A REPORT ON STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

UNDERTAKEN AT

SEVEN UP BOTTLING COMPANY, BENIN CITY,EDO STATE

BY

EHI-LATO OSAMA ANDREW

ENG2101567

DEPARTMENT OF MECHATRONICS ENGINEERING

FACULTY OF ENGINEERING

UNIVERSITY OF DELTA, AGBOR,DELTA STATE

SUBMITTED IN FULFILMENT OF THE STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

AUGUST 2025

DECLARATION
 I, EHI-LATO OSAMA ANDREW, hereby declare that this compiled report was based on the Student Industrial

Work Experience Scheme done in Seven-Up Bottling Company, Benin Plant.

…………………………

EHI-LATO OSAMA ANDREW

LETTER OF CERTIFICATION
 This is to certify that this industrial training exercise was undertaken by EHI-LATO OSAMA ANDREW with the
matriculation number , a student of the department of Mechatronics engineering, University of Delta,
Agbor,Delta state, Nigeria.

…………………………………... …………………………………..

Head of Department Industrial training supervisor

…………….…………………….. …………….……………………..

Date/signature Date/signature

DEDICATION

This work is dedicated to the Almighty God the beginning of everything the one who
gave me the wisdom to write down this report.Also i dedicate this report to my parents
for their endless love and support in every area of my life,most especially my dad who
taught me how reports are been written.

ACKNOWLEDGEMENT

I want to use the medium to acknowledge the presence of God in my life,the one who gave me the wisdom
to write down this report,God i give you the glory.I also want to appreciate my parents and siblings for their
love. Also i appreciate my uncle and co IT students.God bless you all.
Also, i want to use this medium to acknowledge those who took out time from their busy schedule to
impart knowledge and offer training. To mention a few, my sincere appreciation goes to the electrical
Superintendent engr.Ernest Eze and the engineers working with him, person of Mr.Jimoh, Engr
Sebastian Onyedikachi,Mr.Femi Alale and other engineering team and most especially engr.Samuel
Gbolintine who made it lively for me there during my stay at seven up may the almighty God bless you
all. I also acknowledge the entire management and staff of Seven-up Bottling Company, Benin Plant,
Benin City - Edo State, for their support.

ABSTRACT

Student Industrial Work Experience Scheme (SIWES) has been a vital scheme in bridging the
gap between knowledge and application of knowledge. As part of my course requirements, I did my
industrial attachment in Seven-Up Bottling Company, Benin Plant, Edo State. As an intern, I worked in
the electrical engineering department where I was taught the various operations and maintenance done
in the company.

This report documents my industrial attachment experience at SEVEN UP BOTTLING

COMPANY, Benin plant, as a Mechtronics engineering student. The attachment provided hands-on
experience and exposure to the beverage industry’s operations, safety protocols and industrial
automation and teamwork. This report serves as a reflection of my learning experience during my stay
at seven up bottling company.
Table of Contents

CHAPTER ONE

1.0 Introduction to SIWES

1.1 Scope of SIWES

1.2 Aims of SIWES

1.3 Objectives of SIWES

1.4 Functions of SIWES

1.5 Role of Students and Institutions in SIWES

1.6 Relevance of Industrial Training to Career Objectives

1.2 History of Seven-Up Bottling Company

1.3 Nature of the Organization

1.3.1 Food Safety Policy Statement and Objectives

1.3.2 Market/Services Situation of the Company

1.4 Organogram and Responsibilities

CHAPTER TWO – WORK EXPERIENCE

2.0 Detailed Intern’s Role/Responsibilities and Daily Activities

2.1 Engineering Department

2.1.1 The Engineering Workshop

2.2 Electrical Department

CHAPTER THREE

3.1.2 Analysis of the Production Lines, Machineries and Some Manufacturing Processes

3.1 The Production Line

Got it 👍. Based on the subtopics you provided (from 3.2 – 3.13), here’s a clean Table of Contents draft you can
use:

---

TABLE OF CONTENTS (Extract)

3.2. The Bottle Conveyor System

3.2.1. How Do Conveyor Systems Work?

3.2.2. Benefits of Conveyor Systems

3.3. The Uncaser Machine

3.3.1. Key Features

3.3.2. How It Works

3.3.3. Components of an Uncaser Machine

Safety Features

3.4. The Bottle Washer Machine

3.4.1. Loading System

3.4.2. Washing Cycle

Pre-Soak
Soak 1

Soak 2

Soak 3

Hydro Soak

Hydro Wash

Pre-Final Wash

3.4.3. Spraying System

3.4.4. Unloading System

3.5. EBI – Empty Bottle Inspection Machine

3.5.1. How It Works

3.6. Carbo Cooler

3.6.1. The Evaporator (Carbo Cooler)

Suctioning

3.6.2. Ammonia Compressor

3.6.3. The Ammonia Condenser

3.7. Filler and Crowner Machine

3.7.1. Code Machine

3.8. The Crate Washer

3.9. Post Sighting Station/Post

3.10. The Caser Machine

How Does It Work?

3.11. Air Compressor

3.11.1. Key Functions

3.11.2. Machines Connected to Air Compressors

3.12. Boilers (Gas and Diesel)

3.12.1. Boiler and Bottle Washer Connection

3.13. The CO2 Room

---

Would you like me to also format it in academic SIWES report style (with dots leading to page numbers e.g., 3.2.
The Bottle Conveyor System ..................... 25), or just keep it as a clean outline?
Chapter One

Introduction
1.0 INTRODUCTION TO SIWES

The Student Industrial Work Experience Scheme (SIWES) is a structured industrial attachment program
established in 1973 by the Industrial Training Fund (ITF). It was introduced in response to the growing concern
among Nigerian employers about the lack of practical experience and industry exposure among graduates of
tertiary institutions. Initially targeted at students in engineering, technology, applied sciences, and vocational
disciplines, the scheme has evolved into a compulsory part of many academic curricula across Nigerian
universities and polytechnics (ITF, 2004).

SIWES serves as a critical intervention program aimed at bridging the gap between classroom-based theoretical
learning and hands-on experience in real industrial settings. By enabling students to interact with industrial
processes, equipment, and professional personnel, the program enhances the application of academic
knowledge and helps align educational outputs with the demands of the labor market (Akinyemi, 2019).

The success of any nation’s development is closely linked to the quality and practical competence of its
workforce. Therefore, SIWES is not only beneficial to individual students but also contributes to the broader goal
of national industrial development and capacity building.

1.1 SCOPE OF SIWES

The scope of SIWES extends across a wide range of professional disciplines, especially those with practical and
technological relevance. These include:

1. Engineering (Mechanical, Electrical, Civil, etc.)

2. Pure and Applied Sciences
3. Computer and Information Technology
4. Health and Medical Laboratory Sciences
5. Environmental Studies
6. Agricultural and Natural Resources
7. Technical and Vocational Education
SIWES placements are usually conducted in industrial firms, government parastatals, research institutions,
hospitals, manufacturing plants, ICT centers, and engineering companies, where students engage in real job
functions that relate to their fields of study. The duration of the attachment varies between 3 to 6 months
depending on the institution and program.

1.2 AIMS OF SIWES

The main aim of SIWES is to:

1. Bridge the existing gap between theoretical classroom instruction and the practical realities of the workplace.
2. Foster a culture of industrial relevance among students by equipping them with hands-on experience in their
chosen professions (Oladele & Oladimeji, 2011).
3. Prepare students for immediate entry into the labor market and reduce the learning curve on employment.
1.3 OBJECTIVES OF SIWES

The specific objectives of the Student Industrial Work Experience Scheme include:
1. To expose students to industry-based skills and practices before graduation.

2. To provide a platform for the application of theoretical knowledge in practical situations.

3. To build the technical competencies of students in line with global best practices.

4. To foster professional attitudes such as punctuality, responsibility, team spirit, and initiative.

5. To enhance the quality of graduates by promoting experiential learning.

6. To encourage partnership between institutions and industries in training and manpower development (Nse &
Olamide, 2020).

