MALAWI UNIVERSITY OF SCIENCE AND TECHNOLOGY
MALAWI INSTITUTE OF TECHNOLOGY
ENGINEERING DEPARTMENT
ENGINEERING DESIGN AND MANUFACTURING
FROM : LINESS PHIRI CHE/009/22
TO: DR. E. KHUNDI
COURSE CODE: EDEM 310
TITLE: WATER PURIFICATION SYSTEM FOR BREWERY COMPANY
SUBMISSION DATE: 13/09/2024
ASSIGNMENT PARTNERS : MICHAEL CHIKAIMA TXE/003/22
CHIKONDI KAPOMBO TXE/007/22
WATER PURIFICATION SYSTEM FOR BREWERY COMPANY PDS
1. INTRODUCTION AND BACKGROUND
a. Purpose
The purpose of this Product Design Specification (PDS) is to outline comprehensive
requirements for a water purification system specifically designed for brewery operations.
Water quality is critical in brewing, directly impacting the taste, consistency, and quality
of beer production.
b. Scope
This specification covers the design, functional requirements, performance specifications,
safety considerations, and operational parameters for a water purification system
intended for industrial brewery use.
2. FUNCTIONAL REQUIREMENTS
a. Primary Functions
Remove suspended solids, microorganisms, and chemical contaminants
Adjust water chemistry to optimal brewing specifications
Provide consistent water quality for various beer styles
Ensure reliable and continuous water treatment
b. Specific Performance Criteria
Water Purification Capacity
o Minimum throughput: 500 liters per hour
o Peak capacity: 1000 liters per hour
Filtration Efficiency
o Total Dissolved Solids (TDS) reduction: 95-99%
o Microorganism removal: >99.99%
Water Quality Parameters
o pH adjustment range: 6.5 - 7.5
o Hardness reduction: >90%
o Chlorine and chloramine removal: >99%
3. TECHNICAL SPECIFICATIONS
a. System Components
1. Pre-filtration Stage
o Sediment filter
o Activated carbon filter
o Water softening unit
2. Primary Purification Stage
o Reverse Osmosis (RO) membrane system
o Ultrafiltration membrane
o UV sterilization unit
3. Post-treatment Stage
o Mineral adjustment system
o pH balancing unit
o Final polishing filter
b. Materials
Frame and Housing: Food-grade stainless steel (AISI 304)
Piping: Pharmaceutical-grade stainless steel
Membranes: Thin-film composite (TFC) RO membranes
Seals and Gaskets: FDA-approved elastomers
c. Electrical and Control Systems
Voltage: 3-phase, 380-440V
Control Panel: PLC-based with touchscreen interface
Monitoring Parameters:
o Water flow rate
o Pressure
o Temperature
o TDS levels
o Filter condition
Automatic shutdown and alarm systems
4. PERFORMANCE REQUIREMENTS
a. Operational Performance
Continuous Operation: 24/7 capability
Mean Time Between Failures (MTBF): >5000 hours
Warm-up Time: <15 minutes
Automatic recovery from minor system interruptions
b. Water Quality Metrics
Microbiological Standards:
o Total Plate Count: <10 CFU/mL
o Coliform Bacteria: Absent
Chemical Purity:
o Heavy Metals: Below detectable limits
o Nitrates: <10 mg/L
o Residual Chlorine: <0.1 mg/L
5. ENVIRONMENTAL AND SUSTAINABILITY CONSIDERATIONS
a. Energy Efficiency
Maximum Power Consumption: 15 kW
Energy Recovery Systems:
o Pressure exchange technology
o Heat recovery mechanisms
b. Water Efficiency
Water Recovery Rate: Minimum 75%
Concentrate/Reject Water Management System
Potential for water recycling and minimal waste
c. Environmental Compliance
Meets ISO 14001 Environmental Management Standards
Low carbon footprint design
Recyclable and sustainable component selection
6. SAFETY AND REGULATORY COMPLIANCE
a. Safety Features
Pressure relief valves
Automatic shutdown on system anomalies
Leak detection systems
Electrical safety interlocks
Emergency stop functionality
b. Regulatory Compliance
FDA Compliance
NSF/ANSI Standard 61 Certification
CE Marking
Local and international water treatment standards
7. MAINTENANCE AND SERVICEABILITY
a. Maintenance Requirements
Predictive maintenance capabilities
Quick-change filter cartridges
Modular design for easy component replacement
Comprehensive diagnostic system
b. Recommended Maintenance Schedule
Daily: Visual inspection, basic cleaning
Weekly: Membrane integrity check
Monthly: Comprehensive system diagnostics
Annually: Major component inspection and potential replacement
8. ECONOMIC CONSIDERATIONS
a. Cost Parameters
Estimated Initial Investment: $75,000 - $120,000
Operational Cost: $0.05 per liter of purified water
Estimated Lifespan: 10-15 years with proper maintenance
b. Return on Investment (ROI)
Reduced water treatment costs
Improved product consistency
Lower maintenance expenses
Enhanced brewing quality
9. DOCUMENTATION AND TRAINING
a. Technical Documentation
Comprehensive operation manual
Detailed maintenance guide
Electrical and plumbing schematics
Spare parts catalog
b. Training Requirements
Operational training for brewery staff
Maintenance technician certification program
Remote technical support options
10. FUTURE SCALABILITY
a. Expansion Capabilities
Modular design allowing capacity increases
Compatibility with future brewing technologies
Potential for integration with smart brewing systems
CONCLUSION
This Product Design Specification provides a comprehensive framework for developing a
high-performance water purification system tailored specifically for brewery applications,
balancing technical excellence, operational efficiency, and sustainable design principles.
