1. A
REPORT ON
BOTTLERS NEPAL LTD.
(BALAJU, KATHMANDU)
PREPARED FOR::
ER.SUSHIL DANGI
(INSTRUMENTATIO-II)
PREPARED BY::
KULDEEP SHARMA (BEX067-07)
PUSPANJALI SHRESTHA (BEX067-11)
RAJIM ALI MIYA (BEX067-12)
SURESH LAMICHHANA (BEX067-18 )
HIMALAYA COLLEGE OF ENGINEERING
DEPARTMENT OF ELECTRONICS AND COMPUTER ENGINEERING
CHYSAL, LALITPUR

2. ACKNOWLEDGEMWNT
This report on “BOTTELERS NEPAL LTD” is the outcome of the case study of
instrumentation –II andit will fulfill the entire requirement as specified by the syllabus of the
instrumentation –II on the topic CASE STUDY.
This report contains all the detail of the industry including its introduction, block
diagram of the different plants used for the different purpose there. This report also contains our
recommendation to makethe industry more efficient, reliable using the automated system I.e
using the microprocessor based instrumentation. This report makes us very much familiar with
industry andhow it works automatically and how it can be made automatic to give the fine
product. Automatic system always increases the efficiency of the whole plant and it reduces the
number of manpower required in the industry.
We are really grateful to Er. Sushil Dangi for his invaluable help and support in
preparing this report and giving us this opportunity to prepare thisreport. We are also very grateful
to our HOD sir Er.Rajesh kumar paudal for making our visit in the a multinational company.We
are very thankful to Mr.Saurab Thapa plant engineer ,Chiniya Mahat electrical team leader
,Prithivi Thapa security manager of the ‘BOTTLERS NEPAL LTD.’ .At last but not the least we are
very much thankful to all the staff members of the ‘BOTTLERS NEPAL LTD.’and all the teachers
of the ‘HIMALAYA COLLEGE OF ENGINEERING’ who are directly of indirectly involved in
preparing this report.
ALL THE TEAM MEMBERS
Date: January 24, 2013

3. The Head of Department,
Electronics and Computer Engineering,
Himalaya college of Engineering
Chysal, Lalitpur
Subject: A report on case study
Dear Sir,
With due respect we would like to request you to accept the report prepared by the
team formed for the study of any instrumentation system located in our locality. According to
the criteria, we choose Bottler’s Nepal for the study of manufacturing process of Coca-Cola,
fanta and sprite. The authorities, plant engineer, technicians of bottlers Nepal are interviewed
and the system was observed by our team members.
From the case study, we understood the overall process of the manufacturing these
product and system associated with it.
Thank you!
All Team Members
Abstract:

4. This report presents the information about the system carried out by the Bottlers Nepal
during manufacturing of Coca-Cola, fanta and sprite.
During this case-study, members of this team visited the Bottlers Nepal and studied
about the process and analyzed the process. This report contains the process described briefly
with the view point of instrumentation system. Different data, system, diagram were noted
during visiting.
Raw materials required during the process, some are imported from international
market and some are produced in local market. From the case study, we found that process of
manufacturing such products involves various steps like formation of syrup, cleaning of glass
bottle, making pet bottles, labeling, packing etc. The control systems related during the
process are mostly automatically and some of them are manual. Company is aware of
environmental effect which may occur by the process.
Taking consideration of complain of customers on the defect seen in the product, it is
recommended that some of their components should either upgraded or replaced.
Table of contents:

5. Letterof transmittal
Abstract
Table of Content
List of figures
1) Introduction
Objectives
Methodology
1.1)Limitation of Study
1.2)Significance of study
1) Raw material used in product
2) Syrup formation
3) Main operation
4.1) Line 1
4.2) Line 2
5)Recommendation
6) Conclusion