1.4 FUNCTIONS OF SIWES

SIWES functions as a partnership tool among three key stakeholders—students, academic institutions, and
industries. Its key functions include:

1. Coordinating industrial placements and matching students with relevant organizations.

2. Supervising and assessing student progress through logbooks and on-site visits.
3. Enhancing the curriculum of technical and science-based programs based on feedback from industry.
4. Promoting innovation and knowledge transfer between academia and industry.
5. Supporting the development of skilled manpower for national growth (ITF, 2004).
1.5 ROLE OF STUDENTS AND INSTITUTIONS IN SIWES

Role of Students

1. Students are the primary beneficiaries of SIWES and have the following responsibilities:
2. Participate actively and professionally during their industrial attachment.
3. Maintain a detailed logbook to document daily activities and skills learned.
4. Abide by the rules and regulations of the host organization.
5. Submit technical reports at the end of the program to their academic institution.
6. Use the opportunity to build networks, enhance personal skills, and explore career possibilities (Oladele &
Oladimeji, 2011).
Role of Institutions

1. Tertiary institutions play a supervisory and administrative role in SIWES implementation. Their
responsibilities include:
2. Coordinating the placement of students into organizations.
3. Assigning institutional supervisors to monitor and evaluate students’ progress.
4. Reviewing students’ SIWES reports and logbooks and awarding academic grades.
5. Liaising with the ITF for funding, approvals, and training compliance (Nse & Olamide, 2020).
1.6 RELEVANCE OF INDUSTRIAL TRAINING TO CAREER OBJECTIVES
Industrial training is crucial to students’ career development and personal growth. It offers exposure to real-life
work environments, helping students build career awareness, practical competencies, and self-confidence. The
following are key ways

SIWES supports career objectives:

1. Career Alignment and Decision Making

Many students enter tertiary education with limited understanding of workplace expectations. Through SIWES,
students learn about the practical side of their profession, which can help them define their career goals and
choose areas of specialization.

2. Skill Development and Professional Growth

Students gain job-specific skills such as operating machinery, interpreting technical drawings, using industrial
software, or performing laboratory tests. These hands-on experiences cannot be fully replicated in a classroom
setting (Akinyemi, 2019).

3. Increased Employability

Employers increasingly seek graduates with industry experience, not just academic qualifications. SIWES allows
students to stand out in the job market with relevant experience, references, and confidence.

4. Building Professional Networks

Students establish valuable relationships during their industrial attachment that can lead to internships,
mentorship, or even full-time employment offers.

5. National Workforce Development

By preparing students to contribute immediately to the industry upon graduation, SIWES also plays a role in
reducing youth unemployment and addressing the technical manpower shortage in Nigeria (Nse & Olamide,
2020).

REFERENCES (APA 7th Edition Format)

Akinyemi, S. (2019). Industrial training and skills development: Bridging theory and practice in Nigerian tertiary
institutions. International Journal of Vocational and Technical Education Research, 5(3), 25–34. [Journal Article]

Retrieved from https://www.eajournals.org/journals/international-journal-of-vocational-and-technical-

education-research-ijvter/vol-5-issue-3-june-2019/industrial-training-and-skills-development-bridging-theory-
and-practice-in-nigerian-tertiary-institutions/
Federal Government of Nigeria. (1990). Report on the Review of the Student Industrial Work Experience Scheme
(SIWES). [Government Report]

Publisher: Federal Ministry of Education, Nigeria. [Access: University libraries or ITF archives]

Industrial Training Fund (ITF). (2004). SIWES Handbook: Student Industrial Work Experience Scheme. Jos,
Nigeria: Industrial Training Fund Press. [Book]

ISBN: 978-35145-0-7

Nse, A. A., & Olamide, S. R. (2020). Evaluation of Student Industrial Work Experience Scheme in Tertiary
Institutions in Nigeria. Journal of Education and Practice, 11(22), 67–73. [Journal Article]

Retrieved from https://iiste.org/Journals/index.php/JEP/article/view/53719

Oladele, S. O., & Oladimeji, A. O. (2011). An appraisal of the effectiveness of SIWES in Nigeria: A case study of
Lagos State Polytechnic. Nigerian Journal of Educational Administration and Planning, 11(3), 41–53. [Journal
Article]

[Access: Nigerian university libraries or national education archives]

1.2 HISTORY OF SEVEN-UP BOTTLING COMPANY

Seven-Up Bottling Company (SBC) was founded by Mohammed El-Khalil, a Lebanese entrepreneur who migrated
to Nigeria in 1926. He laid the foundation for what would become one of Nigeria’s most prominent beverage
companies. His son, Faysal El-Khalil, played a significant role in expanding the company’s operations and
influence. On October 1st, 1960—the same day Nigeria gained independence—the company produced its first
bottle of 7Up at its original factory in Ijora, Lagos (Media Nigeria, 2018). The company became publicly listed in
1978, marking a major milestone in its corporate evolution (Investment Frontiers Magazine, n.d.).

In the late 1980s, SBC expanded by establishing new plants in Ibadan and Ikeja. The acquisition of 7Up
International by PepsiCo in the early 1990s introduced the Pepsi brand into the Nigerian market (Brand
Communicator, 2017). Currently, SBC operates across Nigeria and has extended its operational presence to
Ghana and Tanzania. Its headquarters is situated in Beirut, Lebanon. The company remains one of Nigeria’s
largest manufacturers and marketers of soft drinks.

1.3 NATURE OF THE ORGANIZATION

Seven-Up Bottling Company is a licensed bottler of PepsiCo Inc. beverages. It manufactures and distributes a
variety of non-alcoholic drinks including Pepsi, 7Up, Mirinda, H2Oh!, Mountain Dew, Teem, and Aquafina bottled
water (Seven-Up Bottling Company, n.d.).

The company operates nine manufacturing plants located in Lagos, Aba, Enugu, Ilorin, Ibadan, Kaduna, Kano,
Abuja, and Benin. The Benin plant, where I completed my industrial training, is located at Iguosa Village, Oluku,
along the Benin-Lagos Expressway. This plant primarily produces returnable glass bottles (RGB) of Pepsi, 7Up,
Mirinda, and Teem. Other product formats, including cans and PET bottles, are typically supplied from the Lagos
headquarters or other plants.

The Benin plant contains essential operational units such as the Water Treatment Plant, Effluent Treatment
Plant, CO₂ Storage Room, Boiler Room, and Cleaning-In-Place (CIP) system, which are vital for ensuring
production hygiene and compliance with quality standards.

1.3.1 FOOD SAFETY POLICY STATEMENT AND OBJECTIVES

Seven-Up Bottling Company is committed to producing safe, high-quality beverages by:

1. Designing food safety into all operations and production equipment;

2. Utilizing high-quality raw materials and up-to-date processing technologies;
3. Maintaining a clean, environmentally friendly facility;
4. Applying traceability mechanisms through 100% product date coding;
5. Investing in trained personnel and laboratory resources;
6. Conducting routine internal process audits.
These efforts align with PepsiCo’s global standards and local food regulatory requirements, ensuring consumer
safety and brand integrity (Seven-Up Bottling Company, n.d.).

1.3.2 MARKET/SERVICES SITUATION OF THE COMPANY

SBC serves the Nigerian market through a network of over 200 distribution depots and employs approximately
3,500 workers nationwide. Its major competitor is the Nigerian Bottling Company (NBC), the authorized bottler
of Coca-Cola products in Nigeria. Both companies collectively dominate more than 80% of the Nigerian soft drink
market (Investment Frontiers Magazine, n.d.).

SBC maintains a competitive edge through its affiliation with PepsiCo, its wide product portfolio, innovative
branding strategies, and social engagement initiatives. These include the “Pepsi Football Academy,” music
sponsorships, and educational programs. The introduction of dietary alternatives such as Pepsi Light and 7Up
Free has also helped it to meet shifting consumer preferences.

1.4 ORGANOGRAM AND RESPONSIBILITIES

The Benin plant of SBC is structured into several key departments, including:

Administration, Accounts, Sales and Marketing, Utility, Production, Quality Control, Warehouse amd Food
Services
Each department is headed by a department manager, who reports to the Divisional Managing Director
responsible for the entire plant. The workforce consists of over 500 staff, working in three operational shifts
(day, afternoon, and night) to ensure continuous production and timely delivery of products across the region.

