KANDHARI BEVERAGES PRIVATE LIMITED

SAMBA, J & K, India

SUBMITTED BY:

Menjo Chemjong

11716486

B. Tech. (Food Technology)

 TABLE OF CONTENT

1. Effluent Treatment Plant (ETP)

1.1 Introduction
1.2 Protocol
1.2.1 Effluent
1.2.2 Grist Chambers
1.2.3 Screen Bar
1.2.4 Oil and Grease
1.2.5 Collection Tank
1.2.6 Equalization Tank
1.2.7 Flash Mixture
1.2.8 Primary Clarifier
1.2.9 Aeration Tank
1.2.10 Secondary Clarifier
1.2.11 Chlorine Tank
1.2.12 Dual Media Filter
2. Specification
3. Testing in ETP
3.1 Total Dissolved Solids (TDS), pH, Dissolve Oxygen (DO) and Temperature
3.2 Total Solids (TS)
3.3 Total Suspended Solids (TSS)
3.4 Mixed Liquor Suspend Solids (MLSS)
3.5 Mixed Liquor Volatile Suspended Solids (MLVSS)
3.6 Sludge Volume Index (SVI)
3.7 Chemical Oxygen Demand (COD)
3.8 Biological Oxygen Demand (BOD)
3.9 Oil and Grease
4. Documentation in ETP
5. Introduction of SIG
6. Procedure of SIG line
6.1 HRS Process System
6.1.1 Product Inlet
6.1.2 Balance Tank
6.1.3 Pasteurizer
6.1.4 Holding Coil
6.1.5 Cooling
[Link] Regenerative Stage
[Link] Cooling Stage
[Link] Chilling Stage
6.2 Filling Room
 6.2.1 SIG sleeve Stacking
6.2.2 Bottom Sealing
6.2.3 De-dusting
6.2.4 Hot air
6.2.5 H2O2
6.2.6 Dry Air
6.2.7 Filling
6.2.8 Steam Injection
6.2.9 Top Sealing
6.2.10 Flap Sealing
6.3 Date Code Punch
6.4 Straw Applicator
6.5 Tray Packer
6.6 Tray Formation
6.7 Shrink Wrapping
6.8 Pellet Formation
7. Testing in SIG line
7.1 Degree Brix
7.2 H2O2
7.3 Gross Weight
7.4 Net Content
7.5 Acidity
8. Conclusion
1. Effluent Treatment Plant (ETP)

1.1 Introduction

Most of the industries produce wastewater also known as effluent, as a bi-product of

their production process. The effluent/wastewater generated varies so greatly in both flow and
pollution strength and consists of several contaminants/pollutants, which can be removed with the
help of an Effluent Treatment Plant [ETP].

Water is the main component which is used in all types of industries. It is generally used for
washing, dilution, fermentation, conditioning the steam, cleaning utensils, etc. On the other hand
waste water discharged from the industry pollutes the local environment. So the effluent must be
treated before releasing to local environment.

1.2 Protocol

Effluent

Grits Chambers

Screen Bar

Oil and Grease

Collection Tank

Equalization Tank

Flash Mixture

Primary Clarifier
 Aeration Tank

Secondary Clarifier

Chlorine Tank

Dual Media Filter

Outlet

1.2.1 Effluent
Effluent includes the used water in CIP, cleaning floor, as raw material and also the
toxic chemicals inorganic matters, solvent, acid, alkali, yeast residues and solid particles
related to brewery, juice, food processing plant etc.

1.2.2 Grits Chamber

Simply the heavy particle in the effluent is settled in grits chamber.

1.2.3 Screen Bar

It aids the settling of the heavy particles. Screen is placed so that no any visual
particles like plastic, rubber, bottle can, etc. are filtered.

1.2.4 Equalization Tank

The effluent is mixed thoroughly with the help of blower. The pH of the equalization
tank must be 9.5±0.5. If the pH is low i.e. 6.5 then caustic soda (100kg) is mixed with the
effluent. The total capacity of equalization tank is 350 Kilo Liter.

1.2.5 Flash Mixture

Flash mixture mixes the two chemicals dosed i.e. alum and polyelectrolyte by the
help of motor. The main purpose of alum dosing is to neutralize water, breakdown of
complex compound, formation of colloid and coagulation of effluent. Polyelectrolyte helps to
make the water basic.
1.2.6 Primary Clarifier
The treated effluent is transferred to primary clarifier. It is the settling tank where
poly electrolyte is attaches the broken compound and helps in settling of the sludge. Primary
clarifier is cylindrical and conical at the bottom. A scrapper is continuously moving which
pushes the heavy, coagulated particles to the bottom. The settled particle is moved to the
sludge bed by pump.

