7 Things You Don’t Know About Production Design For Carbonated Beverage

7 Things You Don not Know About Production Design For Carbonated Beverage

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7 Things You Don not Know About Production Design For Carbonated Beverage

01.

Requirements of the product program

When arranging the product program, we should try to meet the requirements of the main product output. Meet the requirements of comprehensive utilization of raw materials, meet the needs of balanced production in the off-peak season, meet the requirements of market supply and improve economic efficiency. Efforts to achieve product output and raw material supply balance, production season and labour demand balance, production shift balance, equipment production capacity balance, water, electricity, steam load to ratio. When arranging the product program, it should be based on the requirements of the plan task book and the supply of raw materials. Combined with the actual utilization rate of each production workshop, plan how many workshops to arrange production to ensure the smooth implementation of the program.

02.

Determination of shift output

Class output is the primary calculation benchmark in the process design of the beverage factory. The size of the class output directly affects the equipment, layout and floor space of the workshop, the specifications and size of the public utilities and auxiliary facilities and the staffing of the labour force. The constraints of shift yield are mainly the supply of raw materials and market sales, the production capacity and operation of supporting equipment, the conditions of extended production period (cold storage and semi-finished products processing measures), the collocation of product varieties and the degree of factory automation.
MonthDayShift OutputShiftDaily OutputMonthly OutputFruity typeJuice TypeCoke Type
 

(day/

month)

(shift/

T)

 (T)(T)(T)(T)(T)
Jan.2115230630150180300
Feb.15151152256060105
March221511533060120150
April2215230660150210300
May1915230570150180240
June2215230660150210300
July2215230660150210300
Aug.2215230660150210300
September2215230660150210300
Oct.191511528560105120
Nov.221511533060120150
Dec.221511533060120150
From the above table, we can see that the actual working days per year are calculated based on 250 days, which align with the national regulations. The actual working days are 22 days per month based on 4 weeks, excluding 8 days on weekends, and 15 days in February due to the Spring Festival, 21 days in January due to New Year’s Day, and 19 days in May and October due to legal holidays. Carbonated beverages are sold well during the summer and Chinese New Year, so two shifts are produced each day. The rest of the months are low season, so we produce 1 shift per day.

03.

Carbonated beverage production process

There are two kinds of production processes for carbonated beverages. One is to prepare the flavoured syrup, fill it into the packaging container, and then fill carbonated water (i.e. water flushed with carbon dioxide), called ready-to-fill. The other is to mix the flavoured syrup and carbonated water quantitatively and then fill it into the packaging container, which is called pre-conditioned. This design is based on the pre-mixed beverage filling process.

carbonated beverage production workflow 1
carbonated beverage production workflow 1 (1)

Water quality requirements and treatment of beverage water

Water is one of the essential raw materials in beverage production. The quality of water has a direct impact on the quality of finished products. Therefore, the treatment of drinking water is essential.
According to the degree of particle dispersion, impurities in natural water sources can be roughly divided into three categories: suspended matter, colloids, dissolved substances, see Table 3-2.

Table 3-2 Classification and treatment methods of impurities in natural water sources

Table 3-2 Classification and treatment methods of impurities in natural water sources

Preparation of raw sugar syrup

(1) Dissolution of sugar

Dissolving sugar in water is generally referred to as raw sugar syrup or simple sugar syrup. It is necessary to use high-quality sugar, dissolve it in a certain amount of water, make the expected concentration of sugar solution, and then filter and clarify it for use. The water used must also be pure, the quality of which can be the same as the bottling water.

The dissolution methods are cold dissolution and hot dissolution. The syrup of the drinks to be consumed quickly can be dissolved coldly. For fragmented beverages, drinks with high purity requirements or drinks requiring an extended storage period, it is better to use the hot dissolution method.

The advantages of the hot dissolution method are.

1. It can kill the bacteria attached to the sugar.

2. It can separate out the debris in the solidified sugar.

3. Dissolve quickly, in a relatively short period can produce a large amount of syrup.

The advantage of the cold dissolution method is that it saves fuel.

