Week three presentation for syrup room

Prepared by:
1. Mistireselassie Taddese
2. Melkamfrie Adane
3. Alemtsehay Muche
Submitted to:
Wogderes Bayou
Submitted date: June 26/2021
Outline
i. What is a syrup?
ii. What are the key mechanical terms for syrup and the
electrical terms too?
iii. The flow diagram and pictures?
iv. Mass balance
v. What CIP is?
vi. Challenge and problems
vii.Recommendations
viii.conclusion
What is a syrup? + = Simple syrup
Syrup is the solution made with a primarily of a solution of sugar in water,
containing a large amount of dissolved sugars but showing little
tendency to deposit crystals.
Simple syrup is made by stirring granulated sugar into hot water in a
saucepan until the sugar is dissolved and then cooling the solution. 
Flavored or final syrups are made by infusing simple syrups with
flavoring agents during the manufacturing process. For example coke
agent, sprite agent, Fanta pineapple agent and Fanta orange agent
are ingredients for flavored syrups. The concentrate for each flavor is
packed with two different packaging materials, part one and part two.
 Cont.….
Damping process and the parts of each flavor to be damped
Coca-Cola
CC1(Coca-Cola part one)
It is a caramel dark brown and
opaque liquid.
CC2(Coca-Cola part two)
It is a caramel dark brown and
opaque liquid.
Sprite lemon lime(20% sugar
reduced)
Part 1B (odorless white
granular)
Part 1 (odorless white
powder)
Part 1A (odorless white
powder)
Part 3(odorless white powder
granular)
Citrus(opaque light with
yellow color)
Fanta pineapple
Part 1B (odorless white
granules)
Part 1C (odorless white,
powder with lumps)
Part 3 (odorless white
powder)
Part 1(odorless white
granules)
Part 2 (aromatic cream
opaque liquid)
Part 2C(fruity clear colorless
liquid
Part 2A(herbal vegetable dark
yellow opaque liquid)
Fanta orange
Part 1B(odorless white
granules)
Part 1(odorless white/red
powder/granules)
Part 1A(odorless white
powder)
Part 1C(odorless white
powder with lumps)
Part 3(odorless white powder)
Part 2(citrus opaque light
yellow liquid)
What are the key mechanical terms for syrup
and the electrical terms too?
The following are the mechanical and electrical terms found in syrup
preparation
1. Circulation pump for adequate mixing.
2. Heater for heat supply for the dissolving tank and cooler(plate heat
exchanger) for heat absorbing from the final dissolved simple syrup.
3. Sensors for labeling the required simple, final syrup, and water.
4. PLC board for controlling the system.
5. Tankers for storing the water(hot or cold), syrup(simple or final), damping
and pressure balancing.
6. Connectors and valves for opening and closing flow pipe ways or paths.
 The flow diagram and pictures?
AC suspension Water disposal
Carbon damped while tank
local

Local Vacuum
sugar Filtration sludge Sludge tank rotary Cake bin
sugar units
Tubular heat Sugar dissolving drum filter
damping exchanger
station
tanks

Imported
sugar
Sugar
Sugar solution
balance tanks

Back/safety Plate heat Simple syrup Final syrup

filters exchanger storage tank Blender/mixer machine
storage tank

Cooling tower reduces

the temperature to
40oc and chiller finally
reduces to 23oc
Concentrate
damping station

As you see in the above diagram the AC can be supplied with AC suspension tank
or sugar damping station, that currently in damping station
Cont.….
Tabular heat exchanger Simple syrup dissolving tank
for heating the water dissolves the sugar solution
and allowing for sugar for 10 minutes by using its
dissolving circulation pump.

Circulation
pump

Filters for filtering physical

matters from the sugar solution
Balancing tanker for
balancing the pressure
of the sugar solution Filtration units are
before entering back
filters used when local
sugar is used instead
of imported, for
further filtration.
Cont.…. Diaphragm pump for
Finally the simple syrup is
pumping the sludge
store in the simple syrup
from the filtration units
storage tank
to the sludge buffer
tank.

Vacuum rotary filter, which

is used to drain the water
from the sludge and
removes the cake. Currently not used, but it is
the storage tank for an
The valves and connectors for activated carbon for
allowing and blocking the flow
of treated water, simple syrup
removal of the sludge from
and the concentrate in to the the local sugar.
final storage tank
Cont.…. Final syrup storage tanks for
storing the final prepared
syrup, 3 in number for batch
manufacturing.
Concentrate damping and
mixing station for mixing the
concentrate with treated Chiller cooled
water. water

after the concentrate Cooling tower cooled water

solution is formed it must
passed the 30-mesh Plate heat
stainless steel screen for exchanger
filtration purpose.

