Internship Report COKE

COCA-COLA PLANT LAHORE PAKISTAN LTD
Internship Report
Submitted By: Wasim Abbas
BEC-FA07-085
Submitted Date: 20 October 2010
Company: Coca Cola Beverages
Comsats institute of information technology Lahore campus

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Dedication
We dedicate all our efforts to
Almighty Allah,
The creator of universe
And
The holy prophet (P.B.U.H

The cause of the creation of the universe.
To our parents
The symbol of love and kindness
And
To our teachers the light of knowledge in darkness of ignorance
To our friends
The pillars of trust and support
And
To our relatives
The motivators and encouragers.
Acknowledgement
We are thankful to Almighty Allah who has blessed us with the courage, strength and wisdom so that we
have been able to complete this internship report, with the help of He has bestowed upon us.
I would like to express my gratitude to the people who have helped and supported me
throughout my stay at the plant. I am extremely grateful to all the esteemed engineers
and operators of Coca-Cola Beverages Pakistan Ltd. Lahore for their valuable
suggestions and help.

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Table of Contents
INTRODUCTION TO THE ORGANIZATION----------------------------------------------------------
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Water Treatment Plant---------------------------------------------------------------------------------------

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Pretreatment:--------------------------------------------------------------------------------------------------20
Pretreatment of scaling:--------------------------------------------------------------------------------------20
Pretreatment at CCBPL:-------------------------------------------------------------------------------------
20
Filtration:------------------------------------------------------------------------------------------------------21
Disinfection:--------------------------------------------------------------------------------------------------21
Softening process:--------------------------------------------------------------------------------------------21
Water Treatment:-------------------------------------------------------------------------------------------- -22
RO plant:----------------------------------------------------------------------------------------------------- -22
Fundamentals of Reverse Osmosis:---------------------------------------------------------------------- -22
Membrane Assembly:---------------------------------------------------------------------------------------22
RO Process at CCBPL Lahore:----------------------------------------------------------------------------23
Procedure:-----------------------------------------------------------------------------------------------------23
2 Stage RO Process:------------------------------------------------------------------------------------------23
3 Stage RO Process:------------------------------------------------------------------------------------------24
Storage Tanks:-------------------------------------------------------------------------------------------------24
Carbon Purifiers:----------------------------------------------------------------------------------------------24
Polishing Filtration:-------------------------------------------------------------------------------------------24

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Backwashing:-------------------------------------------------------------------------------------------------- 24
Tests carried out at Water Treatment-----------------------------------------------------------------------25
Hardness Determining Tests:--------------------------------------------------------------------------------

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Troubleshooting-----------------------------------------------------------------------------------------------
28
Types of Troubleshooting:-----------------------------------------------------------------------------------29
How to avoid Trouble from Occurring:--------------------------------------------------------------------29
Basic Terminologies:----------------------------------------------------------------------------------------- 31
Brix:-------------------------------------------------------------------------------------------------------------31
Concentrate:----------------------------------------------------------------------------------------------------31
Activated Carbon:---------------------------------------------------------------------------------------------31
Master Mixing Instructions (MMIs):-----------------------------------------------------------------------31
Simple Syrup:-------------------------------------------------------------------------------------------------31
Simple Syrup Preparation-----------------------------------------------------------------------------------

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Continew:------------------------------------------------------------------------------------------------------33
Dump Stations:------------------------------------------------------------------------------------------------33
Storage Tanks:-------------------------------------------------------------------------------------------------33
Types of Mixers:---------------------------------------------------------------------------------------------- 34
Cleaning In Proces (CIP):------------------------------------------------------------------------------------

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Working of CIP Unit:-----------------------------------------------------------------------------------------35
Use of CO2:-----------------------------------------------------------------------------------------------------35
Bottle Making Process----------------------------------------------------------------------------------------

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Bottle Processing Equipment:-------------------------------------------------------------------------------

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Procedure:------------------------------------------------------------------------------------------------------
37
Husky Operation:----------------------------------------------------------------------------------------------38
Sidel Operation:------------------------------------------------------------------------------------------------39
Lab Analysis:---------------------------------------------------------------------------------------------------
39
Tests Of Preforms:---------------------------------------------------------------------------------------------40
Tests Of Bottles:-----------------------------------------------------------------------------------------------40
Waste Water Treatment:--------------------------------------------------------------------------------------

42
Definition:------------------------------------------------------------------------------------------------------42
Purpose:---------------------------------------------------------------------------------------------------------44
Lab Analysis:---------------------------------------------------------------------------------------------------44
QUALITY CONTROL LABORATORY:-----------------------------------------------------------------

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RAW MATERIALS INSPECTION:-----------------------------------------------------------------------46

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INTRODUCTION TO THE ORGANIZATION
Coca-Cola laid the foundation of the beverage industry when it was formed in May 1886 in
Atlanta by Dr. John Syth Pemberton. First glass sold for 5 cents at Jacob’s pharmacy in Atlanta.
May 29, 1886 first news paper advertisement pronounced it “Delicious and Refreshing”. In 1894
Coca-Cola opened its first syrup manufacturing plant outside Atlanta in Dallas Texas. However
it was not until 1895 that the idea of selling Coke in bottles was introduced. With the passage of
time Coca-Cola gained popularity and its product began to get recognized internationally. Thus
from its more beginning in 1886 Coca-Cola has now been transformed into a strong
multinational with its product being currently recognized all over the World. Coca-Cola, infect,
has now become one of the most famous and widely consumed brands in the world. It has not
only established its footings in the beverage industry but is currently heading the list of the most
financially sound companies in the world.
History of Coca-Cola International:
The Coca-Cola Company is rich with history. Since 1886, we’ve been working to refresh people
everywhere.
Coca-cola year by year

1886
The trademark "Coca-Cola" name and script are registered with the U.S. Patent and Trademark
Office. Dr. Pemberton's partner and bookkeeper, Frank M. Robinson, suggested the name and
penned "Coca-Cola" in the unique flowing script that is famous worldwide today. Mr. Robinson
thought "the two C's would look well in advertising."
1891
Atlanta entrepreneur Asa G. Candler acquires complete ownership of the Coca-Cola business for
$2,300. Within four years, his merchandising flair helps expand consumption of Coca-Cola to
every part of the nation.

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1893
The trademark "Coca-Cola" name and script are registered with the U.S. Patent and Trademark
Office. Dr. Pemberton's partner and bookkeeper, Frank M. Robinson, suggested the name and
penned "Coca-Cola" in the unique flowing script that is famous worldwide today. Mr. Robinson
thought "the two C's would look well in advertising."
Coca-Cola began as a fountain product, but candy merchant Joseph A. Biedenharn of Mississippi
was looking for a way to serve this refreshing beverage at picnics. He begins offering bottled
Coca-Cola, using syrup shipped from Atlanta, during this especially busy summer.
1894
Coca-Cola began as a fountain product, but candy merchant Joseph A. Biedenharn of Mississippi
was looking for a way to serve this refreshing beverage at picnics. He begins offering bottled
Coca-Cola, using syrup shipped from Atlanta, during this especially busy summer.
1895
"Coca-Cola is now drunk in every state and territory in the U.S." - Asa Candler

