technical report of summer training at bisleri manufacturing soda plant ,sahibabad. this includes working of hydraulic machine, pneumatic system, RFC machine , and brief working of various other sensors linked with the system , making it a closed loopsystem.

1. Bisleri International Pvt Ltd.
Project Report on Industrial Visit
For
Bisleri International Pvt ltd.
MASTERS OF TECHNOLOGY (M.TECH)
ROBOTICS AND INDUSTRIAL AUTOMATION
UNIVERSITY OF PETROLEUM AND ENERGY STUDIES
Dehradun
Submitted by:-
Anirudh Mehlawat
M.tech Robotics

2. Acknowledgment
The industrial visit to Bisleri International Pvt ltd, located at Sahibabad, Delhi
which started on 26th
may, 2014 was a part of my curriculum of M.tech course as
summer training.
I express my sincere thanks to Mr. Karamjeet singh for allowing me to do my
internship at this esteemed organization and allowing me to learn technical
aspects of machinery involved in manufacturing of Bisleri Soda and mineral water.
I express my thanks to Mr. Anand Prakash and other working staff to help me and
guide me regarding the technical knowledge about automated machinery during
my industrial visit.
This industrial visit is really a great experience for me. After going through the
various processes while visiting the plant, I realized the various operations play a
significant role in manufacturing and production sectors. Lots of queries and
doubts are cleared by the working staff during the visit.

3. Index
Sr. no. Content
1 Introduction
2 Manufacturing Process
3 What we learnt?
4 Problems faced
5 Conclusion

4. Introduction
Bisleri is a brand of bottled water in India. Bisleri has 36%
market share in packaged drinking water in India.
It is available in 8 pack sizes: 250ml cups, 250ml bottles, 500ml,
1 litre, 1.5 litres, 2 litres, 5 litres, and 20 litres. Its operations
run throughout the subcontinent of India and are one of the
leading bottled water supplying companies in India.
In Delhi, Sahibabad there are six lines of manufacturing bottled
water in various sizes of 250ml, 1 litre, 2 litre, 600ml soda,
20litre jar, 250ml cup.
I was assigned to work on 600ml soda line manufacturing belt
and learn its technical aspects of various machines involved in
the manufacturing process.

5. Manufacturing process
Machines used in manufacturing process of Soda line plant.
• Water treatment section
• Bottle making section
• Bottle filling section
• Bottle packaging section
• Utilities
Water treatment section:-
This consists of all the equipments required for all the processing of waters. Broadly it
can be classified into pre filtration, which involves removal of physical impurities, odor
from RAW water. Next is RO filtration that is nothing but the membrane filtration which
is reverse osmosis process. Then after that post filtration which includes U.V ,
Ozonation, and CO2 addition for soda process and added minerals etc.

6. Bottle making section:-
The bottles used for drinking water plant are called pet bottles which are made of plastic
perform, these look like small plastics test tube and when these small test tube are blown with
high pressure air in bottled mould, this is how a PET BOTTLE is made. And these small perform
are made of small plastics granules and manufactured by the injection moulding process.
In this plant, perform and caps for bottles are being imported from other companies
SHREENAINA plastics, solan, himachal.
These machines are controlled by semi automatic instructions, the automatic working of
machine instructions are fed to PLCs. In this blowing machine, the Siemens PLC is working as a
heart of the machine in which instruction are being programmed which can be changed or
managed according to our desired values, but various aspects of machine like speed,
temperature, pressure,etc can be controlled manually through Human Machine Interface(HMI)
panel and operator can handle it easily as it is easy to understand.
This machine has following set of small machines.
• High pressure Air compressor:- It gives high pressure air to the mould of around
32kg/cm-sq and even helps in moving hydraulics system in the machines. The mould
cavity is heavy, so the cavity is moved with the help of hydraulic cylinders and this
system is controlled by the high pressure.
Low pressure air compressor:- It gives low pressure air to the pneumatic cylinders. This
pressure helps cylinders to move in both the direction of forward and backward with
the help of proximity sensors and helps to move the small conveyor belts, which have
preforms mounted on them and made to reach them to the mould cavity.
• Preform heater:- The perform are required to be totally dry before being blown to
maintain the bottle quality. So the heater preheats them to remove the moisture.
There are 3 heaters in this machine and their temperatures ranges from 40-115 degree
Celsius.
• Preform conveyor:- There are small conveyor belts in machine which carry these
preforms mounted on nozzle like structures through heaters and finally place them in
the mould cavity. These conveyor are moved with the help of pneumatic cylinders
which work according to proximity sensors present on the surface of cylinders. These
sensors detect presence of any metallic object in its range and operate accordingly in
both the directions.

