2. Table of Contents:-
1- Acknowledgments
2- Introduction
3- Literature view
(i) Nestle
(ii) Milk Production
(iii) Products
(iv) Market share
(v) Equipment and instruments
(vi) Process
4- Improvement Ideas
1. Safety
2. Health
3. Environment
4. In-Bound
5. Out-Bound
6. Control
5- Key learning
3. Acknowledgements
“In the Name of Allah most Merciful and Beneficent”
I am very thankful to Allah Almighty who gave me the opportunity, courage and insight
to explore more knowledge to complete this whole and for his blessings that have
brightened in all the parts of my life and my parents whose prayers always supported me
in every task.
4. 1- Introduction
(i) About me:
I am Zunaira Khan, student of Mechatronics and Control Engineering, UET Lahore. I was
enrolled in UET in 2011, and currently I have completed three years of my engineering. I
passed my F.Sc. from Govt. College for women Sheikhupura and got highest marks in city
among girls. I am resident of city Sheikhupura.
(ii) About Nestle:
Nestle is the world's leading nutrition, health and wellness company. "Good Food,
Good Life" is the promise we commit to everyday, everywhere – to enhance lives,
throughout life, with good food and beverages. Nestlé owns close to 8,000 brands. Its main
product is water, milk, coffee, chocolates, etc. Nutrition, Health and Wellness is Nestlé’s
strategic direction. It wants you to be able to make healthy choices about your food and
beverages. It also believes that good food sometimes means treating yourself!
It aims to make your life more pleasurable because our products not only taste better; but
they are also more nutritious.
5. 2-Literature view
i) Nestle:
Nestlé Pakistan is proud of its commitment to excellence in product safety and quality and
to providing value and aims to be the leading Nutrition, Health and Wellness Company.
As a socially responsible corporate, we always focus on environment friendly operations,
ethical business practices and our responsibility towards the communities.
Nestlé in Pakistan is operating since 1988 under a joint venture with Milk Pak ltd and took
over management in 1992.
The company’s strategy is guided by Nestlé’s Corporate Business Principles which are in
line with internationally accepted best practices and ethical performance culture. Nestlé’s
existing products grow through innovation and renovation while maintaining a balance in
geographic activities and product lines.
Long-term potential is never sacrificed for short-term performance. The Company’s
priority is to bring the best and most relevant products to people, wherever they are,
whatever their needs are, and for all age groups.
Nestlé Pakistan today is the leading Food & Beverages Company in Pakistan with key
focus on Nutrition, Health and Wellness and reaching the remotest of locations throughout
Pakistan to serve the consumers. Nestlé Pakistan also prides itself in being the leaders in
Nutrition, Health & Wellness. Ever since 1867, when Henri Nestlé invented the first infant
food, nutrition has been in our DNA. Today more and more consumers mirror our
emphasis on nutrition, as they realize that food choices affect their health and quality of
life.
6. Nestlé Pakistan operates in many ways but people, products and brands are the main flag
bearers of the Company’s image, and we continue to enhance the quality of life of
Pakistanis.
Principle Activities:
12. (iii) Products:
This is a selected list of the main brands owned by Nestlé. Overall, Nestlé owns close to
8,000 brands. Brands are categorized by their targeted markets.
Contents
Cereals
Yogurt
Coffee
Water
Other drinks
Shelf stable
Chilled
Ice Cream Brands
Infant foods
Performance nutrition
Healthcare nutrition
Seasonings
Frozen food
Refrigerated products
Chocolate, confectionery and baked goods
Foodservice products
Pet care
As shareholder
Former brands
o Beverages
o Bottled Water
o Confectionery
o Eye care
o Health and Nutrition
o Pet care
13. (iv) Market Share:
The following figures show the market share of Nestle:
i) In food and beverages:
17. Utilities:
1) Steam (saturated)
2) Air ( Sanitary Air for Aseptic Tank and Instrument air for other valves)
3) Water (Raw water for plants, CIPs and treated water for juice production)
4) Electricity
(v) Equipment’s and Instruments used in Nestle
Pumps
Valves
Motors
Filters
PID Controllers
Temperature Sensor
Pressure Sensor
Pump:
Mostly Centrifugal Pumps used in NESTLE except Screw chain pump i.e. type of positive
displacement pump in Fluidor and Pestalic pump to transfer pulp.