ItemStandard
 ColorChromaticity not more than 15 degrees, and does not show other different colors
 TurbidityNot more than 3 degrees, special circumstances not more than 5 degrees
 Odor and tasteShall not have a strange odor
 Visible matter to the naked eyeShall not contain
 PH6.5~8.5
 Total hardness (by calcium carbonate) mg/L<450
 Iron/(mg/L)<0.3
Sensory traits andManganese/(mg/L)<0.1
General Chemical IndicatorsCopper/(mg/L)<1.0
 Zinc/(mg/L)<1.0
 Volatile phenols (as phenol) mg/L  <0.002
 Anionic synthetic washing(mg/L)<0.3
 Sulfate/(mg/L)<250
 Chloride/(mg/L)<250
 Total dissolved solids/(mg/L)<1000
   
 Fluoride/(mg/L)<1.0
 Cyanide/(mg/L)<0.05
 Arsenic/(mg/L)<0.05
 Selenium/(mg/L)<0.01
Toxicological indicatorsMercury/(mg/L)  <0.001
 Cadmium/(mg/L)<0.01
 Chromium(hexavalent)/(mg/L)<0.05
 Lead/(mg/L)<0.05
 Silver/(mg/L)<0.05
 Nitrate(by nitrogen)/(mg/L)<20
 Chloroform/(μg/L)<60
 Carbon tetrachloride/(μg/L)<3
 DDT/(μg/l)<1
 Hexahexane/(μg/l)<5
 Total number of bacteria/(pcs/mL)<100
 Total coliform/(pcs/L)<3
  In contact with water for 30min, the reaction is not less than 0.3mg/L. Centralized
  In addition to the factory water, the end of the pipe network
Bacteriological indicatorsFree residual chlorineWater should not be less than 0.05mg/L
   
 Total alpha radioactivity/(Bq/L)<0.1
Radioactivity indicatorsTotal β radioactivity/(Bq/L)<1

(2) Syrup filtration

After the sugar is dissolved with water, it must be filtered. There are two kinds of filtration methods: natural filtration and pressurized filtration.

Natural filtration uses a hammer-shaped thick flannel filter bag with a pulp filter layer inside, which is extremely simple to operate. However, the filtering speed and flow rate are too slow and not suitable for general factories. Most of the factories use the pressurized filtration method.

Pressurized filtration uses stainless steel plate and frame compression equipment, and each filter plate is equipped with a fine canvas. After the sugar solution is dissolved, paper pulp is added as filtering aid. It is pressurized through the filter plate by a pump. It is passed repeatedly to form a filter layer first and remove impurities to get a clarified and transparent syrup for backup. The filtering aid is made of paper raw materials crushed into pulp, added after the sugar is dissolved. The amount added is about 1Kg of pulp raw materials per 1m2 filtering area. Pressurized by a centrifugal pump, the pressure does not exceed 117.6kPa (1.2kgf/cm2).

The general operating pressure is around 58.8kPa (0.6kgf/cm2). If the pressure exceeds 117.6kPa and the flow rate decreases, the operation should be stopped and replaced with a new pulp and filter cloth. This operation must be carried out under sanitary conditions. The replaced pulp can be reused after cleaning and drying.

Suppose poor quality sugar is used in the production. In that case, it will lead to flocculation and sediment in the beverage, resulting in off-flavours, etc. It will also cause a lot of foam when bottling and affect the production speed. Therefore, the poor quality sugar must be purified by activated carbon. The treatment method is: add the activated carbon for sugar to the hot syrup and stir it continuously with a stirrer when adding. The amount of activated carbon must depend on the quality of the sugar and the activated carbon, which is generally between 0.5% and 1% of the sugar mass. The activated carbon should contact the sugar solution for 15 min, and the temperature should be kept at 80℃. Some filtering aid (such as diatomaceous earth) is added before passing through the filter to avoid the activated carbon blocking the filter surface. The dosage is 0.1% of the sugar mass. When filtering, the activated carbon and the filtering aid are adsorbed on the filter surface. The sugar syrup is repeatedly passed through the filter to achieve a pure and transparent sugar solution. The filtering equipment also adopts stainless steel plate and frame filter press.

Matching of syrup

Raw syrup (add sweetener) → add preservative → add acidifier → juice → flavour → colour → water (carbonated water)

(1) Preservatives

The role of preservatives is to prevent spoilage caused by bacterial contamination in the production of food. Still, it is necessary to first ensure the hygiene of the product production process to expect the effect produced by preservatives.

The preservative commonly used in beverages is sodium benzoate, prepared at a concentration of 25%. i.e. one part of sodium benzoate is dissolved into a solution by adding three parts of warm water, filtered and stored in a clean container for backup. The amount used in soft drinks is less than 0.1%.

(2) Acid

Acids are used in beverages to produce acidity, adjust the sweetness of sugar, and highlight or complement the associated flavour.

1.Citric acid

Since it is a natural component of citrus fruits, it is suitable for orange-flavoured carbonated beverages. Factories generally use 50% citric acid solution.

