VARUN BEVERAGES LTD JODHPUR

SUMMER INTERNSHIP REPORT 2018

SUBMITTED TO SUBMITTED BY GUIDED BY

SHIJI KURIAN PRANAY KUMAR NEERAJ CHAUHAN

MANAGER- HR Govt. Engineering College MAINTENANCE DEPT.
VBL JODHPUR Bikaner. VBL JODHPUR
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ACKNOWLEDGEMENT
I would like to thank Sh. Mukesh Ratauri (Plant Head) VARUN BEVERAGES LTD
JODHPUR who provides me the opportunity to be trained of working in this industry.
Specially I would like to thank my mentor Sh. NEERAJ CHAUHAN under whom I have
completed my summer internship 2018. His working talent and experience will help me
a lot to do better in industry sector.
A special gratitude to the maintenance department headed by Sh. Sunil Kulshrestha
VBL Jodhpur because they are the key persons of my summer internship 2018.
At last I would like to thank the management department for providing me a better
environment to learn in this company.

[PRANAY KUMAR]

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Overview of VARUN BEVERAGES LTD
Varun Beverages is the second largest franchisee in the
world (outside US) of carbonated soft drinks (“CSDs”) and
non carbonated beverages (“NCBs”) sold under trademark
owned by PepsiCo and key player in the Beverage industry.
PepsiCo CSD brands sold by VBL are Pepsi, Diet Pepsi,
Seven-up, Nimbooz masala soda, Evervess Soda, Sting
and Gatorade.
PepsiCo NCB brands sold by VBL are Tropicana, Tropicana
Slice, Tropicana Frutz, Seven-up Nimbooz, Quaker oat Milk
and Packaged Dinking water (AQUAFINA).
As of March 2018 VBL has 20 manufacturing plants.
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 Layout of the
VARUN
BEVERAGES LTD
JODHPUR

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 RO PLANT

SYRUP ROOM

Waste Water
Waste Water

RGB PET LINE 1 PET LINE 2

REFRIGERATION WARE HOUSE REFRIGERATION

PLANT 1 WARE HOUSE 2
1 PLANT 2

EFFLUENT
TREATMENT PLANT 5
WATER PURIFICATION PLANT
Commonly known as RO Plant

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7
There are mainly two water purification plant at VBL
Jodhpur named as
1-> RO Plant 1 (Cap.- 35 cubic meters/hrs)
2-> RO Plant 2 (Cap.- 40 cubic meters/hrs.)
RO Plant is the plant with Reverse Osmosis system.
Firstly we will discuss about RO plant 1

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RO PLANT 1
A SIMPLE FLOW CHART TO UNDERSTAND THIS WATER SUPPLY SYSTEM

RAW DMF (DUAL

BOREWELL WATER MEDIA
STOCK FILTER)

ANTISCALENT ACF 1st SOFTNER

DOSING

MICRON RO FILTERS STORAGE

FILTER (MEMBRANES) TANK 9
RO PLANT 2
A SIMPLE FLOW CHART TO UNDERSTAND THIS WATER SUPPLY SYSTEM

RAW MGF (MULTI

BOREWELL WATER GRADE
STOCK FILTER)

ANTISCALENT
SOFTNER ACF 1st
DOSING

MICRON RO FILTERS STORAGE

FILTER (MEMBRANES) TANK 10
SUPPLY SYSTEM OF PURIFIED WATER
STORAGE TANK

POST ACF PLANT SUPPLY

HEADER
ACF 4th ACF 2nd ACF 3rd

MICRON FILTERS U.V. LIGHT TREATED WATER

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HARDNESS IN WATER AND WORKING
OF NaCl TO MAKE IT SOFT
 There are basically two types of hardness in water:-
1. Temporary Hardness
2. Permanent Hardness
(i) Temporary Hardness:- This type of hardness is caused
due to presence of (Bi Carbonate) ion in the water and this
can be easily removed by just boiling the water.

