A Technical Report on

Student Industrial Work Experience Scheme (SIWES)

AT
TROPICAL CONCERNS LIMITED (TCL)
No. 26 Old Kano Road, Azare Bauchi state

By
Name: Umar Muhammad Ahmad

Matric No.: Basug/ug/sci/chm/18/131

Department.: Chemistry
Faculty: Science
Level: 300 Level

SUBMITTED TO:

Mal. Abbas Ibrahim

SIWES CORDINATOR

Bauchi State University Gadau

IN PARTIAL FULFILMENT FOR THE AWARD OF BACHELOR OF SCIENCE (B.SC)

DEGREE IN CHEMISTRY

Date

August, 2021
1
 DEDICATION
Every challenging work needs self-efforts as well as guidance of elders especially those who are

close to our heart.

I humbly dedicate this report to my loving Father Mal. Muhammad Ahmad, my lovely sweet

mother Hama Muhammad, my capacity big brother Yahuza Muhammad (Abu Jidda) and my

Unforgotable TWO brothers Yaya Ahmad and Yaya Adamu, my lovely Sisters Aunty Halima

(Maman Balkisu), aunty hauwa (maman ummi), Aunty Zainab(Maman Khairat), Aunty

Khadijah(Maman zarah), Auwal Muhammad iyawa and my Unforgotable respective Aunty,

Aunty Maimunat (Maman Ja’afar) and my special thanks goes to Dr. Lawan Umar H.O.D

Physiotheraphy Department Federal Medical Center Azare for your support and advices and

All my siblings whose love, affection, support,encouragement and constant prayers made me

able to accomplish my six months industrial training successfully.

I will also like to thanks my friends among them are;Ibrahim Abubakar Chiriri, Abdullahi S

Garkuwa, Ado Ballama, Aliyu T Aliyu, Khameesu Muhammad, Abdullahi Muhammad China,

Isma`il Umar, Abubakar Japanese, Sa’adatu Hashim, Hauwa’u Jidda, Abdullahi Ali Darazo,

Mujaheed S Abdullahi, Abbati Sabo Bagaje, Aminu Black, Abdullahi Usman Alheri, Bashir

Yusuf Bash.

I also dedicate this report to my supervisor Engineer Yaya and the entire staffs of TCL

Premium Bottling and Sachet water Company Nigeria Limited, Azare Bauchi State, for

their guidance, critics, inspirations, hard works and cooperation.

And most of all to our creator, Almighty Allah the author of knowledge and wisdom who made

this possible.

2
 ACKNOWLEDGME

All praise is due to Allah the cherisher, nourished, provider, sustainer and protector of the world,

the one in whose hands lays the absolute control of every aspect of existence. I thank him for his

love, favour and blessings in my life and for the strength he gave me each day throughout my

industrial training period.

There have been many people who have walked alongside me during my six months SIWES

period. They have guided me, inspired me and placed opportunities in front of me. I would like

to thank every one of them.

My heartfelt gratitude and appreciation goes to my parents without whom there wouldn’t be me.

I would also like to thank my friends, notable among whom are Engineer ACG Abdullahi Babani

(Madakin Katagum), Engineer Mal. Yaya, Mal. Isah, Babangida, Baba umaru, Dattijo and

Lamara etc. for their untiring support, guidance, and encouragement till the successful

completion of my industrial training.

A special thank goes to my teachers and lecturers without whom I couldn’t have achieved so

much in my educational career. Words cannot qualify your role in my life.

I wish to also applaud the supports of, and the entire staff of the Chemistry department Bauchi

State University Gadau. I am very grateful to them for their help and cooperation.

Finally and without hesitation, I wish to express my sincere appreciation to all my training

colleagues, co-workers and friends, and everyone who directly or indirectly helped me

3
throughout my training period.

CERTIFICATION

I, UMAR MUHAMMAD AHMAD with Matriculation number

BASUG/UG/SCI/CHM/18/131, hereby declare that I undergo six full months (24 weeks)

Industrial Training at the TCL Bottling And Sachet water Company Nigeria Limited, No. 15

Old Kano Road, Azare Bauchi State and that this report was written by me to the best of the

practical knowledge and experience I gained during the course of the training programme.

UMAR MUHAMMAD AHMAD _____________

BASUG/UG/SCI/CHM/18/131 SIGN/DATE

4
 CHAPTER ONE

1.0 INTRODUCTION

The student industrial work experience scheme (SIWES) is a programmed designed in most of

the Nigerian Universities which exposed the student of learning to the practical experience,

skills, and techniques within the scope of their profession in the industrial world. It is a 6 months

exercise which is under take at the beginning of every second semester 300 level by the qualified

student of B.sc Chemistry at Bauchi State University Gadau.

It enables students to fully participate in the practical work which they may come across in the

cause of doing this exercise in order to acquire expected practical knowledge from the industries.

It is a prerequisite course which served as a prequalification before the degree in Public health

Technology and in other professional courses is awarded and make the undergraduate aware of

what is happening in the industrial world.

1.1 BACKGROUND INFORMATION ON SIWES

The Government Decree No.47 of 8 th October 1971 as amended in 1990, highlighted the

capacity building of human resources in Industry, commerce and government through training

and retraining of workers in order to effectively provide the much needed high quality goods and

services to the country and the world at large. This decree led to the establishment of Industrial

training fund (I T F) in 1973/1974.