6. List of figures:
Fig: 4.1 Block diagram of the Line -1 plant
Fig:4.2 block diagram of the bottles cleaning section
Fig: 4.3 block diagram of the line-2 (formation of the product in the plastic bottles)
Fig: 4.4 productivity of the company in per day
Fig: 5.1 interfacing circuit part-1
Fig: 5.2 productivity of the company in per day
Fig : 5.2 interfacing circuit microprocessor 8051
Fig: 5.3 interfacing to the output automatic control system
1. Introduction::

7. ‘BOTTLERS NEPAL LTD.’ Is the one of the large company in
Nepal which works under the authority of the COCA-COLA company, 1COCA-COLA Plaza,
Atlanta GA, 30313,USA.This company in Nepal works according to the rules of the COCA-
COLA company which is the multinational company ,whose business is extended all over the
world and in every country of the
world they manufacture coca-cola
and fanta, with the different name of
the company but they have the only
one goal to make people of the
different country feel refreshed in the
hot days .The ‘BOTTLERS NEPAL
LTD’ which manufacture in Nepal is
situated at the ‘BALAJU
KATHMANDU,NEPAL,PO BOX-
2253’ outside the ring road of the
Kathmandu valley. This company is
situated at the ‘Balaju industrial area
‘ in the large area such that its
factory is divided in the numbers of
parts or pants where different
operation related to the product are
performed. .They are
manufacturing coca-cola in Nepal since last a lots of the years. Every year it manufacture a
large number of the coca-cola fanta and other different cold drinks with the different test and
flavor in Nepal to make a large population of the Nepal feel refreshed .
This company invests a large amount of the money for the nation’s
development and it pays a large amount of the money to the Nepal’s government as Tax. It
also financially support different organization in Nepal. This company sponsors to the different
sports club in Nepal and organize different sports event every year which is directly supporting
the players of the Nepal. It also sponsors a large number of the social organization which are
directly of indirectly working for the development of the nation. So we can say that this
company is working for the nation’s development.
A large number of the Nepali workers are working currently in the
BOTTLERS NEPAL LTD. Due to this they are earning a good amount of money from this
company which is enough to support their families. As we all know the present employment
status of the Nepal, this company is helping in the reduction of the unemployment rate in our
country.
In the context of the Nepal the main product this company manufacture are :
1. Coca-cola

8. 2. Fanta
3. Sprite
1.1Objectives::
The main objectives of this case study are as mentioned below::
1. To study how industries are working in Nepal either manually or automatically.
2. To study the way of making the industries in Nepal automatic taking economic conditions
into the consideration.
3. To study the problems in the industries due to the manual operation.
4. To study the difference between the final product of any industry when it is operating
manually or automatically.
1.2 Methodology::
During the case study the research adopted various kinds of the research tools. At first a lots
of information about the industry was taken from the industry. Finally when we were at the
industry we found the system engineer over there and we consult with him for our further study
within the industry area. The block diagrams shown within the industry area were taken into
consideration for the detail of any particular block of the industry. Mostly primary data were
taken for the preparation of this case study report.
Besides that the secondary source of data such as books, reports and internet were reviewed
and visited. At last all the data available from the different source were interoperated and
analyzed carefully during the preparation of the report.
1.3 Limitation of the study::
As we all know that our country is facing the great problems of the load shielding so same
problems was affecting us at the time of our case study. During our study the whole plant was
not in the working mode so we unable to mentioned how it exactly works. Due to the time
limitation of the system engineer we could not able to consult with him for the longer time. As
we were not allowed to use any recorder or camera within the industry area so we un able to
collect all the detail information.
1.4 Significance of the study::
The main significance of this case study is to understand how to convert any manually
operating industries into the automatically operating one. And the way how we can do so
economically.

