Technological diagram of water bottling. Technological diagram of vodka production. Basic requirements for the design of a mineral water bottling department

Mineral waters bottled, depending on the chemical and gas composition, as well as the filling method, are divided into four technological groups: 1) still waters; 2) carbonated waters; 3) carbonated waters containing iron; 4) hydrosulfite and hydrosulfide-hydrogen sulfide waters.

The first technological group includes the most stable mineral waters, which do not undergo oxidation during the bottling process and do not change their chemical composition.

The technological flow diagram for bottling still waters belonging to the first technological group is shown in Figure 1.15.

Mineral water from wells 1 under its own pressure or using a deep pump is supplied to a hermetically sealed collection 3 installed in a capture structure 2. From collection 3, mineral water is pumped by pump 4 into collection 5 for storage and, as needed, supplied by pump 4 to ceramic filters 6 , from where it enters the counterflow heat exchanger 7, and then into the intermediate collection. From this collection, water is supplied by pump 4 to the saturator 9, where carbon dioxide is supplied from the gasification station 35, delivered to the plant in specialized tanks 36. C02-saturated mineral water is sent through a disinfection installation 10 to the tank of the filling machine 22. Delivered on pallets 11 in bags 12 or boxes 13, glass containers are placed in boxes and fed along a conveyor belt 14 to automatic machines for removing bottles from boxes 15.

Bottles removed from the boxes are fed by a conveyor belt 14 to the loading device of the bottle washing machine 18, passing by the viewing screen 17. The washed bottles are sent by a plate conveyor 16 to the viewing screen 17 to check the quality of washing. Then the bottles pass sequentially through a filling machine 22, a capping machine 23, a rejecting semi-automatic machine 24, a labeling machine 25 and enter the machine for placing bottles in boxes 26, to which empty boxes are fed by a conveyor belt 14. Finished products, packed in boxes 27, are placed on pallets in stacks 28 for transportation to the finished product warehouse. The concentrated alkali solution is delivered to the plant in tank trucks 29, from which it is pumped by pump 30 into a collection tank 31 for storage.

As needed, the concentrated alkali solution is pumped from this collection by pump 30 into the measuring tank 32, from where it enters the container 33 for preparing a working alkali solution, or directly pumped into the measuring tank 21. The spent alkali solution is poured into the receiving collector 19 and after settling is supplied by pump 20 to filter 34, then into a container for preparing working solution 33.

Crown stopper for sealing bottles with mineral water delivered to the plant in bags 40, laid on pallets 11. From the bags, the crown cap is poured into hopper 39, from where it enters the receiving hopper of the magnetic lift 38 via a tray and is delivered by a conveyor belt 37 to the hopper of the capping machine.

The second technological group includes mineral waters, the chemical composition of which is subject to change. Since the carbon dioxide they contain is a stabilizer of the chemical composition, bottling of such waters must be carried out under conditions of slight excess pressure created by CO 2, which will minimize the possibility of degassing.

The technological scheme for bottling mineral waters belonging to the second technological group is identical to the one given above, but all technological operations associated with their transportation, storage and bottling are carried out under slight excess pressure of CO 2.

The third technological group includes waters containing from 5 to 70 mg of iron per liter.

To avoid the formation of sediment in the bottle when bottling these mineral waters, conditions must be provided to prevent iron oxidation and degassing of the water during the bottling process. For this purpose, a solution of stabilizing acids - ascorbic or citric - is introduced into mineral water.

Mineral waters containing iron are classified as shallow circulation waters. They are most susceptible to bacterial contamination. Secondary water pollution is possible during pumping, storage, processing and bottling. The introduction of organic acids can serve as a source of nutrition for non-toxic microorganisms found in mineral waters, in particular sulfate-reducing microorganisms. Therefore, mineral waters containing iron must undergo mandatory disinfection. The C0 2 content in the finished products must be at least 0.4% in weight, and for sealing they should use only crown caps with gaskets made of polymer materials.