Types of Pumps:
The selection of type and construction of a pump is very important to meet the process
specification and proper application. Knowledge of the variety of pumps in the market
should be review. It is mentioned before, that there are two general types of pump in
today’s industry: positive displacement and centrifugal (dynamic) pumps.
Positive Displacement Pumps
Positive displacement (PD) pumps work by allowing a fluid to flow into some enclosed
cavity from a low-pressure source, trapping the fluid, and then forcing it out into a
high-pressure receiver by decreasing the volume of the cavity. Some examples of PD
pumps are: fuel and oil pump in most automobiles, the pumps on most hydraulic
systems, and the heart of most animals.
Some general types of the positive displacement pumps are as below:
18. a) Reciprocating Pump
Reciprocating pumps create and displace a volume of liquid, their
“displacement volumes”, by action of a reciprocating element. Liquid
discharge pressure is limited only by strength of structural parts. A pressure
relief valve and a discharge check valve are normally required for
reciprocating pumps
Reciprocating pumps can be further classified into three types of pump as
below,
i) Piston Pumps
ii) Packed Plunger Pumps
iii) Diaphragm Pumps
b) Rotary Pump
Rotary pumps function with close clearances such that a fixed volume of
liquid is displaced with each revolution of the internal element. Rotary pumps
include:
i) Gear Pump
ii) Lobe Pump
iii) Vane Pump
iv) Screw Pump
All those pumps above have the similar working principles: pumping the liquid
with the help of rotating elements. The difference lies on the rotating
elements; they could be gear, lobe, vane, or screw.
Centrifugal Pumps
Centrifugal pumps are dynamic pumps. A centrifugal pump raises the pressure of the
liquid by giving it a high kinetic energy and then converts it into pressure energy
before the fluid exits the pump. It normally consists of an impeller (a wheel with
blades), and some form of housing with a central inlet and a peripheral outlet. The
impeller is mounted on a rotating shaft and enclosed in a stationary casing. Casings
are generally of two types: volute and circular. The impeller design and the shape of
the casing determine how liquid is accelerated though the pump.
Some general types of the centrifugal pumps are as below:
a) Overhung pump
A pump with the impeller(s) cantilevered from its bearing assemblies is
classified as an overhung pump.
Centrifugal pumps are used in more industrial applications than any other kind of
pump. This is primarily because these pumps offer low initial and upkeep costs.
Traditionally these pumps have been limited to low-pressure-head applications, but
19. modern pump designs have overcome this problem unless very high pressures are
required.(4) The single-stage, horizontal, overhung, centrifugal pump is by far the most
commonly type used in the chemical process industry. (3)
Basically, pump selection is made on the flow rate and head requirement and with
other process considerations, such as material of the construction pumps for the
corrosive chemical service or for the fluid with presence solids in the stream.
Five basic criteria for selection and application of
pumps
There are a lot of questions to be answered when choosing a pump. I have found that
there are five basic criteria that need to be determined before any selection is done, or
application of the same. Some of these will sound obvious, and some of the
companies and individuals may say they support all of these criteria. But they take
short cuts in making the choice in order to save money.
The first and foremost thing to be kept in mind is that no one gets hurt. Safety of the
personal is of primary importance. We cannot afford to put people at unnecessary
risk. Secondly, we have to protect the environment. This saves money in the long run,
and according to the law, it is the right thing to do. Preventing and reducing carbon
emissions makes the world a safer place for people to live, and the product can be
sold easily rather than losing it as it can be cleaned up.
Thirdly, the size of the equipment should be determined to calculate the right capacity
of the process unit because throughput is where companies can make a profit. The
fourth and fifth criteria are related. How long the equipment needs to perform its'
function and how to select, install and operate the equipment to accomplish all of the
criteria at minimum life cycle cost are inter-related. Though these sound obvious,
different organizations have different goals.