1.2.7 Aeration Tank

The capacity of aeration tank is 1224 Kilo Liter. The aeration is carried out by
vigorous mixing of liquid with air for the bacterial growth that digest the organic matter in
the aerated water.

1.2.8 Secondary Clarifier

The remaining of the treated effluent is transferred to secondary clarifier and settling
of sludge is done by the help of continuous revolving motor. The sludge is sent to filter press
machine where it is pressed and dried with the air which is provided by the blower.
The clear water is then transferred into chlorine tank where it is treated with chlorine.
The treated water is then sent to dual media filter and filtered water is drained to river or
outside of the plant.

1.2.9 Dual Media Filter

Dual media filter is primarily used for the removal of turbidity and suspended solids
as low as 10-20 microns. Dual media filter provide very efficient particle removal under the
conditions of high filtration rate. Inside dual media filter is a layered bed of filter media.
The bed is graded from bottom to top as follows:
Having the filter media graded this way enables the dual media filter to run for long
time before a backwash is necessary. It consists of two main parts i.e. a composite pressure
vessel with multiport valve & graded beds of sand and anthracite.
Internally, the dual media filter is fitted with an inlet distributed and a bottom
collecting system. Externally, the system is fitted with frontal pipe work and isolation valves.
Sand is used to remove the suspended particles and anthracite is used to remove the odor and
color etc. to make water fit for different applications.

2. Specification
The outlet of the ETP must have:

Parameters Limits

pH 6.5 – 8.5
Total Suspended Solids (TSS) <100 mg/L
Dissolved Oxygen (DO) <1 mg/L
 Biological Oxygen Demand (BOD) <30 mg/L
Chemical Oxygen Demand (COD) <250 mg/L
Total Dissolved Solids (TDS) <2100 mg/L
Oil and grease <10 mg/L

3. Testing Performed in ETP

3.1 pH, TDS, Temperature and DO

PH is a measure of how acidic/basic water is. The range goes from 0 to 14, with 7
being neutral. PH of less than 7 indicates acidity, whereas a pH of greater than 7 indicates a
base. The pH of water is a very important measurement concerning water quality.
These parameters are checked with the help of digital meter. Temperature and pH are
checked with the pH meter. Where, TDS (Total Dissolved Solids) and DO (Dissolved
Oxygen) are checked with Multi-meter. The unit for both TDS and DO is mg/L.

PH testing

Take 100mL of sample in beaker

Switch on the pH meter

Dip the probes in sample

Note the pH and temperature (°C)

TDS testing

Take 100mL of sample in beaker

Power on the multi-meter device

Dip TDS probe in the sample

Note the TDS (mg/L)

DO testing

Take 100mL sample in beaker

Power on multi-meter device

 Dip DO probe in the sample and continuously stir until it shows constant reading

Note the DO (mg/L)

3.2 Total Solids (TS)

Total solid refers to matter suspended or dissolved in water or wastewater, and is
related to both specific conductance and turbidity. Total solids (also referred to
as total residue) are the term used for material left in a container after evaporation and drying
of a water sample.

Take crucible and weigh it (W1)

Add 10 mL of inlet sample (V)

Keep it in muffle furnace at 110°C for 2 hours

Take final weight of the dish after evaporating of sample (W2)

Total Solids (mg/L) = (W2 - W1) × 1000000

V

3.3 Total Suspended Solids (TSS)

Total suspended solids (TSS) are the dry-weight of suspended particles that are not
dissolved in a sample of water that can be trapped by a filter. It is the subtraction of total
solids and total dissolved solids.

TSS (mg/L) = TS – TDS

3.4 Mixed Liquor Suspended Solids (MLSS)

Mixed liquor suspended solids (MLSS) is the concentration of suspended solids, in
an aeration tank during the activated sludge process, which occurs during the treatment
of waste water. The units MLSS is primarily measured in milligram per liter (mg/L. Mixed
liquor is a combination of raw or unsettled wastewater or pre-settled wastewater and
activated sludge within an aeration tank. MLSS consists mostly of microorganisms and non-
biodegradable suspended matter.

