 Line No.

1 & 2 (Glass Line)

The regular (glass) bottle goes through the following operations before filling on both the lines.

 De-Caser
 Zero Light Inspection
 Bottle Washer
 Zero Light Inspection
 Empty Bottle Inspection (EBI - OMNIVISION)
 Carbo cooler (Mixture)
 Filler
 Zero Light Inspection
 Crate Washer
 Caser

 De-Caser:
The main function of De-Caser is to separate the empty glass bottles from the case and via conveyer
system the bottles are passed towards the bottle inspection unit. The de-caser is equipped with a
cam and crank which helps the gripper head to remove bottles from the crate. The gripper heads
provide suction which helps in gripping the bottle firmly while they are being uncased. The cylinder
is loaded and unloaded with air which drives the crank providing motion to the gripper heads.

The pickup consists of 96 bottles/cycle completing 7 cycles/min.

Bottles/min de-cased= 96*7= 672 bottles.

De-Caser
Part
Gripper / Head
Gripper Rod
O Rings
Rubber Seal
Springs
Cam
Cylinder
Crank

 Zero Light Inspection:

The empty bottles from the de-caser are then manually inspected via human eye two times to check
for any damage or unwanted bottle on the line. The bottle inspection unit consists of a white glass
with tube lights (zero lights) behind them for inspection.

M. Wasil Javed PAKISTAN BEVERAGE LTD.

 Bottle Washer:
After the zero light inspection unit the bottles are fed into the pockets of the washer. The bottle is
first washed with water and then with the caustic at different stages to completely wash the bottle
and make it germ free. The shower trolleys and the carriers are made movable with the help of a
main shaft which is driven by a gearbox & motor. The main shaft then drives the secondary shafts
inside the washer which are connected with the main shaft with the help of sprockets and gear
boxes mounted on the main shaft.

Line No. 01 Line No. 02

Tank Caustic/ Caustic Temperature Caustic/ Caustic Temperature
No. Water Strength Water Strength
01 Caustic 2.0 to 2.5% 65 to 75°C Caustic 2.0 to 2.5% 60 to 65°C
02 Caustic 3.0 to 3.5% 70 to 80°C Caustic 3.0 to 3.5% 70 to 85°C
03 Caustic 2.0 to 2.5% 68 to 75°C Caustic 1.5 to 2.0% 65 to 70°C
04 Caustic 1.5 to 2.0% 60 to 70°C Water - 40 to 50°C
05 Water - 40 to 45°C Water - 30 to 35°C
06 Water - Ambient Water - Ambient
07 Water - Ambient -

Description Line No. 1 Line No. 2

No. of Carriers 470 465
No. of Bottle Pockets/Carrier 30 40
No. of Showers (Water & Caustic) 34 34
Fixed Water Showers 03 03
Moving Caustic Showers 16 18
Moving Water Showers 13 13
Shower Nozzles 30 nozzles/shower 40 nozzles/shower
Speed 16 carriers/min 17 carriers/min
No. of Centrifugal Pumps 06 06
Water Consumption Rate 14,000-15,000 ltr/hr 14,000-15,000 ltr/hr
Steam Temperature 200-220°C 200-220°C
No. of Gear Boxes 08 08
Shaft diameter 75 mm 75 mm
Shaft length 15 ft. 13 ft.
No of teeth of Sprocket 20 20
No. of teeth of Main Gear 15 16
Infeed Flying Bar 04 02
No. of shafts 14 15
Bottle washing time 20-23 min 20-23 min
Output 18 carriers/min 17 carriers/min

M. Wasil Javed PAKISTAN BEVERAGE LTD.

 Empty Bottle Inspection (OMNIVISION II):
The empty bottles from the washer are then passed via the EBI station which inspects the bottle
from top to bottom and side by side to check for any damage. The damage bottles are rejected and
are passed to a separate conveyer which are then disposed of properly. The bottles are inspected
with the help of different cameras the first three cameras check for the bottle’s bottom and the top
and the frontal side while the remaining one check for any damage neck. The sensors helps in
stopping and starting the conveyer and helps in damage bottle rejection.

EBI
Part
No. of Cameras 04
Sensors 04
Starwheel Fingers 41

 Carbo Cooler:
The construction of the mixture tank consists of 6 tanks which includes water distillation tank,
small water tank, syrup tank, mixture tank, carbo cooler tank and ammonia tank. It consists of
two pumps, one for the supply of syrup to filler and the other one for CIP. The whole process is
like that first the water from distillation tank flow towards small tank and syrup came to syrup
tank from VDM Room and both get mixed in mixture tank and after that mixture enters in carbo
cooling tank where it gets chilled with the help of tubes in which ammonia liquid is supplied
from ammonia tank and after chilling the mixture the liquid ammonia convert into vapor and is
send back to ammonia compressor room. There are 2 inlet pipes and 2 outlet pipes for the
mixture in carbo cooling tanks. Pressure for ammonia gas is 14.5 bar. In whole process CO 2 is
also used for supply of mixture to filler and its pressure is about 15 bar.

Carbo Cooler (Mixture)

Ammonia Pressure 14.5 bar
CO2 15 bar

 Filler (SIMONAZZI EUROSTAR):

The bottle from the EBI is now ready to be filled with the carbonated syrup. The bottle is fed into the
filler which is filled and then is ready to be crowned. The syrup is stored in the carbo cooler which is
prepared and cooled with the help of ammonia and chiller water to the desired temperature in
order to avoid foaming. After the bottle is filled it is again manually inspected for check for any
further damage or low fills during filling.

FILLER (Line No. 1 & 02)

Part Description
No. of valves 70
No. of crowner heads 15
Temperature 11°C
Bowl Pressure 40 psi
Control Air Pressure 80 psi
CO2 inlet Pressure 48 psi
Back Pressure 60-70 psi

M. Wasil Javed PAKISTAN BEVERAGE LTD.

 MIXTURE (Line No. 1 & 02)
Part Description
Carbo Cooler Pressure 40-45 bar
Ammonia Temperature 2.6°C
Chiller Temperature 8-10°C
CO2 Pressure 9.5 bar

 Crate Washer:
The crates after getting emptied from bottles in De-caser reaches in this tank for washing where 10
big shavers and 10 small shavers operating in it through which hot steam, chemicals and bleach gets
applied for cleaning the crates.

 Caser:
The caser works on the same principle as of de-caser just as it works in the opposite i.e., it helps in
hopping the bottles into the case (crate) while the de-caser helps in separation or removal of bottles
from the case.

M. Wasil Javed PAKISTAN BEVERAGE LTD.