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.
- BOTTLING PURIFIED WATER.
- LABELLING
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: 550 Bottles per hour per machine. 2 nos. machines will give 1100 bottles per
hour i.e. 8800 bottles per 8 hour shift. |
| - |
Bottling : 24 Bottles per minute of 1000 ml. i.e. 1440 Bottles / hour i.e. 11520 Bottles per 8 hour shift. |
| - |
Labelling : Heat Shrink Tunnel would handle 1000 Bottles per hour. |
All the 4 capacities have been nearly matched - for any adjustments some of the machines can be run for longer duration.
PROCESS FLOW
The plant has 6 components :
1] Purification: Water received from the external source is passed through the purification plant and stored in a stainless steel 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.
3] 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.
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.
Expiry date and batch number could be printed on labels or caps prior to their being put on the bottles.
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.
MACHINES / EQUIPMENT
OFFERED
The various machines and equipment being offered by us 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 : 1000 lit / hour
Raw water quality (assumed) : 1000 ppm as TDS
| Description |
Quantity |
| Alum doser 3 lit/hr dosage |
1 |
| 2 nos. pump (1W+1S) (SS) |
1 |
Activated Carbon Filter
Flow Rate : 2000 lit/hr.
MOC : SS 304
|
1 |
Pressure Sand Filter
Flow Rate : 2000 lit/hr.
MOC : SS 304
|
1 |
| Softener |
1 |
Reverse Osmosis System
Permeate Flow : 500 lit/hr.
Consist of :
5 Micron Filter SS-304 PP
H.P. Pump with 3 HP Motor
Membrane - 4 nos.
Pressure Vessel (SS-316) - 4 nos.
Instruments & panel
|
1 |
Ozone Generator
Capacity - 1 gm/hr.
Ozone Dissolution Col.
MOC : SS-316
Flow Rate : 1000 lit/hr.
|
1 |
UV Disinfectant
Flow Rate : 1000 lit/hr.
|
1 |
Storage tank for Pure Water
Capacity : 1000 ltr. SS-316 |
1 |
Total Cost USD 34,300/-
If the quality of the raw water is good it may not be necessary to use some of the above equipment and consequently the cost can come down.
Tanks for Raw water, and alum dosing are to be provided by the client. The output water purification would be in line with WHO specifications - however final results depend on input water quality.
Bottle Manufacturing Section:
To achieve 1100 nos. bottles per hour production.
| Description |
Quantity |
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
|
2 |
Refrigeration Unit : (Chiller)
Cooling Capacity : 1 Ton;
(Standard Make) |
2 |
Air Compressor
:
with after cooler and moisture separator |
2 |
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 |
2 |
| Approx. Spares for 1 Year |
2 |
Total Cost USD 48500/-
It is possible that the air compressor be bought locally.
We are in a position to offer automatic moulding machines also.
However that would result in higher investment hence is not recommended at the initial stages.
Bottling Section :
This section receives the empty bottles, rinses them, fills and caps them.
| Description |
Quantity |
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.. |
1 |
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.
|
1 |
| Change parts for 500 ml and 1500 ml
1 set each |
1 set
each |
| Spare for item 2 for 2 years |
|
| |
|
Total cost USD 33,300/-
|