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REPORT ON BOTTLE CLEANING PLANT
Preprint · February 2021
DOI: 10.13140/RG.2.2.10200.01282
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Sivasankaran Panneerselvam
Mankula Vinayagar Institute of Technology
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REPORT ON BOTTLE CLEANING PLANT
INTRODUCTION
The demand for the hot and cold beverages is increasing day by day due to the increasing
population. But the production to satisfy the need is very difficult and also the production of
the new containers for those beverages is also costlier to produce. In order to equalize the
demand and the production of the containers the recycling of the older one is used. And also
due to the ban of the plastics and for some reasons the usage for the plastics bottles are also
reduced. Then eventually the need of the recycling of the glass bottles is become mandatory.
There are many small scale industries are working based on the recycling of the glass bottles.
But due to the finance status and the manpower, infrastructure the production does not meet
the requirement and also the process is slower when comparatively. The below report deals
with the problems encountered, suggestions and ideas to improve the production.
PROCESS CARRIED OUT
The used bottles from the various sources such as cold drink shops and the scrap dealers
are collected and stored in the storage space. Then the bottles are soaked for more than 3
hours in the soaking tub, which contains 1200 liters of hard water (normal bore water along
with the minerals and dust), 0.5kg of caustic soda and few drops of soap oil. All these
substance along with the old glass bottles of 800 in numbers are kept at rest for the soaking
purpose. After 3 hours 3 labors each for the soaking tub started cleaning the bottles. The
cleaning starts from removing the cap ring at the neck portion followed by removing the
wrappers present around the bottles and finally cleaned the dust and dirt strains present inside
the bottles. All the above mentioned process are carried out with the bare hands and with the
dirt removing sponges. After passing the cleaning process finally the bottles are dipped in the
HCL solution. The cleaned bottles are placed 25 numbers in each crates and transferred to the
beverages filling industries.
THE FACTORS TO BE CONCENTRATED
1. The time should be reduced in the soaking process
2. The automated process instead of the traditional
3. The reduction of the labors or increase the production
THE PRESENT LAYOUT OF THE INDUSTRY
LITERATURE REVIEW
Anna Marie M. Hufemia [1] states The feasibility of recovering caustic soda from bottle
washers of a soft drink plant was investigated at pilot-scale using microfiltration (MF) and
nanofiltration (NF). This study revealed that the MF/NF system can purify the caustic soda to
a certain extent and can bereused back to the bottle washing units. Within the studied
pressure ranges, the optimum applied pressure was determined as 101 kPa for MF, and 1,414
kPa for NF with corresponding permeate fluxes of 235 and 15 L/m2-h respectively. Based on
these figures, a large-scale installation for the Thai Pure Drinks Ltd., Pathumthani plant was
designed and a financial analysis was conducted for the system. The MF/NF system using
MEMCOR hollow fiber membranes and MPS-34 (MWCO=300) gave a payback period of
seven years and an IRR of13.7%, rendering the system not financially feasible.
An overall water balance was drawn to find alternatives for water purification and
reuse in the plant that would lead to reduction of raw water consumption and liquid discharge
into the river. It was found that reuse of micro filtered wastewater treatment plant effluent can
reduce groundwater input by 40% and liquid discharged to the receiving water by 65.5%.
Two proposed options for reclaiming bottle washing rinse water are treatment by reverse
osmosis(RO) or purification by ion-exchange (IE). Based on theoretical considerations, an
MF/Ro system will recover both pure water and concentrated caustic in the process. On the
other hand, IE will recover water fit for reuse in the bottle washers. The two conceptual
designs have a payback period of 3.2 and 3.4 years respectively, while the internal rate of
return are31.3% and 30.5%.
Ankur G. Gajjar [2] postulates The conventional bottle washer machines are suitable only
for medium scale and large scale beverage industry due to their high bottle washing capacity
and mechanical and control complexity. This paper proposes the design and automation of
the economical bottle washer machine for the small scale beverage industry without
compromising its control capabilities. The importance and requirement of the bottle washer
machine in the beverage industry has been discussed. The design of the proposed bottle
washer machine for RGBs(Returnable Glass Bottles) has been created in the Cero software.
The different treatment zones and working of the bottle washer machine has been discussed.
The bottle washer machine has been automatized using the Siemens S7-317-2-PN/DP
PLC(Programmable Logic Controller) and programmed using aladder diagram in the
SIMATIC Manager. The level control for different treatment zones is achieved by means of
limit switches and temperature control for different treatment zones is achieved by using
Pt1000 RTD, SSR (Solid State Relay) and heater. The different control schemes for the
temperature control has been discussed, implemented and compared. The results show that
the PID temperature control is the most effective control scheme for the temperature control
of the different treatment zones. The implementation of the PID temperature control and
auto-tuning of the sample process has been shown. The holistic control of the bottle washer
machine also has been discussed and assessed.
