STUDENT’S INDUSTRIAL WORK EXPERIENCE SCHEME

(SIWES)
A TECHNICAL REPORT
(JUNE 2021 – SEPTEMBER 2021)
AT

SEVEN UP BOTTLING COMPANY(SBC)

BY
OKUNBOR GREAT OSAGIE
17BB004957/1700385
SUBMITTED TO:
THE DEPARTMENT OF CHEMICAL ENGINEERING,
COLLEGE OF ENGINEERING,
LANDMARK UNIVERSITY
IN PARTIAL FULFILMENT FOR THE AWARD OF THE DEGREE OF BACHELOR
OF ENGINEERING (B.ENG.), CHEMICAL ENGINEERING,
LANDMARK UNIVERSITY, OMU-ARAN, KWARA STATE, NIGERIA.

SEPTEMBER, 2021.

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 DECLARATION.
I, OKUNBOR GREAT OSAGIE, hereby declare that this SIWES Report has been carried out

by me, under the supervision of ( ). It has not been presented for award of any degree in any

institution. All sources of information are specifically acknowledged by means of reference.

…………………………… ……………………………

Signature Date

ii
 CERTIFICATION
This SIWES Report by OKUNBOR GREAT OSAGIE meets the requirements governing the

award of the degree of Bachelor of Science in Chemical Engineering and is approved for its

contribution to knowledge and literary presentation.

(Engr. Abayomi Kehinde) Date

(Engr. Abayomi Kehinde) Date

(Dr. Fakinle Bamidele) Date

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 DEDICATION
I dedicate this report to God almighty thanking him for his grace and favor in my life, as well

as safety, protection and provision throughout the SIWES program. Also, thank my parents

Engr. J.E OKUNBOR and Mrs. S.U OKUNBOR for always being there for me through my

academic journey.

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 ACKNOWLEDGEMENT

My Gratitude goes to Almighty God who has been with me throughout this program, Mr.
Oguntade Ibrahim, The Quality Control Manager for giving me the opportunity of learning
and attribute greatly toward my development. And also MR. David Godwin, Mr. Ibrahim,
Mr. Sam Aje, Mr. Monday, Mr. Mike, Mr. Kinsley, Mr. Segun, Mr. Isaiah, and Mr.
Famous, for their Great support and contribution towards the success of my program as well
as all the Quality control team for their assistance in the various section and the entire
management team of Seven-Up Bottling Company Plc, Abuja Plant.

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 ABSTRACT
This report reviews the Student Industrial Work Experience Scheme (SIWES) carried out in

SEVEN UP BOTTLING COMPANY LTD. ABUJA PLANT. This report gives the information

on the background and objectives of ITF and SIWES, the company in which the Industrial

Training was carried out, overview of the works carried out in sections like LABORATORY

WATER TREATMENT, SYRUP/ SUGAR DISSOLVING ROOM, PRODUCTION LINE,

EFFLUENT TREATMENT PLANT. Lots of experience was gained from QUALITY

CONTROL DEPARTMENT AND PRODUCTION (which comprises of the sections above) in

respect to my field of study (CHEMICAL ENGINEERING). In this report, the technical skills

gained during the training period to justifies the relevance of the scheme in equipping students

with needed technical competence to thrive in the real world was also discussed.

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;

TABLE OF FIGURES
Figure 1.0.1: Seven-up company logo.........................................................................................6

Figure 1.0.2: Company Products.................................................................................................6

Figure 1.0.3: Organogram of the seven up bottling company, Abuja plant. (302-304, IDU

INDUSTRIAL ESTATE ABUJA, FEDERAL CAPITAL TERRITORY, NIGERIA.).............8

Figure 2.0.1: Secure seal tester..................................................................................................13

Figure 2.0.2: Torque Tester.......................................................................................................14

Figure 2.0.3: Refractometer.......................................................................................................14

Figure 2.0.4: pH-meter..............................................................................................................15

Figure 2.0.5: Carbo Qc..............................................................................................................15

Figure 2.0.6: Candling Box.......................................................................................................16

Figure 2.0.7: Hot Wire Cutter...................................................................................................16

Figure 2.0.8: Top-load tester.....................................................................................................17

Figure 2.0.9: Water Distiller.....................................................................................................18

Figure 2.0.10: Carbolite.............................................................................................................18

Figure 2.0.11: Magnetic Stirrer.................................................................................................19

Figure 2.0.12: Raw water holding tanks....................................................................................19

Figure 2.0.13: Buffer& Reaction tank.......................................................................................20

Figure 2.0.14: A sand filter tank...............................................................................................21

Figure2.0.15: A carbon filter tank.............................................................................................21

Figure 2.0.16: : Filter Cartridges/ Polishers..............................................................................22

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Figure 2.0.17: A CHEMCAD of Water Treatment...................................................................25

Figure 2.0.18: Boilers Present...................................................................................................30

Figure 2.0.19: Oil Trap..............................................................................................................48

Figure 2.0.20: Equalization Tank..............................................................................................48

Figure 2.0.21: Corrugated Plate Separator................................................................................49

Figure 2.22: Submerged Aerobic Fixed Films..........................................................................49

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 TABLE OF CONTENT

DECLARATION.....................................................................................................................ii
CERTIFICATION..................................................................................................................iii
DEDICATION........................................................................................................................iv
ACKNOWLEDGEMENT.......................................................................................................v
ABSTRACT...........................................................................................................................vi
TABLE OF FIGURES..........................................................................................................vii
TABLE OF CONTENT..........................................................................................................ix
CHAPTER 1................................................................................................................................1
INTRODUCTION.......................................................................................................................1
1.1 Background Of ITF............................................................................................................1
1.2 History Background Of SIWES.........................................................................................1
1.3 Aims and Objectives Of SIWES....................................................................................3
1.4 Brief History On 7UP Bottling Company.........................................................................4
1.4.1 Vision..........................................................................................................................7
1.4.2 Mission........................................................................................................................7
1.4.3 Food Safety Policy Statement and Objectives............................................................7
CHAPTER 2................................................................................................................................9
OVERVIEW OF ACTIVITIES...................................................................................................9
2.1 Soft Drinks.....................................................................................................................9
2.1.1 Fundamental Soft Drinks Concepts............................................................................9
2.2 Quality Control.......................................................................................................11
2.2.1 Steps in Quality Control............................................................................................12
2.2.2 Objectives of Quality Control...................................................................................12
2.2.3 Benefits of Quality Control.......................................................................................13
2.3 Laboratory Equipments And Their Various Functions..................................................13
2.4 Water Treatment Plant.....................................................................................................19
2.4.1 Types of Test.......................................................................................................22
2.4.2 Maintenance Activities Carried Out.........................................................................26

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 2.5 CO2/Boiler room.............................................................................................................30
2.6 Production Lines..............................................................................................................32
2.6.1 Returnable Glass Bottle’s Line.................................................................................32
2.6.2 Quality Control Checks/ Test..............................................................................35
2.6.3 Polyethyleneterephthlate (P.E.T) Bottle Line.....................................................37
2.6.4 Quality Control Checks/Test...............................................................................39
2.7 Syrup Room................................................................................................................41
2.7.1 Operational Process.................................................................................................41
2.7.2 Sweetener............................................................................................................42
2.7.3 Acidulants And Flavours.....................................................................................43
2.7.4 Batching operations.............................................................................................44
2.7.5 Test Carried-Out..................................................................................................45
2.7.6 CIP (Clean-in-place).................................................................................................46
2.8 Effluent Treatment plant (ETP)..................................................................................47
2.8.1 Tests (Treatments under the Equalization Tanks)...............................................50
CHAPTER 3..............................................................................................................................51
PROBLEMS ENCOUNTERED AND PROBLEMS SOLVED...............................................51
3.1 My Field Of Study And Educational Career...................................................................51
3.1.1 Practical Training Vs Theoretical Knowledge....................................................51
3.2 Challenges...................................................................................................................52
3.2.1 Challenges I Encountered....................................................................................52
3.2.2 Challenges Faced by Company...........................................................................52
CHAPTER 4..............................................................................................................................53
CONCLUSION, RECCOMENDATION, REFERENCE.........................................................53
4.1 Conclusion..................................................................................................................53
4.2 Recommendation...........................................................................................................53

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 CHAPTER 1

INTRODUCTION
The following report goes over in detail the work done, experience gained and beneficial

knowledge acquired during the Student Industrial Work Experience Scheme (SIWES)

undertaken at Seven Up Bottling Company Ltd, Abuja plant so as to complement knowledge

gained at my university of study, Landmark University with real life Industrial Experience.

