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Cocacola- automization in production

  1. A PRESENTATION ON...
  2. • Submitted to: - Prof. T.H.Bhatt • Submitted By: - Ami gajjar (07-0140-2013) Hritvika Ghadiyali (07-0142-2013) Pargi Jigisha (07-0148-2013) Patel Hiral (07-0152-2013) Patel Riya (07-0155-2013)
  3. PROCESS FLOWCHART
  4. • The dimensions of the liquid content of a vessel and the dimensions and arrangement of impellers, baffles and other internals are factors that influence the amount of energy required for achieving a needed amount of agitation or quality of mixing. • The internal arrangements depend on the objectives of the operation: whether it is to maintain homogeneity of a reacting mixture or to keep a solid suspended or a gas dispersed or to enhance heat or mass transfer. • A basic range of design factors, however, can be defined to cover the majority of cases, for example as in Figure. MIXING AND AGITATION TANK
  5. BAFFLES • baffles are needed to prevent vortexing and rotation of the liquid mass as a whole. • Four radial baffles at equal spacing are standard; six are only slightly more effective, and three appreciably less so. • When the mixer shaft is located off center the resulting flow pattern has less swirl, and baffles may not be needed, particularly at low viscosities. DRAFT TUBES • A draft tube is a cylindrical housing around and slightly larger in diameter than the impeller. • Usually draft tubes are used with axial impellers to direct suction and discharge streams. An impeller-draft tube system behaves as an axial flow pump of somewhat low efficiency.
  6. IMPELLER SIZE • This depends on the kind of impeller and operating conditions. • For the popular turbine impeller, the ratio of diameters of impeller and vessel falls in the range, d/D,=0.3-0. IMPELLER SPEED • With commercially available motors and speed reducers, standard speeds are 37, 45, 56, 68, 84, 100, 125, 155, 190, and 320rpm. • Two-speed drives may be required when starting torques are high, as with a settled sluny.
  7. IMPELLER LOCATION • Expert opinions differ somewhat on this factor. As a first approximation, the impeller can be placed at 1/6 the liquid level off the bottom. • In some cases there is provision for changing the position of the impeller on the shaft. For off-bottom suspension of solids, an impeller location of 1/3 the impeller diameter off the bottom may be satisfactory. • A second impeller is needed when the liquid must travel more than 4 ft before deflection.
  8.  APPLICATION Continuous degassing and carbonation of Coca-Cola syrup.  PRINCIPLE OF OPERATION • The Carbonator comprises a degassing module and a carbonating module.  DEGASSING • The syrup is fed to the degassing tank through a control valve and an injector. Degassing takes place by means of pressure. Oxygen and nitrogen in the water are expelled by the addition of CO2. CARBONATOR
  9.  CARBONATION • CO2 is dissolved in accordance with the saturation carbonation principle. • This result in the syrup being degassed a second time and carbonated simultaneously. • An integrated controller calculates the pressure required and adjusts it continuously to the current temperature of the drink.  PERFORMANCE RANGE • Three sizes with an output of 15, 30 and 45 m3/h • Carbonation in the range of 3 – 10 g/l CO2 (up to 20 °C) with gas loss minimised simultaneously • Dosing accuracy for CO2 1 sigma = 0.08 g CO2/l (continuous production) • Pressure degassing and carbonation are performed in a hermetically divided two-chamber tank.
  10.  CHARACTERESTICS • Degassing of the product water in accordance with the two-stage pressure degassing principle, with the first stage in the degassing tank and the second stage in the saturation carbonation. • Robust and simple technology without extensive and expensive sensor technology. • Main characteristics of pressure degassing: Prevention of water consumption and little maintenance. • Continuous mode of operation in the range from 80 to 100 % of rated capacity. • Less stress for the operator thanks to the program-controlled performance of all work steps (production including start-up, shut-down and CIP). • All product-dependent parameters can be set on the touch-screen and be saved in the integrated program for type management. • Type parameters can be saved on a USB stick for use in verification and documentation workflows.
  11. BOTTLE WASHER • Empty glass bottles arrived from the market are loaded on a conveyer belt for washing purpose. • This conveyer belt leads the bottles to the bottle washer. Here the bottles are cleaned from inside and outside surface. • The whole process is fully automatic and controlled by PLC system.
  12.  Washing Cycle • The washing cycle consists of distinct phases, depending from the configuration that best suits the need of the customer. • Depending from the machine configuration, all along the path of the bottles, many different stages are realized. • In the most sophisticated machine version, all the following steps are included.
