Company over view:

Shamim & Company (Private) Limited, established in 1967, are one of the
largest manufacturers, sellers and distributors of Pepsi-Cola beverages one
of the world's most recognized consumer brands since 1973 when we
were awarded with the filling rights of Pepsi Cola International products in
Pakistan as first ever franchisee designated in Pakistan. Before that we were
operating under franchise agreement with 7-UP to bottle 7-UP carbonated
soft drinks. Since our establishment in 1967 we not only have managed to
grow rapidly into one of the largest bottling plant in Pakistan but we also
have managed to maintain a commanding 80% plus market share for years
in the region now. We operate in the Southern Punjab Region, covering an
area of over 150,000 Sq. Km., with our bottling plant located at Multan, one
of the oldest known cities of the world. In addition to our commanding
market share, high quality and operational standards, we also have the
privilege of being the Bottler of the Year 2005 in the region. We Bring You
Pepsi it’s the Cola. Our mission states, "We Bring You Pepsi Its The Cola", but
that’s not it, we also bottle the fastest growing carbonated soft drinks like
the Mountain Dew, the Miranda Orange and the 7-UP.

Departments:

 Administration Department
 Production Department
 Management Information System (MIS) Department
 (SIS)Research and sales information system Department
 Finance Department
 Cash Department
 Sales and Marketing Department
 Human Resource Department
 Shipping Department

Introduction to Water:

Water is a compound composed of the two elements hydrogen and

oxygen. This amazing substance can exist near the earth’s surface in all
three physical forms: as a liquid, vapor or gas and as a solid. The humidity in

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the air is a measure of the amount of water vapor suspended within it.
When water vapor condenses it forms droplets (up to 20,000 in a cubic
inch) that in large amounts form clouds and fog.

Physical and Chemical properties:

 Being able to exist in all three physical states on the earth

surface makes water a one of a kind substance that is liquid,
solid (ice), at 32 f and gas (steam) at 212 f.
 Water is a tasteless, odorless liquid at standard temperature and
pressure. The color of water and ice is, intrinsically, a very slight blue
hue, although water appears colorless in small quantities. Ice also
appears colorless, and water vapor is essentially invisible as a gas.

 Water is transparent, and thus aquatic plants can live within the
water because sunlight can reach them. Only strong UV light is
slightly absorbed.
 All the major components in cells (proteins, DNA and
polysaccharides) are also dissolved in water.
 Pure water has a low electrical conductivity, but this increases
significantly with the dissolution of a small amount of ionic material
such as sodium chloride.

The following properties of water make it a universal solvent

(i) Water is a polar molecule

(ii) Water can form hydrogen bonds with other polar compounds.

(iii) Water dissolves many substances by reacting with them

chemically.

Various uses of water are given below:

For drinking purpose. For washing, bathing and cooking etc. For the
generation of steam for industrial use and electricity generation. For
generating hydroelectricity .For the manufacture of hydrogen, oxygen
and water gas.

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Water Treatment process:

Follow a drop of water from the source through the treatment

process. Water may be treated differently in different communities
depending on the quality of the water which enters the plant.
Groundwater is water located underground and typically requires less
treatment than water from lakes, rivers, and streams.

Different steps:

 Coagulation removes dirt and other particles suspended in water.

Alum and other chemicals are added to water to form tiny sticky
particles called "floc" which attract the dirt particles. The combined
weight of the dirt and the alum (floc) become heavy enough to sink
to the bottom during sedimentation.
 Sedimentation
The heavy particles settle to the bottom and the clear water moves to
filtration.

 Filtration
The water passes through filters, some made of layers
of sand, gravel, and charcoal that help remove even smaller particles.

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  DISINFECTION

A small amount of chlorine is added or some other

disinfection method is used to kill any bacteria or microorganisms that
may be in the water.

 STORAGE

Water is placed in a closed tank or reservoir in order for

disinfection to take place. The water then flows through pipes to
homes and businesses in the community.

HOW THE PROCESSES WORK

Coagulation and flocculation occur in successive steps intended to

overcome the forces stabilizing the suspended particles, allowing particle
collision and growth of flow. If step one is incomplete, the following step
will be unsuccessful.

CONVENTIONAL PLANTS:
Conventional plant designs separate the coagulation, or rapid-mix,
stage from the flocculation, or slow-mix, stage. Normally this is followed by
a sedimentation stage, after which filtration takes place. Plants designed for
direct filtration route the water directly from flocculation to filtration. These
systems typically have a higher raw-water quality. Conventional designs
can incorporate adjustable mixing speeds in both the rapid-mix and slow-
mix equipment. Multiple feed points for coagulants, polymers, flocculants,
and other chemicals can be provided. There is generally adequate space to
separate the feed points for incompatible chemicals.

Inorganic Coagulant Reactions:

Common coagulant chemicals used are alum, ferric sulfate, ferric

chloride, ferrous sulfate, and sodium aluminate. The first four will lower the
alkalinity and pH of the solution while the sodium aluminate will add
alkalinity and raise the ph. The reactions of each follow:

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ALUM:

A12 (SO4)3 + 3 Ca (HCO3)2 2 Al (OH) 3 + 3CaSO4 + 6 CO2

FERRIC SULFATE:

Fe2 (SO4)3 + 3 Ca (HCO3)2 2 Fe (OH) 3 + 3CaSO4 + 6 CO2

FERRIC CHLORIDE:

2 Fe Cl3 + 3 Ca (HCO3)2 2 Fe (OH) 3 + 3CaCl2 + 6CO2

FERROUS SULFATE:

FeS04 + Ca (HCO3)2 Fe (OH) 2 + CaS04 + 2CO2

Sedimentation:

Water exiting the flocculation basin may enter the sedimentation

basin, also called a clarifier or settling basin. It is a large tank with slow flow,
allowing flow to settle to the bottom. The sedimentation basin is best
located close to the flocculation basin so the transit between does not
permit settlement or flow break up. Sedimentation basins can be in the
shape of a rectangle, where water flows from end to end, or circular where
flow is from the center outward. Sedimentation basin outflow is typically
over a weir so only a thin top layer-furthest from the sediment-exits. The
amount of flow that settles out of the water is dependent on the time the
water spends in the basin and the depth of the basin. The retention time of
the water must therefore be balanced against the cost of a larger basin.
The minimum clarifier retention time is normally 4 hours.. This is because
large particles settle faster than smaller ones, so large particles bump into
and integrate smaller particles as they settle. In effect, large particles sweep
vertically though the basin and clean out smaller particles on their way to
the bottom

As particles settle to the bottom of the basin a layer of sludge is

formed on the floor of the tank. This layer of sludge must be removed and
treated. The amount of sludge that is generated is significant, often 3
percent to 5 percent of the total volume of water that is treated. The cost of

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treating and disposing of the sludge can be a significant part of the
operating cost of a water treatment plant. The tank may be equipped with
mechanical cleaning devices that continually clean the bottom of the tank
or the tank can be taken out of service when the bottom needs to be
cleaned.

Sand filters:

Sand filters may be used where there is sufficient land and space.
These rely on biological treatment processes for their action rather than
physicalfiltration. Sand filters arecarefully constructed using graded layers of
sand with the coarsest at the top and finest at the base. Drains at the base
convey treated water away for disinfection. Filtration depends on the
development of a thin biological layer on the surface of the filter. An
effective slow sand filter may remain in service for many weeks or even
months if the pre-treatment is well designed and produces an excellent
quality of water which physical methods of treatment rarely achieve.

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Carbon Purifier:

With a carbon filter process, water passes through activated carbon

which is porous, trapping certain particles that are attracted to the porous
material. The size of particles attracted depends on the size of the pores or
micron rating. However, not all particles are attracted to the active carbon
filter. And at some point it loses its ability to attract particulates and must be
changed in order to be effective. Each activated carbon filter is designed to
allow a certain flow of water through the filtering process. Costs of carbon
filters will also vary. Filter effectiveness is measured in terms of size of
particles they can attract.

This is referred to as microns, with thehigher number being the worst

or least effective and the smallest number being the best. A higher micron
number means it can only remove large particles, but a filter with a rating
of 0.05 microns will filter out minute particles - being most effective.

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Bag Filter

Recovery of particulate matter from exhaust gas is vital for any industry
from two aspects .To avoid pollution problems Recovery of finished
product-increasing the plant yield For recovering particulate matter
different options available are – Cyclones, Venturi, scrubbers, bag filters,
electrostatic precipitators etc. Out of these bag filter becomes the best
choice if following are dominant selection criteria’s: Material is expensive
and hence high collection efficiency is desired. Particulate size is very fine.
Material recovery in powder form is desirable & not in solution form. A
conventional bag filter normally has following problems:

Cartridge Filter

Cartridge filters can screen out twice as much dirt and debris as a
sand filter. Its larger filtration area allows the water to progress through the
cartridge removing smaller particles. Maintenance is much easier in that
there is no need for a back-washing step. All you have to do is take the pool
filter cartridge out of the system and either replace it or wash it off. These
filters cut energy costs by utilizing low pump pressure, but can have a
higher upfront price. Since the pressure needed is lower, it can prolong the
life of your pool pump.

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Micron

A micrometer (symbol µm) is an SI derived unit of length equaling

1×10 of a meter (SI standard prefix "micro-" = 10−6); that is, one-millionth of
−6

a meter (or one-thousandth of a millimeter, 0.001 mm, or about 0.000039

inches). The symbol µm is sometimes rendered as um if the symbol µ
cannot be used.

Cartridge Filter: Micron Filter:

Scaling:

The deposition of salt in water is known as scaling. It affects boiler

tubes and many other things also used in water treatment plant.

Corrosion

It is the gradual destruction of materials, (usually metals), by chemical

reaction with its environment. In the most common use of the word, this
means electrochemical oxidation of metals in reaction with an oxidant such
as oxygen. Rusting, the formation of iron oxides is a well-known example of
electrochemical corrosion.

Osmosis:

It is a natural flowing process that moves a solution with a low saline

concentration through a semi-permeable membrane to a high saline
concentration until an equal amount of saline concentration is reached on
both sides or net movement of water molecules through a semi permeable
membrane from an area of higher water potential to an area of lower.

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Reverse Osmosis:

To acquire fresh, potable water, the process of osmosis needs to be

reversed. In order for reverse osmosis to accomplish this task, excessive
pressure needs to be applied to the highly concentrated saline side of the
semi-permeable membrane forcing it to migrate into the side with the
lower saline concentration. (See below Figure) When excessive pressure is
utilized, the tiny pores within the semi-permeable membrane only permit
water molecules to pass through. The purified water is then collected from
the permeate side of the membrane while salts, chlorine, iron, minerals,
mud, etc. are denied and flushed down the drain from the concentrate
side. Reverse Osmosis has emerged as a reliable method for producing
high-purity water. This membrane technology is often used in combination
with other technologies such as ion exchange to meet the purity
requirements for producing deionizer water in the utility, pharmaceutical,
semiconductor, and electronics industries.

How does the process of Reverse Osmosis work?

The actual process involves taking dirty source water from the Raw Water
Storage Tank (A) then putting it through the feed water Pump (B) and with

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the help of pressure, it passes through a Multi-Layer Filter (C) to remove
solids and particles from the water. From there the water passes into the
chemical dosingsystem (D) which removes the last traces of chlorine,
controls ph in water, and prevents membranes from fouling. It then goes
through the Reverse Osmosis System (E) where it passes through semi-
permeable membranes. At this stage, the membranes remove Total
Dissolved Solids (TDS) that the pre filters had missed. Finally leading to the
emergence of purified water on the lower-pressured side that will be stored
in the Product Water Storage Tank (F). Impurities and contaminates are
emptied into the brine stream and then flushed down a drain.

