INTERNSHIP REPORT ON NAUBAHAR BOTTLING COMPANY

GUJRANWALA

Submitted By:
Javeria Masood

Submission Date:
24/08/2022

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 PREFACE

The pre-requisite of Internship Program is to make the students of BSc in Chemical

Engineering aware of the handy expertise and to acquaint them with the real
Production Process.

Getting a chance of working in Naubahar Bottling Company (Pvt.) Ltd. proved to be

very beneficial for me. I think that I gained comprehensive insight into the working
of a Beverage Company. But nothing could have been possible without the co-
operation and guidance of the officers of NBC.

After the completion of Internship Program, Internship Report has been prepared
just in accordance with the practical exposure. It has been my endeavor to stipulate
my experience in a way that the reader may clearly understand the core concepts.

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 EXECUTIVE SUMMARY

This report highlights the basic functions and operations of PEPSI COLA
International’s franchise Naubahar Bottling Company located in Gujranwala where I
did my Four (4) weeks internship. This report contains the history of PCI, when it
was entered in Pakistan and how Naubahar Bottling Company Pvt. Ltd. Gujranwala
changed its business from Coca Cola to Pepsi in 1980-81. This report basically has
detailed information about the workings of the major functions of the NBC i.e.
production, maintenance and water treatment etc.

This report contains observations and findings of NBC working environment in a

summer season which is almost peak season for the bottling companies. It is
dealing in all beverage brands as by PCI internationally e.g. Pepsi, Miranda, Sting,
Mountain Dew, 7-up, 7up Free etc. NBC is not only the largest franchise of PCI in
Pakistan but also the largest one from all working in south Asia.

NBC is the company having many achievements in shorter span of time like; best
bottler of the year, ISO 9000 certified high performance award and many more that
shows that how this organization is working efficiently and effectively. This
organization is expanding more than its expectation that’s why there are some
problems facing this organization which are mentioned in it.

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 VISION

PepsiCo’s responsibility is to continually improve all aspects of the world in which

we operate environment, social, economic – creating a better tomorrow than
today, Tomorrow greater than Today. We believe Sustainability lives at the
intersection of public and corporate interest. It encompasses citizenship and
corporate social responsibility, which are about doing the right things for society
and for the business. It encompasses the health of the Company, which is about
fulfilling our mission of creating financial rewards and growth.

MISSION STATEMENT

“To be the world's premier consumer Products Company focused on convenient

foods and beverages. We seek to produce healthy financial rewards to investors as
we provide opportunities for growth and enrichment to our employees, our
business partners and the communities in which we operate, and in everything we
do, we strive for honesty, fairness and integrity.”

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 ORGANIZATION SET-UP

Director

General Manager

General Manager General Manager

(Local Sales) (Out Sales)

Plant Manger
Marketing & Services
Manager
Production
QC Manager
Manager

HR Audit Purchase Finance MIS Shipping Store

Manager Manager Manager
Manager Manager Manager Manager

S&D Assistant Manager Publicity

Mangers Marketing & Services Manager

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 OVERVIEW OF THE ORGANIZATION
BRIEF HISTORY OF PCI

Born in the Carolinas in 1898, Pepsi-Cola has a long and rich history. The drink is the invention of Caleb
Bradham (left), a pharmacist and drugstore owner in New Bern, North Carolina. The summer of 1898, as usual,
was hot and humid in New Bern, North Carolina. So a young pharmacist named Caleb Bradham began
experimenting with combinations of spices, juices, and syrups trying to create a refreshing new drink to serve
his customers.

He succeeded beyond all expectations because he invented the beverage known around the world as Pepsi-
Cola. Caleb Bradham knew that to keep people returning to his pharmacy, he would have to turn it into a
gathering place. He did so by concocting his own special beverage, a soft drink. His creation, a unique mixture of
kola nut extract, vanilla and rare oils, became so popular his customers named it "Brad's Drink." Caleb decided
to rename it "Pepsi-Cola," and advertised his new soft drink.

People responded, and sales of Pepsi-Cola started to grow, convincing him that he should form a company to
market the new beverage. In 1902, he launched the Pepsi-Cola Company in the back room of his pharmacy, and
applied to the U.S. Patent Office for a trademark. At first, he mixed the syrup himself and sold it exclusively
through soda fountains. But soon Caleb recognized that a greater opportunity existed to bottle Pepsi so that
people could drink it anywhere.

