………………………………………………………………
2.1.8 Carbonation …………………………………………………………………….
2.1.9 Proportioning…………………………………………………………………..
2.1.10 production line……………………………………………………………..
2.1.10.1 Filing process and packing…………………………………………………
2.1.10.2 Filling system…………………………………………………………………
2.1.11packaging …………………………………………………………………….
2.2 material and energy balance……………………………………………………………
2.2.1 material balance ………………………………………………………………………
2.2.2 energy balance ………………………………………………………………………..
Chapter 3…………………………………………………………………………………
3.1 short summery…………………………………………………………………….
3.2 introduction………………………………………………………………….
3.3 statement of problem……………………………………………………………….
3.4 objectives……………………………………………………………………………….
3.4.1 General objectives………………………………………………………………………
3.4.2 Specific objectives ………………………………………………………………………..
3.5 scope of project …………………………………………………………………………….
3.6 literature review…………………………………………………………………………
3.6.1 Physical and chemical properties of carbon dioxide
3.6.2 Application of carbon dioxide
3.7 Metdology
3.7.1 Material and chemicals

3.7.2 Methods
3.7.3 Process description for carbon recovery
3.7.4 Determine the effect of amount of MEA solvent on carbon dioxide
3.7.5 Physio-chemical properties of recovered co2
3.8 equipment sizing ………………………………………………………………..
3.9 result and discussion……………………………………………………..
3.9.1 Determine the effect of amount of mea on recovered carbon dioxide………….
3.9.2 Determine the Physio-chemical properties of recovered carbon dioxide

…………………………………………………………………………………………
3.10 conclusion…………………………………………………………………………….
3.11 recommendation………………………………………………………………………
Chapter four………………………………………………………………………….

Chapter one: introduction
Introduction
Pepsi cola soft drink industry is one of the huge companies that contributing its effort for the
world economy and Dessie Pepsi cola plant is the part of this. Based on 1997 US Census
Bureau The value of shipments for the soft drink industry is about 31.2 billion dollars. In
Ethiopia MOHA has over seven soft drink manufacturing plant. 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 Carbonated
soft drink production is among the most energy intensive processes in food industry.
Significant levels of refrigeration, mixing, purification, and heating are needed in the
carbonation and bottling/canning processes. Refrigeration is required for lowering the drink
mixture to a temperature low enough to absorb the necessary amount of carbon dioxide.
Heating is required to bring the cold cans bottles to a temperature high enough to prevent
condensate from collecting on the containers after packaging and storage and also dissolving
of granulated sugar to activate dissolving and killing of microorganisms at 80 ℃ . in soft drink
production proper jetting and mixing is required to form uniform solution and settling
prevention. Purification of raw material is also the main concerns of the company as it
produce a drink that will directly consumed by human being. Being a food product,
significant energy is consumed in sanitation processes. In addition to cooling and heating,
traditionally the processes use a significant amount of compressed air
1.1Background of company
1.1.1 When and where did Pepsi cola start?
Pepsi cola traces are origin to 1898 when Caleb brad ham, pharmacist in New Bern, north-
Carolina, created a curative drink for dyspepsia cola. Pepsi cola later referred to simply as
Pepsi was mixture of carbonated water, cane sugar syrup, and an extract from tropical kola
net. To sell this product, brand ham formed the Pepsi cola company in addition to selling the
drink at drug store counters; Brad ham bottled Pepsi for sale on store shelves. At this time
bottling was new innovation in food packaging.
1.1.2 When did Pepsi start in Ethiopia?
MOHA soft drink Sc. Was established in Emperor Haile Selassie May 4, 1954(GC). In that
time the company has 62 employer and produce 5000 bottle/day and the products are Snagn

tonic, Snagn orange, Snagn cola, Arenchata and Skish. The employer salary had been blow
50 birr.
Nesfas silk Pepsi cola, in Ethiopia, is the first Pepsi cola plant in Ethiopia and was
established in 1966 as sheer company with initial capital one million birr. The capacity of
bottling line at a time was 20,000 bottles per hour (bph). T/haymanot pepsi cola plant was
established in 1961 as “as saba teg” share company, but nationalized in 1975 replacing Pepsi
cola, mirinda and team brands in January 1978.Other sister companies are: Gonder Pepsi cola
plant, it established in1986, Dessie and Hawssa Pepsi cola plant.
1.1.3 What is the background of MOHA?
MOHA soft drink industry S.C. was formed on the 15 th of May 1996. The company was
formed after the acquisition of four Pepsi cola plant located at Addis Abeba Nefas silk,
T/haymanot, Gonder and Dessie which are purchased by Sheik Mohammed H. Al-Amoudi
the 18th of January 1996 currently with new factory in Hawassa.
MOHA soft drink sc. is holds 52% of the market share in soft drink industry in the country
with an expansion and replacement of absolute machinery production capacity of the plant
has increase substantially. In addition, it is a corporate company, which is located in
AMHARA national regional state, south WOLLO, DESSIE town and 401 km away from
Addis Ababa and with a total land holding area of 37,640 meter square. The company
supplies different soft drinks such as Pepsi cola, Miranda orange, 7-up and carbonated water
products (kool and Tossa) to the society. In addition, the company was setup with the modern
technology in soft drink.
The company aimed to produce quality products to satisfy the needs of the customers. On the
top of this it focuses on implementing an efficient distribution network along with creative
and innovative marketing, giving special attention in training and upgrading the skills and
competence of employees and customers. Furthermore, DESSIE soft drink has contributed
many social activities that are the goal to the good cause of the society.
Generally, the role played by soft drink was significant in supporting and promoting social
activities and the workers show great commitment and dedication to keep the soft drink and
its product popular.
Former logo of the company

FIG 1.1 logo of pepsi cola
1.2 Objectives of the company

The business purposes of MOHA soft drinks Industry S.C. as stipulated in the Memorandum
of Association are: -

A. To manufacture, buy, sell, bottle, distribute and deal in non-alcoholic beverages, mineral
and aerated waters by ingredients thereof in Ethiopian and elsewhere.
B. To manufacture, sell and distribute bottles, corks, corkscrews all type of crates.
C. To manufacture, sell and distribute carbon dioxide.
1.3 vision of the company

 to be the best beverage industry in the country as well as
 improve responsiveness to the needs and concerns of customers,employees,partners
and communities
 to create superior value for shareholders,cusromers and employees
1.4 mission of the company

the Mission of the company is To be the best beverage industry in the country by
continuously improve the company responsiveness to the needs and concerns of
customers,employees,partners and communities in which it serve. This will be accomplished
through the development of its employees, an emphasis on cost efficiency, market expansion
and profitability. Also to expand the company marketing areas to both protect and improve
positions by placing emphasis on innovation and technological improvement to keep ahead of
competition.
1.5 End products and service of the company

MOHA is engaged in the productions of Pepsi cola, 7UP, Miranda orange, Miranda tonic,
Miranda apple and Tossa Minch. The products are available in 300ml returnable bottle, one-
liter plastic bottle and in keg or barrel container. In addition to this MOHA produce 0.5-liter
plastic bottle water and returnable glass by the name of “Kool”, but Dessie plant produce
Pepsi cola, 7UP, Miranda orange, Tossa Minch by plastic bottle and “Kool” by 300ml
returnable bottle.
Figure1.2: Main products of Moha soft drinks S.C

1.6 The main customers or end users of hosting company

Dessie Pepsi Cola plant being distributes the products for local customers. The product from
the company goes to the customers as follows:
Manufacturers Distributers customers
Those above listed product of MOHA Pepsi cola industry has many institutional and
commercial customers. They may be receiving from the distributor or from the company
marketing service.Those customers include hotels, motels, cafeterias, hospitals and finally a
person who enjoy and trust quenching with Pepsi cola product in everywhere.

CHAPTER TWO: PROCESS TECHNOLOGY OF THE FACTORY
2.1 Process description
2.1.1 Water treatment process

Raw water supplies are contaminated by different things. Contaminates in water supplies
present a danger to the taste aroma and appearance of the beverage because of these all water
to be used for syrup or beverage production must be treated. Physical discrepancies in the
water such as turbidity, color, odor or taste can have an almost immediate effect on beverage
flavor or appearance. For instance turbidity, or even small levels of colloidal matter, can
cause foaming problems either at the filler, while the beverage is being filled, or later, when
the bottle is opened by the consumer. Micro organisms’ algae or even small amounts of
organic matter in the water can have an effect on the taste and odor of the product and can
cause unsightly sediment or flock to develop. This is a particular danger when using a surface
supply. Chemicals and minerals present in the water supply can have an adverse effect on the
beverage. High alkalinity, for example, can quickly neutralize the delicate acidity of the
beverage, lessening its tang and making it susceptible to spoilage. Water sources may be
classified in to two categories:
I. Surface Water Supply: It can be highly variable in every respect chemically (total
dissolved solids alkalinity), microbiologically (bacteria, virus), & physically (turbidity,
color).Much surface water are easily subjected to contamination which may present in
many forms including bacteria & other animal wastes, algae blooms, run off. Surface
water law in minerals usually contains more natural organics. This organics loading
varies from season to season.
E.g. streams, lakes, rivers, and reservoirs.
II. Ground Water Supply: Ground water sources includes confined and under confined
aquifers which invade the sub-surface and saturated zone of the environment. They are
more consistent in terms of microbiological, physical and chemical aspects. They have
higher total dissolved solids (TDS), alkalinity, and they are highly protected from
bacteria, protozoa and virus than surface water supplies. They also have lower organic
carbon (TOC), turbidity, color and they are not subjected to pollution via surface run off.
The ground water is considered as a much safer supply, or one which produces purer
water than the surface water supply.
2.1.1.1Treatment Methods
This section will provide an introduction to water treatment for beverage plants.
1. Coagulation:

Historically, in the beverage industry, "coagulation" water treatment technology also known
as conventional lime treatment systems (CLTS) has been a standard where non-brackish, or
low salt, waters are involved.
2. Membrane technology:
Membrane technology has become an important treatment option for almost all water
supplies. Four major types of membrane technology are reverse osmosis, Nano filtration,
ultra filtration, and electro dialysis.
Reverse osmosis: can remove salts that coagulation cannot (sulfate chloride, nitrate, and
sodium) and is extremely efficient at removing organics.
Nano filtration: can remove most mid to large-size organic molecules, hardness, some
alkalinity, and some other inorganic (sulfate, chloride), while operating at lower pressures
than reverse osmosis. It has excellent application for surface supplies.
NOTE: The economics of using reverse osmosis and Nano filtration continue to improve and
they should be considered as an alternative to coagulation for all water supplies. The main
drawback with membrane technology is availability of high performance membranes and
servicing of equipment.
Ultra filtration: addresses most large-size organic molecules, and will remove turbidity
efficiently.
Electro dialysis: is both cost-effective and efficient at removing salts that coagulation cannot
such as chloride, sulfate, nitrate and sodium, and in reducing total dissolved solids
2.1.1.2 Reverse Osmosis water treatment process
Reverse osmosis (RO):- means water flows from a more concentrated (salts) solution through
a semi-permeable membrane into a less concentrated (salts) solution. By applying pressure in
the osmotic pressure process. Water will flow through the membrane leaving most of the
salts, organics and microbial life to remain in the concentrated solution. It is modern way of
treating water.
▪ Chlorine tank: is the tank found before the water treatment room and used to clarify
the ground water before treatment.
▪ Aeration Tank: is used to increase the amount of oxygen and decrease the amount of
carbon dioxide.
▪ Sand filter: used to remove physical matters or dirty materials from the inlet of raw
water like light floating materials present in the tap water. The sand tanks (filter) has
three layers, at the bottom there are sands (gravel) and relatively large in size
followed by medium size sand filter that covers a few height above the gravel . Fine
sand filters are filled above the medium sized sand filter followed by anthracite top up
which enhances effective filtration of foreign matter or suspended particles coming

with raw water that may occur during storage at the concrete tank (reservoir). The raw
water passing through the sand filter stored in three different size storage tanks where
chlorine is added here for microbial disinfection for almost Two hours retention time
(time for effective disinfection process). After this the raw water is transferred
through activated carbon to the reverse Osmosis for effective treatment.
▪ Intermediate tank: -is used store the coming water from the sand filter. In this tank
Chlorine is added for sanitation purpose to kill microorganisms and Aluminum
sulphate is added for coagulation. Then goes to carbon filter one.
▪ Carbon filter 1:-is used to treat (filter) raw water comes from the intermediate tank
using activated carbon helps to remove off tastes and color in the water that may be
produced in the water storage tanks, fine suspended maters in the water, chlorine that
present in the water for disinfection, sanitized weekly by steam in 80°c for 1 hour
then it is going to polisher for further particle filtration.
▪ Polisher 1:- Water enters the reverse osmosis skid under low pressure where a safety
cartridge is used to remove any potential solids carryover from the raw water pre-
treatment. It is an instrument to separate (filter) small precipitates, sands, sulfates,
ferric salt from water2 to minimize the load and avoid damage on the membrane. This
polisher contains 10 bags of filtering material which working together (they are 1
micron) and arranged parallel where they are packed in one. Chlorine has an acidic
property and it reduce the PH value of the water so to adjust the PH to the target value
and to reduce alkalinity a basic solution 45.45% m/v of caustic soda is used with
proper dosing mechanism. The raw water should not contain any oxidants such as
chlorine, ozone and other disturbing compounds such as grease, Manganese, Iron,
Fluorine or other water immiscible. The water until this polishing process is chlorine
containing but the step after this task must be free from chlorine to avoid damage on
membrane. So in order to avoid chlorine from water 19.85% m/v of sodium meta
bisulphate is used by an adjustable dosing mechanism. Chlorine removal may
also do by carbon filter instead of sodium Meta Bisulphate.
▪ UV 1: used to destroy any presence of microorganisms. The treated water after UV1
goes to the reverse osmosis.
▪ Reverse osmosis membrane:- 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. Here high pressure is applied on the water to pass through the RO
membrane and the filtrate water (permeate) is collected in the reservoir tank where
chlorine is added to remove the remaining microorganisms.

In very simple terms, feed water is pumped into a Reverse Osmosis (RO) system and you end
up with two types of water coming out of the RO system: good water and bad water. The
good water that comes out of an RO system has the majority of contaminants removed and is
called permeate. Another term for permeate water is product water they mean the same thing.
The ‘bad’ water is the water that contains all of the contaminants that were unable to pass
through the RO membrane and is known as the concentrate, reject, or brine. All three terms
(concentrate, reject, and brine) are used interchangeably and mean the sam
Figure 2.1: RO diagram
As the feed water enters the RO membrane under pressure (enough pressure to overcome
osmotic pressure) the water molecules pass through the semi‐permeable membrane and the
salts and other contaminants are not allowed to pass and are discharged through the
concentrate stream, which goes to drain or can be fed back into the feed water supply in some
circumstances to be recycled through the RO system to save water. The water that makes it
through the RO membrane called permeate or product water and usually has around 95% to
99% of the dissolved salts removed from it. It is important to understand that an RO system
employs cross filtration rather than standard filtration where the contaminants are collected
within the filter media. With cross filtration, the solution passes through the filter, or crosses
the filter, with two outlets: the filtered water goes one way and the contaminated water goes a
different route. To avoid buildup of contaminants, cross flow filtration allows water to sweep
away contaminant build up and also allow enough turbulence to keep the membrane surface
clean.
After reverse osmosis is done by four respective membranes the water is checked through an
automated sensor for its acceptability to the next process. The membrane treat the water 70%
to the product and 30% to the drainage (hardness and impurity containing water)
based on adjusted standard of acceptability weather to pass or to drain or sometimes 100%
drain unless it fulfill the RO exiting requirement.

▪ By pass:-Used for adjustment of eater flow. This doesn't contain membrane water.
25% of concentrated water loss as waste water.
▪ Product water storage:-It is a tank used to store the water after treated in reverse
osmosis. Storage is required to fulfill the water consumption of production plant. But
when water stored microorganisms cause off test and color so disinfectant must be
added. So in this tank, chlorine is added for disinfection. After chlorinating, the water
will be pumped to carbon filter tanks.
▪ Carbon filter 2:-The chlorinated water from product tank is treated by using activated
carbon to remove chlorine from the water. We check the chlorine amount which must
be zero in 1hr. It sanitized weekly.
▪ Polisher 2:- It works with the same principle and purpose with polisher 1 but
it is 6 parallel arranging straining tube. It used to remove solid impurity that may
come from carbon filter due to the existence of fine carbon.
▪ Ultraviolet 2 (UV):-is the final treatment of the water used to destroy any
presence of microorganisms. The treated water after UV is distributed beverage
production, syrup preparation and for similar uses.
Backwash: is very important consists of reversing the water flow through the unit. By a
combination of water flow and pressure, the sand or carbon bedsore raised, their granules
become suspended in the water and are vigorously agitated. This removes the adhered,
filtered out floc particles, which are washed out of the unit by the backwash water and cleans
the surfaces of the sand grains.
Proper backwashing requires a water flow rate of 5 to 6 times the forward rate i.e. 10 to 12
gallons per minute per square foot of filter/purifier bed area. To assure these flow rates, the
backwash water line should be of the same diameter piping as the filter and purifier manifold.
If the backwash water pressure is too high, sand or carbon could be washed out of the units at
the required backwash water flow rates. This can occur when city water is used for
backwashing. In such cases, a pressure reducing value should be installed in the backwash
line, to lower the pressure rather than cut down on the backwash water flow rate. The key
elements in proper backwashing are the correct water flows, passing uniformly though the
bed.

Service Water
Chlorine Unit Aeration (>O2) Sand Filter Intermediate Tank
RO UV 1
Carbon Filter
Pol
ish
By-pass
UV2
Chlorine Tank Carbon Filter
Pol
ish
er Product
Tank
Figure 2.2: Flow diagram of RO water treatment
 Softener
Soft water is the water used for non-product uses mainly for heat exchange and rinsing
purposes. The water is softened by ion exchange method by adding zeolite to remove
magnesium and calcium from the water.
The characteristics of soft water necessary for the equipment or the operation involved Water
used for package rinsing should be sanitary, free from physical defects, and must be corrected
if there are any scale forming tendencies or if the water is corrosive and water used in heat

equipment, particularly by boilers, should be treated to eliminate scale forming potential and
to address any other organic or inorganic material that would interfere with optimum
performance.
 Clean In Place (CIP)
A process of cleaning internal parts there are different types of CIP. This 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 4 months.
CIP, back wash and regeneration steps
 Sand filter tank first backwash (5steps), second back wash for 1-5 min, then lowering
for 5 min.
 Back wash air for 5 min.
 Back wash 2 for 5 min, Final rinse for 5 min.
RO CIP: it is required when the pressure in the membrane gets 12-14 bars.
1st Step
Circulate the membrane using anthracite at PH>10 and then flush with water.
2nd Step
Circulate the membrane with citric acid at PH 2-3 and then flush with water.
3rd Step
Circulate the membrane with anti-scalant or in order to prevent scale formation and then flush
with product water.
For carbon filter tank CIP done with hot water, then they will be backwashed for
about 5 min, final rinse is done for 20min.
Softener tank regeneration Step
Sodium chloride injection and displacement for 36 min and 60 min respectively, final rinse
with 0.2m3 water.
o Brine tank: is a tank used to prepare sodium chloride solution that is needed for
regeneration of softener tank. It takes about 300kg of sodium chloride for a single
regeneration process.
2.1.2 Washing Machine operation

The purpose of the washer room is to outline the process by which the bottle washer cleans
and sanitizes “Returnable” bottles that have been brought back from the trade.

