Bottlers Nepal Limited

Introduction
Coca-Cola, imported from India, was first introduced into Nepal in 1973,
with local production of Coca-Cola beginning in 1979. Bottlers Nepal Limited (BNL)
is the only bottler of Coca-Cola products in Nepal, and has two bottling plants;
namely Kathmandu (Bottlers Nepal Limited BNL) and Bharatpur (Bottlers Nepal
(Terai) Limited,) which is 160 km from Kathmandu, its capital.
The Marketing, Sales & Distribution strategy for Bottlers Nepal Limited is
entitled Refresh the Marketplace and includes: A robust Consumer Response
System to address any consumer/customer concerns, ideas, suggestions either
on product and its quality or on stock supply, maintenance of equipment etc. All
consumer concerns are dealt with in a fair, timely and friendly manner, so as to
satisfy them and resolve their concerns.
Marketing and advertising communications are focused on POS (point-of-
sale), Radio, TV, hoardings, truck backs, etc. Emphasis is also placed on Consumer
Price to enforce Price Compliance. Marketing and advertising communications are
customized to suit to local sentiments social, religious, ethnic.
Innovative packages and pack sizes are offered to give better value to consumers
and ease of storage to retailers. Prices and packs are introduced in a format that is
affordable to all segments of society. The approach by the Nepal operation to
environmental issues is guided by a simple principle to conduct their business in
ways that protect, preserve and enhance the environment. The fully automatic
Effluent Treatment Plants (ETP) are established in both its plants and have been
operational since 2001, to protect the local environment as well as meet the
standards of The Coca-Cola Quality System (TCCQS).
BNL is committed to strengthening the community through various
programs at the forefront is the health sector. With the lowest per capita public
health expenditure in the world, the state of medical facilities available to the
poor in Nepal is abysmal. The country is affected by outbreaks of communicable
diseases because hygiene and sanitation facilities are scarce. In association with
the local community, BNL supports Free Health Check-up Clinic at Bharatpur. The
health Centre is managed by a qualified MBBS Doctor and trained paramedics,
who extend free check-ups to communities around the plant in the Terai area. The
facility has thus far helped hundreds of families get the best medical attention
locally. Senior citizens and children are the main beneficiaries.

LIST OF ACRONYMS/ABBREVATIONS

B. Tech: Bachelors of Technology

BNL: Bottlers Nepal Limited
QC: Quality Control
WTP: Water Treatment Plant
ETP: Effluent Treatment Plant
RGB: Re-usable glass bottles
CSD: Carbonated soft drinks
PET: Polyethylene Terephthalate
PHE: Plate Heat Exchanger
DG: Diesel Generator
RO Plant: Reverse Osmosis Plant
ACF: Active Carbonated Filter
BPM: Bottles Per Minute
HACCP: Hazards analysis and critical control points
TCCQS: The Coca-Cola Quality system
FO: Furnace oil

CIP: Cleaning in Place

Day 1: - May 30 Tuesday
Visiting the whole company thoroughly in order to know the company plan,
design, utilities used and working of plant under the guidance of Meg Raj Sir and
Saurav Thapa Sir.

Discuss about Internship Plan

Week First for knowing and understanding about Plant and Utilities used in
Company.
Week Second is separated for the various process used in Company like ETP,
WTP and Syrup manufacturing.
Week Third is granted for understanding the process and steps taken for
Quality Control and safety measures applied.
And the final week is separated for the project week.
About Company
Coca-Cola, imported from India, was first introduced into Nepal in 1973,
with local production of Coca-Cola beginning in 1979. Bottlers Nepal
Limited (BNL) is the only bottler of Coca-Cola products in Nepal, and has
two bottling plants; namely Kathmandu (Bottlers Nepal Limited BNL) and
Bharatpur (Bottlers Nepal (Terai) Limited,) which is 160 km from
Kathmandu, its capital.

