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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