The business began to grow, and on June 16, 1903, "Pepsi-Cola" was officially registered with the U.S. Patent
Office. That year, Caleb sold 7,968 gallons of syrup, using the theme line "Exhilarating, Invigorating, Aids
Digestion." He also began awarding franchises to bottle Pepsi to independent investors, whose number grew
from just two in 1905, in the cities of Charlotte and Durham, North Carolina, to 15 the following year, and 40 by
1907. By the end of 1910, there were Pepsi-Cola franchises in 24 states. Pepsi-Cola international provides
advertising, marketing, sales and promotional support to Pepsi-Cola bottlers and food service customers. This
includes some of the world's best-loved and most-recognized advertising.

New advertising and exciting sales promotions keep Pepsi-Cola brands young. The company manufactures and
sells soft drink concentrate to Pepsi-Cola bottlers. The company also provides fountain beverage products.
Pepsi is a leader in convenient foods and beverages, with revenues of about $27 billion and over 143,000
employees. PepsiCo brands are available in nearly 200 countries and territories. Many of PepsiCo's brand names
are over 100-years-old, but the corporation is relatively young.

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PepsiCo was founded in 1965 through the merger of Pepsi-Cola and Frito-Lay. Tropicana was acquired in 1998
and PepsiCo merged with The Quaker Oats Company, including Gatorade, in 2001. PepsiCo’s success is the
result of superior products, high standards of performance, distinctive competitive strategies and the high
integrity of our people.

Pepsi Logos:

The Pepsi logo has changed many times over the years. Here's a chronological history of the various logos. Pepsi
Cola Int. operations in Pakistan are being monitored by West Asia Division of Pepsi Cola International.

The West Asia Division comprised four countries

 Afghanistan
 Bangladesh
 Pakistan
 Sri Lanka

The company in Pakistan had its head office in Lahore. The business with the Bottlers was handled through
Franchise Managers. Ten bottling companies in Pakistan produced the Pepsi brands of soft drink. These
companies bottling plants located in
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  Lahore
 Islamabad
 Multan
 Gujranwala
 Karachi
 Hyderabad
 Peshawar
 Quetta
 Faisalabad

Introduction to NBC

Organization Name: Naubahar Bottling Company

Address: S.I.E. Model Town Gujranwala Pakistan
Pepsi co starts its operation in Pakistan in 1971 first time in Multan. And NBC also establish in 1971 and from
1974-79 NBC was producing the Coca Cola products. In 1980 NBC achieve the licenses of PCI and in May 27,
1981 its start the production of the Pepsi, in the same year NBC achieve the ISO 9002 certification. And in 2008
NBC start the production of 7up. And its unit’s productions capacity is 100000 cases per day with 5
manufacturing’s plants. The Area allotted to it, was Gujranwala Franchise. The franchise area consists of the
following nine districts.

 Gujranwala
 Gujrat
 Hafizabad
 Mandibahaudin
 Jehlum
 Sialkot
 Narowal
 Sheikhupura
 Chakwal

Nature of the Organization

Naubahar Bottling Company (Pvt.) Ltd. is a manufacturing company. It produces various types of carbonated
drinks and Juices. NBC is committed to provide the quality soft drink to the customers. The organization is
equipped with all pre-requisite for meeting the future challenges successfully. Naubahar Bottling Company has
a high number of professionally qualified persons in Sales, Marketing, Production, Shipping, Finance,
Administration and Technical Departments. The company is offering most popular brands of soft drinks.

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Currently Offering Products

By the passage of time company is expanding its offerings. Initially company was involved in manufacturing
soda water. Now it is also producing juices and energy drinks.

 Pepsi Cola
 7up
 7up Free
 Mirinda
 Mountain Dew
 Sting – Energy Drink

Company’s Core Values

1. Focus on customer:
In which our basic focus on customer according to need and want and satisfy the customers to our product.
We treat each of our customer equality & as the most important person while we interact with him/her. We
must ensure that we do everything to meet and exceed the customers’ expectations with perfect to times,
accuracy & quality services.
2. Focus on quality:
We ensure that each moment of our time is spent on value adding activity. We always seek ways for
exceeding expectations of customers & colleagues. We also ensure that we do things right, first time every
time.
3. Focus on employee respect:
In which company respects the customer and employees which is involved in the company working. We
treat each of our employees with fairness, which includes giving constructive feedback for their
development.
4. Team based approach:
We work towards achievement of our vision & mission as a combines group. We encourage inter & intra-
departmental communications. We treat our colleagues as our internal customers & ensure that the
requirements of internal customer focus are always met.