Kathmandu Bottlers Nepal Limited

Company is first started with RGB Plant with 80bpm in 1979A.D. It was
upgraded to 220bpm in 1985,430bpm in 1997 and 450 bpm in 2011.
PET Plant was started from 2001 with 40 bottles per minute and now it is
upgraded to 100 bpm in 2006 to till the date.
2 Shift productions for RGB Plant And 3Shift Production for PET Plant
Major Products are: - Coke, Fanta, Sprite and Kinley Soda

Major Plants: - 1.RGB (Returnable/Refillable Glass Bottle)

2.PET (Polyethylene Terephthalate)
 Utilities: - Boilers, Carbon dioxide Plant, Refrigeration (Central Chilling Plant),
High Pressure Compressor, Low Pressure Compressor

RGB PLANT
(450 Bpm)
This line is used for filling of glass bottles with the carbonated beverages
of different flavors. Usually the production rate of this line is higher than
PET. It produces a beverage of 250ml. These bottles are returned to the
retailer by consumer once they consumed then to manufacturer. So,
these bottles are reused after certain cleaning and inspection procedure.
Major machines, equipment and stations with their function are as
follows:

1.De-Crater(Uncaser)
The Uncaser line has 4 workers. 1st to remove the empty bottles from pallet to
roller conveyer, 2nd to operate Uncaser machine, 3rd to uplift the bottle if it has
fallen down in SS conveyer and 4th to clean the out doing crate for case packer. The
4 workers seem mandatory over here and are fully optimized.
This machine is generally used to convert bottle infeed from mechanical drive
to VFD drive to reduce the down time and to eliminate break down of more
bottles. This machine is provided with lots of sensors and numeric air cylinders to
lift bottle from crates and to place to conveyor belt.
Observations
Many more bottles are picked up by numeric air cylinders and dropped to
respective conveyor belt correctly. But problems like dropping of bottle from air
cylinder without reaching to respective place, air cylinder not taking bottle from
crate, and sensors sometime fails to detect numbers of crates are seen often. And
this leads to breakage of bottles and made not fit for use.
2.Conveyor
Conveyor are generally used to reduce number of short stoppage
of Bottle washer. Whatever the empty bottle is passed from the De-
Crater are passed to Bottle Washer Machine through conveyor belt.
Problems like loosing of conveyor belt is seen.

3.Bottle Washer Machine

Dirty and empty bottles from conveyor are feed to bottle washer which are
washed properly before reaching to bottling hall. It is a vast machine and provided
with numbers of sensor to detect problems and inform the operators with
beeping sound. Various mechanism takes place inside the machine. When bottle
enters to the machine, it preheats the bottle at first. The process of upside down
first removes the coarse dirty particles with high pressure cleaning. Rotating spray
nozzles clean inside of bottle from different angles and upside of bottle are
sprayed from above by jetting units. The level, glass fragments and coarse dirt are
removed and collected to the appropriate provided container. Then the bottle is
passed through the several caustic baths in vertical loops. Generally, it takes 15-20
min to wash a single bottle. Finally, they are discharge with specially designed
fingers which deposit the container quietly and smoothly on to the conveyor and
open bottle shoot made up of one piece germ repellent plastic profiles insures
optimally hygienic conditions.
Observations
Generally inaccurate position during bottle infeed leads to beeping sound
and at that time machine doesnt take infeed. So at least 2 people are mandatory
to be there. Any other problem inside the machine is detected on the screen
through the sensor and as per this care, protection and solution is made.
Problems on gear set box used and rotary teeth are detected based on the
working condition.
Day 2: - May 31 Wednesday
Beginning from Bottling Hall of RGB Plant Line to Packing and observation of
PET Line. Maintenance and CIP work in RGB Plant.