Companies want their projects to be installed at minimum cost and want to get them
running on time. This rarely leads to minimum life cycle cost because better quality
equipment lasts longer with lower maintenance costs. However, the initial cost is
likely to be more.
20. Valves:
A valve is a device that regulates, directs or controls the flow of a fluid (gases, liquids,
fluidized solids, or slurries) by opening, closing, or partially obstructing various
passageways.
Valves in Nestle:
On/off valves are used mostly
Regulator valve is used in balance tank.
Types of Valves
Valves can be classified by:
The operative of the valve closure member
The kind of closure member movement defines both the geometry and operative of the
valve.
• Multi-turn valve (linear motion valves):
The closure member has a linear displacement generally by turning its threaded stem
several times.
This operation is slow, but it gives accuracy and stability to position the closure member,
which is necessary in some control valves.
21. Types of valves:
1) Gate valve
2) Globe valve
3) Fixed cone valve
4) Needle valve
5) Pinch valve.
• Quarter-turn valve (rotary valve):
The closure member as well its shaft turn 0º-90º; from the fully-open position to the fully-closed
position.
They are quick opening/closure valves.
23. The functionality of the valve
• Control: pressure / flow rate regulation.
• Closure at over-speed flow. (i.e. immediate closure if downstream pipeline is broken by
accident).
• Overpressure protection.
• Back flow prevention (check valve).
• On/Off service.
The nature and physical conditions of the flow
• Low/High temperatures.
• Low/High pressures.
• Cavitation risk.
• Corrosive or erosive properties of the flow.
• Viscosity: Gas, liquid, solid.
• Hygiene requirements (for the food or pharmacy industry...).
• Explosion and risk of inflammability (chemical, petrochemical industry).
24. Other forms of valve classification
• Admissible leakage level.
• Connection to the pipe.
• An unique direction of the flow or bidirectional flow.
• Number of ports: most of the valves have two port, named inlet and outlet port. But for
same applications there are multi-port configured valves. They can be three-way and four-
way valves.
• Angle between the inlet and outlet port of the valve.
Valve Type Selection:
Valve type selection should take account of
1. Required function.
2. Service conditions.
3. Fluid type and condition.
4. Fluid characteristics.
5. Frequency of operation.
6. Isolation requirements.
7. Maintenance requirements.
8. Environmental considerations.
9. Past experience in comparable conditions.
10. Weight and size.
11. Cost.
Motors:
All 3 Phase Induction Motors used in NESTLE.
An induction or asynchronous motor is an AC electric motor in which the electric
current in the rotor needed to produce torque is obtained by electromagnetic induction from the
magnetic field of the stator winding. An induction motor therefore does not require mechanical
commutation, separate-excitation or self-excitation for all or part of the energy transferred from
stator to rotor, as in universal, DC and large synchronous motors. An induction motor's rotor can
be either wound type or squirrel-cage type.
25. Three-phase totally enclosed fan-cooled (TEFC) induction motor, with and, at right, without end
cover to show cooling fan. In TEFC motors, interior losses are dissipated indirectly through
enclosure fins mostly by forced air convection.
Cutaway view through stator of TEFC induction motor. Note rotor air circulation vanes.
26. PID Controllers:
A proportional-integral-derivative controller (PID controller) is a control
loop feedback mechanism (controller) widely used in industrial control systems. A PID
controller calculates an error value as the difference between a measured process
variable and a desired set point. The controller attempts to minimize the error by adjusting
the process through use of a manipulated variable.
CL
RESPONS
E
RISE
TIME
OVERSH
OOT
SETTLING
TIME
S-S
ERROR
Kp
Decreas
e
Increase
Small
Change
Decreas
e
Ki
Decreas
e
Increase Increase
Eliminat
e
Kd
Small
Change
Decrease Decrease
Small
Change
27. Thermocouple:
A thermocouple is a temperature-measuring device consisting of two dissimilar conductors that
contact each other at one or more spots. It produces a voltage when the temperature of one of the
spots differs from the reference temperature at other parts of the circuit. Thermocouples are a
widely used type of temperature sensor for measurement and control, and can also convert a
temperature gradient into electricity.