7. • Blowing machine:- on this machine the mould cavity is mounted. When preforms
comes in this cavity region, a high pressure air being blown to the prefroms and this
pressure make the preform to take the shape of cavity of mould and hence turned out
to be bottle . This works with the help of high pressure of 32kg/cm-sq .
• Mould chiller:- As the temperature during the bottle blowing is quite high, it may
distract the bottle shape , so to avoid such instances , we make the mould temperature
lower by the running cooled water through the core of it, to keep the mould cold and to
carry out the process easily and swiftly.
Bottle filling section:-
In this section, RINSER-FILLER-CAPPER machines are used for the desired purposes. An empty
PET BOTTLE is fed to the RFC machine on which it is rinsed, filled to the desired level and cap is
applied at the capping station. The speed of these machines vary from 30 -120 BPM but the
average speed of this machine in this plant is 60 BPM(Bottle Per Minute) capacity.
• The working instructions and controlling power of these machines lies in PLCs of
Siemens but the speed of this machine can be controlled manually by operator.
• Carbonation tank is used in soda line belt, to convert drinking water into soda by adding
and mixing CO2 in it, at a high pressure of 80kg/cm-sq.
• These machines runs on the 3-phase induction motors drives at each and every stage
from rinsing section to the capper section and then these filled bottles moves to the
next level on plastic conveyor belts with the help of induction motor drives.
• HMI (Human Machine Interface) can be used by operator to set various parameters of
the running machine.
RINSER:- As empty bottles enter the position sensor detects the object and send a signal to
counter to make it count and after that stage, bottle moves to the rinser which rinse the bottle
after getting its switched turned on by turning the side wheels, this happens when bottle
moves up on the nozzle of the rinser and then rinser with the rinse the bottle with water at low
pressure of 2kg/cm-sq. This rinser is in semicircular shape and consists of 12 pressurized
nozzles.

8. FILLER SECTION:- This section consist of 12 filling nozzles and a tank to store water. This tank
acts like a refrigerator for cooling thee incoming water and this tank is equipped with 2 gauges
– one for pressure and another for temperature monitoring of water. The pressure would be of
4kg/cm-sq and temperature would be in the range of 8 -10 degree Celsius.
Filler consist of circular shape and 12 filling nozzles connected to it and a rotating wheel attach
to every nozzle, which help in opening and closing of filler valve from the tank to the nozzles. In
first half of rotation period, the wheels open the valves and in next half it close the nozzle
mouth to protect the overflow of water and if somehow extra water comes into nozzle, it
pushes the extra water out with pressure.
In first half of filler, when bottle mounts on the nozzle, when wheel turn on the water inflow,
the CO2 mixed water starts filling in the bottle with pressure to create the gas pressure in the
bottle and in next half, when water flow stops due to closing of valve, the extra pressure pushes
the extra water out of the nozzle to keep nozzle empty for another process.
The bottle filling process consist of smooth movement of circular tank and bottles movement of
up and down smoothly and this up-down movement is carried out with the help of hydraulic
cylinder which carry the bottle filling process smoothly without any interruptions.
CAPPER:- This is a bit complicated system consisting of hydraulic and pneumatic systems,
working individually. Hydraulic cylinder system consist of four rotating cylinder, which used to
tighten the caps on the bottle mouth whenever the bottle reaches to the capper. When this
cylinder got hold of caps and bottle in the lower rotating ring, then the cylinder takes 15 rounds
to tighten the caps on mouth of the bottle and these rounds are called DARK.
And, now the working of pneumatic system is mainly on caps travelling from the hopper to the
capper section. In this process, when caps reaches to a certain level height with the help of
plastic conveyor belts, they got pushed by the air pressure, which was generated from the 3
phase induction motor and was by pass to that level with the help of 2/2 solenoid actuated,
spring return valve of FESTO company.
After the push, the caps travel through the tunnel consisting of 2-3 position sensors which
detect the objects and responds according to that positions and a UV heater which removes the
bacteria present in plastic caps. These position sensors helps to give the signal about the caps
limit , like if there are no caps then sensors will send the signal to conveyor belt to move and
bring more caps upward and through tunnel to the capper system or if the position and if its
filled then the signal to stop the motor of the conveyor.