BOTTLING HALL
Bottle discharge from the bottle washer is passed through the slat conveyor
belt up to filler machine passing through various procedure. Groups of bottle are
first inspected by light to verify the clean bottle and to bottle. If cracks and black
dots are found, if bottles of another types are found, then bottles are taken out
and send back to washer through a loop and they are destroyed properly. After
initial light inspection is made, it is then passed through the Omni Vision
Inspection Machine as reducing microbiological contaminations, internal cracks
are important for quality product. Omni Vision Inspector is provided with sensor
and screen to read the bottle feed to filler machine and bottle sent back to
washer. Then the clean and fresh bottles are sent to filler machine where it gets
filled with necessary ingredients and capped with metal crown.
In Bottling Hall, premix/blender are important things to be known. They are
provided for properly setting or mixing the amount of co2, syrup and water and
glycol is for keeping cold mixture.
4.FILLER MACHINE
Filler machine contains generally four types of valves namely Air valve,
Spring-loaded Liquid valve and Snift Valve. Through Snift valve, atmospheric air
present in bottle as well as excess co2 is released to atmosphere. RGB filler
machine has ability to accept maximum bottle diameter of 95mm. And bowl and
crown height adjustment facility is up ton 350mm.Variable Speed Motor and Vee
belt drive used in it drive it. Here first V shaped lever is opened first when bottle
infeed to the filler then at a condition when bottle pressure is equal to co2
pressure, beverage is filled in bottle. First co2fill the bottle removing atmospheric
air from bottle and the liquid fills the bottle at low temperature. Amount of
beverage filled is already program or planned in machine through controlled
machine. After filing is completed, metal crown from hubber is applied to bottle
and then is send to date code machine.
OBSERVATIONS
It is noticed that bottles are broken in filler machine and produce huge sound. To
detect the fault, first of all valve breakdown time is noted so that to verify
whether it is the fault of machine or there may be any other reason. The
observations show that breaking of valve or glass is not periodic. So, it is not
machine defect. Later on, various reasons are noted regarding the breaking of
bottles. Problems like overfilling and under filling of bottles are also seen which
may lead to loss of lots of beverages.
POSSIBLE REASONS FOR BREAKING OF BOTTLES
1. Unequal pressure inside the bottle and counter pressure (Co2 Pressure).
The pressure of Co2 and inside bottle must be equal and around (3-3.5bar)
range.
2. Due to misalignment and misposition of bottle feeding inside the machine.
3. Random power cutoff and sudden stoppage of machine.
4. Life and properties of bottle and bottle made glass. Generally new bottles
are found to be broken and some old bottles due to excessive use.
5. Since bottles are brittle, working at low temperature also increases the
brittleness of bottle that may leads to breakage of bottle when it collides to
other.
 6. Uneven bottle coming from the conveyor. The gaps of bottles on slat
conveyor are often seen because of falling of bottles, misposition of bottles,
delay bottle coming from bottle washer and sometimes due to failure of
sensors to detect defect in bottles.
7. Delay Maintenance
8. Temperature of bottles coming from high temperature of 70-90-degree
Celsius bottle washer to the room temperature and then to low
temperature of around 5-10 degree Celsius during filling.
9. Filling tubes close to bottom of bottles.

5.Date Coder
Date coder machine is programmed machine where manufacturing date
and manufacturing code is setted at first. Since it is based on the sensor fitted
machine, when filled bottle is passed through the sensor, ink is sprayed on bottle
which prints the current date and manufacturing date. Then it is send for the final
inspection through the slat conveyor belt.

6.Final Inspection
Final Inspection is done in order to verify whether manufacturing date is
applied or not. Also, whether the bottle is overfilled or underfilled is checked is
also verified. If bottle is not filled completely or overfill, then they are taken out
and the liquid on the bottle is thrown out. They are completely wasted.

7.Crater
Like De-Crater, Crater is also provided with sensors that detects the empty
crates coming through conveyor belt and placed the filled bottle that comes after
final inspection through conveyor belt to the crates using numeric air cylinders
using air pumping system. After that, it is send to the final destination. This is the
end of the process of bottling techniques in RGB Bottling System.
OBSERVATION
Air Numeric Cylinders are picking up the full bottle beverages but sometime
this numeric cylinders/air pump is not properly taking the full bottle properly.
Also, it is observed that while dropping to the crate, it is not properly placed to
crate. As a result of it, many bottles are fallen down and gets broken down. So
little more focus should be given on these machine in order to minimize the losses
and to increase the more productions.