CURRENTLY AVAILABLE MARKET EQUIPMENTS
1. BOTTLE WASHERS FOR LOW OUTPUTS (return washers)
2. BOTTLE WASHERS FOR MEDIUM OUTPUTS (return washers)
3. BOTTLE WASHERS FOR HIGH OUTPUTS (return washers)
IDEAS PROPOSED
TO REDUCE THE PROCESS TIME
The soaking of the used glass bottles are put into the tub and half kg of caustic soda is mixed
along with the water and limited amount of soap oil is added to the mixture to enhance the
process. The whole process takes 2.30 to 3 hours to complete. But after introduction of the
hot water into the mixture instead of the cold water the process is boosted up the process time
is reduced to the 1 to 1.45 hours.
But for the whole industry set up, for a single tub the solar water heater of capacity of total
1200 litres are required. The single solar water heater prices starts at the range of 20,000 to
the maximum of 30,000.
TO AUTOMATE THE PROCESS CARRIED OUT
To remove the dirt present inside the glass bottle is removed by the brush specially designed
for this is used by the labors.
Instead of this, an automated machine is made for the process to be carried out.
Then the outer covered wrapper is removed by the labors manually by the coir brush.
But in the automated one the brush is fixed around the bottles to remove the wrappers to
clean up.
REDUCTION OF LABOUR
According to the observation we made the labors can do cleaning process in the normal way
are as tabulated below
During the presence of supervisor
LABOR BOTTLES CLEANED PER HOUR
A 306
B 318
C 295
D 303
Average bottles cleaned per hour 305
During the absence of the supervisor
LABOR BOTTLES CLEANED PER HOUR
A 242
B 254
C 240
D 250
Average bottles cleaned per hour 246
By implementing the above mentioned techniques and ideas the least bottles cleaned per hour
is increased normally to the rate of 150 to 200 per labor.
So as a whole of implementing the newer ideas the total of 1 among 3 employees are reduced
to do the same work.
TIME REDUCTION
The total of the time taken for cleaning up the bottles from the intial to the final process is
originally took 3.30 hours but after implementing all the above mentioned process it is
reduced to the 2.30 hours. And also the reconstructing of the layout will improve the
efficiency of the work and working environment..
In addition to the normal present process, all the above three mentioned process help us to
improve the efficiency of the work.
1. To implement the solar water heater to improve the soaking temperature
2. To fix the brush in the rotating chamber to remover inner dirt present inside the bottle
3. To add the abrasive/coir belt to remove the wrapper present around the bottle.
RECONSIDERATION OF THE LAYOUT
Present layout of the industry
Idea suggested for the industry layout
REFERENCE
[1] Reference manual of the Bottle Washer Machine, KHS Machinery Pvt.Ltd., 2012.
[2] Riikka Juvonen, Vertti Virkajärvi, Outi Priha & Arja Laitila,“Microbiological spoilage and safety risks in
non-beer beveragesproduced in a brewery environment”, Espoo 2011, VTT Tiedotteita –Research Notes 2599.
[3] Mace, Kenneth D. "Microorganisms and sanitation in the carbonatedbeverage indutry." Proceedings of the
Arkansas Academy of Science.Vol. 7. Arkansas Academy of Science, 1955.
[4] Ma, Hui-Min, Jun-Yan Wang, and Zheng Ni. "A glass bottle defectdetection system without touching."
Machine Learning and Cybernetics,2002. Proceedings. 2002 International Conference on. Vol. 2. IEEE,2002.
[5] Caustic Soda Solution Handbook, The Dow Chemical Company.
[6] Ogawa, Masao, and Yutaka Henmi. "Recent developments on PC+ PLCbased control systems for Beer
Brewery Process AutomationApplications." SICE-ICASE, 2006. International Joint Conference.IEEE, 2006.
[7] Das, Rishabh, et al. "Automation of Tank Level Using Plc andEstablishment of Hmi by Scada.", IOSR
Journal of Electrical andElectronics Engineering (IOSR-JEEE), Volume 7, Issue 2 (Jul. - Aug.2013), PP 61-67.
[8] K.J.Astrom, T. Hagglund. "Revisiting the Ziegler-Nichols step responsemethod for PID control [J]". Journal
of Process Control 14 (2004) 634-650.
ONLINE REFERENCE
[1] https://www.youtube.com/watch?v=fDMUNFQR76g
[2] https://www.youtube.com/watch?v=6FvSGhIVtcU
[3] https://www.youtube.com/watch?v=MUfA3Kp4W2w
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