3. PLANT LIST
1. BLOWING SYSTEM.
a) HP Compressor, 40 BAR
b) Chiller Plant
c) SIDEL PET Blowing Plant.
2. Central Syrup & Blending
a) Central Syrup , 4 nosa) Central Syrup , 4 nos
b) Central Blending System
c) CIP Unit
3. Power & Utility
a) 1.5 MW Gas Generator & Gas use Reconciliation.
b) 4000 Amp substation in CAN Building.
c) 100 TPH WTP
d) 80 TPH RO Plant
3. Dual Filler Plant
4. Filler Name: DUAL FILLER
Location: New CAN Building
Capacity: 400 BPM
Filling system : Soft & Hot
Filling Control System : Flow meter controlling.
Filling Valve : Electro-pneumatic Valve.
Filler model : DQRS – 80 x 80 x 18.Filler model : DQRS – 80 x 80 x 18.
Type: Monoblock.
Total No of Nozzle : 80
CO2 Consumption : 180 Kg/hr.
Air Consumption : 24 M3/hr@6 Bar.
Required Chilling water temp:
a) Glycol water = -2 to -4 Deg C
b) Chilled water = 7 Deg C.
5.
6.
7. CSD Hot Fill
Carbo
mixer
Rinser Filler Capper Wrapper
(Packaging)
UHT
PET
Conveyor
Belt
Syrup
Homo
Syrup Juice
Mixing
Over head
conveyor
C
h
e
c
Warmer/
Cooling
tunnel
Conveyor
Blow
Dryer
Band-R
LabelerBlowing
PET
Bottle
Pre form Closure
Hopper
Caper
Rinser
FIG : PROCESS FLOW DIAGRAM (CSD & HOT FILL.)
Date
Coding
c
k
Cycle time : 35-40 Min
9. 1. Filler machine (Rainser + Filler + Capper), 80 x 80 x 18, Tech-long.
2. Carbo Mixer , 16 TPH Tech-Long, China.
3. Cooling Tunnel or Warmer , 4 Chambers, Tech-Long.
4. Air Blower / Dryer , Tech-Long
5. Date Coding Machine, Image Model: 9020.
6. Labeler, OPP, HF SSO-6000, Korean
7. Band-Roll Inserter, LEBAL TRADING CO, LTD.
8. Wrapping Machine: Automatic Shrink Film Wrapping system.
20-25 Min
8. Wrapping Machine: Automatic Shrink Film Wrapping system.
Capacity : 35 Boxes/Min, Model: WSD- LMB35T , China.
9. Homo : GEA, Max Pressure 25 MPa, Rated Flow : 1000 dm3/h,
VFD System, Italy.
10. UHT/Sterilizer : Type: Tabular, (Shell & Tube),
Heating Area = 88 M2 , Max temp = 1500 C
11. PHE : Total 5 nos.
12. Dosing Pump: Grundfos , 5 L/H, 6 Bar, 0.011 KW, 50 Hz.
13. Conveyor Lubrication system.
14. Cap Sterilization System: Cap: 32000 BPH, Pump = 4 Bar, 2 stage.
10. Carbon -Di-Oxide Tank
Installation date : 09:05:2014. C.Run :
Location : Beside CSD CO2 Tank.
Storage Capacity : 10 Cubic meter. y
Storage Condition: Liquid.
Vessel weight : 6500 kg
Operating & test pressure :Operating & test pressure :
Max = 22 Bar, Min: 10 Bar. Test Pr = 25 Bar
Dimension : Dia = 2020 mm , 3 Legs,(@ 70” & 120 deg)
Vaporizer capacity = 150 NM3/H.
Piping : 25 mm SS 40 schedule, with PRV, 8 Bar
Welding System : TIG with filler rod. Leak Test @ 12 Bar by
water only pipe line.
11. CO2 Process Flow Diagram
CO2 Tank Instruments:
1. Two pressure relief valve.
2. Operating pressure gauge.
3. Storage/capacity gauge.
4. High & Low level audible alarm.
Storage Pressure & Temp = 20.5 bar & -17 C.
