Internship Report: Submitted To

Nestle Pakistan Ltd.
INTERNSHIP REPORT
SUBMITTED TO:
Doctor .Khurram Shehzad.
Chemical Engineering Department
SUBMITTED BY:
1.Muhammad Haris Ilyas
(fa-17-che-021), Section A
2. Muhammad Waqas Ali
(fa-17-che-103),Section A
DEPARTMENT: Liquid Dairy Department

(NESTLE KABIRWALA FACTORY)
DURATION:
14-08-20 to 11-09-20
(4 WEEKS)
27
27
PREFACE
Internship at Nestle kabirwala was an attempt to seek experience of the

corporate lifestyle of a successful multinational company. The idea was to understand
the corporate structure, while developing skills needed to thrive, of one of the leading
global multinationals whereas applying the knowledge and skills acquired during the
academic career. This wonderful experience of just 4 weeks proved to be a high
inclination in the graph of my personal learning.
27
ACKNOWLEDGMENT
First, all praises & thanks to Almighty ALLAH that I avail this opportunity for
completing this period of internship, then I pay all my respect and praises to the
greatest man of universe, Holy Prophet Muhammad ( PBUH ) for whom all this
universe was created.
I am heartily thankful to chemical engineering department that provide us the

opportunity to have internship in Nestle.
Muhammad Haris Ilyas

Muhammad Waqas Ali
CHEMICAL ENGINEERING
COMSATS
PRODUCT: Liquid Dairy

Pasteurization is the process of heating every particle
of a product to destroy pathogens. The heat treatment
system to be used depends on the properties of the
product and the results to be achieved. Here GEA
27
offers solutions for all the different requirements.

Depending on your product and the desired shelf life,
you can choose between various methods of heat
treatment, like short time heating – high temperature
(STHT), high temperature - short time (HTST), or ultra
high temperature process (UHT) by means of indirect
or direct heating.
Shelf life is the length of time that a commodity may be stored without becoming unfit for use,
consumption, or sale. In other words, it might refer to whether a commodity should no longer be on
a pantry shelf (unfit for use), or just no longer on a supermarket shelf (unfit for sale, but not yet
unfit for use).
A booster pump increases low water pressure and flow. It provides the

extra boost needed to bring your water pressure to the desired level. A water booster
pump provides pressure to move water from a storage tank or throughout a whole house or
commercial facility.
CAPACITY:
Following plants are working for UHT milk and
cream(Ultra-high temperature processing, ultra-heat treatment, or ultra-pasteurization
is a food processing technology that sterilizes liquid food by heating it above 135 °C – the
temperature required to kill bacterial endospores – for 2 to 5 seconds)
1. Milk = GEA plant having flow rate 30,000L/h

2. Cream = VTIS plant having flow rate 5,000L/h
VTIS plant:
TETRA THERM® ASEPTIC VTIS
Premium quality with direct UHT

o Low overall heat load minimizes impact on taste, colour and
nutritional value
o Suitable for a wide range of dairy and plant-based products
o Highest operational efficiency for direct UHT systems on the
market
27
Tetra Therm® Aseptic VTIS direct UHT treatment

unit
Tetra Therm® Aseptic VTIS has long represented state-of-the-art direct UHT
processing of premium quality, aseptic products. It is an aseptic processing unit
for continuous UHT treatment with direct steam injection. Mainly for heat-
sensitive low-acid products such as milk, enriched milk, cream, soy milk,
formulated dairy products, ice-cream mix, dairy desserts as well as ESL
(extended shelf life) products. The process is also suitable for smooth products
like soups, sauces, non-dairy cream and other starch based products and can
handle smaller particles.
Quickfacts
System for continuous direct UHT treatment of liquid food products
under aseptic conditions
CAPACITY
2,000 l/h to 30 000 l/h (variable capacity 1:2 is standard)
APPLICATIONS
Milk, enriched milk, cream, soymilk, formulated dairy products, ice-
cream mix, extended shelf life (ESL) products, dairy desserts, non-dairy
cream, and smooth soups and sauces.
STEAM INJECTION(PRINCIPLE OF VTIS PLANT)
Product quality and efficiency
Steam is injected rapidly into the product, instant heating it from 80° to
the UHT temperature, followed by condensation (only 0.1 seconds) and
temperature equilibrium. The combination of a high sterilization
temperature and a short heating time ensures that microorganisms and
spores are deactivated with minimal impact on the product's taste and
colour. The process also involves very low fouling, which in turn means
outstanding clean-ability, less downtime for cleaning and overall lower
cleaning costs.
Features
 Product quality and efficiency
 Minimizes impact on product taste, colour and consistency
 Minimal product losses, efficient operation and maintenance
 Low product losses
 Great energy savings potential
 Longer lifetime and exceptional efficiency
 Keeps operating costs down
27
 For longer running times
Location: Khanewal-Kabirwala Rd, Nestle Colony,