5
The major concern among the Industrialists is that the graduates of Institutions of higher

learning, lack adequate practical background studies preparatory for employment in Industries,

this led to the formation of Student Industrial Work Experience Scheme (SIWES) by ITF. The

Student Industrial Work Experience Scheme (SIWES) is a skill training program designed to

expose and prepare students of Agriculture, Engineering, Technology, Environmental Science,

Medical science and pure and applied science for Industrial work situation which they are likely

to meet after graduation.

1.2 BODIES INVOLVED IN THE MANAGEMENT OF SIWES

The bodies involved in the management of SIWES include; the federal Government,

Industrial training fund (ITF), and other supervising agencies which include; National University

commission (NUC), and national council for colleges of education (NCCE), National Board for

Technical Education (NBTE), employers of labour and the various institutions. These bodies

play a vital role in various aspect of SIWES management which includes;

 Ensure payment of allowance for students and supervisors

 Supervise students at their places of attachment and sign their log books and IT forms.

 Appointing SIWES coordinator and appointing staffs.

 Establish SIWES and accredit it’s in approved institution.

1.3 AIM AND OBJECTIVES OF STUDENT INDUSTRIAL WORK EXPERIENCE

SCHEME (SIWES)

1.3.1 AIM OF STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

The aim of students industrial work experience is to help student of learning at higher

institution to know the practical skills and experiences pertaining their courses of study and fill

the gap between the existing theory and the practice of engineering, technology, science,

medical management, and other professional courses in Nigeria.

6
1.3.2 OBJECTIVES OF STUDENTS INDUSTRIAL WORK EXPERIENCE (SIWES)

 To expose student to working situation they are likely to meet after graduation.

 Make the transition from the university to the world of easier work and enhance student

contact for later jobs placement.

 It provides opportunity for student to interact with professionals in the area of their study.

 To train student on how to apply the theory to practical.

 To expose student to the work methods, means and techniques to handle, and operate some

equipment and machinery that may not be available in the institution.

7
 CHAPTER TWO

2.0 BRIEF HISTORY OF ORGANIZATION

TCL COMPANY SUMMARY

Tropical Concerns Limited (TCL) is a wholly Nigerian company registered as a Private Limited

Liability Company under The Federal Republic of Nigeria – Companies and Allied Matters Act,

1990 (CAMA). It is registered to carry on the business of manufacturing, building and civil

engineering services among others. The company has its head office at No. 15 Old Kano road,

Azare, Bauchi state.

The company’s vision is to provide quality services in the most efficient and effective manner

that meet the need of its customers.

Thus, TCL continuously acquires and deploys cutting edge technology in its service delivery;

and the company is striving to build a strong brand with a view to increase its market share in

civil and construction industry in particular and other trading activities in general.

In pursuance of its vision, TCL has a technical support agreement services with competent

consultant teams. The company is also diversifying into manufacturing of table water and fruits

juices.

8
 TCL has a team of highly experienced and skilled Nigerian core staff in the various fields of

modern day civil and building engineering services and are very conversant with local regulatory

standards required in the construction industry.

The company has been in building and civil engineering business for over a decade providing

quality services to its clientele in some public and private organizations.

GENERAL
MANAGER

PRODUCTION ADMIN & FINANCE

MANAGER MANAGER

MAINTENANCE,
HEALTH & STORE KEEPER MARKETERS &
QUALITY DRIVERS
CONTROL SAFETY
OFFICER

TECHNICIANS ENVIRONMENTALS
GENERAL
MACHINE LABOURERS
OPERATORS

9
The desire to produce in house most of all that he needed for production Bottle water, he also

purchased plastic injection machine for the manufacture of Pre-forms and caps. High grade water

Treatment machines and equipments such as;

a. Industrial Filters

b. Reverse Osmosis

c. Ozonizer

d. Micro filters

e. Ultra-violet sterilizer

f. Stainless steel tanks

Reverse osmosis (RO)

Reverse osmosis (RO) is a water purification technology that uses a semi-permeable membrane

to remove ions, molecules and larger particles from drinking water. In reverse osmosis, an

10
applied pressure is used to overcome osmotic pressure, a colligative property, that is driven by

chemical potential differences of the solvent, a thermodynamic parameter. Reverse osmosis can

remove many types of dissolved and suspended species from water, including bacteria, and is

used in both industrial processes and the production of potable water. The result is that the solute

is retained on the pressurized side of the membrane and the pure solvent is allowed to pass to the

other side. To be "selective", this membrane should not allow large molecules or ions through the

pores (holes), but should allow smaller components of the solution (such as solvent molecules) to

pass freely.

In the normal osmosis process, the solvent naturally moves from an area of low solute

concentration (high water potential), through a membrane, to an area of high solute concentration

(low water potential). The driving force for the movement of the solvent is the reduction in the

free energy of the system when the difference in solvent concentration on either side of a

membrane is reduced, generating osmotic pressure due to the solvent moving into the more

concentrated solution. Applying an external pressure to reverse the natural flow of pure solvent,

thus, is reverse osmosis.

