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BUSINESS POLICY
We at Hindustan Coca-Cola Beverages Private Ltd-Ameenpur,are in the business of producing beverages
that refresh people.We believe that Quality,Safety and and Environment Management must function as an
integral part of our operation throughout the value chain.We lead the beverage revolution by providing
safest and world class product.
TPM POLICY
We at HCCB team commits to provide the highest quality product at the lowest possible cost.Delivered
where and when it is needed.Produced in clean factory,that is safe,environmentally sound and respectful of
the people doing the work.
We are passionate about creating excellence in everything we do Our destination is to be World class.
Quality policy
We at Hindustan coca-cola Beverages private Ltd.-Ameenpur ,are committed to deliver refreshing ,high
quality,products.Quality shows itself in our every action,it encompasses everything that we
do.Everyassociate within HCCBPL-Ameenpur,takes this mission seriously and works tirelessly to ensure
that our system keeps its promise of quality products and services
We believe that quality is the cornerston of our success.Inharent in this belief is our dedication to our gold
standard.PERFECT PRODUCT,TRUSTED EVERYWHERE.
FOOD SAFETY POLICY
We at Hindustan Coca Cola Beverages private Ltd-Ameenpur,are committed to ensure uncompromising
food safety standards for the products we produce and distribute to the consumers through effective
implementation of Food Safety system requirements.
Food safety is integral to our gold standard of Quality.PERFECT PRODUCT,TRUSTED EVERY WHERE
.We strive to protect our products and our consumers along the entire food chain-from start to finish.We
aspire to grow the reputition of the brands we produce and maintain consumer confidence in our products.
Environmental policy
Our environmental efforts are focused on key areas where we have the most opportunity to make a
difference and are defined by the following long term aspirational goals
Water sterdship: We will be good stewards of our most critical shared resource in the communities
Where we operate
Climate protection: We will work to reduce our carbon emissions,even as we grow our business.
Cost of Poor Quality
Our COPQ will generally cover the followings :
1.Cost of labour to reduce the cost
2.Cost lf extra material used
3.Cost of extra utilities
4.Cost of lost Opportunities
5.Loss of sales/revenue
6.Potential loss of market share
7.Lower serve level to customer/consumers
The focus of Process mapping
The focus of process mapping is on discovering the current processes of an organization establishing the
root cause problem with those processes,and looking for solutions Process mapping is used to find a
problem and then a solution.Then find the next problem and the solution.
Why process mapping
Process or flowchart convey more that words
Map is a work flow of the activities done by the people.
People perform same tasks differently
Improvements to satisfy customers needs.
Focus of EM Piller
Early management :To develop New product first time right with free from Losses,Defects and Product
should start for mass production at reduced lead Time.
HACCP (Hazard Analysis and Critical Control Point )
There are seven Principles
1.Conduct a hazard Analysis.( Bio-logical,Chemical& Physical).
2.Determine CCP.
3.Establish a Critical Point.
4.Established Monitoring Procedures.
5.Establish Correctve Actions.
6.Establish Record Keeping and Documentation Procedures.
7.Establish Verification Procedures.
The Seven Principles of HACCP, Encompass a systamatic approach to the identification,prevention,
and control of Food Safety Hazards include.
CCP : Critical Control Point is defined as a point,a step, or Procedure in a food process at which
Control can be applied,As a result food safety hazards can be prevented ,Eliminated or Reduced.
PHYSICAL DATA:
Boiling point (91F.) : @ 1 atm 96109.3F (-78.5oC)
Triple point (91F.) : @ 1 atm 76 (-56.66oC and 75.1 lbs/sqin.a)
Vapor pressure (psia) : @ 68F (20C) 831 psia (56,5 atm)
Solubility in water : @ 68F (20C), 1 atm 87.8% by volume
Vapor density (lb/cu ft) : @ 68F (20C), 1 atm 0.115
Specific gravity (AIR=1) : @ 68F (20C), 1 atm 1.53
Liquid density (lb/cu ft) : @ -35 (-37oC) 11 atm 68.74
Specific gravity (H20=1) : Solid @ -110F (-79C),1 atm 1.56
Appearance and Odour:
Carbon Di-oxide is a colourless and odorless a gas or a liquid.It is stored in containers under its own vapour
pressure. If the pressure is suddenly relieved,the liquid repidly cools as it evaporates and sublimes,forming
dry ice at 96109.3F (-78.5C)
SYMPTOMS IF INGESTED,CONTACTED WITH SKIN,OR VAPOUR INHALED
Carbon dioxide does not support life and may produce immediately hazardous atmospheres. At
concentration in Excess of 1.5% carbon dioxide may produce hyperventilation,headches,visual
disturbance,tremor,loss of consciousness and,death.Symptoms of exposure in the concentration ranges of
1.5-5%, may highly variable,but typical symptoms of carbon dioxide intoxication include the following
3-6% :Headache,perspiration
6-10% :Headache,perspiration,tremours,visual disturbance.unconsciousness.