CO2 Uses System:
1. During filling to storage tank use both hoses vapor and liquid to
displaced gas by liquid.
2. Use Non –return valve for Tanker & storage tank.
3. It is better to be safe than sorry , so use 0.01 micron polishing filter.
4. Use PRV after vaporizer. 15 Bar to 8 bar.
15% CO2 Losses in PET Bottle;
1. For 2 ltr = 12 weeks, 2. 500 ml = 9 weeks, 3. 250 ml = 7 weeks.
12. High Pressure Compressor.
Installation date : 24:05:2014.
Commissioning Date : 07:12:2014
Location : HP Compressor area.
Machine Specification :Brand: ABC , Spain
Model: 4HA-6TER- LT, SL# 24472. 4 stage, 6 cylinder, 280 KW
motor (Brazil) , 28 M3 / min. , 670 rpm, Wt : 13 tons. Mainmotor (Brazil) , 28 M3 / min. , 670 rpm, Wt : 13 tons. Main
Base dimension (mm) = 6800 x 2060.
Working Pressure : 35 Bar to 38 Bar
Power status:
Total Connected Load : 291.85 KW
Current at Load : 153-155-156 amp
Current at unload: 17 amp HP Comp#1
13. High Pressure Compressor.
Air drying system/Air Dryer:
Brand: Airsec,Model:FD-300-WH,Flow rate: 1768 M3/H
Type: Refrigeration, R-404A, (3.5 kg), DP = min 3 deg C.
Air input Temp max = @40 Bar,40 deg C. Compressor
Hermetic Type , 3.7 KW, 7A, Condenser water cooled.
Cooling system/Cooling Tower: Model : RMA -101 D, TEVA
Closed cycle , evaporative system with shell & tube .Its blower motor
HP Comp#2
Closed cycle , evaporative system with shell & tube .Its blower motor
permanently lubricated by bush bearing (2Z) , Motor = 3 nos. @ 1.1 Kw
Size : 680 x 1270 mm. Two parts wt = 800 + 1300 = 2100 Kgs.
Piping System :
Total length : 345 ft.
Size : 80 mm , 40 schedule , 40 BAR Grade : 304 L
Welding: V- shaped, SS filler rod .
MS 18” header with Grid system (by pass with HP # 1)
Hydraulic test : 55 Bar , Holding Time : 4 hours, by water.
14. Points / Aspects. ABC HP COMPRESSOR IR HP COMPRESSOR
1. Space Less More
2. Starting load Less (Due to LP air connected) More
3. Cooling system Good (Closed cycle) Poor, open
4. Dryness of air Good , 3 deg C Up to 8 deg C
5. Power consumption Less than IR, due to VLT drive
6. Air Filter 16000 hrs 8000 Hrs
Main Feature of ABC HP Compressor
6. Air Filter 16000 hrs 8000 Hrs
Main motor is 280 Kw, more than 10 Kw bigger than IR. Equipment
setup on base are more complex. Air cylinder also complex.
Plant Safety
1. PPE ( safety shoe, tight dresses)
2. SOP
3. CO2 Fire Extinguisher
4. Proper earthling 90 RM copper cable.
15. Re-Engineering for HP Air Compressor.
Description: As per design schedule we had to made a header by SS
18 inch pipe (40 schedule). So as per design we tried to collect it locally ,
but it was not in local market.12 inch SS pipe is available and market
price is 22,000 Tk per feet. Our demand was 20 feet , total price = 22000
x 20 = 44,0000 Tk.
KAIZEN WORK : We decided to make header by MS alloy pipe which
will be same as SS 40 schedule pipe. MS pipe price is 4000 Tk per feet.
HP Comp#3
will be same as SS 40 schedule pipe. MS pipe price is 4000 Tk per feet.
Here total cost = 80000 Tk.
Total save = 440000-80000 = 360,000 Tk.
So it is re-engineering to select metal.