What are the basic components of a Reverse Osmosis System:

Below Table describes the Components of a Reverse Osmosis System

as shown in above Figure?

Reverse Osmosis membranes serve as high-

engineered, physical barriers that permit the
1. Pressure Vessels &
passage of materials only up to a certain size,
Membranes
shape, or character. They are installed within the
pressure vessels that are made of FRP materials.
The RO Skid is a mild steel material that is powder-
2. RO Skid
coated
The Cartridge Water Filter is used to block the
3. Cartridge Filter
particulate matters that enter the RO membrane
The RO High Pressure Pump is designed to
4. Reverse Osmosis
pressurize RO feed water to overcome the osmotic
High Pressure Pump
pressure.
Control panel is located on the control panel for
5. Control Panel
easy operation.

What types of Commercial/Industrial applications do RO systems serve:

RO systems are becoming very popular among many industrial and

commercial applications due to the substantial amounts of water that’s
needed to be purified.

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Applications:

 Pretreatment of Boilers
 Food and Beverage Services
 Industrial wastewater purification
 Ice making
 Water Bottling

Pretreatment necessary:

If you work with an RO, you understand that the feed water must be
preconditioned to protect the membranes from fouling and premature
failure. An RO membrane functions much like a cross flow filter. The
membrane is constructed of a porous material that allows water to pass
through the membrane, but rejects up to 99% of the dissolved solids at the
membrane surface. The dissolved salts are concentrated in the Reverse
Osmosis reject water, or brine stream, where they are discharge to waste.

Membranes

Membrane is the kidney and liver of water treatment system. They

filter out all the contaminants and particles from the feed water source
once it has passed through pretreatment. Cross flow membrane filtration is
a pressure-driven separation process. Application: Industrial, food, water,
chemical, and biotechnology markets, as well as for those providing
environmental protection. RO membranes are great solutions for many
different applications.

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Fluid system membrane:

Distilled water is water that has many of its impurities removed

through distillation. Distillation involves boiling the water and then
condensing the steam into a clean container.

Applications:

In chemical and biological laboratories, as well as industry, cheaper

alternatives such as deionizer water are preferred over distilled water.
However, if these alternatives are not sufficiently pure, distilled water is
used. Where exceptionally high purity water is required, double distilled
water is used. Distilled water is preferable to tap water for use in
automotive cooling systems.Distilled water is also preferable to tap water
for use in model steam engine boilers and model engines of other types.

Drinking distilled water:

Bottled distilled water can usually be found in supermarkets or

pharmacies, and home water distillers are available as well. Water
purification, such as distillation, is especially important inregions where
water resources or tap water is not suitable for ingesting without boiling or
chemical treatment. Municipal water supplies almost always contain trace
components at levels, which are regulated to be safe for consumption.
Some other components such as trace levels of aluminum may result from
the treatment process. Fluoride and other ions are not removed through
conventional water filter treatments. However, distillation eliminates most
impurities. Distilled water is also used for drinking water in arid seaside

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Ion Exchange system:

An ion exchange system consists of a tank containing small beads of

synthetic resin. The beads are treated to selectively adsorb either cat ions
(positive) or anions (negative) and exchange certain ions based on their
relative activity compared to the resin. This process of ion exchange will
continue until all available exchange sites are filled, at which point the resin
is exhausted and must be regenerated by suitable chemicals.

Ion Exchange Water Softening:

The ion exchange water softener is one of the most common tools of
water treatment. Its function is to remove scale-forming calcium and
magnesium ions from hard water. In many cases soluble iron (ferrous) can
also be removed with softeners. A standard water softener has four major
components: a resin tank, resin, a brine tank and a valve or controller. The
softener resin tank contains the treated ion exchange resin - small beads of
polystyrene. The resin beads initially adsorb sodium ions during
regeneration. The resin has a greater affinity for multi-valet ions such as
calcium and magnesium than it does for sodium. Thus, when the hard
water containing the Calcium and Magnesium Ions is passed through the
resin bed, the calcium and magnesium ions adhere to the resin, releasing
the sodium ions until equilibrium is reached. The water softener has
exchanged its sodium ions for the calcium and magnesium ions in the
water. Regeneration is achieved by passing a NaCl solution through the

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resin, exchanging the hardness ions for sodium ions. The resin’s affinity for
the hardness ions is overcome by using a highly concentrated solution of
brine. The regeneration process can be repeated indefinitely without
damaging the resin.

Applications:

Ion exchange is widely used in the food & beverage,

hydrometallurgical, metals finishing, chemical & petrochemical,
pharmaceutical, sugar & sweeteners, ground & potable water, nuclear,
softening & industrial water, semiconductor, power, and a host of other
industries.

Most typical example of application is preparation of high purity

water for power engineering, electronic and nuclear industries; i.e.
polymeric or mineralinsolubleion exchangers are widely used for water
softening, water purification, water decontamination, etc.

Ion exchange resin beads

Pasteurization:

It is a process of heating a food, which is usually a liquid, to a specific

temperature for a predefined length of time and then immediately cooling
it after it is removed from the heat. This process slows spoilage caused by
microbial growth in the food. Unlikesterilization, pasteurization is not
intended to kill all micro-organisms in the food.

