A PROPOSAL FOR DESIGN AND SETUP SUPPORT FOR WATER BOTTLING

FACTORY FOR XXXX NIGERIA LIMITED BY AMOS ENGINEERING COMPANY.

1.0 SCOPE OF WORK
A design of a water treatment plant that is channelled into XXXX Nigeria Limited for the
purpose of bottle water production as a major and future forecasted product as the minor which
meets regulatory and statutory specifications.
2.0 INTRODUCTION
In view of the scope of this project, the factors that are strong points which ferments the positive
result of the scope of this project are:
 Type of water source
 Treatment process design and construction
 Drinking water quality control
2.1 TYPE OF WATER SOURCE
For the location of water source, hydro geological assessments are carried out to be sure that the
proposed water source is not affected by groundwater, nearby surface water and other
geographical contaminants that might affect the quality of water. It is recommended that the
location of a borehole should be 15metres away from septic tanks and according to the
recommended standard by NAFDAC, the minimum depth value of a borehole is 150ft which is
going to be strictly adhered to for the purpose of this project meeting regulatory standard and
specification. The water obtained from this process is referred to as raw water which is a major
contributor and determinant to the quality and type of treatment to be administered respectively
to achieve the quality of water we desired. At the point of completion, a raw water sample is
collected and taken to the laboratory for analysis for level of impurities and pollution. The
laboratory results point out the level of treatment to be administered.
2.1.1 COST IMPLICATION
 Borehole Drilling:
 Raw Water Laboratory Analysis:
2.2 TREATMENT PROCESS DESIGN AND CONSTRUCTION
From the source (borehole), the water is transferred into two (2) raw water tank of 7500liters
each through the aid of a submersible pump. At this point, aeration of the water takes place
whose purpose is to remove gases from the water through the exposure of the raw water to air.
Chlorination also take place in the raw water 24 hours before production. The aerated water is
the pumped using 1hp surface pump through the sand filter, carbon filter and ion module to
remove suspended matter as well as floating, remove unwanted chemical and organic compounds
and sinkable particles and removal of hardness respectively. After this process, the semi-treated
water is pumped into two (2) treated water tank of 5000liters each. At this point, it is pumped
through the reverse osmosis machine where separations of ions, unwanted molecules and larger
particles takes place with the help of an internally built permeable membrane and passes through
4.5 x 20” filter candles into a stainless water tank called product tank of 2000liters capacity
where an ozone generator is passed into the treated tank to oxidized and eliminates contaminants.
The water is then transfered with an inch pipe with the aid of a 1hp surface pump into the
Monoblock Machine through filter and ultra-violet light. The monoblock does three major
function which are bottle washing, filling and capping. The labelled product is then passed
through the steam tunnel which purpose is to glue the label firmly to the bottle and sterilize the
exterior part of the bottle. The product is then packaged using the shrink wrapping machine by
placing the number of bottles per pack and allowed it to move through the oven which melts and
strengthen the nylon.
Below is the flowchart treatment design

Source (Borehole:150ft depth min)

(submersible pump)
2 Raw water tank (7500 liters each)
(surface water pump, aeration)

Sand Filter Carbon Filter Ion Module

2 treated water tank (5000liters each): (surface water pump)
(1hp surface pump)
Reverse Osmosis Machine
(surface water pump)
Ozone generator Product tank (Stainless,2000 liters)
(surface water pump)
Filter (‘4.5 x 20’’)

UV Light

Monoblock

Fig 1.0: Flowchart diagram of proposed water treatment

2.2.1 COST IMPLICATION
Material Quantity Unit Cost Total Cost
Submersible pump (Industrial) 1
Rubber Tank (Black, 7,500litres) 2
Rubber Tank (Black, 5,000litres) 2
Surface pumps 5
Water treatment module 3
Reverse Osmosis 1
Ozone generator 1
Micron filters 72
UV light 1
Ink Coding machine 1
Monoblock 1
Stainless tank (2000litres) 1
Steam Generator & Tunnel 1
Shrink wrapping machine 1
Heat Extractor 3
Industrial stabilizer 3
Industrial Chiller 1
Change-over switches 3
150kva generator 1