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1898
The Company outgrows its facilities and a new building is erected at Edgewood Avenue and
College Street—later to be called "Coca-Cola Place." This year, the Company enters the markets
of Canada and Mexico.
1899
Large-scale bottling becomes possible when Asa Candler grants exclusive rights to Joseph B. Whitehead
and Benjamin F. Thomas of Chattanooga, Tennessee, for one dollar. The contract marks the beginning of
The Coca-Cola Company’s unique independent bottling system that remains the foundation of Company
soft-drink operations. Within 20 years, the regional bottling system will grow to include 1,000 bottlers,
with operations in Cuba, Puerto Rico, Panama, the Philippines and Guam.
1906
Cuba and Panama become the first two countries outside the U.S. to bottle Coca-Cola.
1915
Around this time, bottles used by companies in the soft-drink industry are very similar. And
Coca-Cola has many imitators, which consumers are unable to identify until they take a sip. The
answer is to create a distinct bottle for Coca-Cola, one that anyone would recognize, even if it
was felt in the dark. As a result, the genuine Coca-Cola bottle with the contour shape now known
around the world is developed by the Root Glass Company of Terre Haute, Indiana. It replaces
the straight-sided bottle, giving Coca-Cola a distinct packaging advantage over the imitations.
1919

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The Coca-Cola Company is sold for $25 million to Atlanta banker Ernest Woodruff and a group
of investors. The same year, the Company's stock is first sold to the public at $40 a share. One of
these original shares was worth about $6.7 million at the end of 1998 (assuming all dividends
were reinvested).
1920
The Coca-Cola Company establishes a manufacturing operation in France. U.S. Supreme Court
Justice Oliver Wendell Holmes rules that Coca-Cola is a single thing coming from a single
source and well-known to the community.
1923
Robert W. Woodruff, son of Ernest Woodruff, becomes president of The Coca-Cola Company.
His insistence on quality and more than six decades of leadership take the business to unrivaled
heights of commercial success, making Coca-Cola an institution the world over.
1926
The Foreign Department becomes a subsidiary later known as The Coca-Cola Export
Corporation.
1928
Annual bottled Coca-Cola sales exceed fountain sales for the first time. Also this year, Coca-
Cola makes its first Olympic appearance when 1,000 cases of Coke accompany the U.S.
Olympic Team to Amsterdam.
1929
Sixty-four bottling operations are located in 28 countries, spreading refreshment worldwide.
Also this year, the fountain glass is adopted as standard, and "The Pause that Refreshes" first
appears in the Saturday Evening Post.
1933
The automatic fountain dispenser is introduced at the Chicago World's Fair. By simply pulling a
handle, soda jerks can now serve uniform, properly refrigerated Coca-Cola.

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1936
This year, The Coca-Cola Company observes its 50th anniversary. A three-day bottlers'
convention, a motion picture chronicling the Company's early years, and even a special
anniversary logo are part of the celebration.
1941
"Every man in uniform gets a bottle of Coca-Cola for 5 cents, wherever he is and whatever it
costs"—Robert Woodruff. Also this year, the trademark "Coke" first receives equal prominence
in advertising with "Coca-Cola."
1942
"It's the Real Thing" is first used in Coke advertising. On December 25, The Coca-Cola Company, in
cooperation with the War and Navy Departments, sponsors a special 12-hour radio broadcast to more than
142 stations. Titled "Uncle Sam's Christmas Tree," the program featured 43 popular orchestras live from
43 widely scattered military bases in the U.S.
1943
On June 29, General Dwight Eisenhower dispatches a cablegram requesting a shipment of 3 million
bottles of Coca-Cola and complete equipment for bottling, washing, refilling and capping twice monthly.
1944
The Coca-Cola Company is rich with history. Since 1886, we’ve been working to
1945

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"Coke" is registered as a trademark by the U.S. Patent and Trademark Office.
1950
Edgar Bergen and his sidekick Charlie McCarthy appear on the first live network television show
sponsored by The Coca-Cola Company.
1955
The 10-, 12-, and 26-ounce king-size and family-size bottles are introduced with immediate
success. Fanta is launched in Naples, Italy. Today, Fanta is the #1 orange soft drink in the world.
1960
Metal cans like the ones sent to troops during the Korean War are now available on market
shelves everywhere. Also this year, The Coca-Cola Company purchases The Minute Maid
Company.
1961
Sprite, the lemon-lime drink, is introduced to the public.
1963
The Company introduces TAB, its first low-calorie drink, and "Things Go Better with Coke" can
be seen in a variety of advertisements.
1969
"It's the Real Thing" makes a comeback.
1971
Young people from around the world gather on a hilltop in Italy to sing "I'd like to buy the world
a Coke."
1976
"Coke Adds Life" campaign is introduced.
1977

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The unique contour bottle, familiar to consumers everywhere, is granted registration as a

trademark by the U.S. Patent and Trademark Office, an honor awarded to only a few other
packages
1979
Coke introduces "Have a Coke and a Smile," a campaign of heartwarming emotion best captured
by the television commercial featuring "Mean" Joe Greene, a tackle on the Pittsburgh Steelers
football team.
1981
Roberto C. Goizueta is elected chairman of the Board of Directors and chief executive officer of
The Coca-Cola Company. He will lead the Company for 16 years.
1982
The Coca-Cola Company introduces diet Coke to U.S. consumers, marking the first extension of
the Company's most valuable trademark to another product. And the "Coke is it!" theme is
translated and tailored to reach consumers everywhere as it is launched worldwide.
1985
In April, after extensive taste testing, the Company introduces a new taste for Coca-Cola in the
United States and Canada—"new" Coke. Consumers respond with an unprecedented outpouring
of loyalty and affection for the original formula, and the Company listens. In July, the Company
reintroduces the original formula for Coca-Cola, as Coca-Cola classic. Also this year, Cherry
Coke is introduced.
1986
In the year of the Company's 100th anniversary, two large U.S. bottlers combine to form Coca-
Cola Enterprises. Over time, this new company will assume responsibility for bottling operations
in Great Britain, France, the Netherlands and Belgium.

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1988
An independent worldwide survey confirms that Coca-

Cola is the best known, most admired trademark in the
world.
1989
The Coca-Cola Company sells Columbia Pictures to Sony Corporation.
1990
World of Coca-Cola, an attraction featuring a historical and futuristic look at Coca-Cola as well
as a chance to sample The Coca-Cola Company products from around the world, opens in
Atlanta.
1994
M. Douglas Investor is elected president and chief operating officer of The Coca-Cola Company.
1996
Coca-Cola sponsors the Summer Olympics in the hometown of The Coca-Cola Company:
Atlanta, Georgia. And the Cisneros Bottling Company, the largest soft-drink bottler in
Venezuela, switches from Pepsi to Coca-Cola.
1997
World of Coca-Cola Las Vegas opens, complete with a hundred-foot-tall Coca-Cola contour
bottle. The Coca-Cola Company sponsors the Winter Olympics in Nagano, Japan, marking the
70th anniversary of the Company's Olympic partnership. New products Citra and Surge hit the
market. And M. Douglas Ivester is named chairman of the Board of Directors and chief
executive officer of The Coca-Cola Company. He is the tenth chairman of the board in the
Company's history.

