This document provides information about an internship at Varun Beverages Limited, including: - The intern's name, educational details, and period of internship from June 1-July 1, 2015. - An overview of the types of water used (raw water and treated water), the water treatment process, and analysis of water quality parameters and wastage. - Details of the multi-step water treatment plant and processes involved (sand filtration, carbon filtration, reverse osmosis, etc.). - Distribution and uses of treated water throughout the beverage plant, including various production lines.

1. NAME: KAUSTUV BOSE
EDUCATIONAL INSTITUTE: JADAVPUR UNIVERSITY
EDUCATIONAL QUALIFICATION: BE-II IN FOOD
TECHNOLOGY AND BIOCHEMICAL ENGINEERING
PERIOD OF INTERNSHIP: 1ST
JUNE 2015 TO 1ST
JULY 2015
VENUE OF INTERNSHIP: VARUN BEVERAGES LIMITED
JL- 47, BARHANS,
FARTABAD,
CHARAKTALA SONARPUR,
KOLKATA - 700084,
WEST BENGAL, INDIA
PROJECT ON : WATER RECOVERY

2. TYPES OF WATER
The plant uses mainly two types of water-
 Raw Water (RW) which is extracted from the groundwater through 4 bore-wells situated within
the plant premises (only 3 are functional at the moment) and
 Treated Water (TW), which is obtained from Raw Water after a series of treatment procedures.
Raw water is mainly used in the washrooms and latrines and for backwashing and rinsing of treatment
tanks. Treated water, on the other hand, is utilized mainly in the production processes i.e. in raw syrup
making, carbonation, ready syrup making, washing and cleaning of machines, tanks and pipelines etc. A
third type of water- Distilled Water (DW) is used only in the laboratory for cleaning of apparatus and
quality determination experiments.
PARAMETERS OF WATER QUALITY
The treatment of water is followed by a quality check based on 5 parameters, the alteration of which
was the aim of treatment.
TES
T
NO.
PARAMETER METHOD OF
DETERMINATIO
N
OBSERVATIO
N
RAW WATER
(RW)
TREATED
WATER (TW)
VALUE RANGE VALUE RANGE
1 TOTAL DISSOLVED
SOLIDS (TDS)
PROBE DIRECT
READING
FROM DEVICE
1500
ppm
- 178.8
ppm
AT
32.1°C
-
2 pH PROBE DIRECT
READING
FROM DEVICE
- - 6.12
AT
32.1°C
4.3-9.0
AT
32.1°C
3 ALKALINITY TITRATION OF
100mL WATER BY
N/50 H2SO4 USING
METHYL ORANGE
AS INDICATOR
COLOUR
CHANGE FROM
YELLOW TO
ORANGE
- BELOW
100
35 BELOW
50
4 HARDNESS TITRATION OF
100mL WATER
(WHOSE pH IS
INCREASED TO
10.0 BY NH3
BUFFER) BY 0.01
M EDTA IN
PRESENCE OF
ERIOCHROME
BLACK T (EBT) DYE
COLOUR
CHANGE FROM
VIOLET TO
CLEAR BLUE
- BELOW
450
60 BELOW
150
5 CONCENTRATION
OF CHLORINE
DEVICE DIRECT
READING
FROM DEVICE
4.9 5.0-7.0 1.0 1.0-3.0

3. WATER TREATMENT
The Raw Water is treated in a multi-step treatment plant (WTP) to obtain Treated Water.
 The water extracted from the Bore-Wells is send via pipelines to two 200kL tanks known as Raw
Water Storage tanks.
 In the RWST, chlorine dosing is done to disinfect the water as the first basic step of water
treatment. The levels of chlorine are maintained according to mentioned standards.
 The chlorinated water is then pumped through the Water Treatment Plant (WTP) – step-by-step
through the
 Pressurized Sand Filters (PSF) which removes any large solid particles present in the
water,
 Activated Carbon Filters (ACF) which remove pesticides, insoluble organic compounds,
colours and haziness in the water and
 Iron Removal Filters (IRF) which removes any iron present in the water.
 The water is then routed through a Cartridge Filter (CF) and into
 Reverse Osmosis chamber (RO), where dissolved solids concentration is drastically
reduced. The pore size for Reverse Osmosis is 0.0001 µ.
 The RO treated water is then passed through another series of ACFs, PSFs and IRFs
before being stored to the Treated Water Storage Tank, from where it is sent to various
parts of the plant after ascertaining quality standards are within limits.
SCHEMATIC DIAGRAM OF WTP
SOURCE
3 3 3 3
3
3
STORAGE
8
5
4 4 4
TREATMENT
4 4 4 4

