MEKELLE UNIVERSITY

ETHIOPIAN INSTITUTE OF TECHNOLOGY-MEKELLE

DEPARTMENT OF CHEMICAL ENGINEERING

INTERNSHIP REPORT

HOSTING COMPANY: MOHA SOFT DRINKS INDUSTRY MEKELLE

PREPARED BY ID NO
Haregot Abadi Eitm/ur115482/10

Advisor; Ms. Alemework F.(MSc)

March 29, 2021

 MEKELLE, TIGRAY, ETHIOPIA

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 Acknowledgment
First and for most we would like to acknowledge the Almighty God for his merciful and
endless guidance through our life and forgiving us a supportive and loving family and friends
that are always there through all our success and failure, supporting and lifting us up morally
and financially. Next to GOD, we would like to express our deepest gratitude to our advisor,
Ms. Alemework. We are grateful for her sincere commitment in offering valuable support,
advice and motivation during the preparation of this project. It is difficult to acknowledge
every individual who contributed valuable efforts when we were in internship program, but it
is worth mentioning some of them. We would like to acknowledge our company supervisor
Mr. Teklay for giving us the chance to see and practice the first section of the company even
if it was for short time.
We would also like to show our deepest gratitude for our inst. Tedros for his willingness to
help us in giving more information regarding the project and others.
Finally, we would like to expand our deepest gratitude for all MOHA employees and our
fellow internship students for their support and encouragement.

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 Abstract
The aim of this paper was to express and present the two weeks internship report. A full
internship report was supposed to be expressed, but unfortunately due to COVID
19(CORONA VIRUS) and some other problems the internship work was not able to be
finished and had to stay only for two weeks. Because of this reason only the first section of
the company was seen which the raw water treatment section is. So here instead of making a
project an internship report has been made. This internship report provides a brief history and
profile of our hosting company that named MOHA soft drinks S.C Mekelle branch. It
consists of five chapters. Chapter one includes the background, objective, mission, vision,
end product and end product user of the hosting company. Chapter two describes about the
overall process technology of the plant. Chapter three is about internship report which is
report of the raw water treatment. Chapter four is over all benefit gained from the internship
even if it was for short time. Chapter five is conclusion and recommendation towards the
hosting company.
MOHA soft drink industry Mekelle plant was the 8 thplant of MOHA companies with a
building capital of 108,654,000 birr. The efficiency of MOHA soft drink Industry was 36000
bottles per hour and the objectives of the company was to manufacture and distribute bottled
soft drinks and concentrates. The company’s mission was to be the best soft drink industry in
the country. It will continuously improve its responsiveness to the needs and choice of its
customers, employees, partners in which it serves. MOHA soft drinks Industry produces 7 up,
Miranda orange, Miranda apple, Miranda tonic, Pepsi, CO2 and the company have five main
sections such as water treatment section, CO2 production section, Syrup preparation section,
Steam generation (steam boiler) section, Soft drink production section. Generally, the
company has its own production process technologies and quality controls mechanisms.

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 Symbols and Abbreviation
A.C- Activated carbon

CCS- Carbon Dioxide Capture and Storage

CCP- Critical Control Point
CIP- Clean in Place
EBI- Empty Bottle Inspection
FBI- Full Bottle Inspection
HEX- Heat exchanger
MEA- Mono Ethanol Amine
MOHA- Mohammed Hussein Al-Amoudi
Pepsi Co- Pepsi Cola
Ppm- Parts Per million
RO- Reverse Osmosis

Table of Contents

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Acknowledgment........................................................................................................................i
Abstract......................................................................................................................................ii
Symbols and Abbreviation........................................................................................................iii
Table of Contents......................................................................................................................iv
List of Figures............................................................................................................................v
1. INTRODUCTION...........................................................................................................1
1.1. Back Ground................................................................................................................1
1.2. Objective of the company............................................................................................3
1.3. Mission of the company..............................................................................................3
1.4. Vision of the company.................................................................................................4
1.5. Suppliers, products & Main services and End users of the company.........................4
1.5.1. Suppliers of the company.....................................................................................4
1.5.2. The Main Products...............................................................................................4
1.5.3. Main Services of MOHA Soft Drink Industry.....................................................5
1.5.4. The Main Customers or End Users of the Company...........................................6
2. PROCESS TECHNOLOGY OF THE FACTORY.........................................................7
2.1. Water Treatment..........................................................................................................7
2.1.1. Concrete Reservoir...............................................................................................8
2.1.2. Aeration................................................................................................................8
2.1.3. Sand Filters...........................................................................................................8
2.1.4. Intermediate tank..................................................................................................9
2.1.5. Activated carbon filter..........................................................................................9
2.1.6. The polisher........................................................................................................10
2.1.7. Ultraviolet (UV).................................................................................................10
2.1.8. Reverse osmosis.................................................................................................11
2.1.9. Softener..............................................................................................................12
2.2. Carbon dioxide Production........................................................................................14
2.3. Syrup preparation section..........................................................................................20
2.4. 2.4 Soft Drink Production Section.............................................................................22
2.5. Wastewater treatment................................................................................................27
2.6. Environmental Considerations of the plant...............................................................29
2.6.1. Occupational Safety and Health Protection.......................................................29
2.6.2. Quality the Key to Performance (Quality Control)............................................29
3. INTERNSHIP REPORT...............................................................................................31
Raw Water treatment................................................................................................................31
3.1. Objective....................................................................................................................31
3.2. Material and chemical used.......................................................................................32

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 3.3. Discussion..................................................................................................................32
3.4. Conclusion.................................................................................................................35
4. OVER ALL BENEFIT FROM THE INTERNSHIP....................................................37
4.1. In Terms of Improving Theoretical Knowledge........................................................37
4.2. In Terms of Improving Practical Skill.......................................................................37
4.3. In Terms of Improving Industrial Problem Solving Capacity...................................37
4.4. In Terms of Improving Team Playing Skill..............................................................38
4.5. In Terms of Improving Leadership Skill...................................................................38
4.6. In Terms of understanding about work ethics related issues.....................................39
4.7. In Terms of Entrepreneurship Skill...........................................................................39
4.8. In Terms of Improving Interpersonal Communication Skill.....................................39
5. OVERALL CONCLUSIONS AND RECOMMENDATIONS....................................40
5.1. Conclusion.................................................................................................................40
5.2. Recommendations.....................................................................................................40
REFERENCES.........................................................................................................................42
APPENDICES..........................................................................................................................43

List of Figures
Figure 1.1: External picture of MOHA soft drink factory, Mekelle..........................................1
Figure 1.2: Structure of MOHA soft drinks factory S.C Mekelle plant.....................................3

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Table 1.1: Raw material and their uses......................................................................................4
Figure 1.3: Main products of MOHA soft drinks factory..........................................................5
Figure 2.1: Sand filter................................................................................................................8
Figure 2.2: Intermediate tank.....................................................................................................9
Figure 2.3:Activated carbon tank.............................................................................................10
Figure 2.4:Figultra violet.........................................................................................................11
Figure 2.5: Reverse osmosis....................................................................................................12
Figure 2.6:Softener...................................................................................................................13
Figure 2.7: Flow diagram of CO2 production...........................................................................15
Figure 2.8:Boiler......................................................................................................................15
Figure 2.9:Soda ash tanker.......................................................................................................16
Figure 2.10:Absorption tower..................................................................................................17
Figure 2.11:After water scrubber.............................................................................................18
Figure 2.12: CO2 compressor....................................................................................................18
Figure 2.13:Freon liquid condenser.........................................................................................19
Figure 2.14: CO2 storage..........................................................................................................19
Figure 2.15: General process flow diagram of syrup preparation batching process................21
Figure 2.16:Crate washer machine...........................................................................................23
Figure 2.17:Bottle washer machine..........................................................................................23
Figure 2.18:Empty bottle inspection machine.........................................................................24
Figure 2.19:Mixer machine......................................................................................................25
Figure 2.20:Filler machine.......................................................................................................26
Figure 2.21:Filler bottle inspection machine...........................................................................26
Figure 2.22:Date coder machine..............................................................................................27

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 1. INTRODUCTION
A soft drink is a drink that typically contains carbonated a sweetener, and a natural or
artificial flavouring. The sweetener may be sugar, high-fructose corn syrup, fruit juice, sugar
substitutes (in the case of diet drinks), or some combination of these. Soft drinks may also
contain caffeine, colourings, preservatives, and other ingredients.
Soft drinks are called "soft" in contrast to "hard drinks" (alcoholic beverages). Small amounts
of alcohol may be present in a soft drink, but the alcohol content must be less than 0.5% of
the total volume, if the drink is to be considered non-alcoholic. Soft drinks are made by
mixing dry or fresh ingredients with water. Production of soft drinks can be done at factories
or at home. Soft drinks can be made at home by mixing syrup or dry ingredients with
carbonated water, or by lacto-fermentation.