Over 10% : Unconsciousness
If the concentration of carbon dioxide exceed 10% unconsciousness can occur without warming,preventing
self-rescue. A t much higher concentrations,carbon dioxide displaces the oxygen in air levels necessary to
support life.
TOXICOLOGICAL PROPERTIES
Carbon dioxide is minor but important constituent of the atmosphere,avaraging about 0.03% or 300ppm by
volume.At higher concentrations if affects the respiratory rate.
REACTIVITY DATA
Stability : Unstable
Incompatibility : If moisture is present,material must resist carbonic acid.
Hazardous polymerizarion : May occur
STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED
Carbon dioxide is small quantities will vaporizes will leaving beind carbon dioxide “snow”. Ventilate
indoor areas well to avoid hazardous carbon dioxide concentrations.Ventilate well and avoid hazardous
carbon dioxide concentrations.Ventilate well and avoid contact with cold vapor or dry ice.Carbon dioxide is
a heavy gas and will remain in low spots without assisted ventilation.
WASTE DISPOSAL METHOD
When disposing of bulk quantities of Carbon Dioxide from refrigerated storage tanks,always dispose of
Carbon dioxide outside in a well ventilated location awa from work areas,where vapours can disperse,vent
to the atmosphere slowly since rapid depressrization of the container will cause the formation of solid
carbon dioxide internally,requiring longer periods to vaporize and risking to the vessel.
SPECIAL HANDLING RECOMMENDATIONS
Prevent contact of liquid Co2, cold vapours,or carbon dioxide “snow” with exposed skin.Prevent
entrapment of liquid in closed systems.Never use direct flame to heat a compressed gas.Also avoid dragging
,or sliding,even for a short distance. Use a suitable hand truck.
SPECIAL STORAGE RECOMMENDATIONS
Store liquid containers in well ventilated areas.Storage should not be in heavy traffic areas to prevent
accidental knocking over or damage from passing or falling objects.Storage areas should be free of
combustible material.Avoid exposure to areas where salt or other corrosive chemicals pressent.
PET-poly Ethylene Terephtalate.
Created by repeated bonding of Terephtalic
Acid Ethylene Glycol
2.Bonding by formation of an ester group and
water shedding.
Pearl : crystallization induced by mechanical overstretching
Pearl is always inside molecules have the longer way and are going to be over stretched first.
The blowing temperature should be 3Degrees higher that the pearl temperature.
Stretch Ratio:
PET hardens by stretching Mechanical properties of bottle depend on stretching process
Optimum perform dimensions can be calculated from bottle.
Radial 1:4.0 -----1:4.5
Axial 1:2.5-----1:3.0
BLOW MOULD OVERVIEW:
1.Conditioned performs are moulded into bottles shape by stretching and blowing inside blowing stations.
2.Preforms are pre-stretched by stretched rods(linear drives)
3.Blowing process is split into two phases.
a.Pre-blowing
b.High pressure
4.Air is fed via volve blocks
5.Pressures are generated in a Pneumatic system.
CO2 Yield
Improveme
nt
Leak
detection
&
Correctio
n
SOPs
and
Process
Check
equipment
setting
Daily
PRS
Stretching System
1.Preform stretching performed by linear electromechanical drive
2.Stretching speed programmable and independent of machine rotation.
3.P1 Start is activated directly by stretching rod position.
1.Preform stretching performed by linear electromechanical drive.
2.Stretching speed programmable and independent of machine rotation.
3.P1 Start is activated directly by stretching rod position.
Adjustment of Stretching Rod:
1.Stretching Rod must be adjusted to height of base mould.
2.A “gap control” in visualization is used for this .
3.Additional information :chapter “Product changeover” in training manual or documentation.
Final report
Fault Finding charts
Malfunction of the machine are prevented as fas as possible by a system of pneumatic ,mechanical and
electronic safety devices.
The malfunction id Indicated:
1.By a red alarm lamp on the top of the electrical cabinet.