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Procedure:

 Put 1400 lit of treated water into pasteurization tank

 Open steam valve that is coming from boiler in order to attain 80°C
for treated water in the pasteurization tank.
 Weight the required amount of sugar that is used for different
beverages like for Pepsi (2174kg), 7up(2218kg),M.Dew(2482kg),Sting
berry blast and gold (1040kg).
 From overhead of pasteurization tanks add sugar with constant
agitation.
 At the side of pasteurization tank pre-coated tank is installed having
activated carbon and diatomaceous earth in the ranges of 0.10%-
0.50% of sugar weight, in order to upgrade the quality of
insufficiently refined suger by the treatment of syrup.
 Maintain temperature to 85°C for repasteurization and its residence
time is should be 1hr.
 After this hot syrup is passed through the filter press that is coated
with DE.
 After this syrup is cooled to 20°C, by passing through heat exchanger.
 Through heat exchanger cooled syrup is sent to syrup room having
mixing tanks.
 In mixing tanks syrup temp should be less than 20°C, there is agitator
inside the mixing tanks.
 There are dissolution tanks in which dry acid i.e. citric acid anhydrous,
sodium citrate and water is in jested to dilute in a specific amount.
 In the last solution from the DS tank is injected to the mixing tanks
and from overhead of the mixing tank required flavor of pepsi,
7up…etc is put into it, to make the final product.
 After mixing sample of syrup are taken and sent to the laboratory for
testing purposes.
 Some lab tests are mentioned below here:
o Brix test
o TA(titrable acidity) test
o Ph test

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Ammonia/Water - Absorption Refrigeration System:
Process Description:

Some liquids like water have a great tendency for absorbing large
amount of certain vapors (NH3) and reduce the total volume quite. The
absorption chiller refrigeration system differs basically from vapor
compression system only in the method of compressing the refrigerant. In
the absorption refrigerating system, the compressor is replaced with an
absorber, generator and pump.

Chiller:
Ammonia vapor is extracted from the NH3 strong solution at high
pressure in the generator by an external heating source. In the rectifier, the
water vapor which carried with ammonia is removed and only the dried
ammonia gas enters into the condenser, where it’s condensed. The
pressure and temperature of cooled NH3 solution is then reduced by a
throttle valve below the temperature of the evaporator. The NH3 refrigerant
at low temperature enters the evaporator and absorbs the required heat
from it, then leaves it as saturated vapor. The low pressure NH3 vapor is
then passed to the absorber, where it’s absorbed by the NH3 weak solution
which is sprayed also in the absorber. After absorbing NH3 vapor by the
weak NH3 solution (aqua–ammonia), the weak NH3 solution becomes
strong solution and then it is pumped to the generator passing through the
heat exchanger. In the pump, the pressure of the strong solution increases
to generator pressure. In the heat exchanger, heat form the high
temperature weak NH3 solution is absorbed by the strong NH3 solution

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coming from the absorber. As NH3 vapor comes out of the generator, the
solution in it becomes weak. The weak high temperature NH3 solution from
the generator is then passed through the throttle valve to the heat
exchanger. The pressure of the liquid is reduced by the throttle valve to the
absorber pressure.

Why Do We Use Ammonia/Water?

Because most commercial and industrial refrigeration applications

occur at temperatures below 32 F and many are 0 F. As a result, a fluid
which is not subject to freezing at these temperatures is required. So the
lithium bromide/water cycle is no longer able to achieve this condition,
because water is used for the refrigerant. Also the required heat input
temperatures must be at least 230oF. It should also be remembered that
the required evaporation temperature is 10 to 15oF below the process
temperature.
What is An Absorption Chiller?

An Absorption Chiller is a machine uses a heat source to generate

chilled water rather than electrical source that is used in vapor compression
cycle. It’s an attractive idea to produce chilled water with heat. As the same
in vapor compression cycle, absorption cycle achieve removing heat using
the evaporation of a refrigerant at low pressure and the ejection of heat
using the condensation the refrigerant at high pressure.

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Compressor:

 Piston (Reciprocating) compressor.

It is a type of Positive displacement compressor. The reciprocating piston
compressor is the most widely used equipment for gas service. The basic
design consists of a piston in a cylinder with pressure actuated check valves
to control suction and discharge flow through the cylinder. Standard
practice is to have the piston driven by a rod passing through a packing
case to seal against pressure leaks. With this double acting design, gas can
be compressed on both sides of the piston. The basic design is more than a
hundred years old, and is well developed. The throughput and loading can
be adjusted by speed variation, addition of clearance to the cylinders,
deactivating cylinders to reduce displacement or active control of valve
closing, which effectively gives variable control of displacement. Efficiencies
of this type of compressor can be more than 85 percent for conversion of
horsepower input to pressure rise.

Syrup Room:
In cooking, a syrup (from Arabic: sharab, beverage, wine, via Latin is a
thick, viscous liquid consisting primarily of a solution of sugar in water,
containing a large amount of dissolved sugars but showing little tendency
to deposit crystals. The viscosity arises from the multiple hydrogen bonds
between the dissolved sugar, which has many hydroxyl (OH) groups, and
the water. Syrups can be made by dissolving sugar in water or by reducing
naturally sweet juices such as cane juice, sorghum juice, or maple sap. Corn
syrup is made from corn starch using an enzymatic process that converts it
to sugars. Technically and scientifically, the term syrup is also employed to
denote viscous, generally residual, liquids, containing substances other
than sugars in solution.

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Preparation of Syrup:
In this section the basis syrup for cola beverages are being made.

Following steps will brief about the manufacturing of syrup.

1) Purified Water from the treatment plant is boiled at high temperature

in Pasteurizer tank using steam (800C).
2) Put 1400 Liter of treated water into pasteurizer tank.
3) Open steam valve that is coming from boiler in order to attain 800C
for treated water in the PT (pasteurizer tank).
4) Weight the required amount of sugar that is used for different
beverages like Pepsi (2174Kg),
7up(2218Kg),Marinda(2732Kg),M.Dew(2482Kg), Sting Red and
Gold(1040Kg).
5) The water is boiled until all contents are fully dissolved in it.
6) At the side of pasteurization tank pre-coated tank is installed having
activated carbon an di-atomaceous Earth in ranges of 0.10% to 0.50%
of sugarweight, in order to upgrade the quality of insuffiently refined
sugar by the treatment of syrup.
7) Maintain temp. to 650C fpr pasteurization and its residence time is
should be 1hour.
8) After this hot syrup pass through the filter press that is coated with
DE.
9) Filtration is done to obtain the desired clarity/color and recirculated
until desired syrup is obtained.
10) After this, syrup is cooled at 200C by passing through heat
exchanger.
11) Through heat exchanger cooled syrup is sent to syrup room
having mixing tanks.
12) In mixing tanks temp. Should be less than 200C, there is agitator
inside the mixing tanks.
13) There are dissolution tanks in which dry acids i.e. Citric acid
anhydrous, Sodium Citrate and water is injected to the mixing tanks
and from overhead of the mixing tank required flavor of Pepsi,7UP
etc. is put into to make the final product.

