BALEZAF ALCOHOL AND LIQORS FACTORY PLC

JIMMA UNIVERSITY

JIMMA INSTITUTE OF TECHNOLOGY

SCHOOL OF CHEMICAL ENGINEERING

INTERNSHIP REPORT ON BOTTLING HOUSE

PREPARED BY: ELIAS TADESSE

SUBMITTED TO: ENG. HABTAMU

ENG.CHALACHEW

DATE: JUL 20/11/2015 E.C

Oromia, Sebeta, Gojeb, Ethiopia

Table of Contents
1.INTRODUCTION......................................................................................................................3
2. PROCESS DESCRIPTION......................................................................................................4
2.1 Alcohol Holding.....................................................................................................................4
2.2 Syrup:.....................................................................................................................................4
2.3 Blending Process....................................................................................................................5
2.4 Filter Press..............................................................................................................................5
2.5 Washer...................................................................................................................................5
2.6 Sighter....................................................................................................................................5
2.7 Filler:......................................................................................................................................5
2.8 Labeling.................................................................................................................................5
3. MATERIALS AND EQUPIMENTS........................................................................................6
3.1 Conveyor................................................................................................................................6
3.2 Washer...................................................................................................................................6
3.3 Filter.......................................................................................................................................6
3.4 Tanks......................................................................................................................................6
3.5 CHEMICALS.........................................................................................................................6
3.5.1 Water:..............................................................................................................................6
3.5.2 Flavors.............................................................................................................................6
3.5.3 Sugar and steam...............................................................................................................6
3.5.4 Caustic soda for washing purposes.................................................................................6
3.5.5 Citric acid for the purpose of prevent bacteria formation...............................................6
4. BLOCK DIAGRAM OF BOTTLING.....................................................................................6
5. CONCLUSION..........................................................................................................................7
6. RECOMMENDATION.............................................................................................................7
7. REFERENCE.............................................................................................................................7

Table of Figure
Figure 1Process diagram of blending..........................................................................................................5
Figure 2 Block diagram of bottling..............................................................................................................7
 1.INTRODUCTION
The bottling section is a critical stage in the production process of beverages, ranging from soft
drinks to alcoholic beverages. The bottling process involves several steps that take place in a
sequential manner to transform beverages from bulk containers into individual consumer-
friendly packages. The bottling section includes various specialized machines and equipment
designed to handle the specific requirements of each beverage type. Beginning with the container
loading and unloading processes, bottles are carefully transported through the different stages. It
involves processes like rinsing, sterilizing, filling, capping, labeling, and packaging. Each step
requires precision and efficiency to ensure consistent product quality and meet production
demands. Quality control measures are implemented throughout the bottling section to monitor
fill levels, detect leaks, and verify label accuracy.

Bottling plays a pivotal role in alcohol and liquor factories, where it is the final step in the
production process before the products reach consumers' hands. The bottling process involves
filling the carefully crafted spirits into bottles, ensuring accuracy, consistency, and hygiene.
Sophisticated filling equipment, such as gravity or vacuum fillers, is employed to precisely
measure and control the fill levels. The bottles are then sealed with closures, caps, or corks to
maintain product integrity. Quality control mechanisms, including inspections for leaks and label
placement, are implemented to guarantee compliance with regulatory standards and brand
specifications. In this unit generally. consists of the bottle washing, liquor formulation or mixing
and filling units. Liquor are alcoholic beverages that can be prepared by the dilution of pure
alcohol (96.6% alcohol by volume) by adding some flavoring agents (essences), sweeteners
(syrup), and mixing with the aid of treated water. The major process takes place in this section is
preparation of ingredients, mixing, filtration, and storing in storage tank.

The bottling section mainly contains blending and packaging room. In blending room, the
ethanol, syrup, raw water color and flavor are mixed in the mixing thank to produce desired
liquor while in packaging room washing, felling, labelling is done. In Balezaf alcohol and
liquors factory there are different varieties of liquors like; ouzo, dry gin, lemon liquor, pineapple
liquor, aperitif, cognac, super mint, zebib are produced. The liquor is prepared in a batch stirrer
tank mixer by adding the ingredients of the liquor. Blending is a process of preparing the final
bottled liquor.
 2. PROCESS DESCRIPTION
Block Diagram of Blending

Figure 1Process diagram of blending

The first process in this unit is blending. It is the process of mixing two or more components
together. At the beginning the distilled alcohol from distillery with alcohol concentration 96.3-
96.6 is transported to alcohol holding tank. Then a sufficient amount of alcohol can be
transferred from holding tank to mixing tank for blending purpose. This alcohol will be mixed in
the mixing tank with syrup, RO water, color, and flavors.