2.An Optical indication on the display of the operating unit.
Bottle Quality :
1.Machine condition
2.Preform Quality
3.Environment
4.Process Settings
Contingencies Pressure and Bottle(P1 &P2)
Pre-blow P1----Material distribution, Height volume,Definition Details
High blow P2-----Height volume, definition Detail.
Heating Process
Heating time------Stress,cristallinity,Pearlescence
Penetration-------------Stress,Material distribution.
Pearlescence :Causes
Overstretched PET Material ------Unequally distributed material
Cristallinity: Cause
Overheated PET Material ----Thermal cristallisation.
Preform:
1. Preform has influence on bottle quality.
2. The stretch blowing process can be negatively influenced by
a.Manufacturing defects.
b.Improper storage of performs (temperature,humidity,exceeding long storage times )
Preform Manufacturing Defects:
1.Preform quality is a key factor for consistent bottle quality.
2.Quality issues during injection molding lead to partly invisible defects.
3.Partial cristallinity
4.Material tensions
5.Uneven layers
Preform Storage:
Preform Age: Preform shall not be used if they are older than 6 months.
Temperature:
PET stands for polyethylene terephthalate, a plastic resin and a form of polyester. Polyethylene terephthalate
is a polymer that is formed by combining two monomers: modified ethylene glycol and purified terephthalic
acid.
PET is a popular package for food and non-food products. Manufacturers use PET plastic to package
products because of its strength, thermo-stability and transparency. Customers choose PET because it is
inexpensive, lightweight, resealable, shatter-resistant and recyclable
Plastics are derived from organic products. The materials used in the production of plastics are natural
products such as cellulose, coal, natural gas, salt and, of course, crude oil.
PARAMIX
Deaerating :
A system area deaerates the supplied product water according to the principle of two-stage
Vacuum cold deaeration with the addition of Co2
A vacuum pump creates negative pressure in the deaeration tank.Special sprays spray the supplied water
into the bottom section.
The gases contained in the water are released in th deaeration tank and the water is collected in the runoff.
The vaccum pump extracts the gases.
The circulation pump pumps the water from the runoff into the top section of the deaerating tank while
adding co2 to the water. The co2 decreases the the particle pressure in the water to facilitate the release of
any remaining gases.
The remaining co2 and any other gases are released in the top section of the deaerating tank.Vaccum Pump
extracts the co2 and gases.The deaerated water is collected in the runoff of the second section and is fed to
the mixing pump.
COOLING :
This system area cools the blended product down to the optimum temperature for carbonating and filling.
If the product temperature exceeds 20 degrees,product pressure is created in the system that hinders the
uptake of CO2 and maintaining the level of co2 in the solution during carbonating.
Carbonating :
This system area carbonates the blended product to the co2 content specified inth erecipe.The recipes
specify the amount of co2 to be dosed based on one liter product.
The mixer mixes the co2 directly in the product.A mixing pump boosts the co2 dissolving process in the
product and feeds the product and feeds the product to the buffer tank.
Buffer Tank
The Buffer tank receives mixed and carbonated product and supplies it to the filling system.
The control applies co2 to the buffer tank.The gas in the buffer tank prevents the pickup of oxygen in the
product.
The blended and carbonated product forces the co2 out of the buffer tank back into the co2 line.
Dosing Pump Maintanence:
1.Every 40 hours the oil must be checked
2.Every 8000 hours
a.Oil to be replaced
b.Dosing diagram should be replaced.
Paramix:
The paramix is complex process equipment in which complicated processes take place due to different
technologies and physical parameters such as vaccum, flow,pressure,temperature,etc.
All said parameters are overlap with each other.Combination and correct settings of each parameters finally
quarentees the quality products.
Certain checks and observations based on experience can help in setting up the process correct and also in
trouble shooting.
Better-De-aeration:
1.A high vaccum is required (>-0.7 bar) for degassing the water.At the time ,the temperature of the water is
also crucial.Warm water (> 30 Deg.C) degasses more easily.Even Co2 addition can also be avoided for De-
aeration process if the water temperature is higher.
2.The vaccum should be >-0.7 bar during continues running.
3.The pressure of Co2 in Deoaeration system should not kept less than 1.5 bar
Visual and Audible Observations :
1.Inspect the flanges and screw connections for leaks.No water leak can be seen in the negative pressure
area during production.Caustic escapes from leaking connections and is deposited as a white film
2.Audible noise or abnormal hammering of air trapping can be easily audible especially in negative pressure
area.