Nau-Bahar is a largest franchiser of Pepsi cola International producing and distributing international brands
like Pepsi & 7up and Mountain dew .plant is situated in Gujranwala, Pakistan.

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 PLANT CAPACITY

Nau-Bahar Pepsi cola industry has a moderate and big plant. It can produce 600 bottles in one minute. It has
also the water treatment plant which can take raw water from 500 depth, treat and filter it and then store
it. Plant can store 20000 gallons.

My Internship time and my Experience:

During my internship in the Naubahar Bottling Company, Small Industrial Estate Model Town Gujranwala, I
really enjoyed to work with the staff of Company, from 26 July to 26 August, 2022 and have a wish to be
employee of Naubahar Bottling Company. It was almost impossible to work in all the departments within
that limited time. But on my request, the staff of the company provided me the opportunity to work in the
different departments for the sake of practical knowledge. During my internship training I work in following
departments.

 Quality Control.
 Quality Assurance.
 HSE and food safety.
 Production and maintenance.
 Water treatment
 Ammonia.

I learn a lot of practical things during working in these departments. Working environment in these
departments which I observe during my internship is really admirable.

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Week 1 Report:
CIP Process:

CIP is a method of cleaning

 Sanitary process lines

 Vessels
 Equipment commonly used in process plants

Without having to remove or disassemble piping or equipment to accommodate cleaning.

CIP can be done in:

 7 steps
 5 steps
 3 steps

7 steps CIP:
1) Pre-rinse
2) Caustic wash
3) Intermediate rinse
4) Acid wash
5) Intermediate rinse
6) Sanitize
7) Potable water rinse (depending on sanitizer & Concentration)

5 steps CIP:

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3 step CIP:

 Pre-Rinse
 Rinse through Chemicals
 Post Rinse

STEP 1: PRE-RINSE

The pre-rinse is a very important step in the CIP process because a well-monitored and well-executed pre-rinse
makes the rest of the wash cycle predictable and repeatable.

The pre-rinse cycle:

 Wets the interior surface of the lines and tanks

 Removes most of the remaining residue
 Dissolves sugars and partially melts fats
 Provides a non-chemical pressure test of the CIP flow path

STEP 2: CLEANING THROUGH CHEMICALS

in this process the cleaning is done through the chemical VC-99.

 Dosage: 0.5-1%
 temperature : 85C
 time : 15-20min
 Conductivity : 20-25ms/cm

STEP 3: POST RINSE

This process involves the cleaning through the treated water to the appropriate temperature. This process
is carried till that point until all the chemical removed. To check this either chemical is present in the water
or not use indicator phenolphthalein.

Time:

Approx. 5-10min

Chemical used:

 CIP (VC-99)
 COP (Hypofoam)

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 Quality control lab
Quality control is the basic organizational objective of NBC. Quality check is made from zero level to final
products. For this purpose samples are taken from the production to check the quality. This sampling is
done after each an hour or half an hour. These samples are tested according to the PCI standards.

M
PRODUC SYRU TRU ALKALINIT
CO P SYRUP E BRI PH INVERTED BEVERAGE Y
2T DENSIT X
GAS BRIX Y BRIX DENSITY
10.40 2.45
PEPSI 3.70 52.20 1.2419 11.55
10.90 1.0399
7 UP 3.70 53.30 1.2480 10.60 3.25 11.20 1.0409 23.52
D=0.99
7UP Free 3.70 N/A 1.0063 4 3.25 N/A 0.9992 25.50
0
M. Dew 3.20 58.10 1.1096 11.80 3.00 12.40 1.0459 19.97
STING B.B 2.60 40.50 1.2755 15.10 3.05 15.80 1.0599 61.36
Marinda 1.80 54.30 1.1791 12.90 2.75 13.65 1.0507 27.62

Laboratory:
In order to maintain the high quality the plant has a well-equipped lab. Laboratory is sufficient to measure
the standards and to test syrup of different flavors. The well-equipped lab enables the smooth flow of
production process.