This structure ensures clarity of roles, departmental accountability, and effective coordination between
management and operations (ResearchWap, n.d.).

References (APA 7th Edition)

Brand Communicator. (2017, March 6). The making of Pepsi Long Throat: How consumers fell in love with it.
BrandCom. https://brandcom.ng/2017/03/06/making-pepsi-long-throat-consumers-fell-love/

Investment Frontiers Magazine. (n.d.). Seven-Up Bottling Company Plc – Company profile overview. Investment
Frontiers Magazine. https://investmentfrontiersmagazine.wordpress.com/stocks/seven-up-bottling-company-
plc/

Media Nigeria. (2018, April 27). History of 7up Bottling Company Nigeria. Media Nigeria.
https://www.medianigeria.com/history-of-7up-bottling-company-nigeria/

ResearchWap. (n.d.). Appraisal of inventory control in a manufacturing company: A case study of Seven-Up
Bottling Company. https://researchwap.com/production-and-operations-mgt/appraisal-of-inventory-control-in-
a-manufacturing-company-a-case-study-of-seven-up-bottling-company

Seven-Up Bottling Company. (n.d.). About us. Seven-Up Bottling Company. https://www.sevenup.org/about-us/

!
 CHAPTER TWO

WORK EXPERIENCE

DETAILED INTERN’S ROLE/RESPONSIBILITIES AND DAILY ACTIVITIES

In this section, I’ll discuss the activities I carried out during the period of my industrial attachment to the
Seven-Up Bottling Company. During my stay in Seven-Up Bottling Company Limited, I was assigned to the
Electrical department of the factory . Duties in the department include carrying out preventive and corrective
maintenance of the machines. Installation and repair of damaged parts of the machines. Setting up, running, and
ensuring proper operation of the machine on a daily routine, troubleshooting machinery (adjusting machine
parts and parameters) to maintain optimum machine performance. Inputting downtime and other relevant
machine performance data into performance logbook. Also, during my stay at seven up bottling company, i
worked with the mechanical engineering team of the company as a mechanical technician. Duties of the team
also includes carrying preventive and corrective maintenance of various heavy machines, machines like the
conveyor,gear box of an electric motor, caser,uncaser, pumps and others.

2.1. ENGINEERING DEPARTMENT

Here’s your revised and expanded version of Section 1.4.3: The Engineering Workshop, with added technical
depth, academic tone, and APA-style in-text citations and reference list at the end. I’ve also included
information from credible engineering maintenance and industrial management sources.

2.1.1. THE ENGINEERING WORKSHOP

The growing global demand for packaged foods and beverages has led to significant pressure on beverage
industries to expand and optimize their production capacities. Meeting this demand requires a robust
infrastructure, particularly a well-equipped engineering workshop that supports continuous and efficient
operations. The engineering workshop, also referred to as the maintenance or repair shop, is a vital component
of any beverage production facility, ensuring minimal downtime and operational reliability (Mobley, 2002).
This workshop is a specialized area where maintenance technicians, engineers, and artisans perform essential
tasks such as machine repairs, equipment fabrication, preventive maintenance, and electrical and mechanical
troubleshooting. A properly functioning workshop directly impacts the overall efficiency and sustainability of the
production line (Gopalakrishnan & Banerji, 2013).

Tools and Equipment in the Engineering Workshop

The engineering workshop is typically furnished with a wide array of tools and machines used for general and
specialized maintenance tasks. These include:

1. Machine tools (e.g., lathes, milling machines, bench grinders)

2. Welding equipment (e.g., arc welding sets, gas welding kits)

3. Hand tools (e.g., spanners, pliers, screwdrivers)

4. Power tools (e.g., electric drills, portable grinders, sanders)

5. Precision instruments (e.g., calipers, micrometers, multimeters)

6. Specialty tools (e.g., hydraulic presses, tube benders, pipe cutters)

These tools enable the engineering team to carry out corrective and preventive maintenance on various
industrial systems, reducing breakdown times and enhancing productivity (Wireman, 2010).

Functional Areas within the Workshop

The workshop is usually organized into multiple bays or departments, each designated for specific categories of
work:

1. Machine Shop: Machining, cutting, and fabrication of spare parts.

2. Electrical Shop: Repair and maintenance of motors, control panels, wiring systems.

3. Mechanical Shop: Maintenance of gears, pumps, conveyors, and other mechanical components.

4. Welding Shop: Welding and fabrication of steel frames, brackets, and pipelines.

5. Assembly Bay: Fitting and assembling of mechanical or electrical sub-units.

6. Inspection and Testing Area: For quality control, diagnostics, and functionality testing.

Each section ensures that equipment used in beverage processing—such as washers, fillers, cappers, and
conveyors—is in optimal working condition (Smith, 2020).

Best Practices for Workshop Management

Efficient workshop management practices are crucial in minimizing production downtime, improving equipment
longevity, and reducing costs. Key strategies include:

1. Preventive Maintenance Program: Regularly scheduled checks and replacements to prevent

breakdowns (Mobley, 2002).

2. Computerized Maintenance Management System (CMMS): For tracking maintenance activities, work
orders, and asset history.

3. Tool and Equipment Inspections: Routine checks to ensure calibration and safety.

4. Continuous Training Programs: Up-skilling technicians in areas like automation, PLC troubleshooting,
and safety procedures.

5. Quality Control Measures: Including equipment testing, calibration, and certification before use.

6. Lean Principles: Streamlining workshop operations to eliminate waste and improve productivity
(Womack & Jones, 2003).

7. Safety Protocols: Strict adherence to PPE usage, fire prevention, and ergonomic work practices.

By adopting these methods, beverage manufacturing firms not only reduce machine downtime but also ensure
that equipment is readily available for uninterrupted operations, thereby improving overall plant efficiency
(Gopalakrishnan & Banerji, 2013).

2.2 ELECTRICAL DEPARTMENT

During my stay at the electrical department of seven up bottling company, i gained many knowledge on various
electrical devices and components. According to my supervisor there at seven up i was told tht the electrical
department there is into maintenance and repairs of various electrical equipment like the electrical motor and
powers sensory devices e.t.c. some of the various electrical equipment I worked on.

2.2.1. THE ELECTRICAL MOTOR

Electric Motors in Beverage Companies

Electric motors are the workhorses of a beverage bottling plant, providing the mechanical power to drive a wide
range of machinery. Their versatility, reliability, and ease of control make them ideal for these applications.
Although, electric motors come in different types, however, they commonly used on production line by seven-
up bottling Company is the AC induction motor.

AC Induction Motors: These are the most common type used in industrial settings due to their robustness,
relatively low cost, and simple design. They operate on AC power and use electromagnetic induction to create
rotation. They come in single-phase and three-phase configurations. Three-phase motors are generally preferred
for industrial applications due to their higher efficiency and power output.

WHAT IS 3 PHASE POWER?

The first concept to understand about a 3-phase induction motor is the first part of its name – three-phase
power.

A single-phase power supply uses two wires to provide a sinusoidal voltage. In a three-phase system, three wires
are used to provide the same sinusoidal voltage, but each phase is shifted by 120°.

If you were to add up the voltage of each phase at any point in time, the sum would be constant. Single-phase
power is fine for residential or other low-power applications, but three-phase power is typically required for
industrial or higher-power applications.

It can transmit three times as much power while only using 1.5 times as much wire, and this makes for a more
efficient and economical power supply.

Faraday’s Law

Another underlying principle of AC induction motors comes from Faraday’s Law.

The British scientist, Michael Faraday, discovered that a changing magnetic field can induce a current, and
conversely, a current can induce a magnetic field. Using the right-hand rule, you can predict the direction of the
magnetic field. To do so, imagine grabbing a straight wire with your thumb pointing toward the current, and
your fingers would wrap around in the direction of the magnetic flux lines.

PARTS OF AN INDUCTION MOTOR

Two main components compose an induction or asynchronous motor: the stator and the rotor.

The stator consists of the outer windings or magnets and is stationary. The stator is stationary. For the rotor, the
inner core is what actually rotates in the motor, making the rotor rotate.

