Water Treatment by RO

Shamim & Company Private Limited Franchise of PepsiCo.
Dated: 02-07-18
Preparedby:
Irfan Ahmad
M.Shiraz
Ahmad Hasan
NFC.IET MULTAN 2K16-CHE-ENGG
Submitted to: Danishsb
[GM Technical]
Internship Report on Pepsi Co.
Shamim & Company (Pvt) Ltd.

Acknowledgement
I pay special thanks to ALLAH Almighty who bestowed me theopportunity, courage and
confidence to obtain more knowledge to complete my internship program, which will facilitate me
greatly in my intellectual development and skills capitalization.
I would like to submit my deepest gratitude to my parents, whose prayers always supported in
every task of my life and my teachers, who really guided me to enhance my learning in Shamim &
Co. (Pvt) Ltd Multan.
To accomplish whatever I have done in my internship, there were many people along the
way who have been responsible for guiding me, advising me, encouraging me. To them, I am
deeply grateful and would like to take this opportunity to offer my heartfelt appreciation.
EXECUTIVE SUMMARY

Shamim & Co. Multan is working in beverages business (PEPSI cola) under a franchise setup
since 1963. PEPSI Multan is currently having 80% market share in Multan and the share is still
rising. Pepsi Multan has not the certified ISO Company because there is no export of Pepsi
drink; it is an international drink encloses their standards.
The Pepsi-cola is the market leader in the Pakistan as well as in the Asia but Coca Cola is the
market leader in the whole world. These industries develop their own marketing policy to meet
the necessities of their respective target market. As for as the Shamim & Co. beverage in Multan
is concerned, it creates its control in its target market, which is based on Multan, Rahim Yar
Kahn and the sub areas of these cities. Shamim & Co. beverage successfully complete the
obligation of its target market. Shamim & Co. beverages think important departmentalization in
their office works and therefore they set up different department to achieve their particular tasks.
There are different departments in the Shamim & Co. beverages like human resource
department, management information system department, finance department, internal and
external audit department, sales & marketing department and shipping department.
Finally, I am thankful to complete management of Shamim & Company (Pvt) Ltd Multan,
particularly Finance Executive Mr. Junaid Shah who provide me opportunity to work with them
and provide chance to learn operation of Shamim & Company Pepsi Cola Multan.
Introduction of PespiCo International;
Mr. Caleb Bradham is the owner of a ting drug store in of North Carolina City In January
1898, which was the starting period of Pepsi-cola. The Drug store owner created a drink, which
is call "the Bred Drink". In 1903 Bred index the name drink Pepsi. At Marco level he ongoing
his own produced and build his own organization. The trade extended and this drink achieved
appreciation time. This company appears at 24 states of America with more than 250 dealers in
1909. First time Pepsi packed in 16.5 ounce packing size. Pepsi-cola has launched its new filler
in 12 ounce in 1932. New promotion struggle is started with the name of "Refresh without
Filling" in 1950 by Pepsi-cola. The chemical formula also changed which caused to decrease
its sweetness and calories. Pepsi acquired so much celebrity that it established new plants at a

rate of thirty per annum with the hardworking of the Sales & Marketing Department. In 1985
the design of the bottle has been changed after 20 years. And a new and eye-catching
packaging has been presented with two new flavors i.e., Teem & Miranda. Pepsi is accessible
now in more than 160 countries of the world including Soviet Union & China..
PepsiCo In Pakistan
Pepsi-cola market share is about 75% in the soft-drink market in Pakistan because it is very
traditional. Pepsi-cola International, a significant name in the cola trade is doing its business in
Pakistan through franchising. PCI has industrial following bottlers in Pakistan till now. Shamim
and Co Company is the largest producer and distributor of Pepsi Cola soft drinks in Pakistan.
These franchises are situated in:
 Karachi
 Lahore
 Multan
 Sukkher
 Gujranwala
 Faisalabad
 Peshawar
 Islamabad
 Hyderabad
Introduction to Shamim & Co. (Pvt) Ltd Multan
Shamim & company (Pvt.) Ltd. is a franchise of “Pepsi Cola International”. The company has
established in 1964. Mr. “Allah Nawaz Khan Tareen” was the inventor of the company and also
chairman. It is a great pleasure of “Shamim & Company” that it was Second Beverage Company
of Pakistan that time, and this time one of celebrated Beverage Company of South Asia.

Pepsi Multan was incorporated in 1963 but it in progress its manufacture in 1967. At that time
Pepsi Multan was having only 1 production plant made by Netherlands. At the start Pepsi Multan
was only manufacture 7-Up because it was the only brand produced by Parent Company. In
1973, parent company got hold of PEPSI so the Multan franchise started producing PEPSI and
Marinda along with 7-Up.
Coke was already in service in the market at the time when Pepsi Multan well-known. At that
time Coke was market leader but with the passage of time Pepsi Multan reserved on focusing on
gaining the market share. Recently Pepsi has launched a new brand with the name of Mountain
Dew. Now Pepsi Multan is working with eight production plants capable of producing more than
200,000 crates per day. “The plant which was installed at ht e time of establishment has now
been grounded. Pepsi Multan is at present market leader with more than 75% of market shares.
The Area allotted to Multan Franchise. The franchise area consists of the following districts.
 Multan
 Muzafar Garrah
 D.G Khan
 Bahawalpur
 Lodhran
 Bahwalnagar
 Sahiwal
 Pakpattan
 Rahim Yar Khan
 Khanewal & Vehari
INTERNSHIP PROGRAM
FIELDS OF ACTIVITIES
Shamim and Co Bottling Company is the franchise of Pepsi Cola International. It performs all
the functions throughout its different types of department, only company receives Concentrate