 Currency is in Naira.
 The prices given above is sustainable for 2 weeks as the Nigerian technology market is
not static due to fluctuation in exchange rate.
2.3 PROCESS WATER QUALITY ASSURANCE AND CONTROL
At the completion of installation of the treatment plant, the water sample is taken to an accredited
public analyst laboratory for analysis to ensure that its physiological and microbial result
conforms with regulatory standards. Process water quality assurance and control are a set of
activities that are to be undertaken to ensure compliance and above all, ensure that the water is
safe for public consumption in a sustainable manner. For a water to be safe, it must be free from
physical, chemical and biological hazard. To avoid cross-contamination after the treatment of
water, we have to ensure that nothing coming in contact with the water is a contaminant. Things
to consider are:
2.3.1 FOOD HANDLER’S TEST
This is a regulatory requirement that is periodically done through a set of tests and medical
examination to certify that those handling food products are medically fit and therefore are not a
threat to food safety. Every quality and production staff must undergo this process.
2.3.2 WATER QUALITY TEST
It is important to daily test all available water samples that are collected from sampling points to
ascertain that the treatment system is functioning perfectly and if the quality of the water source
has deviated from specification. This analysis includes both physiological and microbial analysis.
The titrimetric analysis and physiochemical analysis are documented to show a set of instructions
that describes in detail how to perform a laboratory process or experiment safely. These
documents are referred to as the Standard Operating Procedure (SOP). The physiochemical
analysis of the water samples can be done through the usage of an equipment that aims at a result
and by titrimetric analysis. Among the analysis to be done are: pH, Conductivity, Turbidity,
Hardness, Alkalinity, Fluoride, Nitrate, Total Suspended Solids (TSS), Total Dissolved Solids
(TDS) etc. All analysis is done in conformation to AOAC methods. The microbial analysis of the
water can be contracted to an accredited IPAN laboratory where there is a period microbial
analysis of the water samples.
2.3.2.1 COST IMPLICATION
Material Quantity Unit cost Total cost
Table top scale 1
Grounded weighing scale (1kg- 1
100kg)
Handheld pH meter 1
Handheld conductivity meter 1
Handheld TDS meter 1
Residual chlorine colorimeter 1
Iron test kit 1
 Hardness test kit 1
Beakers 10
SOP 1copy

 N.B: Currency is in Naira

2.3.3 PET BLOWING AND STORAGE
In achieving a quality and cost-effective bottle water plant and a view of future production of
non-alcoholic beverage, it is advisable that XXXX Nigeria Limited has it preform blown into
bottles with usage of pet blowing machine with the aid of a mold which will be designed into the
projection of what the finished goods packaging material will look like. The preform and bottle
are stored in a room under a UV light so as to eliminate all micro-organisms that the bottle or
preform might contain which can cross-contaminate the product.
2.3.3.1 COST IMPLICATION
Material Quantity Unit cost Total cost

Pet blowing machine (2cavity) 2

UV lights for storage room 1

N.B:
 Currency is in Naira
 The prices given above is sustainable for 2 weeks as the Nigerian technology market is
not static due to fluctuation in exchange rate.