9. 2. Raw material used for the product::
A large number of the different raw material are used during the manufacturing of the Coca-
cola .These are as follows::
1. Water, sugar, concentrated chemicals, carbonated water, ACIDULANTS, farming agent,
stabilizer, coloring agent and artificial flavors.
2. It contains permitted synthetic color and preservative.
3. Nutritional information::
Nutrition:: Typical value per 100 ml
Energy 56k cal
Protein 14 gms
Fat 0 gms
These are the raw material which is used in the manufacturing of the coca-cola .These raw
materials are mostly exported from the third country. The third country is selected as per the
economical condition taking into consideration. But the concentration chemicals used in the
product is exported from the USA. Few number of the raw material are used which are
obtained from the Nepali market. Here the sugar used is carbon free which is not available in
Nepal so it is also exported from the third country.
After the manufacturing of the product it is have to pack properly. Such packing products are
manufactured in Nepal like bottles ,crate ,carton. After the raw materials are obtained a proper
mixture is to be made to fill it into the bottles which can be done as.
3) Syrup formation:
Mixture is formed on the basis of the unit format, such that a single unit contains the 320 liters
of the water.8 liters of the concentrated chemicals is mixed in the 320*8 liters of the water and
the mixture is formed. The mixture thus formed is is mixed with the carbon free sugar .About
40*50 kgs of the Sugar is mixed in the 320*8 liters of the mixture formed previously. Then
finally energy ,fat ,protein are mixed as specified above in the material required.
To make the syrup, first of all pure water is taken which is provided by supply department of Coca-Cola
company ,which may be from abroad or from national supplier recommended by the company. The
water taken is then heated to 80’c then the addition of sugar is done in this pure water. The sugar must
be carbon free that is totally white which is provided by the company. Then this mixture is cooled to
about 4 to 5’c and filtered to free it from the dirt if present in the sugar. After filtration the chemical is
mixed in the sugar water thus formed. Coca is the main raw material to make Coca-Cola and is mixed
with various chemicals and finally mixed with proper ratio recommended by the quality control
department of the company (COCA-COLA,COMPANY USA) to the mixture obtained earlier.

10. This is how the final syrup is prepared, which is qualified by the quality control department of the
company by checking its viscosity, ph value ,proper composition of the chemicals etc and various data
and then the final data is supplied to line1(glass bottle line) and line2(plastic bottle line).
4. Main operation::
This company manufactures cold drinks for the customers. The product is formed in the two
different types of the bottles one is the plastic and anther is the glass bottles .Depending upon
the types of the bottles they are manufactured in the two different plants and they are divided
as the Line-1, and Line-2 plant.
4.1line-1::
The detail block diagram of the Line-1, where the coca-cola with the glass bottle are formed:
Fig: 4.1 Block diagram of the Line -1 plant
Cleaning bottles:
First of all empty bottles are taken from the crater to the
machine which is done by decorator. Decorator supplies
the bottles to the pre-infection block in which present of
any dirt which is not washable by the wash chamber is
checked manually. After this the bottles are supplied to the
wash chamber. Inside this block five sub-chambers are
SYRUP
FORMATION
ZONE
BOTTLE
FILLER
QUALITY
CONTROLLER
ZONE
CROWNER
CODER
FINNAL
INSPECTON
ZONE
CRATER
FINAL
PRODUCT
CLEANED
BOTTLE

11. there. Chamber 1 and chamber 2 are those chambers in which washing of bottles with caustic soda
takes place. The bottles are kept inside the chamber for about 45 minutes in 80°C temperature. The
proportion of caustic soda is controlled automatically. If the percentage of caustic soda changes above
or below the predefined level, the machine will stop the process and alarm will blow the beep sound.
Chamber3 and chamber4 are for pre-cleaning the bottles. It removes the dirt as well as caustic soda
present in the bottles. In chamber5 the washing of bottles with pure drinking water is done, which
removes the remaining dirt and chemicals which may present in the bottle.
This is how the bottles are cleaned and are supplied to the line1 to fill-up.
Fig:4.3 block diagram of the bottles cleaning section
Bottle filler:
The cleaned bottles are appeared near the filler through the metal conveyor. The filler which is
full with the previously formed syrup and then the syrup is filled in the cleaned bottles .In this
way the filling of the bottles is completed.
Quality controllerZone::
After the bottles being filled their quality should be checked for the last time .In this zone the
quality controller group checks the product manually and observe the different figures which
signifies the quality of the product every time. Then the bottles are passed to the electronic
EMPTY
BOTTLES
DECRATER PREINSPCTI
ON ZONE
WASH
CHAMBER
CLEANDED
BOTTLES
DISCHARGE

