51811544 coke project report

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A

RESEARCH REPORT

ON

ROLE OF SALES PROMOTION ON FMCG

A Research report submitted in Partial Fulfillment of award of MBA Degree

(2011-13)

SUBMITTED BY: UNDER GUIDANCE OF:

Sukhvant Singh Mr. Vibhore Khandelwal

Roll No-1117270098 (Assistant Professor)

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Acknowledgement

There are people who simply by being what they are try to influenceyou to do things which you could never think of their spontaneous andgenuineHelp as and when neededhave helped me a lot, to gain profound knowledgeand experience in the analytical field.

My sincere thanks to HINDUSTAN COCA-COLA BEVERAGEPVT. LIMITED which have given me the golden opportunity to do my

project.

I would also like to thank Dr. S.K. Bedi (Director, LIMT) for his

proper guidance and help.

In a nutshell it is not a work of one but many others who by theirsincere efforts have contributed towards the completion of this project.

DATE: (Sukhvant Singh)

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TABLE OF CONTENTS:

SR.NO TOPIC PAGE

1 INTRODUCTION TO COCA

COLA COMPANY

2 RAW MATERIAL

3 SANITATION

4 SYRUP MAKING PROCESS

5 MANUFACTURING PROCESS

6 INTRODUCTION TO

QUALITY ASSURANCE

7 MICROBIOLOGY LAB AND

TESTING

8 INVERSION

9 WATER TREATMENT PLANT

10 EFFLUENT TREATMEN

PLANT

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INTRODUCTION

Soft drinks constitute one of the largest beverage industries in the world today.

Tremendous advances have taken place in the process technology in the soft drink

industries in the past one or two decades.

The beverages are divided into two groups i.e carbonated soft drink like coke, thums

up, limca, fanta etc. & non-carbonated soft drink like maaza, minute maid.

The major ingredients of soft drinks are

Water

Sugar and/or sugar substitute

Carbon dioxide

Flavor emulsion and emulsifiersColoring agents

Acids and preservatives

Coca Cola: An InsightCoca Cola: An Insight

Our RootsOur Roots

While much of the world has changed since 1886, the pure and simple magic of

one thing stays the same - COKE. The name and the product represent simple

moments of pleasure for consumers in nearly 200 COUNTRIES200 COUNTRIES around the

globe, who reach for products of The Coca Cola Company hundreds of millions of

times every single day.

John Styth Pemberton first introduced The Refreshing Taste of Coke in Atlanta,

Georgia. It was May of 1886 when the pharmacist concocted a caramel-colored

syrup in a three-legged brass kettle in his backyard. He first distributed the new

product by carrying Coin a jug down the street to Jacobs pharmacy. For five cents,

consumers could enjoy a glass of Coat the soda fountain. Whether by design or

accident, carbonated water was teamed with the new syrup, producing a drink that

was proclaimed

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Delicious and Refreshing.

Dr. Pembertons partner and bookkeeper, Frank M.Robinson, suggested the name and

penner Coke in the unique flowing script that is famous worldwide today. Mr.

Robinson thought the two would look well in advertising.By 18911891, Atlanta entrepreneurAsa G. CandlerAsa G. Candlerhad acquired complete ownership

of the Coca-Cola Business. Within four years, his merchandising flair helped

expand consumption of Coca-Cola to every state and territory. In 1919, The Coca-

Cola Company was sold to a group of investors for $25 million. Robert W.

Woodruff became president of The Coca- Cola Company in 1923, and his more

than six decades of Leadership took the business to unrivaled heights of

commercial success, making Coca Cola an institution the world over.

FIRST BOTTLEDFIRST BOTTLED

COKE began as a fountain product, but candy merchant Joseph A. Bedenharn of

Mississippi was looking for a way to serve this refreshing beverage at picnics. He

began offering bottled Coke, using syrup shipped from Atlanta, during an

especially busy summer in 1894.

In 1899, large-scale bottling became possible when Asa Candler granted exclusive

bottling rights to Joseph B. Whitehead and Benjamin F. Thomas of Chattnooga.

The contract marked the beginning of The Companys unique independent bottling

system that remains the foundation of Company Soft drink operations.

As the Company had many imitators, which consumers would be unable to

identify until they took a sip. The answer was to create a distinct bottle for Coke.

As a result, the genuine Coke bottle with the contour shape now known around the

world was developed in 1915 by the Root Glass Company.

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TRADEMARKSTRADEMARKS

The trademark Coke was registered with the US Patent & Trademark office in

1893, followed by C in 1945. The unique contour bottle, familiar to consumers

everywhere, was granted registration as a trademark by the US Patents &Trademark office in 1977, an honor awarded to only a few other packages.

In 1982, The Coca Cola Company introduced Diet Coke to US consumers,

marking the first extension of the Companys most precious trademark to another

product. Later years saw the introduction of additional products bearing the name

of Coca-Cola, which now encompasses a powerful line of six cola products.

Today, the worlds favorite soft drink, Coke, is also the worlds best known and

most admired trademark, recognized by more than 90 PER CENT90 PER CENT of the worlds

population.

THE PLANT AN OVERVIEW

AREA OF LAND

Total site area 40 acres

Built up area 4 acres

Green belt development 4 acres

Ambitious state-of the-art Dasna Plant. Second Largest as well as the most hi-tech

bottling green Field plant in Northern India, established on 16 th Feb 1999. The

plant in spread on an area of 40 acres which is 45 km away from Delhi.

Commissioned in March 1999, it has a sophisticated facility for bottling the PET,

RGB as well as fountain filling. The plant has1 Kinley, 2 ,1 PET,1 Hotfill, 3 RGB

lines,1 Tetra, 1 Krones. The sales are made through indirect distribution and serve

33000 retailers around 7 districts in total.

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Built up area break up

Main building including Process areas , Packaging areas ,

Warehouse , Stores & ETP

13096 m2

Utility 1755 m2

Caustic , HSD, Cooling towers, carbon dioxide , raw

water tanks

3196 m2

Admin. Block 918 m2

Empty Bottle storage yard 9600 m2

Car parking 490 m2

Truck Parking 1890 m2

Concrete roads 7500 m2

ETP 3000 m2

LPG store 120 m2

Driver amenities 64 m2

Contract Labour amenities 108 m2

Forklift repair area 100 m2

Security building 24.5 m2

Caustic storage area 100 m2

HSD storage area 324 m2

Carbon dioxide storage 1800 m2

Raw water storage area 720 m2

Switch yard 180 m2

HINDUSTAN COCA COLA BEVERAGES PRIVATE LIMITED

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Coca Cola, the name and the product represent simple moments of pleasure for

consumers in nearly 200 countries around the globe.

John Smith Pemberton first introduced the refreshing taste of coca cola in Atlanta,

Georgia. It was May of 1886 when the pharmacist concocted caramel coloured syrup

in a three-legged brass kettle in his backyard. He first distributed the new product by

carrying Coca-Cola in a jug down the street to Jacobss pharmacy. For five cents,

consumers could enjoy a glass of Cola-Cola at the soda fountain. Whether by design

or accident, carbonated water was teamed with the new syrup, producing a drink that

was proclaimed delicious and refreshing. Thus Coca Cola began as a fountain

product.

In 1899 large scale bottling became possible when Asa Candler granted exclusive

bottling rights to Joseph B. Whitehead and Benjamin F. Thomas of Chattanooga,

Tennessee. Today coca-cola products reach consumers and customers around the

world through a vast distribution network made up of local bottling companies. These

bottlers are located around the world, and most are independent businesses. Using

syrups, concentrates and beverage bases produced by the Coca-Cola Company. The

global bottling system packages and markets products, then distributes them to more

than 14 million retail outlets worldwide.

The trademark Coca-cola was registered with the U.S. Patent and Trademark office

in 1893, followed by Coke in 1945.

In 1982, the Coca-Cola Company introduced diet coke to U.S consumers, marking the

first extension of the Companys most precious trademark to another product. Later

years saw the introduction of additional products bearing the Coca-Cola name, which

now encompasses a powerful line of cola products. Today, the worlds favourite soft

drink, Coca-Cola is one of the worlds best-known and most admired trademarks,

recognized by more than 90 percent of the worlds population.

