Bahir-Dar University Bahir-Dar Institute of Technology Faculty of Chemical and Food Engineering Department of Chemical Engineering

BAHIR DAR INISTITUTE OF TECHNOLOGY
BAHIR-DAR UNIVERSITY
BAHIR-DAR INSTITUTE OF TECHNOLOGY
FACULTY OF CHEMICAL AND FOOD ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING
Internship final report: (FEB 16 – JUNE 16, 2017)
Internship hosting company: MOHA Soft drinks industry (Nifas silk plant)
By: Arsima Kiros

Senait Shita
Selam Ambaye
ID: XXXXXXXXX
0601460
0601439
Advisor: - Mr. Tadele N. and Mr. Natnael G.

Submission date: June 28, 2017
MOHA soft drink S.C final report Page 1

ACKNOWLEDGEMENT
First of all we would like to thank the almighty God for helping us on the correct way. we would
like appreciate and respect to the institution for providing these precious opportunities that
enable me familiar with practical skill. Special thanks for our advisors Mr. Tadele N. and Mr.
Natnael G. and the company supervisor w/ro wudie Tibebu for her encouragement, guidance and
the fact that she has provided me with all the supporting materials, facilities and her advice to
complete my project successfully. And also special thanks for Ato Yewlsew belay, all quality
control chemists, carbon dioxide production plant laboratory chemists and technics. Finally I
would like express my gratitude to all MOHA soft drink operators, advisors to help the
internship experience (especially Addis (technics supervisor)).

EXECUTIVE SUMMARY
This report and the project work consists the brief history and profile of our hosting company
including the main raw material used to produce its main products. And also the main customers
that use its main products and supplier, consequently its organizational structure and detail work
flow of beverages production activities in each section and the overall systems of the
organization the report also describes the current practice and activities that take place in the
production Department and other main supportive departments. The factors constrained their
activities was also identified. Following this I tried to describe the analysis made to solve those
problems by using different techniques and recommendation during internship I was able to
understand the company competitive strength and dedications of both the management and
employees in every fate of organization operations. In addition to the overall benefit that I gained
during the internship and the significance of the project these are in terms of improving and
upgrading the practical skill, theoretical knowledge ,team playing skills leadership skills, work
ethics, entrepreneurship skills and interpersonal communication skills


Contents
ACKNOWLEDGEMENT ............................................................................................................................ 2
EXECUTIVE SUMMARY .......................................................................................................................... 3
LIST OF FIGURE......................................................................................................................................... 7
LIST OF TABLE .......................................................................................................................................... 9
ACRONYMS .............................................................................................................................................. 10
CHAPTER ONE: INTRODUCTION ......................................................................................................... 11
1.1 Back ground of the MOHA soft drink industry in Ethiopia.............................................................. 11
1. 2 Objective of the company ................................................................................................................ 12
1.3 Mission and Vision of the company ................................................................................................. 12
1.4 Main product s of the company......................................................................................................... 13
1.5 The main customer of the company .................................................................................................. 13
1.6 Organizational structure .................................................................................................................... 14
CHATER TWO: THE OVERALL INTERNSHIP EXPERIENCE ........................................................... 16
2.1 How we get into the company........................................................................................................... 16
2.2 Production process description of the company................................................................................ 17
2.2.1 Raw materials of carbonated soft drinks .................................................................................... 18
2.2.2 Water treatment .......................................................................................................................... 18
2.2.3 Boiler room ................................................................................................................................ 25
2.2.3 Bottle and case washer room ..................................................................................................... 25
2.2.4 Carbon dioxide production plant................................................................................................ 32
............................................................................................................................................................ 33
2.2.5 Syrup room................................................................................................................................. 37
2.2.6 Filling room ............................................................................................................................... 42
2.2.7 Quality control section ............................................................................................................... 44
2.2.8 Cooling compressor section ....................................................................................................... 50
CHAPTER THREE: OVERALL INTERNSHIP BENEFITS ................................................................... 52
3.1.1 Improving Interpersonal Communication Skills ........................................................................ 52
3.1.2 Improving Team playing skills .................................................................................................. 52
3.1.3 Improving work ethics ............................................................................................................... 52
3.1.4 Upgrading of Theoretical Knowledge ........................................................................................ 53

3.1.5 Entrepreneurship skills ............................................................................................................... 53

3.1.6 Improving leadership skills ........................................................................................................ 53
CHAPTER FOURE: CONCLUSION AND RECOMMENDATION ....................................................... 54
Conclusion ............................................................................................................................................... 54
Recommendation .................................................................................................................................... 56
CHAPTER FIVE: PROECT WORK .......................................................................................................... 57
5.1 Introduction .......................................................................................... Error! Bookmark not defined.
5.2 Problem of the statement...................................................................... Error! Bookmark not defined.
5.3 Objective .............................................................................................. Error! Bookmark not defined.
5.3.1 General objective: ......................................................................... Error! Bookmark not defined.
5.3.2 Specific objective: ......................................................................... Error! Bookmark not defined.
5.4 significance of the project .................................................................... Error! Bookmark not defined.
5.5 scope and limitation of the project ....................................................... Error! Bookmark not defined.
5.6 Literature review .................................................................................. Error! Bookmark not defined.
5.7 Methodology ........................................................................................ Error! Bookmark not defined.
5.7 result and discussion ............................................................................ Error! Bookmark not defined.
Conclusion ............................................................................................. Error! Bookmark not defined.
5.9 recommendation................................................................................... Error! Bookmark not defined.
REFERECE................................................................................................ Error! Bookmark not defined.

LIST OF FIGURE


LIST OF TABLE

ACRONYMS
PI=Pepsi international
S.C=share company
EBI=electronic bottle inspection
CO2=carbon dioxide
CH4 =methane
O2=oxygen
H2O=water
N2=nitrogen
CO=carbon monoxide
CaCO3= limestone
H2SO2=sulfuric acid
CaSO4=gypsum
C2H4=ethylene
C2H4O=ethylene oxide
M reading=methyl purple
P reading=phenophtaline
GMP=good manufacturing practice
HACCP=hazard analysis and critical control point
QAS=quality auditing system
EMS=environmental management system,
NSP=Nefas silk plant
Ppm=parts per millions

CHAPTER ONE: INTRODUCTION
1.1 Back ground of the MOHA soft drink industry in Ethiopia

MOHA soft drinks Industry S.C was established on May 15, 1996 acquiring Nefas silk Plant,
Tekle Haimanot Plant, Gonder Plant, and Dessie Plant from the Ethiopian Privatization Agency
with paid capital of Birr 108,654,000. The Company currently has seven operating units
including Summit Plant, Bure Plant, and the recently inaugurated Hawassa Plant in the Southern
Nations & Nationalities People's Region. The major products of MOHA Soft Drinks Industry
S.C. are: Pepsi Cola, Mirinda Orange, 7-Up, Mirinda Tonic, Mirinda Apple, Mirinda Pine Apple
(all Pepsi Brands), and Kool (Bure Kool and Tossa bottled water products.) The Annual Turn-
over of the company has reached to Birr 556 million and sales stands at an average annual
growth rate of 12%.
MOHA Soft Drinks Industry S.C. has adhered to Pepsi Cola International Standards and Good
Manufacturing Practices (GMP).
MOHA holds 52% of the market share in soft drinks industry in the country. With an expansion
and replacement of obsolete machinery, production capacity of the plants has increased
substantially. MOHA, in addition to the initial purchase price of the Soft Drinks factory, has
invested Birr 8 Million for the expansion of new projects, Birr 153 million for refurbishment and
replacement of existing plants and Birr 241 million for marketing, infrastructure, excluding
advertisement and sponsorship expenses. Also, a significant growth over the years of production,
sales, and profitability due to reorganization of operations has been achieved. Productivity has
improved tremendously with major cost savings and has insured a regular supply of high quality
products. It has also succeeded in reaching new market areas across the country.
The drink Pepsi was firstly introduced as “brad’s drink” in United States. Who made it at his
drug store where the drink was sold, It was renamed to Pepsi cola in 1898, named after the
digestive enzyme pepsin and kola nuts used in the recipe.
In 1903, Bradham moved the bottling of Pepsi cola from his drug store to a rented ware house.
That year Bradham sold 7989 gallons of syrup. The next year Pepsi was sold in six-ounce
bottles, and sales increased. In addition to selling the drink at drugstore counters; Bradham
bottled Pepsi for sale on store shelves .At this time bottling was a new innovation in food

packaging However, due to major increases in the price of sugar, Braham began to lose money
on Pepsi and in 1923 he filed for bankruptcy. The Craven Holding Company of craven country,
North Carolina, purchased the company’s assets. In 1931 Charles G.Guth of the Loft Company
in New York City purchased Pepsi-Cola from the holding company. Guth had difficulty getting
the business going again, but he increased sales by selling larger bottles at an unchanged price.
By 1933 Pepsi Cola was sold by 313 franchised U.S. dealers bottled in the united states, Cuba,
and England and Sold in 83 countries. The consumption of soft drinks in their various forms has
taken place for many centuries in order to meet the body’s fundamental requirement for
hydration. The most obvious source of hydration is water, but in earlier times the consumption of
water was very hazardous as it was frequently contaminated by micro-organisms .Outbreaks of
cholera, dysentery and (other waterborne illnesses were common in many European cities prior
to the twentieth century.
1. 2 Objective of the company