Dry filter paper

 Weigh filter paper (W1)

Take 100 mL aeration tank sample

Oven dry at 105 – 110°C until it dries completely

Weigh the sample (W2)

MLSS (mg/L) = (W2 – W1) × 1000000

Volume of sample (100mL)

3.5 Mixed Liquor Volatile Suspended Solids (MLVSS)

The portion of the MLSS that is actually eating the incoming food is referred to as the
Mixed Liquor Volatile Suspended Solids (MLVSS). The volatile solids concentration in a
sample of mixed liquor will consist mostly of microorganisms and organic matter. As a
result, the volatile solids concentration of mixed liquor is approximately equal to the amount
of microorganisms in the water and can be used to determine whether there are enough
microorganisms present to purify the water.

Take (W2) sample of MLSS

Weigh crucible and sample (W3)

Heat at 500°C for 15 minutes in muffle furnace

Weigh dried sample and crucible (W4)

MLVSS (mg/L) = (W3 – W4) × 1000000

Volume of sample (100mL)

3.6 Sludge Volume Index (SVI)

Sludge Volume Index (SVI) is used to describe the settling characteristics
of sludge in the aeration tank in Activated Sludge Process. It is defined as the volume (in
mL) occupied by 1 gram of activated sludge after settling the aerated liquid for 30 minutes.

Take 500 mL sample from aeration tank

Put it in 500 mL measuring cylinder

 Let it settle for 30 minutes

Note the settled sludge volume

SVI (mL/g) = Settled sludge volume (%) × 1000

MLSS

3.7 Chemical Oxygen Demand (COD)

The chemical oxygen demand (COD) is an indicative measure of the amount
of oxygen that can be consumed by reactions in a measured solution. It is commonly
expressed in mass of oxygen consumed over volume of solution which in SI units is
milligrams per liter (mg/L). A COD test can be used to easily quantify the amount
of organics in water.

Take 3 mL sample from inlet and outlet

Put it in the COD cuvette which contains solution of Sulfuric acid, Mercury (11), Sulphate
and Potassium dichromate

Observe the reading at spectrophotometer at 605 nm

3.8 Biological Oxygen Demand (BOD)

BOD is a measure of the amount of oxygen required to remove waste organic matter
from water in the process of decomposition by aerobic bacteria. The higher the BOD value
the greater the amount of organic matter or “food” available for oxygen consuming bacteria.

Take 2 round bottom flask i.e. for inlet sample 164mL and for outlet 432mL

Put samples respectively

Now put that sample in BOD bottles (Brown Color)

Add nitrification inhibitor i.e. 3 drops in inlet and 9 drops in outlet

(1 drop/50mL)

Put magnetic stirrer

 Then put the Sodium Hydroxide (NaOH) trap at the top of the bottle

Add 2 tablets of NaOH

Then seal the bottle with pressure sensor device

Now keep it in the BOD incubator for 3 days at 27°C

Note the reading after 3 days

3.9 Oil and Grease

Oil and grease is defined as any material recovered as a substance soluble in the
solvent. Therefore, compounds with similar physical properties will be determined as well
as oil and grease (example: sulfur compounds, organic dyes, chlorophyll).

Take 200 mL of sample from outlet of ETP

Add 3-4 drops of Sulfuric acid to maintain pH of 3-4

Add sample in separating funnel

Pour 10 mL of petroleum ether

Mix it properly

Allow it to rest for 2 minutes

Discard lower layer and put upper layer in the pre-weight beaker (W1)

Put it in the oven at 60 - 70°C for 30 minutes

Weigh final sample (W2)

Oil and Grease (mg/L) = W2 – W1 × 1000000

Volume of sample

4. Documentation
 The records of ETP should be maintained on daily basis. This records contain
information such as pH, TSS, TDS, MLSS, BOD, COD, SVI, MLVSS, DO, caustic used and
sludge outlet. There are several recording documents which are described below:

Sr. File Names Parameters Recorded

No.

1 ETP Inlet Total inlet of effluent in 24 hrs.

It is measured in Kilo Liter (KL).
It is measured by metering device.
2 ETP Discharge Total outlet of treated water from ETP in 24 hrs.
It is measured in KL.
It is measured by metering device.
3 ETP pH Record It records the pH of collection tanks, aeration tanks and
outlet samples.
It is recorded hourly.
4 ETP Record It records the pH, COD, BOD, TSS, TDS and DO of inlet
monitoring and outlet samples.
The MLSS of aeration sample is also recorded in this file.
5 ETP Blower Record The total of blowers in ETP is 5.
Each blower runs in 4hrs interval.
The running time of blowers is recorded in this file.
6 ETP Requisition Slip If any requirements is there in ETP such as caustic soda,
alum, etc. then this slip is signed by Head of Department
(HOD) to issue respective items.
7 Sludge Record Total kg of sludge came out of plant in 24 hrs.
This sludge is packed in sac and send it to third party i.e.
sludge contains hazardous chemical so can’t be discarded
to surrounding environment.

