SUBMITTED BY:-
SHASHI KUMAR
GFT-085254

ACKNOWLEDGEMENT This report is based on the Inplant training taken under at HINDUSTAN COCA- COLA BEVERAGE PLANT PATNA, Situated at the north- western zone of Patna at patliputra industrial area. The training was from 8th June to 31st July. During my training I learnt various processes involved in making soft drink along with different treatment plant established here. We would like to express thanks to Mr. M.B.Bera,HOD Food Technology Dept.& Mr. P.Gupta (T&P dept.).for giving us this golden opportunity. And also thanks to our training incharge Mr. Vijay Kumar das & Mr. A.K. Singh who helped us in our training period . SHASHI KUMAR
GFT-085254

CONTENTS SL.NO. | TOPICS | 1 | INTRODUCTION | 2 | ORIGIN AND HISTORY | 3 | Water Treatment | 4 | Soft Water Preparation | 5 | Treated water prepation | 6 | TESTS | 7 | UNIT DESCRIPTION | 8 | PROCESS CALCULATION |

PREFACE
Increase in human population along with the rapid technological advancement gamed by man has led to a number of problems. Deterioration of environment due to pollution and shortage of water are the two major ones. Industries are considered to be the main culprit of these catastrophic conditions which we are facing. Of late man has soon realized the importance of delicate environmental balance existing situation by using certain environmental protection measures as well as optimizing the use of water and also by recycling it. Although the numbers of such companies are very few, still their effort can stand as an example to others.
During my training I learnt various processes involved in making soft drink along with different treatment plant established here. I praise the commitment and consciousness, which Coca- Cola Company has shown in preserving and conserving the treatment. Their effort is really a role model for other such manufacturing units.
I hope that’s reader of this project will have a better idea about the process of soft drink making as well as they may get a clear picture of water and effluent treatment.

Introduction 1. Every day, in more than 195 countries, millions of people enjoy the beverage of the Coca-Cola Company. 2. These beverages are manufactured at bottling and canning plants all around world. At every plant, manufacturing process is a critical link in the value chain. It ensures that customers and consumers always receive the consistent high quality they expect. 3. The beverages manufacturing process, from the time the raw ingredient and empty containers arrive at the plant until the finished product is packaged and put on pallet. 4. To provide both the consumer and customer with the beverages they want. The Coca-Cola Company offers a wide variety of products and packing. 5. The best known brands are carbonated beverage such as Coca-Cola, Diet Coke and Sprite. 6. However, we also produce Non-carbonated beverages, such as Minute Maid, Orange Juice, Nestea and PowerAde. 7. Our beverages are packaged in many different types of Containers-bottles, Cans and boxes. These containers come in sizes ranging from 4 ounces can to 3 liter plastic bottles. 8. Some of these containers refillable and others are not. Refillable bottles are made of either of glass or plastic can be returned to the production facility to be washed and refilled with product. 9. Non-Refillable glass or plastic bottles as well as cans are also commonly used in most areas of world. These containers can be recycled, when properly deposed of by consumer. 10. The equipment and requirement may vary for each type of product and package. However, the basic production process remains the same. 11. The modules also follow the process for manufacturing our most widely recognized product Coca Cola in refillable glass bottles.

12. In every step of this process, as in all areas of value chain, the focus is on quality. To guarantee the consistency of our beverages through the world, all plants authorized to manufacture our products build quality into every operation and procedure. 13. This quality depends on three critical elements a) The right information, b) The right technology and c) The right people 14. These elements are evident throughout the production process. 15. Now let’s take a tour of beverages manufacturing facility and see how the production process works.

DEPARTMENTS | HEADED BY | Manufacturing | Prabhat verma | Finance | Mr. Arup sinha ray | Human Resource | Mr. Manish Kumar | Logistic | Mr. Venugopal | Sales | Mr.Sachin gugnani | Marketing | Mr. Subir Chatterjee | Quality | Mr. Rajesh Ghosh |