1.1 Background Of ITF

Established on the 8th October 1971, the industrial Training Fund has operated consistently

and painstakingly within the context of its enabling laws Decree 47 of 1971 as Amended in

the 2011 ITF ACT. In the four decades of its existence, the ITF has not only raised training

consciousness in the economy, but has also helped in generating a corps of skilled indigenous

manpower which has been manning and managing various sectors of the national economy.

1.2 History Background Of SIWES

SIWES is an acronym which stands for Students Industrial Work Experience Scheme. It is a

skill acquisition program designed for students of most tertiary institutions as a

complementary

program to the theoretical education and laboratory practices engaged in by students in tertiary

institutions, which by industrial standard are inadequate to serve the practical needs of the

industries. The practices are idealistic and therefore necessitate that the student be exposed to

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actual life practice and handling of equipment and machineries which is not offered in the

academic institutional class and laboratory practice. Economists being able to evaluate the

role

technology plays in a country’s economy concluded that for an economy to grow and develop

there be advancement in the technology sector of the country. SIWES was solely funded by

ITF (Industrial Training Fund) during it early stage not until it was difficult to continue for

economic stress: then the responsibility was shared between Industrial Training Funds (ITF)

and the Federal Government. The official Gazette of the Federal Republic of Nigeria made it

clear that the Supreme Military Council then headed by General Yakubu Gowon in the year

1972 promulgated decree No.47 to indigenize the Nigeria Economic Sector. On the 31st of

March 1974, the decree came into effect with its core aim of reducing the dominance of

foreigners in the Nigerian economy and accompanied by a systematic integration of locally

oriented skilled manpower into the economy. The indigenization decree established many

bodies which were charged with different responsibilities to make the nations dream a reality.

Among them include

i. Industrial Training Fund (ITF)

ii. Centre for Management Development (CMD)

iii. Administrative Staff College of Nigeria (ASCON).

SIWES started in 1974 with 748 students from 11 institutions of higher learning participating.

By 1978, participation on the Scheme increased to about 5000 students from 32 institutions.

The ITF withdrew from the management of the Scheme in 1979 owing to problems of

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organizational logistics and increased financial burden associated with the rapid expansion of

SIWES. Consequently, the Federal Government funded the Scheme through the National

Universities Commission (NUC) and the National Board for Technical Education (NBTE)

who managed the SIWES for five years (1979-1984). The supervising agencies – NUC and

NBTE, operated the Scheme in conjunction with their respective institutions during the

period. The industrial Training Fund (ITF) was thereafter directed by the Federal Government

to take charge and resume the responsibility of managing the Scheme in collaboration with the

supervising/regulatory agencies. That is, NUC, NBTE and the National Commission for

Colleges of Education (NCCE).

1.3 Aims and Objectives Of SIWES

This scheme was set out to bridge the gap between the theoretical training of students in

tertiary institutions and the practical application in the labour field. The student will be able to

stand better chance and advantage for acquiring practical skills to his or her theoretical

knowledge than a technical man.

The Objectives of the SIWES program are as follows:

1. To acquaint the student with relevant skills, knowledge, ethics and experience required

of the students in their choice course of study.

2. To help the student in developing good working culture.

3. To expose students to work methods and techniques in handling equipment and

machinery that may not be available in their educational institutions.

4. To help students to acquire communication and interpersonal skills as well as

confidence in their choice course of study.

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 5. To equip students and get them accustomed to some inevitable professional challenges

and respective workable solutions.

6. To provide the students with job opportunities.

7. To introduce students to real work atmosphere so that they know what they would

most likely meet once they graduate.

8. To allow students develop industrial skills needed in their field of study.

9. Enlist and strengthen employer’s involvement in the entire educational process

through SIWES.

1.4 Brief History On 7UP Bottling Company

Seven-Up Bottling Company (SBC) started business in Nigeria in 1960 as a limited liability

company. The company was founded by a Lebanese man named Mohammed El-Khalil.

Mohammed the father of the company’s current chairman Faysal El-Khalil. It was started on

October 1st, 1960 with the first company located in Ijora, Lagos. Seven-Up Bottling Company

Plc is one of the largest independent manufacturer and distributor of well-known and widely

consumed brands of soft drinks in Nigeria; their brands are Pepsi, Pepsi Light, Pepsi Max,

Seven Up, Seven-Up Free, Mirinda (orange, red apple, green apple and pineapple), Teem

(bitter lemon, tonic, and soda), Mountain Dew, H 2OH and Aquafina Table Water. It produces

and markets from all their present nine bottling plants with state of art manufacturing facilities

located strategically across the country. Seven-Up Bottling Company has a well-coordinated

distribution network with an extensive network of over 200 distribution centers located across

Nigeria; the company’s work force is currently in the neighbourhood of 3500 employees

(Seven Up, 2010). Seven-up Bottling Company Plc. is an authorized bottler of the seven-up

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International Company products, and PepsiCo Inc. products. They have nine bottling plants

and 84 depots in various locations within the country. These plants are located in Abuja plant

in Abuja; where I had my industrial training, Aba plant in Abia state, Enugu plant in Enugu

state, Ilorin plant in Kwara state, Ibadan plant in Oyo state, Kaduna plant in Kaduna state,

Kano plant in Kano State, Ikeja plant in Lagos state and Benin plant in Edo State.

Figure 1.0.1: Seven-up company logo

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Figure 1.0.2: Company Products

The Abuja plant is located at Idu industrial Area Airport road. It has three lines for production;

two of them are the returnable glass bottle (RGB) production lines and polyethylene

terephthalate (PET) production line. The company is a large organization with above 500

employees of both permanent and casual members of staff. Seven-Up Bottling Company is an

organization that falls within the large size. The company runs day and night shifts. The Abuja

plant consist of various department which are Peoples & culture department, Operational

department, Production department, Quality Control department, Marketing department,

Account department and Security department. These entire department has the sole aim of

meeting the company’s mission and goal by working together.

1.4.1 Vision
To become the most admired and most innovative company in Nigeria.

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1.4.2 Mission
To inspire and refresh a youthful lifestyle.

1.4.3 Food Safety Policy Statement and Objectives

SBC as a responsible corporate organization is committed to the manufacturing and

distribution of high-quality products that are safe and wholesome for human consumption by:

• Using high quality and safe raw materials.

• Using applicable, up to date and well-maintained technology and machinery.

• Ensuring an environmentally friendly atmosphere.

• Investing in well-equipped laboratories both home and abroad that are capable of pre-

emptying potential hazards and introducing remedial to prevent them.

• Hiring and sustaining appropriate, qualified, and well-trained workforce.

• Instituting a functional process auditing system that ensures the entire above are
routinely followed.

• Designing food safety into our process machinery and buildings.

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 General Manager

Account Human Resource Marketing Key Accounts Quality Control Plant Security Operation
Factory Manager
Manageer Manager Manager Manager Manager Manager Manager

Quality Control Process Control

Superintendents Superintendents

Quality Control Quality Control Water Treatment Syrup Room

Inspector(line) Inspector(lab) Operator Operator

Industrial
Training Students

Figure 1.0.3: Organogram of the seven up bottling company, Abuja plant. (302-304,
IDU INDUSTRIAL ESTATE ABUJA, FEDERAL CAPITAL TERRITORY,
NIGERIA.)