4. WATER TREATMENT PLANT (WTP)
PRESSURIZED SAND FILTER (PSF)
PSFs contain sand bed filters using grains in the range 0.6 to 1.2 mm. The depth of the sand bed is
recommended to be around 0.6-1.8 m (2–6 ft) regardless of the application. PSFs are typically operated
with a feed pressure of 2 to 5 bar.
ACTIVATED CARBON FILTER (ACF)
Activated carbon is a form of carbon processed to have small, low-volume pores that increase
the surface area available for adsorption.

5. REVERSE OSMOSIS FILTER (RO)
Reverse osmosis is the process of forcing a solvent from a region of high solute concentration through a
semipermeable membrane to a region of low solute concentration by applying a pressure in excess of
the osmotic pressure. The membranes used for reverse osmosis have a dense layer in the polymer
matrix where the separation occurs. In most cases, the membrane is designed to allow only water to
pass through this dense layer, while preventing the passage of solutes (such as salt ions). This process
requires that a high pressure be exerted on the high concentration side of the membrane, usually 2–
17 bar.
IRON REMOVAL FILTER (IRF)
The Iron Removal Filter contains the media -Permanganate Treated. When the dissolved iron
comes in contact with the manganese greensand media, it is rapidly oxidized, turning the
ferrous iron into a ferric form which is then mechanically filtered and removed from the water.

6. CARTRIDGE FILTER (CF)
Cartridge filters are defined as fabric or polymer-based filters designed primarily to remove
particulate material from fluids. The primary application for cartridge filters in water treatment is
to remove Cryptosporidium oocysts and/or Giardia cysts from source water. Cartridge filters
typically do not remove bacteria, viruses, or fine colloids.
SOFTENER
Water softening is the removal of calcium, magnesium, and certain other metal cations in hard water. It
is usually achieved using ion-exchange resins. Conventional water Softeners depend on an ion-exchange
resin in which "hardness ions" - mainly Ca2+
and Mg2+
- are exchanged for sodium ions. Ion exchange
devices reduce the hardness by replacing magnesium and calcium (Mg2+
and Ca2+
) with sodium or
potassium ions (Na+
and K+
).

7. WASTAGE OF WATER IN WTP
In the Water Treatment Plant, the wastage of water takes place due to the following reasons:
 Leakage from all of some of the 10 pumps that pump RW from the RWST to the treatment tanks
 Raw water wasted during backwashing and rinsing of the treatment tanks prior to water
treatment procedures for production purposes
 Raw water wasted during Regeneration of Softener and Recharging via salt addition
 Water lost from RO as reject water during Reverse Osmosis
 Water wasted during pre-washing of RO prior to water treatment for production
DETAILED ANALYSIS OF WATER WASTAGE IN WTP
The table below tabulates the water wastage for all pre-treatment processes for RO-1 only
TREATMENT TANK PROCESS FLOWRATE OF
WATER
PROCESS TIME TOTAL VOLUME OF
WATER
2 PRESSURIZED
SAND FILTERS
(PSF)
BACKWASH 150 kL/hr PER PSF 30 mins. PER PSF 75 kL x 2= 150 kL
2 PRESSURIZED
SAND FILTERS
(PSF)
RINSE 35 kL/hr PER PSF 15 mins. PER PSF 8.75 kL x 2= 17.5 kL
2 ACTIVATED
CARBON FILTERS
(ACF)
BACKWASH AND
RINSE
35 kL/hr PER ACF 20 mins. PER ACF 11.67 kL x 2= 23.33 kL
2 IRON REMOVAL
FILTERS (IRF)
BACKWASH AND
RINSE
35 kL/hr PER IRF 20 mins. PER IRF 11.67 kL x 2= 23.33 kL
SOFTENER REGENERATION 35 kL/hr 30 mins. 17.5 kL
TANK ( 20kL
CAPACITY)
FILLING OF WATER - - 10 kL
RO FLUSH DUMP
VALVE
35 kL/hr 10 mins 5.83 kL
RO REJECT WATER 16 kL/hr 24 hours 384 kL
TOTAL WATER WASTED FOR RO-1 PER DAY 631.49 kL
Hence we see that for every 100kL water supplied to RO-1 , 16kL is rejected per hour , hence for a total
supply of 100kL x 24hours=2400kL, we get 2016kL Treated Water.
Additional 247.49kL (=631.49kL-384kL) Raw Water is required for other washing purposes.
Thus we see that for a total withdrawal of 2647.49kL (=2400kL+247.49kL) from the Bore-Wells, we
obtain 2016kL Treated Water per day.
This indicates a conversion rate of 76.147% i.e. for every 100kL Raw Water we get around 76.147kL
Treated Water
Leakage losses from pumps are ignored as measurements for the same could not be obtained.

