This document provides information on various components involved in bottling Coca-Cola syrup, including a carbonator, bottle washer, filling machine, crowning machine. It describes the processes of degassing, carbonation, washing, interior/exterior cleaning, filling, and crowning. Design features and capacities are mentioned for components like carbonators, bottle washers, and crowning machines.

1. A PRESENTATION ON...

2. • Submitted to: - Prof. T.H.Bhatt
• Submitted By: - Ami gajjar (07-0140-2013)
Hritvika Ghadiyali (07-0142-2013)
Pargi Jigisha (07-0148-2013)
Patel Hiral (07-0152-2013)
Patel Riya (07-0155-2013)

3. PROCESS FLOWCHART

4. • The dimensions of the liquid content of a
vessel and the dimensions and
arrangement of impellers, baffles and
other internals are factors that influence
the amount of energy required for
achieving a needed amount of agitation or
quality of mixing.
• The internal arrangements depend on the
objectives of the operation: whether it is to
maintain homogeneity of a reacting
mixture or to keep a solid suspended or a
gas dispersed or to enhance heat or mass
transfer.
• A basic range of design factors, however,
can be defined to cover the majority of
cases, for example as in Figure.
MIXING AND AGITATION TANK

5. BAFFLES
• baffles are needed to prevent vortexing and rotation of the liquid
mass as a whole.
• Four radial baffles at equal spacing are standard; six are only slightly
more effective, and three appreciably less so.
• When the mixer shaft is located off center the resulting flow pattern
has less swirl, and baffles may not be needed, particularly at low
viscosities.
DRAFT TUBES
• A draft tube is a cylindrical housing around and slightly larger in
diameter than the impeller.
• Usually draft tubes are used with axial impellers to direct suction and
discharge streams. An impeller-draft tube system behaves as an axial
flow pump of somewhat low efficiency.

6. IMPELLER SIZE
• This depends on the kind of impeller and operating conditions.
• For the popular turbine impeller, the ratio of diameters of
impeller and vessel falls in the range, d/D,=0.3-0.
IMPELLER SPEED
• With commercially available motors and speed reducers,
standard speeds are 37, 45, 56, 68, 84, 100, 125, 155, 190, and
320rpm.
• Two-speed drives may be required when starting torques are
high, as with a settled sluny.

7. IMPELLER LOCATION
• Expert opinions differ somewhat on this factor. As a first
approximation, the impeller can be placed at 1/6 the liquid level off the
bottom.
• In some cases there is provision for changing the position of the
impeller on the shaft. For off-bottom suspension of solids, an impeller
location of 1/3 the impeller diameter off the bottom may be
satisfactory.
• A second impeller is needed when the liquid must travel more than 4 ft
before deflection.

8.  APPLICATION
Continuous degassing and
carbonation of Coca-Cola syrup.
 PRINCIPLE OF OPERATION
• The Carbonator comprises a
degassing module and a
carbonating module.
 DEGASSING
• The syrup is fed to the degassing
tank through a control valve and
an injector. Degassing takes
place by means of pressure.
Oxygen and nitrogen in the water
are expelled by the addition of
CO2.
CARBONATOR

9.  CARBONATION
• CO2 is dissolved in accordance with the saturation carbonation principle.
• This result in the syrup being degassed a second time and carbonated
simultaneously.
• An integrated controller calculates the pressure required and adjusts it
continuously to the current temperature of the drink.
 PERFORMANCE RANGE
• Three sizes with an output of 15, 30 and 45 m3/h
• Carbonation in the range of 3 – 10 g/l CO2 (up to 20 °C) with gas loss
minimised simultaneously
• Dosing accuracy for CO2 1 sigma = 0.08 g CO2/l (continuous production)
• Pressure degassing and carbonation are performed in a hermetically
divided two-chamber tank.

10.  CHARACTERESTICS
• Degassing of the product water in accordance with the two-stage pressure
degassing principle, with the first stage in the degassing tank and the second
stage in the saturation carbonation.
• Robust and simple technology without extensive and expensive sensor
technology.
• Main characteristics of pressure degassing: Prevention of water
consumption and little maintenance.
• Continuous mode of operation in the range from 80 to 100 % of rated
capacity.
• Less stress for the operator thanks to the program-controlled performance of
all work steps (production including start-up, shut-down and CIP).
• All product-dependent parameters can be set on the touch-screen and be
saved in the integrated program for type management.
• Type parameters can be saved on a USB stick for use in verification and
documentation workflows.

11. BOTTLE WASHER
• Empty glass bottles arrived from the market are
loaded on a conveyer belt for washing purpose.
• This conveyer belt leads the bottles to the bottle
washer. Here the bottles are cleaned from inside
and outside surface.
• The whole process is fully automatic and
controlled by PLC system.

12.  Washing Cycle
• The washing cycle consists of distinct phases, depending from the
configuration that best suits the need of the customer.
• Depending from the machine configuration, all along the path of the bottles,
many different stages are realized.
• In the most sophisticated machine version, all the following steps are
included.