2.1.2.1 Case washer

Pepsi operation began with the process of purchasing, warehousing and washing of bottles
and case. Mostly company use the case with bottles returned market. This case are placed on
conveyer after unloading the bottle and washed with the help of automatic plant. Caustic soda
and boiled water is used to clean the case and bottles returned from the market. This duty is
just rough washing of the case because it does not directly in contact with the drink.
Case washing is one of the special features of MOHA industry unlike the other beverage and
soft drink industry of our country.
2.1.2.2 Bottle washer

Sanitation is one of the most important duties in soft drink industry to the quality and
stability of products. When producing soft drinks, the same sanitation standards and
procedures apply. Sanitation is necessary to insure the keeping qualities, proper appearance
and full flavor of any soft drink. When equipment becomes contaminated, yeast, bacteria or
mold organisms begin to appear in the finished beverage. Increased numbers of these
microorganisms will cause the development of undesirable taste and odors and ultimately
spoilage of the product. So bottle washing is one of the task must be done properly to
overcome this problem. The water used for bottle washing and any other process is through
treated water, especially the final wash is used distilled which is product dilution water.
Figure 2.3: bottle washer

Functional Description
The function of the machine is to properly wash the bottles and remove dirt residing in the
bottles. They are cleaned in such a way that a product is safe to be filled in to the bottle.
 High Pressure Jetting
It is the first step for bottle washing. Its principle is that it uses high amount of pressurized
water (highly pressurized) to wash the internal part of the bottle, slightly the external art of
the bottle will also be washed. As it is the first step of washing, physical matters such as dirty
particl×es, gums and mobile cards will be removed here as a result of pressurized water.
 Pre-Jetting
After highly pressurizing with water, the bottles will be goes to pre jetting. During pre-jetting
caustic is applied to the water present in it and by using the motor pump only the outer part of
the bottle will be washed. Warm water also brought to pre-jetting from warm water in order
to help the bottle washing.
 Caustic One
Caustic soda or sodium hydroxide is the critical element that used to wash a bottle during
bottle washing. The concentration of caustic used for washing is 2-2.5.The reason for using
this chemical is that because of its ability to remove or clean contaminants and dirty
substances from internal and external parts of the bottle. In each 5 minute caustic soda will be
added for 15 seconds and its set point temperature is 700c.
 Caustic Two
In this step the mechanism is almost similar to caustic one. It is applied after caustic one just
for further cleaning. Therefore the only difference between caustic one and two is that the
contact time and set point temperature which means in the case of caustic two, caustic is
added in each seven minutes for 15 seconds and its set point temperature is 65oc.
 Post Caustic
It is simply washing the bottle to remove remaining caustic from caustic one and two found
in the bottle. It is done by high pressurized water. The other point is that during post caustic
washing, it is only the outer part of the bottle will be washed.
 Warm Water One and Two

Both warm water one and two have similar application which is to wash out the caustic in
and out of the bottle. The washing is performed with high pressurized water. Their only
difference is that their temperature. Warm water one applies a 48 oc water whereas 38 oc is for
warm water two.
 Cold Water
The other step for bottle washing and washes the bottle to remove if any caustic is remained
after washing with warm water one and two respectively. It applies low temperature
compared to warm water one and two. The water used for warm water one and two and cold
water must be changed in every 8hrs.
 Fresh Water
The final step is to rinse the bottle with 32oc water, and then the bottles will be discharged.
NB: If the bottle fails one of the above inspections, it will be removed.
2.1.3 Steam generation
2.1.3.1 Boiler plant

This plant mainly engaged in the generation of steam for those production unit that require
steam power but we can also make boiler plant multipurpose for the production of carbon
dioxide by using high quality gas oil. The main raw material (energy source) used to produce
steam are Furnace (Heavy oil), soft water and 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 used high quality fuel oil.
Process of boiler plant
After preparing all the required raw material that is producing steam, the first thing that will
be done is that to bring the furnace from furnace tank to modified furnace storage tank. Soft
water is blind with return condensate in order to pre heat the newly coming soft water and
maintains initial temperature .this is done before it getting in to boiler. Next step will be
boiling the water until 1800℃ , where the water changed in to steam. The furnace which is
used as a base to boil the water is burned by using oxygen gas in the boiler. in this
compartment the water is shell side and the furnace firing into a tube burner so heat
transfer by conduction, convection and radiation will cause boiling of water.

Figure 2.4: Fire tube boiler
When the temperature reaches 1800 CO, the water will completely change into steam and
this steam automatically transferred in to distributer tank. Distributer tank is a tank used
receives the steam from boiler and distribute it to syrup room (in order to boil the sugar),
bottle washer. After completing its task, the steam will return back to boiler room and stored
in to condenser tank in order to change it in to liquid. When the steam changed in to liquid, it
will transfer in to water tank so that any steam will not be lows, instead it will circulate for
the next batch services.
2.1.4 Carbon dioxide production

Carbon dioxide is one of the essential components in beverage production process. The
correct proportioning of carbon dioxide into the beverage enhances both the beverage's taste
and appearance. It also imparts a pungent, slightly acidic taste to the finished product as well
as creating greater eye appeal. To some extent it acts as a preservative.
Carbon dioxide is composed of two atoms of oxygen bonded with one atom of carbon. It is a
colorless inert gas approximately 1.5 times heavier than air and can be in gaseous, liquid, and
solid forms (dry ice) and it smells slightly pungent, has a sweet/biting taste (soda water) and
is highly stable (not easy to separate into its constituents).Gaseous CO2 can be liquefied under
a pressure provided its temperature is below 31°c, this temperature being referred to as the
critical point. Sources of CO2 for carbonated soft drinks can be coal gasification, ethylene
oxide production, acid neutralization, fuel oil, fermentation (in breweries), ethanol plants, and
phosphate rock.
Carbon dioxide supplied in cylinder usually of the following capacities;
 50lb (Total weight when full, 158lbs)
 20 kg (Total weight when full, 60.18kg)
 25kg (Total weight when full, 67.67kg)

The normal discharge of carbon dioxide from a cylinder is at rates up to 4lbs of CO 2 per
hour .For example; if the draw-off for production purposes were to be at a rate of 40lbs of
CO2 per hour, Then at least 10 cylinders would be connected to one manifold to give the
desired 40lbs.Excessive draw-off of carbon dioxide from cylinders causes freezing for
continuous operation two such manifolds should be arranged so that one manifold can be
loaded while the other in use. This will make it possible to replace empty cylinders without
shutting off the supply to carbonated equipment. With cylinders recommended the line from
the CO2 manifold to the carbonator is no longer than 17 meters (soft).The CO 2 gas coming
from the CO2 manifold is relatively high pressure and this pressure must be reduced before
the CO2 enters the carbonating unit. This is accomplished by expanding the gas through an
orifice valve in a regulatory. The regulator valve is operated diaphragm which enabled plant
personnel to maintain a pre-established pressure on the low side of regulator.
It is extremely important that whenever anew bank of cylinders is put in to use the diaphragm
adjusting screw should be released all the way. This is to prevent damage to the diaphragm
from the initial surge of CO2 in to the system. Heat is required to expand the gas before it
enters the regulator, otherwise the regulator should be applied to the gas line at a point just
prior to where the gas passes through the regulating valve.
2.1.5 Syrup Preparation
2.1.5.1 Main raw materials

Water
Water is the most pre dominate ingredient found in soft drinks. The quality of water used is
very important. In specifying standards for water it is obvious that the water should have no
impurities of any nature or kind to interfere with proper taste, color, physical appearance and
carbonation of the product. The raw supply must be from an unquestionable sanitary source.
Municipal water supplies will contain chlorine which should be removed by use of a carbon
purifier. The carbon purifier will also remove other unwanted color, odor and tastes.
The alkalinity of the water is of concern. High alkalinity of beverage water neutralizes the
beverage acid. In most cases we can adjust acid levels to compensate for the high alkalinity.
Carbonated water constitutes about 94% of soft drink
Sweetener
Sugar is one of the major ingredients for the beverage production as sweeteners which are a
critical ingredient of Pepsi cola products and there use must be properly controlled which
greatly affect the sensory experience. Sugar is used in Pepsi cola, 7up, and flavor products to
impact the desired sweetness and body to the beverage and to help carry the flavor. The sugar
must be of a high degree of purity to yield maximum benefits. Impurities in sugar cane
adverse effect the sensory attributes to the possible of product spoilage. There are several
types of nutritive sweeteners suitable for use in the production of Pepsi cola, 7up and other
flavors.

Flavors
The flavoring ingredients used in making soft drinks must be water soluble allowing them to
completely disperse throughout the drink with no separation. There is endless range of
flavoring thy may be natural identical (chemically synthesized imitations) or artificial
( chemically unrelated to natural flavors) since this company uses the natural identical one.
With “Diet” and other “sugar free” drinks the sugar content is replaced with artificial
sweeteners such as Aspartame. Pepsi Diet which is currently introducing new product of this
company is the result of this technology. Artificial or imitation flavorings are derived
from organic compounds such as esters, aldehydes, alcohols and acids. Artificial flavors
make excellent Tasting products and they are readily available, stable, and safe for use in
food, Consistent in composition and cost effective. Extracts - The flavoring oils and
compounds are dissolved in alcohol and water. Normally this form of flavor will produce a
clear type of soft drink. Examples are lemon-lime [7-Up type]. Emulsion is added to soft
drink primarily to enhance eye appeal by serving as clouding agents. Emulsions are mixtures
of liquids that are generally incompatible.
o They consist of water based elements such as gums, pectin and preservatives.
o Oil based liquid such as: flavors, colors and weighing agent’s saponins enhance
the foamy head of certain soft drink live cream soda.
The overall flavor of soft drink depends on an intricate balance of sweetness, tartness
and acidity.
Acids
Acidulates are used in soft drinks formulations to effectively enhance the flavor. They
are referred to as flavoring acids. In some drinks, acid is used to extend the shelf life of the
product. In this case, it acts as a preservative or activates the added preservative.
 The most common acid in soft drink is citric acid which has a lemony flavor
 Ascorbic acid which is vitamin C is not used as a flavoring acid. It is generally used to
eliminate air in the packaged finished drink.
 Air [oxygen] causes off-taste and ascorbic acid is used to prevent this
problem. The ascorbic acid acts as an antioxidant. If the proper quantity is used in the
formulation, it is used up in the process of scavenging the oxygen and none remains in
the finished drink. If too much is added to the product, the excess amount can oxidize
[bleach] the color of the drink.
 Acid will add sharpness to the background taste enhance thirst quenching experience
by simulating saliva flow.
 Acid also reduce PH level, mild preserving the beverage