The bottling of ferruginous mineral waters belonging to the third technological scheme is carried out according to the generally accepted technological scheme shown in Figure 1.2

An additional process of stabilizing the chemical composition of water during bottling is carried out according to the following technological scheme. Mineral water from well 1, located in the hood structure 6, enters a hermetically sealed collector 3, equipped with a safety valve 2 and a pressure gauge. From this collection, water is pumped by pump 4 into collection 5, from where it is transferred to production. A solution of stabilizing acid is added to the supply pipeline to collector 5, a concentrated solution of which is located in collector 8. The working solution is prepared in collectors 7 equipped with stirrers.

Figure 1.2 Technological flow diagram for bottling non-carbonated mineral waters belonging to the first technological group

In the case of transporting mineral waters containing iron over a distance of up to 200 km, sealed tank trucks are used, from which the air is first displaced with carbon dioxide supplied from carbon dioxide cylinders. The stabilizing solution is introduced into a tank or intermediate container, from which the air is also previously displaced.

When using two-chamber tank trucks for transportation, the CO2 air is sequentially displaced and each chamber is filled with water separately. The completeness of air displacement from tanks and intermediate containers is checked by the turbidity of barite or lime water through which the air leaving the tanks or intermediate container is bubbled. After complete displacement of air from the tanks or intermediate container, the supply of CO 2 is stopped. Tankers are filled with mineral water to 9/10 of the volume. Mineral water is transported under slight excess pressure of C0 2.

For bottling hydrosulfide-hydrogen sulfide and hydrosulfite waters, combined into the fourth technological group, mineral waters containing hydrogen sulfide up to 20 mg/l and hydrosulfides up to 30 mg/l can be used. Since the reduced forms of sulfur contained in these waters are predisposed to oxidation with the formation of colloidal sulfur, causing opalescence of the water, and, in addition, neither hydrogen sulfide nor hydrosulfidiones are useful components of water, a technological method aimed at removing them from the composition of mineral waters.

The bottling of mineral waters, combined into the fourth technological group, is carried out according to the technological scheme shown in Figure 1.15, with additional water treatment in a scrubber. To do this, mineral water from a storage tank is pumped into the upper part of a scrubber filled with Raschig rings. At the same time, CO 2 is supplied to the lower part of the scrubber. Water flowing in a thin layer over the surface of the rings. Rashiga, intensively contacts with CO 2, and the equilibrium shifts towards the formation of hydrogen sulfide, which is removed from the mineral water by a current of carbon dioxide. The desulfurized water is pumped into a storage tank, and the carbon dioxide leaving the scrubber can be treated and reused.

Shop for bottling drinking water into bottles of various sizes:

The diagram below shows bottling shop- option for placing a water bottling line with a maximum capacity of 80 bottles per hour. That is, a thermal tunnel for shrinking caps and a packer for 19 liter bottles in PE bags are optional equipment and are purchased at the request of the customer.

This diagram of the bottling shop is approximate - for a preliminary understanding of the required room dimensions. To order a detailed layout of equipment at production sites for your business,

The diagram below shows an option for placing equipment for filling 19 liter bottles with a capacity of 150 bottles per hour. The basis of this line is QGF-150 WellSpring.

The last diagram shows a placement option with a capacity of 240 bottles per hour.

These diagrams are typical and are shown on our website as an example. The engineers of our Service Center will develop a project for placing a bottling line for water and drinks on production sites specifically for your enterprise, taking into account productivity and the supply of communications.

Layout of equipment in the bottling workshop " ":

in a 19 liter bottle, as a rule, includes the following set of equipment:

	Automatic filling line (productive)	detailed information
1	Automatic machine for removing old plugs	The quite understandable desire of the population of large cities to consume environmentally friendly “living” water is actively supported by its producers, who are setting up production for bottling water and supplying this kind of “fuel” both to offices and to private clients. To organize a small business for the production of bottled drinking water (water bottling), a production facility is sufficient, in which the entire production process is carried out in two main stages: water purification and water bottling on special equipment, followed by group packaging. You can find out more about the water bottling process in the description of the equipment on our website.

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Introduction

Liquor production is one of the branches of the food industry that produces alcoholic beverages and alcoholic beverages. Modern production of vodka and liqueurs is based on the use of high-tech and sophisticated equipment, new materials and reagents. For the qualified use of new technologies and materials, a deep understanding of the physical and chemical processes of dissolution, adsorption, diffusion and others is required important processes occurring during the transformation of raw materials and semi-finished products into finished products.

