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SUBMITTED TO SUBMITTED BY

Mr. ATUL JOSHI ASHISH MISHRA


QUALITY MANAGER CHEMICAL ENG(4
th
sem)
PEPSICO,PANIPAT ROLL NO 11001005008
DCRUST,MURTHAL



INTRODUCTION
About PepsiCo
PepsiCo is a global food and beverage leader with net revenues of more than $65
billion and a product portfolio that includes 22 brands that generate more than $1
billion each in annual retail sales. Our main businesses Quaker, Tropicana,
Gatorade, Frito-Lay and Pepsi-Cola make hundreds of enjoyable foods and
beverages that are loved throughout the world. PepsiCos people are united by
our unique commitment to sustainable growth by investing in a healthier future
for people and our planet, which we believe also means a more successful future
for PepsiCo. We call this commitment Performance with Purpose: PepsiCos
promise to provide a wide range of foods and beverages from treats to healthy
eats; to find innovative ways to minimize our impact on the environment by
conserving energy and water and reducing packaging volume; to provide a great
workplace for our associates; and to respect, support and invest in the local
communities where we operate.
PepsiCo India Region: Leadership through Performance with
Purpose
PepsiCo entered India in 1989 and in a short period, has grown into one of the
largest and fastest growing food and beverage businesses in the country. PepsiCo
Indias growth has been guided by PepsiCos global vision of Performance with
Purpose. This means that while businesses maximize shareholder value, they
have a responsibility to all the stakeholders, including the communities in which
they operate, the consumers they serve and the environment whose resources
they use.
One of the largest food and beverage businesses in India: PepsiCo Indias diverse
portfolio includes iconic brands like Pepsi, Lays, Kurkure, Tropicana 100%,
Gatorade and Quaker. PepsiCo India has not only grown to become one of the
countrys largest food and beverage businesses but has also become a powerful
and consistent driver of PepsiCos global growth. Within 2 decades, the company
has been able to organically grow eight INR 1000 crore plus brands in India, which
are household names trusted across the country.
A growing portfolio of enjoyable and wholesome snacks and beverages
PepsiCos portfolio reflects its commitment to nourish consumers with a diverse
range of fun and healthier products. The portfolio includes several healthier treats
like Quaker Oats, Tropicana juices, multigrain Aliva range which is baked,

rehydrator Gatorade, Tata Water plus, Lays baked range and Lehar Iron Chusti
fortified extruded snack with superior quality iron & B-vitamins.
Model partnership with over 24,000 farmers: PepsiCo has pioneered and
established a model of partnership with farmers and now works with over 24,000
happy farmers across nine states. More than 45 percent of these are small and
marginal farmers with a land holding of one acre or less. PepsiCo provides 360-
degree support to the farmer through assured buy back of their produce at pre-
agreed prices, quality seeds, extension services, disease control packages, bank
loans, weather insurance, and the latest technological practices.
Global leader in water conservation: In 2009, PepsiCo India achieved a significant
milestone, by becoming the first business to achieve Positive Water Balance in
the beverage world, a fact verified by Deloitte Touch Tohmatsu India Pvt. Ltd
and has been Water Positive since then. The company made this possible through
innovative irrigation practices like direct seeding, water recharging, and by
reducing the consumption of water in its manufacturing facilities. PepsiCo is
lauded for its efforts for water conservation.
Care for the environment: PepsiCo is focused on reducing its carbon footprint.
Nearly 30 percent of its energy is today generated from renewable sources such
as rice husk boilers and wind turbines. Initiatives such as reduction of use of
chemicals, eco-friendly packaging initiatives and efficient waste management help
reduce load on the environment. PepsiCo Indias award-winning Waste to Wealth
recycling program reaches 465,000 families.
Exemplary employment practices: PepsiCo India presently employs 6,400 people
and provides indirect employment to almost 2,00,000 people. The company
believes in providing employment and growth opportunities to local talent. Its
College of Leadership, ensures early identification of talent, and employees
focused development through critical experiences. The company emphasizes
Winning with Diversity and Inclusion and has a significant number of women in
the leadership team in India. PepsiCo India has won the prestigious Hellen Keller
Award from the National Centre for Promotion of Employment for Disabled
People (NCPEDP).
As one of the largest food and beverage businesses in India, PepsiCo India offers
consumers a wide-ranging portfolio of enjoyable and wholesome products.
Key Facts
Indian headquarters: Gurgaon, Haryana
Employment opportunities: Presently employs 6400 people and provides indirect
employment to almost 200,000 people