Tests performed in QC lab

 Carbo QC
 Degassing
 Titratable Acidity
 Inverted Brix
Test of filled bottles:
1. Carbo QC

Carbo QC is the precise CO2 meter which allows reliable QC on finished packages as well as highly accurate
measurements in the laboratory for product development. It gives you fast, accurate and reliable
determination of dissolved carbon dioxide in beverages. When combined with Anton Paar’s PFD filling
device, sample is taken directly from the package into the measuring chamber of CarboQC - with no loss of
dissolved carbon dioxide during sample transfer.
Pressure maintained during this process is up to 90 psi.

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2. Degassing
Degassing or degasification is a method for removing dissolved gases from liquids. During this process
basically bonds between carbonic acids are break. In this process pressure is taken up to 10-15 psi.
Shake the bottle 30 times in 15 seconds.
Then open the bottle and put it in beaker and then put it in degassing apparatus.
Time for line sample 15 min
Time for market sample 12min

3. Brix and density measurements:

Density meter is used to measure the beverage or syrup density and brix
The apparatus is as follows:

PH Meter
PH meter is used to measure the ph of beverages.
4. Titratable Acidity:
Purpose:

To check the acidity level

Reagents:
KHP (0.8g)
NAOH (4g)
Titrant: Sodium hydroxide solution

Titer: Potassium hydrogen phthalate

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 Carbon dioxide absorption from the air occurs in the sodium hydroxide solution of sodium bicarbonate,
which changes the pH of the titrant. To prevent this, a drying tube filled with soda lime is placed on the
reagent bottle. The exact concentration of the sodium hydroxide solution is determined using the standard
potassium hydrogen phthalate. The potassium hydrogen phthalate is dried in the oven before the titer
determination for 2 hours at 120 °C and cooled in a desiccator.

In a 50 mL beaker, 0.1 to 0.8 g potassium hydrogen phthalate is weighed accurately and dissolved in 30 mL
of dist. water with stirring. It is titrated with 0.1 N/l sodium hydroxide solution.
The pH of each beverage was determined by using a glass pH electrode coupled to a potentiometer. The
tritatable acidity was then measured by adding 0.1N NaOH to each beverage until the pH reached 7.35.
5. Inverted Brix:
Sugar inversion is the chemical conversion of saccharose into glucose and fructose. This process is enhanced
by acids and high temperatures.

Saccharose is subject to sugar inversion which changes the composition of the beverage. Since many soft
drinks are produced using beet or cane sugar as a sweetener, this chemical reaction has to be closely
monitored as the beverage composition gradually changes with progressing sugar inversion.

Measuring the degree of sugar inversion plays a very important role for the production and quality control
before, during, and after the production process and is relevant for producers and bottlers of soft drinks
with sugar.

The inversion of beet or cane sugar is the chemical conversion of saccharose in solution into glucose and
fructose.

This process is enhanced by acids and high temperatures T.

Steps to be followed are:

 Degas the sample (if carbonated)

 Add acid
 Place the sample in a preheated water bath (90 °C, 1 hour)
 Allow the sample to cool
 Measure the density of the sample
 Use an appropriate conversion procedure to calculate the °Brix fresh or °Brix inverted from the
measured density.

If the degree of inversion is also required, the density is measured twice: once after degassing before inversion
and once after inversion. The total time consumption per sample is 60 to 120 minutes.

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 Week 2 Report:

Water Treatment Section:

Water is basic to the finished beverage. Like flavor, it is an integral part of the drink. In the beverage it is
the vehicle or liquid portion that carries the sugar, flavor, acid, color and CO 2. Over 85% of total volume
is water. Water must be of sufficient quality to maintain the correct balance of flavoring ingredients and
at the same time not contribute substances, which will affect the taste or appearance of the drink.
Adulterates such as microorganisms, suspended particles and other impurities may be present which must
be needed to remove. In addition alkalinity is reduced to a set level, water should be free from undesirable
such types of things and added chlorine. To remote contamination and meet established specifications
water treatment systems are used.

Alkalinity in water can neutralize beverage acid resulting in lack off tartness or excessive sweat taste and
microbial resistance. Hence Water treatment process is paramount important for quality control of beverages.