13. 1. PRE-WASH:
• Right after the infeed area the bottles are turned upside-down so that
the liquid residuals and loose dirty particles fall out of the bottles.
2. WASHING :
• The bottles are then taken to the actual washing zone which consists of a
certain number of identical detergent soaks – the exact number depends on
the required treatment time.
• Bottle washing is in three essential stages
1. The bottle is immersed in the soak, where dirt is chemically attacked by the
caustic action of the soda, increased by high temperature
2. The bottle is emptied to remove the dissolved dirt and the used solution
3. The mechanical action of the internal jet removes the dirt, which had been
chemically attacked.

14. 3. RINSING :
• The bottles then move on to the rinsing zone, that usually
includes an immersion zone and a set of spraying zones.
• In this zone the temperature is gradually lowered and the
detergent solution is removed, both from the bottles and from
the carrier beams, through dedicated sets of sprayers.
• All the rinsing water is then recovered to the pre-washing
zone. Every spraying zone consists of a set of high pressure
internal sprays and an external shower.

15. • The bottles enter the
machine on a conveyor
belt.
• At the transfer point, a so-
called “infeed finger” raises
them and pushes them
precisely into the bottle
pocket
LOADING SYSTEM

16. • Special discharge fingers
transport bottles of all
shapes and sizes without
allowing them to fall and
with little noise onto the
conveyor.
UNLOADING SYSTEM

17. BOTTLE TRANSPORT
• As the bottles are conveyed inside the machine, they are housed in mild
steel pockets specifically designed to facilitate label removal and enable
perfectly centered spraying on the bottle neck.

18. • Rotating spraying nozzles
clean the bottle from
different angles of
incidence. This guarantees
that the complete interior is
evenly cleaned.
• The bottle is cleaned from
different angles of
incidence
• Self-cleaning jetting units
INTERIOR CLEANING

19. • The exterior is cleaned from
above
• Special jetting units deluge the
bottles with water and rinse away
any dirt and caustic residues.
• Double spraying nozzles for the
targeted cleaning of the bottle
EXTERIOR CLEANING

20. • All machine functions are
controlled by a PLC.
• All componentry is housed in the
main panel, while the machine
operation controls are located in
the console near the operator’s
station, at the in feed side.
• The main operator panel is a PC
based operator.
ELECTRICS AND OPERATOR INTERFACE

21. • The main advantages of this solution
are:
• A friendly operator interface
• A data acquisition system integrated
in the interface
• The possibility of remote connection
for diagnostics or updating
purposes.
• All cables and electrical components
are properly codified to facilitate
identification.

22. • The main advantages of
this solution are:
• A friendly operator interface
• A data acquisition system
integrated in the interface
• The possibility of remote
connection for diagnostics
or updating purposes.
ELECTRICS AND OPERATOR INTERFACE

23. FILLING MACHINE
• The cleaned bottles are now conveyed to the filing machine.
• Different filling machines can have different technologies for
filling the coca cola into the bottles.
• These machines are capable to fill all type of bottles with
varying speed, volume and flow rate.
• For atomization of filling process the bottle fillers have excellent
other features and sensing devices which can be operated by a
PLC.

24. • Volumetric
• Pressure
• Rotary
• Pressure/Gravity
• Gear Pump
• Gravity
• Vacuum
 Two or more methods in a single machine can be utilized for better accuracy.
• Piston
• Fill-To-A-Level
• Cosmetic Fill
• Electronically Controlled Fill
• In-Line
• Combination Fillers
• Automatic/Semi– Automatic
FILLING METHODS AVAILABLE:

25. FEATURES OF FILLERS
• Stainless steel level sensor for supply tank.
• Adjustable patented bottle gating system (count in, count out).
• NEMA 4 electrical enclosure.
• Main air supply filter/regulator and shut-off with lockout.
• Easy finger-tip controls permit operator easy access to all fill values and
settings.
• Stainless steel conveyors with electronic variable speed controls.
• No bottle - no fill electronic controls.
• Easily adjustable nozzle height settings accommodate vials to gallons.
• All supply tanks are specially designed to accommodate fillers with minimum
waste of product.
• Portable on swivel casters.
• Requires minimal floor space.

26. FEATURES OF FILLERS
• Finger-tip nozzle positioning.
• Standard operator safety guards are provided with all automatic FILLS-ALL fillers.
• Bottle counter.
• Precision stainless steel nozzle rack.
• Stainless steel leveling screws with floor pads.
• Heavy duty one piece welded stainless steel frame.
• Fully adjustable patented stainless steel conveyor guide rails.
• Programmed electronic microprocessor ensures precision filling and repeatable fast
changeovers.
• Nozzles (and valves) available in several sizes, styles and materials for most
applications.
• Modular design - expandable from 1 to 24 nozzles. Electronic access module (Model
• ECF).Stainless steel screws and hardware are standard.