8. TREATED WATER DISTRIBUTION
The water after complete Treatment is called Treated Water (TW) and is stored in the Treated Water
Storage Tank and once the quality standards are checked and met, the TW is sent to the TW Header
from where it is distributed across the plant to desired places
There are 12 such water lines from the Treated Water Header branching off to different parts of the
plant as indicated by the names of the lines. The 5 production lines each have a dedicated water line
i.e. – the PET CSD line, the KETTNER CSD (GRB) line, the Slice(GRB NCB) line , the Hot Fill (PET NCB) line
and the Aquafina line. There is also a line dedicated to the Cleaning-In-Process (CIP) of the Hot Fill line,
tanks and machines, a line that is used to transfer water during syrup-making [Raw (NCB) and Finished
(CSD)], a line that is used for sugar syrup making and two lines dedicated to the Bottle Washers which
wash used glass bottles. There are also 2 utility lines which reuse water from the Bottle Washer and
Cooling Tunnels in the Utility section of the plant.
TREATED WATER STORAGE
TANK
TREATED WATER HEADER
C
S
D
L
I
N
E
H
O
T
F
I
L
L
C
I
P
L
I
N
E
H
O
T
F
I
L
L
L
I
N
E
P
E
T
L
I
N
E
K
E
T
T
N
E
R
L
I
N
E
S
Y
R
U
P
L
I
N
E
S
L
I
C
E
L
I
N
E
A
Q
U
A
F
I
N
A
L
I
N
E
TREATED WATER HEADER
B
O
T
T
L
E
W
A
S
H
E
R
L
I
N
E
1
B
O
T
T
L
E
W
A
S
H
E
R
L
I
N
E
2
UTILITY
OLD
COOLING
TUNNEL
OLD
BOILER
UTILITY
HOT
COOLING
TUNNEL
NEW
BOILER

9. DETAILED ANALYSIS OF TREATED WATER LINES IN THE PLANT
In the following section, each and every Treated Water line in the plant is explained, accompanied by a
schematic representation of each line. The focus is on the identification of unnecessary tap-outs which
lead to loss of treated water.
BOTTLE WASHER LINES 1 AND 2
The RGB production lines (Both CSD Kettner and NCB) are preceded by a Bottle Washer each which
washes the used bottles before recirculating them through the fillers. There are two RGB Bottle
Washers, each having 6 compartments:
I. Pre-rinse Chamber where the inverted glass bottles are pre-rinsed by high velocity jets of
Treated Water. This is an initial wash only which washes away any solid impurities and other
visible undesirables.
II. Caustic Chamber where the inverted glass bottles are completely submerged in Treated Water
dosed with a low amount of caustic alkali. The temperature is maintained at 72-75°C and caustic
acts as a sterilizing agent. The combined sterilizing effect of high temperature and caustic dosing
causes an initial inactivation of micro-organisms.
III. Pre-wash Chamber where the high velocity jets of Treated Water wash away the caustic from
the inverted glass bottles.
IV. Main Chamber where the inverted glass bottles are submerged completely in Treated Water
dosed with high concentration of caustic. This is the largest chamber and the bottles reside in
this chamber for the longest time. The chemical dosing also contains a chelating agent which
chelates heavy metals at neutral pH(6.5-8.5) and a pH maintaining agent which maintains
neutral pH.
V. Pre-Final Wash Chamber where the caustic and other chemical agents are washed off using high
velocity jets of Treated Water
VI. Final Wash Chamber where the final wash takes place.
The resultant bottles obtained post the 6-step cleaning cum sterilization in the Bottle Washer are non-
contaminated and completely sterilized bottles which are comparable to any fresh bottle. Broken
bottles or bottles which have nearly or completely washed away prints are not re-used.