(basic formula) from Pepsi cola international and all other activities are performed by the
company itself.
Through my 6 week internship program, I was motivated through following departments:
 Ammonia Refrigeration
 WTP
Ammonia Refrigeration
Refrigeration is a process of removing heat from a low-temperature reservoir and transferring it
to a high-temperature reservoir. The work of heat transfer is traditionally driven
by mechanical means, but can also be driven by heat, magnetism, electricity, laser, or other
means. Refrigeration has many applications, including, but not limited to:
household refrigerators, industrial freezers, cryogenics, and air conditioning. Heat pumps may
use the heat output of the refrigeration process, and also may be designed to be reversible, but
are otherwise similar to air conditioning units. Refrigeration has had a large impact on industry,
lifestyle, agriculture, and settlement patterns.
As quite similar criteria shall be fulfilled by working fluids (refrigerants) applied to heat pumps,
refrigeration and ORC cycles, several working fluids are applied by all these technologies.
Ammonia was one of the first refrigerants. An American society of refrigeration engineer defines
as "The science of providing and maintaining temperature below that of surrounding
atmosphere". It means that continuously extraction of heat from a body whose temperature is
already below the temperature of its surroundings.
Capacity Ratings
The measured capacity of refrigeration is always dimensioned in units of power. Domestic and
commercial refrigerators may be rated in kJ/s, or Btu/h of cooling. For commercial and industrial
refrigeration systems, the kilowatt (kW) is the basic unit of refrigerationexcept in North
America, where the ton of refrigeration (TR) is used. (Nominally the capacity to freeze one short
ton of water per day, the TR is defined as 12,000 Btu/hr (3.517 kW).)
A refrigeration system's coefficient of performance (CoP) is very important in determining a
system's overall efficiency. It is defined as refrigeration capacity in kW divided by the energy
input in kW. While CoP is a very simple measure of performance, it is typically not used for
industrial refrigeration in North America. Owners and manufacturers of these systems typically
use performance factor (PF). A system's PF is defined as a system's energy input in horsepower
divided by its refrigeration capacity in TR. Both CoP and PF can be applied to either the entire

system or to system components. For example, an individual compressor can be rated by
comparing the energy needed to run the compressor versus the expected refrigeration capacity
based on inlet volume flow rate. It is important to note that both CoP and PF for a refrigeration
system are only defined at specific operating conditions, including temperatures and thermal
loads. Moving away from the specified operating conditions can dramatically change a system's
performance.
Principles of Refrigeration
1. Liquids absorb heat when changed from liquid to gas
2. Gases give off heat when changed from gas to liquid.
For an air conditioning system to operate with economy, the refrigerant must be used repeatedly.
For this reason, all air conditioners use the same cycle of compression, condensation, expansion,
and evaporation in a closed circuit. The same refrigerant is used to move the heat from one area,
to cool this area, and to expel this heat in another area.
 The refrigerant comes into the compressor as a low-pressure gas, it is compressed and
then moves out of the compressor as a high-pressure gas.
 The gas then flows to the condenser. Here the gas condenses to a liquid, and gives off its
heat to the outside air.

 The liquid then moves to the expansion valve under high pressure. This valve restricts the
flow of the fluid, and lowers its pressure as it leaves the expansion valve.
The low-pressure liquid then moves to the evaporator, where heat from the inside air is absorbed
and changes it from a liquid to a gas.
 As a hot low-pressure gas, the refrigerant moves to the compressor where the entire cycle
is repeated.
Note that the four-part cycle is divided at the center into a high side and a low side This refers to
the pressures of the refrigerant in each side of the system
Compressor
The purpose of the compressor is to circulate the refrigerant in the system under pressure, this
concentrates the heat it contains.
 At the compressor, the low pressure gas is changed to high pressure gas.
 high pressure side of the system. This is a small valve located in the expansion valve.
The compressor has reed valves to control the entrance and exit of refrigerant gas during the
pumping operation. These must be firmly seated.
 An improperly seated intake reed valve can result in gas leaking back into the low side
during the compression stroke, raising the low side pressure and impairing the cooling
effect.
 A badly seated discharge reed valve can allow condensing or head pressure to drop as it
leaks past the valve, lowering the efficiency of the compressor.
Two service valves are located near the compressor as an aid in servicing the system.
 One services the high side, it is quickly identified by the smaller discharge hose routed to
the condenser.
 One is used for the low side, the low side comes from the evaporator, and is larger than
the discharge hose

The compressor is normally belt-driven from the engine crankshaft. Most manufacturers use a
magnetic-type clutch which provides a means of stopping the pumping of the compressor when
refrigeration is not desired.
Compressor Relief Valve
Some compressors have a relief valve for regulating pressure. If the system discharge pressure
exceeds rated pressure, the valve will open automatically and stay open until the pressure drops.
The valve will then close automatically.
Compressor Noise Complaints
Many noise complaints can be traced to the compressor mount and drive.
 If a unit is noisy at one speed and quiet at another, it is not compressor noise.
 Many times this kind of noise can be eliminated or greatly reduced by changing the belt
adjustment.
 Usually tightening mounts, adding idlers, or changing belt adjustment and length are
more successful in removing or reducing this type of noise, than replacing the
compressor.
 Noises from the clutch are difficult to recognize because the clutch is so close to the
compressor. A loose bolt holding the clutch to the shaft will make a lot of noise.
 The difference, between suction pressure and discharge pressure, also plays an important
part on sound level.
o A compressor with low suction pressure will be more noisy than one with a higher
pressure.
 Consider whether the system is properly charged, whether the expansion valve is feeding
properly to use the evaporator efficiently, and whether enough air is being fed over the
evaporator coil.
CONDENSER
 The purpose of the condenser is to receive the high-pressure gas from the compressor and
convert this gas to a liquid.