HOW IT WORKS

A current is applied across the stator to achieve torque at the motor shaft. This creates a rotating magnetic field,
inducing a current in the rotor. Because of this induced current, the rotor also creates a magnetic field and starts
to follow the stator due to magnetic attraction. The rotor will turn slower than the stator field, and this is
referred to as ‘slip.’ If the rotor were to turn at the same speed as the stator, no current would be induced, and
thus no torque. The difference in speed ranges from 0.5 to 5%, depending on the motor winding.

KEY MOTOR SPECIFICATIONS:

 1. Power (HP or kW): Indicates the motor's output capacity.

2. Voltage (V): The electrical voltage required to operate the motor.

3. Current (A): The electrical current drawn by the motor.

4. Speed (RPM): The rotational speed of the motor's shaft.

5. Torque (lb-ft or Nm): The rotational force the motor can produce.

6. Efficiency (%): The percentage of input power converted to output power.

7. Frame Size: Standardized dimensions for mounting and interchangeability.

8. Enclosure Type: Indicates the motor's protection against environmental factors (e.g., dust, water).

How Electric Motor Are Used On The Production Line

1. Uncaser Machine: AC induction motors (typically three-phase) are used for the main lifting and conveying
mechanisms. Smaller servo or stepper motors might be used for precise control of individual gripping arms.
Specifications will depend on the size and speed of the uncaser.

2. Bottle Washer Machine: AC induction motors drive the main wash pumps. Smaller motors (AC induction or
sometimes DC) power conveyors, rotating brushes, and other mechanisms. VFDs are frequently used to
control motor speeds for optimizing the washing process.

3. Conveyor System: AC induction motors (three-phase) are the standard choice for conveyor drives. The motor
size depends on the conveyor length, load, and speed requirements. VFDs are often used for speed control.

4. Empty Bottle Inspection Machine: Smaller, high-precision motors are crucial here. Servo or stepper motors
are often used for bottle rotation and precise positioning for cameras or sensors. AC induction motors might
drive the overall conveying system.

5. Carbo-Cooler Machine: AC induction motors power pumps, compressors, and fans. The mix pump, crucial
for blending syrup and water, is also driven by an electric motor (often an AC induction motor). Motor
specifications will depend on the cooler's capacity and operating requirements.

6. Filler-Crowner Machine: AC induction motors are used for various functions: driving filling heads, the
crowning mechanism, and conveyors. Precise control of filling head motors (sometimes servo motors for high
accuracy) is essential. Synchronized operation is key.

CHOOSING THE RIGHT MOTOR:

Selecting the correct motor for each application involves considering factors like power requirements, speed,
torque, duty cycle, environment, and cost. Engineers carefully analyze these factors to ensure optimal
performance and efficiency. Modern beverage plants often utilize VFDs to control AC induction motors, allowing
for variable speed control and improved energy efficiency.

MOTORS CONNECTION
 Electric motors require various control systems and connection methods to ensure efficient and safe
operation.

1. SOFT STARTER SYSTEM:

Soft starters are used to gradually increase the voltage applied to the motor during startup, reducing the starting
current and torque. This minimizes mechanical stress on the motor and connected equipment, and prevents
voltage dips in the power supply.

Operation: Soft starters typically use solid-state devices (like thyristors or triacs) to control the voltage applied to
the motor. The voltage ramps up over a short period (adjustable), allowing the motor to accelerate smoothly.
Once the motor reaches near full speed, the soft starter is bypassed, and the motor operates at full voltage.

Applications: Soft starters are suitable for applications where a smooth start is desired, such as pumps, fans, and
conveyors, especially when large motors are involved. They are preferred over star-delta starting in some
applications because they provide a smoother start and are less likely to cause voltage fluctuations.

2. STAR-DELTA CONNECTION:

The star-delta starter is another method used to reduce starting current, primarily for larger three-phase
induction motors.

Operation: The motor windings are initially connected in a "star" configuration, reducing the voltage applied to
each winding and thus limiting the starting current. Once the motor reaches a certain speed (typically around
70-80% of its rated speed), the connection is switched to "delta," applying full voltage to the windings for
normal operation. The switching is usually done with a timer and contactors.

Applications: Star-delta starters are a cost-effective option for motors that don't require high starting torque and
are not started and stopped frequently. They are less complex than soft starters but do not provide as smooth a
start

3. DIRECT-ONLINE (DOL) CONNECTION

The simplest starting method, where the motor is directly connected to the power supply.
Operation: Full voltage is applied to the motor windings immediately, resulting in high
starting current and torque.

Applications: DOL starting is suitable for small to medium-sized motors where the starting
current does not cause excessive voltage drop in the power system. It is the most
economical option, but it can cause mechanical stress on the motor and connected
equipment due to the sudden surge of torque. It is generally not used for larger motors
due to the high inrush current.
2.2.2. Control Panels, Components

Control panels are the nerve centers of beverage bottling plants, housing the controls and monitoring
equipment for various machines. They provide operators with a centralized interface to manage and
oversee the production process.

Typical Control Panel Components:

1. Programmable Logic Controller (PLC): The "brain" of the control system, executing the
programmed logic to automate machine operations.

2. Human-Machine Interface (HMI): A touchscreen or display panel that allows operators to

interact with the PLC and monitor machine status.

3. Relays: Electromechanical switches used to control various circuits and devices.

4. Contactors: Larger relays used to switch high-power circuits, such as motor circuits.

5. Circuit Breakers/Fuses: Protection devices that prevent overloads and short circuits.

6. Terminals: Connection points for wiring to field devices (sensors, actuators, motors). Indicators:
Lights or displays that show the status of different parts of the system.

7. Switches and Buttons: Allow operators to manually control certain functions

8. Variable frequency drives (VFDs) are a sophisticated method for controlling AC motor speed
and torque. Unlike other starting methods, VFDs offer continuous speed control and can
significantly improve energy efficiency.

How VFDs Work:

1. Rectification: The VFD converts the incoming AC power to DC power.
2. Inversion: The VFD then converts the DC power back to AC power, but with a
variable frequency and voltage.

3. Motor Control: By adjusting the frequency and voltage of the AC power supplied to
the motor, the VFD can precisely control the motor's speed and torque.
Benefits of Using VFDs:
1. Energy Savings: VFDs can significantly reduce energy consumption by matching motor
speed to the actual load requirements. This is particularly beneficial in applications with
varying loads, such as pumps and fans.
2. Improved Process Control: VFDs allow for precise control of motor speed, enabling
better control of the driven equipment and the overall process.
 3. Reduced Mechanical Stress: VFDs provide smooth starting and stopping, reducing
mechanical stress on the motor and connected machinery.
4. Increased Motor Life: By reducing starting current and mechanical stress, VFDs can extend the lifespan of the
motor.

APPLICATIONS IN BEVERAGE COMPANIES:

VFDs are widely used in bottling plants to control various equipment, including:

1. Pumps: Controlling pump speed to match flow requirements, saving energy and reducing wear and tear.
2. Fans: Adjusting fan speed based on cooling needs, optimizing energy usage.
3. Conveyors: Varying conveyor speed to synchronize with other parts of the production line.
4. Compressors: Controlling compressor speed to match air demand, improving efficiency.
5. Uncaser Machine: The control panel manages the sequence of operations: gripping, lifting, and conveying
cases. It interfaces with sensors to detect case presence and position, and controls actuators to perform the
necessary movements.
6. Bottle Washer Machine: The control panel controls the washing cycles, including chemical injection,
temperature control, and conveyor speed. It monitors sensor inputs (temperature, level, pressure) and controls
pumps, valves, and heating elements.
7. Conveyor System: The control panel manages the starting, stopping, and speed of the conveyor belts. It may
interface with sensors to detect bottlenecks or jams and control diverters to route products to different lines.
8. Empty Bottle Inspection Machine: The control panel integrates with cameras or sensors to detect bottle
defects. It controls the bottle rotation and rejection mechanisms based on inspection results.
9. Carbo-Cooler Machine: The control panel regulates the temperature, pressure, and CO2 injection. It monitors
sensor inputs (temperature, pressure, flow rate) and controls pumps, compressors, and valves. The mix pump
control will also be integrated here.
10. Filler-Crowner Machine: The control panel synchronizes the filling and crowning operations. It controls the
filling valves, capping mechanism, and conveyor speed, ensuring accurate filling and proper sealing.
11.
Control Panel Design Considerations:

Safety: Control panels must be designed with safety in mind, including proper
grounding, insulation, and protection against overloads.