Allahabad, Kabirwala, Khanewal, Punjab 58250
27
Departments of Kabirwala Factory:

Nestlé Kabirwala is headed by the Factory Manager of
the company. Presently Mr. Raheel Afzal is performing
the services of the Factory. Directly reporting to the
Factory Manager are the fourteen major Departments
i.e.;
1. Finance & control Department
2. Human Resource Department
3. Logistics Department
4. Safety health & Environment Department
5. Industrial Performance Department
6. Engineering Department
7. IT Department
8. Application Group
9. Rec. & Standardization Department
10. Liquid Dairy Department
11. Powder & Noodle Department
12. Quality Assurance Department
13. Technical Training Department
14. Nestlé Distribution Channel
Manufacturing Processes:
27
1. VTIS(cream)(5000L/hr)
2. GEA (Milk)(30000L/hr)
1. VTIS Plant:(vacuum Thermal

instant sterilizer)(Cream)(3000L/hr)
From STD cream is obtained at 50oC because
it is viscous product thus higher temperature given to avoid high

viscosity. Pre-heaters are used to heat at 80oC and in holding tubes
147oC temperature is obtained for 5 seconds due to viscous product
and direct steam is injected in this plant and negative pressure created
to remove added steam in the form of vapors, and cooled with chilled
water up to 45oC because at this temperature filling and packaging is
done
PFD OF VTIS PLANT:
27
Careem Feed Balance Tank

M2 pump
HEATER
80oC
5000 litre/hr 55 oC
5 sec
Flash vessel Holding o
M5 pump 150 C
Tube Steam
o Injector
146 C
o Homoginizer
Cooler 75 C 80 oC
100 Bar pressure
Cooler
50 Co
Flow Diaghram of VTIS PROCESS

Balance tank:(product leaving has constant uniform
head pressure and constant supply)
The balance, or constant level tank provides a constant supply of milk.
It is equipped with a float valve assembly which controls the liquid level
nearly constant ensuring uniform head pressure on the product leaving
the tank. The overflow level must always be below the level of
lowest milk passage in regenerator.
27
Steam Injector:(main use is to rapidly and gently

heating the product temp increases to 150 and steam
condenses on surface of cream)
Steam Infusion is a direct-contact heating process in
which steam condenses on the surface of a pumpable food product. Its
primary use is for the gentle and rapid heating of a variety
of food ingredients and products including milk, cream, soymilk,
ketchup, soups and sauces.
Holding Tube:
Holding tubes provide a fixed volume of tubing to "hold" a product for a
set period of time at a given flow rate. This is required for processes, like
pasteurization, sterilization, thermal deactivation, or tempering, that
require a dwell time at a given temperature.
Sterilising time (holding period) is the time during which the

microbes themselves should be held at the given temperature
and does not include the heating up time.
27
27
Flash Vessel:(The pressure of high pressure

codensate steam which was formed is reduced to low
pressure to form flash steam by revaporization which
is then used in low pressure heating equipments)
The flash vessel is the main component in any flash recovery system. It
can be used in all steam plants where high pressure condensate is reduced
to a lower pressure , so that flash steam is formed by revaporization. This
steam can be used in low pressure process or heating equipments.
Homogenizer:(Homogenization of cream is done to

convert coarse globules into small globules and to
make uniform composition)
A homogenizer is an industrial equipment used for the homogenization of
cream.
Homogenization is a process in which coarse globules in emulsion

are converted into smaller globules of uniform composition, so that each
measured dose has the same composition. •
Aseptic Tank (Purpose):