The business purposes of MOHA soft drinks industry S.C.as stipulated in the memorandum of
association are:-
1. To manufacture, buy, sell, bottle, distribute and otherwise deal in non-alcoholic

beverages, minerals aerated waters and the ingredients thereof in Ethiopia and elsewhere.
2. To manufacture, sell and distribute bottles, corks, corkscrews and all type of crates.
3. To manufacture, sell and distribute carbon dioxide.
4. To invest in other business enterprises, to establish and manage in Ethiopia or abroad,
such subsidiaries, branches or agencies as may be deemed desirable.
5. Generally, to carry on and engage in other activities which the company may deem
necessary incidental or related to the attainment of any of the above purposes.
1.3 Mission and Vision of the company

Mission of the company
The companies state that its first responsibility and primary focus is to both satisfy and delight
the community of end users whom it exist to serves, to fulfill needs and wants and to improve
their quality of life. It says that knowing the path to the end users lies through the retail and
wholesale trades and its priority that to listen and respond to the

Vision of the company
MOHA’s vision is to make each of the Pepsi products to be a drink of first choice amount
consumers and obtainable throughout the Ethiopian market. The company intends to create
superior value for its shareholders, its customers and employees. raw material and suppliers of
the company
1.4 Main product s of the company

 Pepsi cola(cola flavor)
 Mirinda(orange flavor)
 7up(lemon flavor)
 Miranda Tonic
 Miranda apple (apple flavor)
 Mirinda pineapple (pineapple flavor)
 cool carbonated water(not mineral water)
 CO2 gas
1.5 The main customer of the company

Nefas silk Pepsi plant is the products are distributed to local market mostly urban areas around
Addis Ababa, Nekemit & Jima.

1.6 Organizational structure
Fig 1.1 organization structure
Fig 1.1 general organizational structure

Figure 1.1 general organization of the company
MOHA operates with attend office located at A.A led by a chief executive office (C.E.O)
appointed by the chairman of the ward. The C.E.O is empowered to direct, plan, coordinate,
organize, control and administer the overall operation of the company. Hire and file personal
directly or through this delegated management team. Represent the company in all fields of the
company activities. To approve annual budget and justify to the board chairman or MIDROC–
Ethiopia, keep and maintain the proper booking of the company accounts. Hierarchically the
C.E. chairman of the board currently O is accountable to the activities of the company reporting
to C.E.O are grouped in to the following functions

1. Finance division
2. Human resource division
3. Marketing division
4. Technical division
5. Procurement &stores /supplies division
6. Quality control &production division
7. Audit division
8. MIS service
9. Legal service
10. Plants at different location
11. Regional office

CHATER TWO: THE OVERALL INTERNSHIP EXPERIENCE
2.1 How we get into the company

Bahir Dar University has an internship program for all engineering students, by the program of
the university. that allows the students to get practical knowledge for a four month period.
We are try to find an appropriate internship by applied an internship request for many companies
but we couldn’t get the acceptance. Finally by the help of university industrial linkage
coordinator we get the acceptance of MOHA soft drink S.C in Nifas silk Pepsi cola plant.

2.2 Production process description of the company

1. Water treatment room
2. Boiler room
3. Bottles and case washer room
4. Carbon dioxide production plant
5. Syrup room
6. Filling room
7. Quality room
8. Cooling compressor room

2.2.1 Raw materials of carbonated soft drinks

 Water: - as the main component of a soft drink, usually accounts for between 85−95% of
the product and acts as a carrier for the other ingredients. This water used should be
treated water.
 Sweeter - are a critical ingredient of Pepsi cola products and there use must be properly
controlled which greatly affect the sensory experience.
 Concentrate - receipt and handling must be properly managed ensure good quality
beverage.
 Carbon dioxide - imparts a pungent slightly acidic taste to the finished product as well as
crating greater eye appeal.CO2 to extent used as preservatives
2.2.2 Water treatment

Water is the main component of a soft drink, usually accounts for between 85−95% of the
product and acts as a carrier for the other ingredients. So this water should be treated. Water
treatment is the process of removing undesirable chemicals, biological contaminant, suspended
solids and gases from raw water and that makes the water more clean and acceptable for specific
end use. The source of the water is ground water and sometimes uses municipal water. When
they have shortages of the ground water they use municipal water because the municipal water is
coasty than ground water and can NOT get sufficiently.
Selection of water technology
The water treatment selection is depends on the source of water. The raw water supplies are
contaminated by different pollutants when the water affected by pollutant the water may have
 Bad odor
 Taste
 Smell
But in our plant (Nifas silk Pepsi cola plant) the source of water supply is the ground water
source which is usually free from of natural organic matter but can be high in minerals, alkalinity
compounds such as Ca+ & Mg2+ it is also free from external pollution, but it is not pure water,

there is growth of microorganisms & minerals unless it can’t be treated. To treat this water
MOHA soft drink (Nefas silk) uses coagulation system.
Coagulation
In beverage industry, coagulation water treatment technology also known as convectional lime
treatment systems (CLTS). This mechanism can also use to meet different conditions therefore
they remain a valuable treatment used in different manners to meet our treatment needs.
Chemical used for water treatment
I. Lime: - lime is used for alkalinity reduction. It is also used to increase the pH of the
water. The total alkalinity of the treated water should be below 50 ppm. Lime reduces
alkalinity by converting carbon dioxide to bicarbonate alkalinity, and bicarbonate
alkalinity to the insoluble forms calcium carbonate and magnesium hydroxide, which
precipitate out of the water.
II. Calcium chloride: - reacts with the lime to reduce the water alkalinity. Sodium alkalinity
is present when the total alkalinity is greater than the hardness of the water. Calcium
chloride which forms calcium carbonate from the sodium bicarbonate as the calcium
bicarbonate is formed. In some cases, water contains sodium alkalinity.If sodium
alkalinity is present, it will be necessary to add small amounts of calcium chloride to get
the treated water total alkalinity below the maximum limit of 50 ppm.
Reaction
Na2CO3+CaCl2−−−−−−−−−→ CaCO3 + 2NaCl
III. Chlorine− used for sanitation and to kill microorganism

IV. Aluminum sulphate: - is the most widely used coagulant for water treatment. At high
alkaline (PH) prevalent in the water these salt produce insoluble aluminum hydroxide.
Al2 (SO4)3 +6H2O−−−−−−−→ 2Al (OH) 3 +3H2SO4

3H2SO4+3Ca (HCO3)2−−−−−−−→3CaSO4 +6H2CO3
6H2 CO3 −−−−−−−→ 6CO2 +6H2O
Al2 (SO4)3 + 3Ca (HCO3)2−−−−−−−→2Al (OH)3 + 3Ca SO4 + 6 CO2

Aluminum
Sulphate Calcium Chloride
Raw
water
Intermediate
Lime
Coagulation Tank Sand Filter Tank
Chlorine
Carbon Purifier
UV Polisher
Figure 2.1 process diagram of water treatment
Process description about water treatment section

Coagulation Tank
Coagulation is a chemically water treatment process by doing smaller particles in to heavier that
is they can quickly settle out. In this tank mixing is take place that is as we can see the above
flow diagram the water and the four chemicals (lime, aluminum sulphate, calcium chloride and
chlorine) mixed together. There are three parts the 1st one is the mixing process takes place, the
2nd part is some chemicals settled out, and it looks like slightly pure. The final part will be more
purified than the second part of the tank. Finally the treated water goes to the sand filter.

Figure 2.2 coagulation tanks
Sand filter
The treated water that comes from coagulation tank enters in to the sand filter.in this tank there is
small sand that is used to settle the lime. This used to remove the unwanted chemicals except
chlorine from water.in the sand filter we can checked the lime dosage in the treated water, by
using the formula : A= 2P-M
Where
A -is which tells us whether the lime treatment is correct or not
P-is phenolphthalein indicator
M -is will tell us if all bicarbonate was removed whether we have free lime present.
 When A is positive, that is 2P is >M this implies that free lime is present in the treated
water.
 When A is negative, that is M is> P this implies that bicarbonate is present in the treated
water.
For proper lime treatment A value should be in between 2 and 7.
The Procedure to determine the correct lime treatment
− Prepare 100ml of water from the sand filter

− Add 3 droplet of T-solution.
− Again Add 2 droplet of P-solution.
− Then color can be changed in to pink.

− Then titrate by using 0.02NH2SO4 until the color can be changed into pink into colorless
end point.
− Then the numbers that can be used for titration is record” P” reading.
− After record the number then add 3 droplet of M- solution (methyl purple).
− The color can be changed in to greens
− Continue titration by using 0.02NH2SO4 until the color can be changed green into purple
end point.
− Then record total 0.02NH2SO4 usage M” reading.
Example
P=10, 2*10=20
M= 22
-2 this implies that under treated with lime. This is corrected by addition of lime.
Intermediate tank
This tank is used for only storage purpose.
Carbon purifier
The treated water that comes from the intermediate tank is entered in to the carbon purifier. This
is used to remove chlorine by using activated carbon that present in the water. The presence of
chlorine can be changed the color and test of the final product (Pepsi, Miranda ,7up Miranda
apple, Miranda orange and Miranda tonic). The chlorine dosage in the carbon purifier must be in
between 6and8.
If the color can be hanged the water has chlorine, therefore the treated water can be corrected by
removed chlorine before enter in to the polisher. Because if the water that has chorine is passed
in to the process can be changed the color and test of the products.
5micro Polisher
This is used to remove suspended activated carbon that comes from the carbon purifier and other
unwanted particle that may be passed through the carbon purifier.