Objectives of Water Treatment

 A uniform water supply all the season of year

 Removal of colloidal and suspended matter
 Reduction in alkalinity
 Freedom from microbial hazard
 Removal of color
 Removal of undesirable off taste and odor
As water is major constituent of beverage, any difference from water may cause substantial change
in finished beverage. Alkalinity in water can neutralize beverage acid resulting in lack off tartness or
excessive sweat taste and less microbial resistance. Hence water treatment process is paramount
important for quality control of beverage.
Reverse Osmosis:

Reverse osmosis is a water purification process that uses a semi-permeable membrane (synthetic liner) to
remove large particles such as unwanted molecules and contaminants, as well as sediments such as chlorine,
salt and dirt, from drinking water. Reverse osmosis applies pressure to overcome osmotic pressure and push
water from a high concentration of contaminants to a low concentration of contaminants.

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Reverse osmosis typically involves four stages of filtration:

 Sediment filter
 Pre-carbon block
 Reverse osmosis membrane
 Post-carbon filter

Sediment filters remove the largest particles such as dirt, sand and rust to prevent clogging of downstream
filters. The pre-charcoal filter uses activated charcoal to pass nothing more than flour, attracts and binds
positively charged ions, and prevents compounds like chlorine and chloramines from reaching his third filter.
Prevent. Reverse osmosis membranes remove molecules heavier than water, such as sodium, high levels of
lead, dissolved minerals, and fluoride. Finally, a post-charcoal filter polishes the water.

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Reverse Osmosis Analysis

 98% TDS is removed

 99% microorganisms are removed
 98% inorganic salts are removed
 Weekly check iron, manganese& SDI level of RO feed water.

Function of chlorine

 It destroys bacteria and other microbes

 Oxidizes organic materials
 Destroys odor of H2S

U.V Light
Used for Disinfection

 250nm Wave length

 UV lamp life ,8000 Hrs
 U.V Light of 254 nm is used to remove microbial contamination
U.V lamp is changed when its intensity varies from 20watt/m 2 to 12watt/m2
In other word when lamps intensity changes from 100% to 60%.
After the water is treated it is sent to plant and pasteurizer room.
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The processes used for water treatment are as follows:
 Filter
 Tank
 Reverse Osmosis
 Chlorine is added(0.4-0.6 ppm)
 Reaction tank.
 Carbon purifier.
 Polisher.
 U V light

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The RO plant water treatment process is shown in the flowchart described under:

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Fire Safety Program:
The goal of a Fire Safety Program is to mitigate the risk of fire that has the potential to result in property
damage and personal injury. This is achieved through:
• Compliance with applicable fire safety codes, standards, and regulations.
• Providing fire safety education and training.

• Performing assessments of compliance and program effectiveness.

• Identifying and implementing process improvement opportunities.

Personal protective equipment, commonly referred to as "PPE", is equipment worn to minimize exposure to
hazards that cause serious workplace injuries and illnesses. These injuries and illnesses may result from contact
with chemical, radiological, physical, electrical, mechanical, or other workplace hazards.
Components of Personal Protective Equipment (PPE)
 Gloves
 Shoe and head covers
 Surgical masks
 Goggles
GMP

Good Manufacturing Practice, or GMP, is a system of processes, procedures, and documents that ensure that
manufactured products such as food, cosmetics, and pharmaceuticals are consistently manufactured and
controlled according to established quality standards.

GMP guideline and regulation address are the following:

 Quality management
 Sanitation and hygiene
 Building and facilities
 Equipment
 Raw materials
 Personnel
 Validation and qualification
 Complaints
 Documentation and recordkeeping
 Inspections & quality audits
Hazard Analysis Critical Control Point
Seven basic principles are employed in the development of HACCP plans that meet the stated goal. These
principles include hazard analysis, CCP identification, establishing critical limits, monitoring procedures, corrective
actions, verification procedures, and record-keeping and documentation.

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Week 3 Report
Filler Down time:

When the filler is not running, the entire line in whole or part is shut down suddenly that measure time is called filler
downtime.

Main Focus on fillers maintenance. Fillers must be cleaned and sanitized according to specified methods and
procedures. Personnel assigned to cleaning and sanitizing complex beverage fillers cannot be the normal entry-level
cleanup person. Most cleaning procedures require the filler to be activated, proper clothing must be worn to avoid
machine contact, proper and sufficient tools must be provided for cleanup, and all personnel assigned to cleaning-type
operations must be trained and periodically updated on machinery changes and procedure/method improvements.