The sugar content of carbonated and 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 flavouring or concentrated fruit juice, acidity
regulators, preservatives, stabilizers, antioxidants and colouring. 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.

Figure 1.1: External picture of MOHA soft drink factory, Mekelle

1.1. Back Ground
Pepsi cola traces its origin to 1898 when Caleb Brad Ham, a pharmacist in New Bern, North
carolling, created a curative drink for dyspepsia called Pepsi cola – Pepsi cola later referred to

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simply as Pepsi was a mixture of carbonated water, sugar cane syrup and an extract from
tropical kola nuts. To sell this product, Brad ham formed the Pepsi cola company in
1903.However: due to major increase in price, Brad ham began to lose money on Pepsi and in
1923 he did for a bankruptcy. The craven holding companies of craven, country north,
Carolinian purchased the companies in 1931, Charles G, Guth of the loft company in New
York city purchased Pepsi cola from holding company. Guth had difficulty getting the
business going again but the increased sales by so long larger bottles at an unchanged price
by 1933.pepsi cola was sold by 313 franchised US dealers bottled in US, Cuba and England
sold In 83 countries.
MOHA, the name derived from the company’s owner Mohammed Hussein Al-Amoudin was
founded on May 15, 1996. This soft drink industry was formed after the acquisition of four
Pepsi cola plant located at Nefas silk, Tekle haimanot, Gonder and Dessie plant from the
Ethiopian privatization Agency with paid capital of birr 108,654,000. Currently the company
has eight operating plants which are Nefas silk, Tekle Haimanot, Gonder, Awassa, Mekelle,
Dessie, Summit and Bure plants. MOHA soft drinks industry share 52% of the market in soft
drinks industry in Ethiopia. A significant growth over the years of production sales and
profitability due to reorganization of operations has been achieved.
The location of the plant is in Tigray region Mekelle city 760km far apart from Addis Ababa
and this company is located south east about 3Km far from the Mekelle city. It was
established on 2005E.C with capital of 108,654,000 birr. And through gradual process
February 15, 2007 was graduated and starts its regular process with the efficiency of filler
machine 36,000 bottles per hour. The initial cost of the company is 80,000,000 Dollar
including CO2 gas plant. MOHA soft drinks industry produces five flavours of soft drinks
these are (7 up, Miranda orange, Miranda apple, Miranda tonic, Pepsi). The company is now
one of the leading producers of carbonated soft drinks in Ethiopia. The machines come from
different abroad countries and planted by union engineering company designers and
technicians. There is one line that is glasses bottle line, it produces about 36,000 per day and
the annual turnover of the company have reached to birr 556 million and sales stands at an
average annual growth rate of 12%.
Markets

MOHA holds 52% of the market share in soft drinks industry in the country. With an
expansion and replacement of obsolete machinery, production capacity of the plants has
increased substantially. MOHA, in addition to the initial purchase price of the Soft Drinks

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factory, has invested Birr 8 Million for the expansion of new projects, Birr 153 million for
replacement of existing plants and birr 241 million for marketing, infrastructure, excluding
advertisement and sponsorship expenses. In addition, a significant growth over the years of
production, sales, and profitability due to reorganization of operations has been achieved.
Productivity has improved tremendously with major cost savings and has insured a regular
supply of high quality products. It has also succeeded in reaching new market areas across the
country.

Figure 1.2: Structure of MOHA soft drinks factory S.C Mekelle plant
1.2. Objective of the company

 To produce and supply high quality and safe products that satisfies the need of
customers.
 Creating values to customers and to be owners by making their products the first
choice of the customers.
 To carry on beverage manufacturing, processing and bottling.
 To manufacture, sell and distribute carbon dioxide.
1.3. Mission of the company

The mission of the company is to be the best soft drinks industry in the country. The
company believes it will continuously improve the production capacity in which customers,
employees, partners and the communities served will be satisfied by the products. These will
be accomplished through the development of employees, an emphasis on cost, efficiency,
market expansion and profitability. The company will expand marketing areas to both protect
and improve positions by placing emphasis on innovation and technological improvement to
keep always a head of the competition.

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1.4. Vision of the company

MOHA soft drinks have bright future opportunities and plans:

 To be the best Pepsi cola bottler in the world.

 To make each of its products to be a drink of first choice among consumers and
obtainable throughout the market of Ethiopia.
 It intends to create superior value for its shareholders, its customers, and its
employees

1.5. Suppliers, products & Main services and End users of the company

1.5.1. Suppliers of the company

 Pepsi cola international
 Local sugar factory
 Ethiopia cork factory
 Ethiopia caustic soda plan
 Ethiopia crate factory
enerally, the major raw material for the production of soft drink inputs are water, syrup, sand,
CO2 and caustic soda. At its full capacity operation, the factory use different materials and
power sources. These materials are listed in the table below.
Table 1.1: Raw material and their uses
Raw material Supplier For use
Water Local market(Ethiopia) Use to prepaid syrup and
cleaning purpose
Pepsi powder(syrup) South Africa Use to prepaid Pepsi
Miranda powder(syrup) south Africa Use to prepaid Miranda
Sand Local market(Ethiopia) Use in water treatment process
CO2 Local market(Ethiopia) Use to prepaid soft drink
Caustic soda Local market(Ethiopia) Use to clean bottle for washing
purpose

1.5.2. The Main Products

MOHA Soft Drink Company is one of the soft drinks beverage companies in Ethiopia that
produce six different brand beverages.

These are:

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  Mirinda orange (orange flavor)
 7 up
 Pepsi cola (cola flavor)
 Mirinda tonic
 Mirinda Apple
 cool water gas
 co2 gas

Figure 1.3: Main products of MOHA soft drinks factory

These all products are 300ml (0.3L) and filler machine fills 36,000 bottles per hour. In
addition to these, the plant also produces carbon dioxide gas for the beverage purpose.
According to the efficiency of producing carbon dioxide, the plant could sell it for home
consumption and supply for consumers who need it for food preservation purpose. To
produce the above mentioned products, MOHA soft drinks industry S.C got a franchised
license from international Pepsi Cola Company. This company controls the quality and safety
of the products in the market.

1.5.3. Main Services of MOHA Soft Drink Industry

The company gives the following services:

 Give for the worker’s safety shoe, clothes, glove and mask
 Cafeteria service
 Transport service

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1.5.4. The Main Customers or End Users of the Company
The products of MOHA end user are institutional and commercial customer. Those customers
can get the product from the distributor or from the company marketing service. The
customers are hotels and motels, hospitals, restaurants, bars and cafeterias.

The end users or customers of the company are the whole Ethiopian peoples. Some of the end
users are as listed below;

 Mekelle
 Shire
 South part of Tigray
 South east part of Tigray
 West part of Tigray
 East part of Tigray and central part of Tigray
 Amara (Sokota & kobo)
 Dessie
 Afar (zone two)

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 2. PROCESS TECHNOLOGY OF THE FACTORY
In this section the process technology for water treatment, CO2 production, Syrup
preparation, Steam generation (steam boiler), Soft drink production, and Wastewater
treatment systems are presented.

2.1. Water Treatment

This room is one of the rooms of the company which is used for water treatment process. The
process makes water more acceptable for a desired end use (as raw material for kool water
and soft drinks production and for washing purpose). The incoming raw water from the
source contained enormous dirt, such as suspended particles, organic matter and
microorganisms. The presence of these things in the water causes the water degrade the taste,
colour and odour of the water. Due to this the water used for production and empty bottle
washing purpose must be treated to get the desired quality. Impurities in the water are
removed through a process of coagulation, filtration, chlorination and sterilization.