Features:
 Maintain homogeneity of sedimentation-sensitive products
 Prevents burnt particles entering the product
 Stops contamination from outside the tank
 Increases line efficiency
 Increase workplace safety
Filling Machine:
Liquid fillers or liquid filling machines are important equipment in
various industries like cosmetics, pharmaceutical, food & beverages
industries where liquids are to be packed in various types of containers. ...
that have high viscosity and hence require this method to fill up the
containers.
27
Homogenization: It is a process in which coarse globules in

emulsion are converted into smaller globules of uniform composition, so
that each measured dose has the same composition. •
Principle:
It is based on the principle that when large globules in coarse emulsion
are passed under high pressure through a narrow orifice are broken into
smaller globules having a greater degree of uniformity and stability.
27
27
27
27
27
27
27
2. GEA Plant: (Milk)(UHT

pasteurization is the principle)
Milk is obtained from STD at 8-11oc and then brought to 136oC
for 13-15 minutes by using T.H.E. Two types of holding tubes
are using in this section
a) Pasteurizing holding tubes (95 seconds at 95oC)
b) Sterilizing holding tubes (8 seconds at 136oC)
Since cooling is done after sterilization so it is called
downstream sterilization
27
Boosters are used at 76oC temperature of milk to boost

up milk. T.H.E. is used for heating purpose i.e. indirect
heating.
After that cooling is done from 136-68oC and
homogenization is done & milk is stored in aseptic tanks from
where milk goes for filling and packaging
27
Pasteurization
is a process, that applies heat to destroy pathogens in foods. For the dairy
industry. Apply heat to specific temperature and specific time to destroy
pathogenic bacteria in food product. mainly its apply to milk and
beverage sector
 HTST Pasteurization Technique:(High

temperature short time pasteurization)
like Salmonella, E.coli Escherichia , and Listeria. HTST is the most
common pasteurization technique in the dairy industry. HTST stands
for High Temperature, Short Time. It is also known as flash
pasteurization. It is a method of pasteurizing perishable beverages like
fruit and vegetable juices, beer, and wine. This was first introduced in
1993 and observed 99.99% reduction of harmful bacteria. subjected
27
72°C (161 °F) for about 15 seconds in order to kill pathogenic

bacteria
 UHT Pasteurization (Ultra-High-

Temperature Pasteurization)
Technique UHT Pasteurization is also known as Ultra-High-Temperature
(UHT) Pasteurization. This typically involves heating milk or cream to
146 °C (284 °F) for 5 seconds. UHT is commonly used in milk
pasteurization but is also can be used for fruit juices, cream, soy milk,
yogurt, wine, soups, honey, and stews.
Basic Steps of UHT Pasteurization

Spraying the milk or juice through the nozzles into a chamber filled high
temperature steam under pressure .
After temperature reaches to 146 °C, the fluid is instantly cooled in a

vacuum chamber
Packed in pre-sterilized containers
Deaerators
A deaerator is a device that removes oxygen and other
dissolved gases from liquids:
 From Water, such as feedwater for steam-
generating boilers. Dissolved oxygen in feedwater will
cause serious corrosion damage in a boiler by attaching to
the walls of metal piping and other equipment and
forming oxides (rust). Dissolved carbon dioxide combines
with water to form carbonic acid that causes further
corrosion. Most deaerators are designed to remove oxygen
down to levels of 7 ppb by weight (0.005 cm³/L) or less, as
well as essentially eliminating carbon dioxide.[1][2]
 From products such as food, personal care, cosmetic
products, chemicals, pharmaceutical to increase the dosing
accuracy in filling process, increase product shelf stability,
27
prevent oxidative effects (discolouration, changes of smell,