Efficiency

% efficiency = (actual yield/ theoretical yield)*100

Production loss:

Production loss include:

Packaging material loss

 Glass bottles
 Crown

IR (inside the Run)

OR (outside the Run)

True Efficiency means producing the number of parts or products that can be sold while utilizing the minimum
number of operators and equipment possible. Efficiency is measured by dividing a worker's actual output rate
by the standard output rate and multiplying the outcome by 100 percent.
Schedule compliance
Schedule compliance is a maintenance metric used for determining productivity and the effectiveness of
scheduled maintenance processes. Schedule compliance measures the percentage of work orders completed
on or before the due date over a given period of time.
Refrigeration Ammonia Systems:
Throughout the vapor compression cycle, the refrigerant constantly takes in and releases heat until the
compressor reaches the set temperature.

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For industrial ammonia cooling:
Liquid refrigerant from the receiver enters the expansion valve just before the evaporator. The expansion valve
cools the high-pressure and high-temperature liquid to reduce the pressure, turning the liquid into a vapor-
liquid mixture. This is necessary for proper heat transfer as the ammonia passes through the evaporator. The
liquid refrigerant-vapor mixture absorbs heat from the evaporator coil. The compressor will automatically turn
on and maintain the set temperature or pressure. The suction line begins to draw refrigerant into the
compressor. When the refrigerant reaches the compressor, heat and vapor begin to be compressed under high
pressure. Refrigerant enters the drain as high temperature, high pressure vapor on its way to the condenser.
After the discharge line, refrigerant vapor flows through the condenser coil. At this point, the latent heat stored
in the refrigerant condenses the vapor into a liquid. Water and air are typically flowed through a condenser coil
to remove heat and condense the ammonia vapor. Saturated liquid refrigerant passes through a receiver where

some of it evaporates. Insert and store in the receiver to have fluid readily available when system components
require it. The refrigerant has nearly completed the circuit of the system. After passing through the receiver,
the saturated liquid refrigerant enters the liquid line and reaches the expansion valve to restart the process.

Carbo cooler De-aerator

In De-aerator

CO2 and water up with each other and then it is transfer from de aerator to syrup boll.CO2 enter from the
bottom side and water enters from top of the de-aerator.

Water Bowl
Treated water comes from water treatment plant in the water bowl. Syrup Bowl Mixture of CO2 and syrup
transfer from de-aerator to syrup bowl.

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Mixing Bowl Treated water from water bowl and syrup from syrup bowl mix up in the mixing bowl and then it is
transfer for cooling into the CARBO Cooler.
Pump
Pump is used to transfer mixture of water +syrup+CO2 it also maintain the pressure and remove the air
bubbles. A NR valve is used after pump to stop the back flow from the CARBO cooler.
Working

Ammonia is used for the purpose of cooling of mixture in CARBO cooler. There two ammonia accumulator on
both sides of CARBO cooler. Ammonia move in tubes and syrup shower from the top of the cooler. In this way
before reaching the syrup up to bottom cool down up to 1 to 5 degree centigrade then syrup is ready for filing
in bottles and transfer from CARBO cooler to the filler section.

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Week 4 Report
Pump:

A device that lifts, transfers, delivers, or compresses liquids or vapors, especially by suction or pressure, or both.
Pumps can be classified by their method of displacement into positive-displacement pumps, impulse pumps,
velocity pumps, gravity pumps, steam pumps and valve less pumps. There are three basic types of pumps:
positive-displacement, centrifugal and axial-flow pumps.

A centrifugal pump is a mechanical device designed to move a fluid by means of the transfer of rotational
energy from one or more driven rotors, called impellers. Fluid enters the rapidly rotating impeller along its axis
and is cast out by centrifugal force along its circumference through the impeller's vane tips

The basic principle of operation of centrifugal pumps is – force vortex flow. This means, when a body of liquid is
acted upon by an external torque, it increases the pressure head of the rotating liquid. This increase in pressure
is directly proportional to the velocity of the liquid.

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BEVERAGE PROCESS

Treated water Syrup

De- Syrup
aeration
Tank

CO2
mixer

Heat Exchanger
(OPRP)
Strainer

Empty
Washer
Inspection
Filler

Crown
Crowning Feeding

Checkmate +
Metal
Detector

Date Coding Packer Palletizer

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Bottle Washer:
WASHING CYCLE

1. Pre-wash
Right after the in feed area the bottles are turned upside-down so that the liquid residuals and loose dirty
particles fall out of the bottles. Residuals are collected and discharged out of the machine separately. A sieve-
belt conveyor may be arranged in order to take solid dirt, such as straws, cigarettes, insects out of the
machine. This sieve-belt is at the same time a filter for the waste water. Behind the dirt removal area an
internal jetting pipe can be located is present so to further remove dirty particles from inside the bottles as
early as possible. Bottles are then submerged and filled with warm water.