MOHA Soft Drink Company uses its main source of water from ground water that comes
from Aynalem town specific place called Borehole. The ground water that comes from
Aynalem contains many impurities. Such as; suspended solid particles, microorganisms,
heavy metals, dissolved ions (Mg, Ca, and Fe) and so on.

Therefore the principle of this water treatment process is to remove the different impurities in
the raw water, and to render the water safe and clean and to ensure the treated water quality
meets the standards of water to produce the soft drink. The raw water comes from a small
residential area known as Aynalem is stored in reservoir, consequently a chemical is added
(dosed) in order to treat biological elements goes through the coming raw water. After this
there are different water treatment techniques. Those are:

 Concrete reservoir tank  Uv1 (ultra-violent )

 Aeration  Ro membrane (reverse osmosis)
 Sand water treatment  Activated carbon filter 2
 Intermediate tank  Polisher
 Activated carbon filter  UV2
 Polisher  Softener

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2.1.1. Concrete Reservoir
In water treatment process concrete reservoir is essential because it is where the raw water
(spring water) is pumped and stored temporarily. Chlorine is the chemical added here in this
section of the water treatment plant in the form of Ca (OCl) 2. 0.00-0.6 ppm of chlorine is
added. Chlorine added in the reservoir helps in destroying of microorganisms to ensure the
purity of the water.

2.1.2. Aeration
Aeration with compressed air with or without ozone is used to oxidize ferrous ions to ferric
oxide or hydroxide which separate from the solution to remove carbon dioxide from water,
hydrogen supplied, and volatile organic substances i.e. iron and manganese.

2.1.3. Sand Filters

Before the water is pumped to the sand filter aeration pump is used to give pressure to the
water and to make the iron (Fe) and magnesium (Mg) in the form of foam in order to remove
simply in the sand filter. The water is then pumped through the top of the tank (namely the
sand filter) and because the sand filter is filled with sands having different diameter
ascending from top to bottom which means sand with small diameter on the top and medium
sized on the middle and bigger sized sand on the top. This way the sand filter can trap any
unwanted materials that get on the water when pumped from the source or on transportation.
Three sand filter tanks are used to treat water primarily in MOHA soft drinks Mekelle plant
in order not to stop the production while washing the filters. The sand filter tank is washed
using the back wash process with pressurized water. And while the filtered water leaves the
tanker to the intermediate tank faces a polisher that is used to filter out very fine solid
particles that can go up to 5 µ mm. and enters the intermediate tank.

Figure 2.4: Sand filter

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2.1.4. Intermediate tank
The intermediate tank is used as storage for primarily treated water (water from the sand
filter).But there is no treatment in the intermediate tank. And the water is pumped out to four
different places. Those are;

 To service water (floor wash, hand wash, wall wash)

 To activated carbon filter
 To softener
 To back wash

Figure 2.5: Intermediate tank

2.1.5. Activated carbon filter
The filtration system is used to remove chlorine, odour, colour, taste, rest turbidity and other
organic materials. And when the water leaves the activated carbon filter there is also a10µ
polisher which is a physical treatment to remove carbon.

Chlorinated water is diverted via pumps to the activated carbon filter plant. There is one
carbon filter in operation; with a capacity of 25m³/h and controlled fully automatically. The
backwash steps will be carried out in semi-automatic. An inlet and outlet pressure transmitter
ensures that the filter is not over pressurized and provides an automatic alarm should this be
the case. The filters are backwashed as required to remove the filter cake produced and any
broken carbon particles. During backwash, there can be only two filters in operation.
Backwash is carried out using filtered, chlorinated product water from the buffer tank. In this
process, water is pumped into the filter from the vessel bottom. The water exits the top of the
filter and is passed to drain. This process loosens and removes the filter cake that has been
accumulated on the top layers of carbon. In addition, the backwash step chlorinates the outlet
piping of the filter in order to ensure destruction of microbiology.

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 Figure 2.6:Activated carbon tank
2.1.6. The polisher
Polishing is a step of water treatment; where by any minute suspended particles are removed
from the water. This is done by passing water through a polishing unit containing either
special filter papers or cotton cartridges.

2.1.7. Ultraviolet (UV)

It is used to treat biological wastes in water purification, which are passed through the
previous treatment method. And this method is used to clarify the dead microorganisms
which are forced from the carbon filtration system.
Strong sunlight disinfects water by permanently de-activating bacteria, spores, moulds and
viruses. The part of the electromagnetic spectrum responsible for this well-known effect,
defining the wavelengths as between 200 and 300 nm, often called UV. Ultraviolet
sterilization works by dissociating the DNA structure of living cells, thus preventing their
multiplication. A UV disinfection unit comprises an enclosed chamber with an inner sleeve
of high-purity quartz which contains one or more shortwave ultraviolet lamps. Water passes
through the chamber and is subjected to the UV which shines through the quartz sleeve. As
the genetic structure of bacteria or viruses in the water is exposed to the UV-it destroyed.

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 Figure 2.7:Figultra violet
2.1.8. Reverse osmosis
Before this step there is an addition of anti-sealant chemical to the water in order to slippery
the liquid and applying of high pressure to increase the pressure of the water. And then the
pressurized water is pumped to the Reverse osmosis (RO) tubes.

Ro has been used for the production of demineralized water for over 30 years. In reverse
osmosis water is transported across a membrane under high pressure, leaving a product that
consists mainly of water and a concentrate containing most other components such as
minerals and unwanted residues. Many contaminants including iron, manganese, ammonium,
traces of pesticides and medicines, organic micro pollutants, and radioactive particles can be
removed with reverse osmosis alone. The reverse osmosis system consists essentially of a
membrane component. The reverse osmosis membrane retains salts, whereas the water
permeates through the membrane. To produce the differences in salt concentration across the
membrane a pressure difference is necessary in order to overcome the osmotic pressure. This
pressure difference is achieved by using a high-pressure pump to pass the raw water to the
membrane.

The main work of reverse osmosis is filtering out of microorganisms which are very small
and any solid particles from the water. The permeate water or cleaned water is leaved from
reverse osmosis and the concentration flash goes to waste water treatment plant. and then the
dissolved Ca(OCl)2 is added to the permeate water line by the amount of 6-8ppm.and this
water goes to the product water tanker .from the product water tanker the water goes to the
activated carbon filter two and three in order to remove chlorine. After this the water goes to

11
the critical control point (CCP) which is UV2.UV2 have efficiency above 60% killing of
microorganisms. And finally the product water sends to:-

 Lab
 Syrup preparation
 Bottle washer
 Co2 production plant

Figure 2.8: Reverse osmosis

2.1.9. Softener
The process water softening is carried out through some chemical reactions happened in the
water softener tank. These reactions are between zeolite and other hardening chemicals to
remove carbonate hardness and noncarbonated hardness. When the hard water passes through
the zeolite the hardening elements are caught by this zeolite chemical. The compositions of
hard water are;

 Calcium ion
 Magnesium ion
 Other heavy metals and so on

The chemical reactions that take place between zeolite and the hardening compounds are the

Followings;

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 Removal of carbonated hardness

Removal of non-carbonated hardness

These reactions represent cation exchange, the exchange of positive ions. To replenish
sodium ions used, units need to be regenerated with material containing high amount of
sodium, and normally salt brine is used. This allows to the resin to be used many times.
After we soften the water it is redirected to the soft water tank and to the technical water
(blended water) tank. The technical water tank (blended) contains 35% hard water and 65%
soft water. And the blended and the soft water sends to cooler and boiler respectively.

Figure 2.9:Softener
Generally, in this water treatment section there are three types of water treatment
mechanisms; those are

 Physical treatment (polisher and sand filter1,2 and 3)

 Chemical treatment (activated carbon 1,2 and 3)
 Biological treatment (chlorination, uv1, uv2 and uv3)

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2.2. Carbon dioxide Production
Carbon dioxide (CO2) is a colourless and odourless gas vital to life on Earth. This is naturally
occurring chemical compound is made up of carbon atoms covalently double bonded with to
oxygen atoms i.e. o=c=o. Carbon dioxide exists in earth’s atmosphere as a trace gas at a
concentration of about 0.04 percent by volume. Natural sources include volcanoes, hot and it
is free from carbonate rocks by dissolution in water and acids, because CO 2 is soluble in
water and it occurs naturally in ground water, rivers and lakes in ice caps and sea water. It is
present lives in deposits and natural gas. Carbon dioxide is produced by all aerobic organisms
when they metabolize carbohydrates and lipids to produce energy by respiration.