The process is similar to other membrane technology applications. However, key

differences are found between reverse osmosis and filtration. The predominant removal

mechanism in membrane filtration is straining, or size exclusion, so the process can theoretically

achieve perfect efficiency regardless of parameters such as the solution's pressure and

concentration. Reverse osmosis also involves diffusion, making the process dependent on

pressure, flow rate, and other conditions. Reverse osmosis is most commonly known for its use

11
in drinking water purification from seawater, removing the salt and other effluent materials from

the water molecules.

Ozone water treatment Machine

12
 Ozone can be added at several points throughout the treatment system, such as during

pre-oxidation, intermediate oxidation or final disinfection. Usually, it is recommended to use

ozone for pre-oxidation, before a sand filter or an active carbon filter (GAC). After ozonization

these filters can remove the remaining organic matter (important for final disinfection).

This combination has several benefits:

- Removal of organic and inorganic matter

- Removal of micro-pollutants, such as pesticides

- Enhancement of the flocculation/coagulation-decantation process

- Enhanced disinfection and reduction of disinfection by-products

- Odour and taste elimination

Removal of organic matter and inorganic matter

All water sources contain natural organic matter (NOM). Concentrations (usually

measured as dissolved organic carbon, DOC) differ from 0,2 to more than 10 mg L-1. NOM

creates direct problems, such as odor and taste in water, but also indirect problems such as

organic disinfection byproduct formation, support of bacterial regrowth in the distribution

system, etc. To produce pure drinking water, the removal of NOM is a prior task in modern

watertreatment.

Ozone, like any other oxidant, seldom achieves a complete mineralisation of NOM. Organic

matter is partly oxidized and becoming more easily biodegradable.

This results in a higher amount of BDOC (Biodegradable DOC). As a result, ozone

improves the removal process of NOM by a subsequent filter, when it is used as a pre-oxidant. In

a research paper of Siddiqiui et al. the effect of ozone in combination with a biological filter is

described. The combined treatment resulted in a reduction of DOC of 40-60%. The removal is

13
even greater when ozone is used in combination with a coagulant. This is because ozone can

enhance the coagulation process. The combination coagulation–ozone–bio filtration results in a

DOC reduction of 64%. When only bio filtration was apllied, the reduction rate was only 13%.

The optimal concentration to remove organic matter by ozone was at an ozone dose of: O 3/DOC

= 1 mg/mg. Most inorganic matter can be eliminated by ozone quite fast. After ozonation, bio

filtration is also required for inorganic matter. Namely, oxidation forms un-soluble compounds

that need to be removed during the next water purification step.

Pesticides

Micro- pollutants such as pesticides may occur in surface water, but also increasingly in

groundwater. Drinking-water standards for pesticides in the European Union are strict: 0,1 μg l-1

for each compound. Several surveys show that ozone can be very effective for the oxidation of

several pesticides. At a water treatment plant in Zevenbergen (Holland) it was proved that three

barriers (storage–ozonation–granular active carbon filter (GAC filter)) are effective and safe

enough for the removal of pesticides. From 23 tested pesticides, 50 % was degraded sufficiently

(80 % degradation). Table 1 shows an overview of pesticides that are easily degraded by ozone.

For highly resistant pesticides, a higher dosage of ozone is advised, or ozone combined with

hydrogen peroxide

Reduction of disinfection by products and improved disinfection

Disinfection by-products (DBP) are mainly formed during the reaction between organic material

and a disinfectant. The reaction of chlorine with organic matter can lead to the formation of

chlorinated organic DBP’s, such as trihalomethanes (THM). Ozone can also react with organic

matter and form DBP’s. These are mainly organic disinfection by-products, such as aldehydes

and ketones, which can be easily degradaded in a bio filter (90-100%). Generally, these organic

ozone DBP’s do not form any risk of violation of drinking water standards, when ozone is used a

pre-oxidant. To reduce the amount of DBP’s at a conventional disinfection system (disinfection

14
by chlorine products) it is important that the potential to form DBP’s remains low. This is often

expressed as DBP formation potential (DBPFP). The potential to form DBP’s can be reduced by

the removal of (most of the) NOM, for example by pre-oxidation with ozone (ozone-filtration).

This combination can lower the DBPFP by 70-80%, when chlorine is used as a final disinfectant.

This concerns the DBPFP for THM’s, HAA (haloacetic acids) and chloral hydrate.

Ozone is a more effective disinfectant than chlorine, chloramines, and even chlorine

dioxide. An ozone dose of 0,4 mg L-1 for 4 minutes is usually effective for pre-treated water

(low NOM concentration). Several studies proved that ozone, unlike chlorine products, can

deactivate resistant micro-organisms (see resistant microorganisms page). However, as ozone

rapidly decomposes in water, its life-span in aqueous solutions is very short (less than one hour).

Therefore ozone is less suitable for residual disinfection and can be used only in particular cases

(mainly in short distribution systems). Chlorine and chlorine dioxide often replace ozone

as a final disinfectant. For primary disinfection (prior to the bio filtration), ozone is very suitable.

This will lead to a more complete disinfection and a lower disinfectant concentration.