 Very small quantities of other additives enhance taste, mouth feel, aroma and
appearance of the beverage.
Colors
Many soft drinks contain added colorants. The color is added to enhance eye appeal, making
the drink more psychologically desirable. The brown colored drinks use caramel coloring to
achieve their appearance. Some naturally derived colors are available to the soft drink
industry.
Preservative
Although soft drink manufacturers would like to make their products without the
added preservative, they cannot do so without the threat of off-taste and/or spoilage. The
most widely used and cost effective preservative is sodium benzoate. There are other
preservatives available. Potassium sulphate and sodium chloride can be used in specific
applications.
The amount and application of the preservative is critical and formulation procedure
and sequence must be followed closely. Procedural sequence must be followed to prevent
incompatibility with other product ingredients. Such things as carbonation level and pH affect
how a preservative is used and how effective it will be.
Sanitation
Sanitation is one of the most important duties in soft drink industry to the quality and stability
of products. When producing soft drinks, the same sanitation standards and procedures apply.
Sanitation is necessary to insure the keeping qualities, proper appearance and full flavor of
any soft drink. When equipment becomes contaminated, yeast, bacteria or mold organisms
begin to appear in the finished beverage. Increased numbers of these microorganisms will
cause the development of undesirable taste and odors and ultimately spoilage of the product.
To impend the growth of microorganisms and prevent deterioration preservatives are added
to soft drink anti-oxidant such as ascorbic acid which maintain color and flavor.
2.1.5.2 Preparation of Simple syrup

Simple syrup is a mixture of the treated water and raw sugar in the dissolved tanker dissolves
at the 800c. First the treated water adds in to the dissolving tank which is jacketed vessel and
the water will be boiled up to 800c. The sugar, carbon, and water is measured in acceptable
amounts in Proportion of each other depends on the flavor units. The screw conveyer can
reduce the size of the sugar and the conveyer the sugar enters the dissolving tank. When the

sugar enters to the dissolving tank the temperature of water is decreasing in to 24 0c-300c.
Then we will wait the temperature until 800c.
Activated carbon will be added to the dissolving tank and kept in the tank around 30-40
minute to trap and it removes the organic matter. The sugar and the treated water mixture
from the jacketed vessel will be filled in the sugar filter and half in the filter aid mixer. In
filter aid mixer we add diatomite earth it will be circulated within the sugar filter and filter
aid.
During this circulation filter aid will make cake inside the sugar filter the filter aids by
activated carbon and diatomite earth. There are two types of filtrates
Manual filter
 It filter use water to make cake and trap organic mater
 It used for bottle product
 The plates should be clean up once it is used
 It doesn’t use activated carbon
 But we use activated carbon for Pepsi
Automatic filter
 For filtrate use sugar and filter aid to make cake
 The filter aid are activated carbon and diatoms earth
 It use for PET (POLYETHYLENE TEREPHTALINE)
 It can be used three times once it is clean up
After this filtration the simple syrup will go to the jacketed type heat exchanger. The simple
syrup will exchange heat with water treated the treated water came from the chiller by cooled
100c. It stay around 2 hour in the simple syrup room then it transfer to the finished syrup
room.

Figure 2.5: Flow diagram of syrup preparation
 Conveyer
It is found separated by a wall from the main syrup room, but connected with the dissolving
tank by a pipe through the separator block or wall. Because of its purpose it is put in the same
room with the sugar. It is a material used to receive the sugar and transport it to the dissolving
tank. Before transferring the sugar into dissolving tank, the conveyer filters the sugar by
extracting physically larger unwanted materials and non-sugar particles with the help of
sieves welded on it. After the filtration, the sugar transfers into dissolving tank.
 Dissolving tank
It contains a hot water that boiled about 80oc in order to dissolve the sugar. The heat that
used to boil the water is in steam form which comes from boiler room. The reason to boil the
water till 80oc is that it is the standard for PEPSICO International. In addition, If the sugar s
not boiled to just 80oc, it may not be soluble as we want with the flavors. And if it exceeds
80oc, it may evaporate and we may loss some amount of sugar and this may be occur an error
in the brix reading. There is a chemical called divlo used to filter the dissolved sugar or
simple syrup. This chemical is powder and mixed in water in the filter aid dissolving tank
which is found beside the dissolving tank. The simple syrup then circulates through two
horizontal filters called strainer. There is nothing different thing performed in the strainers
other than filtration. The celatom which mixed with water is added in the dissolving tank in
liquid form. This chemical helps to treat the simple syrup.
 Filter aid and Mixer
It is tank which water and diflo mix and pass to filter press to make filter cake
 Filter Press

It is a tank consists of multiple plates in it. It is used for filtration. Its principle is that water
and diploe (any molecule or radical that has delocalized positive and negative charges) will
be mixed in it and after a while the diploe will form a cake on the plate found in the tank.
Now the simple syrup will let to pass through filter press on the plates. During the simple
syrup passing through the plate, the formed cake will absorb the other diploe that was added
in dissolving tank before and other substances will also be removed. When we see a pure and
colorless liquid in filter press through display glasses, then we can realize that this step is
done.
Figure 2.6: Filter press
 Heat Exchanger
Its purpose is to cool down the temperature of simple syrup before getting to mix tank up to
below 25oc. Decreasing the temperature is needed because if the simple syrup gets into mix
tank with high temperature it may damage the flavor in mix tank, plus to this high
temperature may be suitable for microorganisms. Therefore, it is also important to inactivate
them.
 Polishing Filter Bag
It is the fourth and final filtration step in the syrup room. Its purpose is to filter if anything
passes from the filter press by any means with the simple syrup. The material used for
filtration is called a bag and it is cotton like structure.
 Mix Tank
There are five mix tanks in syrup room, each sized are 11,000L.The simple syrup which has
less than 250c transferring in to mix tank from heat exchanger .Then flavors and dray
component will be mixed with simple syrup in order to give final syrup. Except Pepsi, dry
component and flavors mixed in concentrated tank before getting in to the mix tank.

2.1.5.3 Preparation of Finished syrup

The finished syrup is adding the flavor and the dry components to the simple syrup. When all
the simple syrup is in the syrup storage tank and the brix & amount of simple syrup are
confirmed the next step is to prepare the finished syrup. Where hot sugar processing is used,
the simple syrup should be at ambient temperature (25 0c is maximum) prior to the addition of
concentrate. Otherwise the flavor 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. Add the flavor and dry
components to the sugar solution and agitate for a few minute to mix throughout the solution.
But the addition components and flavors has its own standard amount in each beverage
products. This syrup is made in stainless steel tank by the blending of a flavored concentrate
containing various artificial and natural flavors, sodium benzoate (preservative), sugar and
treated water. The final syrup is checked by the plant quality control for conformance to
established parent company standards and then pumped to the proportionating in the filling
area. The ingredients have two types solid and liquid.
The solid ingredients includes: sodium benzoate (it used for kills bactericides and
fungicides), ascorbic acid (it is vitamin C, make it fresh), citric acid (it used for make the
odor suitable), potassium sulphate (it used for makes it sharp or not to settle) and sodium
chloride (gives a salty taste).
The liquid ingredients includes: Miranda orange (it is liquid having orange flavor) & Pepsi
flavor.
The concentrates are mixed in the mixer one by one with the treated water within
their orders;
1. sodium benzoate
2. potassium sulphate
3. sodium chloride
4. citric acid
5. Miranda orange flavor
6. ascorbic acid
The purpose of mixing order is to prevent precipitation, taste odor appearance and ascorbic is
more oxidant it will be added finally.
NB: The general rule is that no more than four hours should elapse between the time the
sugar is added to the mix tank and the time concentrates are added. Because simple syrup is
highly susceptible to fermentation organisms. With Pepsi cola syrup all concentrates are

added after treatment and finished syrup should be aged for a minimum of 24 hrs before it is
used for bottling or canning purpose. Aging will enhance flavor characteristics of
 CIP of Syrup Room
TO PEPSI MIRINDA MIRINDA 7-UP TONIC

FROM ORANGE APPLE
PEPSI 3-STEPS RINSE 5-STEPS RINSE
MIRINDA 5-STEPS 3-STEPS 5-STEPS 3-STEPS

ORANGE
MIRINDA 5-STEPS 3-STEPS 5-STEPS 3-STEPS

APPLE
7-UP 3-STEPS RINSE RINSE 3-STEPS
TONIC 3-STEPS 3-STEPS 3-STEPS 3-STEPS
Table 2.1: CIP for syrup room
CIP (cleaning in place) is a two-step cleaning method. Those are:
1. The three steps
a) First rinse by 50OC- 60OC water for 10-15 minutes
b) Cleaning by 50OC -60OC using caustic soda for 20 minutes and the concentration of
this soda should be in between 0.5%-2%.
c) Rinse by 38OC -OC water for 10-15 minutes then checking for the absence of
chemicals.
2. The five steps
a) First rinse by 50OC- 60OC water for 10-15 minutes
b) Cleaning by 50OC -60OC using caustic soda for 20 minutes and the concentration of
this soda should be in between 0.5%-2%.
c) Rinse by 38OC -OC water for 10-15 minutes then checking for the absence of
chemicals

d) Sanitize either by hot water at 80OC for 15 minutes or chlorine at 100ppm PH

concentration for 20 minutes finally rinse by water for 10-15 minutes then checking
the absence of chemicals.
2.1.6 Mixing
Mixer is used to mix components of the product. Each of the components comes from their
sources with their own pipe. The water come from water treatment room, the syrup is from
syrup room and carbon dioxide is from the cylinders after passing through Dominic hunter
polisher to ensure the quality of purchased carbon dioxide.
The purpose of this system is mixing raw materials after treatment.
1. For carbonated soft drink raw materials are carbon dioxide, product water and
finished syrup.
2. For KOOL carbonated mineral water, CO2 and treated water are raw materials.
3. For mineral water, ozone and treated water are raw materials.
2.1.6.1 PROCESS OF MIXING SYSTEM

 De-aeration: before water is pumped into blending tank, de-aeration process must
apply. This step removes air from the water, which is then pumped into a carbonation
tank pressurized with carbon dioxide. Carbonated beverages are most commonly
prepared in a beverage mixer/ carbonator which combine the de-aeration of water
with blending and carbonation of the beverage. Water is pumped into a de-aeration
tank under vacuum which removes air from the water. De-aerated water and syrup are
then pumped through a blender.
 Carbonation: means the process of combining the finished syrup, treated water, and
CO2 in correct proportion. 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, it absorbs carbonation.
So, the gas pressure must be increased to maintain the same absorption of CO2.If the
temperature of the liquid is decrease, the CO2 becomes more soluble.

