United Beverage S.
C Mojo
Bottle washer
Teka lemma
November 30,2018 Packaging 1
Anbessa, Waliin
November 30,2018 Packaging 2
Safety and Hazard on Bottle Washer
hot surface and steam burn
work at height
sharp item
mechanical hazard
corrosive chemicals
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Safety and protective devices of the machine
• Control components relevant to safety e.g. master switch, E-
stop
• Signaling and warning devices e.g. indicator lamp, signal
beacon post
• Protective devices e.g. safety P.E sensors, covers
• Machine safety mechanisms e.g. brake, motor protector, fuse
• Machine signs e.g. prohibitive, warning and instruction signs
• Shear pin
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Cont.……
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Causes of hazard
• Hazard caused by mis use of the control devices like E-stop and
master switch
• Hazard caused by unqualified personnel doing work on the
electrical system, hydraulic and pneumatic systems
• Hazard caused by lubricant, cleaning agent that are not fit for use
in the food sector
• Hazard caused by live components after turning off the master
switch ,since the master switch is turned off certain machine
components remain live due to UPS active
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Danger zones
• Moving machine parts e.g. infeed, discharge, conveyor
• Electrical components e.g. control cabinet
• Components that become hot during production e.g. caustic
tank, pipe systems, motors
• Areas around components where media flow out
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Washer Construction
infeed
pre treatment zone
main treatment zones
post treatment zone
discharge
label removal unit
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Cont.........
axial pump
hydrogen and fume extraction system
hydraulic label press
rotating and flat jet-jetting unit
supply and return pipe lines
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Infeed
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Plastic profiles
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Spiral roller
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Carrier chain
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Spray nozzles
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Areas of the machine
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PID
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Factors for Cleaning Bottles
sinner’s circle
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Temperature
• The higher the temperature the higher the cleaning effect
• But too high temperature (T>85 ºC) can reduce the cleaning
effect
• Maximum temperature leads to stability of the bottles kind of
dirt/soil
• Maximum temperature leads to the bottles looses its thermal
strength
• The hotter our cleaning solution is the more dirt it can remove
and the quicker it actually removes it.
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Chemical treatment
• The higher the concentration the higher the cleaning effect
• The maximum cleaning effect is obtained with a sodium hydro
oxide concentration 2-2.5% and additive concentration
• Too high concentration of NaOH decreases the cleaning effect
• Too high concentration of NaOH can increases the fresh water
consumptions
• Too low concentration NaOH can reduce the cleaning
effectiveness of the stump burn dirt
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Cont.…..
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Contact time
• The longer the contact time the more dirt can be removed
• But it can be depend on the design and speed of the machine
• Too long contact time produce too much grey bottles
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Mechanical treatment
• The higher the mechanical effect e.g. rinsing
pressure the higher the cleaning effect
• Too high mechanical effect can forms foams
• Tests show that a soaking step prior to a spray
increase the cleaning effect
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Operating Parameters
Operating pressure of compressed air
Caustic concentration
Temperature on the baths
Pressure of jetting pump
Fresh water jetting pressure
Fill levels on the baths
Output torque from the gear box
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Operating compressed air
Supply customer pressure= 7bar-10bar
Set point on the pressure regulator=5.5 bar
Temperature = (5-30) ºc
Heated medium(saturated steam)
Supply customer pressure=7bar-10bar
Set point on the pressure regulator=5.5 bar
Temperature = (130-160) ºc
Hydraulic operating pressure of piston label press
pressure=150bar-180bar
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Fill levels
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Instruments on Bottle Washer
Flow meters
Thermocouple(TT)
Level probes(LT)
Thermometer
Digital manometer
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Cont.….
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Additives on bottle washer
Divorite/ Mix 100/ or other
recommended
Surfactant agent
act as antifoam
It has a wetting power for labels
prevent formation of microorganisms
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Cont....
WPS10
scale inhibitor
added on warm water tank
consist of phosphoric acid
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Cont.....
Citric Acid Circulation
it has done monthly interval
it removed lime scale
it act as deodorizer
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Cont....
Some bottles are in a very poor state
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Quality checks
Phenophetaine test
Microbial test for cleaned bottle and brew
water
Caustic concentration
Caustic temperature
Caustic activity
Caustic clarity(visual inspection)
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Maintenance system
1.Autonomous maintenance- is the Best Practice of
Production operators taking responsibility for the care and basic
maintenance of their equipment, by operating it correctly,
keeping it clean, doing basic lubrication and inspecting it
regularly.
2. Corrective (breakdown) maintenance
Occurs when there is a work stoppage due to machine
breakdown
Maintenance becomes repair work
Seeks to get the equipment back into operation as quickly as
possible
To control the investment in replacement spare machines.
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Cont.……
3.Preventive maintenance - Perform maintenance before
the machines fails, thus avoiding failure and extending its life
It performs by maintenance artesian weakly and daily.
Daily maintenance activities are performed as CILT
Weakly maintenance activities are performed at the end of
production by the scheduled provided by the maintenance
engineer.
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Cleaning plans
1.Shift cleaning
Drain and clean final rehinse tanks
2.Daily cleaning
Drain and clean post caustic tank
3.CIP time cleaning
Drain and clean prejetting, post caustic and water
tanks
Alcafoam (hypo foam) disinfection of the infeed and
discharge area
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cont.…..
4.Weakly cleaning
Preparations -water hose
-hypo foam spraying
-brush, broom, polish pad etc.
Dis assemble the infeed bottle guides and clean using
polishing pad, alcafoam and rinse with water
Drain and clean the prejetting, postcaustic and water tanks
Generally clean all the activities listed in the cleaning
checklists by following the SSOP and wearing PPEs.
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Washer Management
Caustic replacement and recovery
Caustic disposal
Heat and energy conservation
Water conservation
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Caustic replacement
As the dirt ,soil, oil and label glue are
removed in the washer, they are
broken down by various additives and
to form carbonates
Carbonate level tells us how dirty the
caustic is (effective caustic 1.8-2.2) ％
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Caustic disposal
Caustic and heat kills WWTP bacteria
so before draining caustic should be
neutralized
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Heat and Energy Conservation
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Water Conservation
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Cont....
Each rinse tank pumps the water to
both internal and external sprays, so
that both the inside and outside of the
bottle is repeatedly rinsed.
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Cont.....
The water gets dirtier and warmer
as it moves backwards through the
machine
The bottle gets cleaner and cooler
as moves towards the discharge
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Hydrogen Explosives
Foil labels = aluminum
Aluminum + caustic = hydrogen
Hydrogen is explosive
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Improvement points
Empty bottle pocket runout
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Clean the washer as often as needed!!
Thankyou!!
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