16. Ammonia Plant
Installation Date: 27:12:2014
Commissioning Date: 05.01.15
Plant Origin : DCE Refrigeration Pvt Ltd, India.
Capacity: 676000 + 220000 = 896000 Kcal/Hr(296Ton)
As chilled water = 223.4 Ton, Glycol water = 72.7 Ton.As chilled water = 223.4 Ton, Glycol water = 72.7 Ton.
Chilled water temp = 7 deg C.
Glycol water temp = -4 to -2 deg C.
Total Connected Load:
Space Required : 25’-0” x 45’-0” x 22’ -0”.(LWH)
Type of Plant : Vapor Compression type.
NH3 # 1
19. Machinery & Equipment List of NH3 Plant
Refrigerant Compressor: Brand: KIRLOSKER, Type: Reciprocating,Refrigerant Compressor: Brand: KIRLOSKER, Type: Reciprocating,
Model: KC-4, Single stage, 4 cylinder,
Operating system: Belt drive, Motor 90 KW, 1, 2 No cylinder direct
loading & 3 for 75% and 4 no cylinder 100% on load. Cylinder head
water cooling. Suction = 80 mm, Discharge = 65 mm.
Working pressure status:
a). Low oil pressure alarm = 1.5 Kg/cm2
b). Low suction pressure = 0.5 Kg/cm2
NH3 # 2
b). Low suction pressure = 0.5 Kg/cm2
c). High Discharge Pressure = 15 Kg/cm2
Power Status:
a) Amp at Load = 65 Amp @ 50 % Load.
b) Amp at unload = it is running always at 50% load.
It start at unloading condition, after oil pressure raise (2 Bar) , goes to
loading with 2 cylinder i.e. 50%. Then after load condition rest of
cylinder will open @ of load 75%(3 Cyl) and 100%.(4 cyl).
NH3 # 4
20. Machinery & Equipment List of NH3 Plant
Condenser:
Brand: LAVA, Type: PHE,
Model: MK15-144 PLTS, Capacity = 887770 Kcal / Hr
Qty = 1 No
Medium = Vapor NH3 and CT water.
Brand: LAVA, Type: PHE,
Model: MK10-82 PLTS, Capacity = 307274 Kcal / Hr
Qty = 1 No
NH3 # 5
Qty = 1 No
Medium = Vapor NH3 and CT water.
NH3 Liquid Receiver:
Metallic cylindrical , Design code: ASME SECT VIII DIV 1, ED 2007,ADD
Fluid : Ammonia, Design Pressure: 21 Bar, Working Pressure = 15 Bar, Wt
= 610 Kg, Wr. Wt = 750 kg. Fitting pipe = 40 Sch, Plate Thickness = 8
mm, Painting: a) Primer = 2 coats of red oxide, primer. 30 -40 micron
b) Intermediate = 2 coats
c) Final = 2 coats
21. Machinery & Equipment List of NH3 Plant
Evaporator:
Brand: LAVA, Type: PHE,
Model: MK15-136 PLTS, Capacity = 676000 Kcal / Hr
Qty = 1 No
Medium =
Brand: LAVA, Type: PHE,
Model: MK10-124 PLTS, Capacity = 222000 Kcal / Hr
Qty = 1 No
NH3 # 2
Qty = 1 No
Medium = Liquid NH3 and Hot Chilled water.
Surge Drum:
22. Machinery & Equipment List of NH3 Plant
Cooling TowerCooling Tower
Type: Evaporative , Counter Flow. Sprinkler speed = 3-5 RPM.
Capacity : 200 RT + 200 RT = 400 RT
IN/OUT Let : 6”
CT Fan motor = 4 Kw, Drive = Layer of fins = 2 , Fins Height , Dia =
CT Pump Motor Specification = 4 Nos Pump ( Stand by 2 Nos)
Power = 3 phase, 380 VAC, 15 KW.
Flow rate = 120 M3/Hr.
NH3 #7
Flow rate = 120 M3/Hr.
