INTERNSHIP

REPORT
Lines 5-8 and RO Plant

Submitted by: Hamza Shahid Paracha

Submitted to: Engr. Hassan Kafil
Submitted on: 22nd July 21, 2019
 Haidri 2

Line 5 RO
PET line Plant

Line 6 Line 7 Line 8

PET line PET line Bulk line

LINE 5:
 Has a speed of 24000 bottles per hour
 Machines of 3 companies are used: KRONES, Sidel and Hifei
 Less efficient than line 6 as it is older so uses outdated machines with less
electronics and more mechanical operations
 Due to less efficiency, the beverage is at a lower temperature than at line 5
in order to main the CO2 requirement
1. Line 5 uses a C2 blow mold with mechanical operations, i.e. a cam shaft
used to rotate the spindle. Whereas the C3 model uses an electric motor to
rotate it.
2. There are 14 molds on the blow mold. The lamps are used to heat and
soften the preform and then air pressure is used to mold it into bottles.
3. When the cool mold touches the hot preform a vapor can be seen coming
out of the bottles.
4. Using an air conveyor, the bottles are moved to the labeler. This is where
line 5 differs from lines 1 and 6, the labelling is done before the filling.
5. At the labeler, a sensor senses the eye mark and cuts portions of the film
roll.
6. Before filling, CO2 is filled to check leakages and when the pressure of the
bottle is equal to the pressure of the bowl, the bottle is filled using
mechanical fillers instead of electronic flow controllers like in line 6.
7. The bowl contains 30% beverages and 70% CO2 pressure.
 8. The filling process contains 3 parts: CO2 pressurization; filling (using an
umbrella-like jet; snifting/decompression and then capping. The excess CO 2
is removed from the bottle and some of it is recirculated.
9. The bottles are warmed up and dried to a temperature of 22 degree
Celsius.
10.The SMI SK 452P machine shrink wraps the bottles into packets of 6 or 12
and then the palletizer stacks them into several layers.

LINE 6:
 The fastest line in the factory with a speed of 36000 bottles per hour.
 Used Ergo block machinery in which the 3 machines are synced so if one
faces an issue then all three are stopped. xxx
 The CIP (cleaning-in-pipes) uses a 3-step process instead of 5, i.e. cold
water; Divo flow and then again cold water.
 The syrup arrives in a pipe and in mixed with CO2 and water (carbonated
water). Glycol is used for cooling purposes.

1. Preform arrives in bulk from another manufacturer.

2. The hopper collects some specific amount of preform bottles and loads it
onto the elevator.
3. The elevator brings the preform bottle to a certain height from where the
process starts.
4. There is also a cap hopper, elevator and conveyor with the same process,
that brings the caps to the capper head.
5. A feedback sensor senses unaligned preform bottles and separates them
from the rest.
6. A roller sorter stops the movement of the preform bottles if an unaligned
bottle still passes by the feedback sensor undetected.
7. The Ionizer sucks all the air from the bottle to remove dust.
8. The neck inspection chamber checks the ovality of the necks and discards
the defected ones.
9. The preform enters the blow mold, which is at a temperature of 106-120
degrees Celsius.
 10. A stretch rod is inserted into the preform and, using air at a pressure of
about 30 bar, the preform is expanded into the shape of the mold. There
are 18 molds on the rotating spindle.
11. Water circulates through the mold, cooling the bottle, but the base still
remains warm so base cooling is done using a jet of air.
12. The bottle is then expanded before labelling so that no wrinkles appear on
the label.
13. The label cutter cuts the labels and glue is applied at the glue station. The
glue is at a temperature of about 40 degree Celsius.
14. Another base cooling is done, this time using water.
15. Before filling, CO2 is filled into the bottle so check for leakages. If the
pressure of the bottle is equal to that of the bowl then the bottle is filled.
The filler has 144 valves/dies.
16. By providing a torque, the caps are added onto the bottles. There are 18
dies at the capper head.
17. The checkmat checks for two conditions: underfilling of the bottle and
improper placement of the cap.
18. Next the coder imprints a detailed code onto the surface of the bottle.
19. The flow liner distributes the bottles coming in a single row into 3-4 rows
to reduce the speed of their movement.
20. In the Variopac, a plastic sheet is wrapped around the bottles after
arranging them in groups of 6 or 12. An oven and blower tightly wraps the
sheet onto the bottles.
21. The palletizer stacks the packs in numerous layers with trays in between.
Using sensors, two pushers stack the packs in alternate cycles onto the
transfer carriage/universal present.
22. The robo wrap/stretch wrap wraps the pallets using a sheet of plastic and
is then placed on the pallet magazine to be moved and stored using
forklifts. Each pallet contains 68 packets and 7 layers.