3.Look at under the machine at regular intervals.Both can be become loose and fall down due to vibrations
.Check weather the machine Vibraations and noises are Normal.
Machine Equilibrium:
1.The flow of paramix should be seet 0.5 KL/hr more less than the real Beverage flow requirement by filler.
BEVERAGE FOAM DURING FILLING:
1.Check the finished Beverage in the sight of the Buffer tank.If the beverage is milky or contains the
bubbles ,this is the clean sign that there is air or Oxygen Enrichment in the system.
BEVERAGE COOLING :
1.The incoming pressure of coolent should not be more than 2bar.The pressure above this can damage the
seat area of 3way valve.This will result in leaking of coolent and freezing of PHE.
ERROR MESSAGE:
1.The most frequent cause is a shortage of water in upper stage of the De-aerator.The cause is usually a
defective shaft seal on the circulation pump.No water is pumped but air is sucked hence leakage can not be
seen.
2.Possibly low level floar signal is faulty causing main water feed valve close
GV Not In Limit:
1.The carbonation pressure should not rise in more than 0.3Bar when filler consumption is stopped.
2.When there is Stop-and-Go operation ,the back pressure goes high the Buffer tank. The Co2 upper
pressure setting should be kept only 0.3bar higher than the normal operating pressure so the excessive
pressure will be drained out.It will control the back pressure will result of GV also avoid product flow
variation.
Preparation for Production
1.Displace the air in the Buffer tank with water and force the tank empty or pressurize the tank with Co2
.The first production run after cleaning automatically fill the buffer tank with De-aerated ,non-carbonated
water regardless of the product selected for production
Ratio defining and controller:
1.The Purpose of the syrup ratio control is to continuously meter the Beverage syrup in proportion to the
beverage flow .Inorder to do so,the syrup flow and the Beverage flow are measured by flow meters.
2.Both measured values are displayed and transmitted to the ration control.The control determines the
current ratio of both flows and compares this actual ratio to the set point settings
Water-Syrup ratio : 4.4—1
Propertion of syrup in beverage: Syrup/Syrup+Water
= 1/1+4.4
= 1/5.4
= 0.1851 L/L
= 185.51 ml/L
Dosing and Mixing
This system component continuously doses and mixes the product components with deaerated water
according to prespecified recipes.The recipes specify the amount to be dosed based on one liter of deaerated
water.
The deaerating tank sipplies the deaerated product water to the mixing pump.
The mixing pump mixes the deaerated product water with the product components and pumps the blended
product to a cooler or directly to the carbonator if the cooler is switched off.
The control doses the amounts of product components specified in the recipe into the deaerated by means of
a ration control.
Carbon Dioxide (Co2)
Carbon Dioxide is used in process engineering as a pressurizing gas and for carbonating beverages.
Final report
Final report
Final report
Final report
1.Housing
2.Cutter hood
3.Cutter drum
4.Vacuum connector
5.compressed air connector
6.Vacuum manifold
7.Drive Wheel
8.Cutter adjuster
9.Lifting eyelet
Function :
The lebel web picked up by the lebel drive is cut into appropriate lebel lenghts in the cutter.They are then
transferred to the transfer roller from where they are applied to the container from by the vaccum drum.
The main components of the cutter are a housing containing the rotating cutter drum and a cutter hood that
accommodates and extends the sttic cutter.The cutter hood is equipped with a fine adjuster used to
compensate for cutter wear.The cutter is driven a drive wheel that engages in another gear wheel in the
transfer roller/
Compressed air is used to aid label transfer to the transfer roller.The hose is connected to the compressed air
connector.
The label web is cut as the rotating cutter passes by the stationary cutter.
Transfer Roller:
Final report
1.Vacuum drum segment
2.Color marking on vacuum drum segment
3.Mounting plate for vacuum drum segment
4.Positioning pin for the 1st vacuum drum segment.
5.Colored positioning pins for 3,4 or5 vacuum drum segment
6.Vacuum drum shaft bearing
7.Clamping cover
8.Clamping lock
9.Edge insert holder.
10.Eccentric screws
11.Edge insert,front
12.Edge insert,rear
13.Guard plate
14.Hoses
15.Format shield
16.Stopper
17.Fastening screws
Function of VACUUM DRUM:
The purpose of the vacuum drum is to transport the label within the lebeling machine and then transfer it to
the bottle to be labeled.The label is subjected to negative pressure through holes in the body of the vacuu
drum and in the drum.