ORIGIN AND HISTORY
In 1886 Dr”Penny”pemberton owned a reasonably successful bottled- beverage company in Georgia. He was driving down to street with a wagon full of his wares on a day when his horse was spoked by another delivery wagon that comes around a corner too quickly. In the ensuring confusion, the two horses become entangled and smashed through the front window of a dry goods store, their respective wagons close behind.
But admits the chaos, an amazing discovery was made. A young boy passing the scene of the accident. He noticed a puddle of bubbling brownish liquid just inside the shattered store window and taking care to avoid the broken glass, tasted it. “Wow! This is great, he said, and invited his friends over to “have some of his brown stuff and smile.” Apparently soda water from pemberton’s wagon has mixed with kola nuts and powdered cocoa from the other wagons and sugar and other ingredients from the dry goods store display window and spontaneously created a new beverage. While waiting for someone to help him his horrible head wound, Pemberton had presence of mind to write down the names of the concoctions ingredients and he later used those notes to recreate the beverage.
Dr.JHON’ S Pemberton in Atlanta, Georgia invented coca- cola in May 1886. The name coco-cola was suggested by Dr. Pemberton’s bookkeeper Frank Robinson. He penned the name coco-cola in the following script that is famous today. Willis Venable first sold coco-cola at Jacob’s pharmacy in Atlanta. During the first year, sales of coco-cola averaged nine drinks a day, adding up to total sales for that year of $50. Since the year’s expense was just over $ 70. Dr Pemberton took a loss. Today the product of the coco-cola company is consumed at the rate of more than one billion drinks per day.
Water Treatment

Water is backbone of any industry including soft drink. The quality of finished beverage is a direct reflection of quality of water used to produce it. Hence a single percent change is not taken in terms of quality of water to be used in production procedure.
The Hindustan Coca-Cola Pvt. Ltd. Plant of Patna uses the advanced processes in Purifying water.
Raw water here is processed to produce (1) soft water and (2) treated water. 1. Soft water is produced mainly for:
(a) Boiler. To avoid in crust ruction and sealing.
(b) Bottle washer: For washing bottle in bottle washer.
(c) Uses as lubricant on conveyor.
(d) Is used in cooling paint. (2)Treated water is mainly prepared to produce cold drink and distributed in various places as per requirement (Syrup room, Botthng hall)

Moving forward, 1 first look into general methods used in preparation of soft water and raw water, and then movement will be towards the principles involved in water purification here.

Soft Water Preparation

Raw water tank draws water from the bore well of capacity 20m³ /hr and supplies it to the sand filter. The sand filter is having a diameter of 23.50mm; height 170mm and have a flow rate of 20m3/hr.sand filter removes the impurity by passing the water through different layers of gravel and sand. The carbon filter removes the chorine added as disinfectant in tank, when the water flows through carbon filter. Carbon filter has a dia. Of 1500mm, height 2750mm and a flow rate of 20m3/hr. After the chlorine is removed, in order to soften the water flows through softener. It has dia. 1200mm and height 18mm. The finally soft water is supplied to boiler, bottle washer, Lab, chilling plant pump cooling and so on.

Treated water prepation

The Raw water is taken in treated water tank and agitated after addition of coagulant for about half an hour and is allowed to settle for about four hour. When the coagulant is settled, the water flows through the sand filter of capacity 25m/hr.dia.2600mm and height 1700mm.The sand filter removes the flock particles. One sand filter is used as a standby. After removal of the flock particles the water. Once carbon filter are also used as stand by her. Then water flows to Lead Activate Carbon Filter and Lag A.C.F. for its limit of purification or filteration.The chlorine free water fin up finally goes to 10u, 05u, and 1u micro membrane filters & UV. The finally treated water is supplied to the syrup room for syrup preparation, on paramix for beverage making & on filler.

TESTS
TEST FOR RAW WATER
The following test is conducted of raw water:- (1) Total hardness (2) Ca hardness (3) Mg hardness (4) M- alkalinity (5) PH (6) TDS (7) Chloride (8) Sulphate (9) Taste (10) Odor/appearance

(1) Total hardness:

Reagents:-Ammonia buffer and total hardness indicator.

(a)Take 100ml of water in a conical flask.
(b)Add2-3 drops of ammonia buffer.
(c)Add total hardness indicator
(d)Purple color develops, titrate is with N/50 EDTA.
(e)At end point dark blue color appears
(f)Total hardness=titrate Value X10

(2)Ca-hardness:-
Reagents: - pellets of NaOH, Ca-hardness tablets and EDTA (N/50)
(a)Take 100ml of sample in a conical flask.
(b)Add few pellets of NaOH.
(C)Then add 1-2 tablets of Ca-hardness.
(d)Pink color appears.
(e)Titrate it with N/50 EDTA soln.
(f)At end point purple color develops.
(g)Ca-hardness=titrateX10

(3)Mg-hardness:- Total hardness- Ca-hardness.

(4) m-alkalinity:-

Reagents: - pellets of sodium thiosulphate, methyl orange, N/50 H₂SO₄.