10. 1.5”
3”
0.3 kL/hr
CLEANING OF MACHINES
2.5” 3”
2.5”
2.5”
2”
0.6 kL/hr
ROOM CLEANING
2”
1”
FLEXIBLE PIPE 4”
2.5”
DRAINING
PUMP SEAL COOLING
3”
DRAINING
H
E
A
D
E
R
BOTTLE WASHER LINE 1 - 4”
T
O
U
T
I
L
I
T
Y
POLISHER
RGB
BOTTLE
WASHER
RGB
BOTTLE
WASHER
POLISHER
PET BOTTLE WARMER
AND WASHER
PUMP
PUMP

11. 3” 3”
1”
1.5”
DRAINING
1”
2” 0.5”
2”
2”
3”
0.5” 1” 1”
H
E
A
D
E
R
BOTTLE WASHER LINE 2- 5” TO UTILITY
CONVEYER BELTS (PRODUCTION LINES)
RGB
BOTTLE
WASHER
CONVEYER
LUBRICATING
MIXTURE
RGB
BOTTLE
WASHER
THERMOSTAT
THERMOSTAT
MOTOR
BOX
TANK

12. AQUAFINA LINE
Aquafina is the brand of bottled water from PepsiCo which was first distributed in Wichita, Kansas in
1994 and for the first time in India in 1999 in Mumbai. The Treated Water used in Aquafina fillers goes
through an additional UV Filter and an additional CF before it is channelized to the Aquafina Bottling
Hall.
AQUAFINA LINE – 2.5”
2.5” 2.5”
0.675 kL/hr CLEANING
1” 2.5”
2”
2.5”
0.864 kL/hr CLEANING
2” 2”
PUMP SEAL COOLING (18)
HEADER
ULTRA-VIOLET
FILTER
CF
AQUAFINA
FILLER
PUMP

13. PET LINE
PET stands for Polyethylene Terephthalate which is a thermoplastic polymer resin of the polyester
family used in manufacture of bottles. The name of the line is due to the PET bottles used as packaging
material for the Carbonated Soft Drinks (CSD) such as Pepsi, 7Up, Mirinda Orange, NImbooz Masala
Soda , Lehar Soda and Mountain Dew in three sizes -600 mL, 1.25L and 2L. The PET bottles are made
from small tubular forms known as Pre-Forms, which are blown in the Pre-Blower using hot air. The Pre-
Forms are heated by high voltage lamps to make them pliable, following which they are passed through
moulds in a high pressure air chamber.
1.5” 1.5”
1.5”
0.4736821 kL/hr
ROOM CLEANING
HEADER
P
E
T
L
I
N
E
3
4” WATER TANK
RINSERTANK
PUMP

14. KETTNER LINE
The Kettner line refers to the Recoverable Glass Bottles (RGB) line for Carbonated Soft Drinks (CSD) such
as Pepsi, 7Up, Mountain Dew, Mirinda Orange, Nimbooz Masala Soda and Lehar Soda . The name is
derived from the company that manufactured the initial filler and other machines. Although the line is
no longer using Kettner manufactured fillers and machines, the name has persisted.
KETTNER LINE - 2.5”
2.5”
1”
1”
0.7714286 kL/hr
ROOM CLEANING
HEADER
AERATION
TANK
FILLER
CARBONATION TANK