5. Introduction of SIG

SIG is Swiss International Group Company which uses modern technology to produce juices.
It is totally an automatic system. In SIG line most advance heat exchange technology Heat Recovery
System (HRS) is used where juice is sterilized completely. HRS is controlled by SCADA
(Supervisory Control and Data Acquisition) which is operated by an operator. It uses aseptic
technique or environment to fill the juice to prevent contamination from microorganisms or
pathogens. This line is specifically use for the production of Maaza Refresh (150mL).
6. Procedure of SIG Line

Product Inlet

Balance Tank

Beverage Pump

HRS Process
System

Pasteurizer/Heating Coil

Holding Coil

Cooling

Filling Room

Tetra Pack Sleeve Stacking

 Bottom Sealing

De-dusting

Hot Air

Hydrogen Peroxide (H2O2) Dosing

Dry Air

Filling

Steam Injection

Top Sealing

Flap Sealing

Date Code Punch

Straw Applicator

Tray Packer

Tray Formation

Shrink Wrapping
 Pellet Formation

6.1 HRS Process System

HRS process system is the most innovative and advanced corrugated Tube and Shell and
Tube heat exchanger. It is a complete system for aseptic sterilization of processing juice. It
consists of several parts such as:
6.1.1 Product Inlet
The juice prepared in the juice room is transferred to the HRS process system for
sterilization. The juice must have the concentration of 14.30±0.15°Brix.

6.1.2 Balance Tank

The tank undergoes 5 steps Clean In Place (CIP) before transferring the juice. After
that juice is transferred through pasteurizer with the help of pump.

6.1.3 Pasteurizer
The pasteurizer is also known as heating coil. The temperature maintained in
pasteurizer is between 96 - 98°C. In this process, steam at 110°C is injected to heat of the
water which at last heat up the juice i.e. increases the temperature of juice to 96-98°C.
Hereby water loses some temperature and same water is used to cool down the temperature
of juice in regenerative cooling stage.

6.1.4 Holding Coil

It consists of series of coils which holds the pasteurized juice for 5 – 10 seconds. Its
main function is to hold the juice so that microorganisms present in the juice can be killed.
And also to prevent juice from the direct contact between the hot and cold temperature so that
nutritive value do not deteriorate. The length of the holding coil is around 12-13m.

6.1.5 Cooling
It consists of 3 stages which cools down the pasteurized juice to around 25–26°C.
[Link] Regenerative Stage
It cools down the juice temperature from 96°C to 75°C. The medium used to cool
down the temperature of juice is water which was previously used to increase the temperature
of juice in pasteurizer.
[Link] Cooling Stage
Plate Heat Exchanger (PHE) is used to cool down the temperature of juice where
water at 25-30°C is circulated to cools down the juice temperature from 75°C to 45°C.
[Link] Chilling Stage
Another PHE is used to decrease the temperature where water at 6°C is circulated to
down the juice temperature from 45°C to 25°C.

6.2 Filling Room

The ambient temperature is maintained in filling room i.e. 27°C. The capacity of filling
machine is 24000 Packs/Hour.
6.2.1 Tetra Pak Sleeve Stacking
Tetra Pak composed of 6 layers i.e. Polyethylene, Paper board (For strength and
stability), Polyethylene (Adhesive layer), Aluminum Foil (For oxygen, flavor and light
barrier), Polyethylene (Adhesive layer) and Polyethylene. The Tetra Pak sleeves are stacked
in 6 different columns and opened for further processing.

6.2.2 Bottom Sealing

The bottom portion of pack is provided with pressure at specific temperature sealing.

Range Pressure Temperature

(mBar) (°C)

Maximum 3500 350

Average 3000 340
Minimum 2100 330

6.2.3 De-dusting
The vacuum sucker sucks the foreign particles or matters that may be present inside
the package.

6.2.4 Hot Air

The hot air is provided to package to kill the remaining foreign particles.