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1998
Sales of Coca-Cola and other Company products exceed 1 billion servings per day.
2000
Doug Daft elected Chairman and Chief Executive Officer.
2001
In October 2001 the isotonic sports drink PowerAde was launched, followed by the introduction
of other brands including diet Coke with Lemon, Coca-Cola Vanilla and diet Coke Vanilla.
2004
In 2004, Fanta Apple Splash, our first low sugar brand, was launched.
In 2004 The Coca-Cola Company's share of the carbonated soft drinks category in Great Britain
was 45.3%, and market share of the non-alcoholic beverages was 9.9%. Source: Canadian 2004
2005
In 2005, we launched our fifth diet Coke variant, diet Coke with Lime, and relaunched our range
of diet fruit carbonates (Fanta, Sprite, Lilt and Dr Pepper) as the 'Z', for zero added sugar, range.
We also introduced a new Fanta choice - Fanta Summer Fruits. Another new development in
2005 was the reformulation of Oasis to reduce the sugar content. These developments meant that
by the end of 2005, over 35% of our sales by volume were either low in sugar or diet/light
drinks.
We also launched a sports water - Powerade Aqua+, a new sports water drink with natural fruit
flavours that is free from artificial sweeteners and preservatives.
2005 also saw the launch of brand new choices in the form of Nestea - an iced tea drink, plus a
range of juice and juice drinks under the Minute Maid brand.
2006

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In February 2006, we launched Relentless, a new energy drink - our 21st brand in Great Britain.
On 8th May 2006 we celebrated 120 years of inspiration at The Coca-Cola Company. During
this time the Company has evolved from one product - Coca-Cola - to more than 400 brands in
2006.
In July 2006 we launched Coca-Cola Zero, our biggest brand launch in over two decades. Coca-
Cola Zero has the great Coke taste but with zero sugar.
Coca-Cola Beverages Pakistan Limited: (CCBPL)
Coca-Cola Company started its operation in Pakistan in 1953, at Karachi. This beverage
industry in Pakistan, currently having a size of little over 120 million cases per annum with an
annual growth of around 10-15 per cent, has the potential to double its size in the next 3-5 years.
The beverage industry at the moment has very low per capita consumption of 20 serves whereas in other
countries of our region it varies from 120-250 on the basis of single serve of 250 ml.
Business Areas:
In Pakistan, there are 11 territories where the franchised units produce and sell Coca-
Cola. Some of these territories are:
1: Lahore
2: Karachi
3: Rawalpindi
4: Peshawar
5: Hyderabad
6: Multan
7: Rahim Yar Khan
Regions and Areas

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Out of the 11 territories 8 territories have been purchased by Coca-Cola International

now in Pakistan. Now most of them have operated by the company itself. The Coca-Cola
Company is a global business enterprise that is active in some 200 countries of the world. In
Pakistan, as in each country where it operates, the Coca-Cola Company has very much a local
business. This is the guiding philosophy, which has made the company the proud holder of
several most widely recognized brands in the world. The company’s beverages are produce
locally by Coca-Cola Beverages Pakistan Ltd, which was registered in 1996 and employ
Pakistani citizens and whose products range and marketing reflects Pakistani tastes and
lifestyles.
Products
The Coca Cola Beverages Pakistan has a very narrow product range. It has the following
brand in Pakistan.
 Coca Cola
 Sprite
 Fanta Orange
 Diet Coke
 Sprite Zero
 Sprite 3G
These products are sold in the market in different size of bottles. The sizes are available for all its
products.
 250 ml
 250 ml (Non Returnable)
 500 ml PET
 1.5 PET
 2.25 PET
The Lahore plant:

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The plant is currently running three RGB (returnable glass bottles ) lines ,three PET
(polyethylene terephthalate )plastic bottles lines of 500 mL ,1.5 mL and 2.25 mL bottles. The
capacities of each line is as follows:
Line 1 : 320 bottles / min
Line 2 : 264 bottles /min.
Line 3 : 264 bottles/min
Line 4 : 12480 bottles/hr (500 mL)
Line 5 : 38000 bottles/hr (when running 1.5 L)
Line 5 : 28000 bottles/hr (when running 2.25 L)
Line 6 : 22000 bottles/hr (500 mL)
PRODUCTS OF THE COMPANY
The products of The Coca-Cola Company touch lives everywhere. Our core brands have made
an impact around the world; brands such as Fanta, Sprite and of course, Coca-Cola, are available
and recognized in many countries. Each of our other brands are distributed in one or more
countries, and is tailored to the cultures and tastes of those consumers. So wherever you are,
you're sure to find a Coca-Cola product to enjoy.
Fanta: -

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A favorite in Europe since the 1940s, Fanta was acquired by The

Coca-Cola Company in 1960. Fanta Orange is the core flavor,
representing about 70% of sales, but other citrus and fruit flavors
have their own solid fan base.
Consumers around the world, particularly teens, fondly associate

Fanta with happiness and special times with friends and family.
This positive imagery is driven by the brand's fun, playful
personality, which goes hand in hand with the bright color (particularly orange), bold fruit taste,
and tingly carbonation.
Fanta sells best in Brazil, Germany, Spain, Japan, Italy and Argentina. Fanta distribution was
increased in the U.S. in 2001 with the return of four flavors: orange, strawberry, pineapple and
grape. Orange, the biggest seller, is now available in most of the country.
Sprite:
Introduced in February 1, 1960 Sprite is the world's leading

lemon-lime flavored soft drink. Sprite is sold in more than 190
countries and ranks as the No. 4 soft drink worldwide, with a
strong appeal to young people.
Millions of people enjoy Sprite because of its crisp, clean taste

that really quenches your thirst. But Sprite also has an honest,
straightforward attitude about things that sets it apart from other
soft drinks. Sprite encourages you to be true to who you are and to obey your thirst.

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Maaza:
"Yaari-Dosti Taaza Maaza"
With the real fruit taste kids love, plus added calcium, Maaza's
tagline, "Yaari-Dosti Taaza Maaza" means "Friendship
moments with fresh Maaza" in Hindi.
Maaza was introduced in India in 1984 as a noncarbonated

mango fruit drink. It was acquired by The Coca-Cola Company
in 1993 and is currently available in three flavors, mango,
pineapple and orange -- plus added calcium.
Coke:

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Coca-Cola C2 (also referred to as Coke C2, C2 Cola, or simply C2) is a cola-flavored beverage
introduced by The Coca-Cola Company first in Japan, then later on June 7, 2004 in the United
States (and shortly thereafter, Canada), in response to the low-carbohydrate diet trend. The Coke
product was marketed as having half the carbohydrates, sugars and calories, compared to
standard Coke. It contains aspartame, acesulfame potassium, and sucralose in addition to the
high fructose corn syrup typically found in cola beverages distributed in America. It is an
alternative option for those who prefer the taste of Coke to Diet Coke, with a taste very close to
traditional Coca-Cola but only half the calories. Aside from the high fructose corn syrup, one 12-
ounces can of Coca-Cola C2 contains 19 mg of aspartame, 4 mg of sucralose and 19 mg of
acesulfame potassium. The packaging design differs from other Coke products in that fonts are
printed in black. For marketing on radio and television, the Queen song "I Want to Break Free"
was used. When it was first introduced though, the Rolling Stones song "You Can't Always Get
What You Want" was used.

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Water Treatment Plant
Pretreatment:
The purpose of pretreatment is to optimize the performance and the life of the RO membrane.
Pretreatment performs the following tasks:
1. Insure the compatibility of feed stream with the RO membrane.

2. Reduce or eliminate the potential for scale formation in RO membranes.
3. Reduce the RO cleaning frequency by reducing the fouling potential of the feed stream.
The proper treatment scheme for feed water depends on Feed water source, Feed water
composition and Application. The type of pretreatment system depends to a large extent on feed
water source (i.e., well water, surface water, and municipal wastewater). In general, well water is
a consistent feed source that has a low fouling potential. Well water typically requires a very
simple pretreatment scheme such as acidification and/or antiscalant dosing and a 5-μm cartridge
filter.
Pretreatment of scaling:
In order to minimize precipitation and scaling, it is important to establish well-designed scale

control measures and avoid exceeding the solubility limits of sparingly soluble salts. In an RO
system, the most common sparingly soluble salts encountered are CaSO4, CaCO3, and silica.
Other salts creating a potential scaling problem are CaF2, BaSO4, and SrSO4. There are
different methods in order to reduce or eliminate the membrane scaling some of them are given
below:
 Acid injection.
 Softening process.
 Scale inhibitor injection.
 Ion exchange technique.
Pretreatment at CCBPL:
At Coca Cola Beverages Pakistan Ltd, Lahore, water is obtained from the three
underground turbines. Turbine 3 supplies water for the beverage production and is sent to the
water treatment plant. Turbine 1 and 2 supplies raw water and water for softening and several