 It does it by heat transfer, or the principle that heat will always move from a warmer to a
cooler substance.
 Air passing over the condenser coils carries off the heat and the gas condenses.
 The condenser often looks like an engine radiator.
Condensers used on R-12 and R-134a systems are not interchangeable. Refrigerant-134a has a
different molecular structure and requires a large capacity condenser.
As the compressor subjects the gas to increased pressure, the heat intensity of the refrigerant is
actually concentrated into a smaller area, thus raising the temperature of the refrigerant higher
than the ambient temperature of the air passing over the condenser coils. Clogged condenser fins
will result in poor condensing action and decreased efficiency.
A factor often overlooked is flooding of the condenser coils with refrigerant oil. Flooding results
from adding too much oil to the system. Oil flooding is indicated by poor condensing action,
causing increased head pressure and high pressure on the low side. This will always cause poor
cooling from the evaporator.
Too-High condenser Pressure
 Indicated By: Excessive head pressure on high side gauge.
 Caused By: Restriction of refrigerant flow in high side of system or lack of air flow over
condenser coils.
Too-Low condenser Pressure
 Indicated By: Higher than normal pressure on low side gauge.
 Caused By: Failed compressor reed valve or piston. Heat exchange in the condenser will
be cut down, and the excessive heat will remain in the low side of the system.
EVAPORATOR
The evaporator works the opposite of the condenser, here refrigerant liquid is converted to gas,
absorbing heat from the air in the compartment.
When the liquid refrigerant reaches the evaporator its pressure has been reduced, dissipating its
heat content and making it much cooler than the fan air flowing around it. This causes the

refrigerant to absorb heat from the warm air and reach its low boiling point rapidly. The
refrigerant then vaporizes, absorbing the maximum amount of heat.
This heat is then carried by the refrigerant from the evaporator as a low-pressure gas through a
hose or line to the low side of the compresso, where the whole refrigeration cycle is repeated.
The evaporator removes heat from the area that is to be cooled. The desired temperature of
cooling of the area will determine if refrigeration or air conditioning is desired. For example,
food preservation generally requires low refrigeration temperatures, ranging from 40°F (4°C) to
below 0°F (-18°C).
A higher temperature is required for human comfort. A larger area is cooled, which requires that
large volumes of air be passed through the evaporator coil for heat exchange. A blower becomes
a necessary part of the evaporator in the air conditioning system. The blower fans must not only
draw heat-laden air into the evaporator, but must also force this air over the evaporator fins and
coils where it surrenders its heat to the refrigerant and then forces the cooled air out of the
evaporator into the space being cooled.
BLOCK DIAGRAM OF AMMONIA REFRIGERATON IN PEPSI PLANT

Why ammonia in industrial refrigeration?
Ammonia offers a wealth of benefits for industrial refrigeration
Ammonia was used for refrigeration in 1876, for the first time in a vapour compression machine
by Carl Von Linde. Other refrigerants like CO2, SO2 also were commonly used till 1920s.
Development of CFC’s (Chlorofluorocarbons) in USA, in 1920s swung the pendulum in favour
of these refrigerants, as compared to all other refrigerants used in those days, CFC’s were
considered harmless and extremely stable chemicals. The consequences to the outer environment
of massive releases of refrigerant could not be foreseen in those days. “CFC” refrigerants were
promoted as safety refrigerants, resulting in an accelerating demand and CFC’s success. These
refrigerants became known as God sent and man-made chemicals.
Due to success of CFC’s, Ammonia came under heavy pressure, but held its position, especially
in large industrial installations and food preservation.
In 1980’s the harmful effects of CFC refrigerants became apparent and it was generally accepted
that the CFC refrigerants are contributing to depletion of ozone layer and to global warming,
finally resulting in Montreal protocol (1989) where almost all countries agreed to phase out
CFC’s in a time bound program.
In view of seriousness of damage to atmosphere and resulting dangers due to CFC/ HCFC
emissions as also due to global warming effects, the revisions in Montreal protocol (1990),
1992(Copenhagen) and 1998 Kyoto Japan demanded accelerated phase out schedule. Even
HCFC’s are also to be phased out and Europe has taken the lead.
Many countries in Europe have stopped use of HCFC refrigerants, and new refrigerants as well
as well-tried and trusted refrigerants like Ammonia and Carbon Dioxide are being considered for
various new applications as well.
Ammonia has a number of benefits, which has been proven by many decades of application of
ammonia refrigeration systems.
1. Energy efficiency
Ammonia is one of the most efficient applications out there, with the application range from high
to low temperatures. With the ever increasing focus on energy consumption, ammonia systems
are a safe and sustainable choice for the future. Typically a flooded ammonia system would be
15-20 % more efficient than a DX R404A counterpart. Recent developments of NH3 and CO2
combination contributed to increase the efficiency further. NH3/CO2 cascaded is extremely
efficient for low and very low temperature applications (below -40’C), while NH3/CO2 brine
systems are around 20% more efficient than traditional brines

2. Environment
Ammonia is the most environmentally friendly refrigerant. It belongs to the group of so called
“natural” refrigerants, and it has both GWP (Global Warming Potential) and ODP (Ozone
Depletion Potential) equal to zero.
3. Safety
Ammonia is a toxic refrigerant, and it is also flammable at certain concentrations. That is why it
has to be handled with care, and all ammonia systems have to be designed with safety in mind.
At the same time, unlike most other refrigerants, it has a characteristic odor that can be detected
by humans even at very low concentrations. That gives a warning sign even in case of minor
ammonia leakages. In case it is necessary to reduce ammonia charge, combination of ammonia
and CO2 (as cascade or as brine) could be a good and efficient option.
4. Smaller pipe sizes
In both vapour and liquid phase ammonia requires smaller pipe diameters than most chemical
refrigerants.
5. Better heat transfer
Ammonia has better heat transfer properties than most of chemical refrigerants and therefore
allow for the use of equipment with a smaller heat transfer area. Thereby plant construction cost
will be lower. But as these properties also benefit the thermodynamic efficiency in the system, it
also reduces the operating costs of the system.
6. Refrigerant price
In many countries the cost of ammonia (per kg) is considerably lower than the cost of HFCs.
This advantage is even multiplied by the fact that ammonia has a lower density in liquid phase.
Furthermore as any leakage of ammonia will be detected very quickly due to the odour, hence
any potential loss of refrigerant will also be lower.
Ammonia is not a universal refrigerant, and mainly suitable for industrial and heavy commercial
applications. Ammonia’s toxicity, flammability and material compatibility have to be taken in to
account. At the same time, there is a huge global population of ammonia systems where those
challenges are successfully dealt with.
Properties of Ammonia
Ammonia is a chemical consisting of one atom of nitrogen and three atoms of hydrogen. It is
designated in chemical notation as NH3. Ammonia is extremely soluble in water and is
frequently used as a water solution called aqua ammonia. Ammonia chemically combines with
water to form ammonium hydroxide. Household ammonia is a diluted water solution containing