Odor and taste elimination

Odor and taste production in drinking water can have several causes. Odor and taste

forming compounds can be present in raw water, but they can also be formed during water

treatment. These compounds may derive from the decomposition of plant matter, but normally

they are a result of the activity of living organisms present in the water. Inorganic compounds

such as iron, copper and zinc can also generate some taste. Another possibility is that the

chemical oxidation (chlorine treatment) leads to an unpleasant tastes and odors.

Odor and taste forming compounds are often very resistant. This causes elimination to be a very

intensive process. For the elimination of taste and odor, several processes can be appropriate,

such as oxidation, aeration, granular active carbon (GAC) filtration or sand filtration. Usually, a

combination of these techniques is applied.

15
 Ozone can oxidize compounds in a range of 20–90% (dependent on the type of

compound). Ozone is more effective for the oxidation of unsaturated compounds. As was the

case for the oxidation of pesticides, ozone combined with hydrogen peroxide (AOP process) is

more effective than ozone alone. Geosmin and 2-methylisoborneol (MIB) are examples of

resistant odorous compounds, which are often present in the water. These are produced by algae

and have a low odor and taste threshold. Nevertheless, ozone is still very affectively removes

these compounds

Other machines purchased includes Batching/coding machine, packaging machine,

labeling machine and Laboratory equipments.

After surveying the site, a Bore-hole Drilling company was contracted to sink three (3)

Boreholes at the site upon completion of Drilling work, water samples were taken to NAFDAC

Laboratories in Maiduguri, and Kano. All samples tests conducted came out successful and

NAFDAC, upon meeting other requirements like staffing, gave approval for commencement of

production and issued a NAFDAC CERTIFICATE/NUMBER in the year 2012.

The company started with the production of 75cl Bottle water as soon after induced the 33cl

into the Market. Standards Organization of Nigeria equipments have also been met and SON,

NIS Certificates numbers was issued to the company.

The major problems encountered so far are; the saturated Bottle water market, high

electricity Tariffs, high Import duties, high exchange rates, high cost of diesel, high cost of raw

materials etc. all of these result inn ,high Business losses since some of the cost cannot be

transferred to customers, else they withdraw their patronage.

Generally, Bottle water Manufacture in Nigeria can be a money spinning venture if, and

only if, there is turnover.

16
 Basically there are six (6) major departments which includes:-

1) Plastic Injection Department, where the pre-forms and caps are p[roduce3d and also

rejects are recycled, reducing wastages.

2) PETE Bottles blowing Department; where the pre-forms are blown to different sizes and

shapes of bottles.

3) Bottling Department which takes care Rinsing, filling, capping Batching or coding and

labeling of product.

4) Quality control Department; where quality checks are conducted on the production.

5) Packaging Department takes care of the beautiful packaging of water, either with the

shrink film (for 33cl) or the carton (for 75cl).

6) Store/Dispatch Department takes care of stocking and dispatch. The storing includes both

the raw materials and the finished product.

17
 CHAPTER THREE

3.1 INJECTION DEPARTMENT

Injection Moulding Machines

Injection Moulding Machines:- Are machines that are used for processing and making

PET or Plastic bottles for table water and soft drinks. Those machines are also used for making

various plastic items such as plastic bucket, rubber containers etc.

Injection moulding machines are used for making plastic bottles by using Polyethylene

terephthalate material (PET)

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3.2 PET MATERIALS

Pre-form

Polyethylene terephthalate (sometimes written poly(ethylene terephthalate)), commonly

abbreviated PET, PETE, or the obsolete PETP or PET-P, is the most common thermoplastic

polymer resin of the polyester family and is used in fibres for clothing, containers for liquids and

foods, thermoforming for manufacturing, and in combination with glass fibre for engineering

resins.

It may also be referred to by the brand name Dacron; in Britain, Terylene; or, in Russia and the

former Soviet Union, Lavsan.

The majority of the world's PET production is for synthetic fibres (in excess of 60%),

with bottle production accounting for about 30% of global demand. In the context of textile

applications, PET is referred to by its common name, polyester, whereas the acronym PET is

generally used in relation to packaging. Polyester makes up about 18% of world polymer

production and is the fourth-most-produced polymer; polyethylene (PE), polypropylene (PP) and

polyvinyl chloride (PVC) are first, second and third, respectively.

PET consists of polymerized units of the monomer ethylene terephthalate, with repeating

(C10H8O4) units. PET is commonly recycled, and has the number "1" as its resin identification

code (RIC).

Depending on its processing and thermal history, polyethylene terephthalate may exist both as an

amorphous (transparent) and as a semi-crystalline polymer. The semicrystalline material might

19
appear transparent (particle size less than 500 nm) or opaque and white (particle size up to a few

micrometers) depending on its crystal structure and particle size.

The monomer bis(2-hydroxyethyl) terephthalate can be synthesized by the esterification

reaction between terephthalic acid and ethylene glycol with water as a byproduct, or by

transesterification reaction between ethylene glycol and dimethyl terephthalate (DMT) with

methanol as a byproduct. Polymerization is through a polycondensation reaction of the

monomers (done immediately after esterification/transesterification) with water as the byproduct.

3.3 USES

Because PET is an excellent water and moisture barrier material, plastic bottles made

from PET are widely used for soft drinks (see carbonation). For certain specialty bottles, such as

those designated for beer containment, PET sandwiches an additional polyvinyl alcohol (PVOH)

layer to further reduce its oxygen permeability.