12. quality controller device which will find all the dir particles present in the bottles if present in the
bottles by checking the sensitivity of the dirt particles. It is designed in the such a way that it
checks all the dirt with the samples present in its store and find it and if any present then it will
make a sound which will enable us to find it and remove it quite easily.
Crowner:
This is one of the important section of the system, where the capping to the bottles which are filled with
final product is done and this is also a automatic process. The bottles are then passed to the data
coder.
Data coder:
In this section the information about the product such as batch no. manufacturing date etc. are
wrapped onside the bottle. This is also an automatic process. The bottles are then passed to the crater
Final inspection zone::
In this zone the bottles which have coded are checked again for the last time .in this zone if the
bottles are not coded and not labeled then they are again returned back for the labeling and
coding.
Crater::
It places all the bottles in the crater one at a time .
Final product:
The whole process to obtain the final product is discussed above. The various sections are
there as we discussed and finally, the final product collected from the crater is passed to the
packing zone where bottles are packed in the cartoon for supply to the market.
Line -2:
The line -2 is used for preparing their products in the plastic bottles instead of glass bottles
.The plastic bottles is mainly used for home purpose .the block diagram of the line-2 is as
shown in figure below::
USABLE
PREFORMS
BLOW MOULD
BOARD
PARAMIX FILLER

13. Fig: 4.4 block diagram of the line-2 (formation of the product in the plastic bottles)
Performs::
The plastic bottles are initially small in shape and size which is termed as performs .there are
different performs for the different size of the bottles .these performs are manufactures in
Nepal, Pakistan, Bhutan etc .company is currently using perform which are made in Nepal .it is
passed to blow mould board for proper expansion.
Blow mould board::
This converts the performs in the desired shape and size. during this perform is heated with 8
different temperature zones ranging from 65-85c on corresponding at 8 different zones of the
bottles. After heating for the certain time the bottles in the desired size are passed to filler
through air conveyor by applying 40 bar air pressure.
The bottle is sampled manually for its proper shape, size, strength in every 35 minutes .if
sampling is negative, whole line of bottles is rechecked .the bottle which get busted on
applying 3 bar pressure gets rejected the bottles rejected per day is approximately 50-60 case
per day.
PARAMIX::
The syrup formed in previous state is placed in the paramix in line-2.The syrup continuously
flows to filler for the filling process.
Filler::
CAP,
WARMER
ANDLABEL
CRATERFINAL
PRODUCT

14. Previously formed syrup is filled in the bottles in this section .Filling process is done at a
temperature about 2-3c,so that co2 dissolves in the solution properly.
Cap and label::
Filled bottles are then caped .after putting cap in bottles ,the bottles are warmed for the proper
labeling .in the label ,information about company ,product and other details are mentioned in
plastic piece and wrapped around the bottles. The batch number and manufacture date is
labeled with the help of the date coder.
All the bottles are checked manually if there is proper labeled or not. If not, worker takes it and
put back into the labeling section.
Crater::
All the filled and labeled bottles are packed automatically.
Final product::
Thus formed product is ready for use .It is distributed to the market in the form of the coca-
cola, sprite and fanta.
Daily productivity of the company::
Fig: 5.1 productivity of the company in per day
As above mentioned chart shows clearly about the daily productivity of the company in season
and in off-season. In season daily 350000 liters of the product is produced and in the off-
season daily 4500 liters of the final product is produced.
0
100
200
300
400
SEASON OFF-SEASON
350
4.5
PRODUCTION CAPACITYPER DAY IN
THOUSAND