RAW MATERIAL TESTING

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1. CARBON DIOXIDE STANDARDS

Moisture not more than 20 ppm

Total sulphur Not more than 0.1ppm v/v

Total volatile Hydrocarbon Not more than 50 ppm v/v

Purity not less than99.9% v/v

Appearance No color or turbidity

Taste or Odor Free of foreign taste or odor

TEST FOR CARBON DIOXIDE

a) PURITY

PROCEDURE :-

1. Fill the Zahm CO2 purity tester with water and observe for any airbubbles

2. Attach the connecting tube to the sample valve of CO2 system3. Open the stop cork between reservoir & body of tester.4. Open the stop cork on the body of the tester before attaching the tubing

and allow water to flow out.5. Quickly attach the tubing. Which has CO2 flowing through it, forcing

the water into reservoir

6. Allow the flow of gas to continue for about 30 sec.Close the stopcockon the body of tester. Then close the stamping valve and reservoirstopcock and detach tester from sampling tube.

7. Fill the reservoir with 30% w/v NaOH8. Open the stopcock and allow the NaOH to flow into tester body.

Agitate the tester to be sure all CO2 is absorbed.9. When the bubble remains constant in size close the reservoir stopcock.10. Read % purity from the scale.

b) ODOR (SNOW TEST)

PROCEDURE:-

1. Collect liquid CO2(snow) in plastic bag (approx 550cc)2. To a flask add about 200ml treated water then add about 250cc of

snow and cover immediately.3. Swirl the liquid in flask and sniff odor in headspace. No odor should be

there.

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Typical off odors

Fruity

Rotten egg, sewer,silage,sulfury

Acetaladehyde

Hydrogen sulfide

2. TESTS FOR SUGAR

a) TASTE

1. Make 50 Brix solution.

2. Take 10 ml of this solution and make upto 100 ml3. Check the taste of this sample

b) ODOR

1. Half fill a wide mouth screw capped bottle with dry sugar2. Heat to 50 C3. Smell and note the nature of any off odor

c) ODOR AFTER ACIDIFICATION

1. Smell the 50 brix solution at room temperature and note any off-odor2. Add 0.2ml 75% w/v phosphoric acid to 50 ml of sugar solution in a

100ml glass beaker and mix3. Cover the beaker with a watch glass and heat to 50C in a water bath or

incubator.4. Smell the solution every 10 min for 30min and note the nature of any

off odor.

d) TURBIDITY

1. Prepare 492g of 50 brix solution by dissolving 246g of sugar in 246gdistilled water.

2. Examine the 50 brix solution in a glass beaker.3. Turbidity meter ready must be


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1. Weigh 10g sugar in a sterile 250 ml flask and add sterile100 ml waterupto the mark. Cover with a foil and agitate to dissolve sugar.

2. Pour the solution into filter funnel.3. Cover the funnel, apply vacuum.4. Wash the flask twice with 250ml sterile water.

5. Transfer the membrane to a sterile petridish (M-TGE medium for totalcount and M-green yeast and mold medium on schaufus Pottingermedium for yeast and mold count) and incubate at 35 C or 28 C

6. for total count, count the colonies at 24hrs and at 72 hours. For yeastand count , count colonies at 48 hrs and at 24 hrs interval thereafteruntil 5 days have lapsed.

f) COLOR (ICUMSA)

1.Weight 50gm of sugar sample in a 250ml conical flask, add 50gm ofTriethanol amine Solution ( weigh 7.460gm TEA in a beaker and make

upto 500ml). Dissolve it by swirling.2. filter the solution through 0.45 micron filter.3. set the spectrophotometer at 420nm4.Rinse the cell with sugar solution and then fill with sugar solution.5.keep TEA solution as standard blank.

ICUMSA = ABSORBANCE X 1000

Cell Length (in cm) x conc.(g/cm3)

3. TEST FOR CONCENTRATE

To ensure a good quality beverage, concentrate receipts and handling ought tobe properly managed.

Every possible precaution is taken to guarantee that the containers of flavorconcentrates arrive at the bottling plant in perfect condition. Additional precautionsmust be taken while the concentrate is in storage in the plant. Formulas instructionsand packaging labeling should be followed exactly and will indicate the particularrequirement needed in terms of storage needs and mixing for a particular product.

The following points must be taken care of with regard to concentrates:

1) Sanitary condition: Storage in clean, dry, closed area free from insect infection.2) Temperature: Storage temperature is between 4 to 10*C /ambient for dry base. Norefrigeration should be done until required to do so.3) First in First out: The oldest stock in hand should be used first4) Stacking and Sorting: They should be kept on wooden platforms, above the floorright side up and yet not very high above the ground.5) Inspection: The containers must be scrutinized for seal damage leaks, date of

production and other damages.6) Sealing of containers: Partly used containers contents must be transferred to glassor stainless steel containers and then used as early as possible.

4 AUXILLARY MATERIAL TESTING

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i) Lime testing:-

Requirement:

3N HCL

0.02N EDTA solution (reagent A).

1N NaOH

Hydroxy napthol blue.

A conical flask.

500ml volumetric flask.

A 50ml beaker.

Distill water.

2 pipettes of 10ml.

Procedure

1. Weigh 1.5gm of lime powder in a beaker.2. Add 10ml of distill water in above beaker.3. Then add 30ml of 3N HCL.4. Transfer it to conical flask for thorough mixing.5. Take a 500ml volumetric flask.6. Transfer contents of conical flask to volumetric flask, made up the volume by

distill water.7. Put the cap of volumetric flask and mix thoroughly.8. Pipette out 5ml of volumetric flask content into conical flask.9. Add 10ml distill water, 1.5ml 1N NAOH and 0.30mg of Hydroxy napthol

blue.

10. Titrate it with EDTA solution.11. End point Blackish purple to blue.

Formula used:

Lime % = B.R 3.705 100 0.02

1.5

Where,B.R = Burette readingStandard for lime % = 95

ii) Caustic checking:-

Requirements:-

A conical flask.

Distill water.

50ml beaker.

Dropper.

Measuring cylinder.

Phenolphthalein indicator.

Procedure:-

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1. Weigh 1.5g of caustic sample with the help of dropper in 50ml beaker.2. Add 40ml distill water to the weighed sample and mix it thoroughly.3. Transfer it to conical flask and add few drops of phenolphthalein indicator4. Titrate it with 1N H2SO4 .5. End point- pink to colorless

Formula used:-

Caustic % = B.R 4

1.5

Where,B.R = Burette readingStandard for caustic % = 48

iii) Ferrous sulphate checking:-

Requirements:- 4N H2SO4 .

3 N HCL.

1N NaOH.

0.1N KMnO4.

50ml beaker.

250ml volumetric flask.

Funnel.

Distill water.

Conical flask.

Ortho phosphoric acid. 2 pipettes of 10ml.

Procedure:-

1. Weigh 5gm sample in beaker.2. Add distill water to weighed sample, mix it thoroughly & transfer it to

volumetric flask and make up the volume, again mix it.3. Pipette out 50ml vol. flask content into conical flask, and then add 10ml

H2SO4 and 2ml ortho phosphoric acid.4. Titrate it with 0.1N KMnO4.5. End point Colorless to light pink.

Formula used:-

FeSO4 % = 139 B.R 0.1

Wt. of sample taken

Where,B.R = Burette reading

Standard for ferrous sulphate % = 97

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PACKAGING MATERIAL TEST

The finished products are packaged in cartons and are dispatched for themarket. The tests ensure the suitability of the packet for the market, as a packet ofinsufficient strength would spoil all the efforts of carefully manufactured product.

PACKAGING MATERIAL

# Glass Bottles

# Crowns

# Pets

# Plastic caps

# Wrap around Labels

# Corrugated Cartons

# Shrink films

They are checked for weight dimensions, breaking strength compressionstrength etc. The other details for expiry date, manufacturer date are printed on

the carton.

# RGB(RETURNABLE GLASS BOTTLES)

Procedure for sampling of RGBs

Select 50 samples from each incoming consignment of 22000 bottles

1. Draw samples from min. 5 different crates / bulk packs with bottles of

different mould nos. for equitable sample representation

2. Maintain linkage between samples drawn and the consignment. Thisshall enable resampling, resorting quarantine of the sampled lot ifrequired.

3. Inspect the Glass bottles as per the quality plan.

# CROWNS

Procedure for sampling of Crowns

1. Packet contains 1200 crowns.

2. Different flavors have different crowns.

3. Select 25 samples from each incoming consignment of 100 boxes (5 from eachof 5 boxes).

4. If out of 50 crowns, 5 or 8 found defected then that consignment should berejected.

5. If only one critical defect is there then neglected.

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There are mainly three types of defects.

1. Critical defects.

No liner.

Deformed crowns

Foreign crowns.(like Limca in ThumsUp) Foreign material.

Height out of specification(Go No Go)

OD out of specification(Go No Go)

Incorrect text(Std. color should be there)

2. Major defects.

Rust

Burrs.

Die scratches.

Excess liner

Under fill liner

3. Minor defects.

Litho damage.

Litho off center.

Lith off color.

Scratched decoration.

No decoration.

Smudgy decoration.