(a)Take 100ml of sample.
(b)Add few pellets of sodium thiosulphate.
(c)Add few drops of methyl orange.
(d)Yellow color appears.
(e)Then titrate it with N/50H₂SO₄
(f)At end point orange color appears.
(g) m-alkalinity=titrateX10

(5)Ph: - is done with the help of ph meter.
(6)TDS: - is done with help of TDS meter.

TDS of the sample= value of TDS meterX5

(7)Chloride:-

Reagents:- 0.02N H2SO4, potassium chromate 0.02N AgNO₃ and Indicator.

Procedure
(a)Filtrate sample to remove turbidity if necessary then add 50ml to a white casserole.
Note:-Do not test for chloride in sample containing solution as these interfaces with the end point.
(b)Add 2 drops of potassium chromate indicator. If a pink color develops neutralize to the colorless end point with 0.02N H₂SO₄
(c) Add 5 drops of potassium chromate indicator.
(d)Fill the burette to zero mark with 0.02N AgNO₃ with the constant agitation titrates until a tinge of red is just precipatable.At first the red color will form and then disappear. The end point has been reached when the red color fails to disappear upon surfing.
(e)Calculate the NaCl conc. From the following equation:-
NaCl (mg) = (AgNO₃ in ml- 0.2ml) normality AgNO₃ x 58.44x1000 vol (ml)

TEST FOR SAND FILTER WATER

The following test conducted for sand filter water. 1. Total hardness 2. M-alkalinity 3. P-alkalinity 4. 2P-M 5. TDS 6. Chlorine 7. Ph 8. Turbidity

1. Total hardness:-similar to the raw water testing.
2. M-alkalinity:-similar as water testing
3. P-alkalinity:-pellets of sodium thiosulphate, phenolphthalein indicator. a. Take 100 ml of sample in a conical flask. b. Add few pallets of sodium thiosulphate c. Add few drops of, phenolphthalein indicator. d. Purple color develops e. Titrate it with N/50 H₂SO₄. f. At end point purple color disappears. g. Value of P-alkalinity=Titrate valueX10
4. 2P-M:-Twice of phenolphthalein alkalinity- m-alkalinity=2P-M

5. Iron:- (a) Iron is detected by lovibond tablet. (b) Take 10 ml water. (c) Add iron tablet to it (d) Color is matched (6)Chlorine:- Equipments:- * Lovibond comparator * Lovibond comparator disc 3/40B * 10mm test cells
Reagents: DPD tablets
Procedure:-
(a) Rinse the test cells. Add 10 ml sample and add DPD tablet (b) Dissolve the tablet. (c) Fill the second 10mm cell with untreated test water for the uses as blank. (d) Place the both cells in the comparator, with the sample in the right hand comparator. (e) Holder the comparator up to the right moves the disc until the same color is absorbed in the both central window. (f) The number in third window is the chlorine concentration(mg/ml)

TEST FOR CARBON FILTER WATER

The following tests are conducted for carbon filter water. (a) Total hardness (b) TDS (c) Iron (d) M- alkalinity (e) PH (f) Taste (g) Odor (h) Appearance (i) Turbidity

* Total hardness:-similar to the raw water testing.

* TDS:-Through TDS meter * Turbidity:-Through turbidity meter. * Iron:-As per sand filter testing. * M- alkalinity: - As per the raw water and sand filter water testing. * PH: - Through pH meter.
NOTE: - Where if the the BOD and COD ratio as established by at least one year of testing. If the plant is to be maintained under following condition to meet the above treated water quality. * Dissolved oxygen should be maintained 2-ppm.this can be achieved by running the aerators continusly with the constant retention time. * Toxic compound such as phenol cyanide ammonia sulphide heavy metal and trace organic should be present in the raw water. * Hydraulic loading as well as raw effluent quality should not be present in the raw water * Hydraulic loading as well as raw effluent quality should not have more than +50% Fluctuation.

UNIT DESCRIPTION
BAR SCREEN:-
Bar screen is provided for the removal of the floating particles and debris present in the raw effluent. Bar screen is provided in the bar screen is provided in the bar screen.
OIL SKIMMER:-
Belt type oil skimmer used in this system. It is used to remove the oil and grease from the effluent. Which will affect the growth of the microbiological growth? Oil and grease from the effluent will stick on the belt provided in the skimmer, will be wiped off and collected separately. Oil skimmer is provided in the trap sump.

EFFLUENT TRANSFER PUMP:-
The effluent from the oil trap will by gravity to the effluent collection sump. The use of this pump to transfer the effluent to the equalization tank. As well as nitrogen oxygen phosphorus and other traces of the nutrient required for their growth. As the bacteria grow on matrix and as more chemicals are added to the BIOX units. The stationary biological film continues to build in thickness. The depth of penetration by diffusion of the absorbed materials such as oxygen or the other slime of the plastic media. At some point the film will become sufficiently thick and the portion of the film closest to the plastic media media will not receive any food or nutrient, particularly oxygen.