Facilities:
38 bottling plants
3 food plants
Commitment to Sustainable Growth
PepsiCo Indias employees are driven by the companys global commitment to
sustainable growth, Performance with Purpose (PWP), which works on four
planks: replenishing water, partnering with farmers, converting waste to wealth
and nurturing healthy kids. In 2009, PepsiCo India achieved a significant
milestone, by becoming the first business in the PepsiCo global system to achieve
Positive Water Balance (PWB), a fact validated by Deloitte Consulting.
Brand Facts
PepsiCo nourishes consumers with a range of products from tasty treats to
healthy eats that deliver enjoyment, nutrition, convenience as well as
affordability. Our brands stand for quality and are respected household names.
Beverages
PepsiCo Indias expansive beverage portfolio includes:
Iconic refreshment beverages: Pepsi, 7UP, Nimbooz, Mirinda, Mountain Dew,
Low-calorie options: Diet Pepsi
Hydrating and nutritional beverages: Aquafina (drinking water), Gatorade
(isotonic sports drink)
Fruit juices: Tropicana100%
Juice-based drinks: Tropicana Nectars, Tropicana Twister, Slice
Local brands: Lehar Evervess Soda, Dukes Lemonade, Mangola
Foods
PepsiCos food division, Frito-Lay, is the leader in the branded salty snack market.
All Frito-Lay products are free of trans-fat and MSG. Frito-Lays core products are:
Lay's potato chips
Kurkure
Kurkure Desi Beats
Uncle Chipps
Cheetos extruded snacks (including Cheetos Whoosh made of whole grain and
vegetables)
Other products:
Quaker Oats (high-fibre breakfast cereal)

Traditional snacks under the Kurkure and Lehar brands
Low fat and roasted snack options

WATER TREATMENT PLANT
WATER
By volume water represents most of a Pepsi:
90% of the regular carbonated beverages
99% of the diet carbonated beverages
100% of the bottled water products
Water is the most strictly controlled ingredient from a regulatory
perspective Must be potable (safe) and palatable (good testing)
Water can have a direct impact on the sensory profile and stability of our
products
Process aid Rinsing,cleaning,sanitation,lubrication,warming,boiler
operations,cooling
1. Water treatment Process
Raw Water from bore well(Total alkalinity =290-300ppm&Total hardness
=240-250ppm)
Stored in raw water storage tank
6 to 8 ppm chlorine is added to kill micro-organism
Then water is transferred to coagulation tank (lime,ferrous sulphate and
chlorine solution is added).
Pest storage tank (Just for storage)
Intermediate tank
Sand filter, carbon filters
Activated carbon filter
Micron cartridge
UV light

Treated water obtain (Total alkalinity<50ppm & total hardness <100 ppm)
2. Soft Water
Raw Water from bore well(Total alkalinity =290-300ppm&Total hardness
=240-250ppm)
Stored in raw water storage tank
6 to 8 ppm chlorine is added to kill micro-organism
Carbon filter
Additon of softners
Rinsing
Soft water(0-10 ppm)
Soft water storage tank
3. QUALITY TESTING OF WATER
1. Experiment :Determination of Alkalinity (2P-M & total) value of water
Apparatus:-
1. Automatic burette,self zeroing ,50 ml
2. Two 250 ml glass beakers
3. One 100 ml graduate
4. One magnetic stir bar and stir plate
Reagents /Chemicals
1. N/50 sulfuric acid(H2SO4)
2. P indicator (Phenolphthalein)
3. M indicator (methyl purple)
4. T solution (sodium thiosulphate)
5. Distilled or deionizer water
Test Procedure:-
1. Take 100 ml water sample in a clean and dry conical flask
2. Add 2-3 drops of 10% sodium thiosulphate solution in Water.