Liner adhesive poor.

# Wrap around labels

Procedure for sampling of Wrap around labels

Select 50 wrap around labels, randomly from each incoming lot of 35000

150000 labels

Maintain linkage between samples drawn and the consignment. This shall

enable resampling, resorting quarantine of the sampled lot, if required. Inspect the Wrap around label as per the quality plan taking samples one from

each bundle of 200 labels.

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# Corrugated Cartons

Procedure for sampling of corrugated cartons

Select 20 Samples, randomly from each incoming truck load of approx. 6500 7000 Cartons.

Maintain linkage between samples drawn and the consignment. This shall

enable resampling, resorting quarantine of the sampled lot, if required.

Inspect the Carton as per the quality plan.

# Plastic closures

Procedure for sampling of plastic closure

Select 25 samples randomly from each incoming consignment of 100 boxes of

approx. 2.2mm plastic closure(one container load)

Draw samples from min. 5 different boxes; with closures of different liner no.

for equitable sample representation.

Incase some consignment contains closures of different brands, Draw samples

equitable for each brand.

Maintain linkage between samples drawn and the consignment this shall

enables resampling, resorting quarantine of the sampled lot, if required.

Inspect the plastic closures as per the quality plan.

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SANITATION:

The most important sanitation programme in the beverage plant deals with cleaning

and sanitizing of the surfaces that come in contact with syrup beverage, or ingredients

in their preparation.

Proper sanitation performed at the recommended frequency will minimize and most

likely completely eliminate the potential for bacteria, yeast and mold reproduction and

growth.

3 step CIP

Rinse with treated water

Hot water

Final rinse with treated water

5 step CIP


Hot caustic rinse (1.5% - 2.5% of caustic with a temp. of 73 C)


Hot water rinse (85 C)

Final rinse with treated water

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SYRUP MAKING PROCESS:

SYRUP PREPARATION:

Syrup preparation is carried out by two methods:

a) Batch System

b) Continuous System

BATCH SYSTEM

Treated Water

Sugar dissolving tank

Heating (85 Deg cent)

Addition of sugar

Contact time 30 minFilter

Precoating

Filtration in Plate and frame filter pressPressure difference-In-

2.5kg/cm2 Out-2.0kg/cm2

CoolingPlate heat exchangerRefrigerant-Glycol &cold

Water (by water-up to 35Deg cent followed by glycol

22-40 Deg cent)Simple raw syrup

Mixing with concentrate

Ready syrup

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CONTINUOUS SYSTEM (Capacity: 5000 ltr/hr)

Treated Water

Heating (PHE) to 85 Deg centCarbon Sugar

Contisolv

Mixing and dissolving

Holding (85 Deg cent-30 min)

Filtration

Buffer tank

Bag Filter

Cooling (PHE) [Pasteurization]

Syrup Tank

Concentrate addition

Ready syrup

MANUFACTURING PROCESS

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Depalletizing

Uncasing

Sorting / Removal of Foreign Matter

Bottle Washer

EBI (Empty bottle inspector)

Proportioner

Filling & Capping

Date Coding

Final Inspection

Casing

Palletizing

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1) DEPALATIZING: Separation of bottle cases from palate.

It is carried out manually, and cases are supplied to conveyer, for uncasing.

2) UNCASING: Removing of bottles from case. It is carried out by using uncaser

machine.

3) BOTTLE WASHING:Bottle washing is completed in following stages:

a) Pre-rinse:- Here empty bottles are rinsed by water used in first rinse.

b) First soak: - Bottles are soaked in surface active reagent solution like

caustic(2.8%) and Divo NEF ( 0.2-0.3%) . Here temperature is 60 deg cent and

pressure is 2-3 bars.

c) Second soak: - First soak is followed by second soak, here temperature is

maintained at 74 deg cent and pressure is at 2-3 bars.

d) Third soak: - Here again temperature is maintained as that of first soak.

This section wise soaking is carried to avoid thermal shocks to bottles .the

temperature difference between two soaks should not be more than 25 deg cent.

e) Rinse: - Here rinsing is carried out in four stages as first, second, third and final.

For rinsing, truated soft water is used. The flow of water is from final soak to dirst

soak. Water from first soak is used in pre rinse

Following are major issues and their reasons, during bottle washing.

a) Caustic carry over in bottles*

Chocked jets or disturbed jet alignment

Not proper water pressure.

Too high caustic dose.

Blowers off.

b) Excess breakage

Thermal shocks (high temperature difference between two sections of bottle washer)

Damaoed poskets.

c) M.B. Positive

Dirty bottles in feed

Caustic and additive percent is not up po limit.

Soak wise temperature difference.

d) Excess damage to bottle neck:

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Improper jet alignment.

Damaged pockets

e) M.B. Contamination:

Scales in prefinal and final rinse.

Improper temperature and contect ti}e.

Flow diagram of Bottle washer

Empty bottles handling

Removal of foreign material

Bottle washing in washer

Inspection of returnable bottles

Ready for filling

4) EBI (Empty Bottle Inspector): It is the new technique that is being used in coca

cola company.

It is used to detect 4 kinds of defects in the returnable glass bottles. In this cameras

and sensors are used to check the defects in the bottles.

Four kinds of defects are:

1) BASE :- it checks if the base is 3mm or not.

2) ISW ( Inner Side Wall) :- it checks if the inner side of the bottle wall is 3mm or

not.

3) IR :- it detects the level of water residue.

4) Radio Frequency :- it checks the level of caustic in bottle.

5) PROPORTIONER:

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Machine used for mixing of syrup, carbon dioxide and water in proper

proportion is called as Proportioner

It contains following major parts:

Deairation

Proportioning

Carbonating unit

Cooling unit

6) FILLING:

The operational principle is based on following functions

Positioning

Pressurizing

Filling

Closing & decompression

7) CROWNING:

Crowning applies the closure to the filled bottle.

The basic types of closures and closing equipment are

Crowns: For glass bottles.

Plastic closures : For PET bottles

The function of the crowner is to mechanically apply and seal crowns to bottles. This

uses a crimping technique that applies pressure to the top and sides of the crown.

This pressure causes the crown to adapt to the neck of the bottle

The capper applies a pre-threaded plastic closure on the bottle, centers and pre

tightens the closure onto the bottle. The final stage seals to a pre-set dynamic torque.

When the pre set torque is reached, the clutch steps to prevent further tightening.

8) PACKAGE LABELLING:

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Labellers are used to apply labels to returnable stock bottles and PET containers.

Labels can be used for special sales or promotions. Sleeve labels have the advantage

of more consistent operation with no glue application

Labels can be made of:

Plastic laminate

Paper

Combination of material

9) DATE CODING:

Date coding matter should include following information.

Date of production.

Time of production.

Batch number

Line identification.

The coder is installed on the production line and identifies the filled beverage package

as to establish

Production date

Regulatory requirements

Mandatory information

This informations would allow plant to check back if there were any problems with

that production and to effectively manage the age of inventory in trade.

.10) FINAL INSPECTION:

The beverage filled bottles are again passed through a manual inspection station

where the beverage is scrutinised for appearance, clarity, presence of any particulate

matter, and half filled bottles. Rejected bottles are removed before packaging into

cases

11) CASING:

Mechanically by using caser machine casing is carried out.

12) WAREHOUSING:

The filled bottles are arranged in cases and through a belt conveyor system are taken

to the shipping or warehouse area where they are stored till they are marketed.

INTRODUCTION TO QUALITY ASSURANCE

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It is the total arrangement made with the object of ensuring that beverage

products are of the quality required for their intended use.

The system of quality assurance appropriate to the manufacture of foodproducts should ensure that:

a) Beverages are designed and developed in a way that accounts of the

requirements of GMP and associates codes such as those of good laboratory

practice GLP and good clinical practice (GCP).

b) Production and control operations are clearly specified in a written form and

GMP requirements are adopted.

c) Arrangements are made for the manufacture, supply, and use of the correct

starting and packaging material.

d) All necessary control on starting materials, intermediated products, and bulk

products and other in process controls, calibrations and validations are carried

out.

e) The finish product is correctly processed and checked, according to the

defined procedures.

f) Beverages are not sold or supplied before the authorized person have certified

that each production batch has been produced and controlled in according with

the requirements of the label claim and any other regulations relevant to the

production, control and release of pharmaceutical products.

g) Satisfactory arrangements exist to ensure, as for as possible, that the

pharmaceutical products are stored by the manufacturer, distributed and

subsequently handled so that quality is maintained through out their shelf life.

h) There is a procedure for self inspection and/or quality audit that regularly

appraises the effectiveness and applicability of the QA system.