The inner layer of the film becomes anaerobic and the organism loses their ability to adhere to the media surface. The solids, which slough from the media, will flow out the BIOX system with the effluent and will be removed from the water through clarification in settling module. The exposed portion of the media surface will repeat the process of the slime accumulation and sloughing.

In actual operation of the biox tank biological film will be in the state of the dynamic continuous growth and sloughing. At any given time proportion of the media are always at same point between forming a new film and sloughing.

AREATION TANK:-
Aeration tank flowed by the biox system is provided with a capacity 140m/hr. The effluent from biox tank is taken at the bottom of the aeration tank and it leaves from the top of the aeration tank. Diagonally opposite to the inlet to have a better mixing of the air with the effluent. In the aeration process oxygen transfer takes place by molecular diffusion through the interface film between air and liquid and increases in proportion to the interface area. In this aerobic aerobic process. The effluent will be subjected extend aeration type activated sludge process for bio-de gradation of the organic impurities in the presence of the recalculated biomass Here the F/M ratio is kept low and return sludge arrangement is provided to maintain the design to maintain of MLSS in the aeration tank. Urea and DAP are regularly given to maintain the MLSS value to sustains the biomass urea and DAP to provide nutrient.

SECONDARY CLARIFIER:-
The effluent with sludge mixture from the aeration tank will enter into the secondary clarifier is designed for a hydraulic surface loading of 1.0m/hr.Clarifier mechanism is provided to settle the sludge at the bottom of the secondary clarifier and it will be recirculated to aeration tank to maintain the required MLSS in the aeration tank and the excess sludge will pump to the sludge drying bed at regular intervals.

CLARIFIED WATER TANK:-
Sludge from secondary clarifier to sludge drying bed and to aeration the sludge recirculation pump transfers tank. The clear supernatant from , the secondary clarifier will flows by the gravity to the clarified water tank the clarified water tank will have a capacity 905m.

LIQUID CHLORINE DOSING SYSTEM:-
Liquid chlorine dosing system consists of one dosing tank having capacity of 100lit and one dosing pump having capacity of 6.0 LHP chlorine dosing tank and dosing pump are provided to dose the chlorine for germs killing.

FILTER FEED PUMP:-

Filter feed pump is used to transfer the clear water from clarified water tank to dual media filter. Butterfly valves at suction and discharge are provided for flow control. Pressure gauge is provided at the outlet of the pump to monitor the feed water pressure.

DUAL MEDIA FILTER (DMF):-
Dual media filter comprises of pressure vessel in mild steel construction with graded filter media chosen from carefully cleaned sieved and graded filter sand.
A mixture of the coarse and fine sand is predetermined proportion facilities in the depth filtration. In depth filtration provided longer runs between backed washed and better quality of filtrate compared to surface filtration provided by conventional sand filters in this filtration unit turbidity and suspended solid removed. To monitor the pressure drop pressure gauge are provided at both inlet and outlet.

PHOTOCHEMICAL REACTOR (PCR):-
Photochemical reactor is provided for the destruction of water borne microorganism with a high efficiency of water H₂0₂ is dosed to the PCR for better destruction. H₂O₂ is dosing tank having capacity of 100 lit and dosing pumps.

ACTIVATED CARBON FILTER:-
Activated carbon filter comprises of a pressure vessels in mild steel construction with granular carbon supported on layers of pebbles and activated carbon. The activated carbon provided high iodine value and isopodous structure for maximum adsorption of the color and COD. The activated carbon filter is provided with frontal pipe work and values for easy operation and back wash in this filtration turbidity and suspended solids are removed.
SLUDGE DRYING BED:-
8 no’s of sludge drying beds are provided to drain the water from concentrated sludge from secondary clarifier and formed sludge will be disposed manually.

CLEANING WATER COLLECTION SUMP:-
All the drains in the plant back wash water DMF/ACF will be collected by gravity in the cleaning water collection sump.