3. Add 2-3 drops of phenolphthalein indicator ,if color of water sample is pink
proceed to next step otherwise proceed to step-2
4. Titrate with N/50 H2SO4 solution till pink color disappears .
5. Note down the reading (P).
6. Add 2-3 drops of Methyl orange indicator in the same water sample color
of the solution dark green.
7. Continue adding acid solution to water till the color changes from dark
green to Solmon pink.
P-Phenolphthalein Alkalinity M-Total Alkalinity
2.Experiment:-Determination of hardness(calcium &total) value of the water
Apparatus: Conical flask
Reagent/chemicals
1. Ammonia Buffer solution
2. Hardness tablets
3. 0.02N EDTA solution
Procedure:-
1. Take 100ml water sample
2. Add 4 ml of ammonia buffer solution.
3. Add 1 total hardness tablet.
4. Pink color appears.
5. Titrate with 0.02NEDTA solution till color of the solution changes to sky
blue.
6. Note down reading and calculate hardness
Total Hardness =Titer value *10
3.Experiment:- Determination of Free chlorine of the water
Apparatus:-
1.sample tube
Reagent/chemicals

1. Cl
2
reagent
Procedure:-
1. Take 6 ml sample in tube.
2. Add I micro spoon of Cl
2
-l reagent
3. Take it for one minute.
4. After one minute match the color on slide and calculate free chlorine.
EFFLUENT TREATMENT PLANT
Introduction
Water is one of the most important elements on earth. Every living being needs
water for its survival .Without water ,plants ,animals ,microbes-everything will
perish. Population growth coupled with industrialization and urbanization has
resulted in an increasing demand for water thus leading to water crises and
serious consequences on the environment .The requirement of fresh water for
industrial use will increase from 30 BCM(billion cubic meter) to 120 BCM by
2025AD .A rapid industrialization has lead to the industrial effluents and sewage
,resulting in water pollution which leads to water crisis in India and all over the
World.
Waste water also known as sewage, originates from household wastes,human
and animal wastes, industrial wastewaters, strom runoff, and ground infiltration.
Wastewater ,basically is the flow of used water from community .The nature of
wastewater includes physical,chemical,biological characteristics which depend on
the water usage in the community , the industrial and commercial contributions,
weather and infiltration /inflow.It is 99.4 percent water by weight (water
pollution control federation 1980). The remaining 0.06 % is material dissolved or
suspended in the water .The dissolved and suspended solids in wastewater
contain organic and inorganic material .Organic matter may include
carbohydrates, fats,oils, grease,surfactants,proteins,pesticides and agricultural
chemicals, volatile organic compounds and other toxic chemicals .Inorganic
matter may cover heavy metals ,nutrients (nitrogens and phosphorus), ph,
alkalinity , chlorides ,sulfur,and other inorganic pollutants.


Effluent from Plant

Equalization Tank

UP flow tank

Aeration tank

Clarifier

Final treatment effluent plant

Sand filter


To Disposal
PROJECT ON WATER RECOVERY
1. Design Basis
The plant has been designed for the treatment of wastewater from the
bottle rinsing operation of the bottle washer and CIP water. The plant has
been designed for the following operating conditions:
1. Feed Water Analysis
Temperature : 50 degree C
Caustic alkalinity : 1000 ppm maximum
Sludge drying Bed

2. Treated Water Analysis
Color :colourless
Odor : odorless
Ph :7.0 to8.0
Hardness :<10
Free chlorine :Nil
Turbidity :<5 NTU
Total Count :<25/ml
Coliform :0/100 ml

3. Capacities
Treatment :20 m^3/hr

2. TECHNOLOGY DESCRIPTION
1. Bottle Washer Rinse Water
The water from the prefinal rinse is being collected in the collection
sump from where it is taken for treatment & recycles. The vaccum pump
cooling water &CIP final rinse water is also proposed to be brought into
the collection sump.
The prefinal rinse water has 4 major component to be treated before it
can be reused for bottle washer rinsing again.
a. Temperature: The water exits the prefinal rinse at about 45
0
C and
this has to be cooled to 35
0
C.
b. Turbidity: The water is turbid from the washing operation and the
treatment process must be removed before possible reuse.
c. Caustic alkalinity: The water has caustic alkalinity of the order of
1000ppm &this must be removed before possible reuse.
d. Microbial contamination: The water from the washing operation
is rich in microbe contamination & sterilization & sanitation must
from an essential part of treatment protocol.
In order to achieve all the above objectives the water is first
passed though a plate heat exchange with the necessary
secondary cooling circuit. This brings the water temperature
down to 35
0
C from the initial 45
0
C.