15. 5)RECOMMENDATIONS:
After the depth study of process of manufacturing coca-cola products, we recommend to
interface following extra devices to the microprocessor to boost up the process.
i) Temperature detection and control
ii) Liquid filling Level check and control
These devices are interfaced with 8085 microprocessor through programmable peripheral
interface 8255A.
Since microprocessor processes only digital data, analog quantity obtained from sensor
specified in following circuit diagram will have to be converted into digital using Analog to
Digital converter IC 0808. And after processing in microprocessor, certain system like alarm
will have to control which requires analog value and hence we also requires Digital to Analog
converter.
To the data
busAD0 TO
AD7
Chip selectsignal
Address lineA0,A1ofµp
Temperature sensor IN0
BOTTLE LEVEL
CONTROLLER
IN 1
INPUT DEVICES

16. Fig: 5.1 interfacing circuit part-1
Fig : 5.2 interfacing circuit microprocessor 8051
Here two 8255A is connected. one for interfacing sensor while other is for interfacing output
devices i.e. control circuit. Here input side 8255A is at address 80H and that for output side
8255A is 90H which can be generated using NAND gate decoder with A2-A7 and connected to
the Chip select pin of respective 8255A. since 8255A requires 4 internal addresses,A0 and A1
is connected to both 8255A.
For input read, and input write process we have to generate related signal. For this,a
NAND gate having input IO/M͞ =1 and R͞D=0 results IO͞ R and is connected to R͞D of 8255A of
input side while NAND gate having input IO/M͞
IO/M͞͞͞͞ ANDRD͞͞
IO/M͞͞ AND WR͞͞ PINS
CHIP SELECT SINGNALTO THE
8255A
ADDRES
REQUIR
ED TO
SELECT

17. =1 and W͞ R=0 results I͞OW connected to W͞ R of PPI of output side. Here temperature
measurement and liquid level sensing process will be continuously and there is higher
accuracy due to the higher frequency of microprocessor. It means sampling is done very fast
so that error will get very low chance of being occurred.
Fig: 5.3 interfacing to the output automatic control system
Here the op signal from the microprocessor after being processed is given to the 8255A and
then to the digital to the analog signal converter. As the first one produces the sound as it is
connected to the sound producing device as the temperature of any critical device falls below
the certain value ,which may be dangerous for the product and in turn to the human health.
Hence it will makes us very easy to control the quality of the product.
In, second one it also séances the temperature but the difference is that it séances the higher
temperature. When temperature of any block goes higher than the any specified value which is
very much correct to maintain the quality of the product then it produces sound and it
automatically off the system and it will help to maintain the quality of the product.
TO CONTROL
THE
TEMPERATURE
BELOW
CERTAIN
TEMPERATURE
TO CONTROL
THE
TEMPERATURE
ABOVE CERTAIN
TEMPERATURE
TO CHECK
WHEATHER
THEBOTTLE IS
FILLED OF NOT
BY PRODUCING
THESOUND

18. The third one is a output of the sensor which detects whether the bottle is filled or not. The
sensor uses the infrared light provided with the LDR which will generate the difference in the
voltage at the condition of the bottle filled and not filled. Taking this voltage into consideration
this third block gives output in the form of the sound if the bottle is not filled. Then the bottle will
automatically move out of the track of the conveyer and it will send back to the filling.
7) Conclusion:
As we know, engineering is huge field. We have to be aware of real field application and status
of the system or devices which are related with our academic study. Case study played a vital
role for joining these two fields smoothly.
Different systems, processes were figured out during field visit. Various materials,
components, controlling methods, measurements of physical quantity, display of data in
different ways were observed. Any system or process can be controlled according to the
certain physical quantity like temperature, pressure etc.
In visited industry, different process were applied for washing the bottles returned from the
market but still sometimes there may be some dust. For this, system related with washing
process has to be upgraded.
From the visit, somehow capabilities to make a small scale system, is increased.
Microprocessor implementation in such system gets easier to understand.