It is used for keeping the soft drinks for long period of time (keep the durability of soft drink)
and the company supply for marketing (selling to other companies like MESSEBO, Dessie
MOHA plant). The production capacity of CO2 is 160kg/hr.
In addition, the company uses as a raw material for the production of carbon dioxide are fuel
(diesel), air, mono ethylamine (MEA) and water. The purity of CO 2 produced has
99.99%.The stages for CO2 production are as follows.

Benefits of carbon dioxide in soft drinks industries;

 As a preservative
 Provide mouth good feel and
 Sparkle to drink, as an input for the mixer [blender], for carbonation of the drink
and pressurizing the bottle.

Chemicals used to produce carbon dioxide are;

 Fuel oil
 Mono ethanol amine (MEA), activated carbon and sodium carbonate (NaCO3)

The main properties that make CO2 useful for beverage carbonation and storage are;

 CO2 is less reactive

 Denser than air which makes it preferable for pressurizing CO 2 has good odor
and Diesel

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 FUEL OIL BURNER SODA ABSORBER
TANKER SCRUBB
R

WATER HEAT STRIPPER NOX

SEPARATOR EXCHANGE FLUSH
R
COMPRESSO DEYHEDRATOR
AFTER
WATER R
SCRUBBER
STORAGE REFRIGERATOR
COMPRESSOR CARBON
EVAPORATOR AND CO2
CONDENSOR
Figure 2.10: Flow diagram of CO2 production
In MOHA soft drinks factory carbon dioxide is produced through burning of fuel such as
diesel oil. In order to produce pure desired CO 2 in the CO2 production section it passes some
steps after fuel burning in the boiler as follows. Flue gases leave from boiler after fuels are
burning through burner.

Fuel Oil Tanker: It is a tanker that used to store the basic source for the production of
carbon dioxide, which is fuel oil. The fuel oil is burned in order to give CO2 gas.

Burner: The fuel oil will be brought into burner and the burner will be generating CO 2 by
combustion of fuel oil. In this case the source of O 2 is from the environment. There are also
byproducts such as soot, SO2, CO, SO3 etc. The reaction at burner is composition reaction.

Oil gas + O2→ CO2 + H2O+ Heat + Flue gases

During this reaction amount of oxygen must be 2%-3%. Unless limitations of oxygen happen,
shortage of producing carbon dioxide and access of nitrogen monoxide will occur.

Figure 2.11:Boiler

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Soda Scrubber: The fuel gas from the burner contains some Sulphur oxides (SO 2 and SO3)
that are formed due to Sulphur content in the fuel oil. Sulphur and Sulphur oxide components
are very harm full to the CO2 plant. They cause corrosion on the plant and if entering the
MEA system they will degrade the solution. Therefore, it must be removed before it passes to
further process. So it showers with soda ash solution by circulating in the system by means of
soda scrubber pump and the heat is removed in the soda cooling using cooling water.
Therefore, a chemical called sodium carbonate will be added in soda scrubber in order to
remove the Sulphur.

Figure 2.12:Soda ash tanker

Absorber: Absorption is a gas-liquid mass transfer operation in which a component is
transferred from the gas phase to the liquid. And the rate of absorption is determined by the
rate of molecular diffusion that largely controls this interphase mass transfer. The component
which is being absorbed is called solute and in which it is absorbed is called solvent. So CO 2
in the absorber is fitted a demister at the top, to avoid MEA droplets and to escape from the
gas going to free air. The white smoke coming from the absorber outlet is mainly water
vapour, nitrogen, and O2. The CO2 content out of the absorber is one of the most important
values to know when troubleshooting the generating unit.
This process is used to absorb CO2 by adding a liquid solution of MEA (mono ethanol amine
–CH3CH2OHNH2) at the top of the absorber tower in counter flow with the flue gas. The
parameters of MEA such as normality (> 1.8 N), density (5-8 oBe), PH (approximate 11) and
colour (clear). The rest of the flue gas emitted to the environment because the absorber is
opened at the top. The MEA before mixing with the CO 2 is called lean MEA and after mixing
with CO2 also called rich MEA (CO2 + MEA). In this tower there is a classic saddle packing
to split the rich MEA and unwanted gases.

16
The MEA solution is preferred solvent from other amines because it captures about 85-90%
of CO2 from the flue gases in absorber tower. The MEA tank has a built in MEA filter which
will absorb impurities from the solution. The filter material is activated carbon which is able
to absorb organic material free iron and rust particles from the MEA. The rich MEA goes to
heat exchangers to receive heat from the boiled MEA by body contact with rich MEA
because the temperature has 50-60oc. The CO2 content after absorber has about 1%. In
absorber tower there is a chemical reaction takes place between both;

Exothermic

CO2 + MEA MEA – CO2 + HEAT

Figure 2.13:Absorption tower

NOx Flash: The MEA, which has absorbed the CO 2 in the absorber (rich MEA), is pumped
from the bottom of the absorber through the rich/lean MEA heat exchanger, where it is pre-
heated before it enters the NOx flash column. In the NOx flash column, NO, N 2 and O2is
flashed out.

Stripper: The rich lye containing CO2 is preheated in the lye cooler before entering stripper.
In order to release CO2 from the lye solution, must the solution be heated to its boiling point
The steam and CO2 is separated from the MEA and gases to the gas cooler from the top of the
stripper and MEA is circulated in the boiler. MEA-CO2 +heat→MEA+CO2

Heat Exchanger: It is also called gas cooler. During stripper the mechanism used to separate
CO2 and MEA was heat. Then this heat must be decrease before further processing and it is
done by using heat exchanger. After heat exchanger, CO 2 will be cooled. Water Separator
When CO2 passed through heat exchanger it will be cooled and it may absorb the moisture.
Therefore, this water separator separates the moisture from CO2 if any.

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After Water Scrubber: It is chemical called potassium per manganese. And it has two major
applications. The first one is it removes moisture which presents after water separator. The
second application is that it mainly extracts a substance called ammonia.

Figure 2.14:After water scrubber

Compressor: The compression of the CO 2 gas is done by two double acting two stage oil
free reciprocating compressors. The CO2 gas is pressurized to 16 bar. Between the two stage
compressors the CO2 gas is cooled in an intermediate cooler and after the second stage the
CO2 gas is cooled in an after cooler. Both coolers are cooled by cooling water.

Figure 2.15: CO2 compressor

Dehydrator: This dehydrator is used to remove the moisture contents in the CO 2 gas. Since it
is a process to remove the remaining water which consists of two vessels filled with
molecular sieves one in operation the other in regeneration/standby. And the two dehydrators
are worked by 8hrs interval worked that means if the one is work for 8hrs the second one is
rest and the reverse one.

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Carbon Filter: A non-regenerative activated carbon filter is installed downstream the
dehydrator. The activated carbon filter will primarily remove any H 2S, but also act as a guard
against smelling substances such as aromatic hydrocarbons, oxygenates chlorinated
components like Vinyl chloride. In addition, this uses a layer of carbon packing to increase
the purity of the carbon dioxide to an about 99.99%. Carbon filter removes bad smells, taste,
colours and odours as well as other trace gases.

Refrigerator Compressor & CO2 Condenser: The CO2 gas from the filter unit is going to
the CO2 condenser, it is a heat exchanger where CO 2 is on one side and refrigerant is on the
other side. This is a Freon condenser which is Freon liquid used to cooling CO 2 gas. Carbon
dioxide gas need to be liquefied before storing and sending to the end users.

Figure 2.16:Freon liquid condenser

Storage

The tank is normally insulated with at least 10cm thick. This is normally covered with a pre-
painted aluminium jacket, which is the liquid form of CO 2 will be best to store before
evaporated in to gas form again. The normal storage pressure is in the region of 16 bars and
−18OC.

Figure 2.17: CO2 storage

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Evaporator

The liquid form CO2 will be transferred into evaporator and will be heated until changes its
nature into gas form.