Ergonomics: The layout of the panel should be user-friendly, with clear labeling and
easy access to controls.

Maintainability: Components should be easily accessible for maintenance and

troubleshooting.

Environmental Protection: The panel should be protected from dust, moisture, and
other environmental factors.

Modern control panels often utilize PLCs and HMIs, providing a flexible and powerful way to
automate and manage complex bottling processes. They are essential for ensuring efficient,
reliable, and safe operation of the entire bottling plant.
 CHAPTER 3

3.1.2 ANALYSIS OF THE PRODUCTION LINES, MACHINARIES AND SOME

MANUFACTURING PROCESSES

3.1. THE PRODUCTION LINE

The Seven Up Bottling Company uses a highly efficient and well-organized production process
to produce their popular carbonated beverages. The process begins with loading empty glass
bottles onto a conveyor belt, where they are transported to the uncaser machine.

The uncaser automatically removes the bottles from their cases and places them on the conveyor
belt for further processing. The bottles are transported through the infeed conveyor to the bottle
washer to remove any dirt or debris. The bottle washer uses a combination of hot water and
cleaning agents to ensure the bottles are spotless and free of any contaminants.

After the bottles are cleaned, they are visually inspected by operators at a prefill citing post
station for any defects or abnormalities. Any bottles that do not meet the quality standards are
removed from the production line.

The next step in the production process is the EBI (Empty Bottle Inspection) machine, which
uses advanced cameras and sensors to inspect the bottles for any defects or contaminants.
This ensures that only the highest-quality bottles are used for the next step. The EBI is a high-
tech machine that can detect even the smallest imperfections, ensuring that only perfect bottles
move into the next stage. The filled bottles are then capped with a crown or twist-off cap by the
filler and crowner machine.

Following the filling and capping process, the filled and capped bottles are once again visually
inspected at the post fill citing post station to ensure that they have been filled correctly and are
free of defects. Any bottles that do not meet the quality standards are removed from the
production line.

The filled and capped bottles are then placed into cases by the caser machine. The sealed cases
are then transported to the pallet, where they are stacked and prepared for shipping.

They are passed through the code machine which applies a code to the bottles that includes
information such as the production date and batch number' this code is used for quality control
purposes and can be used by consumers to identify the product

This well-organized and highly efficient production process is a testament to the Seven Up
Bottling Company's commitment to producing high-quality carbonated beverages for their
customers.

3.2. THE BOTTLE CONVEYOR SYSTEM

A conveyor system is a fast and efficient mechanical handling apparatus for automatically
transporting loads and materials within an area. This system minimizes human error, lowers
workplace risks and reduces labor costs — among other benefits. They are useful in helping to
move bulky or heavy items from one point to another. A conveyor system may use a belt,
wheels, rollers, or a chain to transport objects.

3.2.1. HOW DO CONVEYOR SYSTEMS WORK?

Typically, conveyor systems consist of a belt stretched across two or more pulleys. The belt
forms a closed loop around the pulleys so it can continually rotate. One pulley, known as the
drive pulley, drives or tows the belt, moving items from one location to another.
The most common conveyor system designs use a electric motor to power the drive pulley and
belt. The belt remains attached to the electric motor through the friction between the two
surfaces. For the belt to move effectively, both the drive pulley and idler must run in the same
direction, either clockwise or counterclockwise.

While conventional conveyor systems such as moving walkways and grocery store conveyors
are straight, sometimes, the unit needs to turn to deliver the items to the proper location. For the
turns, there are unique cone-shaped wheels or rotors which allow the belt to follow a bend or
twist without getting tangled.

3.2.2. BENEFITS OF CONVEYOR SYSTEMS

The main purpose of a conveyor system is to move objects from one location to another. The
design allows for movement of objects that are too heavy or too bulky for humans to carry by
hand. Conveyor systems save time when transporting items from one location to another. As
they can be inclined to span multiple levels, they make it simpler to move items up and down
floors, a task that, when performed manually by humans, causes physical strain. Inclined belts
can automatically unload material, eliminating the need for someone to be on the opposite end to
receive pieces

There are three main parts of a conveyor system: the belt support, the pulley and the drive
unit. Each component plays an essential role in the conveyor unit’s operation. While all conveyor
systems contain these parts, designs vary in the construction materials and where each
component is located.

Belt support is the component that ensures the belt moves smoothly. If the support unit is not
firm, the belt sags when workers place a heavy object on top, and the sagging causes the
belt not to move smoothly or swiftly as it should. The use of a firm support unit keeps the
belt taut and running efficiently.

The pulley system is an external component used to control the belt movement. Each unit has
at least two pulleys, one that operates under power and an idle one. More complex
conveyor systems may have additional rotors throughout the frame.
The drive unit is typically motorized. The drive unit is responsible for powering the conveyor
belt or chain, and it usually consists of an electric motor, gearbox, and other components
that work together to provide the necessary torque and speed to move the conveyor.
3.3. THE UNCASER MACHINE
The uncaser is a crucial machine in the beverage industry, responsible for removing empty
bottles from their cases. This machine plays a vital role in the bottling process, as it ensures that
bottles are efficiently and safely unloaded from their cases, ready for washing, filling, and
packaging.

3.3.1. KEY FEATURES:

High-speed operation: Uncasers can handle up to 600 bottles per minute, making them a
crucial component in high-volume production lines.

Automatic case feeding: Cases are automatically fed into the uncaser, eliminating manual
labor and increasing efficiency.

Gentle bottle handling: Uncasers are designed to handle bottles with care, minimizing the
risk of breakage or damage.

Adjustable bottle spacing: The machine can be adjusted to accommodate different bottle
sizes and shapes.

Easy maintenance: Uncasers are designed for easy cleaning and maintenance, reducing
downtime and increasing overall equipment effectiveness.

3.3.2. HOW IT WORKS:

Cases are fed into the uncaser via a conveyor belt or automatic case feeder.
The machine opens the case and removes the bottles, using a combination of mechanical
arms and suction cups.

The bottles are then placed onto a conveyor belt or transfer table, ready for the next stage of
the bottling process.

The empty case is then ejected from the machine, ready for disposal or recycling.
SAFETY FEATURES:
Modern uncasers often include safety features such as, Emergency stop buttons, Safety interlocks to
prevent access to moving parts, Sensors to detect jams or malfunctions.
These features help to minimize the risk of injury or damage during operation.

3.3.3. COMPONENTS OF AN UNCASER MACHINE

Gripper Head: The part that directly interacts with the bottles, removing them from the case.

Gripper Fingers: The individual components of the gripper head that wrap around the
bottles to lift and remove them.

Suction Cups: Attached to the gripper fingers, these create a secure seal on the bottles to lift
them out of the case.

Gripper Arms: The mechanical arms that move the gripper head and fingers to remove the
bottles.

Gripper Frame: The structural component that supports the gripper head and arms.
Bottle Guides: Adjustable guides that ensure proper alignment and spacing of the bottles as
they are removed.

Case Clamps: Mechanisms that hold the case in place during the bottle removal process.
Case Supports: Components that support and stabilize the case during processing.
Bottle Sensors: Sensors that detect the presence and position of bottles in the case.
Gripper Actuator: The component that powers the gripper head's movement, such as a
pneumatic cylinder or electric motor.

Gripper Controls: The control systems that regulate the gripper head's movement and
operation.
These components work together to ensure efficient and precise removal of bottles from cases in
the uncasing process.

3.4. THE BOTTLE WASHER MACHINE

The bottle washer is a machine specifically designed to wash and sanitize bottles in the beverage
industry to ensure the removal of dirt, grime, residual flavors and microorganisms from the bottle
before filling.

3.4.1. LOADING SYSTEM

The conveyor belt of the accumulation table conveys the bottles to the automatic loading system,
dividing them into separate rows by means of a set of unscrambler devices.

The infeed mechanism takes the bottles from the loading table and moves them over a plastic
chute, in a nearly horizontal position, into the pockets of the bottle carriers.