3.0 CONCEPTUAL DESIGN AND FACTORY SETUP

The design of the proposed bottle water factory is such that involves the physical arrangement of
industrial facilities which includes space needed for material movement, storage, indirect labour
and other supporting activities or services to enable continuous and steady flow of production
cycle. Figure 2.0 shows the schematic design of the production process considering the available
layout.
Fig 2.0: Design of production room for XXXX Nigeria Limited bottle water
3.0 IDENTIFICATION AND DEFINITION OF ROLES OF EMPLOYEES
The above pictorial representation shows the semi-automatic blowing machine, monoblock
machine, water treatment system and semi-automatic package machine (shrink wrapping
machine). This system is arranged in a linear form for easy of mobility during production. The
entrance into the production room is located at the bottom right corner in the schematic diagram.
Production staffs who might have changed from the cloak room starts production by the blowing
of preforms into bottles. The first production staff brings in the preform from the packaging
material store who also blow the preforms into bottles. The second production staff relocates the
blown pets to the next stage which is the operation of the 3-in-1 monoblock machine that does
the washing of the bottles, filling of the product inside the bottle and cap the bottle. The machine
has sections where production personnel will be active in beyond the first compartment. The
second production personnel is placed the right end of the monoblock whose duty is to fill in
empty the bottles which is to be transported to the washing section with the aid of an air
conveyor. A third production staff is placed at the second compartment of the monoblock
machine to simultaneously run the bottle washing, filling and capping and attend to challenges
that may arise. Immediately after capping, the product comes out and it is batch coded with the
aid of a coding machine which is then conveyed to a point where the label is worn round the
capped and coded bottle. This is done by fourth production personnel and under the supervision
of a quality online inspector (fifth staff) who makes sure all production activities conform to both
organizational and regulatory standard. He also reports and correct inconsistency. The coded
product is allowed to pass through steam/shrink channel where the label is fitly glued to the
bottle. The finished product comes out of the shrink compartment and is received by sixth
personnel who receives and handle it over to the seventh personnel that handles the first section
of the semi-automatic packing machine whose duty is to arrange the bottles in order of agreed
number which is then conveyed into the steam compartment so that the wrapped products with
be glued and fit in the packaging nylon. At the other end of the machine, eight production
personnel collect the wrapped product and place on pallet and transported with a pallet truck into
the finished goods store by the ninth personnel.
During production, a quality assurance (tenth staff) comes to randomly pick sample for analysis
to make sure the product conforms with specification. Another quality assurance staff is
responsible for releasing a batch for market sales and physiochemical analysis of packaging
materials and finished goods and establishing SOPs.
3.1.2 STAFF DISTRIBUTION
▪ Quality Assurance Department: 3
▪ Production Department: 10
3.1.3 PRODUCTION OUTPUT
Factors that can limit the output of production are:
▪ Shortage of raw material
▪ Limited machine hours
▪ Limited labour hours
▪ Limited skilled labour
3.1.3.1 SHORTAGE OF RAW MATERIAL
The major raw material in the proposed production of table water is the bottle and that is largely
handled when you are in control of the bottle by buying enough preforms and blow into bottles.
The challenge of unavailability or disappointed is largely solved.
3.1.3.2 LIMITED MACHINE HOURS
Monoblock machine has a high effectiveness value including the semi-automated pet blowing
and packing machine which has contributed to the high Overall Equipment Effectiveness (OEE).
By this, the production downtime will be largely reduced or eliminated. The monoblock machine
has a capacity of producing 3000 bottles per hour at a slow revolution per minute (rpm).
3.1.2.3 LIMITED LABOUR HOUR
For optimum output, it is recommended that the labour force run on shift so as to also reduce
weariness and overload. For effective cost management, two shifts are recommended.
3.1.2.4 LIMITED SKILLED LABOUR
Skilled labour should be employed only at strategic places in the quality, production and
marketing departments. While unskilled labour should be also employed at less or no strategic
points during production.
4.0 REGULATORY REQUIREMENTS
As it is a standard in Federal Republic of Nigeria, a product can’t be pushed to the public for
sales without an approval by NAFDAC who serve as a regulatory body for start-up food,
cosmetic and pharmaceutical companies. Some vital documents are to be obtained before an
inspection is carried out by NAFDAC. They include:
▪ CAC Certificate
▪ Trademark Certificate
▪ Fumigation Certificate
▪ Food Handler’s Test for staffs
▪ SOP for the product (cost included in proposal)
▪ Product External Analysis Report (cost included in proposal)
▪ Company’s Letter Headed Paper
▪ Production Manager’s Resume
▪ Product Label (Soft Copy)
After the submission of these documents and payment for the product, physical inspection will be
scheduled as NAFDAC officials will pay a visit to see the standard of the factory. Checks will be
made majorly on these rooms/store:
▪ Production Room
▪ Raw Material/ Packaging Room
▪ Cloak Room
▪ Finished Goods Store
5.0 PROJECT TEAM
Chief Engineer:
Food Safety and Quality Manager:
Senior Engineer (Electrical):
Junior Engineer (Mechanical):
Junior Engineer (Mechanical):
6.0 ADVANTAGES OF WATER FACTORY
1. Water has an unshaken market demand-: Water is always in demand because it is
indispensable and everybody needs water to live. That’s the reason why the business is very
lucrative.
2. A growing awareness in health consciousness There is a growing increase in health
consciousness now, as people are being watchful of what they eat and drink; so as to avoid
ailments such as typhoid, cancer, obesity and also live longer. Thus creating a corresponding
need for
bottled water; especially bottled mineral water.
3. A growing awareness of the need to protect the environment IN Nigeria, one of the fastest
selling products is sachet water; otherwise known as pure water. The reason why it is a fast
selling product is because sachet water is cheaper especially when compared to bottled water.
But with the level of regulations, the era of sachet water has come to an end.
4. The profit margin is very high. Water, which is the most important raw material for bottled
water production is readily available for free. Once a borehole is drilled and setup, you will have
a steady supply of water. Other production materials can either be purchased in the marketplace
or outsourced (Bottles and labels).
7.0 RISK FACTOR INVOLVED IN STARTING A BOTTLED WATER FACTORY
1. Setting up a bottled water plant is capital intensive, as you would need to rent a large space or
building for production, purchase heavy machines, etc.
2. The cost of maintenance and repairs for the machines you will be using is quite high.
3. You will need a few technically inclined employees like a production supervisor, production
manager, facility maintenance personnel, machine operators, etc and training these set of
individuals for the job role is quite expensive.
4. You will also have to deal with poor power supply. This will definitely increase operating
expenses as you would have to provide your own power supply using a power generating set.
5. Getting the appropriate license is quite a herculean task due to the stringent terms and
conditions you must meet. You will also need to maintain a high standard of hygiene as the
health officials may bump in at any time for inspection.
6. The water bottling business is sometimes affected by seasonal changes, so you should be
prepared to experience a drastic decline in sales especially during the rainy season or winter. This
is because people consume less water during this season.
8.0 REFERENCE
WATER FACTORY YOU HAVE SETUP
9.0 CONCLUSION
We believe our proposal provides a clear and complete strategy that will add a huge amount of
value to your business. The total cost of achieving this project is NYYYYYY. We deliver quality
embedded project. Please feel free to contact me with any questions you may have. My contacts
are below.
Thanks, and Best Regards
NAME OF CHIEF ENGINEER
COMPANY NAME
EMAIL ADDRESS
PHONE NUMBER