Ultraviolet (UV) ray

This is the final treatment of the process and the main treatment in this section. This is used to
remove microorganisms present in the treated water. It’s also known as the critical control point
for the quality of the water.
Table 1.1 Pepsi cola water standard
Appearance Clear
Taste None
Odor None
Color 5ppm Maximum
Turbidity 1.0ppm Maximum
Total dissolved solids 500ppm Maximum
Chlorides 250ppm as Cl Maximum
Sulfates 250ppm as SO4 Maximum
Iron 0.1ppm as Fe Maximum
Total alkalinity 50 ppm as Ca CO3 Maximum
Organic matter None
Manganese None Maximum
Fluoride 1.0ppm
Chlorine None

Nitrate 25ppm as NO3 Maximum
The purpose of treated water

 Beverage preparation
 Washing the bottles
 Steam generation
 Syrup preparation
 Heat exchange or other cleaning purpose
There is a standard to be reached for the accomplishment of this water purpose. It is mandatory
that beverage plants be in compliance with all regulation regarding water source, water handling,
water treatment and discharge of waste water and sludge’s to the drain.
The other water treatment done is softening the hard water for softener the row water used comes
from municipal. The equipment used for softening purpose
Sodium chloride mixing tank: - It uses to dissolve the salt that used to clean the softener 1 & 2
Softener 1 and 2:-These two softener equipment’s used to change the hardness of water to soft
one by using zeolites in it here chemicals like calcium and magnesium. Remove by ion
exchange. The purpose of softening is to remove scale formation
 The softening water used for bottle washing and steam generation.
CIP in water treatment room

The floor, tables and outer part of the apparatuses cleaned with detergent and water. The sand
filter and carbon purifier back wash to remove solid particles and chlorine. The filter bags in
polisher are soaked in chlorine every day. Coagulation thank chlorinated by 8 ppm and the
intermediate thank is chlorinated by 7ppm.

2.2.3 Boiler room

Boilers are pressure vessels that are designed to heat water or produce steam, which is then
used for many purposes like space heating service water heating in a building, steam
jet cleaning. There are many types of heating sources in a boiler like natural gas fired burner, oil
fired burner and electrical resistance heaters. Steam is preferred than hot water in some
applications including absorption cooling, kitchens, laundries, sterilizers, and steam driven
equipment. The boiler room of the plant is where steam is generated which is used for: bottle
washer, CIP – clean in place and for sugar dissolving. The company’s boiler is a fire tube type of
boiler with a capacity of 3200 kg/hr. And an air intake directly from the atmosphere with the
help of fan controlled with a manually adjusted servo motor, use furnace oil which is the most
commonly used fuel in most companies. The key boiler components involved in this process are
the burner, combustion chamber, heat exchanger, and controls. The burner mixes the fuel and
oxygen together and, with the assistance of an ignition device, provides a platform for
combustion. This combustion takes place in the combustion chamber, and the heat that it
generates is transferred to the water through the heat exchanger. Controls regulate the ignition,
burner firing rate, fuel supply, air supply, exhaust draft, water temperature, steam pressure, and
boiler pressure
2.2.3 Bottle and case washer room

Bottle washer

The bottle washer clean and sanitize returnable bottles that have been brought back from the
trade. Returnable bottles are rinsed to remove beverage residues, straws and any liquids or
suspended material. High strength of caustic, caustic based detergent, or caustic with other
additives, at elevated temperatures are used to clean and sanitize the bottle. The bottle washer
takes dirty bottles from the trade and subjects them to:
1. Water and caustic rinsing

2. Soaking periods in hot caustic
3. A number of inside and outside fresh water flushing’s with sanitary
Water to deliver a clean and sanitary bottle to the conveyer ensure route to the filler. For glass
bottle extending soak time can allow a slight reduction in the basic requirements. Washed bottles
that exist the washer should be checked for caustic carry over at start up and during operation.
Checking for caustic carryover should be performed at start up and twice per shift, testing a
complex row of pockets at the bottle discharge station of the bottle washer and during production
every two hours 3 additional bottles should be spot checked. Generally the washer section is the
major part of the company.in this section the process become started by selecting the most defect
bottles by using manual inspection.then transfer in to the washer machin by using bottle
conveyor.the soap can be added in to the conveyor in order in to reduce friction between the
conveyor and the bottles.then the bottle is interd in to the washer machine.
Figure 2.3 washer machines, during the production of 7up

Empty bottle store
Depalletization
Case washer
Uncasing
Washing compartment 1
Inspection
Figure 2.4 process flow diagram of washer section

Process flow description of bottle washer

The bottle taken out of the cases are taken to bottle washer whereas the cases the cases are taken
to the place where the finished product is cased. The steel belt conveyer takes the bottle to
another conveyer called rotary that has a pocket like structure which aligned around. Rotary
takes 52 bottles in row and 290 bottles in total once to the washing compartments. The bottles
are washed in 3 compartments. For washing we use chemicals such as: soft water, caustic soda,
divo LE, divo AI and chlorine. In the 1st compartment we use soft water and caustic soda. The
caustic soda is added to a separate CSTR thank and enters the compartment with the help of
pumps and lines and the bottles are soaked. Here caustic soda concentration and temperature is
2.5% and 50−60oc respectively. In the 2nd compartment there is 2.5% caustic soda and 65−80oc
temperature. The bottles are cleaned thoroughly in order to get rid of any impurities. In 3 rd
compartment there is 1% caustic soda and 25oc temperature and final rinse takes place. Here pre
jets are used in order to spray the water in a powerful way so there is no trace of caustic soda in
the bottles and also add chemicals like divo LE and divo AI to remove caustic soda residue and
chlorine for disinfection.
case washer
Case Washing: is a process of cleaning the case that can be used again for casing the finished
product. The case washer is a cleaning machine that cleans cases separately from bottles. There
are two partitioned spaces where cases are to be treated. They are treated with by warm caustic
soda and also by cold water by applying high pressure spray jet. The desirable amount of heat is
controlled by heat regulator that heat is transferred by convection system from the steam coming
from the boiler. The water that used to clean both the bottle and case is coming from the water
treatment room from softener.
Important of bottle washer
 Assures product integrity

Unclean(visible and non-visible bottles can result in off-tastes, off-odors foreign
materials, and poor consumer acceptace.

Bottle washing minimum mandate
 Hot caustic soak condition:- as a minimum 2.0% caustic, 65oc temprature, and 6.0
minutes contact time.
 Pre-final rinse:-approved rinse agent must be used, and result in the following pre-rinse
conditions:
− PH of 7.5 +/-0.5
− Free EDTA of 5ppm (minimum)
 Pre-final rinse:- approved rinse agent dosing must be inerlocked with pre-final rinse
recirculation.
 Pre-final rinse recirculation is set to continue when the washer stops.
 Final rinse:- treated or portable water must be used.
 Inspection:- post-wash inspection by human and/or EBI as pre pepsico requarments.
Table 2.2 hot caustic soak tank washer condition
minimum conditions must NOT be below any

of the following
Caustic concentration 2.0%
Temperature 65oc
Contact time 6.0min
General best practice conditions
Concentration 2.25(+/-0.25)%
Temperature 75oc
Contact time 7.5min

Purposes of rinse
 To lower bottle temperature gradually to avoid thermal damage

 To remove detergent, dissolved or suspended dirt from the inside and outside of the
bottles.
 Remove caustic carry over residues
N: B there is a high risk of thermal shock if the cooling temperature differential is >28oc.
Bottles inspection
Inspection removes with dirt or foreign materials, and verifies efficiency of washing process.
 Pre-sorting (upon receipt at plant) is recommended.

 Pre-inspection (before the washer) is recommended.
 Post-inspection (after washer) is mandatory.
Table 2.3 PI requirements for post-inspectors
Inspection Maximum speed-for GRB after washing
Human 150 bottles per inspector per minute.
Photo-cell (light)electronic EBI 200 bottles per inspector per minute.
Camera vision No human inspection required
Acceptable alternative to human /EBI.
In MOHA soft drink there are two types of inspection. These are:-
1. Manual inspection:-in this section the bottles can be checked by human by using light,
there a lot of shifts because one shift can be worked only for 15 minutes.
2. Electronic based inspection (EBI):- in this part the equipment can be worked by capturing
photo. The operator can be worked for one hour.

Parameter of EBI (electronic based inspection)
1. Finish
2. Neck
3. Shoulder
4. Sidewall
5. Bottom

2.2.4 Carbon dioxide production plant

Carbon dioxide is one of the essential components in beverage production process. The correct
proportioning of carbon dioxide into the beverage enhances both the beverage's taste and
appearance. It also imparts a pungent, slightly acidic taste to the finished product as well as
creating greater eye appeal. To some extent it acts as a preservative.In MOHA soft drink they
have their own carbon dioxide production plant. But they are worked separately. Carbon dioxide
are used for production of Pepsi 7up Mirinda (apple, orange and pineapple). The raw materials
for production of carbon dioxide are air, diesel oil, and electrode. Then the raw materials are
inter in to the boiler there are also electrode (positive and negative charge) in order to created
spark, finally the flam become created. In this process there is much equipment. They are boiler,
scrubber, absorber, stripper, heat exchanger, potassium per manganite scrubber, compressor,
dehydrate, carbon purifier and condenser, carbon dioxide storage tank. In the carbon dioxide
production plant there are many laboratory tests. These are the amount of oxygen and carbon
dioxide that comes from the boiler and enter in to the soda scrubber. Normality of mono ethanol
amine (MEA solution) and Na2CO3.The color of H2S NOx, the odor and test of the toxic gas that
comes from before and after carbon filter and storage tank. In carbon dioxide production plant
there are many toxic gases, and also may be produced acid, therefore they must be use safety
unless and otherwise it can be lose many things. They must be NOT careless. As a chemical
engineer carbon dioxide plants are the interested section.
Function of carbon dioxide
 Contribute to the sensory profile (flavor and appearance our beverages).