  13. 1. PRE-WASH: • Right after the infeed area the bottles are turned upside-down so that the liquid residuals and loose dirty particles fall out of the bottles. 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 1. The bottle is immersed in the soak, where dirt is chemically attacked by the caustic action of the soda, increased by high temperature 2. The bottle is emptied to remove the dissolved dirt and the used solution 3. The mechanical action of the internal jet removes the dirt, which had been chemically attacked.
  14. 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.
  15. • The bottles enter the machine on a conveyor belt. • At the transfer point, a so- called “infeed finger” raises them and pushes them precisely into the bottle pocket LOADING SYSTEM
  16. • Special discharge fingers transport bottles of all shapes and sizes without allowing them to fall and with little noise onto the conveyor. UNLOADING SYSTEM
  17. BOTTLE TRANSPORT • As the bottles are conveyed inside the machine, they are housed in mild steel pockets specifically designed to facilitate label removal and enable perfectly centered spraying on the bottle neck.
  18. • Rotating spraying nozzles clean the bottle from different angles of incidence. This guarantees that the complete interior is evenly cleaned. • The bottle is cleaned from different angles of incidence • Self-cleaning jetting units INTERIOR CLEANING
  19. • The exterior is cleaned from above • Special jetting units deluge the bottles with water and rinse away any dirt and caustic residues. • Double spraying nozzles for the targeted cleaning of the bottle EXTERIOR CLEANING
  20. • All machine functions are controlled by a PLC. • All componentry is housed in the main panel, while the machine operation controls are located in the console near the operator’s station, at the in feed side. • The main operator panel is a PC based operator. ELECTRICS AND OPERATOR INTERFACE
  21. • The main advantages of this solution are: • A friendly operator interface • A data acquisition system integrated in the interface • The possibility of remote connection for diagnostics or updating purposes. • All cables and electrical components are properly codified to facilitate identification.
  22. • The main advantages of this solution are: • A friendly operator interface • A data acquisition system integrated in the interface • The possibility of remote connection for diagnostics or updating purposes. ELECTRICS AND OPERATOR INTERFACE
  23. FILLING MACHINE • The cleaned bottles are now conveyed to the filing machine. • Different filling machines can have different technologies for filling the coca cola into the bottles. • These machines are capable to fill all type of bottles with varying speed, volume and flow rate. • For atomization of filling process the bottle fillers have excellent other features and sensing devices which can be operated by a PLC.
  24. • Volumetric • Pressure • Rotary • Pressure/Gravity • Gear Pump • Gravity • Vacuum  Two or more methods in a single machine can be utilized for better accuracy. • Piston • Fill-To-A-Level • Cosmetic Fill • Electronically Controlled Fill • In-Line • Combination Fillers • Automatic/Semi– Automatic FILLING METHODS AVAILABLE:
  25. FEATURES OF FILLERS • Stainless steel level sensor for supply tank. • Adjustable patented bottle gating system (count in, count out). • NEMA 4 electrical enclosure. • Main air supply filter/regulator and shut-off with lockout. • Easy finger-tip controls permit operator easy access to all fill values and settings. • Stainless steel conveyors with electronic variable speed controls. • No bottle - no fill electronic controls. • Easily adjustable nozzle height settings accommodate vials to gallons. • All supply tanks are specially designed to accommodate fillers with minimum waste of product. • Portable on swivel casters. • Requires minimal floor space.
  26. FEATURES OF FILLERS • Finger-tip nozzle positioning. • Standard operator safety guards are provided with all automatic FILLS-ALL fillers. • Bottle counter. • Precision stainless steel nozzle rack. • Stainless steel leveling screws with floor pads. • Heavy duty one piece welded stainless steel frame. • Fully adjustable patented stainless steel conveyor guide rails. • Programmed electronic microprocessor ensures precision filling and repeatable fast changeovers. • Nozzles (and valves) available in several sizes, styles and materials for most applications. • Modular design - expandable from 1 to 24 nozzles. Electronic access module (Model • ECF).Stainless steel screws and hardware are standard.
  27. BOTTLE LOCATING SYSTEM (NECK-CENTERING) • A horizontal comb-type bottle neck centering guide for bottles with small or irregular neck openings provides exact bottle positioning for nozzle entry. • This adjustable system easily accommodates a wide range of container sizes and shapes. • The bottle locating system is available for all models ensuring a trouble-free filling operation.