PROCESS CALCULATION
Parameter value Plant flow capacity | 350m³/day | Hours of operation | 20 hrs | Maximum flow rate | 17.3m³/hr |

Equalization tank

Equalization tank volume period | 210m³ | Retention time | 12 hrs | Type of equalization | Fill and draw | Nos of compartment | 2 | Capacity of each compartment | 105m³ | Liquid depth | 3.5m | Therefore overall size of the tank | 10.0mx3.0mx4.0m |

ACS Biox system Intel COD | 100PPM | COD load | 350kgs/day | Intel BOD | 500PPM | BOD load | 175 kg/day | COD loading for ACS biox | 9 kg/day@48% destruction efficiency | Therefore media required | 39m³ | Therefore volume of the tank | 50m³ | Liquid depth | 3.5m | ThereforeACS biox tank size | 3.0x9.0x4.0m(3.5+0.5mFB) | Outlet COD | 500PPM | Outlet BOD | 150PPM |

Activated sludge process system BOD load at the inlet of aeration tank | | COD load at the inlet of aeration | 175 kgs/day | Design MLSS | 3500 | FM Ratio | 0.15 | Aeration tank volume required | 167m³ | Aeration tank volume provided | Existing | Liquid depth | 3.5m | Size of tank | 14.7x9.0mx4.0(3.5+0.5mFB) | Oxygen required | 2.0 kg/kg of BOD | Oxygen transfer efficiency | 1.2kg/HP | Oxygen required@2kg/kg ofBOD | 175 KG/DAY | Oxygen required/HR | 7.2 kg | Therefore aeration HP required | 7.5HP | Nos of aeration provided | 2 | System efficiency | 95%BOD DESTRUCTION | Oxygen level at the outlet of aeration tank | 2 ppm(min)3 ppm(nor) |

Secondary clarifier Retention time in secondary clarifier | 2.5 hrs | Volume of clarifier required | 43.8m³ | Therefore size of the clarifier | 5.0mDiaX 2.5Mswd | BOD of the secondary clarifier | 26 ppm |

Clarifier water tank Retention time in clarifier water tank | 30 min | Capacity of three tank required | 8.75m³ | Therefore size of the tank | 2.5Mx 2.5Mx2.0 | Tank capacity provided | 9.375m³ |

Liquid chlorine dosing system Flow rate | 10.0m³/hr | Recommended dosage | 6 ppm | Dosing tank capacity provided | 100 lit |

Sludge drying bed BOD load per day | 175 kg | % of excess sludge produced per day | 15% | QTY. of sludge produced per day | 26.25 kg | Consistency of sludge considered | 1.5% | Therefore volume of sludge | 10.8m³ | Sludge layer over bed | 0.2m | Area required | 54m² | Area provided | 72m² | Nos of sludge drying beds provided | 8 no’s | Area of sludge drying bed provided | 3.0m X 3.0m X 1.0m |

Dual media filter Flow rate | 10.0m³/hr | Filtration velocity | 12m³/hr | Diameter required | 1061mm | Therefore filter diameter | 1200mm |

Photochemical oxidation unit Intel COD to PCO | 250 PPM | Final COD required | 100 ppm | H₂O₂ DOSAGE | 1 ppm of H₂O₂ for reduction of 1.0 ppm of COD | Recommended dosage | 150 ppm | Dosing pump capacity provided | 4.0 LPH | Dosing rate | 3.0 LPH |

Activated Carbon Filter Carbon filter capacity | 10.0m³/hr | Filtration velocity | 15m²/hr | Diameter required | 849mm | Therefore filter diameter | 1000mm | BOD level at the outlet or carbon filter | 18 ppm | COD level at the outlet of carbon filter | 100 ppm |

SAMPLING
Location of various sampling points and the parameter that will be analyzed at each of points are as follows
SAMPLING POINT * Intel effluent -COD,BOD,TSS,OIL & Grease & pH * Equalization tank -pH * Biox tank outlet -COD, BOD * Aeration tank outlet -MLSS,DO,COD,BOD * Clarifier outlet -COD, BOD,TSS,OIL& Grease & Ph * Dual media filter -TSS * PCR -COD * Activated carbon filter -COD,BOD,TSS,OIL & Grease & pH

CONCLUSION

In this era the industry growing in a large scale and this is the major cause in the pollution i.e. water as well as air. If we treat our effluent in better way so that it cannot harm to river in which we are going to discharge our waste. The coca-cola company is pioneer in its field and getting a chance for training in such a prestigious multinational company is very truthful to me. It is not an easy task to learn the thing the processing in the company and compile the project in four week. I would like thanks to the official in quality Department of coca- cola Patna for giving me the guidance which was the best of his knowledge and belief.
AAs our topic for the training is the “PROCESSING OPERATION OF E.T.P” at coca- cola plant here I studied about each and every process of E.T.P in this we calculate the COD,BOD,MLSS,MLVSS,DO,oil and grease, pH and also the microbiology lab.