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 CHAPTER 2

OVERVIEW OF ACTIVITIES
At the seven up Bottling plant, I was able to work at different units which included the Water

treatment plant, the sugar dissolving/syrup room, the effluent treatment plant, the CO2/boiler

room, bottling hall and in the laboratory.

2.1 Soft Drinks

Soft drink is the name commonly given to a non-alcoholic beverage that is consumed cooled

or chilled, as opposed to a hot beverage, like tea or coffee. Soft drinks fall into several

categories distinguished by the industry as carbonates, still drinks, juices, dilutable, and

bottled waters. A carbonate, also called a carbonated soft drink (CSD), is a fizzy drink

containing gaseous carbon dioxide, sugar and water. Still drinks are noncarbonated soft

drinks, and they consist of a plethora of varieties, such as fruit drinks, energy and sports

drinks, and health beverages, just to name a few. In the last decade or two, bottled waters have

become very popular, whether still or carbonated, flavoured or non-flavoured, with or without

natural sugars. Usually, these are prepared from natural spring waters or from other

subterranean water sources and have high mineral contents, either naturally or added during

manufacture.

2.1.1 Fundamental Soft Drinks Concepts

In order to fully appreciate the soft drink industry, there are certain concepts that one must be

acquainted with to understand the processes that go into producing soft drinks.

Brix

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Brix is one of the most pivotal technical topics encountered in the soft drinks industry.

Generally, Brix (pronounced “bricks”) is used to indicate the amount of dissolved solids in a

solution. In the soft drinks industry, it is used specifically to quantify the sugar in a beverage,

syrup, or juice. It is defined as the percentage of dissolved sugar in a water solution on a

weight for weight basis and is expressed in degrees Brix (°B). Thus, for example, a 10°B

solution implies that in 100 g of solution, there are 10 g of dissolved sugar. Brix is nothing

more than the measurement of the density of a liquid. Density is defined as the weight of a

specified volume of the liquid.

weight
Density=
volume

In a soft drink, there are, in addition to the sugar, other dissolved solids. They are in extremely

small quantities compared to the sugar content but, nevertheless, contribute slightly to the Brix

measurement. For pure convenience sake, we consider these to be “sugar” as well, that is, as

far as the Brix reading is concerned. The very small error that can be introduced individually

by a variety of different dissolved ingredients in different formulations is accepted on a

universal basis and is ignored most of the time. So then, in the soft drinks industry, all

products, beverages, syrups, juices, etc., are considered as pure sugar solutions as far as Brix

measurements are Concerned. Brix is a very important value in the soft drink industry, as

apart from the water, sugar is by far the largest component of naturally sweetened soft drinks.

It can make up to about 13% of the drink content and gives the beverage its characteristic

sweetness level. Interacting with other ingredients, the sweetness determines the overall

10
characteristic taste profile accepted by the consumer. Brix is a measure of the sugar content in

a beverage and is a major process and product control standard. It needs to be continuously

monitored and controlled online during the production processes involving huge syrup

quantities and high-speed fillers packing hundreds of bottles or cans per minute. For the

purpose of maintaining the sugar content of the drink at the target Brix, the quality control

(QC) standard of most Soft-Drinks companies allows for a tolerance of only 0.15°B above or

below this target. In our example, therefore, the factory is required to produce and fill the

beverage between 10.85 and 11.15°B. This tolerance is allowed to accommodate any

acceptable “experimental errors,” in actual production processes and in laboratory testing

procedures. These could be weight or volume measurements, visual readings, equipment

calibrations, and, of course, plain and simple “human error.” This narrow ±0.15°B tolerance

range in Brix specification seems to take care of the organoleptic factor — the consumer is not

expected to notice the deviation in sweetness and overall taste of the drink within this range.

2.2 Quality Control

According to Juran “Quality control is the regulatory process through which we measure

actual quality performance, compare it with standards, and act on the difference”. Another

definition of quality control is from ANSI/ASQC standard (1978) quality control is defined as

“the operational techniques and the activities which sustain a quality of product or service that

will satisfy given needs; also the use of such techniques and activities (Greenwood, et al.,

2014)”. In every manufacturing process quality control is very important, after all it

determines the success of the manufacturing process. We can then define quality control as the

process of ensuring the quality of a product where the least requirements that quality control

11
should meet are the minimum requirements and specification of the product. However, it is

necessary that the product is satisfactory, dependable and fiscally sound. In other that a

product meets the standard requirements, series of examinations are carried out at different

points of production. So as to determine problems and take the necessary corrective measures,

in time, to rectify them. Quality control starts at the very beginning of production, at which

some stages are observed vividly, and necessary tests are carried out.

2.2.1 Steps in Quality Control

Following are the steps in quality control process:
1. Formulate quality policy.
2. Set the standards or specifications on the basis of customer’s preference, cost and
profit.
3. Select inspection plan and set up procedure for checking.
4. Detect deviations from set standards of specifications.
5. Take corrective actions or necessary changes to achieve standards.
6. Decide on salvage method i.e., to decide how the defective parts are disposed of, entire
scrap or rework.
7. Coordination of quality problems.
8. Developing quality consciousness both within and outside the organization.
9. Developing procedures for good vendor-vendee relations.
2.2.2 Objectives of Quality Control
Following are the objectives of quality control:
1) To improve the company’s income by making the production more acceptable to the
customers, i.e., by providing long life, greater usefulness, maintainability etc.
2) To reduce companies cost through reduction of losses due to defects.
3) To achieve interchangeability of manufacture in large scale production.
4) To produce optimal quality at reduced price.

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 5) To ensure satisfaction of customers with productions or services or high-quality level,
to build customer goodwill, confidence and reputation of manufacturer.
6) To make inspection prompt to ensure quality control.
7) To check the variation during manufacturing.
The broad areas of application of quality control are incoming material control, process
control and product control.
2.2.3 Benefits of Quality Control
1) Improving the quality of products and services.
2) Increasing the productivity of manufacturing processes, commercial business, and
corporations.
3) Reducing manufacturing and corporate costs.
4) Determining and improving the marketability of products and services.
5) Reducing consumer prices of products and services.
6) Improving and/or assuring on time deliveries and availability (Chi and Scott, 2019).

2.3 Laboratory Equipments And Their Various Functions

Secure seal tester:
This is used to determine whether the bottles are properly corked or not so as to eliminate the
tendency of gas lost which invariably impact on the tartness of the final product and reduces
shelf life.

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 Figure 2.0.4: Secure seal tester

Torque Tester:

This is used to check the integrity of the closure on PET bottles. The model is Tornado
Mecmesim. you can choose from the following units of measurement depending on the
capacity of your Tornado(N/m, N/cm, mN/m, gf/cm, kgf/cm, kgf/m, lbf/ft, lbf/in, ozf/in). but
Newton per metre (N/m) is used here.

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Figure 2.0.5: Torque Tester
Refractometer
This is an instrument in the laboratory used to measure the weight/volume of sugar (brix). The
means of measurement here is the refractive index.

Figure 2.0.6: Refractometer

pH Metre
This is used to check the ph of a liquid (beverage, water, syrup etc) to determine if it’s acidic
or alkaline. If the value is less than 7 its Acidic, if the value is equal to 7 its neutral, if the
value is greater than 7 its Alkaline.

Figure 2.0.7: pH-meter

Carbo Qc
This is used to check the carbon level of the bottled beverage so as to know if the bottles CO 2
is within the standard of production.

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 Figure 2.0.8: Carbo Qc

Candling box
This box houses a source which produces light to check if there’s any presence of persons of
contamination or particles in the beverage observed in it.

Figure 2.0.9: Candling Box

Hot Wire Cutter

This equipment is used to cut plastic bottles during PET analysis so as to know the even
weight

16
of the different sections.