To achieve the quality objective reliably there must be a comprehensively

designed and correctly implemented system of QA incorporating GMP

and QC.

MICROBIOLOGY LAB

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To distinguish the food of acceptable quality from food of unacceptable quality

required the application of what are known as microbiological criteria. Three different

types of microbiological criteria have been identified.

1) A microbiological standard is a criteria specified in a law or regulation. It is a

legal requirement that foods must meet and is enforceable by the appropriate

regulatory agency.

2) A microbiological specification is a criteria applied in commerce. It is a

contractual condition of acceptance that is applied by a purchaser attempting to

define the microbiological quality of a product or ingredient, failure of the

supplier to meet the specification will result in the rejection of the batch or a lowerprice.

3) A microbiological guideline is used to monitor the microbiological

acceptability of a product or process. It differs from the standard or specification

in that it is more often advisory than mandatory.

The microbiological laboratory of QA is well equipped and maintained. All the

microbiological work is carried out in it.

COMMONLY USED INSTRUMENTS IN MICROBIOLOGY LAB

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AUTOCLAVE

An Autoclave

An autoclave is a pressurized devicedesigned to heat aqueous solutions above their

boiling point to achieve sterilization. It was invented by Charles Chamberlandin

1879.[1] It is used for moist heat sterilization, which is carried out at 121C for 30

minutes at 15 psi. Media is sterilized by autoclave Under ordinary circumstances (at

standard pressure), liquid watercannot be heated above 100 C in an open vessel.

Further heating results in boiling, but does not raise the temperature of the liquid

water. However, when water is heated in a sealed vessel such as an autoclave, it is

possible to heat liquid water to a much higher temperature. As the container is heated

the pressure rises due to the constant volumeof the container (see theideal gas law).

The boiling point of the water is raised because the amount ofenergy needed to form

steam against the higher pressure is increased. This works well on solid objects; when

autoclaving hollow objects, however, (hypodermic needles,tools, etc.), it is

important to ensure that all of the trapped air inside the hollow compartments is

vacuumed out.

Autoclaves are widely used inmicrobiology, medicine, veterinary science,

dentistry and metallurgy. The large carbon-fibercomposite parts for the Boeing

787, such as wing and fuselage parts, are cured in large autoclaves

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INCUBATOR

An Incubator

An incubator comprises a transparent chamber and the equipment that regulates its

temperature, humidity, and ventilation. For years, the principle uses for the controlled

environment provided by incubators included hatching poultry eggs and caring for

premature or sick infants, but a new and important application has recently emerged,

namely, the cultivation and manipulation of microorganisms for medical treatmentand research. It is used for providing favorable temperature conditions for the growth

of culture organisms. Generally the temperature of incubator is operated at 37C for

the growth of microorganisms

Laboratory incubators were first utilized during the twentieth century, when doctors

realized that they could be could be used to identify pathogens in patients' bodily

fluids and thus diagnose their disorders more accurately. After a sample has been

obtained, it is transferred to a Petri dish, flask, or some other sterile container and

placed in a rack inside the incubator. To promote pathogenic growth, the air inside the

chamber is humidified and heated to body temperature (98.6 degrees Fahrenheit or 37

degrees Celsius). In addition, these incubators provide the amount of atmospheric

carbon dioxide or nitrogen necessary for the cell's growth. As this carefully

conditioned air circulates around it, the microorganism multiplies, enabling easier and

more certain identification.

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CENTRIFUGE

A centrifuge is a piece of equipment, generally driven by a motor, that puts an object

in rotation around a fixed axis, applying force perpendicular to the axis. The

centrifuge works using the sedimentation principle, where thecentripetal acceleration

is used to separate substances of greater and lesser density. There are many different

kinds of centrifuges, including those for very specialised purposes

It is used to separate the suspended matters as pallets/button/residue from the liquid as

supernatant.

MICROSCOPE

A Microscope

A microscope is an instrument for viewing objects that are too small to be seen by the

naked or unaided eye. The science of investigating small objects using such an

instrument is called microscopy. The term microscopic means minute or very small,

not visible with the eye unless aided by a microscope. The microscopes used inschools and homes trace theirhistoryback almost 400 years

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pH METER

A pH meter is an electronic instrument used to measure the pH (acidity orbasicity) of

a liquid A typical pH meter consists of a special measuring probe (a glass electrode)

connected to an electronic meter that measures and displays the pH reading.It is used

to obtain pH value of different sample calibration is done carried out with standard

buffer solution of pH 4.0, 7.0, 10.0

A simple pH meter with its probe immersed in a mildly alkaline solution. The

two knobs are used to calibrate the instrument

LAMINAR AIR FLOW UNIT

A Laminar Air Flow Unit

LAF unit is used for providing sterilized airflow by means of High EfficiencyParticulate Air (HEPA) filters

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HOT AIR OVEN

A Hot Air Oven

It is used for dry heat sterilization. Glasswares, Petri plates and pipettes are

packed in stainless steel containers and kept at 180C for 2 hrs.

BOD INCUBATOR

A BOD Incubator

It is used for fungal growth at 22C.

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CYCLOMIXER

It is used to mix the suspended particles.

STOMACHER LAB BLENDER

It is used for dissolving sample without the destruction of the organism for

which the cost is to be carried out. Sample + dilution is placed in the

recommended bags provided the total volume should be with in recommendedcapacity of the machine (80 400 ml).

WEIGHING BALANCE

It is a precious weighing instrument for small load. It is used primarily in

professional and technical application. It is calibrated against standard weights.

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VALIDATION OF EQUIPMENTS

In general, validation is the process of checking if something satisfies a certaincriterion. Examples would include checking if a statement is true (validity), if

an appliance works as intended, if a computersystem is secure, or if computer

data are compliant with an open standard. Validation implies one is able to

testify that a solution or process is correct or compliant with set standardsor

rules.

In food industry, validationrefers to establishing documented evidence that a

process or system, when operated within established parameters, can perform

effectively and reproducibly to produce a medicinal product meeting its pre-

determined specifications and quality attributes

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MICROBIOLOGICAL TESTING:

Different types of media used in microbiology lab to test microbiological count in

various samples.

Media used for water testing:

Water being the essential component of beverage industry is tested against microbes

using various media.

1. Chloromphenicol yeast glucose agar:

Standard formula:

Yeast extract : 5.00 gms/ltr

Dextrose : 20.00 gms/ltr

Chloromphenicol : 0.10 gms/ltr

Agar :14.90 gm/ltr

pH (at 25 c ) 6.6 + 0.2

Directions: Suspend 40.0 gms of salt in 1000ml distilled water. Heat to boiling to

dissolve the medium completely. Sterilize by autoclaving at 15lbs pressure at 121 c

temperature for 15 mins.

Use : To check yeast and mold in water .

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2. Violet Red Bile Agar:

Standard Formula:

Peptic digest of animal tissues : 7.00 gms/ltr

Yeast extract : 3.00 gms/ltr

Lactose : 10.00 gms/ltr

Bile salts mixture : 1.50 gms/ltr

Nacl : 5.00 gms/ltr

Neutral Red : 0.03 gms/ltr

Agar : 15:00 gms/ltr

pH (at 25 c ) 7.4 + 0.2

Directions : Suspend 41.53 gms of salt in 1000 ml distilled water . Heat to boiling to

dissolve the medium completely. Cool to 45 c and immediately our into sterile petri

plates containing the innoculum. If Desired , medium can be sterilized by autoclaving

at 15lbs pressure at 121 c temperature for 15 mins.

Use : For selective Isolation , detection and enumeration of Coli aerogens bacteria

in water, milk and other dairy food products.

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3.EMB Agar :

Standard formula :

Peptic digest of animal tissues : 10.00 gms/ltr

Dipotassium phosphate: 2.00 gms/ltr

Lactose : 5.00 gms/ltr

Sucrose : 5.00 gms/ltr

Eosin Y : 0.40 gm/ltr

Methylene Blue : 0.005 gms/ltr

Agar : 13.50 gms/ltr

pH (at 25c ) 7.2+0.2

Directions: Suspend 36 gms in 1000 ml distilled water. Heat to boiling to dissolve the

medium completely. Dispense and Sterilse by autoclaving at 15lbs pressure at 121 c

temperature for 15 mins.

Use : Used for differential isolation of Gram-ve enteric bacilli from clinical and non-

clinical specimen.

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4. CC2:

Standard Formula:

Yeast extract: 9 gms/ltr

Cerelose : 50 gms/ltr

Bio Peptone : 10 gms/ltr

Magnesium Sulphate : 2.10 gms/ltr

Potassium sulphate: 2.00 gms/ltr

Diastase : 0.05 gms/ltr

Thiamine : 0.026 gms/ltr

Bromo Cresol Green Agar : 15.00 gms/ltr

pH (at 25 c ) 4.6+0.2

Directions: Suspend 8.82 gms in 1000 ml distilled water . Mix thoroughly. Heat to

boiling to dissolve the medium completely. Dispense and Sterilse by autoclaving at

12-15lbs pressure at( 118- 121 c) temperature for 15 mins.