2.Tartaric acid

Tartaric acid is obtained from the by-products of wine production, which is more acidic than citric acid and is mainly used to prepare grape-flavoured beverages. It is mainly used to prepare grape flavoured drinks. It is dissolved into a 50% solution, which is the same as citric acid.

3.Phosphoric acid

Because of its high concentration and low price, phosphoric acid is the most economical acidifier. When used in carbonated beverages, 25% carbonic acid solution is almost equal to 50% citric acid solution. Used primarily in cola-type drinks.

 4.Lactic acid

Lactic acid is made from lactose and is a colourless and thick solution with a mild taste. Generally used in the same amount as citric acid.

(3) Sweetener (sodium saccharin)

Sodium saccharin is colourless and crystalline because it is a sodium salt, it is easily tolerated in water. Its sweetness is usually equal to 300-500 times the quality of sucrose. China’s maximum use amount is 0.015% of the finished product.

(4) Fruit Juice

Many fruit juices are widely used in carbonated beverages, and the most widely used is citrus juice. Juice can be divided into clarified and turbid. Now all use cloudy citrus juice. The juice must be pasteurized instantly to destroy the pectinase activity to avoid destroying the turbidity in the processing. To save, generally use the juice concentrate, such as vacuum centrifugal juice concentrate.

(5) Color

Since consumers require that the appearance of the beverage should resemble the original fruit or plant hue, various colouring agents are used to attracting consumers.

The colouring agents used in carbonated beverages can be divided into natural colouring and legal food colouring.

There are nine kinds of natural colouring agents, such as bugloss pigment, safflower yellow, chilli red, caramel colour, safflower rice, β-carotene, chlorophyll, turmeric and beet red.

Artificial pigments are lemon yellow, sunset yellow, amaranth red, carmine, indigo and five others.

(6) Flavoring

Flavours are indispensable raw materials in beverages and can be divided into water-soluble flavours and emulsified flavours.

Carbonation

The most crucial property of carbonated beverages is their foaminess. The degree of foaminess is determined by the amount of carbon dioxide dissolved in the beverage. The absorption of carbonic acid gas by water or blended beverages, i.e. the process of mixing carbon dioxide and water, is called carbonic acid saturation or carbonation.

Factors affecting carbonation.

(1) the role of carbon dioxide in carbonated beverages

  1. the role of cooling: drinking soda is actually drinking a certain concentration of carbonic acid, carbonic acid in the abdomen due to the increase in temperature, pressure reduction, that is, decomposition. When carbon dioxide is discharged from the body, it tropicalizes the body out and plays a cooling effect.
  2. hinder the growth of microorganisms, extend the shelf life of soda: carbon dioxide can kill oxygenophilic microorganisms, and because of the pressure in the soda can inhibit the growth of microorganisms. Internationally, it is believed that 3.5 to 4 times the gas content is the safe zone of soft drinks.
  3. highlight the fragrance: carbon dioxide in the soda can bring out the aroma when it escapes, enhancing the flavour.
  4. there is a comfortable braking taste: carbon dioxide with other components in the soda, the output of a unique flavour, different varieties need a different braking taste, some too strong, some too soft, so the gas content of each variety is different. For example, orange juice soda, the gas content (volume times) is 1.5 ~ 2.5; cola soda, the gas content is 3.5 ~ 4; lemon soda, the gas content is 3.5 ~ 4.

(2) The solubility of carbon dioxide in water

At a certain pressure and temperature, the maximum amount of carbon dioxide dissolved in water is called solubility. At this point, the rate of escape of gas from the liquid and the gas rate into the liquid to reach equilibrium, called saturation. The solution that does not reach the maximum solubility is called an unsaturated solution.

The amount of carbon dioxide dissolved in the liquid depends on the following factors.

  1. the absolute pressure of the gas-liquid system and the temperature of the liquid.
  2. the purity of carbon dioxide gas and the nature of the solute present in the liquid.
  3. the contact area and contact time of the gas and liquid.

(3) The effect of air in the beverage

The solubility of carbon dioxide in the liquid is related to the nature of the solute present in the liquid and the purity of carbon dioxide. Pure water is more likely to dissolve carbon dioxide than water containing sugar or salt. Impurities in carbon dioxide gas, on the other hand, prevent the dissolution of carbon dioxide. The most common factor affecting carbonation is air. Air affects the effectiveness of carbonation, but for the product, it can promote the growth of mold and spoilage bacteria and can oxidize the spices so that the flavour is damaged.