Figure 2.0.10: Hot Wire Cutter

Top-Load Tester

Top load tester is used during PET analysis so as to check for the impact strength of the

plastic

bottle. It has already been programmed.

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 Figure 2.0.11: Top-load tester

Water Distiller

This is used to purify water meant for carrying out tests as well as reagent preparation.

18
 Figure 2.0.12: Water Distiller

Carbolite
This is used for the carbonation retention studies; it is more like an oven. Usually the
temperature is been raised to about 38C, the rise in temperature would give a clearer picture of
how the drinks would react to sunlight or warmth during storage.

Figure 2.0.13: Carbolite

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Magnetic Stirrer: This is used to stir liquid to ensure proper mixing during a titration
process.

Figure 2.0.14: Magnetic Stirrer

2.4 Water Treatment Plant

About 71% of the earth’s surface, water-covered of which 96.5% is salt water and only 3.5%

is freshwater; slightly above two-third of this is frozen in Glaciers and Polar Ice caps. Water

comes from the Abuja Municipal(where they treat water already) but due to the fact that it is

transferred through pipes, the water is given minimal treatment at the plant in case of any

contamination through the pipes in the process of transfer. The water comes to raw water

holding tanks, the raw water pump brings the water into the buffer tank then reaction

tank(at the pump house)

Figure 2.0.15: Raw water holding tanks

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 N.B: the pump and tanks work automatically

The float switch is on top of the buffer tank and is connected with float tork which is the one

that has contact w the water inside. Once the water goes below the tork, it signals the switch to

start pumping water because it shows water is going down and vice versa. The pump is always

on. The buffer tank is just a reservoir, holding water as there’s no reaction taking place

inside. Overflow from the reaction tank goes into the buffer tank.

Figure 2.0.16: Buffer& Reaction tank

We have what we call the normal flow of water. The blue arrow signifies the normal flow of

water

 the sand filter tank collects water from the reaction tank pumped by the intermediate

pumps and it comes in like a shower

 From the sand filter tank, it moves through the pump to the next tank called

the carbon filter tank for more filtration

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Figure 2.0.17: A sand filter tank

Figure2.0.18: A carbon filter tank

FILTER CARTRIDGE(S): one with 5 macrons and the other with 1 macron to determine

the size of micro-organisms and get rid of them. If it passes through the 5 macron, it won’t

22
pass the 1 macron. Just say it’s for double checking. They also filter water and polish [ giving

the water a natural definition (colorless, odorless, tasteless)].

UV LIGHT: this is to ensure that any stubborn micro-organism that escapes both polishers is

gotten rid of through the action of a bright light. The UV light pieces the cyst cell and kill the

organisms in that cell

 N.B: It sterilizes the water while the chlorine only sanitizes

After the UV light, we can say the water is good for distribution.

2.4.1 Types of Test

There are 6 different types of tests:

1. CHLORINE TEST (which is the only chemical we’re using): there’s a test tube,

color comparator, DPD(Diethylphenelindiamine)1&4. Water has its own natural

chlorine intake.

 Free/residual chlorine-which is the one that remains after water has taken the

chlorine it needs and that is what DPD 1 checks for. DPD 4 can detect both the

chlorine that has been taken in by water naturally and the one that remains. It is also

called DPD total chlorine. When you want to check, you measure 10ml of water,

put your tablet or water and shake for a minute. The test is carried out at the reaction

tank, [sand filter tank(S tank)- strictly for DPD 1(you’re expected to get between 6-8

ppm) and distribution tank. DPD 4 is for the reaction tank and you’re expected to

get between 8-10 ppm in the reaction tank. There should be no chlorine in treated

water! As this condition is called Chlorine carryover

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Reasons why chlorine could still be found in water;
I. Operational error coming from the operator himself. The operator may have added too

much chlorine

II. Faulty Valves Error coming from leakages in the valves that may be faulty since they are

not properly closed. Most of the valves are tagged

III. Outdated carbon which is to say the carbon is not able to completely remove chlorine

because it’s old or something

1. IRON TEST in some industries, Fe3+(iron three oxide)[ to coagulate the unreacted

chlorine and send it under the tank(the sludge)] is also going into the reaction tank

and lime(reduce hardness and alkalinity of water) are put in the tank.

2. Though we don’t use iron in our treatment plant, we check for iron in the treated

water in the case of rust in the pipes. There could be iron in water but it must not be

more than 0.1mg/L.

3. ALKALINITY TEST: alkalinity is the reaction between acid(0.02N H2SO4

prepared in the lab) and base( present in water naturally; carbon rate or bicarbonate).

Methyl purple is used as an indicator of alkalinity.

PROCEDURE

 Measure 100ml of water sample into the beaker then add 3 drops of methyl purple

 Titrate against the acid( before adding the acid, the colour of water will be blue-ish

when the methyl purple is added)

 Continue to stir until the water turns colourless

24
  At the point where it runs colourless you take your reading and multiply by 10 which

is the correction factor(CF)

 In a test I carried out, it was 18ppm I got as my alkalinity and this test must not be

more than 50ppm

1. Test for hardness of water: we check for hardness in raw water and treated water.

Hardness is a measure of calcium or magnesium ions in water and more than 50ppm

shows there’s too much hardness and it cannot be used. Hardness affect the taste of

the drink

PROCEDURE

 Take 100ml of the water sample into the beaker and add 1 or 2 drops of Erichrome

black into the beaker which is the indicator for hardness

 Add 1ml of hardness buffer which acts as a catalyst since it does not take part in the

reaction, it enables the reaction to take place

 Titrate against 0.01M EDTA

 When you get a blue-black color, you stop and read your value then multiply by the

CF (value must not be more than 50)

1. PH TEST: to check the PH of water and it should be neutral (7). 6.5-8 is allowed

though. Anything more than 8 is dropping toward the alkalinity side while anything

below 6.5 is acidity.

Take your sample to the lab, rinse the probe connected to the PH meter and insert the probe in

the water, the meter continues to read values till it becomes steady and that will become your

PH reading

25
 1. Total Dissolved Solids (TDS) test: water is never pure as it comes from the earth,

these impurities are collectively called total dissolved solids as they cannot be

separated/recovered from the water. TDS in water that can be used must not be more

than 100mg/L. TDS being too much can make the water draw. The procedures are

the same w the PH TEST.

Figure 2.0.20: Using CHEMCAD To show flow in the Water Treatment section

2.4.2 Maintenance Activities Carried Out

DAILY ACTIVITIES

A. Backwashing: This is the act of reversing the flow of water in the carbon and sand

filter. By doing this, particles trapped in the filter are dislodged. It is done to ensure

proper functioning of the equipment, by dislodging adhered materials and it is done at

5 times the normal flow i.e. 125m3/hr., for 20-30 minutes.

Procedure:

26
1. Carry out pre-start of production when equipment is not in use.

2. Ensure there is sufficient treated water available for the task.

3. Flow is reversed by changing necessary valves connected to the vessel.

Weekly Activities:

A. Steaming of Carbon filter tank: Steam is put in the Carbon filter tank to remove

cysts (hard cells) from the carbon by locking high temperature steam at 100oC in the

vessel. This is also done to recharge the bituminous coal in the Carbon Filter. The

steam is trapped in the vessel for about 30 minutes which is called steaming time.

After steaming time outlet is opened and temperature is checked till it comes down to

50oC.

B. Cleaning of Pipe and tank exterior: Top and body of the tanks and pipes are cleaned

weekly using mop, water hose and P3Z solution.

Monthly Activities:

A. Sand filter sanitation: This is done to prevent microbial build up in sand filter.

Sanitizing agents used: Treated Water, 60-70% Calcium hypochlorite or Caustic Soda or HCl

Procedure:

1. Ensure equipment is not in use

2. Prepare sanitizing agent

3. Reduce water in sand filter to a third of the sand bed and add sanitizing agent.

4. Check circulation in outlet using phenolphthalein, DPD no. 1 or methyl blue

depending on sanitizing agent used.