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other purposes. At ccbpl the pretreatment for the RO process is performed in two step, they are
as under;
1. Filtration
2. Disinfection
Filtration:
There are four sand filters, at the plant that preforms the operation of pretreatment before
RO Process. These sand filters contains large stones at the bottom, and as we move above the
size of stones become smaller and smaller and the top they have small sand particles. Through
this assembly water is made to pass, and due to this process raw water is purified. Then sent to
RO Plant for further purification.
Disinfection:
For the purpose of disinfection, chlorine is being used at the plant, but it is added after the
water is being purified by RO Process, because chlorine is harmful for the membranes. While,
antiscalants are added before it enters the RO Process to avoid formation of scale on the
membrane that may cause clogging.
Softening process:
There are two softening tanks at CCBPL plant Lahore, which removes hardness of water
and make it suitable for bottle washing purpose. The tanks contain Na-Zeolite resin. Sodium-
Zeolite (NaZ) softening is an ion exchange-based process designed to remove hardness (calcium
and magnesium) from raw water. NaZ softening will remove other soluble cation species such as
iron and copper and will act as a filter for small suspended solids. Strong Acid Cation (SAC)
resin is used to provide ion exchange removal of the hardness (Ca & Mg).
Once Na-Zeolite is exhausted it is first back washed and then regenerated by brine
solution i.e. solution of NaCl i.e present in another tank nearby.
Ca-Zeolite + 2NaCl Na2–zeolite + CaCl2

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Water Treatment:
RO plant:
Fundamentals of Reverse Osmosis:
Reverse osmosis is a filtration process that is often used for water. It works by using
pressure to force a solution through a membrane, retaining the solute on one side and allowing
the pure solvent to pass to the other side. This is the reverse of the normal osmosis process,
which is the natural movement of solvent from an area of low solute concentration, through a
membrane, to an area of high solute concentration when no external pressure is applied.
Formally, reverse osmosis is the process of forcing a solvent from a region of high solute
concentration through a membrane to a region of low solute concentration by applying a pressure
in excess of the osmotic pressure.
The membranes used for reverse osmosis have a dense barrier layer in the polymer matrix where
most separation occurs. In most cases the membrane is designed to allow only water to pass
through this dense layer while preventing the passage of solutes (such as salt ions).
Osmosis describes how solvent moves between two solutions separated by a

semipermeable membrane to reduce concentration differences between the solutions. When two
solutions with different concentrations of a solute are mixed, the total amount of solutes in the
two solutions will be equally distributed in the total amount of solvent from the two solutions.
Instead of mixing the two solutions together, they can be put in two compartments where they
are separated from each other by a semi-permeable membrane. The semi-permeable membrane
does not allow the solutes to move from one compartment to the other, but allows the solvent to
move. Since equilibrium cannot be achieved by the movement of solutes from the compartment
with high solute concentration to the one with low solute concentration, it is instead achieved by
the movement of the solvent from areas of low solute concentration to areas of high solute
concentration. When the solvent moves away from low concentration areas, it causes these areas
to become more concentrated. On the other side, when the solvent moves into areas of high
concentration, solute concentration will decrease. This process is termed osmosis. The tendency
for solvent to flow through the membrane can be expressed as "osmotic pressure", since it is
analogous to flow caused by a pressure differential.
In reverse osmosis, in a similar setup as that in osmosis, pressure is applied to the compartment
with high concentration. In this case, there are two forces influencing the movement of water: the
pressure caused by the difference in solute concentration between the two compartments (the
osmotic pressure) and the externally applied pressure.
Membrane Assembly:

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RO Process at CCBPL Lahore:

At water treatment section of CCBPL Lahore, there are 3 RO
units, the first two are 3-stage while the last one is 2-stage, having a capacity of cleaning 55m 3/hr
and 30m3/hr of water, respectively.
Procedure:
1. When the plant is switched on, there is one minute UV

flushing, and then two minutes flushing is carried out for
the membranes automatically.
2. Then antiscalant is added to water, to avoid formation of
scales on the membranes, that may cause chocking.
3. Then after flushing pump starts, water first passes through
UV radiations for killing of bacteria. Figure 1: Cartridge filter
4. Then water passes through the cartridge filter, it contains
19 filters having length of 40in and a pore size of 5
microns.
2 Stage RO Process:
1. It consists of five vessels.

2. Each vessel has six membranes.
3. The process is divided into two stages, first water enters into three vessels simultaneously
and pure water is obtained in product line while the rejected water is sent to the
remaining two membranes.

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4. Similarly, they also send the pure water to product line and send the rejected water to
drain line, so that is drained
5. Hence the process is completed in two steps.
3 Stage RO Process:
1. The construction is similar to the 2 Stage RO Process. the only difference is that water
purification takes place in three steps over here.
2. It contains 10 vessels
3. First water is sent to six vessels simultaneously. Similarly, the pure water is sent to
product line and rejected water is sent to three other vessels.
4. Their pure water is sent to product line and rejected water is sent to the last vessel, which
try to filter that water and the water which is still not filtered is drained off.
5. Hence filtration is carried out in three stages.
Storage Tanks:
The filtered water form all three RO units is stored in two storage tanks having the capacity of
60000litres each. Before, entering the tanks chlorine is added by chlorine dozing pumps to kill
bacteria. From here the water is pumped to carbon purifiers.
Carbon Purifiers:
Carbon Purifiers consist of carbon resting on stones. The size of stones inside the carbon
purifiers decreases as we move from bottom to top and at top we have carbon granules. They are
extremely useful in removing any off odour or residual chlorine present in treated water.
Polishing Filtration:
In the final step treated water is passed through filter bags of pore size 20 to 40 microns and
finally through polishing filters with a pore size of 5 to 20 microns. The purpose of this filtration
is to remove any carbon particle from water that may flow with it through carbon purifiers.
Backwashing:
Definition:
In terms of water treatment, backwash refers to the reversal pumping of water, and
sometimes intermittent with compressed air, through the process. Filters get dirty and must be
maintained. Filters can be rapid sand filters, pressure filters, granulated activated carbon (GAC)
filters etc. To keep them functional, they have to be washed periodically.
Explanation:

26
The process, called "backwashing," involves several steps. First, the filter is taken off
line and the water is drained down to the filter bed. Then, the air wash cycle is started which
pushes air up through the filter material causing the filter bed to appear to boil. This breaks up
the compacted filter bed and forces the accumulated particles into suspension. After the air
wash cycle stops, the backwash cycle starts with water flowing up through the filter bed. Clean
water is passed through the filter bed in order to wash the material and remove most of the
accumulated particles. This cycle continues a fixed time or until the turbidity of backwash water
is below a set value. In some cases, the additional step of air/water wash (simultaneously) is done
after air wash cycle and followed by rinse water wash. These use less water compared to
traditional step and have higher removal efficiency which results in the cleaner filter.
Backwashing is a form of preventive maintenance to prevent further clogging of the filter

medium. Backwashing in water treatment plants is an automated process, usually run
by programmable logic controllers (PLCs). The backwash cycle is usually triggered when the
differential pressure over the filter exceeds a set value.
Tests carried out at Water Treatment
To check the quality of water and to check whether water treatment process is going right
or there is something wrong, a number of chemical tests, at certain points are carried out.
Following tests are performed at water treatment plant of CCBPL, Lahore according to
their own standards and methods.
1. Total alkalinity test

2. Residual chlorine tests
3. pH of water
4. Total Dissolved solid
5. Dissolved Oxygen test
6. Chloride test
7. Water hardness
8. Iron test
9. Turbidity test
10. Caustic percentage test