Use : For counting yeast and molds in samples by membrane filter method.

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Media used for checking and controlling microbial count in MAAZA.

5. Orange Serum Agar:

Standard Formula:

Casien enzymatic Hydrolysate: 10 gms/ltr

Yeast Extract : 3 gms/ltr

Dextrose : 4 gms/ltr

Dipotassium Phosphate : 2.50 gms/ltr

Orange Serum Agar ( solid from 200 ml): 17 gms/ltr

pH (at 25 c) 5.5+0.2

Directions: Suspend 45-5 gms in 1000ml Distilled water . Heat to boiling to dissolve

the medium completely. Dispense and Sterilse by autoclaving at 12-15lbs pressure

at( 118- 121 c) temperature for 15 mins. Avoid overheating . Mix well and pour into

Sterile Petri plates.

Use: For Cultivation and enumeration of microorganisms associated with spoilage

of citrus products. Cultivation of Lacto bacilli and other aciduric organism and

pathogenic fungi.

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INVERSION:

INVERTED BRIX: This is the brix which is found after breaking of sucrose in two

parts and molecular weight increases due to water molecule addition in the presence

of acid.

C12H22O11 + H2O C6H12O6 + C6H12O6

(SUCROSE) (GLUCOSE) (FRUCTOSE)

(342) (180) (180)

(A) (B) {360}

(A) Sucrose is 95% of (B) because of that

Inverted Brix * 95 = actual brix

100

Procedure:

1) Expel the CO2 from the sample properly.

2) Take 50 ml of decarbonated Sample in a cleaned and dry bottle after rinsing the

bottle twice with the decarbonated beverage.

3) Add 0.3ml of the HCl stock solution (made for inverted brix checking) in the 50ml

of the sample.

4) Cap the bottle properly and keep in water bath to reflux it at 900C for 90 mins.

5) Now cool down the sample to room temperature.

6) Check the brix and note down it.

Inverted Brix should be = (Std. Brix of the flavour/0.95) +- 0.15

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WATER TREATMENT PLANT

INTRODUCTION

The bottling plant receives its water supply from 3 bore wells .This water is first

treated and then used for beverage preparation.

NEED TO TREAT WATER

Water is treated to remove:

Colloidal and suspended particles.

Undesirable odor, taste and color.

Reduction in alkalinity to desired level.

Micro organisms.

COMMON IMPURITIES IN WATER

Suspended solids: Includes all matter suspended in water that is large enough to be

retained on a filter with a given porosity.

Turbidity: Indicates level of colloidal matter of organic or inorganic origin.

Alkalinity: Indicates the quantifiable quantities of carbonates, bi carbonates and

hydroxides in water.

Total hardness: Indicates the quantifiable quantities of calcium and magnesium.

Total dissolved solvents: Indicates total content of dissolved solids in water.

EFFECT OF CONTAMINATED WATER ON PRODUCT

Contaminants present a danger to taste, aroma and appearance of beverage.

Physical discrepancies in water as turbidity, color, odour, taste can have an almost

immediate effect on beverage flavor or appearance. Even when present in small

amounts, there remains a danger to product shelf life.

Turbidity or small levels of colloidal matter can cause foaming problem either at the

filler or while the beverage is being filled or later when the bottle \can is opened by

the consumer.

Micro organisms like yeast affect taste & odour and can cause sediment or floc to

develop.

Organic matter affects beverage sensory characters and shorten the shelf life

Chemicals and minerals affect adversely the taste of beverage.

High alkalinity _ can quickly neutralize and delicate acidity of the beverage.

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STANDARS OF WATER AT COCA COLA COMPANY

Turbidity Ntu < 0.5 ntu

pH > 4.9

Alkalinity (M as Ca(co)3 < 85 mg/l

Chlorine Nil

Chlorides < 250 mg/l

Sulfates < 250 mg/l

Chlorides + Sulfates < 400 mg/l

TDS < 500 mg/l

TH & Cal Hardness Per product Requirement

Sodium -DO-

Iron < 0.1 mg/l

Aluminum < 0.1 mg/l

Color No visible Color

Taste No detectable off taste

Odor None

Trihalomethanes Below 100 ppb

Microorganisms Coliform Nil/100 ml

Total Count


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WATER TREATMENT PLANT TESTING

It includes various tests under physical and chemical parameters.

These tests are:-

1) Physical Parameter:

TDS

Odour

Taste

Turbidity

Appearance

2 )Chemical Parameters:

Calcium hardness

Sulfate

Iron

Total Hardness

Total and Partial Alkanity

Chloride

Free/Total Chlorine

WATER TREATMENT PLANT FLOWCHART

Bore wells

Raw water storage

3 Streams

Coagulation Softening Domestic

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TREATED WATER

Raw Water Tank

Free chlorine (2-3ppm)

Coagulation Tank

.

Lime, bleaching pd., FeSO4

Clear Water tank

Pressurized Sand Filters (PSF)

Dechlorination

Activated Carbon Filters (ACF)

Lead ACF

Lag ACF

5 micron filter

UV chamber

3 micron filter

1 micron filter

Treated water

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USE OF TREATED WATER

Syrup making, beverage preparation and CIP.

Filler for cleaning and flushing.Water coolers.

Back washing of PSF and ACF of treated water

SOFTENING STREAM

Raw water

P.S.F.

A.C.F.

Softener (24% brine)

Soft water

USE OF CHLORINATED SOFT WATER IN

Bottle washer.

Crate washer.

PET rinser.

USE OF NON CHLORINATED SOFT WATER IN

Boiler.

Chiller.

PET blower.

Cooling system.

KINLEY WATER MANUFACTURE

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Water from bore well

Coagulation

PSF

Storage tank

Dechlorination ACF

Two tier ACF

UV chamber

Reverse osmosis

Reverse osmosis membrane filtration process

Storage tank

Micron filter

Ozonation

Filling and capping

Warmer and blower

Labeling

Date coding

Packaging

Palletizing

VARIOUS WATER TREATMENTS

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Functions of different water Treatment Process

1) Chlorination

Scope

Destruction of micro organisms.

Oxidation of heavy metal ions and organic impurities.

2) Coagulation and Flocculation

Scope

Reduction of alkalinity.

Removal of dirt clay and other suspended matter.

Removes microbial matter

Heavy metals and compounds causing off taste.

Chemicals Used in coagulation and flocculation:

Lime: Reduces alkalinity and temporary hardness.

Bleaching Powder: Removes color, turbidity, kills microbes and acts as a coagulant

aid.

Ferrous sulphate: Used as a coagulant for quicker settlement of suspended particles.

Soda Ash: Reduces permanent hardness and is used when total hardness in water is

higher than total alkalinity.

3) Pressure Sand Filter

Scope

Removes colloidal material

Removes suspended micro particles

Media Used 6 layers of sand ranging from coarse gravel to fine sand.

Optimum Flow Rate

Pressure should not exceed 4.8 m2/hr/sq meter of surface area in case of PSF.

Pressure should not exceed 8.5 m3/hr/sq meter of surface area for$Gravity Sand Filter

Back Wash Frequency Done when turbidity 0.4 NTU (Normally once in 24 hrs.)

Sanitation Done by 50 ppm chlorine solution.

4) Activated Carbon Filter

Scope

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Removes trace level of organic compounds

Removes color, taste and odour causing compounds.

Media Used Activated Carbon0(by adsorption)

Optimum Flow Rate Should not exceed 9.& m3/hr/sq meter of carbon bed

Back Wash and Sanitation(Frequency

Turbidity 0.5 NTU

Depends on the chlorine carry over

Sanitation done by steam at 1.5 kg for around 4 hrs at a temp of 85 C.

Noreal frequency once in 9 days.

5) Softener

Scope To reduce the hardness of water.

Medium Used Sodium resins

Resin0Quantity "1500 ltr. ( Ex: Indion 225)

Working(Priociple Na+ will be exclcnged with the hardness causing

elemunts.MRegeneration

Fepends on the hardness of output wa|er (generally every 4 days)

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It reduces alkalinity and total dissolved solids by more than 90 %

Reduces inorganic such as Na, Cl, SO4

Reduces large organic molecules and organisms at efficiency more than 99%

The usual molecular weight range is below 300 Dalton

Operating pressure range is from 200 450 psi.

Advantages:

Highly effective against a wide spectrum of contaminants.