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 14) After mixing sample of syrup are taken and sent to the
laboratory for testing purpose.
15) These test are done here:
 Brix test
 TA (Tratratable acidity) test.
 Carbonation
 Degassing.
Then the final product of syrup is sent to the main production hall for
filling.

Specification:
Pasteurization Tanks= 6

No. of heat exchanger=02

No. of filter press=04

Pre-coating tanks=02

Temp. of repasteurization=850C

Different Brands Ingredients:

Pepsi:
 Flavor
 Anidulant

7UP:
 Citric acid
 Sodium citrate
 Flavor

Mountain Dew:
 Sodium Benzoate
 Tartarazine (granular)

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  Ascorbic acid
 Citric acid anhydrous
 Caffeine anhydrous
 Sodium Citrate
 Mountain Dew Flavor

Marinda:
 Sodium Benzoate
 Sodium citrate
 Citric acid
 Sunset yellow flavor

Diatomaceous Earth:-
It is whitish-pink powdery material that comes in various size. It is an
inert, non –toxic material of plant origin. It is used to remove suspended
solids and foreign matter from liquid suger solution. Also used as a filtration
aid in suger tretment with carbon powder. Recommended particle size for
liquid suger filtration is 10-30.

Active Carbon Powder:-

It is a black, amorphous porous material made from carbonaceous
raw material. It comes in varying sizes used to remove orgainc impurities

Such as color molecules from liquid suger solutions.

Definition of Term:
Turbidity:
Presence of suspended particles in the solution is called
turbidity which is checked afterfiltration of sample syrup.
 Clarity:
The determination of transperant or translucent appearance of the
solution which is checked after filtration of simple syrup.

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  Color:
Presence of transperancy in the solution is called color which is
checked after filtration of simple syrup.

Ingredients for different Products:

Pepsi 7UP Mirinda Due Sting Sting

Red Gold

1 Flavor Flavor Flavor Flavor Energy Energy

Flavor Flavor
2 Acid Nil Nil Nil Nil Nil
3 Nil Steric C18H36O2 C18H36O2 C18H36O2 C18H36O2
acid
4 Nil Sodium Na3C6H5O7 Na3C6H5O7 Na3C6H5O7 Na3C6H5O7
citrate
5 Nil Nil Sunset Nil Sunset Sunset
(yellow) (yellow) (yellow)
6 Nil Nil Sodium NaC7H5O2 NaC7H5O2 NaC7H5O2
Benzoate

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7 Nil Nil Nil Citrus flavor Nil Nil
8 Nil Nil Nil Caffeine(C8H10N4O2) Nil Nil
9 Nil Nil Nil Ascorbic Nil Nil
Acid (C6H8O6)
10 Nil Nil Nil Tetrazene H4N4 H4N4

11 Nil Nil Nil Nil Potassium C6H7KO2

Sorbate

12 Nil Nil Nil Nil Disodium C10-H12-Ca-

calcium N2-O8.2Na
EDTA
13 Nil Nil Nil Nil Vitamin Vitamin
Premix Premix
14 Nil Nil Nil Nil Oriental Oriental
ginsing ginsing
powder powder
15 Nil Nil Nil Nil Sodiumhexa (NaPO3)6
phosphate
16 Nil Nil Nil Nil Alvora(red) Nil
17 Nil Nil Nil Nil Nil Nil
Boiler:

The term boiler is used for a closed vessel in which water or other
fluid is heated. The fluid does not necessarily boil. (In North America the
term "furnace" is normally used if the purpose is not actually to boil the
fluid.) The heated or vaporized fluid exits the boiler for use in various
processes or heating applications, including central heating, boiler-based
power generation, cooking, and sanitation.

Boiler used in Boiler room at Pepsi Multan Plant is a 3 path biller having
capacity of 3 ton.
Boiler produces steam and its nominal internal temperature is 150 degree
Celsius.
The pressure maintained is 8-10 bar. Boiler shown below is a two path
boiler:
The pressure vessel of a boiler is usually made of steel (or alloy steel),
or historically of wrought iron. Stainless steel is virtually prohibited (by the

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Internship Report.
ASME Boiler Code) for use in wetted parts of modern boilers, but is used
often in superheated sections that will not be exposed to liquid boiler
water.
Fuel:

The source of heat for a boiler is combustion of any of several fuels,

such as wood, coal, oil, or natural gas. Electric steam boilers use resistance-
or immersion-type heating elements.

The type of boiler used here is Fire tube boiler.