  28. EXCLUSIVE SYNCHRONIZED DISPENSING SYSTEMS • Fillers have an exclusive programmed microprocessor and numerous safety features, ensuring that all functions of the filler are synchronized at all times. As examples: 1. The filler cannot discharge product unless the proper number of bottles have entered the filling stage area and until all the previously filled bottles have left. 2. The conveyor speed can be varied at any time during the fill cycle without further timer adjustments. 3. Filled bottles cannot leave until the nozzles are completely up and out of the bottles. 4. Pistons cannot dispense product unless completely aspirated. 5. Filling cannot occur unless nozzles are in the bottles, etc.
  29. • All automatic fillers have an improved method for feeding and positioning containers into and out of the filling stage area. • The microprocessor counts the correct number of bottles to be filled, then closes the gating stage. • The conveyor automatically stops for a more gentle fill before filling begins. • After fill completion, downstream gating opens and counts the bottles leaving to ensure a complete cycle. • Simple control settings allow operator to set the correct number of nozzles being used. • This system also reduces costly set-up time between changeovers, and eliminates the need for time consuming no bottle-no fill delay settings. CONTAINER INDEXING SYSTEMS
  30. DIFFERENT TYPES OF BOTTLE FILLERS 1. Pressure, Gravity and Pressure-Gravity Fillers (COSMETIC/FILL-TO-A-LEVEL) 2. Volumetric Fillers (PISTON FILLER) 3. Compact Volumetric Fillers 4. Gear Pump Fillers 5. Electronically Controlled, Timed-Volumetric Fillers 6. Versatile, High Speed Rotary Fillers
  31. 1. PRESSURE FILLERS (COSMETIC/FILL-TO-A-LEVEL)
  32. 2. GRAVITY FILLERS (COSMETIC/FILL-TO-A-LEVEL)
  33. 3. VOLUMETRIC FILLERS (PISTON FILLER)
  34. 4. ELETRONICALLY CONTROLLED, TIMED VOLUMETRIC FILLERS
  35. 5. GEAR PUMP FILLERS
  36. 6. VERSATILE, HIGH SPEED ROTARY FILLERS
  37. • The crowns are conveyed through a flat crown feeder into a guide chute, thus ensuring very gentle treatment. • The patented crown transfer unit positioned within the machine offers a high degree of reliability and crowning precision. • In addition, the open design of the crowning head allows it to be optimally cleaned, thus guaranteeing a high standard of hygiene. CROWNING MACHINE  CAPACITY • The Crowner can fit crowns on between 1000 78,000 bottles per hour.
  38. • Once the crown has been fed from the crown chute into the transfer segment, a magnet is used for the further guidance of the crown. • A pushing notch is then used to position the crown on the ejection plunger of the capping head. The crowning head is lowered until the crown in the crowning throat is placed on the bottle. • The bottle then holds it in place. Afterward only the crowning throat continues to be lowered. In the first phase, only the force of the guiding springs has any effect on the crown. In the second crowning phase, the ejection spring is pressed and the bottle is subjected to an increased amount of pressure. • The crowning procedure is completed once the crown has been introduced 7.7 mm into the crowning throat. In doing so, the crown is located 1 mm inside the cylindrical area of the crowning throat and the required crown diameter of between 28.6 and 28.7 mm has been exactly obtained. METHOD OF OPERATION
  39. • This completes the crowning procedure. The crowning force once again drops. The delayed activity of the ejection • spring guarantees high crowning quality while applying a low level of pressure on the bottle. • The plunger is then blocked while the crowning throat is further lowered over the crown. At this time, the bottle height is also compensated. • A bottle which is too tall presses the bottle plate downwards until the lowest area of the crowning head has been reached. Controlled by the lifting cam, • the crowning head is raised again and the guiding spring pushes the ejection plunger back to its initial position.
  40.  DESIGN FEATURES : • All main parts made of stainless steel Wst. AISI 304 • Flushing of cap transfer unit and capping head • Motorised height adjustment of the crowner top part with bottle selection feature  ADDITIONAL EQUIPMENT • UV lamp for cap disinfection • Dust blow-off with ionised air and suction • Additional flushing equipment Your benefits
  41.  PRECISION • Crowns enter the line with a defined alignment and are precisely positioned on the transfer plate by a draw-in magnet.  DESIGNED FOR PRACTICAL APPLICATIONS • A bottle-neck centring system ensures that even bottles with inaccurate dimensions are reliably sealed.  CAN BE OPTIMALLY CLEANED • The capping heads can be cleaned
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