taste e.g. rancidity), alteration of Ph and reduce packaging
voume.
There are many different deaerators available from a number
of manufacturers, and the actual construction details will vary
from one manufacturer to another.
There are these basic types of deaerators
Types of deaerators
 Spray type Deaerator Working Principle
 Spray & Tray-type Deaerator
 Vacuum rotating disc type deaerator
 The thermal deaerators
o The spray & tray-type (also called the cascade-type)
includes a vertical or horizontal domed deaeration section
mounted on top of a horizontal cylindrical vessel which
serves as the deaerated boiler feedwater storage tank.
o The spray-type consists only of a horizontal (or vertical)
cylindrical vessel which serves as both the deaeration
section and the storage tank for boiler feedwater.
 The vacuum rotating disc deaerators for low to high
viscous products
 The ultrasound deaerator for very viscous products
Figures 1 and 2 are representative schematic diagrams that depict each
of the two major types of deaerators.
Spray type Deaerator Working Principle
Deaeration relies on the principle that the solubility of a gas in water
decreases as the water temperature increases and
approaches saturation temperature. In the deaerator, water is heated
up to close to saturation temperature with a minimum pressure drop
and minimum vent. Deaeration is done by spraying the feedwater to
27
provide a large surface area, and may involve flow over multiple layers
of trays. This scrubbing (or stripping) steam is fed to the bottom of the
deaeration section of the deaerator. When steam contacts the
feedwater, it heats it up to saturation temperature and dissolved gases
are released from the feedwater and vented from the deaerator through
the vent. The treated water falls to the storage tank below the
deaerator.
Spray & Tray-type Deaerator
A schematic diagram of a typical tray-type deaerator.
spray-type deaerator
is a horizontal vessel which has a preheating section (E) and a deaeration
section (F). The two sections are separated by a baffle (C). Low-pressure
steam enters the vessel through a sparger in the bottom of the vessel.
27
The boiler feedwater is sprayed into section (E) where it is preheated by

the rising steam from the sparger. The purpose of the feedwater spray
nozzle (A) and the preheat section is to heat the boiler feedwater to its
saturation temperature to facilitate stripping out the dissolved gases in the
following deaeration section.
The preheated feedwater then flows into the deaeration section (F), where
it is deaerated by the steam rising from the sparger system. The gases
stripped out of the water exit via the vent at the top of the vessel. Again,
some designs may include a vent condenser to trap and recover any water
entrained in the vented gas. Also again, the vent line usually includes a
valve and just enough steam is allowed to escape with the vented gases to
provide a small and visible telltale plume of steam.
The deaerated boiler feedwater is pumped from the bottom of the vessel
to the steam generating boiler system.
27
A schematic diagram of a typical spray-type deaerator.
Vacuum rotating disc type deaerator

As shown in Figure 3, the product is spread as a thin layer on a spinning
disc via a feed pipe. The centrifugal force slings it through a perforated
cap onto the inner wall of the vessel, which is under vacuum. Air or gas
pockets are released in the process and can be drawn off by the vacuum
pump. A discharge pump carries the deaerated product to the next
machine in the production line. For very viscous products rotating disc is
replaced with static one.
27
Flash evaporation
is the partial vapor that occurs when a saturated liquid stream undergoes a
reduction in pressure by passing through a throttling valve or other
throttling device. This process is one of the simplest unit operations. If the
throttling valve or device is located at the entry into a pressure vessel so
that the flash evaporation occurs within the vessel, then the vessel is often
referred to as a flash drum. If the saturated liquid is a single-component
liquid (for example, propane or liquid ammonia), a part of the liquid
immediately "flashes" into vapor. Both the vapor and the residual liquid are
cooled to the saturation temperature of the liquid at the reduced pressure.
This is often referred to as "auto-refrigeration" and is the basis of most
conventional vapor compression refrigeration systems. If the saturated
liquid is a multi-component liquid (for example, a mixture
of propane, isobutene and normal butane), the flashed vapor is richer in
the more volatile components than is the remaining liquid.
27
Suggestion for improvement:

Here, i will suggest improvement that can be make to
prevent pollution regarding environmental issues
caused by industry.
Three different types of waste are distinguished:
(1): solid waste, which may cause problems with respect
to dumping grounds;
(2): wastewater, which may decrease the quality of
surface waters; and
(3): volatile compounds, which cause air pollution.
Several ways may be followed to reduce the occurrence
of waste:
(1): waste prevention;
(2): development of clean processing methods; and
(3): end of pipe treatment.
27
Treatment of polluted air