The cooled water then is dosed with hypochlorite for
chlorination & ferrous sulphate floc formation . The following
reaction takes place
Feso
4
+ 2 NaOH Fe(OH)
2
Na
2
SO
4

4 Fe(OH)
2
+ Ca(OCl)
2
+ 2H
2
O 4 Fe(OH)
3
+ CaCl
2
A static mixer ensures through mixing of the chemicals & water
before entering a settling tank. The main objectives of the
settling tank is flocculation and settling of turbidity.
The floc formed helps in settling of turbidity & the insoluble
reaction products of the settling tank and clear water goes out of
the overflow into the holding tank.
From the holding tank the water is pumped through a pressure
sand filter for removal of suspended impurities .The filtered
water than enters an activated carbon filter for dechlorination &
removal of any trace organics.
The dechlorinated water is passed through a bed of weak acid
cation exchange resin operating on the hydrogen cycle. As the
water passes through the bed the cations attached to the
hydroxides, carbonates & bicarbonates are exchanged for
hydrogen ions from the resin thus dealkalising the water.
After a certain amount of cations are exchanged the free sites in
the cation bed get exhausted & the resin bed has to be
regenerated with hydrochloric acid .
Carbonic acid is one of the products which will pass out of the
cation exchanger along with trace strong acids. The water is
sprayed into a degassing tower where in counter flow of air strips
the water free of dissolved carbon di oxide.
In order to bring the ph upto 6.5 & above a neutralization line is
provided by drawing part of the caustic powder prior to
dealkalising & blending with the dealkalised water.
The water is thus deausticised.The decausticised water is
rechlorinated & stored in soft water tank.

CAUSTIC WATER COLLECTION , TRANSFER & COLLING
The water is tapped out from the prefinal rinse outlet into the collection tank
which is provided with a bar screen to prevent larger particles from entering .A
monoboloc pump is provided to transfer the caustic water for further processing.
1. Equipment details
M.O.C :MS epoxy
Bar Screen arrangement : Provided
Pump type :Centrifugal, monobolic
Pump capacity :10000 LPH

The water is at temperature of around 45-50
0
C. In order cool it down to
35
o
C it is passed through a plate heat exchanger with secondary cooling
water circuit .A cooling tower is provided for the secondary cooling water
circuit.
2. Chemical,Feeding ,Settling & Transfer
In order to eliminate the microbial ,activity the water is dosed with
hydrochloric solution to provide the necessary chlorine.The chlorine is also
required for the oxidation of ferrous ion to its trivalent state.
3. Solution Preparation
a) In case sodium hypochlorite is being used the standard 9-11%
solution available in the market should be used without further
dilution.
b) In case of bleaching powder the solution should be prepared as
follows:
1. Take 20 kg bleaching powder and add 200 liters of water & make a
uniform solution.
2. Allow the solution to settle for 1-2 hours so that the undissolved matter
will settle to the bottom & the clear supernatant solution is available for
dosage.
4. Dosing

Start the dosing pump & adjust the flow rate such that free chlorine in the
water is maintained between 5 & 6ppm.
In order to aid the settling of the turbidity a flocculent has to be used.
The flocculent to be used in this case is ferrous sulphate.
5.Equipment Details for Ferrous Sulphate Dosing
Type Electronic,pulsating,diaphragm
Capacity 0-6 LPH at 3.5 kg/cm
2

Pump wetted parts Polypropylene
Solution holding tank capacity 200 ltr
Solution holding tank M.O.C HDPE