The vacuum drum receives the label cut to size by the cutter.The leading and trailing ends of the label rest
on the front and rear edge inserts.Edge inserts and are raised on the body of the vacuum drum.

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Final report

  • 1. BUSINESS POLICY We at Hindustan Coca-Cola Beverages Private Ltd-Ameenpur,are in the business of producing beverages that refresh people.We believe that Quality,Safety and and Environment Management must function as an integral part of our operation throughout the value chain.We lead the beverage revolution by providing safest and world class product. TPM POLICY We at HCCB team commits to provide the highest quality product at the lowest possible cost.Delivered where and when it is needed.Produced in clean factory,that is safe,environmentally sound and respectful of the people doing the work. We are passionate about creating excellence in everything we do Our destination is to be World class. Quality policy We at Hindustan coca-cola Beverages private Ltd.-Ameenpur ,are committed to deliver refreshing ,high quality,products.Quality shows itself in our every action,it encompasses everything that we do.Everyassociate within HCCBPL-Ameenpur,takes this mission seriously and works tirelessly to ensure that our system keeps its promise of quality products and services We believe that quality is the cornerston of our success.Inharent in this belief is our dedication to our gold standard.PERFECT PRODUCT,TRUSTED EVERYWHERE. FOOD SAFETY POLICY We at Hindustan Coca Cola Beverages private Ltd-Ameenpur,are committed to ensure uncompromising food safety standards for the products we produce and distribute to the consumers through effective implementation of Food Safety system requirements. Food safety is integral to our gold standard of Quality.PERFECT PRODUCT,TRUSTED EVERY WHERE .We strive to protect our products and our consumers along the entire food chain-from start to finish.We aspire to grow the reputition of the brands we produce and maintain consumer confidence in our products. Environmental policy Our environmental efforts are focused on key areas where we have the most opportunity to make a difference and are defined by the following long term aspirational goals Water sterdship: We will be good stewards of our most critical shared resource in the communities Where we operate Climate protection: We will work to reduce our carbon emissions,even as we grow our business. Cost of Poor Quality Our COPQ will generally cover the followings :
  • 2. 1.Cost of labour to reduce the cost 2.Cost lf extra material used 3.Cost of extra utilities 4.Cost of lost Opportunities 5.Loss of sales/revenue 6.Potential loss of market share 7.Lower serve level to customer/consumers The focus of Process mapping The focus of process mapping is on discovering the current processes of an organization establishing the root cause problem with those processes,and looking for solutions Process mapping is used to find a problem and then a solution.Then find the next problem and the solution. Why process mapping Process or flowchart convey more that words Map is a work flow of the activities done by the people. People perform same tasks differently Improvements to satisfy customers needs. Focus of EM Piller Early management :To develop New product first time right with free from Losses,Defects and Product should start for mass production at reduced lead Time. HACCP (Hazard Analysis and Critical Control Point ) There are seven Principles 1.Conduct a hazard Analysis.( Bio-logical,Chemical& Physical). 2.Determine CCP. 3.Establish a Critical Point. 4.Established Monitoring Procedures. 5.Establish Correctve Actions. 6.Establish Record Keeping and Documentation Procedures. 7.Establish Verification Procedures. The Seven Principles of HACCP, Encompass a systamatic approach to the identification,prevention, and control of Food Safety Hazards include. CCP : Critical Control Point is defined as a point,a step, or Procedure in a food process at which Control can be applied,As a result food safety hazards can be prevented ,Eliminated or Reduced.