2.1.7 Cooling system

Ammonia (NH3) works as cooler, which is used to decrease the temperature and it is highly
compressed by compressor. Ammonia is used to absorb the heat from one area and then
despite it to the cooler system continuously.
Glycol helps to maintain the temperature consistently specially at blowing the perform area.
Usually based on a vacuum system, CO2 stripping or a combination of both. Some de-
aeration units are separate while others are integrated with other parts of the mix-
processor system.
The benefits of de-aeration of the incoming water supply are important, particularly for
canning, high speed bottling lines and ambient filling, and also reduced air is necessary to
meet standards for canned product, less air equals more accurate proportioning and CO 2
control, 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.
Three basic approaches to de-aeration being used in most Pepsi-Cola plants: vacuum, CO 2
scrubbing (Nitrogen scrubbing can also be used), vacuum and CO 2 scrubbing (configurations
vary)
The de-aeration system consists of a de-aeration tank, vacuum pump and circulation
pump. This system combines the efficiency of CO2 and simplicity of vacuum to achieve
consistent, reliable operation. Process water enters the de-aeration vessel through the primary
diffuser. Then water is circulated through a secondary diffuser. Finally small amounts of
CO2 are injected into the circulation circuit to enhance the second stage de-aeration effect
and flush the vessel of O2 as it is released from the process water.
2.1.7.1 Product cooling

Most beverage operations use cooling to 4° C for cold filling. 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. Where filling equipment has been designed for ambient filling, and suitable
control can be exercised, using a temperature targeting 15-20° C offers a significant
cost savings advantage. Such filling is called ambient or warm filling.
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.
2.1.8 Carbonation

Carbonation means the process of combining the finished syrup, treated water, and
CO2 in correct proportion. Most beverage operation use cooling to 4C0 for cold filling. The
use of cold filling process is:
▪ To minimize foaming at the filler
▪ Allows the system to run at lower carbonating pressure
▪ Can give a faster rated speed and
▪ Offers advantages from a microbiologic stand point.
Carbonation processes utilize physical characteristics such as: temperature, pressure,

surface area and contact time to facilitate the absorption of carbonation into beverage. The
most common system in use is the saturation or carbonation tank. In this system, beverage is
distributed over cooling plates in a pressurized CO 2 atmosphere. As the beverage is chilled, it
absorbs carbonation. Accuracy is linked to consistent CO2 pressure control, tank level control
and constant flow rate. Other proven systems, each with specific advantages include in-line
carbonation and membranes. It must be carbonated to the level that, after filling and closing,
results in product within the standards for beverage carbonation. The ability of beverage
products to absorb CO2 gas is largely depending on: efficiency of the carbonated unit, product
type that is current production products, CO 2 pressure, the air content of the products, the
temperature of the products.
If the product temperature is rises, the CO 2 becomes 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. The next process after carbonation (the proportional
mixing of the syrup, treated water, and the CO 2); introduction of the carbonated
finished beverage product in to the packages sealing it in a manner so as to preserve its
integrity.
2.1.9 Proportioning
The two primary types of technology used for proportioning and blending are:
 Head over orifice proportioning systems
 Meter based blending systems
The primary function of the proportioning equipment is to accurately blend finished syrup
with water at the correct ratios, or proportions, as called for in the official Pepsi Cola
formulas.

Table 2.2 Mixing ratio for water and finished syrup
PRODUCTES WATER SYRUP
Pepsi cola 5 1
Miranda orange 5 1
Miranda apple 4 1
Miranda tonic 5 1
7-up 5 1
2.1.10 Production Lines

The hosting company has two production line. These are glass bottled and plastic bottled
production line.
 At glass bottled production line KOOL carbonated mineral water is the only product.
After the returnable bottles are washed and inspected they directly transfer to filler.
 Mirinda orange, Mirinda tonic, Mirinda apple, 7 up, Pepsi and KOOL mineral water
are produced at plastic bottled line. For plastic bottle beverages preform is their raw
material to provide the liquid. So the preform must be stretch to convert its structure.
Steps for converting preform
 First the preform is heated by using radiation lamps and glycol cooler is added to
correct the temperature. The incorrect temperature profile could result distortion of
the neck and will affect the distribution of mass and handling on air blower system.
 The second step is blowing section. The preform inserted between the cavities then
the section closes. The preform initially stretched with metal rod to elongate the
preform lengthwise then the tip of the preform is located into the center of the base
section of mould. Finally, high pressure air of up to 40 bars is applied to stretch the
material sideways into final shape of bottle. And the plastic bottles (PET) rinse and
transfer to filer.

2.1.10.1 Filling process and packaging

Filling machinery is used to automatically fill the Empty bottles and packages with the soft
drink.
The filling equipment is usually located in a Filling room that is separate from the rest of the
Plant machinery to reduce the possibility of Contamination. The equipment is fully
automated, and manufacturers assign minimum Personnel just to ensure that the system is
working properly. Filling machinery could also include automatic capping systems that affix
Bottle caps onto the soft drink bottles.
2.1.10.2 Filling system

Counter pressure and Level filers are types of filing systems, which are employed in the
industry.
1 counters level fillers
These types are used in the PET lines and uses electro-pneumatic control systems. This
procedure is carried out on counter pressure. The complete filling process on counter pressure
filler can be classified in to the following steps:
a) EVACUATION: the bottle is subjected to vacuum and the air content in the bottle is
reduced.
b) PRESSURIZING WITH GAS: pure CO2 flows out of the ring bowl into the bottle.
c) FILLING: product flows into the bottle, the air tubes the pressurized gas, there Is a
small deflector that deflects the liquid to the inside bottle wall to ensure a gentle
product flow. When the gas reaches the return tubes the air flow is interrupted and the
flow stops.
d) Settling and shifting: after the bottles filled and settled, they shifted to fill level
correction (inspection) line to check which bottles are filled correctly, exceeded liquid
and below.
e) Labeling &Date coding: labeling is a process of attaching a label which describes
about the product on its bottle. After labeling production date, expire date and
production address is printed on the bottle. For plastic bottle, laser printing coding
system is used.
2 level filers
This type of fillers is utilized in RGB (returnable bottles) in which uniform level is important.

After filling system labeling and date coding is processed. Labeling may or mayn’t be used
based on the bottle and ink jet date coding system is used for glass bottle.
Figure 2.7 filling machine
2.1.11 Packaging
The primary function of packaging is to protect the product, maintaining its safety and
quality, and ensuring it reaches the consumer in the same condition as when it was first
produced and throughout its shelf life. The soft drinks sector uses a variety of different
Packaging formats. The main types are listed below:
Glass bottle beverage packing
Advantage of glass bottle is protecting quality; odor or taste of product andIt is also strong,
rigid and 100% recyclable. After being filled the glass bottled beverages are packed using
cases
Plastic bottle beverage packing
PET (polyethylene terephthalate) is a popular choice for packaging because it is

lightweight, flexible. It can be used for both still and carbonated products. The bottles are
wrapped by plastic nylon into groups and then tightened by heat treatment.
Cans
Cans, including aluminum and steel, are mainly used for carbonated drinks. They are 100%
Recyclable and lightweight. Using recycled Aluminum to make a new can saves 95% of the
Energy that would be needed to make a can from virgin materials (previously unused
materials)
Beverage cartons

Cartons are a major packaging format for still Drinks and fruit juices. They protect the
Freshness, flavors and nutritional qualities of both fresh and long-life drink products,
enabling Distribution at ambient temperatures or under Refrigerated conditions. They are
made from Natural renewable resources, are low carbon and now 92% of UK Local
Authorities recycle Cartons.
Dessie MOHA soft drinks plant use glass and plastics bottle packaging method
for KOOL carbonated mineral water and carbonated soft drinks respectively.

2.2 MATERIAL AND ENERGY BALANCE

2.2.1 Material balance
Chemical processes may be classified as batch, continuous or semi batch and either steady
or unsteady (transient).
Batch process commonly used when relatively small quantities of product are to be
produced on single occasion, while continuous processing is better suited to large production
rate. Continuous processes are run as steady state. Batch and semi batch processes are
unsteady state.
Material balance on dissolving tank
Water=1500L
Dissolving
Sugar=2570kg
tank
Carbon=3kg
The mass balance equation in a system is
Input - output + generation – consumption = accumulation
Assumptions
For continuous reaction
I. The processes at steady state

II. The accumulation term equals zero
III. No consumption
IV. No generation
Then the equation reduces to input = output
Water balance:
Mass of water = density of water*volume of water

kg 1 m3
MH2O= 1000 *1500L*
m3 1000 L
MH2O= 1500kg
Mass of sugar used: 2570kg mass of carbon used: 3kg
Minput=M output
M output=1500kg + 2750kg + 3kg
M output=4253kg
Mass fraction of each component;
Water sugar carbon
Mwater 1500 kg s Msugar 2750 kg MCARBON

X= = X= = X= =
Moutput 4253 kg Moutput 4253 kg Moutput
3 kg
4253 kg
=0.3527 =0.6466 =0.0007
2.2.2 ENERGY BALANCE