6.Solution Preparation
Take 12 kg of ferrous sulphate accurately weighed in a plastic tank.Add 200 liters
of water & stir manually .Allow the insoluble part to settle down and transfer the
supernatant liquid to the holding tank.
7.Dosing
Open the outlet valve of the solution tank & start the dosing pumps.
Measure the flow rate at the outlet of the delivery tubes & adjust to
required levels.
8.Caution
Pumps are designed for handling clear liquid. Abrasive should not be
entrained.Though suction side strainers are provided care should be taken at the
solution preparation stage.
The water along with the chemicals passes through a static mixer for through
mixing & then enters the central chute of a settling tank.
Equipment Details
Settling Tank

Type Vertical,cylindrical with conical bottom
and top cover
Diameter 3200 mm
Height on straight 4200 mm
Internal surface coating Epoxy painted
External surface coating Red oxide printer

Holding Tank
Diameter 1500 mm
Height on straight 3000mm
Type Vertical,cylindrical with top cover
Internal surface coating Epoxy painted

Transfer Pumps
M.O.C Cast iron
Capacity 20 m
3
/hr at 2.5 kg/cm
2
Operation & Maintenance
The floc formed in the relation between ferrous sulphate & solution hydroxide
acts as a nucleus for coagulating other suspended impurities & settling them
down. The dosage has to be adjusted on the basis of the clarity but a starting
point of 15ppm can be used for ferrous sulphate .The hypochlorite dosage should
be adjusted such that the free chlorine at outlet of pressure sand filter is 5-6ppm.
The floc level at the bottom tap should be monitored & whenever it exceeds 30%
the floc should be drained.
The following must be rigidly controlled:
1) Raw water flow rate.
2) Chemical purities.
3) Chemical weighing ,water addition & preparation
4) Chemical addition rates

SLUDGE CONTROL
An active and dynamic bed of floc must blanket the rising water in order to
achieve efficient clarification. At the same time excessive floc could result in floc
carry over and fixing of reagents before completion of reactions resulting in
erratic chemical control. An active bed of about a meter depth with a floc content
of 12 to 20 percent when settled for 30 minutes has been found to be most
effective. When floc content in the bed exceeds 30% the settled sludge should be
bled for a pre established duration.
PRESSURE SAND FILTER
The settled & chlorinated water is collected in the holding tank. This water has a
certain amount of suspended matter .In order to remove this suspended matter ,
a pressure sand filter has been provided.
The pressure sand filter is designed for a low forward velocity to ensure a high
quality of outlet filtered water. The sand filter is of mild steel epoxy painted
construction .The water enters at the top & percolates down through the bed
.The suspended particles are trapped in the bed and filtered water exits the
vessel.
Media details:
Type Depth
-1 pebbles 133 mm
-1/2 pebbles 100 mm
4-8 Mesh stylex 133 mm
16-32 Mesh sand 650 mm

Operation:
The treated water from the intermediate storage tank is pumped to the top of
filter 7 is distributed through the inverted bell mouth. As the water percolates
through the filter media the suspensions are retained in the media and clear
water passes out through the outlet.

At the sample point on the outlet the water must have the following
characteristics
Free chlorine 6-8 ppm
Appearance Clear

ACTIVATED CARBON FILTER
The filtered and chlorinated water at the outlet of the PSF may contain some
trace organics .In order to remove this organics and dechlorinate the water ,an
activated carbon filter has been provided.
The activated carbon filter is designed for a low forward velocity to ensure a high
quality of outlet water.The activated carbon filter is of mild steel epoxy painted
construction. The water enters at the top and percolates down through the bed.
The trace organic matter and free chlorine is adsorbed on the carbon surfaces
thus dechlorinated the water and making it free of trace organics.
Equipment details:
Type Vertical
Diameter 1400 mm
Height on straight 2750 mm
Distributed system Inverted bell mouth
Free Board 35% of carbon bed
Media details:
Type Depth Qty
4-8 mesh stylex 200 mm 11 cft
Activated carbon 1500 mm 1100 kg