  • 3. PHYSICAL DATA: Boiling point (91F.) : @ 1 atm 96109.3F (-78.5oC) Triple point (91F.) : @ 1 atm 76 (-56.66oC and 75.1 lbs/sqin.a) Vapor pressure (psia) : @ 68F (20C) 831 psia (56,5 atm) Solubility in water : @ 68F (20C), 1 atm 87.8% by volume Vapor density (lb/cu ft) : @ 68F (20C), 1 atm 0.115 Specific gravity (AIR=1) : @ 68F (20C), 1 atm 1.53 Liquid density (lb/cu ft) : @ -35 (-37oC) 11 atm 68.74 Specific gravity (H20=1) : Solid @ -110F (-79C),1 atm 1.56 Appearance and Odour: Carbon Di-oxide is a colourless and odorless a gas or a liquid.It is stored in containers under its own vapour pressure. If the pressure is suddenly relieved,the liquid repidly cools as it evaporates and sublimes,forming dry ice at 96109.3F (-78.5C) SYMPTOMS IF INGESTED,CONTACTED WITH SKIN,OR VAPOUR INHALED Carbon dioxide does not support life and may produce immediately hazardous atmospheres. At concentration in Excess of 1.5% carbon dioxide may produce hyperventilation,headches,visual disturbance,tremor,loss of consciousness and,death.Symptoms of exposure in the concentration ranges of 1.5-5%, may highly variable,but typical symptoms of carbon dioxide intoxication include the following 3-6% :Headache,perspiration 6-10% :Headache,perspiration,tremours,visual disturbance.unconsciousness. Over 10% : Unconsciousness If the concentration of carbon dioxide exceed 10% unconsciousness can occur without warming,preventing self-rescue. A t much higher concentrations,carbon dioxide displaces the oxygen in air levels necessary to support life. TOXICOLOGICAL PROPERTIES Carbon dioxide is minor but important constituent of the atmosphere,avaraging about 0.03% or 300ppm by volume.At higher concentrations if affects the respiratory rate. REACTIVITY DATA Stability : Unstable Incompatibility : If moisture is present,material must resist carbonic acid. Hazardous polymerizarion : May occur
  • 4. STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED Carbon dioxide is small quantities will vaporizes will leaving beind carbon dioxide “snow”. Ventilate indoor areas well to avoid hazardous carbon dioxide concentrations.Ventilate well and avoid hazardous carbon dioxide concentrations.Ventilate well and avoid contact with cold vapor or dry ice.Carbon dioxide is a heavy gas and will remain in low spots without assisted ventilation. WASTE DISPOSAL METHOD When disposing of bulk quantities of Carbon Dioxide from refrigerated storage tanks,always dispose of Carbon dioxide outside in a well ventilated location awa from work areas,where vapours can disperse,vent to the atmosphere slowly since rapid depressrization of the container will cause the formation of solid carbon dioxide internally,requiring longer periods to vaporize and risking to the vessel. SPECIAL HANDLING RECOMMENDATIONS Prevent contact of liquid Co2, cold vapours,or carbon dioxide “snow” with exposed skin.Prevent entrapment of liquid in closed systems.Never use direct flame to heat a compressed gas.Also avoid dragging ,or sliding,even for a short distance. Use a suitable hand truck. SPECIAL STORAGE RECOMMENDATIONS Store liquid containers in well ventilated areas.Storage should not be in heavy traffic areas to prevent accidental knocking over or damage from passing or falling objects.Storage areas should be free of combustible material.Avoid exposure to areas where salt or other corrosive chemicals pressent. PET-poly Ethylene Terephtalate. Created by repeated bonding of Terephtalic Acid Ethylene Glycol 2.Bonding by formation of an ester group and water shedding.
  • 5. Pearl : crystallization induced by mechanical overstretching Pearl is always inside molecules have the longer way and are going to be over stretched first. The blowing temperature should be 3Degrees higher that the pearl temperature. Stretch Ratio: PET hardens by stretching Mechanical properties of bottle depend on stretching process Optimum perform dimensions can be calculated from bottle. Radial 1:4.0 -----1:4.5 Axial 1:2.5-----1:3.0
  • 6. BLOW MOULD OVERVIEW: 1.Conditioned performs are moulded into bottles shape by stretching and blowing inside blowing stations. 2.Preforms are pre-stretched by stretched rods(linear drives) 3.Blowing process is split into two phases. a.Pre-blowing b.High pressure 4.Air is fed via volve blocks 5.Pressures are generated in a Pneumatic system. CO2 Yield Improveme nt Leak detection & Correctio n SOPs and Process Check equipment setting Daily PRS
  • 7. Stretching System 1.Preform stretching performed by linear electromechanical drive 2.Stretching speed programmable and independent of machine rotation. 3.P1 Start is activated directly by stretching rod position. 1.Preform stretching performed by linear electromechanical drive. 2.Stretching speed programmable and independent of machine rotation. 3.P1 Start is activated directly by stretching rod position. Adjustment of Stretching Rod: 1.Stretching Rod must be adjusted to height of base mould. 2.A “gap control” in visualization is used for this . 3.Additional information :chapter “Product changeover” in training manual or documentation.
  • 9. Fault Finding charts Malfunction of the machine are prevented as fas as possible by a system of pneumatic ,mechanical and electronic safety devices. The malfunction id Indicated: 1.By a red alarm lamp on the top of the electrical cabinet. 2.An Optical indication on the display of the operating unit.