28. Thermocouple connected to a multi meter displaying room temperature in °C.
Pressure Sensor:
A pressure sensor measures pressure, typically of gases or liquids. Pressure is an expression of
the force required to stop a fluid from expanding, and is usually stated in terms of force per unit
area. A pressure sensor usually acts as a transducer; it generates a signal as a function of the
pressure imposed. For the purposes of this article, such a signal is electrical.
Digital Air Pressure Sensor
29. Phases of Plant
1) CIP
2) Sterilization
3) Water Circulation
4) Production
5) Product Circulation
6) Water Circulation
7) CIP
Phases of Aseptic Tank
1) CIP
2) Sterilization
3) Cooling
4) Production
5) CIP
Dairy Plant
UHT (Ultra High Temperature)
It has 4 plants.
APV Plant has three Aseptic Tanks whose capacities are as follows;
T1= 30,000 tons
T2= 20,000 tons
30. T3= 30,000 tons
Flex 100 Plant has two Aseptic Tanks whose capacities are as follows;
T1= 30,000 tons
T2= 30,000 tons
T1=T2
VTS Plant has two Aseptic Tanks whose capacities are as follows;
T1=20,000 tons
T2= 30,000 tons
Alpha Laval Plant has only one Aseptic Tank whose capacity is as follows;
T1= 8,000 tons
Products made here are;
1) UHT milk
2) Cream
3) Nesvita
4) Milo RTD
5) MacDonald’s Mix
6) Nescafe
7) Everyday
It has further 2 types
i. Local
ii. export
38. 1) ASU ( Automatic splicing unit)
2) ASSU (Automatic strip splicing unit)
3) FFU (Final folder unit)
Functions:
ASU is used for packet/paper change.
ASSU is used for strip change.
FFU is used for final packing of packet.
Components:
ASU
i. It has packing material.
ii. It has head. Hot air is used for the head movement.
iii. Cutter that operates at 157 C.
iv. Servo motor that operates at Sensor Signal.
ASSU
i. It has two servo motors for two strip applicators.
ii. Strip applicators has opposite directions.
Clockwise
Anti-clockwise
FFU
i. It has Jaw. In Jaw photomark cell exists.
ii. Chain Station has two parts.
Nozzle and Squizzer belt
a) Nozzle that has four flaps. It operates at 550 C. Medium is hot air.
b) Squizzer belt.
Both nozzle and squizzer belt gives shape to the packet.
iii. Two brushes
First brush for accurate alignment otherwise packet may damage.
Second brush is used to hold packet and it has no friction.
Sensors:
Following sensors are used in Filling Machine.
39. 1) Object Sensor
2) Metal Detector
3) Magnetizer ( Approximately Sensor)
4) Flow Sensor
Valves:
Two valves are used here,
1) Regulating valve
2) On/Off Valve
Electrical Components:
1) VFD
2) Three Generators: TPIH Tetra Pack Induction Heating
2500 Hz
3) Five Inverters for
Conveyor
Drive Roller
ASU loop (Auto Splicing Unit)
ASU magazine (Auto Splicing Unit)
Strip Applicator
4) Transformer
It has mutual induction to attach splice to paper.
Calibration:
Filling Machine is calibrated in two manners
After every 7 Days
It is calibrated by operators. They can calibrate
Jaws
Rollers
Refill Hydrogen Peroxide
Clean all the main parts of machine
1. ASU
2. ASSU
3. FFU
40. After every 10,000hours
It is calibrated by Instrumentation Department. They can calibrate
Bearings
Pushes for punching force
Station Change
Nozzle
Squizzer Belt
Brushes
Types of Ceilings:
Filling Machine has two type of Ceilings
TS: Transverse ceil
Two TS per packet at top and bottom
Process of Filling
41.
42.
43. General Faults:
a) No air supply to valves
b) Solenoid valve not working
c) Output signal on I/O unit not working
d) I/O unit not working
Calibration of Temperature Sensor
1. Purpose
Calibration procedure of Temperature Transmitter.
2. Scope
To ensure the reliability and accuracy of Temperature Transmitter.
3. Procedure
1. Remove the sensor from the line.
2. Adjust the temperature of oil bath at 25% of the working range of Temperature
Transmitter.