15. SLICE LINE
Slice is a Non-Carbonated Beverage (NCB) manufactured by PepsiCo which contains pulp of Totapuri
mangoes and Alphonso mangoes. The plant manufactures two types of Slice- Ambrosia Slice which
contains Totapuri pulp, Alphonso pulp and citrus pectin and Alphonso Slice which uses Alphonso pulp
only. The Slice line is for hot filling of Slice into Recoverable Glass Bottles (RGB).
SLICE LINE – 2”
2”
PUMP SEAL COOLING (19) 1.5”
1” 1”
PUMP SEAL COOLING (20)
PRODUCTION LINE 1.5” DRAINING STEAM GENERATOR (21)
(FILLER) 0.825 kL/hr
ROOM CLEANING
HEADER
PASTEURIZER
PUMP
STEAM GENERATOR
PUMP

16. HOT FILL CIP LINE
The Hot Fill Cleaning-In-Process (CIP) line supplies Treated Water for the cleaning of pipelines and tanks
in the Hot Fill Line. All pipelines and tanks in the NCB Hot Fill line are subjected to a 3-Step DivoFlow CIP.
The 3-step DivoFlow CIP involves
 600 seconds Pre-Rinse with Treated Water
 1800 seconds Lye Circulation at minimum temperature 85°C and minimum conductivity
11mS/sec with DivoFlow solution in Treated Water
 600 seconds Final Rinse using Treated Water. This Final Rinse water is not thrown away, it is
instead recycled as the Pre-Rinse water for the next CIP
The Pasteurizer and Filler in the NCB Hot Fill Line are subjected to a 5-step CIP, not through the Hot Fill
CIP Line but instead through individual CIP tanks in the respective rooms. The 5-step CIP involves:
 600 seconds Pre-Rinse with Treated Water
 1200 seconds Lye circulation at minimum temperature 85°C and minimum conductivity
11mS/sec
 600 seconds Lye Rinse
 1200 seconds Hot Water Wash at temperature 95°C
 600 seconds Final Rinse
The CIP of the Pasteurizer and Filler is followed by a Sterilization-in-Process (SIP) using hot water at 95°C
for 15 minutes.
3”
3”
3”
2”
H
E
A
D
E
R
HOT FILL CIP LINE – 3”
HOT WATER LYE BTD
BEVERAGE 1
BEVERAGE 2
PW TANK
INGREDIENTS TANK
BLENDING 1
BLENDING 2
PULP PUMP TANK
PECTIN TANK
BEVERAGE 1
SYRUP TANK
HOMOGENIZER
PASTEURIZER
PUMP
PHE

17. SYRUP LINE
There are two types of syrup involved in beverage production in the plant, namely
 Raw Syrup which is basically a solution of sugar in Treated Water
 Ready Syrup which is basically a mixture of Raw Syrup and Concentrates
Syrup preparation can be basically explained via the following points
I. The preparation of sugar syrup begins with a 5-step sanitation of all pipelines and tanks in this
line,
II. Following which sugar dumping takes place in Treated Water with continuous steaming at 80°C.
III. 0.25-0.3% Activated Carbon is added and after 15 minutes 0.25-0.3% Hyflow is added. Carbon
removes off-odour, inactivates micro-organisms and clears the colour at 80°C while Hyflow
increases viscosity and hence ensures easy passage through the filter press.
IV. The syrup is then circulated in the Raw Syrup Tanks (RST) through the filter press to filter out the
Carbon.
V. 15 minutes after this the colour, odour and turbidity are checked.
VI. If all values are within desirable and legally mandated limits, then the syrup is transferred
through Plate Heat Exchangers (PHE) to the Finished Syrup Tanks (FST).
VII. The PHEs decrease the temperature from 80° to about 20-24°C which aides in containing in the
flavouring compounds.
VIII. The BRIX factor and TA of Finished Syrup are calculated.
IX. If they are within limits, then Finished Syrup is transferred to the Fillers.
If the value of the BRIX is above the standard BRIX, then a certain volume of water must be added to
obtain the standard BRIX. This is in accordance with the following formula:
Volume of water to be added= [(Actual BRIX-Standard BRIX) X Volume of batch]/Standard BRIX
In case the value of the BRIX is below the standard BRIX, then there are no calculations and sugar must
be added according to rough estimations based on the experience of the personnel-in-charge.
The Treated Water in the Syrup Rooms is supplied through two dedicated lines, namely
 The Syrup Line
 The CIP Water Line In the Syrup Rooms