2.1 Alcohol Holding: First the distilled alcohol from distillery with alcohol concentration 96.3-
96.6 is transported to alcohol holding tank.

2.2 Syrup: Preparation: Syrup is prepared by mixing the sugar and water in the syrup mixing
tank by applying steam temperature at 65 0C. The main components in this process are sugar and
RO (reverse osmosis) water. The reason that we use RO water is to avoid side reactions. Then
steam inters from the top to boil the water. Then the sugar is transfer from the sugar tank to the
syrup preparation tank using a pump. After a few minutes until the sugar is dissolved add some
amount citric acid in order to prevent bacteria formation, other contaminants and uses as
preservation. Then after all the prepared syrup pass through filter sheet for clarification and then
syrup transported in to syrup holding tank.
2.3 Blending Process: Blending process is a process in which two or more materials have
mixed properly to produce liquor. In this process the raw material for mixing purposes are pure
alcohol, color, raw water, syrup sugar and flavor. It is the main process in bottling room, which
takes place in mixing tank. The mixing tank has a mixer inside it. After the mixing tank has
cleaned, about 96.3% alcohol of ethanol is poured to tank. Then add some amount of RO water,
flavor, and color. At the end add the prepared syrup and wait until it’s well mixed.

2.4 Filter Press: In this factory, filter press uses for filtering the prepared syrup and liquor by
using the filter sheets. The filter sheet retains the contaminants. Filtration takes place due to
pressure drop when there is pressure difference between the inlet and outlet of the liquor.

2.5 Washer: Bottles are collected and transported by chain conveyor. By using out packer the
bottles are pickup and sent to washing machine the same time the crates go to the crate’s washer.
In the bottle washer, the bottles have washed through a different step. First, fill the washer with a
solution that contains 2% caustic soda (NaOH) and all intermediate(31c) warm(55c) and
cold(23c)-water tank inside the washer, then turn on the washer’s motor. Fresh water comes from
the water treatment. The warm solution that contains the 2% caustic soda washes the bottle at a
temperature of 76.5c. at this step labels be removed, the caustic solution can be recycled.
Finally, the bottles have dried by using blower and goes to filling section.

2.6 Sighter: The purpose of the sighter is to identify if there is breakage or uncleaned bottle.
There are two types of sighters those are empty bottle and full bottle sighter.

2.7 Filler: Is a process of filling a desired product in to the empty bottle. This process is done by
level sensing. The filling operation is processed by sucking the vacuum air inside the bottle, then
when the vacuum air becomes equal to the atmospheric air the filling process stop.

2.8 Labeling: This machine is responsible for the application of labels carrying the brand name,
product information, logos, and other important details on to the bottles.

3. MATERIALS AND EQUPIMENTS

3.1 Conveyor: Is used for the transport of bulk solids.
3.2 Washer: Is a machine used for washing bottles.

3.3 Filter: There are 2 types of filters her those are filter sheet and filter bag they are uses for
separate liquors from different particles.

3.4 Tanks: different types of tanks such as, alcohol holding tank, liquor holding tank, syrup
holding tank, syrup mixing tank, mixing tank, packer, labeling, filler, different types of pipe and
pumps.

3.5 CHEMICALS

3.5.1 Water: In this unit operation there are different types of water uses such as RO (revers
osmosis water), soft, and hard water for the different purposes.

3.5.2 Flavors different types of flavors they are imported.

3.5.3 Sugar and steam

3.5.4 Caustic soda for washing purposes.
3.5.5 Citric acid for the purpose of prevent bacteria formation.

4. BLOCK DIAGRAM OF BOTTLING

Figure 2 Block diagram of bottling

 5. CONCLUSION
Bottling is the final process for the overall desired alcohol and liquor production. In this final
unit operation so many processes are proceeded such as syrup preparation, mixing, preparation
of different types of alcohols like Cognac, Ouzo, Zebib, Pernoud, Lemon liquor, Pineapple
liquor, Dry Gin etc… then for making different types of alcohol we used different types of
flavors and colors. Finally after making of the mixture of desired alcohol content, after passing
the labeling, coding, and packing process then it becomes stored.

6. RECOMMENDATION
As we have seen the bottle after moved out from the washer contains its labeling which indicates
the washer is less efficient which may be caused by the lowering of operating temperature and
the amount of caustic soda we used. So we would like to advise that increasing of the steam
supply which increases the operating temperature and either adding the caustic soda or reviewing
of the effect of caustic soda on the washing process.

7. REFERENCE
Jimma university Process Industry II PPT

Wikipedia.