Biaxially oriented PET film (often known by one of its trade names, "Mylar") can be aluminized

by evaporating a thin film of metal onto it to reduce its permeability, and to make it reflective

and opaque (MPET). These properties are useful in many applications, including flexible food

packaging and thermal insulation (such as space blankets). Because of its high mechanical

strength, PET film is often used in tape applications, such as the carrier for magnetic tape or

backing for pressure-sensitive adhesive tapes.

Non-oriented PET sheet can be thermoformed to make packaging trays and blister packs. If

crystallizable PET is used, the trays can be used for frozen dinners, since they withstand both

20
freezing and oven baking temperatures. As opposed to amorphous PET, which is transparent,

crystallizable PET or CPET tends to be black in colour.

When filled with glass particles or fibres, it becomes significantly stiffer and more

durable.

PET is also used as a substrate in thin film solar cells.

Terylene (a trademark formed by inversion of (polyeth)ylene ter(ephthalate)) is also spliced into

bell rope tops to help prevent wear on the ropes as they pass through the ceiling.

PET is used since late 2014 as liner material in type IV composite high pressure gas cylinders.

PET works as a much better barrier to oxygen than earlier used (LD) PE.

PET is used in the 3d printable thermoplastic, PETG

3.4 History

PET was patented in 1941 by John Rex Whinfield, James Tennant Dickson and their employer

the Calico Printers' Association of Manchester, England. E. I. DuPont de Nemours in Delaware,

USA, first used the trademark Mylar in June 1951 and received registration of it in 1952. It is

still the best-known name used for polyester film. The current owner of the trademark is DuPont

Teijin Films US, a partnership with a Japanese company.

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 CHAPTER FOUR

QUALITY CONTROL AND WATER TREATMENT

4.1 LABORATORY

Laboratory quality control test provide the necessary information to monitor the

treatment processes to safeguard and provide water that is good tasting and safe for all human

purpose. To relate laboratory results to treatment operations, operators need to first select the

most effective operational procedures, then determine the efficiency of the treatment processes

and finally identify potential problems before they affect finished water quality.

Laboratory analyses can be used for the determination of optimum chemicals dosage and

consumption standard, thereby reducing the production cost of water. Water quality depends on

the physical, chemical and bacteriological quality of drinking water.

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4.2 PHYSICAL CHARACTERISTIC OF WATER

 TASTE AND ODOR

Taste and odor are objectionable in water and are cause by dissolved impurities which are

organic in nature; they are difficult to measure and differ according to individual feeling.

Taste and odor are usually detected by sense of taste and odor respectively when

presented only in a few milligrams per litre. It is difficult and often impossible to identify

the exact odor producing chemical substance.

 TURBIDITY

Turbidity can say to be very small particles invisible to the naked eyes, which have

electrical charges on their surface which repel each other and remain in suspension. This

gives a cloudy appearance which is unattractive and may be harmful. Turbidity is caused

when substances like silt, clay and finely divided organic materials are present in water.

Turbidity is determined by using direct reading spectrophotometer and has a unit of NTU

(Nephelometric Turbidity Unit)

 COLOUR

Water should be colorless which has a pale blue-green tint in large volumes, this

true color is due to dissolved matter and the presence of color indicates that it contains

dissolved colloidal material in the water. This is usually objectionable.

We determine color at Gubi laboratory using direct reading spectrophotometer

and expressed in term of standard unit, which is defined as color produced by 1mg/L of

23
 platinum in terms of chloroplatinic acid in the presence of 2mg/L of cobaltous chloride

hexahydrate (Pt Co unit).

Fig.5 is spectrophotometer used to determine turbidity and color.

 CONDUCTIVITY

This depends on the ionic strength of the water which is related to the nature of different

dissolved substance and their concentrations. The concentration of electrolyte can be

estimated through conductivity determination.

Conductivity is determined using conductivity/TDS meter and has unit of micro seconds

per centimeter (µs/cm)

 TOTAL DISSOLVED SOLIDS

Dissolved solids are objectionable in low concentration. This occurs in the presence of

soluble substances like Calcium (Ca), Sodium (Na), Magnesium (Mg) and Manganese (Mn).

24
They occur in combined form of bicarbonates, sulphates and chlorides. They are present not

only in inorganic form but also in organic form.

Total dissolved solid is also determined using conductivity/TDS meter and has a unit of

milligram per liter (mg/L).

 TEMPERATURE

The solubility of chemical and bacteriological activity is influenced by temperature; they

also increase the taste and odor. Very hot or cold water is not desirable. Temperature affects

the properties of water such as viscosity, density and surface tension.

Temperature can be determined by the conductivity meter having a sensor at its tip end.

The conductivity meter is usually inserted in a sample and set to the temperature scale i.e.

degree Celsius (°С) which give reading directly.

25
Fig.6 Conductivity meter

4.3 CHEMICAL CHARACTERISTICS OF WATER

 PH VALUE

This is frequently carried out on water and aqueous solutions. PH value is used to

measure the degree of acidity or alkalinity of water. PH value of water helps to control

coagulation process, remove iron, manganese and corrosion.