Easy to operate.

Cost effective when designed properly

Minimum space requirement

Can handle changes in water supply and level of impurities.

Disadvantages:

Polyamide membranes must be protected against effects of chlorine.

Cellulose acetate membranes are biodegradable.

Efficiency of unit affected by the temperature of raw water.

Higher the organic content of incoming water, less effective the unit.

The effluent waste water from system pose disposal problems.

9) Decaustisizer:

Decaustisizer

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Bottle Washer

Rinsing water from bottlewasher

PHE

(Plate Heat Exchanger)

Chlorination

Settling Tank

Overflow Tank

PSF

ACF

Decaustisizer (here the pH decreases)

Chlorine dozing

Degaser

Decausitisizer Storage Tank

Rinsing water bottle washer

WATER TREATMENT PLANT TESTING

1. Chloride test:-

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Take 50ml sample in a conical flask

Add 2 drops of P. indicator

Add 0.02N H2SO4

(Until pink color disappears).

Add 5 drops of potassium chromate or 0.5ml

(removes turbidity)

Titrate it with N/50 AgNO3

(End point brown color)

NaCl (mg/ltr.) = (R-0.2ml) 23.376

Where,

R Reading

2. Sulphate test:-

100ml sample

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2 drops of P. indicator

Add 1N HNO3 until the color disappear

Boiling to expel CO2

Make up to 200ml by distill water

Cool it & allow to settle

From above soln. take 50ml

Add 1ml NH3 buffer

Add black tincti-cation

Titrate with N/50 EDTA

End point Blue color

3. Total hardness:-

Standard for total hardness (< 100 ppm)

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Procedure:-

Take 100ml of water sample in a conical flask

Add 3 4 drops of ammonia buffer

Add a total hardness tablet

Mix thoroughly

(Pink color appears)

Titrate it with N/50 EDTA soln

Development of blue color

(Indicates the presence of total hardness)

Result: - Observation is less than 100ppm.

4. Alkalinity:-

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Standard for alkalinity(< 85 ppm)

Procedure:-

Take 100ml of water sample in a conical flask

Add 2 3 drops of Ph indicator

Add 4 5 drops of Methyl orange or Methyl purple

Development of orange yellow color

Titrate it with N/50 H2SO4

Darkning of orange yellow color(Indicates the presence of Alkalinity)

Result: - Observation is < 85ppm

Note: - Burettereading should be multiplied by 10 to get alkalinity

5. Chlorine test:-

Standard for chlorine (b/w 3 5ppm)

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Procedure:-

Take 10ml of sample in micro quant bottle

Kept it in colorimeter

Add one Cl2 1A tablet powder

Observe color

Development of dark pink color(Indicates the presence of chlorine)

# To observe mid readings do testing as follows:

Take 50ml of chlorinated water and50ml non chlorinated water in a measuring cylinder.

Mix it thoroughly and fill it into two cubettes

Add powder of one DPD tablet to one cubette

DPD gives pink color(Pink color indicates the presence of chlorine)

6. Calcium Hardness:-

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Procedure:-

Take 100ml of sample water

Add 3 4 drops of NaOH

Add one CaH tablet powder

Gives light pink color

Titrate it with EDTA soln.

Pink color slightly darkens with purple touch(Indicates the presence of CaH)

7. Magnesium hardness:-

Procedure:- Same as Calcium hardness

MgH = TH CaH

Where,MgH Magnesium hardnessTH - Total hardnessCaH Calcium hardness

8. Turbidity:-

Collect the sample in a clean dry glass beaker, transfer the sampleto the sample cell quickly

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Rinse the sample cell with the water to be tested

Cap the cell and dry the outside surface of the cell with a tissue

paper

Pour the sample into the sample cell

Examine the water sample in the cell before placing it in theinstrument. If bubbles have formed on the inside wall of the cell;gently tapping on the cell wall or mildly agitate the cell to releasethe bubbles

Gently invert sample once to agitate any particulate that may

have settled

Place the cell in the turbidity meter with the direction mark on the

cell forward

Lower the light cover and the turbidity will be displayed

Record the turbidity

9. P test (alkalinity):-

Phenolphthalein indicator gives pink color if alkalinity is there.

10.TDS (total dissolved solids):-

Measured by TDS meter

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EFFLUENT TREATMENT PLANT:

INTRODUCTION

Treatment plants remove impurities contained in wastewater so that the treated

wastewater can be safely returned to the environment. This same stabilization process

occurs in nature to break down wastewater into its most basic components of carbon

dioxide and water. Common methods of treatment include physical, biological and

chemical treatment steps to stabilize the wastewater.

The effluent treatment facility is installed for biological treatment of the effluent

emanating. The effluent bears large amounts of organic matter. The direct discharge

of the effluent into the water bodies causes depletion, of DO of the water. Hence, in

order to meet the recommended standards of quality of the effluent, it is necessary to

treat the effluent before it is finally disposed off. This treatment facility provides for

removal of major pollutants from the effluent.

There are three reasons why most companies consider on site treatment of

wastewater: -

a) To avoid prosecution

b) To remove restriction on the output of the factory

c) To save money

d) To protect public health in the service area

e) To protect the water quality in the waterway which receives the treated

effluent from the processes.

f) To protect the environment which receives any residuals from thetreatment processes.

Industries carry out cost/benefit studies to show how to achieve the greatest benefit

from the investment in effluent treatment. They design plants for the treatment of

industrial effluents tailored to the requirements of the site and the industrial process,

and they can arrange a complete service through to installation and commissioning of

the effluent plant.

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Wastewater from industrial processes can be difficult to treat. The cost of disposing

of the effluent to the public sewer is determined by the volume, the polluting load, the

suspended solids in the flow and the treatability of the effluent.

It may not be possible to treat the effluent with municipal sewage, or it may be cost-

effective to treat the effluent on site. The plant may be designed to reduce the strength

of the effluent to a level suitable for discharge to the sewer, or to a standard suitable

for discharge to the environment, or to optimise the balance between on-site costs and

disposal charges.

Industrial wastewaters are typically much stronger than domestic sewage, and require

a different approach if they are to be treated economically.

Many of the existing treatment plants are developments of municipal technology. It

can be difficult to achieve the required effluent standards, and large amounts of

sludge are produced.

Sludge disposal is becoming one of the greatest problems both for the industrial

wastewater treatment plants. The available routes for disposal are reducing rapidly,

and costs are escalating.

Modern aerobic treatment plants produce far less sludge with a smaller footprint on

the site. Anaerobic plants produce minimal sludge with a by-product of methane,

which can be used in the upstream processes for heating or power generation.

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TREATMENT PROCESS

PROCESS CONCEPT

The raw effluent, bears large amount of suspended solids and oxygen consumingorganic matter. The conceptual approach of the treatment includes the removal ofsuspended particles, dissolved organic matters and handling of sludge for disposal.

The heart of this treatment scheme is the aerobic biological reactor, which aredesigned on the basis of activated sludge process. The activated sludge treatment

process basically involves the stabilization of organic matter by the action of variousmicroorganisms as depicted in the following equation.

Organic + Microorganisms + Oxygen + Nutrients = New cells + Carbon dioxide

+ Ammonia + Energy

This could be restated in engineering term as-

Waste + Sludge + Air Surplus Sludge + End products

In this biological process, a part of the newly synthesized sludge undergoes oxidationcalled, Endogenous respiration.

Cells + oxygen End products + Less cells

The preformed biological flocks (MLSS) come in contact with the incoming waste inthe aeration tank under highly aerobic environment, and oxidize the organic matter tomore stable materials. The efficiency of the system mainly depends upon theconcentration of active microorganism present to perform the assimilation of organic

matter. The activated sludge, in general, consists bacteria and protozoan, rotifers etc.in the presence of DO. The desirably environmental condition like sufficient DO,substrate and nutrients are required for cell growth and energy for various metabolicfunctions. It is essential that the biological flock should readily separate from thetreated wastewater in the final clarifier.

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The oxygen supply is required for the following: -

1. Oxidation of organic matter (substrate removal)

2. Endogenous respiration of microorganisms.

3. Nitrification

Oxidation of nitrogenous materials is slower. Nitrification generally begins aftercarbonaceous demand is satisfied and occurs in two steps: -

Nitrosomonas

2 NH + 3O 2 NO + 2HO + 4 H

Nitrobacter2 NO + O 2 NO

Excess or deficient quantity of food (incoming BOD) adversely affects the physicalquality of biological sludge. The activated sludge system is designed on the basis of a

particular food to microorganism ratio. This ratio is in practice indicated by thequantity of BOD in influent per unit quantity of mixed liquor suspended solids perunit time. This may be expressed as kg, BOD/kg, MLSS/day. The volatile suspendedsolid, which repression is between 60 70% of MLSS is used as a measure of activecells in the system. The optimal pH for an active biological aeration system is

between 6.5 9.0.