The mechanism consists of pairs of fingers mounted on a rotating and swinging shaft. During the
bottle transfer from the chutes into the pockets the chutes move synchronized with the bottle
carriers.

The infeed mechanism is able to handle a big range of different bottle sizes without any
adjustment. Only the guiding plates on the loading table have to be changed if the bottle
diameters differ too much.

If movement is hindered by obstacles, a pneumatic safety device is activated, stopping the

machine. When the safety devices, positioned both on the rotating and on the swinging shafts,
are activated, the operator can reset the fingers back in production position or in opposite
direction in order to remove crashed bottles. The switch-off force can be adjusted by setting the
air pressure on a control valve. Fingers are made of treated steel with wear and protection caps
are made of special plastic material. The caps can be easily changed by snapping them off and
on.

3.4.2. WASHING CYCLE

Stages of the Bottle Washer Machine
1. Pre-Soak
Purpose: Softens and loosens stubborn residues, labels, adhesives, or organic material on the bottles.
Temperature: ~37.4°C (Set to 45°C)
Details: Uses a mild detergent or caustic solution. Soaking improves cleaning effectiveness in later
stages.
2. Soak 1
Purpose: Primary chemical cleaning stage to remove labels, glue, sugar, or beer/wine residues.
Temperature: ~66.4°C (Set to 60°C)
Details: Stronger caustic or alkaline detergent is used. Higher temperature accelerates chemical
action.
3. Soak 2
Purpose: Continuation of label and dirt removal, especially for bottles with heavy residues.
Temperature: ~65.3°C (Set to 60°C)
Details: Ensures bottles are fully free of remaining label adhesives or organic deposits. Often uses
recycled solution from Soak 1 to conserve chemicals.
4. Soak 3
Purpose: Final high-temp soaking before rinse to ensure all chemicals and dirt are removed.
Temperature: ~74.2°C (Set to 70°C)
Details: High temperature here ensures sanitation and breaks down remaining residues.
5. Hydro Soak
Purpose: Water-based soaking to begin rinsing and dilute leftover chemicals.
Temperature: ~49.0°C (Set to 45°C)
Details: Reduces concentration of caustic chemicals. Prepares the bottle for water-only rinsing
stages.
6. Hydro Wash
Purpose: Primary rinse with clean hot water to remove all chemical residues.
Temperature: ~36.5°C (Set to 40°C)
Details:Uses filtered or pre-heated water. Ensures chemical residues do not carry over to final
stages.
7. Pre-Final Wash
Purpose: Final rinse stage before bottles proceed to final rinse or sterilization.
Temperature: ~32.6°C (Set to 33°C)
Details:Could use fresh potable water or deionized water. Bottles should be residue-free at this
point.

SPRAYING SYSTEM
Apart from the freshwater one, each jetting zone consists of a pump, internal jetting pipes,
external spray pipes, filter and tank. The rotary type sprayers are driven synchronously by the
carrier beams by means of a plate mounted the carrier beams themselves.

At a certain distance from the nozzles to the mouth of the bottles the jet stream hits exactly into
the bottles and follows their continuous movement due to the rotation effect. Since the shaft is
driven by the bottle carriers themselves, proper centering is always ensured.

Due to the continuous rotation the flow in the nozzle reverses. In this way, the dirt that may
eventually obstruct the entrance of the nozzles is blown out during the next cycle. The jet is
switched off when the nozzle is not in contact with the hole in the sealing bush. That means that
bottles are treated only internally. It's possible to provide motorized sieve belt filters in front of
each jetting pump.

Since there is only a little dirt to be discharged, the filter is driven only in short intervals. In this
interval, the sieve belt is cleaned by a water spray pipe. It flushes the dirt into a discharge
channel.

3.4.3. UNLOADING SYSTEM

After the washing process
3.5. EBI – EMPTY BOTTLE INSPECTION MACHINE
Empty bottle inspection (also known as EBI) ensures that glass and refillable bottles are
clean, free of damages, and free of contaminants before they move to the filler on your product
line. Rejecting contaminated or flawed containers before they reach the filler helps to reduce
expensive product waste as well as avoid container leaks or breaks, which could result in serious
downtime.

Glass bottles in beverage filling line must be inspected prior to filling. Located after the bottle
washing machine and before the filling. It is an intelligent equipment with machine vision,
precision machinery and real-time control, which mainly consists of pre-inspection unit, wall
inspection unit, mouth inspection unit, bottom inspection unit, control unit and human-computer
interaction unit and man-machine interface unit. The main functions include bottle mouth
breakage inspection, the dirt and foreign body inspection of the bottle mouth, bottom and the
wall and rejecting the bottles unqualified in time. The study of an empty bottle inspection system
mainly focuses on how to improve the detection accuracy, speed and reliability.

Electronic Bottle Inspection (EBI) is a quality control process used in the beverage industry to
inspect bottles for defects or contamination.

3.5.1. HERE'S HOW IT WORKS:

Bottles are transported on a conveyor belt or transfer table to the EBI machine, where they
enter an inspection chamber and are rotated and positioned for inspection. An array of sensors,
including cameras, infrared sensors, and ultrasonic sensors, inspect the bottles from various
angles, checking for cracks, breaks, chips, damage, contamination, defects, and fill level.

The sensor data is processed and analyzed using software, which compares the bottle's condition
to predetermined standards. If a defect or contamination is detected, the machine signals the
presence of a faulty bottle, which is then rejected from the production line through a rejection
mechanism such as an air jet or pusher arm.
Inspected bottles that meet quality standards continue on the production line for filling, and
packaging. EBI machines can inspect bottles at high speeds, up to 1,200 bottles per minute, and
detect defects with high accuracy, ensuring the quality and safety of beverages.
(1) Initial inspection (2) Residual liquid inspection (3) Bottle wall inspection (4) Operation and
control unit (5) Control panel and bottle mouth image acquisition device (6) Bottle bottom image
acquisition device (7) Gearing (8) Bottle wall inspection (9)

Reject apparatus (10) Rejection confirm.

EBI is an important quality control measure in the beverage industry, helping to prevent
defective or contaminated bottles from reaching consumers. By detecting and rejecting faulty
bottles, EBI machines help maintain the highest standards of product quality and safety

3.6. CARBO COOLER

The carbo cooler is a critical component in the production of carbonated beverages, and it plays
a vital role in chilling and carbonating the beverage to the perfect temperature and pressure.

The carbo cooler is essentially a specialized heat exchanger that is designed to cool the
beverage to a precise temperature, usually around 2-4°C (36-39°F), before filling and packaging.
The carbo cooler is typically a vertical or horizontal tube-and-shell heat exchanger, with a series
of tubes and plates that are specifically designed to maximize heat transfer.

HERE'S HOW IT WORKS:

The warm beverage from the batching tank is pumped into the carbo cooler, where it flows
through the tubes and plates. The carbo cooler is surrounded by a refrigerant, ammonia, which is
cooled to a very low temperature. As the beverage flows through the tubes, it comes into contact
with the cold refrigerant, causing the temperature to drop rapidly.

At the same time, carbon dioxide gas is injected into the beverage, which dissolves into the
liquid under pressure. The carbonation process occurs because the beverage is chilled to a
temperature that allows the carbon dioxide to dissolve easily, creating the fizz and bubbles that
are characteristic of carbonated beverages.

The carbo cooler is designed to control the temperature and pressure of the beverage to
precise specifications, ensuring that the carbonation process occurs consistently and efficiently.
The chilled and carbonated beverage is then transferred to the filling line, where it is filled into
bottles or cans and packaged for distribution.

Overall, the carbo cooler is a critical component in the production of carbonated beverages, and
its precise temperature and pressure control ensures that the final product is consistent,
refreshing, and enjoyable for consumers.

3.6.1. THE EVAPORATOR (CARBO COOLER)

An evaporator is a heat exchanger that transfers heat from the surrounding medium to the
refrigerant causing the liquid refrigerant to evaporate into a gas.

HOW DOES THE EVAPORATOR WORK

Liquid ammonia entry: Liquid ammonia enters the evaporator through the inlet.

Heat absorption: The liquid ammonia flows through the evaporator coils, absorbing heat
from the surrounding medium (e.g., chilled water or air).