 Act as an effective inhibitor and preservative against many microorganisms.
 Makes the beverage be perceived as refreshing and simulating to the consumers.
 Aids in providing package integrity.

Boiler Scrubber Absorber Stripper Gas cooler
Condenser Carbon Potassium

purifier Dehydrator Compressor
scrubber
Storage tank
Purging
Figure 2.5 process flow diagram of carbon dioxide production plant
Processes description of carbon dioxide production plant
 Boiler
used as a closed vessel in which water or other liquid is heated; steam or vapor is generated, by
applying heat.in the case of carbon dioxide production plant they are generate carbon dioxide by
using air and diesel oil. Diesel oils are organic compounds they are hydrogen, oxygen and carbon
sometimes sulfur.in the boiler there are two reactions, this are complete combustion and
incomplete combustion. Complete combustion is produced by sufficient amount of oxygen and
the amount of oxygen can be in the range of 3-5%. In the case of incomplete combustion the
amount of oxygen is less than one. If there is incomplete combustion they can be produce very
dangerous gases (H2S, CO, SO2, HCN, NOx).

 Soda scrubber
Scrubber system are a diverse group of air pollution control device of alkaline material usually
hydrated lime soda ash, or sodium bicarbonate in to the gas stream to react with acid gases.
The flue gas that comes from the boiler is enters in to the soda scrubber.in the scrubber there is
ceramics used to the reaction media and Na2CO3 in order to remove H2S, SO2.
 Absorber
The absorber is exothermic because it is open system .it is release heat. On absorber is forced
and counter current In absorber the MEA and co2 mixed to use is double heat exchanger cool
dawn to 40oc using cooling water. In absorber the temperature 35oc -40oc when the
temperature is cold MEA can capture the co2 when the temperature is hot MEA can fled the
co2 so the MEA can capture the co2 in absorber. The flue gas enters the absorber bottom .The
lean lye (MEA-lye without CO2) is led to the absorber through a distributor in the top. The
distributor ensures that the lean lye is evenly distributed throughout the entire surface of the
absorber To increase the contact between the lean lye and the flue gas is the upper section of
the absorber filled with plastic tower packing The lean lye trickles through the tower from
above entering the tower packing, while the flue gas containing CO2 flows from the bottom
to the top. At this counter flow the CO2 contained in the flue gas will be absorbed by the
relatively cold lean lye. The Lye pumped out of the absorber contains now the CO2 from the
flue gas and is called Rich Lye. The Rich Lye pump is pumping the lye to the stripper
through the lye cooler. The absorber is fitted with a demister in the top, to avoid MEA
droplets to escape with the gas going to free air. The white smoke coming from the absorber
outlet is mainly water vapour, nitrogen and oxygen .The rich MEA goes to heat exchanger
and the T 96oc
 Stripper
The Rich Lye containing CO2 is preheated in the lye cooler before entering the stripper. In order
to release the CO2 from the lye solution must the solution be heated to its boiling point.in striper
we use steam to Increase the TO rich MEA from 96oc-110oc and not to let reaction occur The
heat input is coming from the burner, and in the boiler a mix of steam and CO2-gas will be

generated and flow through the stripper. The Rich Lye from the absorber (MEA-lye with CO2) is
led to the stripper, where it enters through a distributor in the top. The distributor ensures that the
Rich Lye is evenly distributed throughout the entire surface of the stripper. To increase the
contact between the Rich Lye and the steam from the boiler is the upper section of the stripper
filled with ceramic tower packing. The Rich Lye trickles through the tower from above entering
the tower packing, while the mixture of steam and CO2 flows from the bottom to the top. At this
counter flow the CO2 contained in the Rich Lye was released efficiently. The mix of steam and
CO2 flows from the top of the stripper to the gas cooler.
 Gas cooler
The steam and CO2 developed in the boiler and stripper must be separated before entering the
purification and liquefaction unit. For this purpose is the gas cooler installed. Using cooling
water is the steam condensed, and the CO2 is cooled down to approx. 40˚C. The condensed
water is send back to the lye tank through. The cooled CO2 gas will flow from the top of the
water separator to the liquefaction unit. The water separator is equipped with a demister which is
preventing water droplets to escape with the gas.
 Potassium permanganate scrubber
This is the most important part of the carbon dioxide production plant. PPM solution is used as
an oxidizing agent. It oxidizes other gases except co2 and it removes all organic materials and
impurities. It increases contact and surface area.
 Compressor
A gas compressor is a mechanical device that increases the pressure of a gas by reducing its
volume.an air compressor is a specific type of gas compressor.in the case of carbon dioxide
production plant, in order to pressurize the CO2 and transport in to the hydrator.

 Dehydrator
Dehydrator is used for removes water or moisture from the carbon dioxide. Although water has
been removed from the CO2 gas in intermediate and after cooler, it still contains some water.
To remove the remaining water the gas is led through a dehydrator. The dehydrator system
consists of two vessels filled with molecular sieve. The molecular sieve has the capability to
absorb water.
 Carbon filter
Carbon filtering is the method of filtering that uses a bed of activated carbon to remove
contaminants and impurities, using chemical adsorption. Each granule of carbon provides a large
surface area/pore structure, allowing contaminants the maximum possible exposure to the active
sites within the filter media. Carbon filter can be used to remove, Odor, Test, Smell.
 Condenser
A condenser is advice used to condense a substance from its gaseous to its liquid state, by
cooling it.in that case ammonia used as a coolant, and the gas form of carbon dioxide are
changed in to liquid.
 Storage tank: Used store the final product of carbon dioxide.

 Purging: Purging is the process used to remove no condensable gas.

2.2.5 Syrup room

Syrup can be divided in to two
 simple syrup
 finished syrup
Preparation of simple syrup
Simple syrup is prepared from nutritive or non-nutritive sweeteners and treated water. Nutritive
sweetener includes cane sugar, beet sugar, liquid sucrose, medium sugar. Nonnutritive
sweeteners are artificial sweeteners such as aspartame. First the treated water adds in to the
dissolving tank. The dissolving tank is jacketed vessel and the water was boiled up to 800c.Then
the sugar will be fed to the screw conveyer. The screw conveyer can reduce the size of the sugar
and the conveyer the sugar enters the dissolving tank. When the sugar enter to the dissolving
tank the temperature of water is decreasing in to 240c-300c.Then we wait the temperature is
800c.To rise the temperature to 800c and agitate. Activated carbon added to the dissolving tank
and kept in the tank around 30-40 minute to trap and it remove the organic matter. The sugar and
the treated water mixture from the jacketed vessel were filled in the sugar filter and half in the
filter aid mixer. In filter aid mixer we add diatoms earth .and it circulated with in the sugar filter
and filter aid. During this circulation filter aid will make cake inside the sugar filter the filter aids
by activated carbon and diatoms earth
There are two types of filtrates

 Manual filter
 Automatic filter
Manual filter
 It filter use water to make cake and trap organic mater
 It used for bottle product
 The plates should be clean up once it is used
 It doesn’t use activated carbon
 But we use activated carbon for Pepsi
Automatic filter
 For filtrate use sugar and filter aid to make cake
 The filter aid are activated carbon and diatoms earth

 It can be used three times once it is clean up

After this filtration the simple syrup go the plate type heat exchanger. The simple syrup
exchange heat with water treated the treated water came from the chiller by cooled 100c. It stay
around 2 hour in the simple syrup room then it transfer to the finished syrup room. The simple
syrup of temperature is 240c-300c.
b Granulate
Water Celatom
sugar
Heat
Sugar Polisher exchanger
dissolving
Filter
Activated tank
paper
carbon
Figure 2.6 process flow diagram of simple syrup preparation

The preparation of finished syrup

PREPARATION OF FINSHED SYRUP

The simple syrup comes from simple syrup room and enters the tankers for finished syrup the
concentrate ingredient add to the simple syrup. The concentration will be prepared in mixing
tank with treated water. Finished syrup is prepared by adding concentrate ingredients into simple
syrup. Ingredients can be in two forms, these are solid and liquid form ingredients. The finished
syrup is combined with treated water and carbon dioxide to create the finished beverage. Steps
for preparation of finished syrup
 Nutritive sweeteners include cane sugar, high fructose corn syrup, liquid sucrose and
medium invert sugar, all meeting Pepsi cola sweetener specifications.
 Non-nutritive sweeteners are artificial sweetener such as aspartame.
 Concentrate components can be solids emulsions, and extracts, and liquid components.
 Treated water is always fully treated water meeting all Pepsi cola water specifications.