After it has changed into gas, finally the CO2 can be going to filler room in order to mix with
syrup and water for the final product.
2.3. Syrup preparation section

A. Sugar dissolution

Sugar is used in soft drinks industry to have the proper taste of the soft drink of the products.
In this plant the sugar dissolves at high level of temperature. And the sugar comes from local
area wengi sugar factory and also from South Africa product most of time MOHA soft drinks
industry uses the South Africa sugar.
Sugar can be delivered either as liquid sugar, normally at 67 ◦Brix, or in granulated form. The
type of delivery used is dependent on the usage, cost and availability of the sugar. The row
materials needed for syrup preparation are

 treated water
 raw sugar and
 activated carbon
Raw sugar in the dissolved tanker is dissolves at the 80 0c. The sugar, carbon and water is
measured in acceptable amounts in Proportion of each other depends on the flavor units. This
solution is filtered using different method like carbon filtered air. After filtration the treated
sugar solution must be cooled from 80 to 24 OC by using chiller process and the treated sugar
solution is pumped to the final syrup storage tanker and stored.

B. Syrup preparation

In this room, most chemist control the proportion of the solution and time control due to
different material has different property. Such as Mirinda and Pepsi syrup time interval
relatively to water. Mirinda syrup can use immediately but Pepsi syrup must wait one day or
24 hours. The soft drink powder concenters are mixed with water to make a thick solution
called syrup. That contains 20% soft drink powder and 80% water.

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  Five steps of syrup preparation

I. Pre-Batch Inspection:

Pre-batch is important in order to check the following things:

 Ensure tank cleanliness

 Check treated water quality
 Check strainers
 Check salts dissolution tank
 Confirm absence of sugar for diets

II. Staging: Ensure correct amount of concentrate ingredients for the number of units to be
batched inspect concentrate containers for breakage. Ensure concentrate rate is within shelf-
life record plant information and concentrate data on batch control record.

III. Batch: Ensure simple syrup contains the correct quantity of sugars. (If Brix is on target,
but the volume is high or low, then the finished syrup will not be on target.) By knowing the
Brix value (and associated density volume is in the tank, the sugar weight can be calculated:
Mass=density/volume Follow Beverage Document instructions. Match final volume target.
Thoroughly rinse all concentrate containers.

IV. Analytical Verification: Check finished syrup bricks. Prepare control drinks for fresh
finished syrup. Then, Prepare control drinks for aged finished syrup, if needed.

V. Syrup Use: -Age, if necessary

Generally, the process of syrup preparation is shown in the figure 2.15

Pre-batch inspection

Staging

Batching

Analytical verification

Syrup use

Figure 2.18: General process flow diagram of syrup preparation batching process

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2.4. 2.4 Soft Drink Production Section
In this section, the preparation of soft drink takes place in the production sector we have seen
and understood all the production flow of the organization systematically with the help of our
supervisor and operators. The Steps to prepare the final product passes the following series of
machines and areas, which are:
 Unpacker and Packer machine
 Create washer machine
 Bottle washer machine
 Empty bottle inspection machine
 Mixer machine
 Filler and crowner machine
 Full bottle inspection machine
 Date coder machine

A. UnPacker Machine

This machine is used to pick up the bottles from the craters and put into the bottle conveyor.
Firstly, empty bottles are unload from forklift truck to de palletize zone. The palletize bottles
de palletize and put to conveyor using workers manually and convey to unpacker machine.
The unpacker machine is fully automatic machine with the speed of 40,000 bottles per hour.
And it helps to remove the bottle from the crate by pneumatic (air) system. This machine has
six sensors which help the machine for proper timing and gripping the bottle, also order the
next creates and stop it.
The unpacker machine have components such as pusher which press the four create and stop
it, blocker which help to block the four crate to stay in a fixed and in a right position and
gripper to hold the 96 bottles and put it on the conveyor. After that the empty bottles it can
pick four crates of bottle at once. The empty bottles are passing on to the bottle washer and
the empty crate passing to the create washer.

B. Crate Washer Machine

This machine use to wash the crate with warm water and high-pressure spray from different
direction. The crate washer is used to wash the empty crate as its name indicates by receiving
from the de-crater by means of the conveyor belt. At the de-crater, the empty glass and the
empty crate are separated by the de-crater and move in different direction to reach their

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washing station (washer machine). The washing station for the empty crate is crate washer.
The crate washer cleans the dirty materials from both the inside and outside of the crate.
Lastly, the cleaned crate is transferring to the re-crater (packer machine) where the filled
glass with the soft drink is returned it.

Figure 2.19:Crate washer machine

C. Bottle Washer Machine

Bottle washer machine is the most important machine which is used to disinfect and wash
dirty bottles. The bottles are introduced to bottle washer by introducer and pusher. Bottle
washer machine can wash 40,000 bottles per hour in four stages. The bottles are washed
internally and externally.

Figure 2.20:Bottle washer machine

This machine has its own washing cycle and consists of four distinct phases.
1. Pre-wash
The pre-soaking stage takes place in one or two stages; after leaving the presoaking area, the
bottles are over turned and emptied, the dripping waterfalls onto a collection pan and is
filtered before returning into the presoaking area itself. The presoaking area is maintained at a
constant temperature and continuously renewed by hot water coming partly from the first
rinsing area and partly from the detergent sprayer’s tank without any additional energy
consumption. An internal sprayer and an external shower perform a double step heat recovery

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process to increase bottles and carrier’s temperature before immersion in the main detergent
tank.
2. Washing
The washing stage takes place in the main detergent bath where also two label extraction
stations are located. The time of immersion and the temperature can be set according to the
specific characteristics of the bottles being cleaned.
3. Caustic spraying
After the soaking in the hot caustic solution the bottles are turned upside down until they’re
completely emptied. A final washing stage is then performed by a set of sprayers directing a
jet of detergent solution inside the bottle.
4. Rinsing
The rinsing stage is divided into four gradually decreasing temperature zones. The first three
ones perform rinsing with internal and external sprays of re-circulated water supplied by
Centrifugal pumps while the final one with just internal sprays of fresh water. After
completion of the rinsing cycle, the rinsing water is conveyed to the presoaking station.
Bottles are then properly emptied before being discharged.

After completing this washing cycle some additives are added to the final stage of rinsing i.e.
Divot help to control the water hardness, Divot Le help to control the pH level, Divot Bright
help to remove un erased date prints and chlorine help to kill micro-organisms.

Visual Inspection: - The washed bottles might have dirty, cracks or broken so such defects
will be identified and removed during visual inspection by human.

D. Empty Bottle Inspection Machine (EBI)

The washed bottles might have dirt, cracks or broken so such defects will be identified and
removed during visual inspection.

Figure 2.21:Empty bottle inspection machine

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E. Mixer Machine

The star blend plus evolution blender is a system for the preparation of drinks in which the
correct quantity of basic ingredients (water, syrup and CO2) is measured and dosed in a
continuous electronically controlled process which leads to very high product quality (high
precision Brix and CO2 Volume values) in all operating conditions (steady−state and during
transitory phases).

Figure 2.22:Mixer machine

Generally, mixer machine mixes three different things. These are:
 Carbon dioxide (CO2)
 Syrup
 Water
Mixing ratio of syrup to water Pepsi cola, 7up, Mirinda tonic and Mirinda orange, Mirinda
Amanas was 1:5; but Mirinda apple is 1:4. Amount of CO2 by the volume: Pepsi is 3.5, 7up
is 3.7, Miranda orange is 2.1, Miranda apple is 3.0, Miranda tonic is 4.0 and Miranda Ananas
is 2.4.

F. Filler Machine

Is a machine that used to fill the washed bottles with soft drink that coming from mixer
tanker. Filling process: First the bottle is connected to the vacuum chamber where the air
inside the bottle is sucked then CO 2 at a certain pressure is filled with soft drink, finally bottle
discharge to which crowning after filling sterile water jet is installed before the crowner who
continuous sprays a thin stream of sterile hot water drowns out. This cause the soft drink to

25
foam and oxygen is removed by foam before closing the bottle with crown cork. The average
filling speed of the filler is about 36,000 bottles per hour.

Figure 2.23:Filler machine

G. Crowner/Capper Machine

After the individual bottle are filling and conveyed to the capper/closure machine. The bottles
transferred by a star-wheel conveyor to a crowner that applies the cap or crown to the bottle.
In the crowner, the bottles supported on a rotating table and as the crowner rotates, the crown
applied and crimped to the bottle.