Energy is required to run most chemical processes. Energy balance is use to account the
energy that flows into or output of each unit of process and to determine the net energy
requirement for the process. The total energy of process system has three components
1. Kinetic energy; energy due to motion of the system as a whole.
2. Potential energy; energy due to the position of the system in potential field
such as the earth’s gravitational field.
3. Internal energy; energy due to the translation, rotation, vibration and

electromagnetic interactions of molecules, toms within the system.
ENERGY BALANCE ON DISSOLVING TANK
Energy is the sum of kinetic, potential, internal and other energy. But in almost chemical
reactor situations the kinetic, potential and other energy terms are negligible.
Motor energy
Water=1500L
Dissolving
tank
Sugar=2570kg
Carbon =3kg
The temperature difference is 80-91ºC
General formula of energy balance
Input − output = Esystem
Assumption
Steady state
Potential and Mechanical Energy is Zero
E= Q-W
If Q&W are heat energy and motor energy
Q= ΣmCpΔT
kj kj kj
Where Cp of water is 4.2 , Cp of sugar is 1.24 and Carbon is 7.5
kg . k kg . k kg . k
For water
kj kj
1500kg*4.2 =6,300
kg . k k
For sugar
Sugar dissolving Tank
kj kj
2570kg*1.24 = 3186.8
kg . k k
For Carbon
kg kj
3kg*7.5 = 22.5
kg . k k
kj
Q= (6,300+3186.8+22.5) *(91-80) K
k
Q= 104,593.5KJ

3
m
q=45
s
CHAPTER THREE: PROJECT (CASE STUDEY)
3.1 SHORT SUMMERY

3.2 INTRODUCTION
The chemical industry is one of importance in terms of its impact on the environment. Wastes
from this industry are generally strong and may contain toxic pollutant. Beside the
wastewater carbon emission from industries became alarming issue in the world. The global
average of carbon dioxide hit a new record in 2019; 409.8 parts per million. Carbon dioxide
concentration is rising because of fossil fuels that are burning for energy. Combustion of
fossil fuels and resultant increase in atmospheric co2 during the past century has had a
multitude of effects on this planet, including acidification of world’s oceans
We rarely witness evolution a time frame short enough for single human life to take notice.
These changes usually occur over many lifetimes. Creatures are changing their DNA to
survive in their environment. But in one case in the 1700s humans witnessed evolution with
their own eyes, and they caused it. This metamorphosis coincided with human’s rapid
industrialization. We began burning coal on levels never before seen, and its bi-products
rapidly changed the landscape for not just humans, but for the animals that shared the planet
with them. The peppered moth was one of those animals, getting its name from its speckled
white and black coloring, designed to camouflage moth white it lay on lichen covered tree
barks. A black variant was first observed in 1811. At first the mutation was rare, but humans
influence on environment grew, so did their numbers.in 1895,98 percent of the peppered
moths had this black coloring moths in Manchester had this black coloring surely this black
coloring would leave them exposed, making them easier to spot for hungry birds. In reality,
these moths had adapted to be harder to spot in this newly industrialized world, one stained
by soot. And it may be time for humans to follow their lead, to evolve or die. The rate we
have been spewing this pollutants in to our atmosphere has only risen since this discover. Our
carbon dioxide emissions have been raised from 1600 million metric tons to 36000 metric
tons since 1865. Human population and development are continuing to outpace our effort to
curbed our carbon dioxide emission. Just as alcohol producing yeast will eventually create an
environment too toxic for itself to survive. Humans are pumping the world’s atmosphere with
a gas that will eventually render the world unlivable for many, if something is not done. So
we have to ask ourselves now, are we going the way of mindless single cell fungi that
continue to poison their habitat until they die, or are we going to recognize that the survival
of the next generation is more important ?

Carbon dioxide is used in the food industry in carbonated beverages, brewing, and flash
drying. Its industrial uses include enhanced oil recovery (EOR), welding, chemical
feedstock, inert gas, firefighting, and solvent extraction as a supercritical fluid. It is an
essential ingredient in medical oxygen, where in low concentrations it acts as a breathing
stimulant. The largest potential market for CO2 is in EOR. The major CO2 sources that can
be considered for the EOR market are:
 Natural sources
 CO2 wells
 Industrial byproducts
 natural gas
3.3 statement of problem

In Dessie Moha soft drinks s.c, they have not carbon dioxide production area. CO2 is
purchased from other suppliers. Moha soft drinks company known by producing and
distributing carbonated soft drink and specifically in dessie carbonated mineral water (Kool
water). this means carbon dioxide is one of the most necessary raw material in carbonated
soft drink industry
3.4 Objectives
3.4.1 General objective
The general objective of this project was Recovery of carbon dioxide from existing flue gas.
3.4.2 Specific objectives
The specific objective of this project were
 determine the effect of solvent(MEA)
 characterize the phiso-chemical property of recovered carbon di oxide
 determine absorber and striper diameter
3.5 scope of the project

The area of the case study was at dessie Moha drinks plc. The bond includes recovery of flue
gas existing in a boiler to carbon dioxide production for reuse at dessie plant Moha soft
drinks industry s.c in Ethiopia, and to determine the effect of solvent as well as to
characterized the phso-chemical property of recovered carbon di oxide.
3.6 Literature review
At the recent Paris Conference, many countries agreed to reduce the emissions of greenhouse
gases into the atmosphere or at least to keep them at the current level. Carbon dioxide (CO 2)
has been proven to be a greenhouse gas, contributing to the increase of the earth’s surface
temperature and producing long term climate changes.

Several techniques to remove CO2 from gas mixtures have been studied since 1970, since
most of those systems work better with higher CO2 concentrations than those in the flue gases
from fossil fuel fired plants. Some of these studies investigate the field of massive CO 2
emissions capture (80%v/v plus), produces from fermentation. Many CO 2 separation methods
such as gas absorption and cryogenic separation are now being developed to recover CO 2
which is produced in fermentation process to prevent global warming. Although CO 2
emissions are coming from different sources such as fermentation, power plants, industry,
domestic heating and so on, this case study reviews the latest processes for CO2.[3]
3.6.1 Physical and Chemical Properties of Carbon Dioxide

Table 1: Physical and chemical properties of carbon dioxide
Physical properties Chemical properties

Freezing point = -78℃ Its vapor pressure = 58.5 bar
Inert or non-flammable Its melting point = -57℃
pressurized
Nontoxic and heavier than air Its latent heat vaporization = 571.08
Kj /Kg
Odorless and taste is neutral Its boiling point = -78℃ sublimes
Liquid CO2 density = 50.32kg /m3 Organic solvent
3.6.2 Application of Carbon Dioxide

Carbon dioxide produced mainly in to two forms Liquid and solid. Solid CO 2 is also known
as “dry ice” and is used as refrigerants in food industry and for all small Shipments CO 2 is
widely utilized during the storage and shipping of ice cream and other frozen foods. And also
it has many applications as follows;
A fire extinguisher: CO2 can be used to extinguish flames by flooding the environment
around the flame with the gas. It does not itself react to extinguish the flame „but starves the
flame oxygen by displacing it. Some fire extinguishers especially those designed for
electrical fires contain liquid carbon dioxide under pressure.

Beverages: This gas is used to make carbonated soft drinks and soda waters.
Fumigation: Used as a fumigant to increase shelf life and remove infestations.
Chemical industry: It is used as a raw material in the chemical process industry especially for
urea and methanol production.
Pressured gas: It is used as the cheapest noncombustible pressurized gas pressured CO 2 are
inside tins in life jackets compressed CO2 gas is used in paint ball markers, air guns, for
ballooning bicycle tires
Solvent: Liquid CO2 is considered as a good dissolving agent for many organic compounds.
Here it can be used to remove caffeine from coffee.
Plants: require CO2 to execute photosynthesis and greenhouses can promote plant growth
with additional CO2.
In medicine, up to 5% CO2 is added to pure oxygen. This helps in provoking breathing and
to stabilize theO2/CO2 balance in blood.
There are three types of carbon dioxide recovery methods, those are;
A. Chemical and physical absorption
B. Solid physical adsorption – pressure swing and temperature swing adsorption
C. Cryogenic separation (Low temperature distillation). [2]
A. Physical and Chemical Absorption
I. Physical Absorption
CO2 can be physically absorbed in a solvent according to Hennery’s law and hence more
applicable to gases with high partial pressure of acid gas. Physical solvents are favored by
high pressures and low temperature. The solvent regeneration step is relatively simple for
physical absorption as it is carried out by pressure let down. However, if physical solvents
were utilized, not only compression power would be required but also extensive energy
requirements for solvent .[8]
II. Chemical Absorption
The chemical absorption process for separating CO 2 is borrowed from the ethanol processing
tank which is fermentation tank. The chemical absorption method is widely used in chemical
and other industries to separate and recover CO 2 from process gas. Amine based processes
have been used commercially for the recovery of acid gas (CO 2). Alkanolamines recover CO2
from the gas stream by the exothermic reaction of CO 2 with the amine functionality of the
alkanolamine
 Alkanolamines can be divided into three groups:

 Primary amines whose members include monoethanol amine

 Secondary amines whose members include ethanolamine and
 Tertiary amines whose members include triethanolamine
In the amine gas processing operation, the gas stream and liquid amine solution are contacted
by countercurrent flow in an absorption tower. Conventionally, the gas to be scrubbed enters
the absorber at the bottom, flows up, and leaves at the top, whereas the solvent enters the top
of the absorber, flows down (contacting the gas), and emerges at the bottom. Dilution of the
circulating amine with water is done to reduce viscosity of the circulating fluid.[6]
The liquid amine solution containing the absorbed gas is then flowed to a regeneration unit
where it is heated and the acid gases liberated. The solvent regeneration can be carried out at
low pressures to enhance desorption of CO2 from the liquid. Some amine solution is typically
carried over in the acid gas stream from the regeneration step and the amine solution is
recovered using a condenser. The hot lean amine solution then flows through a heat
exchanger where it is contacted with the rich amine solution from the contact tower and from
there the lean amine solution is returned to the gas contact tower. [7]
3.7 methodology
3.7.1 Materials and chemicals
Table 2: materials needed in the lab
No Materials Uses
1 Absorption To store liquid solvent

tanker
2 Stripper To rotate the solvent

column through flue gas to
absorption tanker
3 Thermometer To measured temperature
4 heat To generate heat from the