Figure 2.7 syrup room
CIP METHOD
CIP (cleaning in place) is a two-step cleaning method. Those are:

1. The 3 steps
a) First rinse by 50OC- 60OC water for 10-15 minutes
b) Cleaning by 50OC -60OC using caustic soda for 20 minutes and the concentration of
this soda should be in between 0.5%-2%.

c) Rinse by 38OC -OC water for 10-15 minutes then checking for the absence of
chemicals.
2. The five steps
a) First rinse by 50OC- 60OC water for 10-15 minutes
b) Cleaning by 50OC -60OC using caustic soda for 20 minutes and the concentration of this
soda should be in between 0.5%-2%.
c) Rinse by 38OC -OC water for 10-15 minutes then checking for the absence of chemicals
d) Sanitize either by hot water at 80OC for 15 minutes or chlorine at 100ppm concentration
for 20 minutes
Rinse by water for 10-15 minutes then checking the absence of chemicals.

2.2.6 Filling room

Process takes place in the filling room:
 Empty bottle inspection
 Mixing
 Filling
 Packaging
 Full bottle inspection and
 Date coding
Empty Bottle Inspection
In this process the washed bottles are inspected manually by peoples and electrically through
light screening in order to check any UN treated bottle. The inspection includes properly UN
washed bottles, rust and bottles that cannot be used for specific kind of product. The purpose of
inspection is to insure the safety of the work in the processes. People inspect manually 150
bottles per minute and 18,000 bottles per hour. Whereas EBI is done by machine that uses light
to inspect the bottles and when unsuitable for production is found, it is taken on a separate line.
The machine can inspect 200 bottles per minute and 24,000 bottles per hour.
Mixing
Mixing is a process takes place by using a machine called Paramix. This machine controls
processing and preparing the product mix such as Pepsi cola, Mirinda orange, Mirinda tonic,
Mirinda apple, 7up and Mirinda pine apple. The system is working with cooperatively with a
digital computer used for automation of electro mechanical process such as control of
machineries on the factory which is called PLG (programmable logic control). Three
components come through the pipe these are water, co2 and syrup.
In the filling room there are two tanks
 Water buffer tank :-it is used for receive the treated water from water treatment room
 Syrup buffer tank :-it is used for receive the finished syrup
The Carbon dioxide will come from CO2 plant and entered in the carbon dioxide polisher, And
the water from water buffer tank are mix in line to make carbonated water. Then the carbonated
water and finished syrup are mixed in the mixer. The mixing for mirinda apple and mirinda
orange should have 1:4 ratios (for one liter syrup four liter water) and for peps, tonic and 7 up
1:5 ratio (for one liter syrup five liter water) finally the beverage goes to the filler.
Filling
Filler is a machine which is used to fill the bottle with the drink that has been prepared in the
Para mix. It is connected with the Para mix and the crowner cork. In nifas silk pepsi company
there are two fillers one of the filler (the new one) has a better capacity than the older filler and
the maximum filling capacity of this machine is 24000. This machine has bowl pressure, bowl
level, bowl liter, capacity, mode filler, bottle counter and temperature and controlled by PLC
system. These all things have their own purpose. The various filling processes are selected at the
operator panel. First the drink is stored in the bowl and above this drink car bon dioxide gas will
be placed and then when the empty bottle is transported by the in feed conveyer through the in
feed worm gear which pushes the bottles in sequenced manner. Then the bottles are pressed
against the filling valve by a lifting element called piston. The piston will perceive the existence
of the bottles during the lifting process. If the bottle is present the processes is started and the
bottle is filled. The corresponding filling valve remains closed if the bottle is missing. The
machine works by lubrication system automatically .there are also 60 filling valves called vents
and expanding tubes where these tubes have small holes that are used to transport the gas as well
as the drinks respectively. In this section the co2 should be filled first in the bottles in order to
balance the temperature and pressure as well. When the fluid (drink) poured in to the bottle the
gas occupying the remaining space of the bottle goes up to the returned gas media through the
vent tube.
Full bottle inspection: filled bottles are also inspected manually and by EBI. First they are
inspected by EBI for any defect i.e. if the crowns are not placed at the right place or if the bottles
are perfectly filled. Manual inspection is done by people who check if the bottle is of the right
fill height. Products should not be under filled or over filled.

2.2.7 Quality control section

As a Pepsi cola plant and food handling company NSP follows standards which ensure to apply a
good manufacturing practice so as to produce safe and quality products. The standards have their
own audit program regularly (weekly, monthly, quarterly, by the plant committee, which are
certified management members and annually by third party). The standards applied are the
following:-
1. GMP
2. HACCP
3. QAS
4. EMS
1. GMS :- is a good safety system which lay out, control and evaluate the implementation
of the following program:-
− Training program
− Personal hygiene program
− Company visits health checks
− Food handling practice
− Pest control
− Cleaning and sanitation
− Handling breakable
− Process equipment machinery layout
− Structure and fabrication
2. HACCP:- it is a safety management system with the following program
− Food safety policy
− HACCP team description
− Prerequisite programs description
− Product description
− List of ingredients and indirect raw materials
− Process description
− Process flow diagrams
− Factory flow diagram lay out
− Hazard analysis

− CCP FAILURE FORM

3. QAS: - this procedure applies to all PepsiCo beverage plants, franchises, and co-packers.
4. EMS:- this is establish and implement a functional waste collection and disposal system
for solid wastes generated by households, factory and office operations,
The overall processes in the company can be checked in this section. According to the
laboratory test whether the processes continue or not can be decided in this section. One of
the main goal of the quality control is to present the consumer with a product that is NOT
consistently with in standards, but that has a long shelf life .the primary purpose of quality
control and plant testing program is
 The beverage meets prescribed standards.

 The production lines and processing systems are functioning properly.
 The syrup is prepared correctly.
 The all ingredients used in preparing syrup and final beverage and correctly treated,
handled, stored and within standards.
Table 2.5 sugar quality parameter
A Specification
1 Color 162.66*absorbance of filter 45max
2 Turbidity 162.66*(absorbance before filter – 25max

absorbance of after filter)
3 Conductivity of water @ Conductivity of water @ 25oc/1.13.

20oc.
4 Conductivity of syrup @ Conductivity 28oc Brix syrup @ 25oc

20oc /1.13
5 Corresponding A4/1.13-(0.35*A4)
conductivity
6 Ash A5/1667.6 0.02(%w/w)

7 Moisture 0/04%
8 Total bacteria 200CFU/10mgDSE

count(CFU)
Yeast $ mold 10CFU/10mgDSE
Laboratory test in quality control
For color and turbidity
 Measure Accurately 100 grams of sample in to the beaker.

 Multiply the above number by actual brix number and then divide the result by 50
units.
 Add distilled water up to the result that can be calculated from the above.
 Stir the sample by using magnetic stirrer until the solution (the brix and the distilled
water) becomes completely uniform.
 Then the sample can be filtered by using microspore, the amount must be divided two
equal parts.
 Finally measure the amount of the absorbance by using spectrophotometer. In this part
they have two result, before filtered and after filtered
For conductivity
 Measure accurately 50 grams of sample

 Multiply the above number by actual brix number and divided the result by 28 units
 Stir the sample by using magnetic stirrer
 Finally we can measure the sample of conductivity
NOTE: all the final result can be inserted in to our computer and we can get the result.
Example, for color and turbidity
Given
The actual brix number before treated=71.22
Sample=102

Unit=50
Required
Absorbance for both before treated and after treated sample?
Solution
S=M*J/T
Where S: the amounts of distilled water added
M: the actual brix number
J: sample
T: unit
S=71.22*102/50=145.288
This implies that the amount of distilled water add in to the sample. Then stir gently until
completely dissolved. Then divide the sample in to two equal portions by using vacuumed
filtration apparatus that is microspores. Finally read the absorbance of the sample by using
spectrophotometer first blank the instrument with distilled water.
Example; for conductivity
Given
The actual number of brix=71.22
Sample=50
Unit=28
Required; conductivity for both before treated and after sample?
Solution
S=M*J/T
Where S: the amounts of distilled water added

M: the actual brix number
J: sample
T: unit
S=71.22*50/28=127.178
This number implies that the amount of distilled water added. Then read the conductivity of the
sample.
NOTE: by using the same procedure we can calculate the amount of absorbance and conductivity
of the finished simple syrup.
Absorbance for; AA=0.281
AB=0.384
BA=0.196
BB=0.518
Conductivity for; CW=27.05
CSB=50.6
CSA=80.2
Where;
AA: the sample after treated and after filtered
AB: the sample after treated and before filtered
BA: the sample before treated and after filtered
BB: the sample before treated and before filtered
CW: conductivity of distilled water
CSB: conductivity of the sample before treated
CSA: conductivity of the sample after treated

N: B finally all the result that can be calculated above must be inserted our computer we can
know color, turbidity, and ash content of the sample.
Raw water test before inter in to the coagulation tank
M-alkalinity test
− Prepare 100ml of raw water that comes from the bore

− Add 3 droplet of T-solution
− Add 3 droplet of M-solution then shake the solution until the color can be
changed.
− Then titrate the sample by using 0.02 N H2SO4 solutions until the color becomes
changed into colorless into pink end point.
− Finally record ml 0.02 NH2SO4
− The result can be M-alkalinity.
Total hardness
− Prepare 100ml of raw water

− Add 10-12 droplet of 10% NH3 buffer solution
− Add 3 droplet of EBT
− Shake the solution
− Then titrated by using EDTA until the color can be changed in to blue
− Recorded the number, the result can be the total alkalinity.
Calcium hardness indicator
− Prepare 100ml of raw water

− Then add 4ml of 1N NaOH
− Add calcium hardness indicator by guessed
− Shake the solution
− Titrated the solution by using EDTA until the color become changed in to
purple
− Finally recorded the number that can be used for titrated purpose, the result
can be calcium hardness indicator.