27
Alkalinity Test
Purpose
The purpose of this test is to determine the total alkalinity of raw water and
treated water.
Residual Chlorine Test
Purpose
The purpose of chlorine test is to find out the amount of Cl2 in water.
pH of Water
Purpose
The purpose of this test is to determine the concentration of hydrogen ions in

water.
Dissolved Oxygen Test
Purpose
The purpose of this test is to determine the amount of oxygen dissolved in

water.
Hardness Determining Tests:

Total Hardness:
In order to determine total hardness the following test is carried out;
Take 100ml of the sample water from RO Plant, add 2ml hardness buffer, then
add few drops of Erichrome Black T as an indicator and titrate it against
EDTA solution. The amount of EDTA used tells us about total hardness
present in ppm.
It was found to be zero for water sample taken from RO Plant.
 Ca hardness:

28
In order to determine Ca Hardness the remaining chemicals are same as in

determining total hardness the only difference is the that here we use Ammonium Perpurate
as an indicator.
It was also found to be zero.
Iron Test
Purpose
Purpose of this test is to detect the iron in treated water, in filtered water and in
raw water.
Turbidity in Water
Purpose
The main purpose of this test is to determine the effectiveness of disinfection,

because at the low turbidity disinfection is more effective than at high turbidity. This test
also tells us about the carbon and san filter leakage and also the floc carry over of treated
water.
At water treatment plant of CCBPL, Lahore some chemical tests related to washers are
also carried out. Because water treatment operator is responsible for washing/rinsing quality
control tests and will inform to washer operator to quantities of caustic and addiditives require to
be added in washers for maintain concentrations within defined limits.
Caustic Test
Purpose
The percentage of caustic in each washer tank is very important for effective
washing, sterilization, and avoiding caustic carry over in the bottles.
Stabalon Test

29
Stabalon is used for the purpose of shining of glass bottles. It is added in the main
tank of every washer.
Purpose
The purpose of this test is to check the percentage of stabalon in main tank.
Total Dissolved Solids(TDS):
Purposes
The purpose of this test is to determine the total dissolved solid present in water.
In this test a TDS sensor is placed in a beaker containing sample water, adjust the meter
at same temperature at which water is being processed and get the reading. It was found
out to be 0.14mg/L.
Troubleshooting
Troubleshooting can be defined as the problem occurring with our unit operation of interest due
to some upstream equipment or processing, or some unfamiliar or unknown problem occurring
with our unit operation.
Here we will be specifically discussing the troubleshooting occurring in Reverse Osmosis

system. How they we can identify the problem, find its source and find a solution for it. We will
also discuss that how we can avoid these troubleshooting and what precautionary measures can
be taken to identify and handle them properly.

30
Types of Troubleshooting:
i). One which can be handled on site. Without removing the system from its position.
ii). One for which the equipment is removed from the site. It could involve the replacement
of whole equipment or replacement of its damaged parts.
But before going into these types first we will go through those steps or methods by using which
we can avoid the troubleshooting for a Reverse osmosis system.
How to avoid Trouble from Occurring:
Below are given few methods, by following them we can avoid the troubles occurring with
Reverse Osmosis system. They include some design parameters and some precautionary
measures.
1) Designing the R.O (Reverse Osmosis) system in such a way that the operator has access
to whole water analysis of the R.O system. The R.O system should be able to provide
whole analysis, for example about the inlet and outlet streams, and there should be points
on the R.O system at critical location from where we can determine the composition of
the flowing stream. A data base should also be kept with which the analysis could be
compared. Like there are seasonal variations in the composition and amount of dissolved
solids in the surface water sources. Mostly such types of variations do not occur in
industrial water treatment plants.
2) Pulsating flow of the liquid can be used to stop the deposition of particles on the surface
of the membrane and providing greater filtration area.

31
3) One of the easiest way to avoid the troubles from occurring in your R.O system is the
choice of right type of module. While choosing a membrane few points should be kept
in mind like the maximum flow rate, Temperature, Pressure , Particle mean size, pH of
the fluid which is to be handled, upstream process and working conditions etc.
4) In a certain designs the Cross flow velocity of the feed stream and permeate stream is
maximized. A cross flow velocity reduces the concentration of salts and flocculants (in
some cases) at the membrane surface by increasing their diffusion back into bulk feed
stream above the membrane surface. Shearing effect is also used to tear of the particles
deposited on the membrane surface due to high cross flow.
5) Controlling the rate of flow of water through the membrane like an R.O taking water
from a clean well can be designed and handled more aggressively than an R.O system
taking surface water. The membrane should not be overloaded or operated at low flow
rates. It should be operated at optimum condition as instructed by designer given in
operators manual.
6) One reason due to which R.O system starts malfunctioning is not carrying out the proper
pretreatment of water. Proper pretreatment of the water should be carried out before
entering it in to R.O system.
7) Proper startup procedure should be followed while starting the R.O system. This is
provided by the company.
8) Proper cleaning and flushing of the membrane should be carried out after certain time,
change in the composition of the permeate below required level or change in the flow
rate of permeate.
THE SYRUP ROOM:

Syrup Making Process

32
Basic Terminologies:
Brix:
Degrees Brix (symbol °Bx) is a measurement of the dissolved sugar-to-water mass ratio of a

liquid. A 25 °Bx solution is 25% (s/w), with 25 grams of sugar per 100 grams of solution. Or, to
put it another way, there are 25 grams of sucrose sugar and 75 grams of water in the 100 grams
of solution. It is measured with a saccharimeter that measures specific gravity of a liquid or
more easily with a refractometer.
Concentrate:
Term refers to the liquid parts containing the flavouring components, colouring and acids
manufactured by company concentrate plant used in the preparation of the Coca-Cola syrup and
beverages.
Activated Carbon:
Carbon having increased adsorptive properties generated by special chemical and thermal
treatment. Activated carbon removes colour, off odour and off taste compounds from the syrup.
Master Mixing Instructions (MMIs):
The written formulation of the specified instructions for manufacturing final syrup and
beverages of company.
Simple Syrup:
A solution of nutritive sweetness in treated water after filtration and before the addition
of concentrate or beverage base.

33
Simple Syrup Preparation
At ccbpl syrup is manufactured by two methods i.e cold process and hot process. But the process
being used these days is the cold process, which is explained below.
 Sugar is added into the hopper manually , screw conveyer takes it to the mixing tank
where heated water after passing through the tube heat exchanger is mixed with sugar.
 Firstly the dissolving tank is filled 10% with treated water, i.e 400 liters of 4000 liters and
then turn on the sugar hopper and maintain a brix of the required level.
 This solution is then passed to UV unit to kill the microorganisms.
 After UV unit, this solution is taken to bag filters which are also known as security filters
having a pore size of 10micron.
 Bag filters are basically used to filter the dust particles.
 After bag filters this solution is carried to heat exchanger where this solution is cooled to
20oC using ethylene glycol which is itself cooled by ammonia.
 This solution at 20oC is then stored in simple syrup storage tanks and is ready to use for
final syrup preparation.
The hot process is as follows:
 Sugar is added into the hopper manually , screw conveyer takes it to the mixing tank
where heated water after passing through the tube heat exchanger is mixed with sugar.
 This solution enters T100 after passing through two strainers.
 The brix of the solution is checked in T110.
 Then syrup from T110 goes to plate heat exchanger i.e. H300 which rises its temperature
to 85⁰C. This is done to kill micro-organism or bacteria present in the syrup i.e.
pasteurization.
 Then the syrup is transferred to T200.
 Then the syrup passes through filters F210 where cake filtration is done, and
diatomaceous earth is used for filtration purpose.
 Then syrup is transferred to T230.
 The syrup then again passes through F240 where polypropylene bags are used for further
filtration.
 Then the temperature of the syrup is lowered to 20⁰C, by passing it through H320.
 Finally, the syrup is ready to be mixed with concentrate. For the purpose it is stored in
storage tanks from where it can be sent to Continew, Dump station A or B.
Continew:

34
Continew is used for the preparation of the of syrup of coke only, because both of its
concentrate are liquid parts.
Construction:
It has four tanks two are larger one and the remaining two are smaller ones. The former
contains water and simple syrup, while the latter contains concentrate part A and B. A
flow meter and a pump is attached to lines coming out from each tank and entering into
the mixer.
Mixer is funnel shaped contain all the components of final syrup to be mixed, it is
also provided with the brix meter. Then a pump pushes this syrup into final syrup storage
tanks from where it can be attached to any lineon demand.
Dump Stations:
There are two dump stations i.e. A and B, and they are used to prepare the concentrate of
all the other flavours other than coke, because the other flavours contains liquid part as well as
the solid part.
Construction:
The dump station has two parts , each have a tank and a hopper attached to it. The
purpose of the hopper is to add solid part in it, press the clutch and it will move toward the tank
where it mixes with water and then transferred to the storage tank. The liquid part is added
directly to the tank and transferred to the storage tank where all these parts mix with simple
syrup. This result in the formation of final syrup which can be sent through any line to the filler.
A control panel is attached to all these dump stations. There are four buttons to operate these
dump stations, they are;
a) End
b) Open valve
c) Start pump
d) Send concentrate
Storage Tanks:
There are 14 total tanks in the syrup room of CCBPL, Lahore. Out of them six are
operated by previous system and eight are new and are operated by the new system. Right
now five are operational.

35
Types of Mixers:
There are two types of mixers:
1. Jet Mixers:
New tanks which are operated by metico system have jet mixers in them. The
purpose of these mixers is to mix final syrup homogeneously. Jet mixer contains a
pump at bottom that takes the fluid from bottom and shower it from above, due to
this process mixing takes place.
2. Agitator Mixer:
Older tanks have agitator mixers in them. They have a
long shaft which is attached to an agitator at bottom and
has a motor at top that makes it to rotate, when switched
on.
Figure 2: Agitator Mixers
Cleaning In Place (CIP):

CIP or Cleaning In Place is auto-washing of tanks and lines after their use.
There are two types of sanitations;
a) 3-Step
b) 5-Step
Normally, 3-step sanitation is used when we just want to clean a tank or line. We use 5-step
sanitation when we have to prepare sugared syrup after syrup that does not contain sugar e.g.
If we want to prepare a syrup of coke after diet coke.
Construction:
CIP unit has four tanks of 20,000litres having four different components .i.e.,
I. Fresh water
II. Recovery water
III. Hot water
IV. Caustic soda
There are three CIP units, the purpose of having three units is that we can operate all of them at
same time, this result in cleaning or sanitataion of three tanks or lines simultaneously. All of
them have same construction.

36
Working of CIP Unit:
When we want to clean a tank we connect its CIP line line to the main CIP supply panel
and its syrup line to CIP recovery.
I. 3-step Sanitation:
 Recovered water is showered for 300 seconds.
 Then hot water is showered for 900 seconds.
 Finally, last water i.e. fresh water is showered for again 300 seconds.
II. 5-step Sanitation:

 Recovered water is showered for 300 seconds.
 Then caustic solution is showered for 1200 seconds.
 Fresh water is showered for again 300 seconds.
 Then, hot water is showered for 900 seconds.
 Finally the last water i.e. fresh water is made to pass for 300 sec.
This is how CIP is done of all the tanks and lines in the syrup room
Use of CO2:
CO2 is used in syrup room to clean or remove if any syrup present in the lines or tank.
Actually what happen is that CO2 at high pressure is made to pass through the lines and tanks
involved in syrup making process. Due to its high pressure it carries water and syrup present in
small amount. Hence by doing so it completely clears the line or tanks.
Bottle Making Process
Raw material used for the manufacture of bottles is PET.
Polyethylene terephthalate (sometimes written poly(ethylene terephthalate)), commonly

abbreviated PET, PETE, or the obsolete PETP or PET-P), is a thermoplastic polymer resin of

37
the polyester family and is used in synthetic fibers; beverage, food and other liquid containers;
thermoforming applications; and engineering resins often in combination with glass fiber.
Figure 3: chemical structure of PET
Bottle Processing Equipment:
Blow molding, also known as blow forming, is a

manufacturing process by which
hollow plastic parts are formed. It is a process
used to produce hollow objects from
thermoplastic.
In general, there are three main types of blow

molding: extrusion blow molding, injection
blow molding, and stretch blow molding.
The blow molding process begins with melting

down the plastic and forming it into a parison
Figure 4: Injection moulding machine
or preform. The parison is a tube-like piece
of plastic with a hole in one end in which compressed air can pass through.
The basic process has two fundamental phases. First, a preform (or parison) of hot plastic resin in
a somewhat tubular shape is created. Second, a pressurized gas, usually air, is used to expand the
hot preform and press it against a mold cavity. The pressure is held until the plastic cools.
Procedure:
The resin is first dried before it is sent to injection mounding machine. The moisture of
the resin is dried up before it is sent to the melting unit. We fill the hopper with resin upto certain
level, and electrically heated hot air is made to pass from bottom to top and this process is
carried out for 6 to 7 hours till the resin is completely dried up. Air takes that moisture and goes
to resin drier. Here we have bed of Silica Gel and they adsorb the moisture from air. Then dry air

38
again goes to heater then to hopper. This circle continues and dried resin is sent to chamber
where melting is done.
There are two basic moulding methods for PET bottles, one-step and two-step. In two-
step moulding, two separate machines are used.
 Two Step Moulding:
The first machine injection moulds the preform. The preform looks like a test tube. The bottle-
cap threads are already moulded into place, and the body of the tube is significantly thicker, as it
will be inflated into its final shape in the second step using stretch blow molding.
In the second process, the preforms are heated rapidly and then inflated against a
two-part mould to form them into the final shape of the bottle. Preforms (uninflated
bottles) are now also used as containers for candy.
 One Step Moulding:
In one-step machines, the entire process from raw material to finished container is
conducted within one machine, making it especially suitable for moulding non-standard
shapes (custom molding), including jars, flat oval, flask shapes etc. Its greatest merit is
the reduction in space, product handling and energy, and far higher visual quality than
can be achieved by the two-step system.
Bottle Making Process at CCBPL:
At CCBPL, Lahore they observe two step process for the manufacturing of bottles i.e the
machine used for making performs is known as ‘husky’ machine and the machine that is used for
preform blowing purpose is ‘sidel’ machine. The two machines are explained below:
Husky Operation:
In this operation bottle preforms are manufactured. Resin is used as raw material for
manufacturing of preforms. Resin is up lifted into the hopper through vacuum, 40-50 mmHg
vacuum is required for up lifting of resin. From hopper resin is pumped into drier, where

39
temperature is maintained at 175oC. In drier there is silica gel which absorbs the moisture from
the resin. The dry resin is then pushed to the injection molding machine or heat chamber by
hydraulic pressure, where temperature is maintained at 280-290 oC that melts the dry resin. Here
color dozing is done for Sprite preforms.
PET Preforms
In husky machine there is an installing cone plate, the melted mold is pushed into
installing cone plate where preforms are formed. Circulation of cold water (6-7 oC) from chiller is
also in process here, which reduces the temperature of mold and as a result preforms are formed.
In one stroke 72 preforms are formed. The ejection stroke cylinder eject the preforms, and the
ejected performs are collected and placed in bins and cartons.
At CCBPL, Lahore only 1500ml bottles are manufactured. The preforms manufactured at
Lahore plants are also supplied to other plants, like Rahim Yar Khan, Gujranwala, and
Faisalabad. While preforms of 500ml and 2500ml are supplied to Lahore plant by other plants
for manufacturing of 500ml and 2500ml bottles.
Sidel Operation:

40
In this operation bottles are manufactured from the preforms in sidel machine or bottle
blowing machine. The preforms are feed into preform hopper from where they are up lifted to
orentator drive and then are pushed into unscumbler drive through preform elevator. From
unscumbler preforms are move towards the oven one by one in a single line. When oven gains
the desired temperature of 100oC, then preforms are entered into the oven.
Oven
There are two ovens in the bottle blowing machine; distribution oven and penetration
oven. Each oven contain 36 rod lamps of 2500 watts each, these lamps increase the temperature
of oven. For different size and shapes of bottles different temperature is set. When preforms gain
the desired temperature, are moved towards wheel.
Wheel
There are eight rods in the wheel; these rods lengthened the preforms to the required size
by applying pre-blow pressure. Then the lengthened preforms are passes to the moulds of
required shape and size, where pressure of 40bar is applied in each preform, due to this huge
pressure bottles are formed from the preforms. Circulation of cold water (8-9 oC) from chiller
reduces the temperature of bottles.
Lab Analysis:
To check the quality of perform and bottles there is a lab setup near the bottle processing
machines. Here, various tests are carried out to check whether the quality of bottle meets
international standards or not. If it does it is sent to the filler otherwise disposed off.
Tests Of Preforms:
The list of tests carried out here to check the quality of preforms is as follows:
1. Visual Inspection:
Polarized light is used here to check cracks or bubbles in the performs.

41
2. Weigh the Preforms: Preforms are weighed on the weighing balance, and the weight
should be in limits i.e 28g for 500ml bottle, 48g for 1.5ltr, 54.5g for 2.25ltr.
3. Perpendicularity Test:
In this test they check whether the preform is straight or not.
4. Wall Thickness Test: In this test wall thickness is checked, whether it is of uniform
thickness or not.
5. IV Test:
The lab staff makes sure that the PET used has an IV of 0.82.
6. Gas Chromatography:
Gas Chromatography is done to check that PET shouldn’t contain acetaldehyde
more than15µg/g. because it is carcinogenic.
Tests Of Bottles:
1. Section weights:
Hot wire cutter is used to obtain various sections. There are four sections
 Base
 Label
 Body
 Shoulder
They are separately weighed to check that material is properly distributed throughout or not.
2. Visual inspection:
It includes:
 It should be colourless i.e. transparent.
 Gate area shouldn’t be off centre.
 External diameters are checked
 PCO 28mm neck
3. Exterior Dimension Test:

This test is designed to ensure that PET bottles comply with the
dimensions and allowable tolerance specified on the respective bottle design
drawing.
4. Finish Dimension Test:

42
The purpose of this test is to ensure that all thread finishes on bottles and
preforms comply with the dimensions and allowable tolerances specified on the
respective bottle design drawing.
5. Perpendicularity Test:
The perpendicularity test is designed to ensure that the plastic bottles stand
upright in an orientation that is completely perpendicular to the bearing surface
on which they stand.
6. Caustic Stress Crack Test:

This test is designed to determine the level of resistance of a PET bottle to
Sodium hydroxide (NaOH) induced stress cracking. A bottle that has more
resistant to NaOH attack should be more resistant to stress crack initiators that a
bottle may be exposed to during its lifetime. (One known mode of stress crack
attack on plastic bottles is by hydroxide ion).
7. Drop Impact Resistance Test:

This test is designed to ensure that plastic bottles filled with carbonated water
will meet minimum performance specification for vertical drop under cold and
ambient conditions.
8. Top Load Test:

Here a load of 20kg is applied to check the strength of bottles.
9. Burst Test:
Here water along with air at 12 bar pressure is filled inside the bottle to check its
pressure resistant ability.

43
10.ASC (accelerated stress crack test):

Accelerated Stress Crack test is done to check the base of the bottle because
bottles usually burst due to the weakness of this area.
After all these tests it is assured that the bottle is perfectly fine to be used for beverage selling
purpose.
Waste Water Treatment:

Definition:
Process that modifies wastewater characteristics such as its biological oxygen demand
(BOD), chemical oxygen demand (COD), pH, etc., to enable it meets effluent standards.
At CCBPL, Lahore for the waste water treatment they use Active Sludge Process.
Active Sludge Process:
The activated-sludge process is a biological method of wastewater treatment that is

performed by a variable and mixed community of
microorganisms in an aerobic aquatic environment.
Components:
I. Reception Sump
II. Balancing tank
III. CTP unit
Reception Sump:

44
Reception Sump collects only two type of water Process water and sanitary water,
because only they are treated before discharging to water bodies. The purpose of Reception
Sump is only to receive dirty water and pump that water into Balancing Tank.
Balancing Tank:
Here we have bacteria that is not a harmful one, it actually facilitates in avoiding water
pollution. To allow them to multiply, we have to provide them the proper environment. We add
supplements such as DAP and Urea, for maintaining the pH of this alkaline water we add some
acid to neutralize it and along with it we also have to blow oxygen in all the three tanks with the
help of air blowers. The bacterial action reduces harmful organic materials and converts them
into harmless biological floc. The combination of raw sewage (or industrial wastewater) and
biological mass is commonly known as Mixed Liquor. This liquor is then transferred to main
CTP tank.
CTP Tank:
When the mixed liquor enters the Compact Treatment Plant Tank here a polymer is added
that acts as a flocculant, as a result of which sludge is formed that is heavier and settles down.
While clean water remains at top and this clean water is discharged into the water bodies. Part of
the settled material, the sludge, is returned to the head of the aeration system to re-seed the new
sewage (or industrial wastewater) entering the tank. This fraction of the floc is called Return
Activated Sludge (R.A.S.). Excess sludge which eventually accumulates beyond what is returned
is called Waste Activated Sludge (W.A.S.). W.A.S is removed from the treatment process to
keep the ratio of biomass to food supplied (sewage or wastewater) in balance. This is called the
F:M ratio. W.A.S is stored away from the main treatment process in storage tanks and is further
treated by digestion, either under anaerobic or aerobic conditions prior to disposal.
Fish pond:
There is a fish pond that is used to demonstrate that water which is being discharged is perfectly
fine for aquatic life.
Purpose:

45
 In a sewage (or industrial wastewater) treatment plant, the activated sludge process can
be used for one or several of the following purpose:
 Oxidizing carbonaceous matter: biological matter.
 Oxidizing nitrogenous matter: mainly ammonium and nitrogen in biological materials.
 Removing phosphate.
 Driving off entrained gases carbon dioxide, ammonia, nitrogen, etc.
 Generating a biological floc that is easy to settle.
 Generating a liquor low in dissolved or suspended material.
Lab Analysis:
To check whether the water being discharged meets the standards or not, for that purpose
there is laboratory setup that carries out test after regular intervals.
Tests Carried Out at Wastewater Treatment Laboratory

 Sludge Volume
Sludge Volume is a visual measurement of the volume of sludge accumulation
when mixed liquor is allowed to settle for half an hour.
 Dissolved Oxygen Test
Dissolved O2 is measure of oxygen present in an aqueous solution such as mixed
liquor. In the activation sludge process the cultivation of microorganisms is very
much dependent on the presence of adequate quantities of oxygen (derived from
aeration) in the mixed liquor.
 pH Test
To maintain the pH level between 7-8, is tested after short intervals of time.
 BOD Test