H. Full Bottle Inspection (FBI)

Bottle inspection system for the beverage industry inspects filled bottles at high production
line speeds for proper fill level 300ml (it detects whether the bottle filled in proper quantity of
soft drink or not), cap position (missing, incorrect, skewed and under- or over-torqued cap)
and tamper band integrity; defective bottles are automatically rejected.

Figure 2.24:Filler bottle inspection machine

I. Visual Inspection: There may be the bottles which are not well crowed and well filled
that are not rejected by the FBI machine. So these bottles are pickup/reject by the workers.

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J. Date Coder Machine: Date coder uses to print information’s such as; expire date,
company name (tells where the soft drink produce) and time on the surface of the pet filled
with the soft drinks. To perform this activity, it uses different materials and mechanism. The
sensor is very important in this system of date coder machine. The sensor senses the
movement of the pet filled with the soft drinks and sends the message to the Plc. which is
connected to it.

Figure 2.25:Date coder machine

K. Packer Machine

It is used to pack the washed crates coming from the crate washer with labeled bottles these
passed through date coder machine from filler machine. The function of this machine is the
inverse of that of the de-crater means there-crater is used to takes the glass filled with the soft
drink from the conveyor belt and puts in the washed crate. As the de-crater the photo electric
sensors plays the great role in this machine. The sensors are very sensitive to the movement
of the glass filled with the soft drink and empty crate. The sensor sends the message to the
plc. Then by receiving the message from plc orders the re-crater to takes the glass filled with
the soft drink under this machine and puts in the empty crate that is used to handle and for
guarding of the glass with the soft drinks during transportation.

L. Boiler Plant and Air Compressor

Boiler plant produces softened and hot water at 80 °C for the bottle washer, crate washer,
syrup room plant to dissolve the sugar and for water treatment plant. The main parameters
used to produce steam are: -Furnace (Heavy oil), soft water. The reason behind for choosing
furnace over fuel (Light oil) is that it is cheaper than fuel. Raw materials and materials of
boiler have stainless steel, aluminium spring, distilled water, steam hose and water hose etc.
Air compressor produces pure air for the boiler, burner and other processes. It is also an
interesting plant for the company.

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2.5. Wastewater treatment

Waste water treatment is a process to convert waste water which is by neutralizing the waste
water i.e. dosing acid (H2SO4) or base (NaOH) to the waste. Treatment means removing of
impurities from water being treated and is expected to avoid or minimize environmental
degradation or health problems. After neutralizing the waste adjusts the PH value between IS
6.5-7.8 then opened the draining valve to the plant area.

Source of Waste Water Treatment:

 From bottle washer and create washer

 From Water treatment plant
 From Syrup preparation room
 From weakly and daily cleaning etc.

The MOHA soft drink industry uses mechanisms for waste water treatment and it has three
stages;
 Physical treatment
 Chemical treatment
 Biological treatment

A. Physical treatment

The physical treatment is used for removing of suspended solid particles. Some equipment’s
and steps are used in this like.

1) Pump pit - this two pipes are used to pump the waste water to the defender and it recycle
back this pumps remove small objectives.

2) Metal sieve - it captures the suspended particles (Large particle).

3) Primary filtration - filters the large particles by using mesh with wide holes.

4) Secondary filtration – filters the remaining solid particles passed through the primary by
using very narrow mesh’s to become free from the solid waste particle’s.

B. Chemical treatment

Consists using some chemical reaction or reactions to improve the water quality. Probably
the most commonly used chemical process is chlorination. Chlorine, a strong oxidizing

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chemical, is used to kill bacteria and to slow down the rate of decomposition of the
wastewater. A chemical process commonly used in many industrial wastewater treatment
operations is neutralization. Neutralization consists of the addition of acid or base to adjust
pH levels back to neutrality. Since lime is a base it is sometimes used in the neutralization of
acid wastes.

 This is used in the neutralization tanker by measuring our PH difference our PH must
be between “6.5-8”.
 Chemicals like sulfuric acid (H2SO4) and sodium hydroxide (NaoH) are used to
balance the PH level.
 If our PH is acid (below 6.5) it needs dosing of base, if our PH is base (above 8) it
need dosing of acid.

C. Biological treatment

It uses biological method for aerobic and anaerobic methods.

 Anaerobic is used in the absence of oxygen.
 Aerobic requires free oxygen for growth so in presence of oxygen by using the blower
mixer it helps for destroying of microorganism and stopping bad smell.
 Anti-foam chemical used for removing the foam from the tanker.

2.6. Environmental Considerations of the plant

Even though environmental protection at MOHA is an ongoing process of continuous

optimization of the environmental management and a comprehensive approach involving
communication, research and development of new products, operation of the plants and
facilities, there are some problems like bad smell around waste treatment department and
release of CO2 to the environment, which pollutes the environment and affects the workers
and the people who leaves around there.

2.6.1. Occupational Safety and Health Protection

MOHA aims to minimize all risk and hazards at all workplaces in order to protect the health
and well-being of the Employees, contractors, and visitors etc.

2.6.2. Quality the Key to Performance (Quality Control)

What is quality? Quality can be simply defined as a level of excellence. Excellence can be
described as having great merit. Merit, in turn, can mean having a feature of quality deserving

29
of praise. Quality determines the performance of a beverage in the market- place. A quality
beverage is one that meets the standards of performance expected by both the manufacturer
and the consumer. To perform well, the beverage must meet the following basic quality
standards:

 The beverage must have the sensory properties that satisfy the consumer’s
expectations.
 It must present no health hazard to the public, in general, and to the consumer, in
particular.
 The beverage must retain its initially produced quality for the prescribed shelf life in
the marketplace.
 The product must meet the description offered on its label and in media advertising.
 The full range of a company’s beverage products must reflect a positive image of the
company.
 The cost of the beverage to the purchaser must be reasonable.
 Quality control is done measuring certain parameters and comparing to the set value
or set point. Quality control is made in, Waste water treatment plant, Water treatment
plant, Carbon dioxide plant, Simple syrup, final syrup and final full bottle.
 The quality of the waste water can be identified by measuring different parameters
like, Sludge volume index, Biological oxygen demand, Chemical oxygen demand,
Total dissolved solids and Phosphorus content.
 Beverage quality can be analysed by measuring the parameters like Microbial content,
Carbon dioxide content, Degree brix and Beverage Bottle pressure. There are also
other quality measurements for Incoming bottle, Thickness or stretch of the plastic
bottles, Incoming sugar quality and Carbon dioxide quality.

2.7.

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 3. INTERNSHIP REPORT
The aim of the internship was to identify a problem and state a solution for that problem, but
unfortunately due to COVID 19(CORONA VIRUS) and some other problems it were
difficult to identify a problem and /or to finish the internship work and had stayed for only
two weeks. Because of this reason only the first section of the company which is raw water
treatment section were observed. So here instead of making a project an internship report is
made.

Raw Water treatment

This room is one of the rooms of the company which is used for water treatment process. The
process makes water more acceptable for a desired end use (as raw material for cool water
and soft drinks production and for washing purpose). The incoming raw water from the
source contained enormous dirt, such as suspended particles, organic matter and
microorganisms. The presence of these things in the water causes the water degrade the taste,
colour and odour of the water. Due to this the water used for production and empty bottle
washing purpose must be treated to get the desired quality. Impurities in the water are
removed through a process of coagulation, filtration, chlorination and sterilization.

Material Water treatment is any process that makes water more acceptable for a specific end
use. The end use may be drinking, industrial and water supply. Water treatment removes
contaminants or reduces their concentration so that the water becomes fit for its desired end
use. Here the company uses its main source of water from ground water this water contains
some unwanted impurities like; suspended solids, microorganisms, heavy metals and
dissolved ions. So water treatment is used to remove these unneeded impurities and some
unnecessary materials. The water from the ground is pumped into the raw water tank and
passes through different unit process for final treatment.
3.1. Objective

 To remove the different impurities in the raw water, and to render the water safe and
clean
 To ensure the treated water quality meets the standards of water to produce the soft
drink.