Carbon dioxide test-
− The carbon dioxide test result can be 8-12ppm.
Finally all the result that can be get from the above four result can be inserted in to the computer.
Then the results that get the computer tell as how much lime, aluminums sulphate, calcium
chloride and chlorine added in to the coagulation tank.
2.2.8 Cooling compressor section

Ammonia is one of the most cooling agents in MOHA soft drink industry. Glycol freezes at
low temperature and also used for the cooling agents of the final product (Pepsi, Miranda
orange, Miranda apple,). As a result, it is convenient to used cooling media below 0oc.there
is heat exchanged between the final product and the glycol. Glycol is used recycle

Ammonia
cylinder
Glycol tank Glycol

Evaporator Return after before
cool the enter in
product to the
process
Compressor
Oil separator
Condenser
Figure 2.8 process flow diagram of cooling compressor

CHAPTER THREE: OVERALL INTERNSHIP BENEFITS

During this internship program helped me to practice the theoretical knowledge into important
insight on the practical side of engineering which will help me to a great deal to make good
understanding of knowledge.
 Improving Interpersonal Communication Skills

 Improving Team playing skills
 Improving work ethics
 Upgrading of Theoretical Knowledge
 Entrepreneurship skills
 Improving leadership skills
3.1.1 Improving Interpersonal Communication Skills

Developing Interpersonal skills are very important. In MOHA Soft Drink Company (Nefas silk
plant) there are a lot of workers (above 1500) and they have different behaviors. Therefore I can
simply develop interpersonal skills and I can develop smooth relationship with the workers.
3.1.2 Improving Team playing skills

Team playing skills are one of the major advantages for the proper working of a good company,
regardless of its size and service. Team playing is a basic requirement for getting solution for a
specific problem and to share experience. During internship I have developed a team playing
skills with operator mostly laboratory chemists, technical and chemical and mechanical
engineers to get experience, to grasp knowledge.
3.1.3 Improving work ethics

I have been guided and obeyed by the rule and regulation of the MOHA soft drink company.
Some of the work ethics include or to develop strong work ethics you should;
 smooth relation with partners
 good communication skill and cooperation with colleagues
 focus primarily on work related issues
 Respect what others contribute to the work environment
 Accountable and Responsible

3.1.4 Upgrading of Theoretical Knowledge

This internship program provided us with the opportunity to expand our intellectual knowledge
and practical skills .As we know coming before in the previous theoretical awareness or
familiarity and actual place could be distinguishable, so the objective reality and theoretical
knowledge may be slightly different. The above theoretical learning is upgrading during my
internship program by seeing and doing some work. So the internship program is essential for me
to upgrade theoretical knowledge’s.
3.1.5 Entrepreneurship skills

Emphasizing the growth of entrepreneurship would not only lead to a new robust industry of its
own but also is a base for improving the social and economic capability of the country. I had a
wide range of entrepreneur skills from above skills including personal traits and management
skills. In this internship program I learned small business startup skills where we should be
empowered with knowledge and skills to become effective entrepreneur. The state of being an
entrepreneurship can be realized when one engages in profitable risks and creates something of
value. It is defined by their habit of innovating and redefines market trends and limits. Generally,
entrepreneurs who are able to create worthwhile good and services give a greater impact to
society; have faithful and often tested with good results. Generally, entrepreneurship can be
realized when we engage in profitable system and create something value from theoretical to
practical learning. This means a person who is able to develop a new business area and affect the
global economic condition.
3.1.6 Improving leadership skills

A leadership skill is a critical management skill, which is the ability to motivate a group of
people towards a common goal. Always trying to share your opinions with workers frankly is the
Key way to achieve the goal and it makes your company profitable.

CHAPTER FOURE:
CONCLUSION AND RECOMMENDATION
Conclusion
The plant produces six products with well-organized and a good quality standards & distributed
to the consumer with a short time due to the number of the consumers that accept the product and
the products are checked by the executive organizational office members on unknown days. So
the plant should produce an acceptable, standard, and legal products to satisfy the consumer’s
needs.Internships are the reflection of the real world work environments. Our experience as an
intern at MOHA soft drinks is full of exciting memories as it is the preview of the coming
chapter of our life. We had acquired new knowledge, developed essential skills, experienced the
practical work settings, met experts in our field and made new friends in four months which is a
great accomplishment for an undergraduate student like us. Beside the practical knowledge and
skills we built up during the internship, we had developed proper work ethics and essential
qualities every engineer shall have. Some of the most important qualities we developed are

industriousness, team work, communication skill and accountability. In conclusion, during our
stay at MOHA soft drinks we have achieved most of the goals we set up at the beginning of the
internship.

Recommendation
From the time of internship duration in NIFAS SILK beverage plant there are some
limitations/short coming that are challenges the workers, affect environment and obstacles for
the operators. Some of these are:-
 Since the condition is very warm and noisy, which is difficult for the workers in order to
3perform their activities, the air ventilator should be necessary especially in co2
production plant some measures have to be taken to reduce the noise.
 Enough operator instructions and manuals should be present in the worker and there
should be have full structural flow diagram of the unite operations /operators for each
section to perform appropriate activities.
 Most of the operators are done their activities in habitual actions so educated chemical
engineers should be necessary for the safety and security of the machines and
equipment’s especially for co2 plant.
 The manual inspection becomes replaced by machine is more appropriate for the
company.
 The drainage of the waste water from the compartment may contain caustic soda;
therefore further water treatment mechanism can be important.
 If the source of the ground water is insufficient, added more ground water.
 To preventing NOx formation in carbon dioxide production plant by reducing the

temperature of the boiler, increase retention time, chemical reduction of NOx, oxidation
of NOX, removal of nitrogen from combustion, sorption (either adsorption or absorption)
, both adsorption combustion of these method and reduce excess oxygen supply.
 Use recently fabricated machinery and material to operate properly and effectively.
 Increasing height, and size of absorber in order to increase CO2 absorption capacity and
also changing
 Knowing the life time of the ceramics i.e. soda scrubber, potassium per manganite
scrubber, stripper and absorber.

CHAPTER FIVE
PROECT WORK
Project title: Increase the efficiency of absorber by changing the solvent
5.1 Introduction
Absorber is process equipment used to remove one or more gaseous components. From gaseous
mixture by using suitable type solvent mostly present in less quantity.
Absorption: in absorption column or tower, a gas fed from the bottom of an absorption tower.
The tower is packed with packing to increase contact time and efficiency. Based on absorbent
(chemical reaction between the solute and the solvent) there are two types of absorption
processes: physical and chemical absorption. Physical absorption occur when there is no
significant chemical reaction between the absorbent and the solute. Chemical absorptions are
processes for absorbing CO2 and H2S with aqueous solution of mono ethanol amine (MEA), di
ethanol amine (DEA). It depends on whether there is any chemical reaction between the solute
(CO2) and the solvent (MEA). In the case of MOHA soft drink they chemical absorption method.
Principle operation of absorber
In the absorption of carbon dioxide by caustic soda, the carbon dioxide reacts directly with the
caustic soda and the process of mass transfer is thus made much more complicated. Again, when
carbon dioxide is absorbed in an ethanolamine solution (MEA), there is direct Chemical reaction
between the amine (MEA) and the gas (carbon dioxide gas).In the case considered, the chemical
reaction is irreversible and of the type in which a Solute gas A (CO2) absorbed from a mixture by
a substance B (MEA) in the liquid phase, which combines with according to the equation
A + B → AB
As the gas approaches the liquid interface, it dissolves and reacts at once with B. The new
product AB, thus formed, diffuses towards the main body of the liquid.

5.2 Problem of the statement

In MOHA soft drink Company there is carbon dioxide (CO2) production plant which is used for
different purpose. During the production of carbon dioxide, there is a release of CO2 from the
absorber tower to the environment. Such released product can affect the surrounding
environment and also the loss of money. Released of CO2 caused by absorber performance (i.e.
inefficient), absorbent type (solvent type) and others. The solvent that currently used in MOHA
Company is MEA (monoethanolamide) but it is costy and unable to absorb all the CO2.
Therefore, this project aimed at finding alternative solvent type for the company which is cheap
and more efficient than MEA.
5.3 Objective
5.3.1 General objective:

Increase the efficiency of absorber by changing the solvent to reduce the amount of carbon
dioxide (CO2) released from absorber.
5.3.2 Specific objective:

 The effect of temperature and pressure of the solvent on the absorber
 effect of MEA (Mono ethyl amines) concentration on CO2 absorption
 to compare MEA with potassium carbonate
 economic evaluation of solvents (MEA and Potassium carbonate)

5.4 Significance of the project

This project is concerned based on
 Add values of money for the company.
 Increasing the amount of carbon dioxide production.
 Reducing the effect of CO2 on the plant surrounding (around the Company there are
many condominium)
5.5 Scope and limitation of the project

Scope
This project works increasing carbon dioxide production by choosing best solvents and doing
cost estimation between the solvents, up to theoretical evaluation of efficiency increment due to
change of solvent type.
Limitation
When we doing this project there are many difficulties, these are
 Lack of related work in quality control room.
 Lack of chemical such as potassium carbonate in the company
 The absence of absorber in laboratory scale, in MOHA soft drinks.
 The nature of carbon dioxide (CO2 )

