Drinking Water Production

ABC drinking water production

Introduction

It is especially different from other plants for drinking water (ABC) production.

   Three types of water is produced in ABC PLANT.

   1.Treated water  2.Soft Water  3.Reverse Osmosis (RO) water

   Our drinking water (ABC) is  Treated with water.

SPECIFICATION OF ABC drinking water

ABC is the brand name of the drinking water of ABC PLANT. Different Pack size SKU  such as 250 ml, 500 ml,1500 ml ABC produce in this plant.

                                                 Composition of ABC drinking water:

                                                                TDS--------<500mg/l

                                                                Ca-----------<75mg/l

                                                                As------------Nill

                                                                Cd------------Nill

                                                                Pb------------Nill

                                                                CN------------Nill

                                                                N𝑂_2-----------Nill

                                                                NO3……….<0.5

                                                                〖𝐶𝑙〗^−------------<250mg/l

                                                                Mg-------------<35mg/l

                                                                𝑝^𝐻---------------6.4-7.4

 FLOW DIAGRAM OF ABC drinking water PRODUCTION IN ABC PLANT

 AT A GLANCE OF TREATED WATER  PRODUCTION

OZONATION

Ozonation is a process in which ozone is used to kill the microorganisms of treated water. The half-life of ozone is very short.

HOW OZONE(𝑶_𝟑) IS PRODUCE AND KILLED MICRO ORGANISM?

Here high voltage electricity is used to produce ozone.

When high voltage electricity is passed through dry air it produces ozonized air.

This ozonized air is passed through water and killed microorganisms.

𝑂_2   −−−−−−>𝑂. +  𝑂.

                                                                                                                                                     O. +   𝑂_2 ------------&gt;  𝑂_3

Ozone comes into contact with the bacteria. One of the three atoms of ozone molecules is unstable and absorbed by the bacteria. That oxygen atom penetrates the cell wall of micro organism which leads to the complete destruction of bacteria and only 𝑂_2 remains.

𝑂_3+ Micro organism ------------------&gt; Dead micro organism + 𝑂_2

UV TREATMENT

In Ultra Violet(UV) treatment, UV light is used to kill residual microorganisms.

UV light consists of light of wavelengths between 40 to 390 nm, but wavelength in the 200 -265nm range is most effective in killing microorganisms.

When microorganisms are subjected to UV light, the cellular DNA absorbs the energy by purines and pyrimidine bases, and adjacent thymine molecules link together. Link thymine molecules are unable to encode the adenine of RNA molecules during the process of protein synthesis. Thus replication of the chromosome in binary fission is impaired and the microorganisms are die off.

Here mercury vapor lamp is used to create UV light.

This process is simple but effective, and destroy 99.99% of harmful microorganisms without adding chemicals to the water.

Disadvantage: The radiation is not very penetrating so the microorganisms to be killed must be directly exposed to the rays.

FILTRATION

Before entering the treated water into the filler, it is filtrate with 1µm filter.

FILLER

The capacity of filler is 24500bph. It has 77 no Of vent tube. Water is filled into an empty bottle (come’s from blow mold) by gravitational force.

BLOW MOULD

Blow mold is a machine by which the bottle is prepared from a preform. It has 14 molds and capacity is 24000bph.

How bottles are produced in blow mold?

1.  Preform from preform hopper goes to blow mold through the conveyor, here dust collector removes dust from the preform.

2. Preform enters into the heating chamber by in-feed star wheel and mental.

3. In this heating chamber, there are 14 heating boxes ( 7 on each side). Each of the heating boxes contains 9 heating tubes. The power of no. 1st  heating tube is 3000w and the others are 2500w.

4.  when preform passing through the heating chamber its temp. becomes ≤ 150° according to wt. and color and it becomes soft.

5. The soft preform enters into the mold.

In-mold The following steps occur:

         a. At first stretching rod and pre blowing pressure enters into the preform and pre blown bottle is form. This process occurs within an angle of ≤ 120° and pressure ≤ 15 bar.

         b. Then stretching rod removes and final blowing pressure (≤ 40 bar) enters into the pre blew bottle and forms a final bottle. When the final bottle has formed the wall of the blown bottle touch the wall of mold to become cool. Here cooling temp. is 8-12° C.

The complete bottle goes to the filler to fill with water.

CAPPER HEAD

There are 11 no. of capper head which used to set closure with filling the bottle. Here we maintain capper head setting 17. And the torque of filling the product is in the range 12-16 lbs-inch.

CHECKMATE

After filling and capping, the filled bottle goes to checkmate where fault bottle automatically separated (such as low filled, empty bottles,).

LIGHT INSPECTION

In this point, the worker checks the following point-

• Unwanted particles may be present in bottles.

• Closures check ( Fitting & Ring).

• Bottles volume ( High & Low fill).

• Bottles leakage.

DRYER

A dryer is used to drying the product before labeling it.

Labeling AND BAND ROLLING

Labeling in CSD-2 is two types

                1. Control

                2. Sleevematic.

Usually in spa control label is used. The capacity of this m/c is 24000bph. Her glue is used to attach a label with a bottle and the temp. of glue is 145°c.

Size of label     1. For 250ml- 175mm(length), 36mm(width).

                         2. For 500ml- 216mm(length), 36mm(width)

Here Band rolling is also done.                           

                         3. For 1500ml- 292mm(length), 66mm(width)       

Here band rolling is also done.

Band roll heater temp. the range is (250-300)°c.

SHRINK MATE

Shrink tunnel is used to shrink label ( usually for schematic) band roll.

Here steam is used to shrink label.

DATE CODING

Date code machine automatically prints date code bottle to bottle. The capacity is 24000bph.

Such as MRP TK

                     P 02.12.15

                     BB 01.12.16

                     Batch 078abc15

WRAPPING

Wrapping m/c is used for wrapping of Final product. The capacity of this m/c is 24000bph. Here Wrapping temp. is about 250ml 190°c, 500ml 168°c, 1500ml 175°c,  and the dwelling time 12s.

Length and width of shrink film:

                                                a. For 250ml spa are length 815mm and width 470mm.

                                                b. For 500ml spa are length 885mm and width 425mm.

                                                c. For 1500ml spa is length 1085mm and   width 425mm

PALLETIZING

At Last, Palletizing is done with 150 cases 12 finished (500ml) products are present in a case.

Different parameters of a good plate:

Q.C RESPONSIBILITIES

In the case of ABC production, the chemist will maintain the following parameters:

                1. To measure 𝑝^𝐻  ( 6.4- 7.4)

                2. To measure TDS( total dissolved solid)

                3. Conductivity

                4. Residual Ozone

                5. TOA test

                6. Torque (12-16 lbs-inch)

                7. Labeling, date coding, and wrapping condition.

                8. To ensure the switch on of BAXX, four-light of UV tube

CLEANING &CIP

Before starting spa production we have to maintain the following parameters:

1.  7 step CIP using (1-2)% NaOH, (1-2)% HN𝑂_3   and hot water ≥85 °C (return) and 100ppm         〖𝐶𝑙〗_2 for      20min.

2. Foam cleaning using P3 Topaz 19( 2.5%), Fumigation using Divosan Forte.                                                        

3. Preform hopper, Closure hopper, Air conveyor, Closure on the filler will be cleaned by 70% alcohol.

4. The air filter must be changed, Dust Collector of blow the mold must be cleaned.