Evaporation occurs: The absorbed heat causes the liquid ammonia to evaporate into a gas.

Vapor formation: The evaporated ammonia gas is formed, which is then drawn into the
compressor through the suction line.

CHARACTERISTICS OF THE EVAPORATOR

Low pressure: The evaporator operates at a low pressure, typically around 2-3 bar.

Low temperature: The evaporator operates at a low temperature, typically around -33°C (-
27°F).

High heat transfer: The evaporator is designed for efficient heat transfer, ensuring effective
cooling.

The evaporator in ammonia refrigeration is a critical component that absorbs heat, evaporates the
ammonia refrigerant, and provides the cooling effect, making it a vital part of the refrigeration
cycle.
SUCTIONING

This is the process of creating a pressure difference to draw the ammonia vapor from the
evaporator (carbo cooler) to the compressor

HOW SUCTION WORKS

The ammonia has fully evaporated, absorbing heat from the refrigerated space, so it is a low
pressure and low temperature vapor

The compressors port created a pressure difference, generating a partial vacuum

The pressure difference pulls the ammonia vapor from the evaporator but the compressor
through the suction line to be compressed by the compressor

3.6.2. AMMONIA COMPRESSOR

The ammonia compressor is a crucial component of the ammonia refrigeration system,

responsible for compressing the ammonia gas to high pressure and temperature.

HOW THE COMPRESSOR COMPRESSES AMMONIA GAS

The compressor consists of a cylindrical chamber with a piston that moves up and down, driven
by an electric motor. The chamber is divided into two sections: the suction side and the discharge
side.

As the piston moves down, it creates a vacuum on the suction side, allowing low-pressure
ammonia gas from the evaporator to enter the chamber. The piston then moves up, reducing the
volume of the chamber and compressing the ammonia gas. This compression raises the
temperature and pressure of the gas.
The compressed gas is then discharged through a valve into the condenser, where it releases its
heat to the surrounding air and condenses back into a liquid. The compressor's continuous
motion ensures a constant flow of compressed ammonia gas, maintaining the cooling cycle.

The compressor's efficient operation is critical to the overall performance of the ammonia
refrigeration system, and regular maintenance is essential to ensure reliable and safe operation.

3.6.3. THE AMMONIA CONDENSER

The ammonia condenser is a vital component of the ammonia refrigeration system, responsible
for cooling the high-pressure ammonia gas coming from the compressor and converting it back
into a liquid.

HOW IT WORKS

The condenser consists of a coiled tube, or a series of tubes surrounded by a shell, with a coolant
(such as water or air) flowing through the shell. The high-pressure ammonia gas from the
compressor enters the condenser coils and flows through the tubes.

As the ammonia gas flows through the coils, it releases its heat to the surrounding coolant,
causing the gas to condense into a liquid. This process is facilitated by the cooler temperature
and pressure of the condenser, which allows the ammonia to return to its liquid state.

The condenser plays a crucial role in the ammonia refrigeration cycle, as it enables the
conversion of the high-pressure gas back into a liquid, allowing the cycle to repeat and maintain
the cooling process.

3.7. FILLER AND CROWNER MACHINE

The filler and crowner machine are a crucial piece of equipment in the beverage industry,
responsible for filling and capping bottles with precision and speed.

Here's how they work:

The machine consists of a rotating turntable with multiple filling and capping stations. Bottles
are placed on the turntable and as it rotates, they are positioned under the filling nozzles, which
pour the beverage into the bottle at a precise rate. The filling process is typically done under
pressure to ensure the bottle is filled to the correct level.

Once filled, the bottles are then moved to the capping station, where a crown cap or screw
cap is applied. The capping mechanism tightens the cap to the correct torque, ensuring a secure
seal.

The machine is designed to handle various bottle sizes and shapes and can fill and cap a high
volume of bottles per minute. The filler and crowner machine are typically used in conjunction
with other equipment, such as a labeler and packager, to complete the packaging process.

The machine is equipped with sensors and control systems to monitor and adjust the filling and
capping process in real-time, ensuring precise control over the entire process. This results in
consistent and high-quality packaging, which is essential for maintaining product integrity and
consumer satisfaction. Overall, the filler and crowner machine play a vital role in the beverage
packaging process, enabling efficient and accurate filling and capping of bottles, and helping to
ensure the quality and safety of the final product

How is the carbo cooler connected to the filler machine?

The carbo cooler and filler machine are connected through a system that enables the efficient and
precise filling of carbonated beverages. Here's how they are connected:

The carbo cooler is a temperature control unit that chills the beverage to a precise temperature,
usually between 2-4°C (36-39°F), before filling. This is necessary to prevent the carbonation
from being released too quickly, which can cause foam and reduce the beverage's shelf life.

The chilled beverage is then transferred from the carbo cooler to the filler machine through a
network of pipes and valves. The filler machine is equipped with a metering system that
measures the exact amount of beverage to be filled into each bottle.

As the bottles move through the filler machine, they are positioned under the filling nozzles,
which are connected to the pipes carrying the chilled beverage. The beverage is then filled into
the bottles at a precise rate, ensuring the correct fill level and minimizing foam. The connection
between the carbo cooler and filler machine is crucial to maintain the perfect balance of
temperature, pressure, and flow rate, ensuring that the beverage is filled efficiently and with the
right amount of carbonation.

In summary, the carbo cooler and filler machine are connected through a system that enables the
precise temperature control and filling of carbonated beverages, resulting in a high-quality final
product.

3.7.1. CODE MACHINE

A code machine, also known as a coding machine or date coder, is a device that prints important
information, such as expiration dates, batch numbers, and product codes, onto bottles or cans as
they move through the filling and packaging line.

In relation to the filler and crowner machine, the code machine is typically positioned after the
filling and crowning process, just before the bottles or cans are packaged and prepared for
shipping.

The code machine consists of several components, including:

A printer head that applies the code onto the bottle or can
A control system that determines what information to print and when
A sensor that detects the presence of the bottle or can trigger the printing process
A ink or ribbon supply that provides the necessary ink for printing
The code machine is usually connected to the filler and crowner machine through a conveyor
belt or other transfer system, which moves the bottles or cans from the filling and crowning
process to the coding machine.

HOW IT WORKS

Bottles or cans are conveyed into the machine on a conveyor belt.

A sensor detects the presence of the bottle or can and triggers the printing process.
The printer head, which is typically an inkjet or laser printer, applies the code onto the
bottle or can.
 The code is printed in a specific format, such as a date, time, batch number, or product
code.

The printer head moves along the conveyor belt, printing the code onto each bottle or can as
it passes through.

The code machine is programmed to print the correct information, such as the expiration date
or batch number, based on the product and packaging line.

The machine can print on various types of packaging materials, including glass, plastic, and
metal.

The printed code is clear, legible, and durable, ensuring it remains readable throughout the
product's lifecycle.

The code machine is an essential component of the filling and packaging line, as it provides a
quick and efficient way to apply important information to the bottles or cans, ensuring that
products are properly labeled and ready for distribution.

3.8. THE CRATE WASHER

The crate washer is an essential equipment in the beverage industry, used to clean and sanitize
crates or containers used to transport and store bottles or cans. The crate washer is typically a
large, industrial machine that uses a combination of water, detergent, and sanitizing agents to
remove dirt, grime, and bacteria from the crates.

The crate washer operates by:

Loading crates into the machine
Spraying a cleaning solution onto the crates
Washing the crates with high-pressure water jets
Rinsing the crates with clean water
Sanitizing the crates with a sanitizing agent
Drying the crates with hot air or a drying agent
The crate washer is designed to ensure that crates are thoroughly cleaned and sanitized,
preventing contamination and spoilage of beverages. It is typically used in breweries, soft drink
manufacturing plants, and other beverage production facilities.

The benefits of using a crate washer include:

Improved hygiene and sanitation
Reduced risk of contamination
Increased efficiency and productivity
Extended crate lifespan
Compliance with food safety regulations
Overall, the crate washer plays a critical role in maintaining the cleanliness and sanitation of
crates, ensuring the quality and safety of beverages.

3.9. POST SIGHTING STATION/POST

In a bottle manufacturing company, a sighting post (also known as an inspection post) is a
designated area where trained professionals inspect bottles for defects and ensure they meet
quality and safety standards before being transported to consumers.