5.6 Literature review

James T. et al, they were studied carbon dioxide absorption and desorption in packed column.
The aim of the study was in order to investigate: (1) to obtains first-hand data on the effect of
structured packing versus traditional random packing on the carbon dioxide capture rate; (2) to
obtain carbon dioxide capture rate data by mono ethanolamine (MEA) and by a sterically
hindered (2-amino-2-methyle-1-propane (AMP)); (3) to compare carbon dioxide stripping rates
between CO2-rich MEA and CO2-rich sterically hindered amine. From the experiment they got at
the same bed geometry, convectional MEA performed much better during absorption studies
than the sterically hindered amine,AMP.However,in the regeneration step the carbon dioxide
releasing rate from the saturated AMP solution is over 80% greater than from saturated MEA
solution.
Ter V. el al (2011), they were studied about amine based solvent for carbon dioxide absorption
“from molecular structure to process”. The aim of the study was the development of improved,
energy efficient amine based solvents in targeted, through experimental work and by further
understanding of the role of molecular structure on the solvent absorption properties for amine
based solvent in carbon dioxide absorption process and focuses on the development of an energy
efficient solvent for a carbon dioxide post-combustion absorption process, by evaluating the
absorption properties of amine based solvents with different molecular structure. to achieve this
goal: (1) knowledge on structure-activity relationships for amine based absorbents for CO2
absorption is developed both by experimental work and molecular calculation; (2) focuses on
understanding the reaction mechanism between an amine and CO2 and on the identification of
the solvent properties influencing their performance for CO2 absorption.
(3) solvent with carbon dioxide, was studied using quantum mechanical calculations; (4) in the
solvent screening experiment various solvent molecular structural aspects were tested on their
influences on carbon dioxide absorption capacity; (5) for the more promising identified in
number 4 subsequent solvent screening experiments were performed at low carbon dioxide
partial pressure to determine their carbon dioxide absorption and regeneration capacity under
more realistic conditions. From this work the potential solvents 1,6-hexamethyl-diamine
(HMDA) and 1,6-hexamethyl-diamine,N,N’-dimethyl (HMDA,N,N’) were selected for further
investigation; (6) the carbon dioxide solubility for the selected solvent candidate 1,6-hexamethyl-

diamine (HMDA) and 1,6-hexamethyl-diamine,N,N’-dimethyl (HMDA,N,N’) was determine

experimentally at different solvent concentrations and temperatures; (7) focuses on determining
kinetics of carbon dioxide absorption in aqueous solution of 1,6-hexamethyl-diamine (HMDA)
and 1,6-hexamethyl-diamine,N,N’-dimethyl (HMDA,N,N’) using a stirred cell collector; (8) the
results of these corrosion testes are reported together with the carbon dioxide capture
performance in the pilot plant. From the result the kinetics of CO2 aqueous solution 1,6-
hexamethyl-diamine (HMDA) and 1,6-hexamethyl-diamine,N,N’-dimethyl (HMDA,N,N’) was
performed at a concentration ranging from 0.5 to 2.5mol/L and temperatures from 10 up to
30,the kinetic data were determined by CO2 absorption experiments using a stirred cell reactor
with flat inter face between gas and liquid. These new CO2 solvents were identified in early work
for their high CO2 capacity and limited corrosiveness. The reaction order with respect to HMDA
was found to N, N’ was found to be very reactive towards CO2 and showed a lower temperatures
dependency. Boththe new solvents are good CO2 capture capacity.
MONOJIT K. et al (2012), they were studied about CO2 capture/separate technologies. The aim
of the study was examine the current status of various methods and technologies used for CO2
capture and separation from thermal power plant flue gas. The result shows that absorption is
matured technology for post combustion capture but solvent loses corrosion and high cost of
separation the main issues for this process.
Anushakothadaraman, (2006) studied about the effect of
 absorber height
 solvent temperature and
 pressure
In his work, he investigated that the absorber height on the energy consumption in re boiler, the
diameter of the column was kept constant and the absorber height was varied .As he stated with
increasing in the absorber height, the attained rich loading increased and hence, the re boiler duty
decreased.

The increasing in height of the absorber entails two additional costs.
1. Capital cost− the capital cost of the equipment increase

2. Power required in blower − due to pressure drop power required in the blower will
increase.
As the temperature of absorption decrease the driving force for absorption increases.
However, the rate of the reaction and diffusivity decrease as temperature is decreased.
Simulations were run at solvent temperature of 20, 30and 40oc and the re boiler duty for
these runs did not differ significantly. Hence, the temperature of the solvent does not have a
significant effect on the performance of the system because the solvent has a low specific
heat and it takes up the heat of absorption quickly.

5.7 Methodology
Material and chemicals
Material
Table 5.1 laboratory test equipment’s that can be used the production process
No Equipment Function
1 Beakers Used for testing the presence of odor, oil and grease after
carbon purifier and carbon dioxide storage tank, used to test
water hardness.
2 Fyrite Used to measure the amount of oxygen in the boiler, and the
proportionate amount of carbon dioxide in the boiler and
released from absorber.
3 DT tester To test the presence of NOX, H2S, HCN, CO, HOCO, SO2,
Soot Paper Used test whether complete or incomplete combustion in the

boiler
4 Bume Testing for density of MEA and soda
5 Zahm and Nagel Used to test the purity of carbon dioxide gas in both after
purity tester carbon and storage tank.
6 Refrigerator Reduce the temperature of MEA solution, to measure the

density of MEA.
7 Burette Used for titration (MEA, soda, and hard water) purpose
8 Measuring cylinder Used to take sample
9 Pipette In order to suck MEA and soda
10 Thermometer For reading temperature

Chemical
Table5.2 chemical that are used for production in laboratory
No Chemicals Function
1 Mono ethanolamine(MEA) For absorbing carbon dioxide
2 Soda ( Na2CO3) For separating carbon dioxide from other flue gas
3 0.1N Hydrochloric acid (Hcl) Used for titrating MEA and soda (neutralizing purpose)
4 10% NH3 buffer solution Its indicates water hardness
5 Methyl orange Indicates MEA and soda solution.
6 Eriochrome Black T: It indicates water hardness.
7 EDTA (ethylene di amine Used for titrating water hardness.

tetra acetic acid)
8 KmnO4 for purification of carbon dioxide gas
9 1M H2SO4 To determine the life time of potassium per manganite

(Kmno4).
Laboratory Procedure for Monoethanolamine Normality
Firstly we take 250 ml of MEA by using 250 ml of measuring cylinder. Then by using pipette
instrument we can take one ml of MEA and transfer to 250 Erlenmeyer flask (beaker).then after
we add three drop let of methyl orange in one ml of MEA solution. Finally we titrate the above
solution by using 0.1NHcl solution drop by drop until the color changed from orange into light
red and record the normality of MEA.

Laboratory Procedure for Monoethanolamine density
We begin with filling mea solution into 250 ml measuring cylinder.by using refrigerator reduce
the temperature of the solution until the temperature can be 20 up to 24 oc.then we immerse bume
to the MEA solution. Finally we measured the density of MEA.
Laboratory Procedure for carbon dioxide released from the Absorber
We start by taking CO2 fyrite (containing red fluid) and adjust the CO2 fyrite to zero mark by
passing the top tester. Then we insert the tip of the absorber fyrite tester sucker into the top of the
absorber. Right then we Sequeez and release the plastic sucker of the CO2 18 times to absorb the
sample gas. Then we take off the sucker. Then invert the sample gas into fyrite until fluid drain
into the bottom the fyrite. And hold fyrite at 45o angle momentarily to allow fluid droplets drain
to the bottom fyrite. Finally fyrite held upright to permit fluid in column to sterilize a few second
and read % CO2 scale at point corresponding to top of the fluid column.
To make cost analysis on MEA solution we use the efficiency of CO2 plant and amount of CO2
enter in to storage tank per day, from data and to know % amount CO2 released per day we
measure release CO2 Amount 4 times per day for consecutive 6 day, and takes the average.
Finally we get the amount of CO2 by using the following formula:-
 % production of CO2 store in a day=total % production of CO2 in a day− % amount of

CO2 released from absorber in a day.
 Amount of CO2 released from absorber in a day= Amount production of CO2 stored in a
day* %amount of CO2 released from absorber in a day
Amount percentage production of CO2 store in a
The factor to be consider for solvent selection

5.8 Result and discussion

Selection of solvent
The solvent to be used in the absorber is a very important design consideration. Traditionally,
monoethanolamine was chosen to absorb the carbon dioxide from the feed. However for many
crucial and convincing reasons most new plants are designed to use potassium carbonate.
First of all, potassium carbonate is a more efficient absorbent of carbon dioxide than either
monoethanolamine. This means that for a given amount of solvent potassium carbonate can
absorb more carbon dioxide than MEA.
Why is this important?
If less solvent is needed, then piping systems and absorber volume can be smaller. In addition,
the cost of solvent is less because less is needed and potassium carbonate is cheaper than
traditional solvent (MEA).
Secondly the use of potassium carbonate over the other solvent eliminates the need for a heat
exchanger between the absorber and stripper. In potassium carbonate system the stripper runs
cooler than the absorber this is not true for the MEA, because MEA required the heating of the
bottoms stream from the absorber before it reaches the stripper. But the potassium carbonate
system requires no such heating. The elimination of this heating exchanger increases the
profitability of our plant because heat exchangers are both coasty to purchase and maintain.
Thirdly, potassium carbonate increase the safety of carbon dioxide removal system MEA absorbs
not only carbon dioxide but also small amount of hydrogen as well. This hydrogen is then
continuous throughout the stripper and the top stream with the carbon dioxide. Beside,
decreasing the purity of product carbon dioxide stream, this hydrogen possesses a safety threat.
Flashing of hydrogen can cause fires or explosions if proper precautions are not taken. Using
potassium carbonate reduces the risk of such accidents.
Finally, the most convincing argument for the use of potassium carbonate as a solvent is that this
is the present industry standard ,in plant (MOHA) must convert over to potassium carbonate as
our solvent of choice, Because potassium carbonate is significantly better than MEA.