5 to 10 percent ammonia. On the other hand, anhydrous ammonia is essentially pure (over 99
percent) ammonia. "Anhydrous" is a Greek word meaning "without water;" therefore, anhydrous
ammonia in ammonia without water.
Refrigerant grade anhydrous ammonia is a clear, colorless liquid or gas, free from visible
impurities. It is at least 99.95 percent pure ammonia. Water cannot have a content above 33 parts
per million (ppm) and oil cannot have a content above 2 ppm. Preserving the purity of the
ammonia is essential to ensure proper function of the refrigeration system.
 Keeping Ammonia Pure
 Physical Properties
 Chemical Properties
 Health Effects
Impurities can enter the ammonia system:
 While charging the system.
 Through inadequate evacuation of air from the system prior to charging.
 From valve stem packing.
 From piping repairs.
 From piping leaks.
 From the normal breakdown of ammonia.
Potential Hazards:
 Release of ammonia due to excess water within the system freezing,
which causes broken pipes and equipment.
 Ineffective refrigeration due to excess oil within the system, causing the
system to work harder than necessary, thus stressing the system
components.
 Oxygen levels of more than a few ppm in liquid ammonia or a few
thousand ppm in gaseous ammonia can promote stress corrosion cracking
in steels.

 This may result in a catastrophic failure of bulk storage vessels.
 This may result in ammonia weeping from a crack within the
refrigeration system.
 Stress corrosion cracking proceeds more rapidly at high
temperatures.
Possible Controls:
 Provide employees information pertaining to the hazards of ammonia.
 Ensure ammonia being introduced to the system is refrigerant
grade.
 See Physical and Chemical properties of ammonia for more
information.
 Conduct a process hazard analysis.
 Provide operating procedures to ensure proper operation of the system.
 Follow operating procedures for charging the system to prevent
impurities from being introduced.
 Provide training specific to the handling of ammonia.
 Conduct a pre-startup safety review prior to introducing ammonia when
the equipment is new or modified significantly enough to require a change
in the process safety information.
 Ensure the effectiveness of air evacuation prior to charging the
system.
 Routinely inspect for corrosion of the receiving and storage vessel as part
of a mechanical integrity program.
 Install a non-condensable gas (oil and water) separator (purge
units) into the system.
 Maintain the purge unit according to manufactures
specifications.

 Test and analyze the ammonia periodically for oxygen and water
content.
 Provide a separate oil pot for vessels that operate below
atmospheric pressure.
 Establish and implement written procedures to manage changes to
equipment, procedures, and to facilities.
 Investigate incidents.
 Investigate accidents and near misses that could have resulted in a
release of ammonia.
 Establish and implement an emergency action plan in case of release.
Physical Properties
Anhydrous ammonia is a clear liquid that boils at a temperature of -28°F. In
refrigeration systems, the liquid is stored in closed containers under pressure.
When the pressure is released, the liquid evaporates rapidly, generally forming
an invisible vapor or gas. The rapid evaporation causes the temperature of the
liquid to drop until it reaches the normal boiling point of -28°F, a similar effect
occurs when water evaporates off the skin, thus cooling it. This is why ammonia
is used in refrigeration systems.
Liquid anhydrous ammonia weighs less than water. About eight gallons of
ammonia weighs the same as five gallons of water.
Liquid and gas ammonia expand and contract with changes in pressure and
temperature. For example, if liquid anhydrous ammonia is in a partially filled,
closed container it is heated from 0°F to 68°F, the volume of the liquid will
increase by about 10 percent. If the tank is 90 percent full at 0°F, it will become
99 percent full at 68°F. At the same time, the pressure in the container will
increase from 16 pounds per square inch (psi) to 110 psi.
Liquid ammonia will expand by 850 times when evaporating:
Anhydrous ammonia gas is considerably lighter than air and will rise in dry air.
However, because of ammonias tremendous affinity for water, it reacts

immediately with the humidity in the air and may remain close to the ground.
The odor threshold for ammonia is between 5 - 50 parts per million (ppm) of air.
The permissible exposure limit (PEL) is 50 ppm averaged over an 8 hour shift. It
is recommended that if an employee can smell it they ought to back off and
determine if they need to be using respiratory protection.
Summary of properties:
Boiling Point -28°F
Weight per gallon of liquid at -28°F 5.69 pounds
Weight per gallon of liquid at 60°F 5.15 pounds
Specific gravity of the liquid (water=1) 0.619
Specific gravity of the gas (air=1) 0.588
Flammable limits in air 16-25%
Ignition temperature 1204°F
Vapor pressure at 0°F 16 psi
One cubic foot of liquid at 60°F expands to 850 cubic foot of gas
Chemical Properties
Anhydrous ammonia is easily absorbed by water. At 68°F, about 700 volumes of
vapor can be dissolved in one volume of water to make a solution containing 34
percent ammonia by weight. Ammonia in water solution is called aqua ammonia
or ammonium hydroxide.
Ammonia, especially in the presence of moisture, reacts with and corrodes
copper, zinc, and many alloys. Only iron, steel, certain rubbers and plastics, and
specific nonferrous alloys resistant to ammonia should be used for fabrications of
anhydrous ammonia containers, fittings, and piping.
Ammonia will combine with mercury to form a fulminate which is an unstable