Fire-tube boiler:

Here, water partially fills a boiler barrel with a small volume left above
to accommodate the steam (steam space). This is the type of boiler used in
nearly all steam locomotives. The heat source is inside a furnace or firebox
that has to be kept permanently surrounded by the water in order to
maintain the temperature of the heating surface just below boiling point.
The furnace can be situated at one end of a fire-tube which lengthens the
path of the hot gases, thus augmenting the heating surface which can be
further increased by making the gases reverse direction through a second
parallel tube or a bundle of multiple tubes (two-pass or return flue boiler);
alternatively the gases may be taken along the sides and then beneath the
boiler through flues (3-pass boiler). In the case of a locomotive-type boiler, a
boiler barrel extends from the firebox and the hot gases pass through a
bundle of fire tubes inside the barrel which greatly increase the heating
surface compared to a single tube and further improve heat transfer.
Specifications of boiler being used at Shamim & Company, Multan:

Capacity 6 ton
Heating Surace area 100 sq. ft
Internal Temperature (avg.) 130-150 degree Celsius
Type of Steam produced Saturated Steam
Path Type 3 path boiler
Alignment Horizontal
Pressure 150 psi/ 10 bar

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Internship Report.
 COMPONENTS OF BOILER:

Safety Valve
Regulator Control Valve
Feed Check Valve (for inlet water feed check)
Bowden Valve (for draining water)
Gauge Glass (for level check)
Stop Valve (supply output valve)
Butterfly Valve (for gas fuel control)
Slowen Valve (for Automatic Flow control)
Steam Valve
Pressure gauge
Gate Valve
Glop Valve
Temperature Gauge
Multi-Stage Pump
Fan Motor
Check Valve (allows flow of fluid in only one direction)
Steam Cork (for gauge glass)
Water Cork(for gauge glass)

Simonazzi™ and Sidel™: the art of filling:

Now that Simonazzi has joined the Sidel Group, its range of fillers is

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Internship Report.
the most complete and highest quality in the world.

Simonazzi™ and Sidel™

Fillers guarantee top performances both as regards speed and quality

precision filling. Together they provide one of the most complete ranges
available on the market from a single supplier in terms of:

Products treated:

The range includes fillers dedicated to water, carbonated soft drinks,

beer, sensitive products, liquid dairy products, and viscous products with
pieces or pulp reach the highest standards in terms of hygiene,
productivity, speed, and reliability.
Containers:

The range includes fillers for plastic bottles (one way and returnable),
glass (one way and returnable), and cans;

Filling systems:

The range includes machines with an isobaric system (with pre-

evacuation, double pre-evacuation, self-leveling, flushing), gravity filling,
high vacuum and low vacuum, mechanical volumetric, volumetric flow
meter, gravity weight;
Types and number of valves:

The range of machines is equipped with mechanical and/or

electronic valves. The number of valves ranges from 16 to 180;

Output:

From 3,000 to more than 120,000 containers per hour.

Electrical and Instrumentation Section:

Electrical & Instrumentation Department install, service, troubleshoot;
and perform preventive and predictive maintenance functions on
equipment. This includes plant lighting equipment and receptacle circuits,

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Internship Report.
motors, starters, motor control centers, programmable controllers, control
panels, electrical control systems and transformers. They may also service
high voltage electrical systems, and ensure that work is in accordance with
relevant codes. They repair, test, adjust, calibrate or install electronic
equipment, such as industrial controls, transmitters, and antennas.
Instrument used in Plants:
Sensors
A sensor (also called detector) is a converter that measures a physical
quantity and converts it into a signal which can be read by an observer or
by an (today mostly electronic) instruments.
Types of Sensors Used in Plant
 Photo Electric sensor (with and without reflector)
 Proximity sensor (Inductive)
 Metal detector
 Capacitive
 Level sensor
 Megnatic sensor
 Pressure sensor
Commonly used sensor in plant is Photo electric sensor.below are the
uses of Photo electric sensor.

Non-stop Detection in Dusty Environment with High Vibration.

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 Detecting Shiny/Mirror Transparent Film.

Precisely Detects and Counts PET Bottles.

Advantages and disadvantages of photoelectric sensors

Advantages of photoelectric sensors:

 Interpretation-distance: All these sensors can take information away

from the goal or target. This practice is an asset for fragile objects,
very hot, food, liquids, etc.
 Suitable for industry: These sensors are mostly produced in a
traditional way that allows them to be easily replaced in case of
breakage or malfunction. In addition, the values are quite similar from
one sensor to the other so no need to reprogram all, a simple
calibration should suffice.
 Simplicity: The photoelectric sensors have a wide range of choice, so
even if there is little knowledge of electronics, it is relatively easy to
find a sensor which responds more specificaly to your needs. The
price, however, can not be related to its simplicity.
 Some of them have high sensibility and have very high detection
capabilities.

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  High response speed: Response time is very fast, because light travels
at high speed. The sensor does not perform mechanical tasks,
because these circuits are composed solely of electronic parts.
 Detection of various materials: These sensors operate on the principle
that an object absorbs or reflects light. They are not limited by the
material of which an object is made unlike proximity sensors which
require that the objects are metal. They can be used to detect almost
all objects, including glass, plastic, wood and liquids.

Disadvantages:

 Aging with time and use: Despite the fact that no physical contact is
made, light emmiters lose their intensity with time. This loss of
intensity is unstable. In other words, it can be good for some time,
then fall, then remains stable for a while and then it drops again.
Inspections must be planned and a technician needs to make a
calibration of the sensors.
 The nonlinear response: Response curve of these sensors is not linear.
This implies that the control unit or PLC must take into account a
corrective calculation during the process of measured information.
This will more accurately meet what is expected by the photoelectric.

Inverters:
A power inverter, or inverter, is an electrical power converter that
changes direct current (DC) to alternating current (AC). The input voltage,
output voltage, and frequency are dependent on design.
Applications:
DC power source utilization:

Inverter designed to provide 115 VAC from the 12 VDC source

provided in an automobile. The unit shown provides up to 1.2 amperes of

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Internship Report.
alternating current, or enough to power two sixty watt light bulbs.

An inverter converts the DC electricity from sources such as batteries,

solar panels, or fuel cells to AC electricity. The electricity can be at any
required voltage; in particular it can operate AC equipment designed for
mains operation, or rectified to produce DC at any desired voltage.

Micro-inverters convert direct current from individual solar panels into

alternating current for the electric grid. They are grid tie designs by default.

Uninterruptible power supplies:

An uninterruptible power supply (UPS) uses batteries and an inverter

to supply AC power when main power is not available. When main power
is restored, a rectifier supplies DC power to recharge the batteries.