Water remains within the bottles until they are turned upside-down in the following jet section. The water
running out returns to the pre-soak through a sieve-belt filter. This is the first occurrence where the bottles
are turned upside down and so broken glass and dirt are collected in the lower part of the tank. An automatic
dirt and glass debris removing system is available optionally.

The bottles are then pre rinsed with a set of internal sprayers and external showers and moved to the heat
recovery submerge bath, where heat is transferred from the cooling zone without any water mixing. The
temperature is gradually raised in this zone, exploiting the residual heat of the water received from the rinsing
zone.

2. Washing
The bottles are then taken to the actual washing zone which consists of a certain number of identical
detergent soaks – the exact number depends on the required treatment time. Bottle washing is in three
essential stages: first, the bottle is immersed in the soak, where dirt is chemically attacked by the caustic
action of the soda, increased by high temperature; at the second stage, the bottle is emptied to remove the
dissolved dirt and the used solution; at the third stage the mechanical action of the internal jet removes the
dirt, which had been chemically attacked, so that the remaining dirt comes into direct contact with the
detergent solution of the next soak.
3. Rinsing
The bottles then move on to the rinsing zone that usually includes an immersion zone and a set of spraying
zones. In this zone the temperature is gradually lowered and the detergent solution is removed, both from the
bottles and from the carrier beams, through dedicated sets of sprayers. All the rinsing water is then recovered
to the pre-washing zone.
Every spraying zone consists of a set of high pressure internal sprays and an external shower. Before
discharging the bottles a final injection with fresh water takes place and, after sufficient drip-off time, the
unloading system places the bottle on the conveyor belt.

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Block Digram Washing stages:

1. Bottle in feed conveyor

2. Bottle accumulation

3. Bottle loading

4. Residual liquid collection plate

5. 1st prewash stage

6. 2nd prewash soak stage

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7. Prewash sprayer

8. Heat recovery immersion

9. Double top detergent soak

10. Caustic spraying

11. Heat recovery spraying

12. Heat recovery immersion

13. Rinse soak

14. 1st rinse spray

15. 2nd rinse spray

16. 3rd rinse spray

17. Fresh water spray

18. Bottle discharge

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Chemical use:
Line # 1,3,5
 Ferisol (Surface cleaning, metal Removal)
 Horolith ( Ph Regulator)
 Stabilon ( Cleaning used in tank with caustic)
Line # 4

 Dive LE-92 (Surface cleaning, metal Removal)

 Divo AI-93 ( Ph Regulator)
 Kompleet (Cleaning/ Rust)
 Bright wash ( Cleaning)
Lubrication Chemical:

 DicoLube (Diversey chemical)

Bottle uncaser:
This machine automatically unpacks many styles of glass and plastic containers from necks-down reshipper
cases and ensures a continuous supply of empty bottles to the packaging line.

Electronic bottle inspector:

An electronic bottle inspector having particle and liquid detection capabilities through the use of sensing
systems in the visible and infra-red light range. For particle inspection in the visible light range, light from a
source, typically an incandescent source passing through the bottom of a bottle, is focused above the neck of
the bottle to preset an image of the bottom of the bottle on a rotating scanner characterized by a generally
non-reflective background having one or more reflecting segments thereon. The scanner rotates at high speed
so that the reflecting segment or segments scans the image focused thereon, with at least the reflective
segments being contoured so the light falling thereon from the respective portion of the bottle bottom image is
focused onto a detector.
The particulate matter on the bottom of the bottle will block the light, creating a dip in detector output when
that portion of the image is scanned. For liquid detection one or more holes are provided through the non-
reflective portions of the scanner, with an infra-red detector being located there behind to detect the infra-red
radiation passing through the holes.
Filtering of the light received by the detector allows peaking of the sensitivity of the system around one of the
absorption bands of the liquid, with a drop in AC coupled amplitude of the infra-red detector providing an
indication of the presence of the liquid.

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