18. 1” 1”
PUMP SEAL COOLING (10)
PUMP SEAL COOLING (11)
2.5” 2.5”
1.5” 0.77kL/hr ROOM CLEANING
1”
1”
2”
PUMP SEAL COOLING (12) PUMP SEAL
COOLING (13)
2.5”
PUMP SEAL
COOLING (15)
1.8kL/hr
ROOM CLEANING
PUMP SEAL COOLING (14)
1.8kL/hr
ROOM CLEANING/HAND-WASHING (4)
S
Y
R
U
P
L
I
N
E
H
E
A
D
E
R
SYRUP LINE – 3”
PUMP
PUMP
CONCENTRATE
MIXING TANK
FST
S
Y
R
U
P
L
I
N
E
CIP HOT WATER
CHLORINE TANK
PUMP
TANK NOT IN
USE
PHE
TANK
PHE -1
PHE -2
PCT
PUMP
S
T
E
A
M
M
A
I
N
CARBON AND HYFLO
ADDITION TANK
PUMP
PUMP
RST
PCT
RST

19. CIP WATER LINE IN THE SYRUP ROOMS DRAINING
2”
2”
2.5”
2”
2”
2” 2”
3” 3”
1.5” 3”
1”
CAUSTIC TANK CIP HOT WATER
CHLORINE TANK
PUMP
PHE
RST 1
RST 2
TANK NOT IN USE
CARBON AND HYFLO
ADDITION TANK
CONCENTRATE
MIXING TANK
W
A
T
E
R
L
I
N
E
PUMP
FST -1
FST -2
FST -3
FST -4
FST -5
FST -6
FST -7
TANK NOT IN USE
PET FILLER
PUMP
KETTNER
FILLER

20. UTILITY LINES
The utility section of the plant re-uses the water from the bottle washers in 6 cooling towers , which
produces cooler water, which in turn via Plate Heat Exchangers (PHEs) cools ammonia. Ammonia is
condensed in a condenser to liquid ammonia, which is used to cool glycol via a Plate Heat Exchanger
(PHE). Cold glycol is transferred to the syrup room.
3”
3” 2”
2
PUMP SEAL COOLING (16) 1” 3”
PUMP SEAL COOLING (17)
1.08kL/hr PISTON
H HOUSEKEEPING COOLING
0.84kL/hr 6” 0.2kL/hr
10” CLEANING
RECOVERY
CF
RECOVERY
DEGASSER
PUMP
PUMP
HOT COOLING TUNNEL NEW BOILER LINE – 3”
BOTTLE WASHER LINE 1 – 4”
BOTTLE WASHER LINE 2 – 5”
OLD COOLING TUNNEL OLD BOILER LINE – 3”
TW TANK
H
E
A
D
E
R
PUMP
AIR REC
AIR REC
RADIATOR HP
COOLING
TOWER X 6
PHE PISTON