Operation
The filtered water from the sand filter is directed to the top of the carbon purifier
and distributed through the inverted bell mouth. As the water passes downward

through the bed of carbon the free chlorine and organics are removed from the
water and purified water flows out of the outlet.
Monitoring
It is the most important that chlorine never breaks through to the treated water.
In order to ensure this the following additional features are incorporated in the
system.
CHLORINE BREAK HOLDER
This is installed in the bed 200mm above the bottom of the bed with a sampling
same should be nil. As the bed gets exhausted one days traces of chlorine will
appear in the water through this sampling cock but will still be nil at the outlet
sampling point. The unit need not be stopped but the operator is warned that the
carbon bed is nearing complete exhaustion and he should get the replacement
must be carried out at the first available opportunity.
SANITIZATION
Steam (not grater than 110
0
C)is introduced into the vessel from the bottom at 0.3
kg to 0.5 kg/cm
2
after draining the vessel to the chlorine header level .Higher
temperature or pressure must not be used as it may damage the carbon. As the
body and carbon heats up it will be indicated on the temperature gauge. Achieve
a temperature of 90
o
C to 95
0
C and hold for 1 hour.
After holding for 1 hour stop steam supply and allow natural cooling to 60
o
C.
Maintenance
Once a year the filter should be emptied and inside paint renewed.
WEAK ACID CATION EXCHANGER
The dechlorinated water is directed to the top of a weak acid cation bed .As the
water passes through the bed the cations attached to the hydroxides ,carbonates

and bicarbonates are exchanged for hydrogen ions from the resin.The water thus
gets dealkalised.
Equipment Details
Type Vertical
Vertical 1800 mm
Height on straight 3000 mm
Distribution system Inverted bell mouth
Resin type Weak acid cation
Resin volume 2400 liters
Regenerant Hydrochloric acid
Regeneration 500 liters as 30% HCl
Acid tank capacity 1000 liters
Acid tank M.O.C HDPE
Acid injection By hydraulic ejector

Operation
Open the cation inlet valve & the air release valve.
Once all the air has been expelled close the air release valve & open the
rinse outlet valve.
Check the ph and p- alkalinity.
If ph is less than 8 and p-alkalinity is nil close the rinse valve and take the
water into the degassing system after adjusting the blending valve suitably
if required .Ensure degasser blower is on.
Regeneration and Backwas
Once the ph at outlet of weak acid cation exchanger exceeds 8 the cation bed is
exhausted and needs to be regenerated as follows:
Take 500 liters of technical grade HCL (30 % HCL) in the acid tank.
Open backwash inlet valve and backwash outlet valve and backwash for 10
minutes at a flow rate of 15000 LPH.
Close backwash inlet valve and backwash outlet valve.

Open the power water valve and the cation rinse outlet valve and throttle
the power water valve keeping the rinse outlet valve fully open.
Open the acid suction valve fully and adjust the power water valve such
that the entire acid is injected in 25-30 minutes.
Once all the acid is injected close the acid suction valve and continue to
rinse for 30 minutes.
Close the power water valve and open the cation inlet valve and rinse at
the service flow rate after expelling air through the air release valve.
Rinse till ph is more than 3.5.
The unit is now ready for its next service cycle.
Sanitization
The exchanger can be sanitized by using formaldehyde as
Make a 1 % strong solution of formaldehyde sufficient to submerge the entire
resin volume i.e. 1500 liters. Add the above into the vessel & leave it overnight
.Rinse out the formaldehyde and double regenerate.
Degassing system
The dealkalised water at outlet of the weak acid cation exchanger contains
carbonic acid due to the replacement of cation attached to bicarbonate
alkalinity.This carbonic acid is unstable and the carbon dioxide is easily stripped in
a degassing tower.
In the degassing tower the water is sprayed from the top into a packed tower
where in the water drops are further broken into smaller droplets. A counter flow
of the air strips the water free of the dissolved carbon dioxide.
Equipment Details
Type Packed tower
Diameter 800 mm
Height on straight 3000 mm
Distribution system Perforated spray header
Packing media Pall rings

No of pall ring 14000
Air supply Centrifugal blower
Blower 600 m^3/hr

Rechlorination & Transfer
In order to eliminate the microbial activity the water is dosed with hypochlorite
solution to provide the necessary chlorine.
Equipment Details For Hypochlorite Dosing
Type Electronic ,pulsating Diaphragm
Pump wetted parts Polypropylene
Solution holding tank capacity 200 liters