explosive compound.
Anhydrous ammonia is classified by the Department of Transportation as
nonflammable. However, ammonia vapor in high concentrations (16 to 25
percent by weight in air) will burn. It is unlikely that such concentrations will
occur except in confined spaces or in the proximity of large spills. The fire
hazard from ammonia is increased by the presence of oil or other combustible
materials.
Anhydrous ammonia is an alkali.
Health Effects
Ammonia is not, strictly speaking, a poison and repeated exposure to it produces
no additive (chronic) effects on the human body. However, even in small
concentrations in the air it can be extremely irritating to the eyes, throat, and
breathing passages.
Anhydrous ammonia primarily affects three areas of the body:
 Eyes
 Lungs
 Skin
Eyes
Everything from mild irritation to destruction of the eye can occur depending on
whether a spray or gas is involved. Ammonia penetrates the eye more rapidly
than other alkalis.
Lungs
In the lungs, liquid anhydrous ammonia causes destruction of delicate respiratory
tissue.
Exposure to ammonia vapor may cause:
 Convulsive coughing.
 Difficult or painful breathing.

 Pulmonary congestion.
 Death.
Skin
Skin damage depends upon the length and concentration of exposure and can
range from mild irritation, to a darkened freeze-dry burn, to tissue destruction.
Because liquid ammonia boils at -28°F, the expanding gas has the potential to
freeze anything in its path of release, including human flesh and organs.
Because water can absorb ammonia so readily, it is a factor that contributes to
human toxicity. Ammonia will keep spreading across contacted skin until the
chemical is diluted by skin moisture.
Alkalis effect tissue differently than acids, which tend to burn and seal off a
wound. Alkalis, such as ammonia cause liquidization of tissue and turn tissue into
a sticky "goo" and mix with this tissue, causing further damage. As a result,
anhydrous ammonia burns keep spreading until the chemical is diluted.
In addition to liquidization, super-cooled anhydrous ammonia spray causes a
freeze dry effect like frost bite when it hits the skin. The spray is also capable of
freezing clothing to skin so that if the clothing is removed incorrectly whole
sections of skin can be torn off.
High concentrations in the air can also dissolve in the moisture of the skin or
perspiration and result in a corrosive action on the skin and mucous membranes.
First Aid
Decontaminate the victim as quickly as possible.
 First, flush the eyes with clean water. Then flush the whole body or the
exposed area with generous amounts of water; includes the hair, ears,
under chin, and armpits. Any water source is acceptable; such as showers,
hoses, or stock tanks.
 Remove contaminated clothing, but only after careful flushing and
warming to prevent the previously mentioned problem of skin sticking to
the clothing.

What Is Glycol? How is it Usedin a Chiller?
Glycol is a water-miscible coolant that is frequently used in heat transfer and cooling
applications. It provides better heat transfer parameters than water, and can be mixed with water
to provide a variety of heat transfer characteristics. Glycol comes in two varieties: ethylene
glycol and propylene glycol. Though both materials are bad for living things, propylene glycol is
most often used near food and ethylene glycol is most often used in industrial applications.
To understand the purpose of glycol, you must first understand how a chiller works. A chiller
consists of two key parts: a refrigeration unit which uses electrical energy to produce a cold
fluid, and heat transfer coils which move cold fluid from the refrigeration unit to the target area
and hot fluid from the target area to the refrigeration unit. Typically, the target area is the inside
of a freezer or some other object that you want to cool. The refrigeration unit often consists of a
compressor with some compressible heat transfer fluid such as freon.
Every chiller has an operating temperature range. This temperature range is determined by
several variables, the most important of which are the boiling point and freezing point of the heat
transfer fluid. Glycol is prized as a heat transfer fluid because it can operate at a wide range of
temperatures and can be mixed with water. The boiling and freezing points of glycol mixtures
are a function of the relative amounts of glycol and water in the mixture.
Pure water freezes at 0 degrees Celsius (32 F) and pure ethylene glycol freezes at -12.9 C (8.9 F).
In between, freezing points are non-linear. For instance, a solution of 10% ethylene glycol
freezes at -3.4 C (25.9 F), 30% ethylene glycol freezes at -13.7 C (7.3 F) and 60% ethylene
glycol freezes at -52.8 C (-63 F). The freezing point of a 60/40 ethylene glycol/water mixture is
much lower than that of either pure ethylene glycol or pure water. Mixtures of propylene glycol
with water follow a similar pattern, with a 60/40 mixture of propylene glycol with water having a
freezing point of -48 C (-55 F).
The low freezing points of glycol mixtures make them ideal for cooling items below the freezing
point of water. Thus, glycol/water mixtures are often used to cool freezers and similar
environments.
Glycol is useful even when you do not want to cool an item below the freezing temperature of
water. The rate of heat transfer is proportional to the difference between the temperature of your
coolant and the temperature of the item being cooled. The heat capacity of the coolant, which is a
chemical characteristic of the material, is important as well, but we will put it aside for the
moment. A 60/40 ethylene glycol/water mixture cooled to -40 C can chill an item at 20 C much
more quickly and efficiently than pure water at 10 C. Although ethylene glycol has a lower heat
capacity than water (each kilogram of glycol is easier to heat than a kilogram of water), the
larger temperature difference allows a glycol mixture to carry heat away much more quickly than
pure water.
The low temperatures associated with glycol mixtures make them useful for applications where a
chiller must carry a large amount of heat must away quickly. Heat is a byproduct of many