The main sources of air:

  1. Carbon dioxide gas impure.
  2. The airline has a gap.
  3. Dissolved oxygen, air bubbles in the water.
  4. The pumping line has a gap.
  5. Dissolved oxygen, air bubbles in the syrup.
  6. Syrup line and the proportioner line in the nest of air.
  7. Air in the mixer and in the pipeline.

The air in the water can be treated with degasser.

Bottle pre-treatment

(1) Depalletizing

Depalletizing is to move empty bottles or cans from boxes or pallets into the chain lane. The bottle unstacker of the glass bottle line uses a vacuum adsorption device to grip the bottles by suction jaws and send the bottles from the case to the chain lane. This process requires pre-inspection of the glass bottles to pick out broken bottles, dirty bottles that cannot be cleaned and miscellaneous bottles, etc. The bottle unloading machine of plastic bottle line and can line is mainly for tray packaging products. The tray containing empty bottles is raised to the same horizontal position as the platform using a lifting device. The empty bottles within the same layer are moved to the chain lane through pushing devices to complete the conveying work.

(2) Bottle washing

The glass bottle is recycled packaging, so the bottle is dirty, the use of decontamination ability of the stronger cleaning of caustic soda, the general concentration of caustic soda is 2% to 3.5%, lye temperature of 55 ~ 60 ℃, contact time of 10 ~ 20min. Suppose the concentration of caustic soda in more than 4% or the temperature exceeds 77 ℃. There will be damage to the glass bottle. Glass bottle cleaning is now commonly used is a mixture of washing liquid method。  Adding caustic soda in caustic soda (6/4) to make it easier to wash, adding sodium phosphate to improve the hard water scaling, and avoiding hard water to wash out the bottle wall dirt。 Adding sodium gluconate to facilitate the bottle mouth rust, etc. PET bottles and cans due to sealed packaging, pollution is tiny, just use the chlorine content (3 ~ 10) × 10ˉ6 Softened water can be rinsed instantly. The rinsing pressure is kept at 0.2~0.4kPa.

The bottle washing method is divided into three kinds of immersion, spraying and brushing.

Quality indicators of carbonated beverages

(1) Sensory indicators
  1. colour and transparency: colourless, clear, transparent (colouring soda should be consistent with the colour of the species). Mixed juice type soda should have a certain sense of turbidity.
  2. appearance: clean inside and outside the bottle, no solid oil ring on the inner wall of the bottleneck, no rust spots on the teeth of the bottle cap, no leakage of water and gas.
  3. Aroma and taste: pure aroma, smooth taste, moderately sweet and sour, and in line with the variety’s flavour. No odour, no bad taste.
  4. impurities: no foreign impurities visible to the naked eye (fruit juice type soda allows a small fruit pulp).
  5. uniformity: no stratification, liquid level from the bottle cap 6cm.
  6. foam: poured into the cup, the foam is more than 2cm high, the duration of 2min or more.
(2) physical and chemical indicators
                      CategoryJuice type and fruit flavor typeCoke typeOther type
ItemHigh sugar Medium sugar Low sugar
Soluble solids (20℃ refractometer method) %≥10≥6.5≥4.0≥7.0 
Carbon dioxide gas volume (20℃ volume multiplier)≥2.5≥3.0≥2.5
Total acid (by 1 molecule water citric acid) (%)≥0.12≥0.10≥0.06≥0.08≥0.30
SweetenerAccording to GB 2760
Sodium benzoate content (g/kg)0.2
Coloring agentAccording to GB 2760
EmulsifierAccording to GB 2760
Edible spicesAccording to GB 2760
Arsenic (as As) (mg/kg)0.5
Lead (as Pb) (mg/kg)1
Copper (as Cu) (mg/kg)10
(3) microbial indicators: total number of bacteria ≤ 100 / ml, E. coli ≤ 3 / 100 ml, pathogenic bacteria shall not be detected. (4) Shelf life: 3 months without precipitation and deterioration.

04.