At the sighting post, inspectors carefully examine each bottle for:

Visual defects: cracks, chips, uneven shapes, or other visible flaws.
Dimensional accuracy: ensuring bottles meet precise size and shape specifications.
Finish and appearance: checking for proper labeling, capping, and overall aesthetic
appeal.

Safety and functionality: verifying that bottles are properly sealed, capped, and able to
withstand transportation and handling.

By conducting thorough inspections at the sighting post, companies can:

Prevent defective or unsafe bottles from reaching consumers
Maintain high-quality products and brand reputation
Reduce the risk of product recalls or liability claims
Ensure compliance with regulatory standards and industry guidelines.
 The sighting post plays a critical role in ensuring the quality and safety of bottles before they
are shipped to consumers.

3.10. THE CASER MACHINE

The caser machine, also known as a case packing machine or packaging machine, is a device that
automatically packs bottles or cans into cases or crates, preparing them for shipping and
distribution.

The caser machine consists of several components, including:

A conveyor belt or feed system that brings the bottles or cans to the

machine

A case feeder that loads empty cases or crates into the machine

A product loading system that places the bottles or cans into the

case

A closing system that shuts and seals the case once it's full

A discharge conveyor that removes the packed cases from the machine

The caser machine is designed to streamline the packaging process, increasing efficiency
and reducing labor costs. It can be adjusted to accommodate different sizes and types of bottles
or cans, as well as various case configurations. As the bottles or cans enter the machine, they are
aligned and positioned into the case, which is then closed and sealed. The packed cases are then
discharged from the machine, ready for shipping or storage. The caser machine is an essential
component of the packaging line, as it enables fast and efficient packaging of products, ensuring
they are protected and ready for distribution.

HOW DOES IT WORK

 The caser machine works by automating the process of packing bottles or cans into cases or
crates. Here's a step-by-step explanation of its operation:

Bottles or cans are conveyed into the machine on a feed system, such as a conveyor belt.
Empty cases or crates are loaded into the machine from a case feeder.
The bottles or cans are aligned and positioned into the case by a product loading system,
which may include guides, laners, or other mechanisms to ensure proper placement.

Once the case is full, a closing system shuts and seals the case. This may involve folding and
tucking the flaps of the case, applying glue or tape, or using other closing mechanisms.

The packed case is then discharged from the machine on a discharge conveyor, ready for
shipping or storage.

The machine repeats this process continuously, packing case after case with bottles or cans.

The caser machine is programmed to handle specific case sizes, product configurations, and
packing patterns, ensuring efficient and accurate packaging. Its automated operation enables
high-speed packaging, reducing labor costs and increasing productivity.

3.11. AIR COMPRESSOR

Air compressors play a vital role in the beverage industry, providing a reliable source of power
for various machines and processes. Their primary function is to generate compressed air, which
is used to drive pneumatic tools, equipment, and machinery.

3.11.1. KEY FUNCTIONS:

Powering Pneumatic Tools: Air compressors supply compressed air to power pneumatic
tools such as drills, sanders, and wrenches, used for maintenance, repair, and production
tasks.

Operating Machinery: Compressed air is used to power machines such as conveyor belts,
sorters, mixers, and bottling lines, ensuring efficient production and processing.

Cleaning and Drying: Compressed air is used for cleaning and drying equipment, bottles,
and cans, ensuring sanitation and quality control.
 Packaging and Filling: Air compressors power machines used in packaging and filling
processes, such as capping, labeling, and filling bottles and cans.

3.11.2. MACHINES CONNECTED TO AIR COMPRESSORS:

Conveyor Belts: Air compressors power conveyor belts that transport bottles, cans, and other
materials throughout the production process.
Mixers: Air compressors power mixers used in the production of beverages.
Bottling Lines: Air compressors are connected to machines used in the bottling process,
including filling, capping, and labeling.
 Pneumatic Tools: Air compressors supply compressed air to power pneumatic tools
used for maintenance, repair, and production tasks..

Case Packers (Casers):

Air compressors supply compressed air to power the pneumatic cylinders and valves
that control the movement of the case packing machinery. This includes:

Picking up and placing bottles or cans into cases

Closing and sealing cases
Labeling and packaging cases

Uncase Packers (Uncasers):

Air compressors also supply compressed air to power the pneumatic cylinders and
valves that control the movement of the uncase packing machinery, which includes:

a. Opening and unloading cases

b. Removing bottles from cases
c. Placing empty cases onto a conveyor belt for reuse
The compressed air from the air compressor is used to actuate the pneumatic
cylinders, which in turn drive the mechanical components of the case packer and uncase
packer machines. This ensures efficient and reliable operation of the machinery and helps
to maintain the high production rates required in the beverage industry.

3.12. BOILERS (GAS AND DIESEL)

Gas and diesel boilers are used in the beverage industry to provide steam and hot
water for various processes.Industrial gas or diesel boilers generate steam through
combustion.

Fuel (gas or diesel) is burned in the boiler's combustion chamber, producing hot flue
gases.

The hot flue gases pass through a series of tubes and heat exchangers, transferring their
heat to the water in the boiler.
The water is heated to a high temperature (around 180-200°C) and turns into steam.
The steam is collected in a steam drum or header, where it is separated from the water
and any impurities.

The steam is then distributed to the various processes or machines that require it, such as
turbines, heat exchangers, or industrial equipment.

In a gas boiler, natural gas or propane is used as the fuel source, while in a diesel boiler,
diesel oil is used. The combustion process is typically controlled by a burner system,
which regulates the amount of fuel and air used to achieve efficient and safe combustion.

The boiler is connected to the bottle washer to provide hot water for the washing process.
The hot water is used to:

Clean and sanitize the bottles

Remove labels and residues
Rinse the bottles thoroughly
The boiler supplies hot water to the bottle washer at a high temperature (usually around
140°F to 180°F) to ensure effective cleaning and sanitizing of the bottles. This is
especially important in the beverage industry to prevent contamination and ensure the
quality of the final product.

3.12.1 Here's a breakdown of the process:

The boiler heats water to a high temperature.
The hot water is pumped into the bottle washer.
The bottle washer uses hot water to clean and sanitize the bottles.
The clean bottles are then rinsed and prepared for filling.

Gas Boiler:
Uses natural gas or propane as fuel
More environmentally friendly than diesel boilers
Typically, more efficient and cost-effective
 Can be connected to a steam generator or hot water tank

Diesel Boiler:
Uses diesel fuel as energy source
Often used in areas where natural gas is not available
Can be more expensive to operate than gas boilers
Also connects to steam generators or hot water tanks

LBoth gas and diesel boilers can be used in conjunction with various machines and
systems to provide the necessary steam and hot water for beverage production and
processing.

3.13. THE CO2 ROOM

The CO2 room, also known as the carbonation room, is a critical area in the beverage
industry where CO2 gas is stored, managed, and used to carbonate beverages. The CO2
room is typically a designated space that houses: CO2 storage tanks, CO2 gas
cylinders, Carbonation equipment (e.g., carbonators, injectors), Control systems (e.g.,
pressure regulators, flow meters), Safety equipment (e.g., gas detectors, ventilation
systems)

The primary function of the CO2 room is to:

Store CO2 gas in a safe and secure environment
Regulate CO2 pressure and flow to the carbonation equipment
Monitor CO2 levels and usage
 Ensure consistent carbonation levels in beverages
Maintain a safe working environment for operators

The CO2 room is typically managed by a trained operator or technician who is

responsible for:

Monitoring CO2 levels and usage

Performing regular safety checks and maintenance.
Ensuring compliance with safety regulations and industry standards
Troubleshooting issues with carbonation equipment.
Optimizing CO2 usage and efficiency

Some key considerations in the design and operation of the CO2 room include:
Safety features (e.g., ventilation, gas detection, emergency shutdown)
CO2 storage and handling procedures
Carbonation equipment selection and maintenance
Operator training and certification
Regular cleaning and sanitizing schedules

By effectively managing the CO2 room, beverage manufacturers can ensure consistent
product quality, reduce waste and costs, and maintain a safe working environment for
operators.