In order to remove carbon dioxide from the freedom stream two main vessels are needed, the
absorber and stripper. Inside the absorber chemical reaction will occur in which CO2 is
chemically absorbed onto the solvent and this compounds, along with water, will flow out of the
bottom of absorber. That stream will then go through a flash chamber to lower temperature and
pressure of liquid (and to separate out some co2) before proceeding onto the stripper where the
CO2 will separate out from the solvent.
Data collection and analysis
Table 5.3 collected data from CO2 plant
DT test
(NOX,so2,HC
MEA % of CO2 Soda Water O2
N,FORMAL
hardness(
Date (Mono ethyl amine) (carbon dioxide) DEHYDE)
ppm)
Density Normality Boiler Released Normality Density

in from
boiler Absorber
02/09/2009 10 2 12 1.3 1.6 12 8 Ok 3.5
03/09/2009 9 2.1 12 1.16 1.4 7 10 Ok 4
14/09/2009 5.12 1.97 13 1.5 1.45 7 6 Ok 3.5
15/09/2009 6 1.95 12 2.4 1.5 7 8 Ok 3.2
16/09/2009 6 1.9 11.5 2.6 1.6 9 10 Ok 3.5
17/09/2009 4 2.25 12 1.15 1.1 11 8 Ok 3.2
From the above table we can observe that as MEA normality increase the amount of CO2
released from absorber decrease and this is advisable according to environmental point of view.
However as MEA normality (concentration) increase the cost required also increase. Also the
released amount of gas that released from absorber is high.

Let us calculate the amount of carbon dioxide released.

In a day=16 hour production
Amount of CO2 gas produce per day =2400kg
% amount of CO2 released from absorber (during 6 day) = = 1.72%

Total % production CO2 = amount of CO2 store in a day+ CO2 gas released from absorber
Total % production of CO2 =94%
Percentage amount of CO2 released from absorber in a day=1.72%
The Amount of CO2 production store in a day=?
% production of CO2 store in a day=total % production of CO2 in a day− percentage amount of

CO2 released from absorber in a day
% CO2 store in a day =94−1.72 =92.28%
Then calculate amount of CO2 released from the absorber in a day:
Given
Amount production of CO2 stored in a day =2400
Amount percentage production of CO2 store in a day=94%
Percentage amount of CO2 released from absorber in a day=1.72%
Required
Amount of CO2 released from absorber in a day=?
Solution
By using formula, A=
Where A= Amount of CO2 released from absorber in a day
B= Amount production of CO2 stored in a day
C=%amount of CO2 released from absorber in a day
D= Amount percentage production of CO2 store in a day

=44.73kg
Variation of co2 emission with MEA
co2
3
2.5
1.5
co2
0.5
0
1.9 1.95 1.97 2 2.1 2.25
Normality of MEA
Comparison between MEA and new solvent (potassium carbonate)

Table 5.4 comparisons between MEA and potassium carbonate
MEA Potassium carbonate
chemical name Monoethanolamine Potassium carbonate
Formula C2H7NO K2Co3
Molar mass 61.08g/mol 138g/mol
Temperature 40−50oc 30-40oc
Pressure 3.5-20kpas
CO2 Absorption
rate
Cost comparison between potassium carbonate and MEA
 Cost of MEA=0.69 $/lb.
Then, convert lb. in to kg
1lb=0.453kg,
0.69 $ lb. = 0.69$ = 1.523 $/kg
lb. 0.453 kg 0.453kg
1kg=1.523$
=1.523$*22
=33.506 birr/kg
 Cost of potassium carbonate=0.4285$/lb.

Then convert lb. in to kg,
0.4285$ lb. = 0.4285$ = 0.946$/kg
lb. 0.453kg 0.453 kg
1kg=0.946$
=0.946$*22
=20.812 birr/kg
Table Amount of MEA company purchase during the time 01/01/2017-31/05/2017
Month Amount of MEA solution
January 651.5
February 67.9
March 228.6
April 40
May 177
Total 1165 kg
In 5 month of duration the CO2 plant use 1165 kg of MEA

1165kg *33.506 birr/kg=39034.49birr

But when we see the cost of potassium carbonate
1165kg*20.812birr/kg=24245.98birr
 The cost difference between MEA and potassium carbonate in 5 month are
(39034.49-24245.98) birr
14788.51 birr
So, company lose during 5 month are 14788. 51 birr.
5.9 CONCLUSION AND RECOMMENDATION
Conclusion
Generally carbon dioxide production plant can be produce 2400kg per day. During the
production there are many side effects, these are the concentration of MEA (mono ethanol
amine), temperature, surface area.as we see the relation between MEA and carbon dioxide, as the
concentration of MEA increase the amount of carbon dioxide released from the absorber increase
vise verse, and these also precede increase surface area. As the temperature of absorption
decrease the driving force for absorption increases. As the solution we can conclude that in the
place of MEA solvents replace the new solvent, which is potassium carbonate. Because
potassium carbonate is more efficient than MEA by cost, the working temperature is lower than
MEA.


Recommendation
 As much as possible replace the oldest solvent (MEA) by new solvent (potassium carbonate).
 Do further analysis and laboratory test on potassium carbonate.
 Use more concentrated MEA solution.
 Increasing height and size of absorber in order to increase CO2 absorption capacity and
also changing.
 Knowing the life time of the ceramics in the absorber tower.


Reference
1. Anusha kothandaraman (2006)
2. Coulson volume 2 and 6
3. James T. et al, “Carbon dioxide absorption and desorption in packed column”.
4. J. Tim C. et al, “properties of concentrated aqueous potassium carbonate/ piperazine
for CO2 capture”,
5. Jason U. et al, -"design of CO2 absorption in an ammonia plant",
6. Monoji K. et al “CO2 capture/separate technologies”. (2012).
7. Pepsi international quality manual, analytical method (1999).
8. PepsiCo beverages international quality manual, manufacturing processes (2002).
9. Ter V. el al “Amine based solvent for carbon dioxide absorption “from molecular
structure to process”. (2011).

Bahir-Dar University Bahir-Dar Institute of Technology Faculty of Chemical and Food Engineering Department of Chemical Engineering

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Bahir-Dar University Bahir-Dar Institute of Technology Faculty of Chemical and Food Engineering Department of Chemical Engineering

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BAHIR DAR INISTITUTE OF TECHNOLOGY

By: Arsima Kiros

Advisor: - Mr. Tadele N. and Mr. Natnael G.

MOHA soft drink S.C final report Page 1

MOHA soft drink S.C final report Page 2

MOHA soft drink S.C final report Page 3

MOHA soft drink S.C final report Page 4

MOHA soft drink S.C final report Page 5

3.1.5 Entrepreneurship skills ............................................................................................................... 53

MOHA soft drink S.C final report Page 6

MOHA soft drink S.C final report Page 7

MOHA soft drink S.C final report Page 8

MOHA soft drink S.C final report Page 9

EBI=electronic bottle inspection

GMP=good manufacturing practice

HACCP=hazard analysis and critical control point

QAS=quality auditing system

EMS=environmental management system,

NSP=Nefas silk plant

Ppm=parts per millions

MOHA soft drink S.C final report Page 10

CHAPTER ONE: INTRODUCTION

1.1 Back ground of the MOHA soft drink industry in Ethiopia

MOHA soft drink S.C final report Page 11

1. 2 Objective of the company

1. To manufacture, buy, sell, bottle, distribute and otherwise deal in non-alcoholic

1.3 Mission and Vision of the company

MOHA soft drink S.C final report Page 12

Vision of the company

1.4 Main product s of the company

1.5 The main customer of the company

MOHA soft drink S.C final report Page 13

1.6 Organizational structure

Fig 1.1 organization structure

Fig 1.1 general organizational structure

MOHA soft drink S.C final report Page 14

MOHA soft drink S.C final report Page 15

CHATER TWO: THE OVERALL INTERNSHIP EXPERIENCE

2.1 How we get into the company

MOHA soft drink S.C final report Page 16

2.2 Production process description of the company

MOHA soft drink S.C final report Page 17

2.2.1 Raw materials of carbonated soft drinks

2.2.2 Water treatment

Selection of water technology

MOHA soft drink S.C final report Page 18

Chemical used for water treatment

III. Chlorine− used for sanitation and to kill microorganism

Al2 (SO4)3 +6H2O−−−−−−−→ 2Al (OH) 3 +3H2SO4

MOHA soft drink S.C final report Page 19

Figure 2.1 process diagram of water treatment

Process description about water treatment section

MOHA soft drink S.C final report Page 20

Figure 2.2 coagulation tanks

A -is which tells us whether the lime treatment is correct or not

P-is phenolphthalein indicator

The Procedure to determine the correct lime treatment

− Prepare 100ml of water from the sand filter

MOHA soft drink S.C final report Page 21

This tank is used for only storage purpose.

MOHA soft drink S.C final report Page 22

Ultraviolet (UV) ray

Table 1.1 Pepsi cola water standard