In the aeration tank required MLSS concentration is maintained by recirculating thebiological solids separated in the final clarifier.

The surplus biological sludge (and the sludge from the secondary clarifier) needsfurther dewatering, which is achieved in sludge drying beds. The final effluent issuitable for discharging into the inland surface water.

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PROCESS UNITS

The units are designed for maximum of efficiency within certain flow range and

effluent characteristics. Close control and coordination of the operation of different

units are required within limits of design.Efficient plant operation is possible only

when the operator is fully conversant with the equipments and function of each unit.

This effluent treatment facility consists of the following units: -

1) Storage tank

2) Equalization tank

3) Neutralization tank

4) Primary clarifier

5) Anaerobic Hybrid Reactor

6) Aeration tanks 1 & 2

7) Final clarifier 1

8) Final clarifier 2

9) Sludge drying beds

UNIT DISCRIPTION AND OPERATION -

1) STORAGE TANK -

OBJECT

The function of storage tank is that it collects and store the raw effluent from

different part of the factory.

PROCESS

The raw effluent is collected from the different part of the factory and stored. The

storage tank is of 40 feet in height. The capacity of the tank is two lack liters. Now

from the storage tank the raw effluent is passed to the equalization tank with the help

of pump. The pH of the raw effluent in the storage tank is 5.5 6.5, which generally

come out from the factory.

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2) EQUALISATION TANK -

OBJECT

The function of equalization tank is to equalize the raw effluent emanating from

different processing units.

PROCESS

The effluent is collected in an existing combined effluent from where it is pumped to

the existing aeration tank, which serves as an equalization tank. The floating aerator

is operated to homogenized effluent is pumped to the neutralization tank.

3) NEUTRALIZATION TANK -

OBJECT

The function of the neutralization tank is to neutralize the raw effluent, which is

generally acidic in nature.

PROCESS

The raw effluent, which is usually acidic (pH-5.5 to 6.5) in nature is neutralized by

adding the saturated solution of NaOH, So, the final pH of the neutralization tank is

adjusted to pH- 8.0 to 9.0. Then the raw effluent after has been treated in

neutralization tank is allowed to passed in the primary clarifier through gravity.

4) PRIMARY CLARIFIER

OBJECT

The function of PC is to remove suspended heavy particles from the raw effluent.

PROCESS

In this tank, the heavy particles along with the sludge, which the bacteria have

degraded settles down at the bottom of the tank and the water flows on top of it. A

rotator is fixed in the middle of the tank, so that the heavy particle along with the

sludge which has been settle down does not block the outlet of the PC. In this tank

mostly the inactive heavy particles along with little amount of sludge is thrown out in

the Sludge drying beds. The pH of the PC is maintained to 7.0 to 8.0.

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5) ANAEROBIC HYBRID REACTOR -

OBJECT

This unit is provided for the anaerobic treatment of the effluent.

PROCESS

The effluent after treated in PC is passed to the AHR through gravity. The design of

the AHR is in a way that at the bottom of this tank anaerobic bacterias beds are

made. The effluent which comes from PC react with the anaerobic bacteria and the

break up of organic compounds takes place with the production of Methane gas

which can be seen in the form of bubbles on the upper layer of the water in the tank.

The pH of the AHR is maintained to 7.0-7.5 because the anaerobic bacteria are stable

in this pH. If there is much fluctuation in the pH of this tank the anaerobic bacteria

can die.

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6) AERATION TANKS 1 & 2 -

OBJECT

This unit is provided for aerobic biological treatment of the effluent for the reduction

of organic matter in the effluent.

PROCESS

The effluent from the AHR is received in the aeration tank stage-1 by pumping and is

aerated by the help of OXYRATOR mechanical surface aerators in the presence of

previously developed biological sludge (Mixed Liquor Suspended Solids i.e. MLSS).

The food / microorganism ratio is maintained at about 0.6 and 0.137 in the first and

second stage aeration tanks respectively which correspond to about 3500 mg / ml.

OPERATION

The start up of the activated sludge process can be accomplished by using seed

sludge available from night soil develop a suitable microorganism population

expressed as MLSS.

The following method is recommended for the initial development of MLSS in the

aeration tank: -

The use of seed sludge (Night soil) provides the reliable means of start up. Seed

sludge may be added in the aeration tank to provide approx. 500mg/ltr. MLSS. The

tank is to be filled up with fresh water prior to the addition of seed sludge. The seed

sludge is to be aerated by running both the aerators and be continued for at least 24

hrs. in order to make the sludge into aerobic. With the seed sludge aerated, raw

effluent into the aeration tank is to be introduced at approx. 25% of the design flow.

If possible, aeration must be continued by all aerators and feeding of effluent

increased in daily increments of 25%. If there is no indication of the process

deterioration. This enables the treatment process to produce a quality effluent as the

MLSS concentration is increasing. During this operation also be added the requisite

quantity of nutrients in aeration tank.

Required nutrients viz. N and P are added with aeration tanks by pumping a solution

of Urea and DAHP. The aerators also help to keep the biological solids in suspension.

The mixed liquor from the aeration tanks is subjected to gravitational settling in the

hopper bottom secondary clarifier.

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7) FINAL CLARIFIER 1 -

OBJECT

The function of final clarifier-1 is to separate biological solids from the mixed liquor

first stage aeration tank.

PROCESS

The mixed liquor from the first stage aeration tank is received in the clarifier by

gravity. The clarifier is hopper bottom type. The sedimentation of sludge is

withdrawn by pumps and is recirculated back into the aeration tank stage-1 for

maintaining the MLSS. Provision is given to transfer the sludge into the stage-2

aeration tank through the necessary connections given on the delivery line of the

sludge recirculation pump.

OPERATION

The clarifier is filled up with effluent by gravity. The biological solids get settled by

gravity at bottom. Keep the suctions valves corresponding to each hopper portion of

clarifier open. Recirculate the settled sludge by operating pump back into the aeration

tank continuously. If the MLSS exceed the required level, or sludge needs to be

wasted, divert the sludge into aerobic.

8) FINAL CLARIFIER 2 -

OBJECT

The function of final clarifier-2 is to separate the biological sludge from the mixed

liquor from the aeration tanks before the final effluent is disposed off.

PROCESS

The mixed liquor from the aeration tank is received in the clarifier by gravity. Final

clarifier-2 is a circular sedimentation tank with the central chute inlet peripheral

overflow laundar. The sedimentation of sludge takes place by gravity setting. The

settled sludge is collected to a central circular channel around the inlet chute by a

rotating scarper. Scraper is driven by a central drive head. The settled sludge is

pumped back into the aeration tank. The clarified effluent from the annular laundar is

disposed off through the V- Notch.

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Discharge through V-Notch: -

The raw effluent, which has been treated through different process, lastly clarified, is

now discharge into the water bodies through the V-Notch. This is a pipeline made

which have a V shape ending and having a scale mark from which height and

discharge of the effluent can be calculated. The following table shows the discharge

through V- Notch

Height in cms. Discharge cubic

meter/hour

Height in cms. Discharge

cubic meter/hour

7.00

7.50

8.00

8.50

9.00

9.50

10.00

10.50

6.48

7.92

9.00

10.08

12.24

14.04

16.20

18.36

11.00

11.50

12.00

12.50

13.00

13.50

14.00

14.50

15.00

20.52

22.68

25.56

28.08

30.96

34.20

37.80

40.68

44.28

9) SLUDGE DRYING BEDS -

OBJECT

This unit is meant for dewatering and drying the excess biological sludge.

PROCESS

The excess biological sludge from the stage-1 aeration tank after aerobic digestor is

conveyed to the sludge drying beds by gravity. The excess sludge from the stage-2

aeration tanks withdrawn to the sludge drying beds by pumping. Each bed comprises

of course sand broken stone as sand media support and under drain.

OPERATION

Allow the sludge to flow to the drying beds. Once the sludge thickness comes to about

300 mm charging of sludge is to be stop and the bed is isolated to dry up by natural

evaporation. This takes about 10 days.

After drying and dewatering, the sludge cakes are removed manually and are

disposed off.