Production material accounting

Calculation of raw and auxiliary material dosage.
The following is an example of a cola-type carbonated beverage.
Coke flavor 0.1%, sugar 7%, citric acid 0.06%, sweetener 0.05%, phosphoric acid (85%) 0.06%, caramel color 0.18%, sodium benzoate 0.015%.
Let the loss of finished products in the production process is 0.5%
Then: the amount of loss 15000 × 0.5% = 75 kg
The amount of finished product to be produced is 15000+75=15075 kg
This design uses plastic bottle packaging. Its capacity is about 500mL, about 0.5 kilograms, then each shift can produce cola-type carbonated drinks. N=15000/0.5=30,000 bottles
15 tons of finished products in a shift need to add sugar: 15075×7%=1055.25kg
Citric acid: 15075×0.06%≈9.05 kilograms
Sweetener: 15075×0.05%≈7.54kg
Caramel color: 15075×0.18%≈27.14 kg
Coke flavoring: 15075×0.1%≈15.08 kg
Sodium benzoate: 15075×0.015%≈2.26 kg
Phosphoric acid (85%): 15075×0.06%≈9.045 kg
The drinking water required for 15075 kg of finished product is approximately
15075-(1055+9+7.5+27+15+2+9)=13950.5 liters
The amount of packet turn containers consumed per shift (one / shift) = (1000 / 0.5) × 15 = 30,000
Usually 24 bottles for a box, then the amount of cartons consumed per shift (only / shift) = 30,000/24 = 1250

05.

Equipment selection

Equipment selection must be based on a production scale, class output, process flow characteristics and plant conditions, generally according to the following principles and requirements.
1. To meet the process requirements to ensure the quality and yield of the product,large and medium-sized beverage factories should choose technologically advanced, high degree of mechanization, continuous, automated equipment. Small plants prefer simpler equipment, pay attention to equipment utilization and cost accounting.
2. advanced. The quality performance of key equipment, service life, energy consumption, automation level should be as close as possible to or reach the advanced international level or domestic leading level.
3. applicability. The selected equipment should be compatible with the construction scale, product program, and the quality of factory staff and management level, with the possible availability of raw materials, auxiliary materials and fuel; and environmental protection requirements.
4.Reliability. The selected equipment should be tested by production and operation and have a good reliability record.
5. safety. The selected equipment in normal use to ensure safe operation, to examine whether the equipment used will cause personal injury to the operator. Whether it will damage the natural environment and ecological balance, the availability of protective measures can be prevented.
6.Economic rationality. Analysis of the equipment used is economically reasonable, whether it is conducive to saving project investment and reduce production costs.
7.the selected equipment should meet the food hygiene requirements. Easy to disassemble and clean, and food contact parts made of stainless steel or non-polluting materials are not easy to corrode food.
8. in temperature, pressure, vacuum, concentration, time, speed, flow, liquid level, counting and procedures, have a sound control system and use automatic control methods.

Water treatment equipment

Water purification and treatment equipment
This design uses a sand filter rod filter. This equipment, after a long period of filtration, impurity adsorption will make the filtration rate drop, should be flushed, disinfection. Disinfection, usually with 10% bleach solution or other chlorinated solution soaked 30min, can also be used 75% alcohol soak sterilization. The water required for this design shift is about 12 tons. Therefore, the model and parameters of the sand filter rod filter are as follows.
Model 101 aluminum alloy water filter Specification (height × inner diameter × thickness)/mm: 800 × 500 × 20 Operating pressure/MPa: 0.294 Flow rate/t-hˉ1: 1.5 Number of sand filter rods/(root – unitˉ1): 19 (Model 101)
This design requires 1 unit.

Water softening treatment equipment
Due to the high hardness of water, more ions can not meet the production needs, so the use of automatic softening equipment, using the principle of ion exchanger to reduce the hardness of the water. According to the output of only one, its technical parameters are as follows.
Working pressure: 0.2-0.6Mpa Working temperature: 4-40℃ Feed water turbidity: < 5 degrees
Feedwater hardness : <6mmol/L Output water hardness : < 0.03mmol/L Water output : 2m3/h
Regeneration method: counter-current regeneration Water consumption: <20% of water production Resin volume L: 75
Salt consumption : <130g/g equivalent Salt barrel capacity:72L Regeneration salt consumption:18kg
Power supply : 220V/50HZ AC12V 3W- 40W
Can size : 350×1625( Φ×H mm
Do not use iodized salt or calcium salt as regenerate, add salt to the salt barrel regularly to ensure that the brine is in saturated concentration.

Disinfection of water
After the original water is precipitated and filtered with chlorine for disinfection, the amount of chlorine added is small, generally 0.5~2.0mg/L.