CaHCO3 Heating CaCO3+ CO2 + H2O

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(ii) Permanent Hardness:- Permanent hardness is caused by
the presence of carbonate ion in the water i.e. carbonate salt of
calcium or magnesium ( CaCO3 or MgCO3).
Permanent hardness can be removed by discharging NaCl or
common salt to the water.
The chemical working of NaCl in removing the hardness is as
follows:-
CaCO3 + 2NaCl Na2CO3 + CaCl2
MgCO3 + 2NaCl Na2CO3 + MgCl2
The above has explained that why we have discharged NaCl in
the softner tank or how resins are charged.
We use 5% sol of NaCl in the tank.
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SYRUP ROOM
Sugar Dumping

Heating tank
Cilate High flow
(pressure flow)
Filter Press Line Supply

Check the quantity

Ready Syrup of sugar using Concentrate mixing
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(Refractometer)
 SUGAR DUMPING- Making of syrup starts from sugar
dumping. Sugar is dumped into the tank (different units of sugar
dumped for different flavour of beverages.
 HEATING TANK- After dumping of sugar the sugar is passed
into heating tank because sugar will always dissolves in warm
water. There are two heating tanks ( Heating tank 1 and 2) in
which 60% of water and 40% sugar present in heating tank.
Temperature of heating tank is 65 degree of centigrade. The
temperature of heating tank will raised to 80 degree of
centigrade when 60% of total sugar is dumped. After all the
above process the circulation starts in heating tank and
continued for 20 mins.
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 FILTER PRESS- Filter press is used to purify sugar solution. In
filter press filter paper of hole of 30 micron is present. Before
going to filter press the solution passes through ciliates these
are like sieves which doesn’t allows the dirt of bigger size to go
to filter paper and avoid choking. After the ciliates by HIGH
FLOW (pressure flow) the solution moves to filter press. The
temperature in the filter press is continuously maintained at 25
degree of centigrade. With the help of glycol obtained from
refrigeration room the temperature is maintained.
 READY SYRUP- After above all processes the syrup is ready.
Ready syrup is the optimum mixture of water and sugar i.e. 40%
sugar and 60% of water.
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 After the syrup is ready the quality department checks the
quantity of sugar in the 100g of total quantity using a device
called REFRACTOMETER.
 When the quantity of sugar is checked then CONCENTRATE is
mixed with the sugar. After the concentrate is mixed then the
syrup is converted into BEVERAGE.
 The ready BEVERAGE is supplied to line for paramix or
intermix.

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SUGAR AND SYRUP QUANTITY
FLAVOUR UNIT SUGAR (Kg) SYRUP (Lit.)

Pepsi 1 1109 1703.4

M. Orange 1 470.5 681.3

Mountain Dew 1 417.9 567.8

7 up 1 389.7 567.8

M. Lemon 1 376.7 567.8

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 MOUNTAIN DEW
Sodium Benzoate

Caffeine Anhydrous

Citric Acid anhydrous

Cloud Component
Sodium Citrate

Tartrazine (Granular) M.dew/ citrus flavour

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Pepsi
Pepsi Acidulate (B2D) Pepsi Flavour (ABDS)

7 up
Sodium Benzoate 7up Flavour

Sodium Citrate Citric Acid Anhydrous Malic Acid

M.Orange
Sodium Benzoate Orange Flavour

Sodium Citrate Citric Acid Anhydrous colour yellow

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REFRIGERATION
REFRIGERATION CYCLE

COMPRESSOR

EVAPORATOR CONDENSOR

EXPANSION
VALVE
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REFRIGERATION SYSTEM OF VBL JODHPUR

EXPANSION
COMPRESSOR CONDENSOR
VALVE
COOLING
TOWER
---------------------
RECEIVER ---------------------
FLOAT UNIT
---------------------
---------------------
--------

EVAPORATOR

GLYCOL TANK

P1 22 P2 P3
PARAMIX
PHE
 Ammonia (NH3) is used as refrigerant in that plant.
 Propylene Glycol is used as cooling medium.
 Maker of the compressor of the chilling plant is KIRLOSKAR.
 There are three compressors working in the chilling plant.
 Capacity of compressing unit is 360 TR (120 TR each). TR=Ton
Refrigerant.
 Plate heat exchangers are fitted in Condenser and Evaporator.
PHE is a type of heat exchanger that uses metal plates to
transfer heat between two fluids.