Prevention of waste production, as a method mentioned for solid waste and
wastewater, is an even more important method for polluted air. Compared to solid
waste and wastewater, awareness of air pollution has only recently developed. As a
result data of produced polluted air are hardly available and methods for prevention
or treatment have as yet not been developed on a wide scale. Research of methods
for treatment of polluted air is in progress.
Available reports state that air pollution from red meat processing operations is
minor, and that most problems usually involve odours from improper waste
treatment. These had better be controlled by correction of deficiencies in the
troublesome process than by attempts to treat the odorous air. Also for poultry plants
is true that a good design and good operating practices may help prevent odours.
In the dairy industry much energy is required for all kinds of activities and in particular
for cooling and heating (pasteurizing, sterilizing, vaporisation). Energy production
may lead to excessive discharge of CO2, NOx and CO. Reduction of energy
consumption leads to an decrease of the discharge of these gases.
Air pollution from tanneries and slaughterhouses may also be caused by such
components as NH3, SO2, Volatile Organic Compounds (VOC), etc. These can in
principle be removed by means of adsorption, absorption, chemical reactions,
microbial conversion. These processes often require highly sophisticated technics
and entail high costs.
Adsorption is a process in which gasses are adsorbed to solid material such as
carbon. In the case of absorption a liquid is used. Usually these physical processes
are combined with a chemical conversion process to fixate the polluting compound.
Other chemical reactions involve oxidation at high or low temperatures, reduction
with hydrogen or methane. Biodegradable compounds can be converted by micro-
organisms, suspended in water or fixated on solid material such as compost.
Waste water Treatment:
Discharged water will consume dissolved oxygen,disrupt the ecological
balance of water,and endanger the survival of fish and other aquatic
organisms.Organic substances sinking in the bottom of the water will generate
harmful gases such as hydrogen sulfide due to anaerobic
decomposition,deteriorating the environment.
Methods include advanced oxidation processing, distillation,
adsorption, ozonation, vitrification, incineration, chemical immobilisation or
landfill disposal. Some materials such as some detergents may be capable of
biological degradation and in such cases, a modified form of wastewater
treatment can be used.
Dairy Industry
Except for packing material etc. and sludge (in case of wastewater purification),
dairies do not produce solid waste. The potential use as fertilizer of stabilized sludge
from wastewater treatment plants of dairies has no environmental limitations,
provided the sludge contains no toxic compounds.
27
END REPORT
27

Internship Report: Submitted To

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Internship Report: Submitted To

Uploaded by

Copyright:

Available Formats

Nestle Pakistan Ltd.

DEPARTMENT: Liquid Dairy Department

Internship at Nestle kabirwala was an attempt to seek experience of the

I am heartily thankful to chemical engineering department that provide us the

Muhammad Haris Ilyas

PRODUCT: Liquid Dairy

offers solutions for all the different requirements.

A booster pump increases low water pressure and flow. It provides the

1. Milk = GEA plant having flow rate 30,000L/h

Premium quality with direct UHT

Tetra Therm® Aseptic VTIS direct UHT treatment

 For longer running times

Location: Khanewal-Kabirwala Rd, Nestle Colony,

Departments of Kabirwala Factory:

1. VTIS Plant:(vacuum Thermal

it is viscous product thus higher temperature given to avoid high

PFD OF VTIS PLANT:

Careem Feed Balance Tank

Flow Diaghram of VTIS PROCESS

Steam Injector:(main use is to rapidly and gently

Sterilising time (holding period) is the time during which the

Flash Vessel:(The pressure of high pressure

Homogenizer:(Homogenization of cream is done to

Homogenization is a process in which coarse globules in emulsion

Aseptic Tank (Purpose):

Homogenization: It is a process in which coarse globules in

2. GEA Plant: (Milk)(UHT

Boosters are used at 76oC temperature of milk to boost

 HTST Pasteurization Technique:(High

72°C (161 °F) for about 15 seconds in order to kill pathogenic

 UHT Pasteurization (Ultra-High-

Basic Steps of UHT Pasteurization

After temperature reaches to 146 °C, the fluid is instantly cooled in a

Packed in pre-sterilized containers

prevent oxidative effects (discolouration, changes of smell,

Spray & Tray-type Deaerator

A schematic diagram of a typical tray-type deaerator.

The boiler feedwater is sprayed into section (E) where it is preheated by

A schematic diagram of a typical spray-type deaerator.

Vacuum rotating disc type deaerator

Suggestion for improvement:

Treatment of polluted air

You might also like