Head = 30 M
Inlet / Outlet = 5”
Type : Reciprocating, inline vertical.
Pipe line connection : GI Pipe, Grade B
Total No of CT = 2 Nos ,
Purpose: For NH3 Condenser.
23. Machinery & Equipment List of NH3 Plant
TANKS:
CHW = 1, Glycol = 1
Dimension : 1.5 x 3.0 x 1.0 (M), Metal: SS 304, Insulation :Rubber foam
75 mm thick with alu covering.
PUMPS:
NH3 # 8
25. Name : PET Bottle Blowing Plant.
Capacity: 450 BPM.
Model : SBO 14, Sl # 11779.
System : SBO
Using Medium : High Air Pressure ,35 to 38 BAR1527 M3/Hr(1 Ltr)
LP Air Pressure : @7 Bar 190 M3/Hr
Features : Dual system , CSD & Hotfill
Purpose : For New Dual filler room.Purpose : For New Dual filler room.
Location : Ground Floor ,CAN Building.
Power Consumption : 324 KW+ 30 KW
Total Power = 480 KW
Chilled water = 12 deg C, 30 M3/Hr
4 Bar pressure
Origin : Sidel, France
26. At the start of the bottle blowing process, the perform is heated to about
90°C. At this stage it is critical that the neck finish is protected in the oven, as
the incorrect positioning of heat shields could result in distortion of the neck
finish which in turn will affect handling on any air conveyer system on route
to the filling and closure application affect filling. Once heated the perform is
transferred by the neck to the bottle mould. The perform is then initially
stretched with a metal rod to elongate the lengthwise so the tip of the perform
is located into the centre of the base section of the mould. Low pressure air at
ca. 7-8 bar is applied at the same time in order to form a balloon inside theca. 7-8 bar is applied at the same time in order to form a balloon inside the
mould and then finally high pressure air of up to 40bar is applied to stretch
the material sideways into the final shape of the bottle mould. These two
operations must be done sequentially in order to get maximum biaxial
orientation of the polymer chains.
Orientation is the process of aligning the polymer chains in an orderly fashion
by stretching, in biaxial orientation the amorphous polymer (the random
arrangement chains) is stretched in both longitudinal and transverse directions
simultaneously. Biaxial orientation improves both the tensile strength and the
stiffness of the PET bottle.
27. Preform specification
RESIN
CSD STILL PRODUCT PREFORM
I.V. (dl/g)intrensic 0.80 – 0.85 0.72 to 0.75 Maxi IV drop = 0.02dl/g
Preform : injection system at 275o C.
for blowing it hates 90 o C in oven,
NH3 # 2
I.V. (dl/g)intrensic
viscosity
0.80 – 0.85 0.72 to 0.75 Maxi IV drop = 0.02dl/g
A.A.Acidaldihide < 2ppm < 1ppm CSD / 5 to 6ppm
Mineral Water / 3 to 4ppm
MOISTURE PICK-UP After drying < 100ppm Just before blowing
≤ 2000 ppm recommended
2500ppm maxi
28. PET Bottle Specification
1. Bottle height : a) Mitutoyo height gauge (or equivalent)
b) Roch marble surface standard.
2. Bottle Diameter
a) Pi Tape
b) Caliper Gauge
3. Bottle metarials Distribution by Cutting & Weighting.
a) Hot wire bottle cutter (3 or 4 wires) supplied by SIDEL.
b) Digital laboratory scales (Mettler PR 8100 or équivalent).b) Digital laboratory scales (Mettler PR 8100 or équivalent).
4. Volume Mesurement
5. Vertical Compression Strenght.
6. Drop Test
7. Creeping test
8. Burst Test
9. Weight
31. Difference Between RIP Sidel & AMCL Sidel (SBO -14).
Points / Subject RIP SBO -14 AMCL SBO -14 Remarks
Model SBO Universal SBO Universal HR(
Heat Resistance)
PET Bottle Production
Type
1. CSD
2. Warm Filling PET.
(Filler Temp < 80 o C)
1. CSD
2. Hot Filling PET.
(Filler Temp > 80 o C)
HP air Cooling System
during blowing in
mould.