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3.2. Material and chemical used
 Chemical like; chlorine (Ca(OCl)2 ), Zeolite(NaAlSiO3) and Sodium chloride(NaCl)
were used
 Material such as; Concrete tank, Carbon filter, Polisher and Ultraviolet (UV) were
used.

3.3. Discussion

The source of the raw water is ground water of Aynalem and its found five kilometres more
far apart from the industry. The raw water comes into the industry through tubes by the help
of pumps. The ground water source is usually free from natural organic matter but can be
high in minerals, alkalinity compounds such as Ca & Mg, it is also free from external
pollution, but it’s not pure water because there is growth of microorganisms and minerals that
will be treated in the plant.

Raw Water Reservoir: It is a tank made from concrete used to receive the pumped water
from the Aynalem at a rate of 60-64m3/hr. and store before transferring to sand tank. The
reason required to store the water in concrete tank is to have a consistent supply of water and
to treat the water with chlorine (0.1-0.6 ppm) to reduce the amount of microorganisms. The
concrete tank is capable of storing 300,000-liter water and the tank is separated into two tanks
for the reason of standby during cleaning and when there is risk of leakage. In addition, there
is circulation line inside the tank for the purpose of well mixing chlorine and refreshments of
the raw water.

Dissolving tanker: is a tanker in which a 4 kg of powdered chlorine is dissolved by 160L of

water. The reason to use powdered chlorine than liquefied chlorine is because of its stability.
After this the mixture is added to the concrete tank.

Aeration: Aeration with compressed air with or without ozone is used to oxidize ferrous ions
to ferric oxide or hydroxide which separate from the solution to remove carbon dioxide from
water, hydrogen supplied, and volatile organic substances i.e. iron and manganese.

Sand Filter: Is an equipment that is used to remove suspended solid and floatable material
from the water. In other word, here physical treatment takes place. There are total of three
sand filter tankers which has three partitions inside of each. At the upper part of the tank there
are sands which also called gravels that are relatively larger in size. On the medium part of
the tank there are also sands which are lesser in size than gravels and also they cover a few

32
height compared to the gravel. Finally, the bottom of the tank is filled with fine sand filters
followed by anthracite that enhances filtration of foreign matter or suspended particles
coming with raw water which may occur during storage at concrete tank.

Intermediate Tank: There are two raw water storage tanks used to receive and store the raw
water that passed through sand filter tanks. Each storage tanks receive from their proportional
sand filter. Then chlorine will be added in these tanks for disinfection of microorganisms and
the water will be stored for about two hours. The amount of chlorine added must be five per-
cent of the size of the tank or 5ml/l.

Then from this tank the water will be transferred in to four different parts such as;

 Activated carbon filter

 Softener
 Service water (floor wash, hand wash, wall wash)
 Backwash water

Activated Carbon Filter (A.C1): Is one of the three carbon filter tanks and it has activated
carbon in it that is mainly used to dechlorinate the raw water which had a chlorine added at
the raw water storage tank. Also uses to remove flavour, odour, colour etc. so due to this a
chemical filtration takes place.

Cartridge Filter (Polisher, 10µ): It is used to filter the dechlorinated water by using a 10
micro sized polishing filter bag. This bag prevents particles whose sizes are greater than one
micro which is a physical filtration. Then after passing through this bag, the water will be
available for the next treatment, which is ultraviolet.

Ultraviolet Light (Uv-1): is used to treat biological wastes, UV light intensity meters are
available which indicate the penetration of UV light through the glass sleeve and the water.
Low intensity means the UV dose is too low to provide adequate disinfection. This meter will
indicate when cleaning or lamp replacement is needed.

Cartridge Filter (Polisher, 5µ): This cartridge filter is the same application with the first
one, But the mesh`s size of both differs. Also it is very small particles than the ten (10) micro
polishers.

Reverse Osmosis (RO): Before this step there is an addition of anti-sealant chemical to the
water in order to slippery the liquid and increase the pressure of the water using a high-
pressure pump to pass the raw water through a membrane. The pressurized water is pumped

33
to the Reverse osmosis (RO) tubes. The reverse osmosis system consists essentially of a
membrane component which retains many contaminants including iron, manganese,
ammonium, traces of pesticides and medicines, organic micro pollutants, and radioactive
particles. While the water permeates through the membrane, The permeate water or cleaned
water leave from reverse osmosis and a dissolved Ca(OCl) 2 is added to the permeate water
line by the amount of 6-8ppm.This water goes to the product water tanker and the
concentration flash goes to waste water treatment plant.

Product Water Tank: It is a tank used to store the water after it is treated in reverse
osmosis. After this the water will be distributed into two carbon filter tanks, which are carbon
filter two and three in order to remove chlorine.

Carbon Filter Tank (A.C2&3): the working principle of these tank is similar to that of tank
one, which is DE chlorinating the water that chlorinated in product water tank by using the
activated carbon in it. Generally, these activated carbon (2&3) addressees the following
activities: -

 Reduction in inorganic compound including metals

 Removal of mid to large size organic molecules
 Removals of physical discrepancies (turbidity, colloidal matter, odor, color).

After dechlorinating is performed, the water will be transferred to a one micro size cartridge
filter now almost all microorganisms are died or removed.

Ultra Violet (Uv-2): It is the final treatment for the product water, Used for destroying any
present microorganisms. It’s known as the critical control point (CCP) for the quality of the
water. After passing through UV, our effectual treated water is gained. This product water
can be used for:

o Laboratory o Bottle washer

o Syrup preparation o CO2 gas production
o Mixer o chiller
o Filler

Softener Tank: Soft water is the water used for non-product uses mainly for heat exchange
and rinsing purposes. Softening is reduction or removal of Mg++ and Ca++ ions which could
increase the hardness of the water and plus to this, those minerals could have itching effect on
boiler and bottle washer machines by forming scales on the machines body. The softener

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contains zeolite, the water is softened by ion exchange (zeolite- exchanger) method so the
hardness ions are continually trapped and the water becomes soft.
Soft water: it is redirected to the soft water tank to be used for boiler
Blend water: is directed to the technical water tank (blended) contains 35% hard water and
65% soft water.

Brine Tank: is a tank used to prepare sodium chloride that is needed for regeneration of
zeolite that has been already used in the softener tank. This is necessary because the zeolite
will have less of performance when the Mg++ and Ca++ ions are suspended on it. It takes
about 300 kg of sodium chloride for a one time regeneration process.
Backwash: -For the sand filter 1, 2 & 3
-For the activated carbon filter 1, 2 & 3
-For the RO membrane clean in place
3.4. Conclusion

In this raw water treatment section, water which comes from Aynalem will be purified using
different process steps for product or non-product use, and this company produces 36,000
bottles per hour. The process makes water more acceptable for a desired end use (as raw
material for cool water and soft drinks production and for washing purpose). The incoming
raw water from the source contained enormous dirt, such as suspended particles, organic
matter and microorganisms. In order to purify, first the raw water is pumped out from the
ground and is stored in a primary tank. Then it is pumped in to the treatment room to be
filtered in the sand filter tank. This tank contains layers of sands with different sizes. This
removes different kinds of physical hazards such as stone, trashes and the like from the raw
water. Being controlled by valves it is then pushed to the next tank which is the intermediate
filter tank. This tank destroys the biological and chemical hazards using chlorine substance.
This in turn gives three kinds of water which are pumped towards their respective tanks.
Those are:

1. Soft water (For syrup and mixer)

2. Technical water (For plants)
3. Water treatment
The water from the water treatment tank is to further purified using different processes. The
first one would be the Carbon filter-1 tank which is responsible for removing the chlorine
smell and killing microorganisms in the water. Flow meter is used to measure the volume of

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the water flowing in to the tank. Then there is polisher which is better filter than sand filter
for removing tiny solid particles. The next step is killing the remaining microorganism
completely using ultraviolet ray. This UV has six buttons for controlling purposes and it uses
1000 watt power. There are two UV devices in the water treatment room both doing the same
job. After passing through the UV rays the next step would be Reverse Osmosis (RO) which
removes any chemical molecules and biological hazards since it allows only water molecules
to pass through. This proceeds towards the AtisCanode which removes all of the unwanted
chemicals which were used to purify the water previously such as chlorine. Finally the water
is treated with 5 μpolisher which is the ultimate filtering process. At the output 70% of the
raw water is the treated one and will travel through different pipe lines towards the other
plants for usage. Transmitter PH sensor is used to measure the chlorine volume in the water.
However the remaining 30% of the water is waste water and is washed out of the plant.