LINE 7:
 Produces Aquafina in the sizes 500ml and 1500ml
 The blow mold is of the company Sidel and the filler and capper machines
are of KRONES.
 The line has a production speed of 9750 bottles per hour
  The water is at room temperature

1. A hopper collects a specific amount of preform bottles and places them on

the elevator that takes the preform to a specific height from where the
process begins.
2. The preform enters the blow mold. Using 2 catchers and a rotating spindle,
a stretching rod is inserted into the preform and using pressurized air, the
preform is expanded into bottles corresponding to the mold being used.
3. Using an air conveyor, the bottles are transported to the labeler.
4. A center bell pressurizes the bottle before labeling starts in order to avoid
wrinkles in the label.
5. The labeler has a cutter drum and a glue unit that applies the label on the
bottle.
6. The bottle is rinsed with ozonated water coming out at a pressure of 2.5-3
bar.
7. The filler has 48 valves and the water flows by gravity. Nitrogen is added to
the bottle after filling it with water. This is to ensure the bottle doesn’t get
pressed during packing.
8. The capper mechanism has 12 heads.
9. Coder imprints the code onto the surface of the bottle. There are two types
of coding: ink coding on the cap which shows the best before date and
there is also laser coding which shows the details of manufacturing.
10. SMI shrink wrapper uses a blower of 165 degree Celsius. Polyfilm sheet is
used which has a thickness of 55 microns and a width of 370mm.
11. There is no automated palletizer. Palletizing and wrapping are done
manually. Each pallet contains 104 packets and 4 layers of 1500ml bottles
or 168 packets and 6 layers of 500ml bottles.

LINE 8:
 This line produces 18.9-liter bulk bottles at a speed of 500 bottles per hour.
 Old bottles arrive at the plant where they are manually checked against a
fluorescent screen like RGBs
 External washing of the bottles is done using oxofoam.
  Internal washing is then done on bars which can wash 4 bottles each. There
is a total of 40 bars in which 14 are used for washing.
 The washing consists of 5 steps: chemical wash (Diver wash); intermediate
rinsing; oxonium (detergent); rinsing with water and finally rinsing with
ozonated water.
 The filler has 4 valves.
 The capper performs two operations: first it places the cap onto the bottle,
next, it presses it to fix it in place. There is no screw cap in bulk bottles.
 Coding is imprinted onto the surface of the bottles.
 Neck sleeve is added to the bottles.
 The bottles are either placed on racks or stacked in pallets without any
wrapping. 1 rack contains 40 bottles and 1 pallet contains 23 bottles.
 CIP (Cleaning-in-pipes) unit operates in 5 steps and uses Costic. Both lines 7
and 8 are cleaned by the same unit after every period of production
although the SAP says to wait 72 hours for the next cleaning.


LINE 10:
• Tetrapak brick box is used as container
• Aseptic filling is done (free from any contamination)
• Hydrogen peroxide, MPM and paper are the raw materials
• Hydrogen peroxide is at a temperature of 70 degree Celsius and 30-50
concentration
• MPM is a thin plastic applied on the joints to stick them together and
prevent leakages or anything to enter
• The tetrapak paper has 6 layers: (out) plastic, printing, cardboard,
aluminum foil, double layer of plastic (in)
• Reel of tetra brick, when finished, is sensed by the sensor and moved to the
right. It is cut, heated and joined to the new reel and production continues.
• 1 reel contains 15,500 bricks
• The machines are also of tetrapak
• MPM applied on one edge through heat induction of the aluminum layer
• The brick goes through hydrogen peroxide bath and removes germs
• Squeezy rollers remove excess hydrogen peroxide from the paper. An air
knife removes all the hydrogen peroxide ppm using hot air of 160 degree Celsius.
A UV lamp removes the remaining microbes.
• Next is the aseptic chamber. In the forming section, paper is bent and then
joined using the MPM (using heat induction by LS heater)
• Aluminum in the paper if for strength and to allow heat induction to melt
the plastic
• Juice is filled in the whole hollow tube and then enters into the jaw unit
• Seals and cuts are made using pressure and a box shaped fixture having a
volume flap
• Seals are made using induction
• 4 air heaters heat and fold the remaining paper into a complete box
• Encoder encodes the data on the box
• Line controller syncs the whole system
• Accumulator helix improves the line efficiency by keeping some boxes in
reserve in case of stoppage
• Hot gum is used to attach the straws.
• Finger/ arm mechanism attaches the straw
• Manual packing intro trays
• Shrink wrapping is done using TS machine

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