B. Cleaning and sanitation of the Buffer Tank

27
 Carried out to prevent cross contamination in treated water by ensuring that the buffer

tank is properly cleaned and sanitized.

Materials for cleaning: Calcium hypochlorite, P3Z (Detergent), Clean potable water.

Procedure:

1. Ensure that the buffer tank is not in use.

2. Ensure that sufficient water and cleaning materials are available to clean the buffer

tank.

3. Drain the residual water in the buffer tank

4. Scrub the internal walls with a hard brush using 10% P3Z

5. Rinse the internal wall with clean potable water

6. Scrub the external walls with a hard brush and 10% P3Z

7. Rinse the external walls with clean potable water.

C. Cleaning of the polisher and change out of the filter cartridges:

To ensure proper functioning of the polisher and prevent water contamination.

Materials: 10% P3Z, 25 ppm chlorinated water, new polisher cartridges.

Procedure:

1. Ensure the polisher is not in use.

2. Prepare 25 ppm chlorinated water, 10% P3Z

3. Collect new polisher cartridges from the store and keep them on site.

4. Drain the water in the polisher by opening up connected valves

5. Remove vessel cover, head plate, Teflon spring and the O ring and scrub with P3Z

28
6. Remove cartridge holder and scrub with P3Z

7. Scrub polisher interior with P3Z for 10 minutes and rinse properly

8. Put all the polisher accessories in the bowl and sanitize with 25 ppm chlorine for an

hour.

9. Assemble the unit without the cover or the cartridges. Then rinse properly till free of

sanitizer when tested with DPD No. 4

10. Arrange the new spools accordingly, cover the vessels and rinse together once again.

Yearly Activities

A. Washing of the reaction tank: The reaction tanks interior and exterior are cleaned to

ensure its proper functioning.

B. Washing of the Raw Water Holding Tank: Done to ensure proper function of the

tank as a water storage unit and to prevent microbial growth in the tank.

Procedure:

1. External walls of the tank are washed with P3Z and cleaned with potable water

2. The interior is drained of residual water and tank is then filled with 100ppm

chlorinated water.

3. It is then drained after 1 hour and rinsed with potable water, and then treated water.

4. A test is then carried out for TBC. Change of the U.V light tube: This is carried out to

reduce risk of microbial growth, by ensuring that the U.V. lamps are well maintained.

29
C. Change of Carbon in Carbon Filter: The Bituminous Coal used in the carbon filter

requires yearly changing to ensure proper function of the equipment as well as check

filter faults such as channelling, corrosion, pitting Etc.)

Tri-Yearly Activities:

A. Change Out of sand in Sand Filter: The sand filter uses three types of sand namely

Sharp sand(5-10mm), Coarse Sand(3-5mm) and Fine Sand(1-2mm) with pebbles and

big stones at the bottom. The different grades of sand every three years need to be

replaced with new sanitized sand.

Materials: 20% HCl solution, 100ppm chlorine solution, Treated water, Sand of different

grades.

Procedure:

1. Different Grades of sand are washed with 20% HCl and rinsed of the acid completely

with treated water. Rinse water should test negative with phenolphthalein indicator.

2. Old sand is then removed and new sand is loaded into the sand filter.

3. The sand and gravel is then disinfected with 100ppm chlorine solution.

4. Drain of the solution through the under drain valve.

5. Fresh water is then let into the sand filter from the buffer tank.

6. This is then left running for 45 minutes, after which drained water is tested for residual

chlorine with DPD no. 1

7. The sand filter is then backwashed, after which differential pressure is checked to

ensure proper functioning.

30
2.5 CO2/Boiler room
There are two boilers, one bigger than the other, The bigger one is called 4 ton boiler and the

smaller one is called a 2 ton boiler collectively called water-in-tube boilers. The Boiler is a

closed vessel that generates steam/vapour. Water is poured into the vessel and heated up till it

steams up. The water that returns from the steam sent from the line is called the Condensate

water and it is returned from the lines to make heating easier. Steam is a supernatural heated

water that can be sent to anywhere in the plant.

Figure 2.0.21: Boilers Present

There’s a water storage tank up above from which the water comes and a diesel tank to store

the diesel which the boiler operates on. Feed Pumps are used to pump the water into the

boiler. There’s a feed pump float level/boiler foot control switch that signals the pump on

when to send water and to stop sending the water. The pumps work one after the other.

There’s a fixed pump gauge to check whether the pumps are operating well or not. There’s

a control panel where all the indicators are connected and to control everything in the boiler

room. There’s a pressure guage used to detect the pressure which must not be more than

31
100pa. A water indicator is present to sight the level of water present. Air lock is when air is

present in the feed pump and it reduces the rate at which the pump is able to send water into

the tank. There are safety valves to reduce the pressure of the boiler if it is getting too much

which could be dangerous. A boiler burner is present which works w the diesel storage

tank. Burner is a machine that heats gas(diesel),air and light as one combustion. A pump

sends diesel from the diesel storage tank to the burner. Just as the name implies, it’s where the

heat is supplied from. A panel is used to control it.

 Nozzles (first stage which sprays the diesel and second stage that adds more pressure

to the flame) to spray the diesel to aid the fire

 Electrodes to ignite the spark.

 Photocells are the brains behind the light (it’s like a thermostat).

 The blower to blow air

An Oil pressure gauge is mounted close to the blower on the burner to monitor the oil

coming in. The photocell sends electrons to the nozzles to aid sparking. There’s a chamber

door and an exhaust pipe where all the smoke exists. It is cleaned weekly for maintenance to

avoid unnecessary heating whenever steam is generated from here, it transferred to other parts

of the plant using pipes.

2.6 Production Lines

The bottling process of a carbonated soft drink takes place in the production hall. The process

involves series of steps which starts in the warehouse and ends there. Seven-up bottling

company (Abuja plant) has two functioning production halls with the state of the art

32
production equipment for maximum efficiency. One is for RGB and the other for PET. These

production’s equipment are positioned in a line format for step by step process.

2.6.1 Returnable Glass Bottle’s Line

These bottles have been used and when coming back they are contaminated, probably not

even useful again. RGB classifies its bottles into three grades, which are:

GRADE A: These bottles don’t need too much washing as they are still very much clean and

may have little molds around it.

GRADE B: This involves bottles which needs to be washed and sanitized twice before they

are fit for use. They are characterized by molds, Iron rings on the neck, oil stains and mild soil

stains.

GRADE C: These sets of bottles are too contaminated and not fit for use or should be hand
washed; mostly old bottles, cement stained, paint stained, soil stained and heavy microbial
activity.

The bottles from the Ware-house goes straight to the Loading bay, from the Loading bay to

the DE-PALLETIZER which helps remove the bottles, with the crates, from the pallet and is

placed on the CONVEYOR. The conveyor carries the bottles to the UNCASER which

removes the bottles from the crates and places them on the conveyor. As the bottles are

conveyed to the BOTTLE-WASHER, there are Sorters who help to separate the bottles,

removing all unwanted bottles (i.e. Grade C and B and foreign bottles, bottles with chipped

necks, chipped bottom, broken bottles) as well as foreign materials in bottles such as straws,

wrappers, or waste. When the bottle gets to the washer, the bottles are taken into the pocket by

bottle knives, and there is a body that holds the pockets together in the same line known as

33
Carrier. On getting into the Bottle-Washer Machine which is divided into 3 parts (Soaking

Tank, Caustic Tank, Rinse Tank).The bottles are carried into the soaking tank on the same line

with the aid of the carrier where the bottles are being sprayed with the spray jets at a

temperature slightly above room temperature (i.e. at 45°C - 50°C). The bottles move into the

caustic tank which is divided into two (2) compartments which are Caustic-Tank 1 and

Caustic-Tank 2. In this caustic tank, the caustic soda (NaOH) and the additives (Aco-Booster,

a washing aid) are introduced. Also, the temperature of the water in the Caustic-Tank 1

temperature is at 70°C but ranges from 65°C to 75°C while the temperature of water in caustic

tank 2 is at 75°C but ranges from 70°C to 80°C. The turbulent flow of the bottles in the

washer machine of caustic tank with high temperature aids the effectiveness of the caustic but

temperature above 80oC would lead to pitting of bottles as well as scalding of dead microbes

on the bottle. As the bottles leaves the caustic tank it moves to the Rinse Tank which is also

divided into 2 parts pre-rinse and final rinse tanks.At the pre-rinse tank, the bottles are rinsed

primarily with the aid of a Spray Jet and also help to bring down the temperature of the bottles

coming from the caustic tank to prevent thermal shock (i.e. sudden change in temperature)

which may leads to breakage of the bottles. Another operation that takes place in this tank is

the Lead Remediation Program; involve the use of DIVO LE in combination with DIVO A1,

where the major constituent of DIVO LE is EDTA which helps to remove heavy metals (e.g.