9. The above system of RFC machine is a perfect example of a closed loop system where every
stage is linked to every stage via sensors at each stage and even at intersections. These sensors
are position sensors only, which when detect any discrepancy of overloading or emptiness
these give back a signal to the respected motors to stop or to move and even in some cases it
turns on the alarms system of the RFC machine.
BOTTLE PACKAGING SECTION:- There are 3 major stages in this region, which includes Labeler,
Bottle coding machine and last shrink packaging machine.
• Labeler machine:- in this machine , bottles get a label on it with the company name ,
but to align that label on the desired space on bottles that is the task of this labeler
machine. This process includes various interfacing of sensors and other parts of the
machine. The sensors are zero mark senor, print mark sensor, label present sensor and
infrared sensor.
Zero mark sensors- This sensor marks the position of label at the lower and upper side
space where this label have to stay to match the level.
Print mark sensor- This sensor marks the position of label at upper side by reading its
black print mark and adjusting it to stick to space made for label on the middle, big
rotator.
Label present sensor- This sensor is placed at the first cutter of labeler machine, which
will cut the label of required length after getting a signal from the sensor which detects
that the label is coming into the labeler machine.
Infrared sensor-this sensor is placed at the centre rotating wheel, where this labels
sticks on the space and this infrared sensor used to detect the presence of it and to
count the number of it.
This machine consist of a rotor kind of cylinder in between on which this label sticks on
the desired space for the label with the help of air, first air pressure and then air
pressure pulling it in through the holes located at space bound and then the label gets
soaked by hot melt gum, which was in a column and this gum comes from the hotmelt
gum chamber which have temperature of about 115-150 degree Celsius. While taking
the round, when bottles comes in the label machine the glue soaked label get stick to it
on the desired space of the bottle.

10. Bottle coding:- This machine is used to give regular date of manufacturing and batch no. of the
product on the bottles surface. The coding for this purpose is fed into the coding machine and
can be altered by the button panel on it, and this regular changing coding machine is
programmed, again with the help of PLCs and this machine is also mounted with a infrared
sensor, with the help of which the machine will only print when there is any product is in front
of sensor and the printing nozzle.
Shrink Packaging:- After all this process cycle, the drinking soda or mineral water is ready for
packaging, where these are packed in a shrink packaging machine. In this machine, these
bottles are packed in plastics sheets and then these packing went through the machine with
burners of temperature of around 300-350 degree Celsius and this temp range can be altered
depending on the plastic sheet material.
When some number of bottles are placed on this machine, the pneumatic system working
plank hold the bottles under plastics sheets and with the help of thermocouple cutter cum
heater, those bottles are packed and then that packet moves through the shrink heater
machine where it shrinks the plastics and tightens the packaging, and then the product is ready
to be dispatch to the loading department.

11. What we learnt?
• Practical knowledge of theoretical fundamentals with various technical
aspects and under various conditions.
• A working condition of the machines and their interfacing with other
machines.
• Brief and basic working terminologies and requirement of manufacturing
of mineral water plant.
• Defects and problems we can face in various machines at various stages
and how to respond to it.

12. Problems occurred
• Mould defects in blow moulding machine.
• Pressure leakage in blow moulding machine.
• Pressure leakage in Filler section of RFC machine.
• Improper cutting of labels on labeler machine.
• Thermocouple was not working properly.

13. Conclusion
This period of training has proved to be quite faithful. It proved an opportunity to
encounter such machines and their co- operations with other machines.
The architecture of BISLERI, Sahibabad , was a example of space utilization and
the way various units are linked and the way the working of whole plant is
controlled makes the visitor realized that engineering is a greater part of planning
and management. It means that it provides a opportunity to learn technical things
easily, use of places properly, which save lot of time and labor.
However, training turned out to be satisfactory.