chemical reactions; glycol’s ability to carry heat away quickly makes it useful for maintaining
the temperatures of chemical reactions. For this reason, propylene glycol/water mixtures are
often used to cool fermenters in brewery applications.
Glycol is an important heat transfer fluid in industrial applications. In addition to offering
excellent heat transfer parameters, ethylene glycol tends to discourage algae growth in heat
transfer equipment. For more information, please contact us. This article is not engineering or
food production advice.
BLOCK DIAGRAM OF AMMONIA-GLYCOL REFRIGERATION SYSTEM
WHAT IS PROPYLENE GLYCOL?
Propylene Glycol is a Food Grade Antifreeze. A food grade antifreeze is required when a food
product is being cooled. The glycol, mixed with city water, enables us to operate our chiller
systems in the 25-27 F temperature range that breweries require.
WHAT TYPE OF GLYCOL SHOULD I USE?
Our recommendation is USP Grade Propylene Glycol. USP (United States Pharmacopeia) is the
official standard setting authority for medicines, supplements, and health care products in the

United States. Any glycol carrying the USP Grade provides assurance the product is definitely
approved for Food Applications and is of the highest quality.
here are many inexpensive, low quality, glycol based solutions out there. Some of these, such as
RV rated antifreeze, are not designed for a recirculation system and could breakdown quickly
causing equipment damage as the result of freezing up or gumming up the heat exchangers in
your system.
If your system contains Black Iron (Steel), Galvanized, or other ferrous metals, a rust inhibitor
will need to be added to your solution.
WHAT PERCENTAGE OF PROPYLENE GLYCOL WILL MY SYSTEM REQUIRE?
Many customers don’t understand why they need to add so much glycol to their chiller system.
They assume that if their chiller system is at +27 F Glycol, the freeze point of the solution only
has to be below +27 F. One must remember that the temperature of the refrigerant will be 10 –
15 F below your glycol solution temperature. So if your operating with a +27 Glycol
Temperature, your refrigerant temperature is probably +12 to +17 F.
We require the freeze level of your Glycol/Water Solution to be 20-25 F. below your chiller
system setpoint.
Example: CHILLER SETPOINT: +27 FAHRENHEIT
GLYCOL FREEZE LEVEL: + 7 to +2 FAHRENHEIT
In colder climates, make sure that the glycol freeze level is lower than extreme ambient
conditions. We do not require the freeze level to be 20 F. below winter extreme conditions.
The average brewery will operate with a 35% Glycol to 65% Water Solution. This will protect
from freeze up to +1 F.
****WARNING****
It is very important to use the proper percentage of glycol to water in your system. Not
enough glycol could lead to the system freezing up and possibly causing your chiller
evaporator to rupture internally. Too much glycol will drastically reduce your chiller
systems efficiency.
I HAVE DETERMINED MY PERCENTAGE, HOW MUCH GLYCOL WILL I NEED
FOR MY SYSTEM?

You will need to calculate your total system volume. Add the estimated volume of your total
system piping, plus your tank jackets, and the reservoir size on your chiller system. Your
plumbing contractor and tank manufacturer can help with piping and jacket volume estimates-
the chiller system tank capacity should be available from the equipment manufacturer.
HOW DO I FIND OUT THE SOLUTION PERCENTAGE (GLYCOL FREEZE POINT) OF
AN EXISTING SYSTEM?
The easiest way is to use a Refractometer, in fact many breweries and wineries have instruments
that will provide a reading in degree brix. Although propylene glycol doesn’t contain sugars, it
affects the refractive index in a similar fashion. Most chiller system manufacturers would also be
happy to test the freeze point/concentration of solution samples that are sent to them.

WHERE DO I PURCHASE GLYCOL FROM?
Suppliers:
A) Pro Refrigeration Inc. is an authorized distributor of Safe-T-Therm Propylene Glycol Heat
Transfer Fluid. Safe T Therm is a USP Grade Propylene Glycol Solution that not only contains
an orange colored die to help identify leaks in your system, but also rust inhibitors. We can ship
the product from any of the seven warehouses located across the country. For a quote please call
Pro at 800-845-7781, or visit the website at www.prochiller.com.
B) DOW Chemical Corporation
Phone: (800) 447-4369
Notes: Dow also manufactures a product with rust inhibitors.
C) Most Major Chemical Suppliers Notes: It is likely that your current chemical supplier offers
USP Grade Propylene Glycol
WHAT TYPE OF PIPING MATERIAL SHOULD BE USED FOR MY GLYCOL PIPING?
Recently there has been a lot of debate on the subject of PVC
Glycol Piping. Until there is more information available, Pro is going to strongly encourage all
of our customers to chose either Copper or ABS Piping for their glycol cooling loops. We
understand there are literally thousands of installations that have utilized PVC, many without any
issues. But with the recent reports of some catastrophic failures of PVC piping systems,
discussions with a PVC manufacturer and with an installation contractor, we feel this is
definitely justified.
We are currently limiting our recommendation for glycol piping to two options; Copper Tubing
or ABS Piping.