PH value is determined by using PH meter having a sensor at its tip end. The PH meter is

usually inserted in a sample and the value reads directly. The PH value is expected to be in

the range of 6.5-8.5 for potable water.

26
Fig.7 pH Meter

CARBON DIOXIDE(CO2)

Excess carbon dioxide is not advantageous because it can make the water corrosive to

metals. Corrosion is due to high CO2, low PH value and low alkalinity.

 CHLORIDE

Chloride impacts bad taste in excess concentration, even though chloride is not harmful to

human health but the water may be unpalatable for drinkers.

 MANGANESE

This is generally found in water along with iron, it cause taste problem when the

concentration exceed 0.5mg/L.

27
 *IRON

Iron gives a bitter taste, color and odor problem and also results in red water. Iron

occurs in the form of bicarbonate or sulphate. Whenever iron comes in contact with

oxygen, dissolved iron may precipitate as flocs of ferric oxide.

 CHLORINE

This involve the use of diethyl-phenylenediamine(DPD) method developed by DR

A.T Palin and now internationally recognized as the standard method of testing for

chlorine and other disinfectant residuals. In this method, the reagents are in the form of

tablets for maximum convenience and simplicity of use.

Free chlorine reacts with diethyl-phenylenediamine (DPD) in buffered solution to

produce pink color. The intensity of the color is proportional to the concentration of the

free chlorine. Subsequent addition of potassium iodide induces a further reaction with

any combined chlorine present. The color intensity represents the combine chlorine

concentration. In this way, it is possible to differentiate between free and combined

chlorine present in a sample. The color intensities are measured using direct reading

spectrophotometer and has wavelength of 530nm.

 TOTAL HARDNESS

Hardness occurs due to the occurrence of calcium and magnesium ions. Anions

associated are mainly sulphate (SO42-), Nitrate (NO3-), and chloride (Cl-). Hardness causes water

not to foam with soap. Total hardness can be determined using complexometric method of

disodium salt of ethylene diamminetetraacetic acid (EDTA).

28
DEGREE OF HARDNESS HARDNESS OF CaCO3

Soft 0-55

Slightly hard 56-100

Moderately hard 101-200

Very hard 201-500

 JAR TEST

Fig.8 Stirring machine

Jar test is a test designed to show the effectiveness of chemical treatment facility.

Many chemical we add to water can be evaluated on a small laboratory scale by the use

of jar test. The most important of these chemicals are those for coagulation such as alum

and polymer. Using the jar test, the operator can approximate the correct coagulant

dosage for plant use when varying amount of turbidity, color or other factors indicate raw

water quality changes. The jar test is also a useful tool in evaluating new coagulants or

29
polymers being considered for use on plant scale. Therefore, raw water for optimum

coagulant dose, which varies depending on coagulants used and water quality, is what is

tested.

THE APPARATUS

 A stirring machine with six paddles capable of variable speed from 0 to 100

revolutions per minute

 An illuminator located underneath the stirring mechanism (optional)

 Beakers (1000ml)

 Pipette (10ml)

 Volumetric flask (1000ml)

 Analytical balance

PROCEDURE

1. Collect liters sample of the water to be tested.

2. Immediately measure six 1000ml quantities and place into each of six beakers on

stirring apparatus.

3. With a measuring pipette, add increasing dosages of coagulant solution to the

beakers as rapidly as possible. Select a series of dosages so that the first beaker

will represent an under-dose and the last an over-dose.

4. With stirring paddles lowered into the beakers, start stirring apparatus and operate

it for one minute at a speed of 80 revolutions per minute (rpm).

5. Reduce the stirring speed for the next 30 minutes to 20rpm.

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 6. Observe and evaluate each beaker as to that specific dosage, flocs quality. Record

results.

7. Stop the stirring apparatus and allow samples in beakers to settle for 30 minutes.

Observe the flocs settling characteristics. A hazy sample indicates poor

coagulation. Properly coagulated water contains flocs particles that are well-

formed and dense, with the liquid between the particles clear. Describe result as

poor, fair, good or excellent.

PRECAUTIONS

There are number of test that can be performed to improve he jar test and the

interpretation of results. These tests include:

i. Alkalinity(before and after)

ii. PH(before and after)

iii. Turbidity of supernatant(before and after)

iv. Filtered turbidity of supernatant

After estimating the optimum coagulant dosage, run another jar test with the

optimum coagulant dosage constant but vary the PH. These results give you the optimum

PH.

Alkalinity must be monitored very carefully before and after the jar test. The alkalinity

must always be ATLEAST half of the coagulant dose.

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4.4 BLOWING SECTION

Pre-form Blowing Machine

This machine is used for blowing of PET bottles, the machine comprises of electric system,

water system and pyenoumatic system (air). Also the machine contain heating lamps, electric

switch (sensors), the mould and PLC (Computer Panel) to regulate the machine for making bottle

blowing.

Pre-form before blowing Bottle after blowing

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 4.5 FILLING LINE DEPARTMENT

UV Sterilizer

Filling Machine Tank

Stanless Steel Tank

Micro Filter
Industrial Filter A & B Ozonizer
Reverse Osmosis Stanless Steel Tank

Micro Filter

WATER TREATMENT CHART

3-IN-1 MACHINE

I. Overview

CGF24-24-8 unit is a new machine independently developed by the Company on the

basis of years' experience in washing-filling-capping 3-117-1 unit, suggestions of various users

and reference to overseas advanced technologies. It conforms to the requirement that the user can

fill bottles of different types on one machine, and since it is designed to cramp bottle neck in a

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 suspended manner, bottle replacement is easy and quick. This unit mainly applies to

wash, fill and cap the bottle containing still beverage (e.g. purified water, mineral water).