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AIR COMPRESSORS
Air compressors are used in VBL Jodhpur mainly for proper working
of machines for e.g. compressed air is passed in preform to make it
bottle in blow moulding machine.
There are 4 types of air compressors present in the plant.

Description Maker Capacity

High Pressure Air Compressor Chicago Pneumatic (CP) 1500 CFM
4 stage Air Compressor 40 kg/cm2 (max)
High Pressure Air Compressor AF 1050 CFM
3 Stage Air compressor 40 kg/cm2 (max)
Low Pressure Air Compressor Chicago Pneumatic (CP) 472 CFM
10 kg/cm2 (max)
Low Pressure Air Compressor Chicago Pneumatic (CP) 283 CFM 24

10 kg/cm2 (max)
HIGH PRESSURE AIR COMPRESSOR
(CP)

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HIGH PRESSURE AIR COMPRESSOR
(AF)

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Features of High Pressure air
compressor (AF)
 It is a three stage Air Compressor.
 Installed power is 350 KW.
 It is an oil free piston air compressor.
 Max 40 bar of air pressure can be generated.
 intercoolers between each stage and after-cooler.
 3 micron air inlet filter suitable for dusty conditions.
Supplied with filter condition indicator.
 Thermostatic water valve to maintain ideal operating air
temperatures with in cylinders. 28
Low pressure Air Compressor

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Features of Low pressure Air
Compressor
 High temperature resistant operation
 Constant high efficiency throughout the lifetime
 Robustness
 Low Total Cost of Ownership, low energy, low maintenance
cost.
 Energy savings due to:
 Low idle consumption: 10% of full power.
 Lower maximum power.
 Superior regulation between idle and full load.
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Pet Filling Line (Cap. – 600 BPM)

Preform Blow
Hopper Filler Warmer
Moulding

Shrink
Palletizer Coding M/c Labeller
wrapping

Warehouse
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BLOW MOLDING MACHINE
The job of blow
molding machine
is to create the
bottle from the
preform in the
mold by blowing
high pressure air
inside the
preform.

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The preform enters in the
machine and it is taken to
the heater or oven in
queue like this. There are
22 ovens and temp. of it
is about 100 degree of
centigrade

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 1. Stretching tube increases the
length of preform at 10 bar
pressure.
2. At 25 bar pressure the base
of the bottle is created.
3. At 40 bar pressure complete
bottle is made.
4. Bottles are out of mold and
water is sprinkled on it to
avoid unwanted deformation.

**Air pressure is obtained from High pressure air compressor

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 PARAMIX
PARAMIX:- It is known as mixing of water, syrup and CO2 in proper proportion.

Water Syrup Syrup

RO Plant SYRUP+WATER Control valve Control valve
tank Tank Room

GLYCOL
TANK
Pressure Plate heat
inside tank exchanger
is 4.7 bar
approx.

Beverage 35
tank BEVERAGE Control Valve CO2 Tank
(SYRUP+WATER+CO2)
FILLER MACHINE
The job of filler machine
is to fill the empty bottles
with the beverage and fit
the cap which is
obtained by blow
molding machine.

1. 117 Filling Valves

2. 18 caper head

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 Working
Temperature
pressure of
of filler is
filler is 4.7 bar 130C
approx.