  • 10. Bottle Quality : 1.Machine condition 2.Preform Quality 3.Environment 4.Process Settings Contingencies Pressure and Bottle(P1 &P2) Pre-blow P1----Material distribution, Height volume,Definition Details High blow P2-----Height volume, definition Detail. Heating Process Heating time------Stress,cristallinity,Pearlescence Penetration-------------Stress,Material distribution. Pearlescence :Causes Overstretched PET Material ------Unequally distributed material Cristallinity: Cause Overheated PET Material ----Thermal cristallisation.
  • 11. Preform: 1. Preform has influence on bottle quality. 2. The stretch blowing process can be negatively influenced by a.Manufacturing defects. b.Improper storage of performs (temperature,humidity,exceeding long storage times ) Preform Manufacturing Defects: 1.Preform quality is a key factor for consistent bottle quality. 2.Quality issues during injection molding lead to partly invisible defects. 3.Partial cristallinity 4.Material tensions 5.Uneven layers Preform Storage: Preform Age: Preform shall not be used if they are older than 6 months. Temperature:
  • 12. PET stands for polyethylene terephthalate, a plastic resin and a form of polyester. Polyethylene terephthalate is a polymer that is formed by combining two monomers: modified ethylene glycol and purified terephthalic acid. PET is a popular package for food and non-food products. Manufacturers use PET plastic to package products because of its strength, thermo-stability and transparency. Customers choose PET because it is inexpensive, lightweight, resealable, shatter-resistant and recyclable Plastics are derived from organic products. The materials used in the production of plastics are natural products such as cellulose, coal, natural gas, salt and, of course, crude oil. PARAMIX Deaerating : A system area deaerates the supplied product water according to the principle of two-stage Vacuum cold deaeration with the addition of Co2 A vacuum pump creates negative pressure in the deaeration tank.Special sprays spray the supplied water into the bottom section. The gases contained in the water are released in th deaeration tank and the water is collected in the runoff. The vaccum pump extracts the gases. The circulation pump pumps the water from the runoff into the top section of the deaerating tank while adding co2 to the water. The co2 decreases the the particle pressure in the water to facilitate the release of any remaining gases. The remaining co2 and any other gases are released in the top section of the deaerating tank.Vaccum Pump extracts the co2 and gases.The deaerated water is collected in the runoff of the second section and is fed to the mixing pump. COOLING : This system area cools the blended product down to the optimum temperature for carbonating and filling. If the product temperature exceeds 20 degrees,product pressure is created in the system that hinders the uptake of CO2 and maintaining the level of co2 in the solution during carbonating. Carbonating : This system area carbonates the blended product to the co2 content specified inth erecipe.The recipes specify the amount of co2 to be dosed based on one liter product. The mixer mixes the co2 directly in the product.A mixing pump boosts the co2 dissolving process in the product and feeds the product and feeds the product to the buffer tank. Buffer Tank
  • 13. The Buffer tank receives mixed and carbonated product and supplies it to the filling system. The control applies co2 to the buffer tank.The gas in the buffer tank prevents the pickup of oxygen in the product. The blended and carbonated product forces the co2 out of the buffer tank back into the co2 line. Dosing Pump Maintanence: 1.Every 40 hours the oil must be checked 2.Every 8000 hours a.Oil to be replaced b.Dosing diagram should be replaced. Paramix: The paramix is complex process equipment in which complicated processes take place due to different technologies and physical parameters such as vaccum, flow,pressure,temperature,etc. All said parameters are overlap with each other.Combination and correct settings of each parameters finally quarentees the quality products. Certain checks and observations based on experience can help in setting up the process correct and also in trouble shooting. Better-De-aeration: 1.A high vaccum is required (>-0.7 bar) for degassing the water.At the time ,the temperature of the water is also crucial.Warm water (> 30 Deg.C) degasses more easily.Even Co2 addition can also be avoided for De- aeration process if the water temperature is higher. 2.The vaccum should be >-0.7 bar during continues running. 3.The pressure of Co2 in Deoaeration system should not kept less than 1.5 bar Visual and Audible Observations : 1.Inspect the flanges and screw connections for leaks.No water leak can be seen in the negative pressure area during production.Caustic escapes from leaking connections and is deposited as a white film 2.Audible noise or abnormal hammering of air trapping can be easily audible especially in negative pressure area. 3.Look at under the machine at regular intervals.Both can be become loose and fall down due to vibrations .Check weather the machine Vibraations and noises are Normal.