Solution preparation
a) In case sodium hypochlorite is being used the standard 9-11% solution
available in the markets should be used without further dilution.
b) In case of bleaching powder the solution should be prepared as follows:
1) Take 20 kg bleaching powder & add 200 liters of water and make a
uniform solution.
2) Allow the solution to settle for 1-2 hrs so that the undissolved matter
will settle to the bottom and the clear supernatant solution is
available for dosage.
Dosing
Start the dosing pump and adjust the flow rate such that the free chlorine
in the water is maintained between 5 & 6 ppm.
For detailed operation and maintenance procedure please refer to the
attached pages on metering pump.
STEAM SANITISATION PROCEDURE


1. In Activated Carbon filter
Frequency : once a week
a) Close water outlet valve and fill treated water in the ACF upto a level
of inches above the carbon charge surface.
b) Close all the valves and release steam through the steam inlet valve
at the bottom of ACF.
c) Continue steam till the inside pressure shows 15psi.Take a sample of
water from air vent or backwash pipe and check temperature .It
should be above 90
0
C
d) Is the temperature OK ?
e) If no, continue steaming
f) If yes, close steam inlet valve and hold for 30 minutes.
g) After 30 minutes ,release the steam pressure completely
h) Allow the water to cool to 50
0
.Check temperature of a small water
sample
i) Is the temperature between 50
0
-60
0
C
j) If not continue cooling
k) If yes ,backwash the ACF as per the standard backwash procedure
l) Rinse and cool down the ACF to ambient
2. In Sand Filter
Frequency :once in 3 month
a) Backwashes the sand filter and close all the valves
b) Open bottom drain valve and drain enough water so that the
manhole cover can be removed
c) Remove manhole and continue to drain till water level is 100 mm
below the top of the manhole cover.
d) Pour adequate chlorine solution into the water above the sand to
give 100 ppm chlorine solution
e) Add water and rinse level upto the manhole opening, mix thoroughly
f) Open drain valve and drain solution till water level `15 mm above the
sand level.
g) Check chlorine solution for the strength
h) Is it 100 ppm?

i) If no, drain and repeat procedure from step 1
j) If yes ,hold for 30 minutes contact time
k) Replace manhole cover and open bottom drain valve
l) Flush with treated water till the chlorine residue is down to 6-8 ppm
3. In Cation Exchanger
Frequency : Once in a month
a) Empty out the acid measuring tank and clean the same thoroughly
with treated water
b) Prepare a 2% solution of formaldehyde in the cleaned salt mixing
tank.
c) Before charging the formaldehyde solution to the cation exchanger,
backwash and rinse cation exchanger with treated water.
d) Charge formaldehyde solution to the cation exchanger in the same
way as salt solution is charged for regeneration of the cation
exchanger
e) Hold formaldehyde solution in the cation exchanger overnight for
maximum contact time of the solution with the cation exchanger
resin
f) Before starting production next day , backwash and rinse the cation
exchange thoroughly to remove any traces of formaldehyde
g) Check presence of formaldehyde by odour
BACKWASH PROCEDURE (SAND FILTER AND CARBON FILTER)
Frequency : Daily at the production
a) Close all valves completely except the backwash water inlet and
drain valve
b) Adjust the backwash flow rate slowly(sand filter 5 m
3
/hr and
carbon filter 2.5 m
3
/hr)
c) Continue backwasing for 15 minutes
d) Check the water at the drain valve
e) Is it clean ?
f) If no , continue backwashing till it is clear

g) If yes , close backwash valves and open water inlet and outlet
valves. Continue rinsing with treated water till it is clean. Keep the
vent valve open to allow entrapped air to escape.
h) After backwash fill underbed of the ACF with 6-8 ppm chlorine
water from backwash inlet valve.
i) Leave the chlorine water in the underbed of ACF till the next
production run
j) Before next production run ,rinse the ACF with water from
backwashed sand filter
k) Check for clarify and chlorine carry over
l) Is it ok ?
m) If yes ,start production ands keep record
n) If no go to step 11


CONCLUSION
This one month training in Pepsico ,panipat was a memorable experience .It
provides an practical exposure to the water treatment plant. This help me to
learn to produce a product of superior quality .It gave me an chance to
understand the functioning of a large beverages industry.
This training will help me to gain confidence and opportunity to rectify some
un known mistakes and develop industrial professionalism.

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