Flow
Chart
model
of RGB
Plant
Line

Employers Detail in RGB Plant

To understand the later chart, designation for each unit is given as
below -

Designation Unit
1 Palletized crates from ware house
2 De-Crater(Uncaser)
3 Visual Inspection
4 Bottle washer
5 Initial Light Inspector
6 Omni vision Inspection
7 Paramix/Blender
8 Filler
9 Date Coder
10 Final Light Inspection)
11 Crater (Case packer)
12. Palletized Crates to Warehouse

The observation was made for several days where we found no. of
working peoples at different sections and their rest period are as
follows. And this combination may fluctuate depending upon the
number of people in leave. Fluctuation is only by 1 or 2 people in every
shifts and day.

W 1 1 1 Tot
Dayy 1 2 3 4 5 6 7 8 9 0 1 2 al
 By
Vechil Automa Set by Shift Set by Shift
1 e 4 1 2 2 tic Engineer 2 Engineer 2 1 2 16

By
Vechil Automa Set by Shift Set by Shift
2 e 3 1 1 2 tic Engineer 2 Engineer 2 1 2 14
By
Vechil Automa Set by Shift Set by Shift
3 e 4 1 2 2 tic Engineer 2 Engineer 2 1 2 16

By
Vechil Automa Set by Shift Set by Shift
4 e 4 1 2 2 tic Engineer 2 Engineer 2 2 2 17
By
Vechil Automa Set by Shift Set by Shift
5 e 3 1 1 2 tic Engineer 2 Engineer 2 1 2 14

By
Vechil Automa Set by Shift Set by Shift
6 e 4 1 2 2 tic Engineer 2 Engineer 2 1 2 16

CIP (Clean in Place) and maintenance of machine is done generally when the
flavor of beverages is changed so that flavor wont gets mixed and pure beverage
can be obtained.
Result:
We found that the number of employees working in 450 BPM are optimized and
the task they are performing in certain interval of time is ergonomic enough to
keep them healthy and give their one hundred percentage in the work they are
performing. Also, the employees are satisfied in the running system of the 450
BPM.

Conclusion:
We concluded that the number of employees working under the 450 BPM are
optimized. If the number of employees are to be decreased then the efficiency,
morale and health of the employees may also decrease which may ultimately
result in the decrease in production.

Day 3: -June 1 Thursday

Day 4: -June 2 Friday
From the beginning of the day 3 to end of day 4 PET line system is
observed and studied about various machines, ways and techniques
used is studied.

Day 5: -June 3 Saturday

Day 6: -June 4 Sunday
 Visited in Engineering Workshop Department.
Gear box setup is separated from the 3-phase induction motor
setup and each and every part of gear box are separated for
identifying the problem existed in that gear box. This setup is used
in De-Crater machine.
Purpose: - To check the condition of gear box and to detect the problem
existed in that setup.
Setup Used: - Used to drive De-crater machine and supply change of
conveyer.
Reasons: - Produces unusual sound that seems to the improper working
of machine and supply chains.
Problems Identified: -Failure of bearing and Driven Gear Teeth
Solution: -New Conveyer drive motor setup along with Gear Box is used
because of unavailability of parts.

Visited the Water Treatment Plant and Observe the Plant

thoroughly.
Visited in the High Compressor Setup under Utility Section and
observe the plant, process and working thoroughly.
Known about various types of induction motor and their used.
Centrifugal Pump: -Electro-Mechanical Pump that uses impeller to
move water or other fuels.
Impeller: -the rotating part of a centrifugal pump, compressor, or other
machine designed to move a fluid by rotation.
Vacuum Pump: - Pump used for creating vacuum. Device that removes
gas molecules from a sealed volume in order to leave behind a
partial vacuum.

Revision of working of Lathe machine, Radial Drilling Machine,

Hydraulic Machine, Grinding Machine, Hand Grinder, High Speed
Cutter, Milling Machine, Arc, TIG And MIG Welding.
Study of various types of Gears and their uses like spur gears,
helical gears, crown gears, bevel gears, worn gears in various
machines used in Coca-Cola company.

Day 7: - June 5 Monday