3. Dip the sensor into the oil bath.
4. Check the reading at display if it is within normal (25% value ± 0.5 ºC) then ok otherwise
adjust from controller.
5. Repeat this procedure for 50%, 75%, 100% and 100% + 5ºC of the working range of
Temperature transmitter.
6. Also check by decreasing the temperature.
44. 4. Precaution:
1. The oil used should be able to withstand the required temperature.
2. The surface of the sensor should be clean.
3. Use the certified calibrator.
Calibration of Pressure Sensor
1. Purpose
Calibration procedure of pressure transmitter
2. Scope
To ensure the reliability and accuracy of pressure transmitter
3. Procedure
1. Dismantle the pressure transmitter from the line.
2. Adjust the proper fitting with gasket on the pressure transmitter.
3. Check the zero at display and 4 mA on reference digital multi meter at 0 Bar.
4. If any deviation is found, adjust from the zero adjustment.
5. Then apply the pressure of 25%, 50%, 75%, 100% and 100% + 5bar of the working
range of Pressure Transmitter.
6. Check the display and reference digital multi meter accordingly.
7. The digital meter should display 8.0 mA, 12.0 mA, 16.0 mA and 20.0 mA
respectively.
8. If there is any deviation in span, then adjust it from the span adjustment accordingly.
45. 9. Calibrate / verify the pressure loop by increasing and decreasing the pressure of
CALIBRATOR in the same sequence.
4. Precaution:
1. When pressure is applied the exhaust of calibrator should be closed.
2. The battery of the display should not be discharged as it may create problems.
3. The O-ring (fitting gasket) between the pump and the display should not leak, as it
will develop inaccurate pressure.
4. Any abnormal finding relating to linearity or hygiene should be reported to the higher
management.
5. Use the certified calibrator.
Motor Ratings
5- Improvement Ideas
Safety:
There should be proper protective devices for heavy Electrical machinery, in
case of any short circuit or other fault; the expensive machinery should remain safe
along with the life of personnel. There should fire extinguisher clothes in close range
of every worker that is working in plant.
Hazards without safety signs drastically increase the risk of death or serious injury.
Health:
The health of the workers working in plant area should be good. There should be a
proper regular medical checkup for them. The workers suffering from diseases like
Asthama, t.b. etc should not work near the suffocating regions i-e boilers.
Environment:-
The overall environment of the industry is good, but there should be a better way to
dispose off waste materials, so that it may not affect any human or marine life. The
whole factory should be a smoke free region.
46. CHECK for leakages and that all unions are tightened.
CHECK that all covers are mounted correctly.
Hygiene:-
There should be a proper sanitation system. There should more cleanliness inside the
factory. The authorities should conduct some seminars to introduce the practice
through which people maintain or promote good health by making themselves and their
surroundings clean, by cleaning and – when needed- disinfecting surfaces, units,
surroundings and items of personal use in order to break the chain of infection.
Never clean the floors or the equipment in the process room when the equipment is in
process.
Keeps your hands and gloves clean.
Do not wear a watch, ring, necklace, earrings, or any other exposed jewelry .
Compressed air used for cleaning purposes should only be used outside the process room.
IN-bound:-
There should be an improvement in inbound marketing. People just know nestle due
to its water and milk, but actually it has a lot more food brands and people are
unaware of it. The Company should be promoted through
blogs, podcasts , video, eBooks, enewsletters, whitepapers, SEO, social media marketing,
and other forms of content marketing which serve to bring customers in closer to the brand.
Out-bound:-
Outbound marketing of nestle in very good, and I don’t think there is any need of
improvement in it.
Data acquisition:-
Data acquisition process is fairly good enough, but it should be a bit fast and the most
advanced new software should be used to increase speed and reliability.
Control:-
47. The sensors used in the machines should be checked and tested on a regular basis.
There should be a proper calibration of all instruments. This will make our products
better in every way, and more close to health
6- Key Learning
Communicate Effectively and Often
Set Goals
Observe
Know Your Role and How You Fit into the Organization
Be Flexible
Be Responsible
Take it All In
Network
Keep in Contact