6.2.5 H2O2
The hot air previously provided also helps to spread hydrogen peroxide in all the
possible direction inside the package. Its main function is to provide the aseptic environment
for the filling of sterilized juice. It acts as sterilizer which kills the left over microorganisms.
The hydrogen peroxide concentration of final product must be <5ppm.

6.2.6 Dry Air

Dry air is provided to maintain the filling environment i.e. cools down the
temperature to ambient temperature.
6.2.7 Filling
The filling of juice is done in 2 steps i.e. to prevent the foaming. The total amount of
juice filled in the package is 149mL for 150mL Refresh Maaza. The juice is filled at room
temperature.
First Filling: 40%
Second Filling: 60%

6.2.8 Steam Injection

Steam is injected less to remove the atmospheric air and to make the head-space
sterilize.

6.2.9 Top Sealing

The top portion of pack is provided with pressure at specific temperature for sealing.

Range Pressure Temperature

(mBar) (°C)

Maximum 2900 441

Average 2700 431
Minimum 2500 421

6.2.10 Flap Sealing

The top side portion of pack is sealed at 120-125°C.

6.3 Date Code Punch

The date code is punched at the top surface of the package. It consists of Price of product,
Date, Batch and Time of production. The size of date code is between 2.5-4mm.

6.4 Straw Applicator

Straw is applied in package surface by automatic straw applicator machine. Glue ADV 9275
is used to paste the straw. First glue is heated at 160-170°C then 2 nozzles apply glue in two
points (one in upper side and next one in bottom side). After that within a second straw is applied
in the package surface.
This machine automatically removes the defaults package with the help of sensor at the end.
Also it shows the images of straw application and data.

6.5 Tray Packer

Products are passed through this line when it needs to pack 3×4 (12 packets). First, products
are aligned in 3 rows then wrap with LDPE plastic film and shrink wrap at 140°C.

6.6 Tray Formation

 Products are passed through this line and packed in 4×10 (40 packets). First, products are
aligned in 4 rows then packed in cartoon. The upper portion of cartoon is kept open which are
wrapped with LDPE plastic film at next step.

6.7 Shrink Wrapping

In this both 3×4 and 4×10 packs are shrink wrapped. But 3×4 packs are again align in 3×1
then shrink wrapping is done with LDPE and 4×10 packs are directly shrink wrapped at 180-
200°C.

6.8 Pellet Formation

Lastly packs are kept in the pallets and stored in the warehouse. Products are sent outside in
market according to market demand.

7. Testing in SIG Line

7.1 Degree Brix
Degrees Brix 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. It is measured by Refractometer.

Take sample from the running line (1 hour interval)

Switch on the Refractometer

Rinse sampling point with water

Again rinse with sample and then keep sample for reading

Observe the result

7.2 H2O2
Hydrogen Peroxide is used as sterilizing agent. Its concentration should be less than 0.5
mg/L. It is checked with Peroxide strips.

Take sample in beaker

Dip 15 sec strips in sample

Check the color and observe the reading

 (Must be < 0.5 mg/L)

7.3 Gross Weight

Gross weight is the total weight of the juice and packaging material.

Take 5 packets

Switch on the weighing balance

Weigh it individually

Note the reading

7.4 Net Content

Net content is the amount of juice present in the product. It is calculated with the help of
packaging weight, gross weight and apparent density of juice.

Net Content = Gross Weight – Empty package weight

Apparent density of juice

Note: Empty package weight: 7.4g

Apparent Density of Juice: 1.05517 g/mL

7.5 Acidity
It is made with mango juice so acid present is citric acid. It is checked with the help of
titration and range should be 0.230.

Take 20g of sample in a beaker

Add 20mL distilled water

Mix it properly

Put magnet in beaker and keep it in the magnetic stirrer

Switch on the magnetic stirrer

Place the pH meter probe in the beaker

 Titrate it with 0.1N NaOH

Stop the titration when pH reaches to 8.2

Note down the reading

Acidity = Titration value × 6.404 × 0.1 × 100

Weight of the sample

8. Conclusion
I have learnt that how waste water coming from the plant is treated and drained out to the
outside environment. I have gained experience in different testing performed in ETP such as pH,
DO, TDS, TSS, MLSS, MLVSS, SVI, COD and BOD. Also I have known the limits of outlet
sample that is drained to the surrounding. I observed that more than 150 Kilo Liter of waste water
comes to the ETP from plant in a single day which is processed and finally drained the same
amount of water out to the surrounding.