SPECIFICATION OF ETP -

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S.No. Test Tank name Specification

1. pH Raw

PC

AHR

FC-1

FC-2

Neutralization tank

5.00 6.50

7.00 8.00

7.00 7.50

5.50 9.00

5.50 9.00

7.50 9.00

2. COD Raw

PC

AHR

FC-1

FC-2

NMT 3500 mg/ltr

NMT 3000 mg/ltr

NMT 2500 mg/ltr

NMT 250 mg/ltr

NMT 250 mg/ltr

3. DO AT-1

AT-2

NMT 5.0 mg/ltr

NMT 5.0 mg/ltr

4. BOD Raw

AHR

FC-1

FC-2

NMT 1800 mg/ltr

NMT 1500 mg/ltr

NMT 30 mg/ltr

NMT 30 mg/ltr

5. SS Raw

PC

FC-1

FC-2

NMT 2000 ppm

NMT 1500 ppm

NMT 100 ppm

NMT 100 ppm

6. MLSS AT-1 NMT 2000 ppm

TESTING -

GENERAL

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Full spectrum of water and wastewater testing can be performed to evaluate the

specific characteristics of water, wastewater or treated effluent. The ability to

determine what is happening within a plant, including evaluations of plant

performance, can only be done when proper sampling, storage and transportation

techniques have been followed

It is imperative to analyze regularly the operational parameters and maintain a

systematic record as a ready reckonar. Sampling and testing should be done as per the

methods prescribed in:

1) Standard methods for the examination of water and wastewater. (APHA,

AWWA, WCPC 1975)

2) Manual for the examination of water, sewage and industrial waste.

(ICMR)

3) Methods of sampling and test for sewage and industrial effluent.

SAMPLING POINTS

S.No. SAMPLE SAMPLING POINTS

1)

2)

3)

4)

Raw effluent

Final effluent

Mixed liquor suspended solid

Return sludge

Equalization tank

Final clarifier launder

Aeration tanks

Return sludge line (Stage 1 & 2)

METHODS OF ANALYSIS -

pH -

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The pH of water refers to its hydrogen ion activity and is expressed as the logarithm

of the reciprocal of the hydrogen ion activity in moles per litre at a given temperature.

The practical pH scale extends from 0 (Very acidic), to 14 (Very alkaline), with 7

corresponding to exact neutrality at 25C. Whereas alkalinity and acidity are measures

of the total resistance to pH change or buffering capacity of a sample, pH represents

the free hydrogen ion activity.

PRINCIPLE

Although the hydrogen electrode is recognized as the primary standard, the glass

electrode is less subject to interferences and is used in combination with a calomel

reference electrode.

The glass reference electrode pair produces a change of 59.1 mg/pH unit at 25C.

APPARATUS

1) Electronic pH meter with temperature compensation arrangement.

2) Glass electrode; are available for measurement over the entire pH range

with minimum sodium ion-error types for high pH- high sodium samples.

3) Reference electrode; Use calomel, silver-silver chloride or other constant

potential electrode.

PROCEDURE

Firstly, calibrate the pH meter with the buffer solution of pH -7.0 and then the pH -

4.0. After calibrating it the electrode is washed with DM water and finally the pH is

taken of the sample. After doing the work again the electrode is washed with DM

water and then the electrode is dipped in DM water.

One-Day Analysis: -

Raw 6.70

PC 7.28

AHR 7.20

FC 8.6

N-TANK 8.58

SUSPENDED SOLID

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Estimation of suspended solid plays a important role for the process evaluation. These

solids are mostly of organic species and contributes pollutants load to the treatment

system. SS is analysed once in a week.

PRINCIPLE

This test is based on the evaporation of the residues obtained after filtering a known

volume of sample, to dryness under standard conditions and weighing the residue

after drying.

APPARATUS

Gooch Crucibles - 50 ml. Capacity

Measuring cylinder - 100 ml. Capacity

Vacuum pump

Dry heat Oven

SAMPLE

Raw - 100 ml.

PC - 100 ml.

FC - 50 ml.

PROCEDURE

1) Firstly weigh the apparatus without any sample.

2) Filter the well-known sample (Raw, PC, and FC) through the Gooch

crucible under suction, dry at 103 to 105 C to constant weight. Cool and weigh.

The increase in weight equals the total suspended solid.

CALCULATION

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Weight of crucible Weight of empty

Suspended solids + dry residue - crucible

Mg/litre = ________________________________________ X1000

Volume of sample

One-Day Analysis: -

RAW: - 43.9035gm 43.8786gm = 0.0249 X 10

= 249 X 2mg

= 498 ppm.

PC: - 44.4568gm 44.4371gm = 0.0197 X 10

= 197 X 2mg

= 394 ppm

FC: - 55.8496gm 55.8484gm = 0.0012 X 10

= 12 ppm

MIXED LIQUOR SUSPENDED SOLID (MLSS)

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MLSS is a rough quantitative measure of the microorganisms that are playing an

important role in biological degradation of organic matters in the aeration tank. MLSS

is analyzed once in a week. Routine analytical estimations of the mixed liquor solid is

essentially required to enable an effective functioning of the aeration system and its

significances are represented as follows: -

1) Indicates whether the quantum of biomass presence in aeration tank is

sufficient to meet the biological degradation or not.

2) Whether the biomass population is more or less in compared to the

designed food supply (BOD) to the aeration system.

3) Helps controlling the adjustment of biomass in the aeration tank.

PRINCIPLE

The tests are based on the evaporation of the mixed liquor sample to dryness under

standard conditions and weighing the residue after drying. MLSS is the weight of

residue, of the known filtered mixed liquor, on evaporation at 103 to 105C.

APPARATUS

Gooch Crucible - 50 ml.capacity

Measuring cylinder - 100 ml. Capacity

Vacuum pump

Dry heat Oven

SAMPLE

AT 1 - 50 ml.

AT 2 - 50 ml.

PROCEDURE

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1) Firstly weigh the apparatus without any sample.

2) Filter the well-known sample (AT-1 and AT-2) through the Gooch crucible under

suction, dry at 103 to 105 C to constant weight. Cool and weigh. The increase in

weight equals the total suspended solid.

CALCULATION

Mixed liquor Weight of crucible Weight of empty

suspended solids + dry residue - crucible

Mg/litre = ________________________________________ X1000

Volume of sample

One-Day Analysis: -

AT-1: - 44.1165gm 44.0909gm = 0.0256 X 10

= 256 X 2mg

= 512 ppm

AT-2: - 44.0905gm 44.0166gm = 0.0739 X 10

= 739 X 2mg

= 1478 ppm

SLUDGE VOLUME INDEX

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The sludge volume index (SVI) is the volume in milliliters occupied by 1 g of a

suspension after 30 min settling. SVI typically is used to monitor settling

characteristics of activated sludge and other biological suspensions. Although SVI is

not supported theoretically, experience has shown it to be useful in routine process

control.

In an activated sludge sewage treatment process, the suspended microbial mass

coming out of the aeration tank is separated from the bulk of the liquid phase by plain

sedimentation of the suspended matter. Further, since the microorganisms are

recirculated to the aeration tank it is advisable to have a concentrated sludge. Due to

overloading of the activated sludge plant, the sludge does not settle properly resulting

in a poor effluent. A poorly settling sludge may also result from an unbalance of

nutrients in the incoming sewage. The sludge volume index (SVI) is primarily

measured to know the settling characteristic of the sludge. After settling the mixed

liquor for 30 min. the sludge settlebility characteristic may be assessed from values of

sludge volume index as follows: -

SVI VALUE

Less than 20 Settlable solids

20-40 Sludge formation Stage

40-70 Settled sludge excellent

70-100 Well settled sludge

100-150 Reasonably good settled

More than 150 Poor settled sludge

APPARATUS

Measuring cylinder - 1000 ml.

SAMPLE

AT 1 and AT 2 - 1000 ml.

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PROCEDURE

a) Fill 1000 ml. of sample in 1000 ml. measuring cylinder.

b) Allow settling for 30 minutes and noting the volume of sludge occupied in

ml.

c) At the same time determine the MLSS.

CALCULATION

SVI is computed from the following equation: -

ml. settled sludge X 1000

SVI = ________________________

mg. /liter MLSS

One-Day Analysis: -

97 X 1000

SVI = = 74.61

1300

CHEMICAL OXYGEN DEMAND

The COD determination provides a measure of oxygen equivalent of that portion of

he organic matter in a sample that is susceptible to oxidation by a strong chemical

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oxidant. In the absence of a catalyst however, this method fails to include some

organic compounds (such as acetic acid), which are biologically available to the

stream organisms, while including some biologic compounds, which are not part of

the immediate biochemical load on the oxygen assets of the receiving water.

The use of exactly the same technique each time is important because only a

part of the organic matter is included; the proportion depending upon the chemical

oxidant used the structure of the organic compounds and the manipulative procedure.

The dichromate reflux method has been selected for the COD determination

because it has advantages over other oxidants in oxidizability, applicability to a wide

variety of samples and ease of manipulation.

The bas

51811544 coke project report

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