INTRODUCTION
The demand for mineral water is increasing at a rapid rate, as people become more health conscious and take precautions against water borne diseases.
Bottled mineral water provides easy transportability and assured water quality.
THE PROJECT INVOLVES MACHINERY FOR
- PURIFYING WATER
- BOTTLE MANUFACTURING. (OPTIONAL)
- BOTTLING PURIFIED WATER. (OPTIONAL)
- LABELLING (OPTIONAL)
CAPACITY
The plant is being designed for minimum economically viable capacity, such that the capital outlay is optimized.
The capacity of the various units are as under:
| – | Purification: 1000 litrers / hour i.e. 8000 litres / 8 hour shift |
| – | Bottle Manufacturing: (Optional) |
| – | Bottling : 100-200 Bottles per hour of 19 Liters. |
| – | Labelling : Heat Shrink Tunnel/Hand Held would handle 100-200 Bottles per hour. |
PROCESS FLOW
The plant has 6 components :
1] Purification: Water received from the external source/Bore Well is passed through the purification plant and stored in a PE-Fiber Tank. Thereafter it is fed to the bottling section – and continuos operation achieved.
2] Bottle Manufacturing: Pet preforms are blown into bottles and a sufficient number of bottles, say 1000 nos., kept ready while the machine continues to produce more during the shift, when the bottling has been started. (Optional) Usually purchase readily available in Market with various bottles manufacturers.
3] Auto Rinsing – Filling – Capping: The bottles are fed into the machine which automatically rinses, fills and screws the cap on it. Caps are stamped with the date of manufacture and expiry before being put into the hopper for screwing on to the bottle. (Optional)
Economically can be done by manually as well both Rinsing/Washing and Bottle Filling.
4] Labeling: We are proposing use of heat shrink labels and tamper evident heat shrink sleeve on the neck of each bottle.
The label and the neck sleeve are to be manually put on the bottles which will then pass through the shrink tunnels and onto packing conveyer. (Optional)
Expiry date and batch number could be printed on labels or caps prior to their being put on the bottles. (Optional)
It can be done with Handy Heating Gun for Labeling and Shrink Sealing with heat control.
5] Heat Shrinking: The bottles are passed through heat shrink tunnel so that the label and neck sleeve, shrink and stick to the bottles.
6] Final Packing: This could be in cartons – done manually – and no machines have been provided for it.(Small Bottles).
MACHINES / EQUIPMENT REQUIRED
The various machines and equipment being offered by us and required is explicitly listed here. This does not include miscellaneous items like pipes, electricals etc., which are specific to the site and each project.
Purification Section:
Flow rate : 10000 Gallons / Day (24 Hours)
Raw water quality (assumed) : 1500 ppm as TDS
|
Description |
| Raw Water Feed Pump |
| Multimedia Sand Filter Flow Rate : 30 GPM. MOC : Fiber Glass |
| Activated Carbon Filter Flow Rate : 30 GPM MOC : Fiber Glass |
| Antiscalant Dosing System |
| Reverse Osmosis System Permeate Flow : 10000 Gallons/Day. Consist of : 5 Micron Filter Opaque- PP Fiber H.P. Pump with 5 HP Motor Membrane – 2 8X40 nos. Pressure Vessel 8×80” (Fiber Glass) – 1 nos. Instruments & panel |
| Ozone Generator Capacity – 3 gm/hr. Venturi Inline Process Flow Rate : 3000 lit/hr. |
| UV Disinfectant Flow Rate : 3000 lit/hr. |
| Storage Tank for Pure Water Capacity : 500 Gallons |
The output water purification would be in line with WHO specifications – however final results depend on input water quality.
Bottle Manufacturing Section: (Optional)
To achieve 1100 nos. bottles per hour production.
|
Description |
| Stretch Blowing Machine: upto 2 ltr. Capacity (Preform Manual Loading Machine from Conveyor to Stretch Blowing Machine) – 2 cavity bottle upto 2 ltr. (Neck dia upto 46 mm) – Hydro-pneumatic locking system – With Infrared heating system conveyor and separate Control Panel with Microprocessor. – Production : 550 Bottle / Hour – Model No. TPD 2000 |
| Refrigeration Unit : (Chiller) Cooling Capacity : 1 Ton; (Standard Make) |
| Air Compressor : with after cooler and moisture separator |
| Mould sets : Double Cavity 1.5 ltr. Round shape mould in aluminium Double Cavity 1 ltr. Round shape mould in aluminium Double Cavity 500 ml. Round shape mould in aluminium |
It is possible that the air compressor be bought locally.
Bottling Section : (Optional)
This section receives the empty bottles, rinses them, fills and caps them.
|
Description |
| Stainless Steel Conveyor: Made of S.S, 8 meter long for conveying of empty washed bottles onto the filling machine. The different operations like rinsing, filling, capping are done on the conveyor. Electrical Details: 0.5 H.P. with variable speed drive.. |
| Rinsing, Filling, Capping: This machine is designed to fill 24 bottles per minute for 1 ltr bottle & is capable to fill 500 ml, 1000 ml, 1500 ml bottles. Machine speed is depended on the volume to be filled. The bottles are holded in groups of 6 & moved on the conveyor together. These grouped bottles are rinsed by means of spraying pressurized water inside the bottle. After Rincing the bottles are again placed on the conveyor & are loaded on the filling & capping machine one by one. Filling & capping takes place by indexing mechanism. There are total 8 indexes. |
| Change parts for 500 ml and 1500 ml 1 set each |
LABELLING & PACKING SECTION :
|
Description |
| Shrink Tunnel: This is fitted on the online conveyor to shrink labels and neck sleeves. The labels & neck sleeves are to be manually inserted on the bottle. Machine will be provided with suitable capacity Heaters, Blower, Reduction Gear Box and Electric Motor, complete in all respects ready to use. |
| Printing Machine (for mfg. Date & batch nos.) Semiautomatic machine is proposed. This is a table top coding machine with a printing area of 35 mm x 25 mm & capable of printing 3 variable line message on labels or caps. |
RAW MATERIAL
The water source is of critical importance and the continuity of the plant would depend upon it. Apart from water following items are required and can be supplied by us.
1] Preform – for blowing into bottles. (optional)
2] Caps for the bottles
3] Labels
4] Neck sleeves
5] Cartons for final packing.
COSTS
The various cost elements involved are :
1] Raw material
2] Packing cost
3] Operating cost – Electricity
4] Manpower
ELECTRICAL LOAD
The total Electricity load would be about 6.0 KW
MANPOWER
Number of people required to operate various machines is
1] Bottling – 1 nos.
2] Labeling – 2 nos.
3] Bottle making – 2 nos.
4] Printing – 1 no.
5] Packing – 2 nos.
6] Miscellaneous – 2 nos.
Total – 10 nos. (On manually operation 3-5 people enough for man power depend what size of bottle produce.