Nil. No system Available After blowing high
pressure air are
released by nozzle to
cold bottle and
mould.
Oven Lamp Infra Red ECO Lamp ECO is good.
Best For CSD CSD & Hot Fill
32. Difference Between Sidel &RJM
Aspects Sidel RJM(Tech-Long) Remarks
Oven Lamp ECO Lamp IR (Infra-red) Lamp ECO lamp takes low
current consumption.
No. of spindle 180 206 Maintenance costs high
for RJM
HP Air consumption Less High Sidel has HP air recoveryHP Air consumption Less High Sidel has HP air recovery
system.
Extra LP Air No need Need More utility need.
Efficiency 95% 75% 18000 BPH RJM machine
could not give 18000
BPH. Its maximum output
15000 BHP(incase of RJM-
10)
33. POWER (ELECTRICITY)POWER (ELECTRICITY)
SL # Machine Name ELECTRICAL CONSUMPTION,
KW
RUNNING LOAD, KW
1 DUAL FILLER PLANT 363.5 285
2 WTP 52 42
3 RO 125 125
4 Ammonia Plant 517.5 365
5 Blowing 480 4205 Blowing 480 420
6 HP Air Compressor 300 300
7 All CTs (Process) 80 50
8 All Chillers 40 40
9 Blending 190 175
10 CIP Unit 20 15
TOTAL (CONNECTED) = 2168 KW 1815 KW
34. GAS RUN
BOILER RUN GENERATOR RUN
PRESENT , CFH BEFORE , CFH PRESENT , CFH BEFORE, CFH
36240 45440
69555 60360
We have increased gas run for 1.5 MW Gas Generator by re-conciliation
of gas using machinery.
36. SubSub--StationStation
• The LT panel has to modified to 7000Amp.
• Create provision for synchronous run for all generators.
37. Power TransmissionPower Transmission
• For the first time we are going to transmit 2.2MW power for
distribution to a separate building named canning building.
Cable Specification:
1 X 500 RM, 53 Nos Run.
Total = 12 Kilometer Cable.
It’s is the biggest cable
laying in our group by own
employee.
38. Control roomControl room
• The transmitted power will be distributed from the control
room located near to the lift on Ground Floor.
Fig : Verming Proof.Fig : New LT Panel, 4000 A.
41. Technical info for New Substation.Technical info for New Substation.
• LT panel 7000A for Synchronizing Generator
Sp. Incoming 6000A, ACB; outgoing 5000A, ACB one, two 2000AACB
• LT Panel 6000A for distribution
Sp. Incoming 5000A, ACB; outgoing one 2000A, ACB; twelve 630A
MCCB
• For transmission Cable used 15 run/phase & 10 run for Neutral;
sp. Aluminium Cable 1x500rm XLPE & Al Cable 1x400rm XLPE
• For Distribution cable used 2 run/phase & 1 run for Neutral;
Sp. Al Cable 1x300rm XLPE
42. Name : Water Treatment Plant.
Capacity : 100 Ton / Hr.
Treatment System : Softening system with ACF.(Activated Carbon
Filtering)
Vessel of Metal : SS 304 L
Purpose : For New 4 AMCL Lines.(Dual , Hot, PE & Alu CAN)
Features : It has sterilization system by LP steam to bacteria kill. Drive
regulated by Inverter.regulated by Inverter.
Location : North – West of CAN Building.
Electrical Power : 40 KW
Steam Consumption : @ 1 Bar, 100kg
Origin : CHINA.
Output Water parameter:
1. Ph = around 6.5 to 7.5
2. Hardness = 0 to 3 ppm
3. Iron = 0.1
4. Free from Bacteria.
43. Accessories & Required Materials
• Row water pump
• Chemical dosing device
• Dosing tank
• Mechanical filter
WTP pipe
• PLC
• Liquid level switch
• ACF
• Regenerator
• Salty water tank
• WTP valve
• Manual butterfly valve
• Cartridge
• Conductivity meter
• VFD
• Control cabinet
• Sand
• Resin
• Activated carbon
44. Name : RO Plant.
Capacity : 80 Ton / Hr.