Pb) that may be present on the walls of the bottles and that of DIVO A1 which is an acid helps

to regulate the pH of the pre-final rinse water for further rinsing of the bottles and a safe guard

to caustic. At the final rinse tank, this makes use of ordinary treated water and the up-side

down positioning of the bottles allows proper drainage of residual water. And the bottles are

discharged from the washer onto the conveyor to the Empty Bottle Inspectors, who check for

34
dirty bottles, bottles with coding, wrappers in bottles, broken bottles, grease on bottles and

chipped necks. Then, the bottles pass in front of white-bright light for Empty Bottle Inspection

are then conveyed to the ELECTRONIC BOTTLE INSPECTOR (EBI), for further

inspection of the bottles for any cracks or defects both at the neck and base of the bottles. The

EBI sensor detects any defected bottles and rejects them immediately along the conveyor and

other bottles moves to the filler. At the FILLER, we have what we refer to as filler bowl; the

syrup and water is being mixed by the MOJOINNER which has a graduation for dilution

using the data from the control drink test, when flowing to the CARBO-COOLER, CO² is

infused into the drink before it then reaches the carbo-cooler carbonation (dissolving gas in

water), CO² can only dissolve in water at a very low temperature and later stored at the filler

bowl. As the bottles enters the filler with the help of the Infeed Screw, then the Star Wheel

which places the bottles on the Lift Cylinder and the lift cylinder helps the bottles up to the

level that the Vent Tubes which has Spreader Rubber can able to enter each bottle. The vent

tubes and the spreader rubber are always together. After the bottles have been filled it moves

to the PLUNGERS (Crowners)which has eighteen (18) organs and it helps to cork the bottles

before moving out and on getting out it moves straight to the CODING MACHINE, the

coding machine prints the batch number, the date, the plant, the production line, and the

expiring date in which the product will expire on the bottles. Then, the bottles move to the

Full Bottle Inspectors, they check for any bottle that has contaminants, they also sight for

bottles that are over filled or under filled with the aid of white light. Then, the bottles move to

CASER MACHINE which helps to case the filled bottles and the PALLETIZER places the

crates on the pallet and from the pallet back to the Ware-House.

35
2.6.2 Quality Control Checks/ Test
The lines work towards bottling of quality non-alcoholic carbonated drinks (soft drinks); this

is achieved with the aid of QC department, which set a QC Inspector (QCI) on each line in

order to maintain, control and sustain production standards. So as to control the process to the

best quality, the QCI on each line carries out some set of tests on a regular basis which are:

S/N TEST STANDARDS FREQUENCY LOCATION

1. Caustic Tank 1= 65oC ± 5oC Start-up and Bottle Washer

Temperature every hour

Tank 2=70oC ± 5oC (Display Panel)

2. Free Chlorine Less than 1ppm Start-up and Bottle Washer

every four hours

(Final Rinse)

3. Spray Jet pressure No nozzle blockage, no Start-up and Bottle Washer

an nozzle pressure loss, all jets every four hours

(All spray Jets)
alignment should align

4. Caustic Carryover To check for caustic in Start-up and Bottle Washer

bottles using every four hours

(Discharge)
Phenolphthalein. Test

should be negative

5. Methylene Blue To check for Mold by Start-up and Bottle Washer

36
 staining bottle with every four hours

Methylene blue. Test

(Discharge
should be Negative

6. EBI Test Bottle Using the metal, paper, Start-up and EBI

Check caustic and chipped every four hours

neck in different bottles

so as to test if the EBI

is working.

7. Brix Using the Every 15 Filler

refractometer, Test minutes

should fall within

target.

8. CO² Using the Carbon- QC. Every 30 Filler

Test should fall within minutes

target.

9. Titratable Acidity Every Tank Filler

Change

10. Sensory Analysis Every Tank Filler

Change

11. Crimpage Using GO NO-GO to Start-up and Crowner

37
 check the diameter of every four hours

the crowning. Which is

between 1.125o and

1.135o

12. Net Content Should be ±3% of Full round of Filler

target volume. filler weekly

First and last

container every

4 hours

13. Production coding The code should be Start up and Coding machine

visible every hour

14. Visual Inspection Random sampling on Start up and Packaging area

products every hour (before caser)

2.6.3 Polyethyleneterephthlate (P.E.T) Bottle Line

This is line is partially automated (90%) but are controlled by operators. Firstly, the pallet of

preforms is loaded on the HUMPER, which pours the preforms in the PREFORM BOWL.

Then the preforms are moved from the Preform Bowl by CONVEYOR into a FEEDER and

run through an UNSCRAMBLER, which orients the preform for feeding into the OVEN. In

the Oven, the preform is being held by SPRING BAR, which are 152 in numbers and holds

38
the preform and turns it upside down for the DUSTER to remove dust, this dust is emptied in

the DUST REMOVER. After the duster, the preforms are heated by passing by QUARTZ

HEATERS which pre-heats the preforms and then enter the MOLD. Here, a thin steel rod,

called a MANDREL, slides into the neck of the preform where it fills the preform with highly

pressurized air, and STRETCH BLOW MOLDING begins. As a result of the pressurized

air, heat, and pressure, the preform is blown and stretched into the mold axially and radially,

where it assumes the mold’s internal shape. This process produces what is called a BI-

AXIALLY ORIENTED BOTTLE which provides a CO² barrier ideal for containing

carbonated beverages. The mold must be cooled relatively quickly, so that that the newly

formed component is set properly. Water, which is cooled by the CHILLER, is coursed

through pipes surrounding the mold, which indirectly cools the mold and plastic. Once the

bottle, has cooled and set, it is ready to be removed from the mold to the FILLER. In the

filler, the bottles are being filled with beverage. The is beverage is coming from the CARBO-

COOLER, the amount of syrup, water and CO² entering is controlled by an equipment called

the CARBO-QC. The bottles, being filled, are moved to the CROWNER where it is being

crowned. Then to the FULL BOTTLE INSPECTOR, an electronic machine designed to

check the bottle by taking pictures of the bottles and relating it to pictures of bad bottles stored

in its memory and removing these bad bottles. Then the bottles are conveyed to the AIR

DRYER, which has air-knives targeted at the label section of the bottle so as to dry the bottle

from water around it, due to the cold temperature of the bottle. The bottles are then conveyed

to the LABELLER, which labels the bottle and is transferred to the PACKAGER. The

packager carries out four (4) functions; to arrange the bottles in a 4×3 format; shawl with

shrink wrap; pass through oven to shrink the wrap around the bottles; and blow the pack

39
reduce the temperature. Then, the PALLETIZER which is done by manual labour to stack

the packs.

2.6.4 Quality Control Checks/Test

S/ TEST STANDARDS FREQUENCY LOCATION

1. Pet Analysis Series of test for the preform, Every new pallet Preform

closures and molded plastic bowl,

bottles from each mold. Using closure

the measurements of the bowl and

weight, height, diameters of mold eject.

body sections, Topload tester,

sectional weight, and relate it

with standards.