Glycol Piping Choices:
Copper
Copper Pipe should be a first option for your glycol loop. Although materials and installation
will be higher than PVC Pipe, when correctly installed you will receive years of trouble free
service. Consult with your plumbing contractor to insure your piping is correctly sized,
undersized piping will cause increased Glycol Line pressures, possibly jeopardizing your tank
cooling jackets.
ABS Plastic Piping
ABS Piping is very similar to PVC. The benefit of the ABS Piping System is the rating to
operate between -20 F and 110 F. It is more expensive than PVC, but significantly less than
copper and also easier to install and repair. ABS can be purchased with or without the Insulation.
The Pre Insulated Piping Option is quickly becoming one of the most common choices for new
breweries in the United States.
Cool Fit Pre-Insulate Piping
It is not hard to justify the investment of the Cool-Fit Piping System. A complete pre-insulated
plastic pipe system designed specifically for low temperature glycol systems. This product
requires little to no maintenance with a designed service life span of 25 years. Please visit
www.cool-fit.georgefischer.com for more information.
It is highly recommended that a Y-Strainer be installed on your glycol system.
HOW SHOULD MY GLYCOL LINES BE INSTALLED?
Several factors should be considered when designing and laying out your glycol piping.
1. Set your chiller system as close to vessels as possible. You want the least amount of restriction
as possible between the chiller system and vessels.
2. Be careful not to use too many pipe fittings or undersize the piping. Undersized piping and
fittings will cause increased Glycol Line pressures, possibly jeopardizing your tank cooling
jackets.
3. Use the “FIRST IN / LAST OUT” Piping method for your Fermenters. The FIRST Tank to be
supplied with Glycol from your SUPPLY Header, should be the LAST Tank connected to your
RETURN Header. Please see illustration below. This helps balance the system flow, ensuring
equal flow distribution to each vessel connected to your system.

4. Install pressure (0-50 lb.) and temperature (0-50F.) gauges in the SUPPLY header. Place them
in a high visibility location. These gauges can alert you to a cooling system problem and / or a
pressure problem.
5. Although most brewery designed chiller systems are supplied with an internal Pressure Bypass
Valve on the Supply Line, installing an additional one at the end of your SUPPLY header is
recommended. These adjustable valves will bypass flow from your supply header to your return
header, protecting your tank cooling jackets from over pressurization.
6. Each Fermenter should have a dedicated chilled water solenoid valve controlled by a
temperature control that senses the product temperature. When your product temperature drops
to the set point temperature the solenoid valve will close shutting off the flow of glycol. It is a
good idea to install a manual bypass around each solenoid valve. This manual bypass will allow
the ability to cool each vessel in the event of a temperature control failure or solenoid coil burn
out.

Watertreatment
Water treatment is any process that improves the quality of water to make it more acceptable for a
specific end-use. The end use may be drinking, industrial water supply, irrigation, river flow
maintenance, water recreation or many other uses, including being safely returned to the
environment. Water treatment removes contaminants and undesirable components, or reduces
their concentration so that the water becomes fit for its desired end-use.
Treatment for drinking water production
Treatment for drinking water production involves the removal of contaminants from raw water to
produce water that is pure enough for human consumption without any short term or long term
risk of any adverse health effect. Substances that are removed during the process of drinking
water treatment include suspended solids, bacteria, algae, viruses, fungi, and minerals such as
iron and manganese.
The processes involved in removing the contaminants include physical processes such as settling
and filtration, chemical processes such as disinfection and coagulation and biological processes
such as slow sand filtration.
Measures taken to ensure water quality not only relate to the treatment of the water, but to its
conveyance and distribution after treatment. It is therefore common practice to keep residual
disinfectants in the treated water to kill bacteriological contamination during distribution.
RO is reverse osmosis process.
Osmosis is a naturally occurring phenomena and one of the most important processes in nature.
It is a process where a weaker saline solution will tend to migrate to a strong saline solution.
Examples of osmosis are when plant roots absorb water from the soil and our kidneys absorb
water from our blood.

If we have any solution which is less concentrated will have a natural tendency to migrate to a
solution with a higher concentration.eg if we have container full of water with a low salt
concentration and another container full of water with a high salt concentration and both are
separated by a semi-permeable membrane, then the water with the lowest salt concentration
would begin to migrate towards water container with the high salt concentration.
Reverse Osmosis:
Whereas Osmosis occurs naturally without energy required, to reverse the process of osmosis
you need to apply energy to the more saline solution. A reverse osmosis membrane is a semi-
permeable membrane that allows the passage of water molecules but not the majority of
dissolved salts, organics, bacteria and pyrogens. However, you need to 'push' the water through
the reverse osmosis membrane by applying pressure that is greater than the naturally occurring
osmotic pressure in order to desalinate (deionize)water in the process.

The desalinated water that is deionized, is called permeate (or product) water. The water that
carries the concentrated contaminants that did not pass through the RO membrane is called the
reject (or concentrate) stream.
the water molecules pass through the semi-permeable membrane and the salts and other
contaminants are not allowed to pass and are discharged through the reject stream (also known as
the concentrate or brine stream), which goes to drain or can be fed back into the feed water
supply in some circumstances to be recycled through the RO system to save water.
Reverse Osmosis Performance & Design Calculations
There are a handful of calculations that are used to judge the performance of an RO system and
also for design considerations. An RO system has instrumentation that displays quality, flow,
pressure and sometimes other data like temperature or hours of operation. In order to accurately
measure the performance of an RO system we need the following operation parameters.
1. Feed pressure
2. Permeate pressure
3. Concentrate pressure
4. Feed conductivity
5. Permeate conductivity
6. Feed flow
7. Permeate flow
8. Temperature

Spiral wound membrane:
Basic Components to all RO systems:
Cold Water Line Valve: Valve that fits onto the cold water supply line. The valve has a tube
that attaches to the inlet side of the RO pre filter. This is the water source for the RO system.
Pre-Filter: Water from the cold water supply line enters the Reverse Osmosis Pre Filter first.
There may be more than one pre-filter used in a Reverse Osmosis system. The most commonly
used pre-filters are sediment filters. These are used to remove sand silt, dirt and other sediment.
Additionally, carbon filters may be used to remove chlorine.
Reverse Osmosis Membrane:The Reverse Osmosis Membrane is the heart of the system. The
most commonly used is a spiral wound.
Post filter:After the water leaves the RO storage tank, but before going to the RO faucet, the
product water goes through the post filter (s). The post filter (s) is generally carbon (either in
granular or carbon blocks form). Any remaining tastes and odors are removed from the product
water by post filtration.
Automatic Shut Off Valve (SOV): To conserve water, the RO system has an automatic shutoff
valve. When the storage tank is full (this may vary based upon the incoming water pressure) this
valve stops any further water from entering the membrane.
Check Valve: A check valve is located in the outlet end of the RO membrane housing. The check
valve prevents the backward flow or product water from the RO storage tank.