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 4. OVER ALL BENEFIT FROM THE INTERNSHIP
Internship program is a method of letting the students to assume themselves as potentially
responsible workman for a particular work by assigning them to actively participating in
production, control and maintenance in industrial company.
This internship program is very essential program because the students develop their skill
practically and share different idea with their community. It also gives us the way to decide
their future job and company. But we couldn’t get all benefits because of the pandemic
decease COVID 19(CORONA VIRUS) and due to some other problems. But the benefits that
we could have gained are listed below.
4.1. In Terms of Improving Theoretical Knowledge

This internship can help to relate the practical professional world to the lesson that has been
learned in campus. To know some unit operation throughout the production process and the
flow process of the industry. To read further about soft drink production this internship also
can gives a valuable knowledge as a lesson learned in formal classes.

4.2. In Terms of Improving Practical Skill

 How to control the quality of the raw materials, the flow rates of each process, the
parameters of the unit operations Describing the overall organization and work flow
of the company
 Identifying every raw material and additive used in production
 Understanding the processes of Pepsi cola production
 Understanding process data and parameters and how to record them
 Conducting material and energy balance and performance analysis on selected unit
operations
 Executing quality control procedures in the laboratory and interpreting results
4.3. In Terms of Improving Industrial Problem Solving Capacity

Industrial problems can be material or machine faults and efficiency faults. Machine faults
are damage or malfunctioning of parts sometimes the whole parts of specific process
mechanical equipment like absorber, heat exchanger, stripper etc. Efficiency faults are
inability of certain machine to make the desired output or quality of products.

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 Problem solving generally and industrial problem solving specifically is much related
with theoretical knowledge i.e. theoretical knowledge is used as basic tool for solving
industrial problems.
This theoretical and practical knowledge made better tool (help) for solving industrial
problems.
Grasping practical knowledge equipped with theoretical knowledge can help;

 To locate the faults accurately

 Search better and sustainable solution
 Minimize time waste for fault finding
4.4. In Terms of Improving Team Playing Skill
Team work has a dramatic effect on organization performance. Students can develop very
interesting behaviours which are important in the working environment. In general, the
following assets can be able to be upgraded;
 To share ideas with colleagues openly and willingly
 To become more confidence on handling tasks
 To give attention to other’s idea
 To accept advices and technical supports
 To increase the ability of active participation
 To help and co-operate with others
4.5. In Terms of Improving Leadership Skill

There was no enough time and place of responsibility given for internship students to lead
any task, so that leads not to get full benefit from leadership skills during our stay at the
company. But by observing the leader of the company leading the workers it help us to
understood short internship time to give relevant and important solution to the problems.
There are some set of qualities which makes an individual a leader:

 Well-mannered communication skill

 Being responsible for ones did Great listener
 Good management skill
 Inspirational
 Commitment, integrity and passion

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4.6. In Terms of understanding about work ethics related issues
Work ethics includes both how one feels about their job, career or vocation and how one does
his /her job or responsibilities. It demonstrates many things about whom and how a person is.
It also involves such characteristics as honesty and accountability. Essentially, it breaks down
to what does or would do in particular situation.
4.7. In Terms of Entrepreneurship Skill
Entrepreneurship skills are making certain individuals able to create a new set of ideas that
may help in the construction stream not only in the production process, but also any form of
activity that has certain land product to it. There are different types of entrepreneur skills
including personal traits and management skills. The basic entrepreneurial skills listed below:

 Self-confidence and self-motivation

 Communication skills
 Personal relationships and sales
 Listening skills, morals and ethics
 Risk taking and time management

4.8. In Terms of Improving Interpersonal Communication Skill

Inter-personal communication is communication scholar in which numerous ways, always

describing participants who are dependent upon one another and have the shared history. It
can involve one on one conversations or individuals interacting with many people within a
society. Since the aim of the company is to accomplish the work in good way, good
communicative skills are needed.

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 5. OVERALL CONCLUSIONS AND RECOMMENDATIONS
5.1. Conclusion
MOHA soft drink industry Mekelle plant is legally producing a safe and quality beverage
products (Mirinda orange, Mirinda apple, Mirinda tonic, 7-up & Pepsi Cola) and services that
Continue to satisfy the growing needs and requirements of the customers. Product safety and
quality is the responsibility of everyone in the plant and they are totally committed to meet
food safety and product quality requirements and continue to improve at all levels and within
all function of the plant to ensure production of safe products and customer satisfaction. The
plant produces five products with well-organized and a good quality standard. Products are
distributed to the consumer within short period of time after production due to the high
demand and extensive customer base. As part of its quality control, products are checked by
the executive organizational office members randomly at an unspecified time. The company
also works for an extended time to increase its production volume and meet product demand.
Generally, the internship program is very necessary and important to apply the theoretical
knowledge to the practical skills and to develop communication, team spirit and managerial
skill.
This internship program is very beneficial and necessary for students to apply the theoretical
knowledge they have acquired in to practice. It also helped to develop communication, team
work and the leader ship skills. Therefore Mekelle University should give special attention to
the internship program so that the students are able to obtain the stated benefits.

5.2. Recommendations
Although our internship time was for a short time, we can recommend a few things from
what we have observed and from what we have read. These are;
 The working environment especially around the production area and the laboratory is
very warm and noisy. This makes it difficult for the workers to perform their task
efficiently. There should be ventilators installed and measures should be taken to
reduce the noise.
 There is lack of engineers in the company particularly chemical engineer while it
directly concerns them.
 It is better to use computer based management control the overall workers and process
of the whole company.

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 From what we have read, there are no measures taken to prevent pollution in the
environment. Gases such as argon, hydrogen, nitrogen and etc. are released into the
environment from the carbon dioxide plant. so there must be an air filtration method
employed.
 There are some companies having no understanding about internship program in
detail. Because of this reason there are some disagreement in between students and
host company employer. So that we want to forward our recommendation to our
university, that they have to introduce and create a good understanding about the aim
and objectives of internship program to all companies.
 Generally, MOHA Soft Drink Company should solve the stated problems to ensure
the safety of their workers and quality of their products. It also needs to give
consideration to the environment. It must minimize air pollution and treat the
wastewater to prevent hazardous materials from entering the soil and affecting human
health and the natural environment

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 REFERENCES
A. J. Mitchell. (1990). Formulation and production of carbonated soft drinks, 1st edition
Blackie.
Anderson Hill Road, N. (2005). Quality manual pepsico international manufacturing
processing Vol-1 700. Pepsico.New York, USA.
Clifford D. A. (1999). Ion Exchange and Inorganic Adsorption, In: Water Quality and
Treatment (5th Edition), R. D. Letterman (Ed.), pp. 9–91, American Water Works
Association, McGraw-Hill, New York, USA.
Russell D. L. (2006). Practical Wastewater Treatment, John Wiley & Sons, Inc., ISBN-13:
978, Hoboken, New Jersey, USA.
Smisek M. and Cerney S. (1970). Active carbon: manufacture, properties and applications,
Elsevier: Amsterdam.

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 APPENDICES
Aerobic: a process in the presence of air or oxygen
Anaerobic: a process in the absence of oxygen
Brix: Sugar content of an aqueous solution
Compressor: make the scattered gas molecules close by pressurizing
Cylinder: a sealed tank to hold gases for different use
DE chlorination: removing of chlorine
Distillation: a physical method of separation by volatility (boiling point) difference
Flue gas: a gas which contains different constitute like CO 2, NO2, SO2 and others
Freon: a group of refrigerant used to cool things
Polisher: a filter media that polishes out solid particulate from water
Screen: a physical barrier that trap solid particulates according to size
Scrubbing: removal of unwanted (contaminant) materials from process
Soft water: a water with relatively less amount of dissolved ion mainly Ca+ and Mg+
Wastewater: used and disposed water from a process or Non process
Zeolite: hydrated sodium alumina silicate compound used in water softening
Simple syrup: Mixture of treated water and sugar
Finished syrup: Prepared by adding concentrate ingredients to simple syrup

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