Temporary storage tank

In the production, we can’t handle water only when used, and we should have a certain amount of sugar water in reserve when we mix syrup. Then there should be temporary storage tank storage after the water treatment and sugar.
Water storage tank material: stainless steel capacity: 5000L Size (Ф×H): 2000×2800mm
Sugar water storage tank material: stainless steel capacity: 3000L size (Ф×H): 1600×2300mm

Stainless steel beverage pump

Stainless steel beverage pump is suitable for conveying milk and other similar gelatinous liquid foodstuffs with the maximum temperature of 70-80 ℃. This pump is a single-suction fully enclosed centrifugal pump. The pump is a single-suction fully enclosed centrifugal pump. The gear pump is selected for conveying syrup.
Flow rate: 3T/H Head: 18M Power: 0.75KW Rotation speed: 2850r/min
Impeller diameter: 126mm Inlet diameter: 40mm Outlet diameter: 32mm
Dimension (mm): 450×240×330 Weight: 31kg
Gear pump technical parameters: Model: NYP-7.0 Viscosity cst: 2000/6000 Pressure: 0.8MPa
Caliber: 40mm Flow: 1.74 m3/h Speed: 960/500-640 Power: 2.3/3KW

Sugar melting tank

The sugar tank is mainly used to dissolve white sugar. The methods are the cold dissolution method and hot dissolution method. The sugar tank is divided into cylinder body, cylinder cover, stirring paddle, inlet and outlet valve made of imported stainless steel. According to GB741-80 technical conditions, polished inside the rigid body and stirring paddle inside, which plays the role of stirring. This design only needs 1 unit, its technical parameters are shown in Table 3-5, and the models are as follows
Model: DH-G2000 Capacity: 2000L Motor power: 2.2KW Weight: 1000k
Jacket inner diameter: 1500mm Dimension: 1850×1650×2400m

Inside the jacketInside the container
Design pressure (Mpa)0.4Design pressure (Mpa)Atmospheric pressure
Design temperature (℃)142Design temperature (℃)15~126
Test pressure (Mpa)0.6Test pressure (Mpa)Atmospheric pressure
Main material1Cr18Ni9TiMain material1Cr18Ni9Ti
Storage mediumWater, steamStorage mediumDissolved sugar solution

Diatomaceous earth filter

The filter is made of 1Cr18Ni9Ti high-quality stainless steel with diatomaceous earth filtering aid. It has a beautiful appearance, easy operation, low filtration cost, high efficiency, and the clarification degree of filtration can reach 99.8%.
Model: KW250
Filtration area: 2m2
Number of filter sheets (sheets): 20
Valve diameter: Dg32
Dimension (mm): 1100 × 350 × 450
Theoretical flow rate:(1-3)t/h
Working pressure (MPa):≤0.2
Need to match the pump model: YLB3-20Y
Because the output of finished products per shift is 15075 kg.
The theoretical flow rate of this filter for 8 hours is (8-24) tons.

Syrup blending tank

This batching tank is an upper open type, lower sloping bottom three-layer structure, heating automatic temperature control, heat preservation, stirring function; fast heat transfer, adapt to temperature difference, easy to clean and other advantages.
Capacity 1000L
Vacuum degree (MPa): <-0.09
Motor power: 5.5KW
Working temperature (℃): 0~100
Working pressure (MPa): Normal pressure
Material heating temperature:≤350℃
Stirring speed (r/min): 35~51
Dimension (mm): Φ1500 X2750
Since the capacity of this model is small, 3 units are needed.

Vacuum degassing tank

Model: TQ-2
Production capacity:2000L/h
Working vacuum degree:6.4~8.7×10Pa
Dimension (mm): 1135×780×3040
Net weight of equipment: 300kg

Ultraviolet sterilization machine

Model: YBZX-2.0
Flow rate: 2.0T / H
Pressure (Mpa): 4
Sterilization power: 60w
Inlet and outlet diameter: DN20mm
Power supply: 220V/50Hz
Lamp life:>9000h
Dimension (mm): 700×350×700

Carbon dioxide purifier

Since the purity of carbon dioxide is not high, it should be purified to improve the purity before carbonation. Carbon dioxide cylinder: 105263/260=405 pcs
Model: D-51-350
Diameter: 51mm
Capacity: 350mL
Weight: 260g
Length:295mm
Gross weight: 1400g
Bottle mouth connection: M10×1.0
Water temperature test: ≤60℃
Now the container is 0.5L of plastic bottles, each box contains 24 bottles of drinks, then the CO2 capacity of each box of soft drinks is
0.5 × 24 = 12 (L)
Coke type soda in the amount of dissolved CO2 is 3 times the volume, then the amount of CO2 required for each shift is: 1250 × 3 × 12 = 45 (L)
1250×3×12=45000(L)
Since the average utilization rate of CO2 is about 70%, the required amount is
45000/0.7=64285.71 (L)
Since the volume of CO2 in the standard state is 22.4L, the amount of CO2 consumed in 8 hours per shift is: (64285.71/22.4)×44=126.276(kg)
According to the calculation of the minimum model of purification equipment required, the model is as follows.
Model: QJ-30
Filtration capacity: 30kg/h
Filtration purity: 99.8%
Working pressure (Mpa): <0.6
Size (mm): Ф300×850