27. BOTTLE LOCATING SYSTEM
(NECK-CENTERING)
• A horizontal comb-type bottle
neck centering guide for bottles
with small or irregular neck
openings provides exact bottle
positioning for nozzle entry.
• This adjustable system easily
accommodates a wide range of
container sizes and shapes.
• The bottle locating system is
available for all models ensuring
a trouble-free filling operation.

28. EXCLUSIVE SYNCHRONIZED DISPENSING SYSTEMS
• Fillers have an exclusive programmed microprocessor and numerous safety
features, ensuring that all functions of the filler are synchronized at all times.
As examples:
1. The filler cannot discharge product unless the proper number of bottles have
entered the filling stage area and until all the previously filled bottles have
left.
2. The conveyor speed can be varied at any time during the fill cycle without
further timer adjustments.
3. Filled bottles cannot leave until the nozzles are completely up and out of the
bottles.
4. Pistons cannot dispense product unless completely aspirated.
5. Filling cannot occur unless nozzles are in the bottles, etc.

29. • All automatic fillers have an improved
method for feeding and positioning
containers into and out of the filling
stage area.
• The microprocessor counts the correct
number of bottles to be filled, then
closes the gating stage.
• The conveyor automatically stops for a
more gentle fill before filling begins.
• After fill completion, downstream
gating opens and counts the bottles
leaving to ensure a complete cycle.
• Simple control settings allow operator to set the correct number of nozzles being used.
• This system also reduces costly set-up time between changeovers, and eliminates the need
for time consuming no bottle-no fill delay settings.
CONTAINER INDEXING SYSTEMS

30. DIFFERENT TYPES OF BOTTLE FILLERS
1. Pressure, Gravity and Pressure-Gravity Fillers
(COSMETIC/FILL-TO-A-LEVEL)
2. Volumetric Fillers (PISTON FILLER)
3. Compact Volumetric Fillers
4. Gear Pump Fillers
5. Electronically Controlled, Timed-Volumetric Fillers
6. Versatile, High Speed Rotary Fillers

31. 1. PRESSURE FILLERS (COSMETIC/FILL-TO-A-LEVEL)

32. 2. GRAVITY FILLERS (COSMETIC/FILL-TO-A-LEVEL)

33. 3. VOLUMETRIC FILLERS (PISTON FILLER)

34. 4. ELETRONICALLY CONTROLLED, TIMED VOLUMETRIC FILLERS

35. 5. GEAR PUMP FILLERS

36. 6. VERSATILE, HIGH SPEED ROTARY FILLERS

38. • The crowns are conveyed through a flat
crown feeder into a guide chute, thus
ensuring very gentle treatment.
• The patented crown transfer unit
positioned within the machine offers a
high degree of reliability and crowning
precision.
• In addition, the open design of the
crowning head allows it to be optimally
cleaned, thus guaranteeing a high
standard of hygiene.
CROWNING MACHINE
 CAPACITY
• The Crowner can fit crowns on between 1000 78,000 bottles per hour.

39. • Once the crown has been fed from the crown chute into the
transfer segment, a magnet is used for the further guidance
of the crown.
• A pushing notch is then used to position the crown on the
ejection plunger of the capping head. The crowning head is
lowered until the crown in the crowning throat is placed on
the bottle.
• The bottle then holds it in place. Afterward only the
crowning throat continues to be lowered. In the first phase,
only the force of the guiding springs has any effect on the
crown. In the second crowning phase, the ejection spring is
pressed and the bottle is subjected to an increased amount
of pressure.
• The crowning procedure is completed once the crown has
been introduced 7.7 mm into the crowning throat. In doing
so, the crown is located 1 mm inside the cylindrical area of
the crowning throat and the required crown diameter of
between 28.6 and 28.7 mm has been exactly obtained.
METHOD OF OPERATION

40. • This completes the crowning procedure. The crowning force
once again drops. The delayed activity of the ejection
• spring guarantees high crowning quality while applying a low
level of pressure on the bottle.
• The plunger is then blocked while the crowning throat is further
lowered over the crown. At this time, the bottle height is also
compensated.
• A bottle which is too tall presses the bottle plate downwards
until the lowest area of the crowning head has been reached.
Controlled by the lifting cam,
• the crowning head is raised again and the guiding spring
pushes the ejection plunger back to its initial position.

41.  DESIGN FEATURES :
• All main parts made of stainless steel
Wst. AISI 304
• Flushing of cap transfer unit and capping
head
• Motorised height adjustment of the
crowner top part with bottle selection
feature
 ADDITIONAL EQUIPMENT
• UV lamp for cap disinfection
• Dust blow-off with ionised air and suction
• Additional flushing equipment Your
benefits

42.  PRECISION
• Crowns enter the line with a defined alignment and are precisely
positioned on the transfer plate by a draw-in magnet.
 DESIGNED FOR PRACTICAL APPLICATIONS
• A bottle-neck centring system ensures that even bottles with
inaccurate dimensions are reliably sealed.
 CAN BE OPTIMALLY CLEANED
• The capping heads can be cleaned