exchanger source
5 dehydrator To remove water after

recovery of carbon dioxide
6 Burner To burn the fuel

7 PPM To removed odor, flavor

scrubber
Table 3 chemical used in lab
No Chemicals Use
1 MEA To absorb flue gas
2 Water To wash the material
3 Fuel To produce steam
3.7.2 Methods
3.7.3 Process description for CO2 recovery
The fuel was burned by flame in burner from flue gas was interred in to the burner at a
pressure of 11bar. the section flue was cooled down and sculpture removed soda ash solution
was added to soda scrubber pump and by circulated in the system and removed the surplus
which was present in fuel gas. Sulphure and Sulphure dioxide were removed by soda ash
through flashing system carbon dioxide were weighted in exhauster which comes from flue
gas. Carbon dioxide was absorbed in absorber from smokes and removed other gas like water
vapor, nitrogen oxygen by using MEA. Carbon dioxide and MEA were passed through rich
lye pump which added absorbed then where cooled lye cooler heat exchanger from 180oC-
40OC using cooling water. Carbon dioxide was separated from MEA by evaporation of
carbon dioxide from MEA by application of temperature at 180 oC-200oC. The carbon dioxide
separated from MEA was gone to gas cooler and mea was circulated in the boiler. carbon
dioxide was cooled down in the gas cooler to 50% approximately by using cool water. The
moisture was separated carbon dioxide solution after water was separated the carbon dioxide
gas was interred to PPM scrubber. Carbon dioxide was condensed then the condensed was
flown by gravity to the storage tank. The sample was taken to check the purity. If thr purity
is greater than 90% it come to refrigerator were not reject it, But the purity was greater than
90%. So carbon dioxide gas was converted to liquid carbon dioxide by using iron refrigrator
at a temperature of greater than 30oC. in general, the needed of liquefying carbon dioxide gas
into liquid was to make storage easy economical storage then liquid carbon dioxide was
stored in storage tank.
Figure3.1: General flow diagram of Co2 Productions
3.7.4 Determining the effect of amount MEA solvent on carbon dioxide

recovery
Firstly mono ethanol amine was taken at different amount (100, 200 and 300 ml) and
the amount of carbon dioxide was recorded. The reason that I used this solvent was:-
 Reduce corrosion rate

 React quickly
 High circulation rate
3.7.5 Physio-chemical properties of recovered CO2
 Determining the vapour pressure
The vapour pressure of recovered carbon dioxide in an absorber was measured using a
barometer and the result was recorded.
 Determinig freezing point, boiling point, and melting point of recovered co2
The freezing point, melting point, and boiling point of recovered CO 2 was measured with
in thermometer separately and the amount was recorded.
 Determining the density of co2

the density of the recovered CO2 was determined by using the following formula:-
M
ρ= .............................................................................1
V
WHERE M--- mass of carbon dioxide= 100.9Kg
V -- Volume of co2 =2M3
ρ−→density of carbon dioxide
3.8 Equipment sizing

Absorption & Stripping Design
•  Common assumptions:
–  Dilute and immiscible gas-liquid phases
– L and V streams are constant from stage to stage
–  Concentrated or miscible
– L and V streams can increase or decrease from stage to stage
–  How will this affect the number of theoretical stages?
–  Are the analytical equations still valid?
•  What is the goal of absorption or stripping operations?
–  Maximum extraction with 100% efficiency (i.e. actual # of stages = theoretical)
–  High throughput (low residence time)
–  Smallest and simplest possible system (low capital)
•  How do we accomplish this?
–  Choose the right absorbing (liquid) or stripping (gas) phase (equilibrium and
immiscibility)
–  Optimize column diameter and height
–  Maximize contact area/volume within column WITHOUT flooding the column or making
it unreasonably “slow
Absorber diameter
Absorber diameter m, =A.squrt (te/d)/%Co2
Where
A=0.56 at 3%Co2 to 0.62 for 13% Co2

Te/d = tone/day co2 recovered
%Co2= volume %CO2 in flue gas before cooling
Assumption
-there is 100% recovery
-the fuel is fully burned (no carbon monoxide formation)
-boiler working continuously for 24 hours
Known value
Amount of diesel fuel in liter Time

564009 4:00
564020.4 4:10
564031.7 4:20
564043 4:30
564054.5 4:40
564066 4:50
564077.4 5;00
Table 3.1 fuel consumption of boiler room
From this data the boiler use 1.14 liter of fuel in one minute. This means 68.4 l/hr.
One liter of diesel fuel contain 2.67 kg of co2 (shown in appendix B )
Amount of co2 in diesel fuel per day = 1642l of disel ×2.67kg of co2
=4384kg of co2
Te/d=tonne/day recovered
=4.384 tonne of co2 /day
 The flue gas %volume is between 10-13%
absorber diameter m,= A.squrt(te/d)/%co2
= 0.62.squrt (4.384)/13
= 0.10m
=10 cm
Stripper diameter m, = 0.13.squrt (te/d)

= 0.13.squrt (te/d)
= 0.27m
=27cm
3.9Result and Discussion

3.9.1 Determine the effect of amount MEA on recovered carbon dioxide
Table 4: effect of solvent
No Amuont of MEA(L) amount of

CO2(Kg)
1 5 40
2 10 48.574
3 15 56.67
From the table high amount of carbon dioxide was determined at higher amount of MEA
(15L) so the amount of solvent have a great effect on recovery of carbon dioxide.
3.9.2determine the Physio-chemical properties of recovered carbon dioxide
 After measured the vapour pressure of co2 was determined as 62.1bar.
 by measured with thermometer the value of freezing point, boiling point and
melting point was -75, -80 and -54oC respectively.
 The density of carbon dioxide was calculated by equation 1 and gives
( 100.9 kg+12 kg ) −12kg
=50.5 kg /m 3
2 m3
Generally the standard value and experimental values of recovered carbon dioxide is
summarized as follows.
Table 5 characterization of phiso-chemical propertis recoverd co2
Properties Standard value Experimental value

Freezing point -78℃ -75℃
Vapour pressure 58.45 62.1
melting point -57℃ -54℃

Liquid CO2 density 50.32 Kg/m3 50.5 Kg/m3
boiling point -78℃ -80℃

From the table I have seen that the expremental value of recovered carbon dioxide is closed
with the standered valus so it is used as raw materials for production of soft drinks

3.10 Conclusion
Because of environmental and economic incentives, this project has mainly focused on
carbon dioxide separation (recovered) from flue gases. Based on the above findings it can be
concluded that flue gas properties (mainly concentration of CO2, Temperature and pressure)
are the most effective factors for selection of suitable process for recovery of carbon dioxide.
Since flue gases have high temperature, low-pressure high carbon dioxide concentration
absorption striping column is the most suitable for this process. From the finding carbon
dioxide can be recovered from flue gas through absorption process using solvents. The
recovered carbon dioxide has been cooled between 318ok to 323ok. The produced carbon
dioxide has not color and non-toxic. Using this process we can recover above 90% of carbon
dioxide which exists from boiler room. In Moha Soft Drink Company they consume 400Kg
of of carbon dioxide in 8 hours that means 1200Kg per day (maximum value). At the same
time the boiler room produce 4384 kg of carbon dioxide per day (average value). This is
more than the company need.so by using absorption method with mono ethanol amine the
company can save the environment from pollution as well as minimize their scarcity of
carbon dioxide resources.

3.11 Recommendation

CHAPTER FOURE
4. OVERALL BENEFITS OF THE INTERNSHIP
The internship time has been the most educating and challengeable time. I understand how
well I have understood the literatures, theories and formulas we had taken in our previous
courses but when it comes to the actual world, it was hard to tell how competent we were. It
is very understandable that parallel to the theoretical part, experience is very important in real
world. Being familiar with the workflow is a key to understand ones role properly and be able
to make competent decisions. For something, that takes inputs there is something in return, a
benefit. In our internship too, there were some benefits gained accordingly. The benefits are
discussed from the above objective. This internship program provided us with the opportunity
expand our horizon, broadening our intellectual knowledge and gives us a chance to improve
our theoretical and practical knowledge from this grateful experience.
Therefore, I gained the following essential things.
 Creative and logical approach to solving problems.
 Clearly understand different unit operations and working principles of the machineries.
understand how to operate and maintain different equipment’s in the industry
 Able to give maintenances for different equipment is which are used in industrial
application. Effective assessment and management of risk, resource & time.
 Possess mathematics skills necessary to solve problem.
 Demonstrate knowledge of the process industry and different course.

 Aware of continued educational opportunities through such resources as academic

institutions, the work place, and professional societies.
4.1 Improving practical skills
The theoretical knowledge that I have learned three years in the past must be fulfilled in
advance to practical skills through this internship program on different department of the
company at different working machines.
4.2 Improving interpersonal communication skill
Developing interpersonal communication skill is essential to organic life in today work place.
Interpersonal communication skill is the process by which we exchange information,
feelings, and meaning through verbal and non-verbal messages. It is face-to-face
communication. Interpersonal communication is not just about what is actually said - the
language used - but how it is said and the non-verbal messages sent through tone of voice,
facial expressions, gestures and body language. This covers verbal and written
communication, and listening. It's about being clear, concise and focused; being able to tailor
your message for the audience and listening to the views of others.
4.3 Improving team playing skill
Team playing skill is one of the basic requirements for the proper working of a good
company regardless of its size and service. I got an improvement over things like;
 Listen actively
 Communicate constructively
 Share openly and willingly
 Cooperate and help others
 Show commitment to the team
 Work as problem solver and
 Treat others in a respectful and supportive manner
4.4 Improving leadership skill
Leadership skill is one portion of the work that acquires managing skill in different aspects
such as managing workflow, assigning the Forman and the team leaders to their respective
tasks, properly allocating and insuring. During my internship program, I saw how the project
manager monitors the workers. In addition, I was developing my leadership skills by giving
comments, sharing ideas and participating in the works, I already knew for experience.
Some learnt points from leadership are:
 Seeking of self-improvement
 Being technically skillful

 Taking responsibility for the actions
 Making sound and timely decisions
 Keeping the workers informed for necessary information
 Developing a sense of responsibility in all workers
 Ensuring that tasks are understood, supervise, and accomplished
 Using the full capability of the organization
4.5 Understanding about work ethics and related issues
One of the qualities of professional worker respects the work ethics in work place and I learnt
some of the work ethics during internship.
Some of them are -
 Punctuality: - we arriving the work place on time.
 Honesty: - Spending working hour and resources on work place.
 Willingness to learn: - understanding the way of doing work and try to do it better.
 Initiative:-being prepared to see what needs doing and to do the work without being
asked.
 Responsibility:- is having a duty of something and taking the blame Reliability
 Accountability
 Loyalty
 Transparency and openness.
 Integrity
 Avoiding probable or apparent conflict of interests
 respecting the work ethics
 combating corruption and
 Presenting the report on time
4.6 Entrepreneurship skill
Emphasizing the growth of entrepreneurship would not only lead to a new robust industry of
its own but also is a basis for improving the social and economic capability of the country. I
had a wide range of entrepreneur skills from above skills including personal traits and
management Skills.
 The ability to manage the time and people (both others and myself successfully.
 The ability to work both as part of a team and independently.
 Able to plan, coordinate and organized effectively

 How to improve Self- motivation and discipline.