Induction heating:

Inverters convert low frequency main AC power to higher frequency

for use in induction heating. To do this, AC power is first rectified to provide
DC power. The inverter then changes the DC power to high frequency AC
power.

HVDC power transmission:

With HVDC power transmission, AC power is rectified and high

voltage DC power is transmitted to another location. At the receiving
location, an inverter in a static inverter plant converts the power back to
AC. The inverter must be synchronized with grid frequency and phase and
minimize harmonic generation.

Variable-frequency drives:
Main article: variable-frequency drive:

A variable-frequency drive controls the operating speed of an AC

motor by controlling the frequency and voltage of the power supplied to
the motor. An inverter provides the controlled power. In most cases, the
variable-frequency drive includes a rectifier so that DC power for the
inverter can be provided from main AC power. Since an inverter is the key
component, variable-frequency drives are sometimes called inverter drives

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Internship Report.
or just inverters.

VFDs that operate directly from an AC source without first converting

it to DC are called cycloconverters. They are now commonly used on large
ships to drive the propulsion motors.

Electric vehicle drives:

Adjustable speed motor control inverters are currently used to power

the traction motors in some electric and diesel-electric rail vehicles as well as
some battery electric vehicles and hybrid electric highway vehicles such as
the Toyota Prius, BYD e6 and Fisker Karma. Various improvements in
inverter technology are being developed specifically for electric vehicle
applications.[8] In vehicles with regenerative braking, the inverter also takes
power from the motor (now acting as a generator) and stores it in the
batteries.

Air conditioning:
Main article: Inverter air conditioning:

An inverter air conditioner uses a variable-frequency drive to control

the speed of the motor and thus the compressor.

Electroshock weapons:
Electroshock weapons and tasers have a DC/AC inverter to generate
several tens of thousands of V AC out of a small 9 V DC battery. First the
9VDC is converted to 400 - 2000V AC with a compact high frequency
transformer, which is then rectified and temporarily stored in a high voltage
capacitor until a pre-set threshold voltage is reached. When the threshold
(set by way of an airgap or TRIAC) is reached, the capacitor dumps its entire
load into a pulse transformer which then steps it up to its final output
voltage of 20 - 60 kV. A variant of the principle is also used in electronic
flash and bug zappers, though they rely on a capacitor-based voltage
multiplier to achieve their high voltage.

PLC:A Programmable Logic Controller, PLC or Programmable Controller is a

digital computer used for automation of electromechanical processes, such
as control of machinery on factory assembly lines, amusement rides, or light
fixtures.

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Motors:
An electric motor is an electric machine that converts electrical
energy into mechanical energy.
There are two major types of Motors being used in plant
1) Servo motors
2) Induction motors
Servo Motors:

A servomotor is a rotary actuator that allows for precise control of

angular position, velocity and acceleration.[1] It consists of a motor coupled
to a sensor for position feedback. It also requires a relatively sophisticated
controller, often a dedicated module designed specifically for use with
servomotors. Servomotors are used in applications such as robotics, CNC
machinery or automated manufacturing.

Advantages:

 If a heavy load is placed on the motor, the driver will increase the
current to the motor coil as it attempts to rotate the motor. Basically,
there is no out-of-step condition.
 High-speed operation is possible.

Disadvantages:

 Since the servomotor tries to rotate according to the command

pulses, but lags behind, it is not suitable for precision control of
rotation.
 Higher cost.
 When stopped, the motor’s rotor continues to move back and forth
one pulse, so that it is not suitable if you need to prevent vibration.

Servomotors are used in applications such as machine tools,

packaging, factory automation, material handling, printing converting,
assembly lines, and many other demanding applications robotics, CNC
machinery or automated manufacturing.

Induction motors:

Induction motors use shorted wire loops on a rotating armature and

obtain their torque from currents induced in these loops by the changing

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Internship Report.
magnetic field produced in the stator (stationary) coils.

Advantages of Induction Motor:

 Squirrel Cage Induction motors are cheaper in cost compared to Slip

Ring Induction motors.

 Requires less maintenance and rugged construction. Because of

the absence of slip rings, brushes maintenance duration and cost
associated with the wear and tear of brushes are minimized

 Squirrel Cage Induction Motors requires less conductor material than

slip ring motor, hence copper losses in squirrel cage motors are less
results in higher efficiency compared to slip ring induction motor

 Squirrel cage motors are explosion proof due to the absence of

brushes slip rings and brushes which eliminates the risks of sparking.

 Squirrel Cage motors are better cooled compared to slip ring

induction motors

 Squirrel cage motors operate at nearly constant speed, high over load
capacity, and operate at better power factor.

Squirrel Cage Induction Motor Disadvantages:

Some of disadvantages or demerits of squirrel cage induction motors are

listed below:

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Internship Report.
  Main disadvantage of squirrel cage induction motor is that they have
poor starting torque and high starting currents. Starting torque will
be in the order of 1.5 to 2 times the full load torque and starting
current is as high as 5 to 9 times the full load current. In slip ring
induction motors, higher starting torque can be attained
by providing an external resistance in the rotor circuits during
starting of the slip-ring induction motor. This arrangement in slip-ring
induction motors also reduces the high inrush currents during
starting of induction motor.

 Squirrel cage induction motors are more sensitive to the supply

voltage fluctuations. When the supply voltage is reduced, induction
motor draws more current. During voltage surges, increase in voltage
saturates the magnetic components of the squirrel cage
induction motor.

 Speed control is not possible in squirrel cage induction motor. This is

one of the major disadvantages of squirrel cage induction motors.