2. Secure Seal Using 150psi of pressure. Start-up and Filler

Test Should not burst every four hours

3. Torque test Using the torque tester Start-up and Filler

every four hours

4. Net Content Should be ±3% of target Full round of Filler

volume. filler weekly

First and last

40
 container every 4

hours

5. Brix Using the refractometer, Test Every 15 minutes Filler

should fall within target.

6. CO² Using the Carbon- QC. Test Every 30 minutes Filler

should fall within target.

7. Titratable Every Tank Filler

Acidity Change

8. Sensory Every Tank Filler

Analysis Change

9. Production The code should be visible Start up and Coding

coding every hour machine

10 Visual Random sampling on products Start up and Packaging

Inspection every hour area (before

caser)

2.7 Syrup Room

Syrup is defined as a concentrated sugar solution. Syrup can also be referred to as a sweet

liquid, which is made by sugar dissolved in hot water. The syrup room houses both the

dissolving of sugar to syrup and the mixing of the syrup with acidulants and concentrate.
41
2.7.1 Operational Process
The syrup room is made of two sections which are the Sugar Dissolving Room and the

Batching Room.

Sugar Dissolving Room

 SUGAR DISSOLVING TANK: The sugar dissolving tank has the capacity of

10,000ltrs. The quantity of water entering the tank is measured by a flow rate meter.

The water is heated by the Heat Exchanger which gets its heat from the boiler room.

When the water is heated to about 70oc, the sugar granules are poured from the bags

into the Sugar Dissolving Tank and agitated till it forms simple syrup. There is a need

to check the brix of the syrup. Brix is defined as the percentage of dissolved sugar in a

water solution on a weight for weight basis and is expressed in degrees Brix (°B).

Thus, for example, a 10°B solution implies that in 100 g of solution, there are 10 g of

dissolved sugar. If the brix is low more sugars should be poured and if high, then more

water should be poured. When you have gotten the desired brix it is then transferred to

the convel filter.

 CONVEL FILTER: The convel filter is a used to filter the simple syrup of particles.

The filter aid is composed of microscopically small, hollow particles and filters syrup

without removing or altering the colour, taste or nutritional properties. The syrup goes

enters here and is filtered and transferred to the cooler (heat exchanger).

Batching Room

In the final syrup process, Concentrates are added to the simple syrup, which are the

Acidulants and Flavours. This is where all kinds of flavors of the soft drinks are

42
manufactured adhering to the standards set by PepsiCo International and all Standard

Operating Procedure of the plant so as to attain the desired results. The filtered syrup is

pumped into a Mixing Syrup Tank. The syrup tank is a Continuous Rotation Reactor which

mix the syrup and the concentrate. The concentrate is first mixed in the Concentrate Dosing

Tank and then pumped into the mixing syrup tank. When the syrup is batched it is sent to the

production line.

2.7.2 Sweetener
Sweeteners are what gives the food a sweet taste and they are of two types

NATURAL SWEETENER: This is a type of sweetener that is gotten from a natural source.

And they are also called Nutritive sweeteners because they provide the body with calories.

 Honey and fruits are abundant natural sources of unbounded simple sugar.

 Sucrose (sugar) is more concentrated in sugarcane and sugar beet making them ideal

for efficient commercial extraction to make refined sugar.

QUALITY PARAMETERS OF SUGAR INCLUDES:

o COLOUR: The more whitish the color, the purer the sugar will be. For

standard sugar here the ICUMSA is ≤401(i.e. the specification). ICUMSA is

the international body that governs the analysis of sugar. ICUMSA-

International Commission of Uniform Method of Sugar Analysis

o TURBIDITY: The turbidity has to do with the cloudiness of sugar. The

cloudier the sugar the more impurities it contains. The turbidity level is 25ICU.

43
 o ASH CONTENT: The ash content is 0.015 weight by weight. The more the

ash contents the more the impurities in the sugar (working standard is

0.02%ash).

o MOISTURE CONTENT: The moisture content has to do with the amount of

moisture or water the sugar must contain. The more the moisture content the

lesser the shelf life (working standard is 0.04%moisture).

o TASTE, ODOUR, AND APPEARANCE (TOA): It is the further treatment

of sugar

 ARTIFICIAL SWEETENER: Also known as sugar substitute, they provide a sweet

taste, even sweeter than sugar, while containing significantly less food energy than

sugar-based sweeteners thereby making them non-nutritive. Aspartame, Acesulfame-

K, Neotame, Saccharin, Sucralose and Stevia.

Aspartame and Acesulfame-K is used in the non-sugar based beverages.

2.7.3 Acidulants And Flavours

Concentrates performs vital and significant roles in making soft drinks a reality. They are the

essential food ingredients of soft drinks and have a wide range of activities that helps the soft

drink attain its life shelf life. The following are the main functions of concentrates;

 ACIDULANTS: This is very important for mouth feel and taste as well as nutritional

value. Phosphoric acid (gives a flat and drier flavor) used in Pepsi cola, Citric acid

(gives a light and fruity character) used in other products or Malic acid creates an

acidic environment. Acidity also helps in repelling acid-intolerant microbes.

44
  PRESERVATIVES: Acidulants provide some protection but acts as safe guard not a

primary barrier to microbial growth. Sodium benzoate and Potassium sorbate is a type

of preservative added to beverages to inhibit molds and yeast. By this process, it acts

as protection against microbiological spoilage of our soft drinks.

 COLOURING AND FLAVOURING SUBSTANCES: Coloring and flavoring

substances. The colorants help to give a characteristic color e.g. tartrazine, yellow

sunset. While the flavors determine the distinct taste of each of the products. Flavors

and colors comes in sealed kegs and sachets.

2.7.4 Batching operations

 Ensuring the tanks are well sanitized, free from any contaminant.

 Ensuring the pipes are well connected, for efficient storage and supply.

 Calculating the targeted brix using the standard sugar table and volume of water.

 Staging of each concentrate accordingly closely to the batching area, for easy

proximity.

 Pre-dissolving of each concentrate in sequential order, in other to achieve a

homogenous mixture.

 Check for the brix using the refractometer.

After preparation, it is either sent to the line immediately for bottling or, as in the case of

Pepsi cola, be allowed to mature for at least 24hours. The reason for this being that organic

acids are weak acids and are easily dissociated in a solution but inorganic acids take longer

time to achieve this aim and because of its high concentration and corrosive nature, it is given

at least 24hours to dissolve and achieve the required result.

45
2.7.5 Test Carried-Out

CONTROL DRINK; This is done as a pilot scale to what is going to be run on the line.
Apparatus and Equipment used: Beaker, Refractometer, Burette, Pipette, 10% Tri-
potassium citrate, 0.1N NaoH, magnetic stirrer, 500ml volumetric flask, water bath, vial
bottle, and Weighing Balance.

Procedure:

 Check the Brix using the Refractometer and be sure it falls within the target.

 Find the density using the brix on the sugar log.

 Using the dilution formula, find the weight of the needed

500 ml
weight of syrup= ×density of syrup
1+ 5

 With an already degassed beaker weigh the syrup using the weigh balance

 Dilute with water in the volumetric flask and stir for 4mins

 Measure 100ml of the diluted sample in a beaker, if Pepsi, put 2ml of 10%

Tripotassium citrate.

 Titrate until pH reaches 8.75 and take the reading

 Also with the diluted sample, check the brix using the refractometer.

 With the diluted sample measure 30ml in the vial bottle

 Add 0.1ml of HCL and seal

 Allow bath to reach 100oC ±2 then put the vial bottle in for 40 minutes.

Allow to chill to about 20oC ± 2 and check the brix.