 Innovative skills
 Self-Motivated
 Self-confident
 Results-orientated
 A risk-taker
 Total commitment
 Ability to work independently
3.7 Major duties of the internship
Internship provides the opportunities to build a relationship with the company, network with
other people in the field and gain valuable first-hand experience. It gives us the knowledge
and experience we need to be confident in our career activities.
I understand that our duties include the following tasks.
 To be involved into the company at the set time
 Obey the rules of the company
 Work the given tasks in the company with the guidance of the company supervisor
 Write and submit monthly and final reports
4.8 Problem solving during the internship
I have developed skills of Analytical approach to solving problems and resolving issues. It's
also good to show that I can approach problems from different angles.
Confidence
In the workplace I need to strike the balance of being confident in myself but not arrogant,
but also have confidence in my colleagues and the company I work for. This is about being
able to put forward my way, but also being able to understand where the other person is
coming from so that we can both get what we want or need and feel positive about it.

CHAPTER FIVE
5. OVER ALL CONCLUSION AND RECOMANDATION

5.1 Conclusion
Drawing from our internship duration it is, therefore, concluded that:
Dessie MOHA soft drink factory produces carbonated soft drinks, carbonated mineral water
and mineral water with international accepted quality standards and delivered to their
consumers. During their production processes precision making system is ensured to get
accurate and attractive products, which starts from producing utilities up to converting into
desired products by passing different unit operations.
The internship program was beneficial in that it helped boost our motivational levels and
internships helped us to understand theories learnt in classroom and enhanced our learning
and understanding of issues relevant to the specified areas of study and Also it helps us to
aware us what look like the real job’s world. MOHA soft drink Sc. Give me practical and
theoretical knowledge. That will help me by strengthen what I have learned before. And will
also increase my confidence to work anywhere by performing a given task.
5.2 Recommendation
From the time of internship duration in Moha dessie pepsi cola plant there is some
limitations/short coming that are challenges for the workers, affect environment and obstacles
for the operators. To overcome those challenges I recommend that;-
 The company should have enough operator instructions and manuals should be
present for the worker or operators in each section to perform appropriate activities.
 High fuel consumption, this may be results from scale formation and insulation of the
heat transfer surface. To reduce this, the boiler has to be cleaned and the water
entering the boiler should be heated up to the boiling temperature.
 Zeolit is not replaced for over a year as a result it is working for only six hours
instead of its full capacity performance of performing for eight hours. Hence, zeolite
should be timeworn should be switched with fresh zeolite.
 Water tank is made of mild steel that causes corrosion of the tank itself and it causes
fouling when the water is distributed to heat exchangers that are in lines. It leads to
scale formation inside the heat exchangers deteriorates lifetime of heat exchangers.
Therefore, mild steel should be changed into stainless steel to avoid fouling.
 Additionally we recommended for the Company that the company should employee
skilled worker, the company should be pay fair payment for workers and the
company should be having good clinic.
Recommendation for the Department

The department of chemical engineering is very wide and interesting department but in our
campus has no its own well organized laboratory access for the students to practice office
works, so the department should arrange enough access for the next interns so that they
practice office works.
REFERENCE
[1]. dessie Moha soft drink shard company module
[2]. Hart, A.; Gnanendran, N. Cryogenic CO2 capture in natural gas. Energy Procedia 2009,
1, 697–706.
[3]. Ishibashi M, Ota H, Akutsu N. Technology for removing CO2 from power plant flue gas
by the physical adsorption method. Energy Conver Manage 1996; 37:929–33.
[4]. Wilson MA, Wrubesk RM, Yarborough L. Recovery of CO 2 from power plant flue gases
using amines. Energy Conver Manage 1992; 33:325–31.
[5]. Yagi T, Shibuya H, Sasaki T. Application of chemical absorption process to CO 2
recovery from flue gas generated in power plants. Energy Conver Manage1992; 33:349–55.
[6]. Desideri U, Paolucci A. Performance modelling of a CO2 removal system for power
plants. Energy Conver Manage 1999; 40:1899–915.
[7]. Dragos L, Nada O, Flueraru C, Scarlat N. Romanian research for CO2 recovery. Energy
Conver Manage 1996;37:923–8;Sada T, Fujii M, Yoshida K. Development of flue gas CO2
recovery technology. Energy Conver Manage 1992; 33:317–24.
[8]. Zhang J, Webley PA, Xiao P. Effect of process parameters on power requirements of
vacuum swing adsorption technology for CO2 capture from flue gas. Energy Conver Manage
2007; 48:1715–32.





APPENDEX A: CALCULATION OF COMPOSITION OF FLUE GAS
Consider 100 kg of biomass (pine wood) with an Ultimate Analysis on a dry ash free basis given in
Table A.1. This calculation assumes that all the carbon is burned i.e. there is no carbon in the ash or
carbon monoxide formed. If there is the unburned carbon has to be subtracted from the value of
carbon in the above table. Also that the S, N and Cl are negligible and there is no ingress of N2 in the
flue or sampling system. Moisture content given in the Proximate Analysis has to be allowed for in
the calculation as well. Assume the combustion reactions are
Composition of the dry flue gas from the stoichiometric combustion of 1 kg of biomass: N2 from
theoretical air = 4.94 × 0.79 = 3.90 m3. N2 from biomass = 0.001 × 0.224 = 0.0002 m3. CO2 from
biomass = 4.33 × 0.224 = 0.97 m3. Total amount of dry flue gas per 1 kg wood = 4.872 m3. If the
concentration in the wet flue gas is required then the water content has to be included in the above
calculation.
C + O2 = CO2
2H 2 + O2 = 2H 2O
Oxygen required for stoichiometric combustion = 4.33 + 1.6 − 1.3 = 4.63kg-mol
Air requirement = [4.63 × 100 × 22.41]/[21]=494.1 m3 at NTP
Element Molecular weight Moles of oxygen required

C,52.00 12 4.33
H,6.20 2 1.6
O,41.60 32 -1.3
N,0.20 28
TABLE A.1: calculation of flue gas composition
Therefore % CO2 = 0.97/4.872 = 19.91 assuming stoichiometric combustion (0 % O2).
For 20 % excess air = 16.6 % CO2
For 40 % excess air = 14.2 % CO2
For 50 % excess air = 13.27.

APPENDEX B
CARBON DIOXIDE COMPOSITION DISEL FUEL

Final Intenship Report and Project: Acknowledgment

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Final Intenship Report and Project: Acknowledgment

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FINAL INTENSHIP REPORT AND PROJECT

MEU – CHEMICHAL ENGINEERING Page 1

MEU – CHEMICHAL ENGINEERING Page 2

Symbol and abbreviations

CO2 Carbon dioxide

M.ORENGE Mirinda orange

MEU – CHEMICHAL ENGINEERING Page 3

2.1 process description ……………………………………………………………………

2.1.1 Water treatment process…………………………………………………………………

2.1.2 Washing machine operation…………………………………………………………….

2.1.2.1 Case washer………………………………………………………………………….

2.1.2.2 Bottle washer…………………………………………………………………………

2.1.3 Steam generation………………………………………………………………………….

2.1.3.1 Boiler plant……………………………………………………………………………..

2.1.4 Carbon dioxide production…………………………………...............................

2.1.5 Syrup preparation………………………………………………………………..

2.1.5.1 Main raw materials…………………………………………………………….

2.1.5.2 Preparation of simple syrup…………………………………………………

MEU – CHEMICHAL ENGINEERING Page 4

2.1.5.3 Preparation of finished syrup………………………………………………….

2.1.6.1 Process mixing system………………………………………………………………….

2.1.7 Cooling system……………………………………………………………………………

2.1.7.1 Product cooling………………………………………………………………………

2.1.8 Carbonation …………………………………………………………………….

2.1.10 production line……………………………………………………………..

2.1.10.1 Filing process and packing…………………………………………………

2.1.10.2 Filling system…………………………………………………………………

2.2 material and energy balance……………………………………………………………

2.2.1 material balance ………………………………………………………………………

2.2.2 energy balance ………………………………………………………………………..

3.1 short summery…………………………………………………………………….

3.3 statement of problem……………………………………………………………….

3.4.1 General objectives………………………………………………………………………

3.4.2 Specific objectives ………………………………………………………………………..

3.5 scope of project …………………………………………………………………………….

3.6 literature review…………………………………………………………………………

3.6.1 Physical and chemical properties of carbon dioxide

3.6.2 Application of carbon dioxide

3.7.1 Material and chemicals

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3.7.3 Process description for carbon recovery

3.7.4 Determine the effect of amount of MEA solvent on carbon dioxide

3.7.5 Physio-chemical properties of recovered co2

3.8 equipment sizing ………………………………………………………………..

3.9 result and discussion……………………………………………………..

3.9.1 Determine the effect of amount of mea on recovered carbon dioxide………….

3.9.2 Determine the Physio-chemical properties of recovered carbon dioxide

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Chapter one: introduction

1.1.1 When and where did Pepsi cola start?

1.1.2 When did Pepsi start in Ethiopia?

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1.1.3 What is the background of MOHA?

Former logo of the company

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FIG 1.1 logo of pepsi cola

1.2 Objectives of the company

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C. To manufacture, sell and distribute carbon dioxide.

1.3 vision of the company

1.4 mission of the company

1.5 End products and service of the company

Figure1.2: Main products of Moha soft drinks S.C