Back filters
Mass balance
Simple syrup for Coca-Cola mass balance
Sugar + B water= C simple syrup
The brix of sugar is 63.4obrix and the mass of sugar to be damped for 1 unit concentrate is 203.225kg. Then brix=mass of
sugar/(total mass of the solution).
(203.225/(203.225+B))*100=63.4. B=117.29kg. C = Sugar + B,
C = 320.52kg of simple syrup is needed for 1 unit of Coca-Cola concentration.
Final syrup for Coca-Cola mass balance
49.99 kg of water is needed
Beverage for Coca-Cola mass balance
1589kg of water is needed
The same to that of sprite, Fanta pineapple and Fanta orange.
 Cont.….
The mass of water needed for one unit of concentrate
Mixing place Fanta pineapple Coca-Cola Sprite lemon lime(20% Fanta orange
sugar reduced)

Simple syrup(63.4obrix) 113.373kg 117.29kg 94.496kg 140.144kg

Final syrup 123.864kg 45.29obrix 49.99 kg 54.85obrix 109.988kg 44.46obrix 73.747kg 53.16obrix

Beverage 1580.611k 9.75obrix 1589kg 10.37obrix 1655.193k 8.09obrix 1607.57kg 11.76obrix

g g
What CIP is?
CIP or cleaning in place is a method of automated cleaning the
interior surfaces of pipes, vessels, equipment's, filters and
associated fittings, without major disassembly. CIP is commonly
used for equipment such as piping, tanks, and fillers and blender
or mixers. CIP employs turbulent flow through piping, or spray balls
for large surfaces. In some cases, CIP can also be accomplished
with fill, soak and agitate.
In this company CIP is applicable since continuous change of
flavors and also microorganism adaptations in the storage tanks,
pipes and fillers, washers and mixers have to be cleaned through
this system.
Cont.….
Three different CIP technique are used in this company.
1. Rinse with treated water when there is no flavor change.
2. 3 step CIP with treated water and hot water when there is flavor
change.
3. 5 step CIP with treated water, hot caustic and hot water when there
is a flavor change from Fanta pineapple and also tankers over 48
hours out of usage.
 Cont.….
Flow diagram of CIP process
Hot Caustic tank CIP return
Hot water tank
Recuperation
tank

CIP supply Tankers, fillers and mixer

heater

Treated Caustic
water solution
Cont.…. Gauge pressure indicating
the pressure of steam.

Heater which releases

heat from steam of
boiler in to the caustic
and the treated water.

CIP control
board

Condensate return The three tanks are the storage tanks of water
pump for pumping
the condensate into recovery, hot caustic and hot water passed
the makeup tank of over the heater to overcome the rinse, 3 step
boiler room. and 5 step CIP processes.
Cont.….
Caustic preparation
Caustic is a chemical used for cleaning and removal of fats, and reducing
the reproduction of micro organisms.
In this company caustic is prepared with caustic soda and stabilon with
water the required amount for cleaning purpose.
Circulation pump is used for agitating purpose. Stabilon is used for date
code removal.
But the solution must be with the required ration and step to relief health
effects
 Cont.….
5 step CIP

3 step and 5 step CIP sample date

Type temperature(o Time set(s) Actual(s)
with in standard and actual. c)
3 step CIP Recup. Water 25 600 608
Type Tempera Time set(s) Actual (s)
ture (oc) Drain 25 5 307
Recup. water 25 600 857 Hot caustic 80 1200 2034
Empty(recovery 25 5 62 Empty(recovery) 80 5 398
Hot water 85 900 1313 Treated water 40 180 1042
Empty (recovery) 85 5 73 Empty(recovery) 85 5 410
Treated water 40 120 380 Hot water 85 900 1537
Treated water 20 180 597 Empty(recovery) 85 5 383
drain 25 5 133 Treated water 40 180 670
Treated water 25 120 1051
Drain 25 5 314
Challenges and problems
1. The plant layout seems a bit wrongly installed.
2. The sugar damping station and concentrate needs manual damping
of sugar and concentrate, which leads ergonomic effects.
3. The AC suspension tank in the simple syrup room is not working.
Recommendations
1. The plant layout caustic damping and dissolving station, the sugar
damping station should installed perfectly with plant layout
calculation to enhance the productivity level.
2. The damping technique for both concentrate and sugar should be
really automatic using robotic arms and PLC in order to reduce
ergonomic effects.
3. Because of the real advantage of the AC suspension tank the system
must use this tank while local sugar is used by applying simple
maintenance.
Conclusions
Let’s summarize syrup preparation, final syrup is a mixture of simple
syrup and concentrate/ flavored ingredients and the concentrate unit
for every flavor like Coca-Cola, Fanta orange or pineapple and sprite
differs with in sugar and water, but it seems a bit negligeable. As we try
to generalize above the final syrup should pump into the blender/mixer
mix with de-aerated water and carbon dioxide.

THANKS ALL