2.7.6 CIP (Clean-in-place)

There are 4 tanks in CIP room;

46
i. Water buffer: stores treated water from water treatment. it basically serves as a storage.

ii. Caustic Chemical Tank: (filler operator and washer) so the flavor is not contaminated

and wash the whole pipes it is from here that the caustic is transferred to line for the washing

process and it is only meant to be available from 0.1-0.2% so it is not harmful does not affect

the flavor on the bottles after washing or so water buffer tank to store water + excess.

iii. Recuperation tank: where most of the water and caustic soda is stored before it is

properly disposed. Caustic soda is not disposed anyhow cause it is hazardous to the

environment

iv. Hot water/ Chlorine tank: To wash over after the caustic soda has already washed over

residue remaining in the tank. There are 2 types of CIP;

3-step CIP
 Rinsing with cold water

 Clean with caustic

 Rinse with cold water again

5-step CIP
 Rinsing with cold water

 Clean with caustic

 Rinse with cold water again

 Sanitize (you use hot water and chlorine)

 Rinse with cold water

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2.8 Effluent Treatment plant (ETP)
Effluent treatment is the part of quality control that deals with waste treatment by

neutralization

processes before discharging such water to the immediate environment for use by plants and

animals. The water coming to the ETP are from: production hall, syrup room/sugar dissolving

room. Machines used in the production hall use grease and oil and when it comes to the ETP

there’s an oil trap blocking the oil coming and it is stopped on a daily basis

There are eight (9) components namely:

1. Manual Screen Bar: It is found in the inlet, that has a strainer attached to it. It removes

all solids like straw, leaves etc. that are not miscible with water.

2. Inlet Turning Valve: this helps to direct water to tank A or tank B which are two in

number and are turned open or close simultaneously.

3. Equalization Tanks: Each tank has 24 diffusers. The diffusers enable air to pass through

it so that the following will happen.

 Fermentation won’t take place

 Micro-organisms would survive

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 Figure 2.0.22: Oil Trap

Figure 2.0.23: Equalization Tank

4. CPS (Corrugate Plate Seperator): Water moves from the equalization tank to the CPS

with particles and pressure. The baffles in the CPS placed vertically that reduces the

pressure. Any present oil, grease and suspended particles go up and moves out through the

adjustment channel.

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 Figure 2.0.24: Corrugated Plate Separator

5. SAFF Tank: Water from the CPS is sent to the tank where micro-organism are being

cultured in order to remove the sugar in the water. Conditions to be considered for sending

raw effluent to SAFF tank;

 Maintain constant Aeration in the SAFF tank

 Keep supplying micro nutrient e.g urea, NPK, DAP ( Diammonium

phosphate).

Figure 2.25: Submerged Aerobic Fixed Films

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6. Tube Deck Clarifier: The tank is to settle the sludge in the water and the clear water

formed passes through a channel called louder into a chlorine tank. The sludge is sent to

the “Sludge drying belt”.

7. Chlorine Contact Tank: Water comes in from the channel called louder into the tank.

Chlorine is dosed in the tank so as to kill micro-organism and to oxidise organic

compound; urea, NPS etc.

8. The Multi-grate Filter: Here it is basically about filtration. It removes suspended solids.

The water comes in from the chlorine contact tank.

9. Drains: The water moves out from the MGF to the drains and it is discharged out to the

environment outside the company. Before this happens, water from the drains is directed

to a fishpond, so that the quality of water would be tested on the fishes. If the fishes

survive, it is believed all it well.

2.8.1 Tests (Treatments under the Equalization Tanks)

i. pH Adjustment/regulation: The pH is regulated between 6.5 to 7.5. If tested and the pH

is high HCl would be used, if pH is below 6.5 caustic soda would be used

ii. Dosing of Aluminium Sulphate: Aluminium Sulphate is dissolved in a tank and it is

dosed into tank A or tank B. The Aluminium Sulphate helps to settle sludge at the

water bottom (Segmentation).

iii. Dosing of Magnafloc: It is dissolved in a bucket and applied round the equalizing tank.

This is done to breakdown the oil content and coagulates or bring suspended particles

together, so as to help the CPS function without problems.

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 Chapter 3

PROBLEMS ENCOUNTERED AND PROBLEMS SOLVED

3.1 My Field Of Study And Educational Career
As an aspiring Chemical Engineer, my time at the Seven-up bottling company helped me

witness a lot of the theoretical knowledge acquired in the classrooms come to life in the form

of practical knowledge. I was privileged enough to say I acquired most of my knowledge from

one of the largest production firms in the world.

I was able to see how processes are carried out and the manner in which they are carried out

to obtain a desired final product. At SBC, I witnessed many aspects of my course of study get

put into practical action. I also got a better grasp of courses like CHE 414 (Principles of Plant

Design I), CHE 411 (Unit operations) and in Chemical Kinetics and Reactor Design

(CHE416).

3.1.1 Practical Training Vs Theoretical Knowledge

The training I received at the Seven-up Bottling Company went beyond my expectations.

Asides learning and carrying out analyses, I witnessed the process flow diagram of the

effluent treatment plant. Unlike when it was taught in Principles of Plant Design I (CHE 414),

it was not really a big deal to me till I saw it in the plant and how it was used for identification

and easier understanding of that particular plant. Also, when it came to the Sugar

dissolving/Syrup room, I was able to appreciate courses like CHE 413(Transport Phenomena)

when it came to the aspect of the heat exchangers and their uses in the plant and CHE

416(Chemical Kinetics and Reactor Design) when it came to the aspect of the mixers and

reactors.

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 3.2 Challenges
3.2.1 Challenges I Encountered
 Lack of PPE: Personal Protective Equipment (PPE) were not provided for the IT

students at SBC. To overcome this, I personally had to source for my own lab coat and

safety boots. Despite that fact, other items like goggles and ear plugs were still not

provided.

 Language Barrier: As I mentioned earlier, the company is a big one and various

people from different backgrounds are employed. Due to this, communication with

some of the staff was difficult if you could not speak in their native dialect.

3.2.2 Challenges Faced by Company

Some of the challenges I observed the company faced include:

 Use of old equipment: Most of the plant equipment were not in proper shape, thus

resulting in reduction in efficiency. Maintenance designated for the plant was

never strictly adhered to, as the condition of their equipment was neglected

sometimes.

 While I was at the plant, I observed that one of the production lines (line 2) was

down and due to that fact, the company was making a loss for each day that the

line was not in production.

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 Chapter 4

CONCLUSION, RECCOMENDATION, REFERENCE

4.1 Conclusion
At Seven-Up Bottling Company (SBC), I was given such an invaluable exposure to the

manufacturing industry and the operation possibility and technique of beverage

production. The company also has a friendly atmosphere for learning.

While at the Production Plant of the SBC my eyes were opened to the prowess of a

chemical engineer in the production sector and how diverse the role of a Chemical

Engineer is. I now realize that a chemical engineer can truly work anywhere in which raw

materials are being processed into finished goods. The knowledge, values and work ethics

I have gained during this 18-months industrial training program are absolutely priceless.

4.2 Recommendation
In every organization or company, there will always be room for improvement and here

are some of the observations I have made that will help make the work experience at SBC

even better. I recommend that PPE be provided for staff regularly as some of these staffs

may tend to lose their PPE due to forgetfulness or carelessness and are left to work at their

own risk.

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Reference(s)
 Wikipedia.com, History on Seven-Up Bottling Company, 1998.
 Federal Ministry Government (1990). Industrial Training Fund (Amendment)Decree,
1990.
 Experience Scheme. http://itf.nigeria.org/siwes-op-guide.pdf.
 SBC (2010). About Us. Retrieved March 11, 2016 fromhttp://sevenup.org/home.
 7up Employee Handbook.
 Basu, S., McKee, M., Galea, G. and Stuckler, D. (2013). Relationship of soft drink
consumption to global overweight, obesity, and diabetes: a cross-national analysis of
75 countries. Am J Public Health.103:2071–7.

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