II. Technical Performance and Parameters

1. Production capacity: 4000-10000BIH

2. Filling volume: 250-2000ml

3. Leveling method: liquid level

4. Spec. of bottle: PVC/PET plastic bottle, diameterQ50-Q100mm height 150-300mm,

5. Driving mode: Y112M-4 3KW motor ->V-belt transmission -rWP0135 worm

reducer(l=30:1)

6. Primary structure and characteristics of equipment

(1) 24 sets of bottle clamping robot for washing, provided with inside & outside washing

and reflow mechanism of rotary seal;

(2) 24 filling valves;

(3) One set of cap sorter:

(4) 8 sets of full-tooth screwing head with magnetic torque; when torque exceeds the

preset magnetism, screwing head will slip automatically to ensure that bottle cap is firmly

screwed while not damaged;

(5) 4 sets of bottle poking safety, no filling and capping in case of no bottle;

(6) Main unit is designed with advanced VWF control technology.

7. Gross power of motor: 4KW

8. Water consumption: washing water ≤ 1T/H+ filling water 3 ~ 4T/H

9. Pressure of air source: O.6MPa

10. Weight: approx 5500kg

11. Overall dimensions: 2750 x 2180 x 2200mm

III. Structure of Equipment

CGF24-24-8 three-in-one unit mainly consists of 11 external components.

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 (1) frame (2) bottle-in & bottle-out device (3) cramp (4) washing device (5) filling

transmission (6) filling valve (7) cap capturing device (8)cap sorter (9)cap screwing

device (10) cap slide groove (11) bottle-out carrier (12) Pneumatic conveying unit

IV. Working Principle

CGF24-24-8 machine could be divided into three units based on its major functions.

4.6 Washing Unit

Washing unit is composed of the cramp and water distributor. Pneumatic conveying unit

blows the bottle into the bottle poking wheel which transfers the bottle to bottle clamp robot, the

jaw firmly captures bottle neck, cramp upturns the bottle 180"to vertical state under the action of

guide rail, the bottle washed comes to the filling position through level 2 bottle poking wheel.

(This unit totally has 18 sets of cramps). Water distributor is mainly composed of upper wearable

ring and lower distribution disk. The ring is suppressed by high-pressure spring to lower

distribution disk which has 18 water outlets. On wearable ring are long holes for water flushing,

with 4 flushing positions.

4.7 Filling Unit

Filling unit mainly consists of filling valve, filling transmission and liquid feeding device,

etc. Washed bottle is transferred to filling position via the poking wheel, while bottle clamping

plate of filling unit clamps the bottle and moves upward to seal bottle mouth, filling valve is then

opened. The liquid is injected into bottle, when inside liquid comes to air return pipe of filling

valve, the system will stop filling. Liquid in the tank is conveyed by water pump which is

controlled by liquid controller mounted on the cover of tank, automatically feeding liquid in case

of low level and stopping operation in case of full level.

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4.8 FILTRATION

After separating most flow, the water is filtered as the final step to remove remaining

suspended particles and unsettled flow. The most common type of filter is a rapid sand filter.

Water moves vertically through sand which often has a layer of activated carbon or anthracite

coal above the sand. The top layer removes organic compounds including test and odor. The

space between sand particles is larger than the smallest suspended particles, so simple filtration

is not enough. Most particles pass through surface layers but are trapped in pore spaces or adhere

to sand particles. Effective filtration extend in to the depth of the filter. This property of the filter

is key to its operation; if the top layer of sand were to block all the particles, the filter would

quickly clog, the accumulated particles prevent water from going there.

To clean the filter, water is passed quickly upward through the filter, opposite the normal

direction (called backwashing or back flushing) to remove embedded particles. Prior to this,

compressed air may be blown up through the bottom of the filter to break up the compacted filter

media to aid the backwashing process; this is known as air scouring. This contaminated water

can be disposed of, along with the sludge from the sedimentation basin, or it can be recycle by

mixing with the raw water entering the plant.

The filtration unit at the treatment plant has six simple bed filters. The water comes from

the sedimentation unit through the clarified water pipes DN 600 to the inlet filtration channel.

From this inlet channel the water flows in to the six filters through the opening of six electrically

operated penstocks.

For clear process description, filter number 1 is taking as an example from the process

sheet diagram. Through the automatic penstocks the water enters the filters from the head side

and then falls down on the filter bed through a weir. The water passing through the filter media

will be filtered and all the impurities still remaining as algae, clay, and settled flocs will be

36
captured in the filter bed. The filtered water will flow to the filter bottom, passing the filter

nozzle installed in the concrete platform. From the filter bottom the water comes through the

outlet pipe DN 350, the butterfly valve VF 113 and the float operated valve LCV 101.