1. When the bottle reaches the filling

valve the NECK GUARD takes the
bottle up.
2. Vent tube enters in the bottle and
completely fills the bottle with CO2.
3. By the counter pressure the
Beverage starts entering in the
bottle and CO2 starts moving out of
bottle from vent tube itself.
4. The Beverage reaches to the filling
level and closes vent tube so the
rest of CO2 .moves out by snifting
valve
5. The bottles moves to Caper Head
Fig: Filling Valve which are 18 in number and the
caps are tightened.37
 Temp. inside

WARMER warmer is 32
degree
centigrade.

Warmer is installed to
raise the temperature
of the bottle so that the
label stick to the bottle
properly because when
the temperature is low
the condensation
occur on the surface of
the bottle and this
resist the glue action
on the bottle

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  The nozzles are fitted in
the warmer which
continuously sprinkle
warm water on the
bottles to raise the
temperature.
 Temp of water is raised
by the action of steam.
 Steam is obtained from
boiler.
 And water is taken from
sump from the pump.

 Travel time of bottle in warmer is 20 mins

 Blower is attached at the end to remove water on the cap of the bottle
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LABELLER
Features
Rotary Machine
Specially for round
shaped bottles
2 labelling station
Splicing
Servo drive technology

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  A feed roller continuously
pulls the label film and guider
make sure that the label
should be straight.
 The labels are precisely cut.
Computer gives the exact
cutoff point
 Heated glue is applied on
label’s leading and trailing
edges.
 Label is being applied on the
rolling bottles. During this
process the label is
stretched.

Advantages
 High labelling precision
 Low glue consumptions
 Time savings. 41
Di MAC SHRINK WRAPPING MACHINE

In feed
Conveyor connection
conveyor

Separation
Area

Tunnel Product Zone

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Features of Shrink Wrapping Machine

 18-20 cases are there at an instant of time in tunnel.

 Maximum length of film that can be cut is 1345 mm.
 Temp. of tunnel is ranging 180-200 degree centigrade.
 Minimum speed of tunnel is 20 case per minute.
 Maximum speed of tunnel is 60 case per minute.
 There are 3 zones present inside the tunnel. 1 zone has 18 heaters so in
total there are 54 heaters in the tunnel.
 Power of 1 heater is 2500 watt.
 Capacity of 1 zone is 65 kg.
 Cooling fans are installed to cool down case and tunnel belt. 43
PALLETIZER
Palletizer is a machine
used to palletize the
cases received from
Shrink Wrapping
machine. Need of
palletize is for ease of
storing the products
by using forklift.

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Technical Features of Palletizer

 Product infeed can be

orthogonal or in line.
 The whole range is designed
to accept a variable number
of product infeed (from 1-4).
 Robotized fast layer
preparation device is
installed.
 Fully automatic system
requiring limited operator
intervention, operating in
complete safety.
 Extremely simple
 Output up to 330 layers/hour.
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WAREHOUSE
The place where
produced
beverages which
are ready to supply
is stored and
supplied further is
known as
warehouse

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EFFULENT TREATMENT PLANT (ETP)

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 Low BOD stream (influent from High BOD stream (influent from bottling hall and
bottle washer and warehouse) syrup room)

Bar screen and oil grease trap Bar screen and oil grease trap

Low BOD Equalization tank High BOD Equalization tank

PAC
LIME Flash mixture Anaerobic Digester
PE

Primary Clarifier Sludge sump

pump

UREA Sludge
Aeration Tank
DAP Recycle

Sludge sump
Secondary clarifier
pump

Final Effluent Storage Discharge to gardening

Sludge drying bed Sludge bed filtrate 48

 Chemical Name USES
Lime It is used to maintain the pH of water
PAC (POLY ALUMINIUM CHLORIDE) It is used as coagulant.
PE (POLY ELECTROLYTE) It is used to settle down suspended dirt.
UREA It is used to produce oxygen.
DAP It is used to produce oxygen.

Reaction in AERATION TANK

Bacteria
Organic matter + O2 CO2 + H2O + Heat

Capacity of ETP is
750 KL/day
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THANK YOU

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