21. HOT FILL LINE
The Hot Fill Line is dedicated to the production of NCBs in PET bottles, namely Slice and 7Up Nimbooz in
this plant. The production can be explained briefly as follows:
I. Production begins with a 3-step DivoFlow CIP for all Hot Fill tanks and pipelines and a 5-step CIP
and SIP for the pasteurizer and filler.
II. Post CIP and SIP, sugar syrup is transferred from the RST to the Hot Fill Room where the
ingredients part and flavor parts are dissolved.
III. The fruit pulp is added next and the volume made up to batch volume using Treated Water in
the Blending Tank
IV. The BRIX and TA are checked and adjusted if necessary.
V. When desired BRIX and TA are obtained , the final Ready syrup is homogenize in a 2-step
Homogenizer (Stage I at 175 bar and Stage II at 35 bar)
VI. The completely homogenized syrup is stored in the Beverage Tank
VII. The Ready Syrup is then pasteurized in a Tubular Heat Exchanger (THE) type pasteurizer with
holding time 30-180 seconds at 90-95°C
VIII. Post pasteurization , the syrup is trim cooled in a PHE to about 80-82°C
IX. The pasteurized syrup is then transferred to the Filler bowl, from where 85% of the syrup is used
for filling. The remaining 15% is returned to the pasteurizer via a Return tank and BTD
X. Filling takes place at 78-80°C followed by 21-23 seconds of cap sterilization
XI. The filled bottles are then passed through the cooling tunnel which reduces temperature
gradually in 5 steps to 36.8°C from 80°C
XII. The bottles are then sleeved, coded, steamed and packaged in cases after shrink wrapping.
Degrees Brix (symbol °Bx) is the sugar content of an aqueous solution. One degree Brix is 1 gram
of sucrose in 100 grams of solution and represents the strength of the solution as percentage by mass. If
the solution contains dissolved solids other than pure sucrose, then the °Bx only approximates the
dissolved solid content. The BRIX value is adjusted according to the method mentioned previously.
TA, on the other hand, is Titre value of Acidity and is defined as the volume of NaOH required to
increase the pH of a solution to 8.75. The TA is adjusted according to the following calculation
Mass of citric acid that must be added in gm = (Standard TA - Actual TA) X 238 X No.of units in batch

22. 2”
1.5”
2”
0 .23077kL/hr
PUMP SEAL
COOLING (7) 0.23077kL/hr
PUMP SEAL COOLING (8)
2”
3” 3”
1.5” 0.5625kL/hr
CLEANING 5”
4”
1”
PUMP SEAL
COOLING (6)
1.5” 0.54kL/hr CLEANING
1”
0.3255kL/hr 0.159kL/hr CLEANING
0.63kL/hr 0.54kL/hr CLEANING
CLEANING WASHBASIN(5) 4” 1.5”
0.3255kL/hr 0.95kL/hr CLEANING 2.647kL/hr DRINKING WATER COOLER
CLEANING 3” 1”
SS TANK
HOMOGENIZER
PUMP
INGREDIENTS
TANK
PULP PUMP
TANK
PHE
PW TANK
PUMP
HYDRAULIC
CAN
CUTTER
PUMP PECTIN
MIXER
PECTIN TANK
PASTEURIZER
PHE COOLING TUNNEL
FILLER
TANK
BEVERAGE 2
HEADER
HOMOGENIZER
PRODUCT LINE
BLENDING 1
BLENDING 2
BEVERAGE 1
H
O
T
F
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HEADER
PUMP SEAL COLLING (9)
PUMP

23. MISCELLANEOUS WATER LINES
Apart from the aforementioned lines, there are multiple tap-outs from other miscellaneous Treated
Water lines which utilize Treated Water for a plethora of activities ranging from housekeeping to
drinking.
0.257kL/hr 0.23077 kL/hr
CLEANING OF ROOM DRINKING WATER
(RGB PRODUCTION ROOM)
0.5625 kL/hr 0.78261 kL/hr
HOUSEKEEPING WASHBASIN (1)
0.78261 kL/hr
0.24 kL/hr 0.24 kL/h WASHBASIN (2)
DRINKING WATER DRINKING WATER
0.257 kL/hr 0.5625 kL/hr
HOUSEKEEPING IN PET HOUSEKEEPING
PRODUCTION ROOM
0.78621 kL/hr
WASHBASIN (3)
GEYSER