The filters installed at the treatment plant are the constant level type, meaning that during

the whole filtration cycle the water above the filter bed remain nearly constant. The differences

of head loss that will take place during the filtration circle in the filter bed is compensated by the

variation of the head loss on the regulation valve, i.e at the time zero, the head loss of the filter

bed is at the minimum valve and the whole head loss of the system is on the regulation butterfly

valve that is closed 600.

As the water continues to pass through the filter media, the filter begins to get clogged,

and as the water level above the filter tries to increase, the floating device drives the regulation

valve towards the open position. At the completely opened. Outlet filtered water, air scour inlet

and backwashing inlet valves are manually operated by means of local pillars installed in the

filter gallery. The filter is now ready for a new filtration cycle. The filtered water flow into a

general collecting channel, discharging the filtered water into the final clear water tank. In this

channel, chlorine is added for final chlorination.

4.9 DISINFECTION

Disinfection is normally the last step in purifying drinking water. Water is disinfected to

destroy any pathogens which pass through the filters. Possible pathogens include viruses,

bacteria, including Escherichia coli, Campylobacter and Shigella, and protozoans, including

G.lamblia and other Cryptosporidia. In most developed countries, public water supplies are

required to maintain a residual disinfecting agent throughout the distribution system, in which

37
 water may remain for days before reaching the consumer. Following the introduction of

any chemical disinfecting agent, the water is usually held in temporary storage-often called a

Contact Tank or Clear Well to allow the disinfecting action to complete.

The most common disinfecting method is some form of Chlorine or its compounds such

as chloramine or chlorine dioxide. Chlorine is a strong oxidant that can easily kill or destroy

many micro-organisms. Because chlorine is a toxic gas, there is a danger of a release associated

with its use. This problem is avoided by the use of sodium hypochlorite, which is a relatively

inexpensive solid that releases free chlorine when dissolved in water. Handling the solid,

however, requires greater routine human contact through opening bags and pouring than the use

of gas cylinders which are more easily automated. Both disinfectants are widely used despite

their respectives drawbacks. A major drawback to using chlorine gas or sodium hypochlorite is

that they react with organic compounds in the water to form potentially harmful levels of the

chemical by-products trihalomethanes (THMs) and haloacetic acids. The formation of THMs and

haloacetic acids is minimized by effective removal as many organics from the water as possible

before disinfection. Although chlorine is effective in killing bacteria, it has limited effectiveness

against protozoans that form cysts in water. (Giardia lambliaand Cryptosporidium, bothof

which are pathogenic).

For post chlorination, when the filtered water in into the general collecting channel,

chlorine is added before the water goes to the clear water tank. The clear water basin is divided

into three compatments; contact tank, storage tank and pump suction pit. The contact tank is

provided with an overflow device to grant that the tank is always full, so to give a sufficient

contact time to chlorine for a complete disinfection of the water.

38
 Form the overflow, the chlorinated water enters the storage tank; in this part of the clear

water tank the water level will not be constant but it will go up and down according to the

pumping rate and the filtration rate in order to perform the storage duties.

4.10 Cap Screwing Unit

This unit consists of 8 sets of cap screwing head, screwing transmission unit, cap setting

pipe unit and cap sorting unit. Plastic bottle from filling step enters the cap screwing position via

the poking wheel. Before the bottle enters this position under the action of poking wheel,

photoelectric sensor detecting liquid level gets signal to open the cap setting cylinder on cap

setting pipe, cap blowing valve blows to enable the cap enter into cap poking disk, the screwing

head with magnetic torque descends to capture bottle cap, afterwards descends to align with

bottle head for cap screwing. When torque exceeds the preset magnetism, cap screwing head will

slip automatically, thus avoiding the cap being damaged by cap screwing sleeve. The bottle

screwed with cap is then transferred to conveyor belt by the poking wheel. On the cap setting

pipe are upper and lower photoelectric sensors.

The upper one is to control the start and stop of cap sorter, with the function of stopping

cap sorter in case of plenty caps and starting cap sorter in case of few caps, thus protecting the

motor of cap sorter and saving the compressed air; the lower one is to stop the unit in case of no

cap, thus avoiding the filled bottle being transferred to conveyor belt in case of no cap. Cap

sorter sorts caps in a horizontal, pneumatic manner, featuring fast cap setting and no cap damage,

and reverse cap could be automatically returned to the cap sorter through reverse cap recovery

pipe.

39
 CHAPTER FIVE

5.1 PACKAGING DEPARTMENT

The two machine of packaging which include cutting machine and shrink wrapping machine.

Packaging size depends on the size of bottle e.g 20 bottle per pack for 33cl and 12 bottles per

pack for 75cl.

I was shown how to arranged bottles water on the cutting machine how the film is cut by

pressing the push bottle, after cutting is goes to shrink wrapping machine.

CONCLUSION

The Student Industrial Work Experience Scheme (SIWES) provides knowledge of practical

aspect which enables students to be competent and creative in their field of study.

40
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Frerichs, Ralph R. "History of the Chelsea Waterworks". John Snow. Fielding
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Lienhard, John H.; Thiel, Gregory P.; Warsinger, David M.; Banchik, Leonardo
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Metcalf & Eddy, Inc. (1972). Wastewater Engineering. McGraw-Hill. ISBN 0-07-
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Lienhard V, John H. (2015). "Entropy Generation of Desalination Powered
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