CO2 Carbonation Machine

As the mixing of syrup and clean water determines the ratio of various components of the product, which directly affects the quality of the product. So it is required to mix accurately according to the predetermined ratio.
Proportioning (mixing) machine: 2000L/H
Dimension: 2600×1100×3100
Flow rate:Carbonation tank:2000L/H
Power: 6kw

Automatic bottle rinsing, filling and capping machine

Due to the enormous workload of manual bottle washing and filling, this equipment is necessary for beverage factories.
Model:SLC24-24-8
Production capacity: 1800~5000 bottles/hour
Power:2.40KW
Overall dimension (mm): 1784×1700×2500
Weight: 3.8 tons
Applicable bottle neck:Ф50~90mm
Applicable bottle height:140~300mm.

Automatic laser code printer

Model: DYM type
Power supply: 220V
Power:50W
Working speed: 2000-8000 only / hour
Dimension (mm): 620×1100×1820
Weight: 76kg

Single-side bottle labelling machine

Due to the manual labelling workload, can not successfully complete the work of pasting labels. Therefore, the labelling machine is chosen to replace the manual labeling. Each hour production (15000/0.5)/8=3750 bottles, so only 1 unit is needed.
Overall machine size: 3048×1200×1650mm
Power: 1.5KW
Labeling speed: 80 bottles / min
Labeling accuracy: ± 1.0mm (not counting the packaging pieces and label error)

CIP cleaning system

In food processing, cleaning and hygiene are the first, and measures must be taken to prevent any food from being contaminated, so CIP cleaning equipment is essential. It can effectively control the high organic waste generated. Microorganisms. Bacteria etc., and the equipment pipeline and tanks are forced to be cleaned by CIP circulating cleaning fluid without any disassembly, reducing labour intensity. One CIP-0.5 cleaning machine is used in this design. Its parameters are as follows.
Model:CIP-0.5
Acid tank:500L
Alkali tank:500L
Hot water tank: 300L
CIP pump: 5t/h
Pump head:24m
Pump power: 1.5KW
Dimension: 2700×1100×1300(mm)

EquipmentModelProduction capacityPowerSize(mm)Quanty
Sand filter rod filter101 Aluminum Alloy1.5t/h1KW800×500×201
Water softening equipment2t/h3-40WΦ350×16251
Sugarification tankDH-G20002000L2.2KW1850×1650×24001
Diatomaceous earth filterKW250(1-3)t/h2KW1100×350×4501
Sugar syrup blending tank1000L5.5KWΦ1500×27503
Vacuum degassing tankTQ-22t/h1.2KW1135×780×30401
Ultraviolet sterilization machineYBZX-2.02t/h60W700×350×7001
Carbon dioxide purifierQJ-3030kg/h80WФ300×8501
Cooling, mixing and carbonating machine1.8t/h6KW2600×1100×31001
Automatic bottle punching, filling and capping machineDGX16-20-61800-5000 bottles/h2.4KW1784×1700×25001
Automatic plastic bottle coding machineDYM type2000-8000bottles/h50W620×1100×18201
Single side plus round bottle labeling machineSL-5218S80bottle/min1.5KW3048×1200×16501
CIP cleaning systemCIP-0.55t/h1.5KW2700×1100×13001

06.

Calculation of water and electricity consumption

Calculation of water consumption
According to the above, the finished product needs to be treated with about 14 tons of water. In the softening treatment step of water treatment, water consumption is less than 20% of the water production, water production of 2m3 / h. Calculated by the maximum water consumption, water consumption per hour: 2000 × 0.2 = 400L
As it takes 7 hours to process 14 tons of drinking water, the maximum water consumption is 2800L, about 2.8 tons.
Therefore, the production water consumption is: 14+2.8=16.8 tons

Electricity consumption calculation
Electricity consumption for production: add up the power of each piece of equipment
1+0.04+2.2+2+5.5×3+1.2+0.06+0.08+6+2.4+0.05+1.5+1.5=34.53KW
The above is the power consumption of a production line for one hour, then the power consumption of a production line for eight hours is
34.53×8≈276KW
The electricity used for lighting and living is about 10W/m2 by estimation.