  • 14. Machine Equilibrium: 1.The flow of paramix should be seet 0.5 KL/hr more less than the real Beverage flow requirement by filler. BEVERAGE FOAM DURING FILLING: 1.Check the finished Beverage in the sight of the Buffer tank.If the beverage is milky or contains the bubbles ,this is the clean sign that there is air or Oxygen Enrichment in the system. BEVERAGE COOLING : 1.The incoming pressure of coolent should not be more than 2bar.The pressure above this can damage the seat area of 3way valve.This will result in leaking of coolent and freezing of PHE. ERROR MESSAGE: 1.The most frequent cause is a shortage of water in upper stage of the De-aerator.The cause is usually a defective shaft seal on the circulation pump.No water is pumped but air is sucked hence leakage can not be seen. 2.Possibly low level floar signal is faulty causing main water feed valve close GV Not In Limit: 1.The carbonation pressure should not rise in more than 0.3Bar when filler consumption is stopped. 2.When there is Stop-and-Go operation ,the back pressure goes high the Buffer tank. The Co2 upper pressure setting should be kept only 0.3bar higher than the normal operating pressure so the excessive pressure will be drained out.It will control the back pressure will result of GV also avoid product flow variation. Preparation for Production 1.Displace the air in the Buffer tank with water and force the tank empty or pressurize the tank with Co2 .The first production run after cleaning automatically fill the buffer tank with De-aerated ,non-carbonated water regardless of the product selected for production Ratio defining and controller: 1.The Purpose of the syrup ratio control is to continuously meter the Beverage syrup in proportion to the beverage flow .Inorder to do so,the syrup flow and the Beverage flow are measured by flow meters. 2.Both measured values are displayed and transmitted to the ration control.The control determines the current ratio of both flows and compares this actual ratio to the set point settings Water-Syrup ratio : 4.4—1 Propertion of syrup in beverage: Syrup/Syrup+Water = 1/1+4.4 = 1/5.4 = 0.1851 L/L
  • 15. = 185.51 ml/L Dosing and Mixing This system component continuously doses and mixes the product components with deaerated water according to prespecified recipes.The recipes specify the amount to be dosed based on one liter of deaerated water. The deaerating tank sipplies the deaerated product water to the mixing pump. The mixing pump mixes the deaerated product water with the product components and pumps the blended product to a cooler or directly to the carbonator if the cooler is switched off. The control doses the amounts of product components specified in the recipe into the deaerated by means of a ration control. Carbon Dioxide (Co2) Carbon Dioxide is used in process engineering as a pressurizing gas and for carbonating beverages.
  • 20. 1.Housing 2.Cutter hood 3.Cutter drum 4.Vacuum connector 5.compressed air connector 6.Vacuum manifold 7.Drive Wheel 8.Cutter adjuster 9.Lifting eyelet Function : The lebel web picked up by the lebel drive is cut into appropriate lebel lenghts in the cutter.They are then transferred to the transfer roller from where they are applied to the container from by the vaccum drum. The main components of the cutter are a housing containing the rotating cutter drum and a cutter hood that accommodates and extends the sttic cutter.The cutter hood is equipped with a fine adjuster used to compensate for cutter wear.The cutter is driven a drive wheel that engages in another gear wheel in the transfer roller/ Compressed air is used to aid label transfer to the transfer roller.The hose is connected to the compressed air connector. The label web is cut as the rotating cutter passes by the stationary cutter. Transfer Roller:
  • 22. 1.Vacuum drum segment 2.Color marking on vacuum drum segment 3.Mounting plate for vacuum drum segment 4.Positioning pin for the 1st vacuum drum segment. 5.Colored positioning pins for 3,4 or5 vacuum drum segment 6.Vacuum drum shaft bearing 7.Clamping cover 8.Clamping lock 9.Edge insert holder. 10.Eccentric screws 11.Edge insert,front 12.Edge insert,rear 13.Guard plate 14.Hoses 15.Format shield 16.Stopper
  • 23. 17.Fastening screws Function of VACUUM DRUM: The purpose of the vacuum drum is to transport the label within the lebeling machine and then transfer it to the bottle to be labeled.The label is subjected to negative pressure through holes in the body of the vacuu drum and in the drum. The vacuum drum receives the label cut to size by the cutter.The leading and trailing ends of the label rest on the front and rear edge inserts.Edge inserts and are raised on the body of the vacuum drum.