46
Biochemical Oxygen Demand is a measure of quantity of oxygen absorbed by a

volume (in liter) of an effluent stream over a fixed period of time (5 days) under
standard condition. It is expressed in mg/l.
 COD Test
Chemical oxygen demand is a measure of quantity of oxidizing agents expressed
in terms of oxygen absorbed by a volume (in liter) of an effluent stream over a
period of 2 hrs under 150oC temperature. It is also expressed in mg/l.
Tests Duration:
 Determination of pH
After every hour
 Determination of DO
 Determination of TSS
 Determination of TDS After every 2 hours
 Determination of BOD
 Determination of COD After every 15 days
Every week
QUALITY CONTROL LABORATORY:

Here the quality tests are performed on the beverage bottles so that the final product is fine
enough to be sent in the market, that is it should meet the quality standards of the ccbpl plant.
The following tests are performed on the final bottle:
 Date code is checked e.g,

RP 24.36+ST 4.14
RS 28.50 UC U4 0710
BB 06 NOV 10
 Taste: the bottle taste is checked, it should be fine and according to the standards.
 Odor: there should not be any odor present in the bottle. It should smell fine.
 Appearance: appearance of the bottle should be according to the standards.
 Container condition: container condition is examined. It should also be fine and
according to the standards of ccbpl.
 Target brix (line brix) comparison
 Carbo QC: it tells the volume of CO2 dissolved in the final beverage

47
 Density meter: it tells the brix level of the final beverage, and it’s very important to have
the brix (sugar concentration) under the required limit i.e the brix level of all the flavours
are given below:
Coca-cola: 10.370 brix
Fanta: 12.900 brix
Sprite: 10.000 brix
Sprite 3G: 12.00o brix
 Crown Crimpage: Crown’s fixing is checked so that the gas doesn’t leak out.
 Net Contents: Net contents are calculated to see the filled bottle level and it
should be under limits i.e 1.5% for 1.5lts and 2.25lts and 2.5% for 500ml and
250ml.
 Torque test: bottle’s opening and closing is checked in this test, i.e how much
torque is needed to open or close the pet bottle.
 Secure seal test (SST): in this test final beverage bottle is pressurized and
sustained for about one minute at a pressure of 100 to 150 psia, if no bubbling of
carbon-dioxide occurs then the bottle’s seal is secured otherwise not.
Concentration of sweetner in sprite zero is determined by titration method

and in diet coke is determined by UV spectrophotometry.
RAW MATERIALS INSPECTION:

The carbonated beverage industry is vitally interested in quality of water, syrup, and
final beverage. At Coca-Cola Beverages Pakistan Limited (CCBPL), Lahore the quality
related tests are carried out at quality control laboratory. Each and every raw material is
very important at its place, so there is a need to inspect every raw material very
carefully in order to maintain the quality standards of ccbpl. Raw materials are
classified in three stages i.e.
1. Primary raw materials
2. Secondary raw materials
3. Tertiary raw materials

48
a. The raw materials used at ccbpl Lahore plant are as follows:

1. Sugar
2. Carbon-dioxide
3. Wooden pellets
4. Crowns
5. Closures
6. Plastic crates(PET lab)
7. Packing trays for NRB
8. Shrink Wrap(PET lab)
9. Labels(PET lab)
10. Cardboard pads(PET lab)
4. For sugar testing, the following tests are preformed:
5. Odor test
6. Turbidity
7. Taste
8. Odor after acidification
9. The lab chemists take 1kg sugar as a sample and perform the above mentioned tests in
order to meet the quality control standards.
10. Similarly, the tests for carbon-dioxide are as follows:
1. Zahm test: This test is performed to check the purity level of carbon-dioxide in a tank,
and the purity level should be above 99.9% If not then the tank is rejected and sent back.
This test is performed by using an apparatus which is known as zahm’s testing apparatus.
2. Taste test: To check that the gas should taste according to the standards and no unwanted
taste should be present.
3. Snow test: This test is performed to check the purity of the gas that is there should be no
extra smell or particles present in the gas as in oil particles or any other impurities.
4. Acetaldehyde test: This test is performed to see that is there any traces of acetaldehyde present
in the gas.

49
5. References:
6. http://www.lenntech.com/troubleshooting-of-reverse-osmosis-membrane.htm
7. http://www.lenntech.com/wwtp/wwtp-activated-sludge-process.htm
8. http://en.wikipedia.org/wiki/Activated_sludge
9. http://encyclopedia.airliquide.com/Encyclopedia.asp?GasID=26
10. http://en.wikipedia.org/wiki/reverse-osmosis-membrane-working
11. http://en.wikipedia.org/injection-moulding-machine
12. Wastewater Engineering Treatment and Reuse by (Metcalf and Eddy)

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COCA-COLA PLANT LAHORE PAKISTAN LTD

Comsats institute of information technology Lahore campus

We dedicate all our efforts to

The creator of universe

The holy prophet (P.B.U.H

The symbol of love and kindness

To our teachers the light of knowledge in darkness of ignorance

The pillars of trust and support

The motivators and encouragers.

Comsats institute of information technology Lahore campus

Water Treatment Plant---------------------------------------------------------------------------------------

Water Treatment:-------------------------------------------------------------------------------------------- -22

Fundamentals of Reverse Osmosis:---------------------------------------------------------------------- -22

RO Process at CCBPL Lahore:----------------------------------------------------------------------------23

Comsats institute of information technology Lahore campus

Tests carried out at Water Treatment-----------------------------------------------------------------------25

Hardness Determining Tests:--------------------------------------------------------------------------------

How to avoid Trouble from Occurring:--------------------------------------------------------------------29

Master Mixing Instructions (MMIs):-----------------------------------------------------------------------31

Simple Syrup Preparation-----------------------------------------------------------------------------------

Cleaning In Proces (CIP):------------------------------------------------------------------------------------

Working of CIP Unit:-----------------------------------------------------------------------------------------35

Bottle Making Process----------------------------------------------------------------------------------------

Comsats institute of information technology Lahore campus

Bottle Processing Equipment:-------------------------------------------------------------------------------

Waste Water Treatment:--------------------------------------------------------------------------------------

QUALITY CONTROL LABORATORY:-----------------------------------------------------------------

RAW MATERIALS INSPECTION:-----------------------------------------------------------------------46

Comsats institute of information technology Lahore campus

INTRODUCTION TO THE ORGANIZATION

History of Coca-Cola International:

Coca-cola year by year

Comsats institute of information technology Lahore campus

Comsats institute of information technology Lahore campus

Comsats institute of information technology Lahore campus

Comsats institute of information technology Lahore campus

Comsats institute of information technology Lahore campus

"Coke" is registered as a trademark by the U.S. Patent and Trademark Office.

Comsats institute of information technology Lahore campus

The unique contour bottle, familiar to consumers everywhere, is granted registration as a

Comsats institute of information technology Lahore campus

An independent worldwide survey confirms that Coca-

Comsats institute of information technology Lahore campus

Comsats institute of information technology Lahore campus

Coca-Cola Beverages Pakistan Limited: (CCBPL)

7: Rahim Yar Khan

Regions and Areas

Comsats institute of information technology Lahore campus

Out of the 11 territories 8 territories have been purchased by Coca-Cola International

The Lahore plant:

Comsats institute of information technology Lahore campus

Line 1 : 320 bottles / min

Line 2 : 264 bottles /min.

Line 3 : 264 bottles/min

Line 4 : 12480 bottles/hr (500 mL)

Line 5 : 38000 bottles/hr (when running 1.5 L)

Line 5 : 28000 bottles/hr (when running 2.25 L)

Line 6 : 22000 bottles/hr (500 mL)

PRODUCTS OF THE COMPANY

Comsats institute of information technology Lahore campus

A favorite in Europe since the 1940s, Fanta was acquired by The

Consumers around the world, particularly teens, fondly associate