Flow Restrictor:This device maintains the flow rate required to obtain the highest quality
drinking water (based on the gallon capacity of the membrane).It also helps maintain pressure on
the inlet side of the membrane.
Faucet: The RO unit uses its own faucet, which is usually installed on the kitchen sink.
Drain line: This line is used to dispose of the impurities and contaminants found in the incoming
water source.
All RO Systems work the same way.
All RO Systems have the same basic components.
The real difference is the quality of the filters and membranes inside the RO.

Block Diagrame RO Process
Syrup Room:
Initially we take treated water in our pasteurization tanks according to batch preparation. Once it
done then we add purely refined sugar in the tanks in order to get simple syrup. Steam coils are
present in the pasteurization tanks for dissolving sugar at 80 degree centigrade normally.our
simple syrup is ready now which is of yellow color. now we need to remove this yellow color.for

this purpose we add carbon powder and DE in simple syrup.after this activity our syrup will be
passed from plate and frame filter press where the carbon powder removed from simple syrup
which was added previously.now the yellowish fluid has changed into white fluid.
After getting simple syrup.we notice that it’s hot.so we simply pass it from plate and frame heat
exchanger where the temperature of the simple syrup goes below 22 degree centigrade.now we
will transfer this simple syrup into finish syrup tank through pumps having rating normally 3 to 4
HP.
Liquid and dry components added into finish syrup tank.dry components of concentrate
dissolved in dissolution tank and then mixed up with syrup in finish syrup tank.whilst adding
liquid and dry components we start the agitator motor in order to get mature mixing. Our finish
syrup is ready for beverage.
Flow Chart
Main Equipments: Hoppers for sugar feeding, continuous sugar dissolvers, batch sugar
dissolvers, tanks for simple and composite syrups with hydrodynamic agitators,simple syrup
heaters and coolers, syrup pasteurizers, CIP system, process-pipes, instrumentation, automation.

Batches capacity:
No of batches Batch capacity
1 3407 liters
2 6814 liters
4 13628 liters
3407 liter means 3407 cases of 250ml bottles.
1 liter syrup is equal to 1 case of 250ml bottles.
Common components for each CSD are
 Citric acid
 Sodium citrate
 Sodium benzoate
 Flavor
Finish
syrup
tanks
Divert
plate
Piping

RM and PM section:
In RM & PM lab inspection is done in accordance with the raw and packaging material.
Raw materials
Granulated sugar caustic soda sodium hypo chloride NAOCL2
Hydrated lime ferrous Sulphate FESO4 carbon powder
Simple syrup
Packing materials
Glass empty PET empty Preform
Closures metal crown multi cartoon
Half depth shell full depth shell PET label
Layer pad shrink wrap stretch wrap
Plastic pallets
Instruments in RM & PM Lab
1. D-Gasser
It is used to calibrate the process of D-gas.
2. water bath
It is used to achieve water at desired temperature.
3. Thermo
Currently used to dry things at desired temperature 100 degree centigrade.
4. magnetic plate
It is used to steer magnetically.
5. conductivity meter

We used this meter to check the conductivity of the materials.
6. Desiccators
We used this instrument to remove moisture.
7. Spectrophotometer
With double beam used to check the color and turbidity in sugar and simple syrup.
Test of simple syrup carried out during orientation
Solution of 50% BRIX
Filtered absorption=0.210
Unfiltered absorption=0.225
Focal range=162.66
Color=0.210*162.66=34.15
Turbidity= (0.225-0.210)*162.66
Boilers:
Manufacturer name: multipack
Glasgow England
Boilers are of two types:
Water tube boilers and fire tube boilers. In beverage industry preferable boiler are fire tube
boilers of 5 tons and 7 tons capacity. they might be vertical and as well as horizontal. but
now here we using horizontal boilers.

Fire tube boilers
In fire tube boilers hot gases exists inside the tubes and the water in surroundings and it looks
like a sealed container. Normally 270 tubes and each tube has 2”diameter. Boiler produces
steam which we used in washing our empty bottles and as well as in CIP of MIXER and
FILLER.
HIGH PRESSURE (HP) COMPRESSOR
HP compressor or High Pressure compressor is a machine that produces pressure at different
levels.
•These kinds of Compressors have special working areas as in PET blowing sector.
• On the other hand, you can use these kinds of compressors in different sectors. For instance,
• - Chemical Industry
• - Food Industry
• - Medical Air
• - Medicine Industry etc.
Components:
1. Compressor unit

2. Microprocessor Control Unit
3. High Pressure Air Dryer
4. High Pressure filters
5. High Pressure Air tank
6. Water Cooling Tower
7. Water Cooling Tank
8. Water Pump
It is 3 stages high pressure compressor. Different level of pressure is produced in these stages.
1st Stage 4 Bar
2nd Stage 16 Bar
3rd Stage 40 Bar
The Compressor Unit:
Specifications:
• Design is V type.
• It is 3 stages depending on pressure range.
• Cylinders are water cooled.
• V belt driven.
• Valves, piston rings, oil and pressure wiper packing is designed especially for this compressor.
• GG25 cast iron is used at bare unit body and stage cylinders.
• GGG60 ductile iron is used at Crank shaft and Connecting rods.

• At each stage after the cylinders there are water inter coolers which cool down the air
temperature before the suction.
• Water separators inside of the separator tank are separating water from cooled down air.
• Oil pump is driven by the crank shaft instead of the electrical motors and its our design and
production.
• Carbon alloy steel is used at piston rods and the 3. Stages piston which has high strength.

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