Treatment System : RO Filtration.
Vessel of Metal : FRP, & 13 Nos.
Purpose : For New 4 AMCL Lines.
Features : Drive regulated system.
Location : Ground Floor of CAN Building.
Power : 125 KW
MEMBRANE
Size : 8” x 40”
2 Pass system.
Brand: FILMTECH, USA
Filter range: 0.0001 Micron.
Total Number: 78
Power : 125 KW
Origin : CHINA.
46. Accessories Used for RO Plant
• RO unit
• High pressure pump
• VFD
• RO membrane
• Pressure meter
• Flow meter
• Pure water pump
• UV sterilizer
• Ozone pump
• Mixing tower
• Asepsis water tank
• Ozone generator• Flow meter
• Resin valve
• Rising device
• Rising tank
• CIP pump
• Pure water tank
• Breath filter
• Ozone generator
• RO pipe & fitting
• Flow rate adjusting valve
• Single direction valve
• Pure water tank
47. Name : Central Air-Conditioning System
Capacity: 50 TR
System : Vapor Compression system & AHU
Using Refrigerant: R-22
Total no of Chiller : 2
Purpose : For New Dual filler room.
Location : Roof of New Building.
Origin : TICA, China.
Cooling Coil Chamber
Origin : TICA, China.
Pre-filter chamber Bag-Filter Chamber HEFA Filter Chamber
49. Central BlendingCentral Blending
1. 16 Ton per hour syrup process system for DUAL Filler.
2. 12 Ton per hour juice process system for HOTFILL.
3. 6 Ton per hour juice process system for ALU-CAN.
4. 5 Ton per hour Yogurt process system for PE-Lassi Line.
51. Proper Clean In Place (CIP) & Sanitation Ensure
System Sterility
CIP Cycle Example:CIP Cycle Example:
Hot water (>60Hot water (>60°°°°°°°°C) circulated for 10 minutesC) circulated for 10 minutes
Hot caustic, 80Hot caustic, 80°°°°°°°°C circulated for 20 minutes (with an active alkalinity of atC circulated for 20 minutes (with an active alkalinity of at
least 2%)least 2%)
Rinse 5Rinse 5 -- 10 minutes with Hot water (>6010 minutes with Hot water (>60°°°°°°°°C) waterC) water
Hot Acid circulated for 20 minutes (with nitric acid of 0.6Hot Acid circulated for 20 minutes (with nitric acid of 0.6 -- 0.8 % v/v)0.8 % v/v)
Rinse 5Rinse 5 -- 10 minutes with Hot water (>6010 minutes with Hot water (>60°°°°°°°°C) waterC) waterRinse 5Rinse 5 -- 10 minutes with Hot water (>6010 minutes with Hot water (>60°°°°°°°°C) waterC) water
Rinse 5 minutes with treated waterRinse 5 minutes with treated water
Hot sanitation step must be performed prior toHot sanitation step must be performed prior to
production startproduction start--upup
An chlorinated water or acid sanitizer solutionAn chlorinated water or acid sanitizer solution
must be left in the system during downtimemust be left in the system during downtime
52. Merits & DeMerits & De--meritsmerits
1. A good team work.
2. Zero accident up to 5000 working hours.
3. Re-engineering.
4. 12 KM Cable laying by own-team.(Newly joint people)
1. GMP Space no consideration.
2. As per VUCA , need UV or Polishing filter for RO & CO2
delivery line.
3. Materials collection was not a good way.
53. Some Moments.
Fig: Support Fig: Unloading. Fig: MeetingFig: M/c Base
Fig: Set up
Fig:Tank setup Fig: m/c setup Fig: Unloading Fig: Pipe welding
Fig: Positioning Fig: Lifting. Fig: Gen Set.