07.

Workshop process layout

The principles of the production plant process layout are as follows.

(1) to have the overall concept in line with the overall design requirements.
(2) Workshop equipment layout should make the equipment flexibly mobilized to meet the possibility of a variety of production and leave a suitable margin for the replacement of equipment. At the same time, should also pay attention to the spacing between equipment and equipment and building safety maintenance distance to ensure easy operation, maintenance loading and unloading and cleaning and sanitation convenience.
(3) In addition to some special equipment according to the same type of appropriate concentration, the rest of the equipment should be arranged by the process line as far as possible.
(4) to use the transport space of the workshop as far as possible, personnel, materials separate access.
(5) pay attention to the workshop lighting, ventilation, heating, cooling and other facilities.
(6) consider production health and labour protection.
(7) can be set in the outdoor equipment as far as possible set in the outdoor.

Production workshop layout

Since the output of this design is small, only one production workshop is needed. This design plant is a single-story plant, rectangular in shape. As there is a certain safety distance between equipment and equipment and between equipment and building.
Then the length of the workshop is 30m, width is 12m, height is 6m.

Door
(1) The workshop’s door should meet the access of machinery and equipment, and the size is 2000×3800mm.
(2) The warehouse’s door should be 4000×3000mm in size to meet the access of large transportation.
(3) All other doors are wooden doors with the size of 1000×2200mm. The door of the dressing room is 800×2200mm.

Lighting
The workshop is assisted by natural lighting and artificial lighting. Natural lighting generally adopts steel windows, with screens on the outer layer. The size is 3000×2400mm, and the distance from the ground is 1.2m. The window of the dressing room is designed to be 1200×1000mm. Artificial lighting generally uses double tube fluorescent lamps. The local operating area requires intense lighting, which can be suspended near the operation surface. The height of the lamp is 2.8m above the ground, and the lighting requirement is 10W/m2, so a total of 30×12×10=3600W, each of which is 40W, so 81 lamps are required.

Flooring
Since the flooring of beverage workshop is often attacked by water, acid, alkali and other corrosive substances, it adopts a high standard concrete floor, generally using No. 300 concrete. The flooring’s surface needs to be scribed or printed with a full star lattice for anti-slip treatment.
The flooring should have a slope of 1.8% and be equipped with open ditch or floor drainage.

Interior wall surface
The food factory has high requirements for the hygiene of the inner wall of the workshop, which should be mould-proof, moisture-proof, anti-corrosion, and conducive to hygiene. The corner should be preferably designed with a rounded shape. The lower part of the interior wall surface of this design is made of white tiles or plastic tiles with 1.8~2.0m high wainscoting. The interior wall is painted with porcelain-like paint, which is waterproof and mildew-proof.

Floor Covering
The floor cover is made of cast-in-place reinforced concrete. A moisture-proof layer between the floor slab and the surface layer, a slope of 1.5% to 2%. And a drainage trench or floor drain to ensure that the floor cover does not seep.

Column
The column of 500×500mm thickness is chosen with reinforced concrete. The thickness of the outer wall is 370mm, and the thickness of the inner wall of the workshop is 240mm. Use green bricks.

Calculation of labour force

The factory calculates the number of workers by position. That is, the number of workers needed for each operation position and each position is used to calculate the number of workers for production, and the situation of each position is shown in Table 3-7.
The number of workers required for each shift is basically the same.
Since the production is basically fully automated, the number of people required is not large.
The water treatment process requires one person.
1 person for syrup blending
1 person is needed for the bottle inspection section.
1 person is needed for the filling machine.
1 person for coding and labelling section
1 person for product inspection, 1 person for product stacking
2 persons are needed for product stacking.
In total, 8 workers are needed for each production shift, 16 workers for 2 shifts per day. To ensure the normal production, in order to consider some workers have sick leave, leave of absence and other special circumstances, someone to take care of the production, so it can be relaxed to 20 people.
The front-line production workers in the workshop are required to be familiar with each section’s process operation to cope with any unexpected situation.
Table 3-7 Factory labour force quota table

JobR&D, quality control AdministrationTechnicianWorkerLogisticsTotal
People55220850

Please click below to watch the production process of bottled water production.

John Lau.

John Lau.

John Lau, a project manager holding an engineering bachelor's degree, became fascinated with optimizing beverage production equipment during his university days. As an overseas project manager, he firmly believes that educating clients on achieving efficient workflows through customized equipment design is one of the most impactful aspects of his job.

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