24. SOLUTIONS TO RECOVER WATER
The aim of the project i.e. maximum recovery of water can be achieved with respect to the two issues as
follows:
 To combat Loss of Treated Water we can undertake the following measures:
 Closing of taps marked 1, 2, 3 [in the miscellaneous water lines], tap 4 [in the Syrup Line] and
tap 5 [in the Hot Fill Line] which are presently being used for washbasin purposes will lead to
saving of a total maximum hourly loss of 4.68783kL of Treated Water . Since these taps
presently consume Treated Water, hence the ratio of Treated Water actually used in production
to the Treated Water obtained from RO-1 will increase, hence increasing efficiency of water
usage in the plant. The three taps in the miscellaneous water lines can be replaced by a direct
line from borewell-3, which will be the most efficient construction monetarily and
materialistically as it covers the shortest distance. Tap 4 in the Syrup Line in the CIP Room must
be permanently closed without replacement as it leads to high loss due to leakage and
unnecessary usage. Tap 5 outside the Pulp Room can be replaced by a single branch from the
RW tank [shortest distance].
 Taps 6-21 cannot be closed as they are involved in pump seal cooling, draining from machines
etc. which are necessary functions during, pre or post-production. However to facilitate
maximum recovery , all rooms which have such usage of Treated Water should have sloping
floors towards the walls and a depression at the end of the slope all along the walls to collect
water. This water can be recycled via a pump to further cool the pump seals. Hence Treated
Water usage reduces drastically as Treated Water is being utilized apparently for only a single
round of cooling but effectively for all rounds. The Treated Water used is reduced by a factor
which is proportional to the time for which the pumps operate, hence higher the production,
greater the volume of water saved. When production stops this water can be utilized for
backwashing and rinsing of WTP tanks the next morning.
 For the tap [tap 21 in the Slice line] that drains out the steam generator, the water drained out
during production can be collected in a separate tank and utilized for rinsing or backwashing
WTP tanks. This reduces Raw Water wastage and improves efficiency of Raw Water conversion
to Treated Water in the plant.
 Pumps in the WTP which leak must be attended to immediately. This also applies to any pipeline
in the plant which develops leaks. In case the leakage from the pumps cannot be immediately
stopped, the water lost due to leakage can be transferred by means of a collection tank to the
tanks for backwashing and rinsing as suggested in the next part.
 To combat wastage of Raw Water we can undertake the following measures:
 The Raw water used for backwashing and rinsing of the WTP tanks can be recycled back into the
Raw Water tank instead of being disposed of. To do this, the water that is obtained after
backwashing and rinsing can be stored temporarily in a tank and then passed through the WTP
till it attains quality standards matching those of RW sufficient to be utilized for backwashing
again. This ensures usage of the same Raw Water for multiple backwashes and rinsing
operations at the cost of construction of extra tanks and pipelines.

25.  Recycling of the water used for rinsing and backwashing ensures that the only effective wastage
of water remains from the RO itself I.e. the Flush Dump Value and the RO Reject Water. The
water that is flushed out can be recycled back through the WTP and re-utilized for backwashing,
rinsing or pre-washing of the RO itself. The effective wastage that remains is the RO reject which
has high TDS concentration and the volume of which is dependent on the RO itself. Hence the
total wastage is reduced by 39.19% on days re-cycling water for backwashing and rinsing. The
conversion of Raw Water to Treated Water also rises from 76.147% to 84% on such days.
Parameter Present Condition Improved Future
Condition
Net Change
Conversion of Raw
Water to Treated
Water
76.147% 84% on days of
recycling
+7.86%
Total Wastage of
water in plant
631.49kL + Leakage loss
from pumps
384kL on days of
recycling
Greater than
-39.19%
Total loss of water
in plant
4.68783kL + Loss due to
Pump Seal Cooling and
Draining from Steam
Generator
0kL -100%
CONCLUSION
In conclusion, the recovery of maximum water from loss as well as wastage can be achieved by following
the measures mentioned. The volume of water recovered will be substantial at the cost of an initial
monetary investment and a recurring maintenance and operation cost but the aim of preserving our
most important resource – Water will be achieved.
ACKNOWLEDGEMENT
This project on water recovery was conducted in the Varun Beverages PepsiCo Plant, JL- 47, Barhans,
Fartabad, Chakratala, Sonarpur, Kolkata - 700084, West Bengal, India under the guidance of Madam
Soma Sen. The project would not have been possible without the help and support of all the people
involved with the day-to-day working of the plant, starting from the doorman to the manager. This
project would not have been possible without the support and encouragement and the opportunity
provided by Mr.Mukesh Patro and Mr.Rajesh Giri among others. I would also like to acknowledge the
role played by my professors in the Jadavpur University Department of Food Technology and
Biochemical Engineering in the compilation of the project.
I would also like to thank everyone in the plant who took time out to answer all our questions and clear
all our doubts. We remain forever grateful for the opportunity. I hope that this project is of some
assistance to the management.Thank You.