 The total energy loss during starting of squirrel cage motor is more
compared to slip ring motors. This point is significant if the application
involves frequent starting

Production Section:
(Simonazzi Bottle Washer / Krones Plant):

Simonazzi Bottle Washer:

Manufactured by: ITALY

Bottle washing rate: 66000 bph

Standards:
Caustic tank-1: 1.5-2.0% Temp. Tank-1; 65-750C

Caustic tank-2: 2.0-3.0% Temp. Tank-2; 70-750C

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Internship Report.
Caustic tank-3: 1.5-2.0% Temp. Tank-3; 60-650C

Total chlorine in final rinse water 1-3 ppm

Soft water hardness<15ppm

Rinse Jet Pressure 1.5 bar

WASHING
1. Washing is done by the washer packets and there are about 68 lifters in a
single liter. There are 424 lifts in the whole assembly and the caustic soda is
used for washing of the bottles inside the tank.
2. In the first section the bottles are treated with 1.5-2% caustic soda at a
temperature of about 50’C. High temp is maintained by steam.
3. In the second section the bottles are treated by 2.5% caustic and the temp
is raised to about 60’C.
4. In the third section the bottles are treated with 2.5-3% soda and the temp
is raised to about 80’C.
5. After that the bottles are rinsed with soft water at room temperature to
lower down the high temp.
6. This process is done slowly so that bottles may not crack due to sudden
cooling.
7. In last 3 tanks the LE and AI agents are used for rinsing and also they
remove caustic from the bottles.

The total time consumed is about 17’25”. Bottles remain in detergent for about 7
mints and then detergent contact is for about 10’59’’.

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Internship Report.
Test Frequency:

 Jet Pressure 1-Hourly

 Temperature Caustic Conc. 1-Hourly
 Water Hardness 2-Hourly
 Caustic carry over 2-Hourly
 Methylene blue test 2-Hourl

LINE NO.7:

Krones Plant (250 ML RGB & PET):

Krones is a German packaging and bottling machine manufacturer. It
is the world’s leading manufacturer of lines for filling beverages in plastic
and glass bottles or beverage cans. The company manufactures stretch
blow-molding machines for producing polythene terephthalate (PET)
bottles, plus filters, labellers, bottle washers, pasteurizers, inspectors, packers
and palletizer’s.

Production Rate: 52000 bph for 250 RGB

Process description:
Glass bottles are washed, filled and then packed to carats in this line. First
the bottles are taken inside the hall where the labor men collect all the straws
and the wrapers (if any) from the bottles and then they are sent to the
decamedics. Decamedics take the bottle out of the carat working on the principle
of suction of the air from the inside membranes at a pressure of about 7psi.
These bottles are then passed to the conveyers which move the bottles to the
washer line and carats are moved to a steel machine where they are washed with
warm water and all the garbage is removed from the cases. After then they are
moved to the decmedics and the bottles coming from filling section are inserted
in them again.

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FILLING:
Bottles are washed and then entered the filling room where the labor men
observe the bottles and the cracked or the bottles having any impurities are
removed from the conveyers and then bottles are moved to the filling section.

Bottles are then entered into the filling machine which moves at a high
speed filling about 58,000 bottles per hour.

Washing is done in the following 4 processes:

1. Flushing (removing air)

2. Pressurization (4.5 bar)
3. Filling (after sensor senses the bottle)
4. Snifting

After this the bottles are filled and moved to caps section where they are caped
with crowns and then moved back to the conveyers where the bottle liquid level

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is checked and the codes are checked by the labor men.

BOTTLE TESTS:
 CO2 test (carbo QC)
 Density measure (Brix)

Anton Paar Density meter (Brix Test). Anton Paar (Latest).

CarboQC For Co2 Test.

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CIP (Clean in Place):-
3-Step CIP:

i) Flushing:

Circulation of treated water at room temperature for 20-25

ii) Sanitizing:

Circulation of hot water at 850C for 20-25 min.

iii) Rinsing:

Circulation of treated water at room temp. for 20-25 min.

Frequency of 3-Step CIP:

On every product flavor change over.

5- Step CIP:
1) Pre-Rinsing:Circulation of treated water for 5-15 min.

2) Cleaning:

Circulation of 1.5to 2.5% caustic soda solut at 50-700C for 20-25 min.

3) Intermediate Rinsing:

Circulation of treated water for 5-15 min.

4) Sanitizing:

Circulation of hot water at 850C for 20-25 min.

5) Final Rinsing:

Circulation of treated water at room temp. For 20-25 min.

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LINE NO.8:
In Hall no. 8 there are 4 scaled pet bottles that can be produced
simultaneously.

1. 500ml
2. 1000ml
3. 1500ml
4. 2250ml

The bottles are first blown inside the blower room and then they are gone to
the labeller. Bottles are then sent to the filler section where first bottles are
washed with soft water and then they are filled with the beverage.

VARIOPAC:
Bottles coming from the filling sections are then packed into the polyethylene
sheets which are rolled around the pack of 6 pet bottles. They are then conveyed
to then oven where the temp is about 180’C to stiffen the sheet around the
bottle. These packed bottles are then moved to the multi divider where the
bottles are divided into specific arrangements so that the pallets formed may not
fall or waste the bottles. This operation is carried out by the palletizer which then
arranges the bottles in layers form. These layers are then moved to the robot
pack which packs these layered bottles into a long polyethylene sheet by
revolving around the pack. Which are then moved to depots.

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Blower Room:
First the pet bottle is in the form of a preform that has different mass ranges
about the capacity of the bottle.

1. 25g for 500ml

2. 36/39g for 1000ml
3. 45/48g for 1500ml
4. (45g is used in winter season when pressure inside the bottle is moderate
whereas in summer the pressure is increased so 48g is used)
5. 54g for 2250ml

The bottle is blown inside the mold. Preform is first sent to the oven where the
temp is carried at about 100-120’C after the hot preform is sent inside the mold
which carries about 7bar pressure at first stage and then 40 bar pressure s applied
to the bottle so that bottle may not burst. Bottle is then showered with room
temperature water so that bottle may slowly cool down and moved to the labeller

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section by the help of air conveyers.

BOTTLE TESTS:
 A.S.C (Ascelated stress cracking)
 Bursting
 Top load
 Fill point
 Height gauge
 Hot wire cutter
 Wall thickness

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