IN last years There have been major changes in water treatment technologies. Reverse osmosis water conditioning units have become widespread, but their use requires a different approach to the organization of the entire production as a whole, knowledge of the essence of the processes underlying reverse osmosis and the ability to manage this process.

Washing bottles is a necessary condition for ensuring product quality, since when using returnable containers, bottles may bear old labels or have persistent contamination. Before washing dishes, they are sorted depending on the degree of contamination. Normally soiled bottles are sent directly to the bottle washing machine. Over-normally soiled bottles are pre-washed (soaked).

Bottles with excess contamination are sent to the pre-wash, which is divided into alkaline and acid-base washing.

Alkaline washing is a dishwashing that requires the use of an alkaline solution of high concentration, carried out on bottle washing machines in the following mode:

The alkali concentration in the baths is 3%;

The machine's productivity is halved;

If there is a second bath, the temperature in it is maintained at 70-80°C;

Injection and external washing of bottles is carried out with water at a temperature of 40-45°C;

Pre-washed contaminated dishes are sent to the machine for a regular wash.

Acid-alkaline washing. For heavily soiled dishes (salt deposits, rings on the walls, etc.), which must be pre-treated with acid, as well as for contaminants that require treatment with a high concentration of alkali (residues of grease, etc.), manual pre-acid-base treatment is used. processing in special washing troughs or other devices. Heavily soiled dishes are washed in a separate room, isolated from the washing and filling shop. In this case, it is necessary to follow the safety rules provided for when working with acids and alkalis.

Depending on the type of contamination, bottles are treated with solutions of soda ash or hydrochloric acid using a brush.

1. Technological part

Selection, justification and description of the technological scheme.

Vodka and other alcoholic beverages are bottled in glass bottles. This course project presents a good scheme for purifying water for washing bottles with the possibility of its reuse. Water is a very expensive commodity for businesses, so the ability to reuse it will significantly reduce financial costs. Another advantage is the complete automation of the washing process, water purification and detergent regeneration.

Water from the water supply is directed to the sand filter (1), then to the AQUA-Electronics microfilter (2). With the help of these filters, water is freed from suspended matter and iron salts. After pre-treatment, the water flows into the water collector (16). If necessary, stabilizing additives are supplied to it using metering pumps (15) - dilute solutions of sulfuric acid from the tank (13) and polyphosphates from the tank (14). For ease of use, reagent solutions are prepared once a day. Next, the water is processed in a bactericidal installation (17) and sent to a storage tank (18), from where it is pumped into a cascade of reverse osmosis devices (21) through a hydraulic accumulator system (19) using a three high-pressure plunger pump (20).

The quality of purified water is controlled by a salinity meter (23), and the quantity is controlled by a flow meter (22). Using the pump (6), the softened water is directed to the pressure tank (7). Water obtained by the method described above has the following indicators: total hardness 0.02-0.22 mg*eq/dm³, alkalinity 0.16-0.3 mol/dm³, oxidability 0.2-1.5 mg O2/dm³, low content of microelements.

The reverse osmosis unit operates on water with a salt content of up to 0.5 g/dm3. When using the installation, no pre-treatment of water is required. When the salt content is from 0.5 to 30 g/m3 and above, as well as when the water turbidity is more than 1.5 mg/dm3, microfiltration, ultrafiltration and Na-cationization must be introduced before reverse osmosis treatment of water.

A simpler method for preliminary water preparation is Na-cationization. If the total hardness of the water is high, it is treated by passing it through filters (1), (2) and a Na-cation exchange filter (4). Regeneration of the Na-cation exchange filter is carried out with a salt solution supplied from a salt solvent (3). Softened water is collected in a collector (5), after which it is sent to a pressure tank (7), and then treated according to the previously described method. This water is needed to rinse bottles in a bottle washing machine.

Boxes with dirty bottles come from the warehouse to a machine that removes bottles from boxes (24). Boxes with bottles are fed to the machine and stop under the head with grippers. The head then lowers into the drawer and grabs the necks of the bottles, lifts up and carries the bottles to the table. The empty box moves further along the conveyor, and the next box takes its place.

The bottles are sent by a plate conveyor (25) to a bottle washing machine (26) with an alkaline solution coming from the tank (10). In a bottle washing machine, new bottles are only rinsed, while return bottles are pre-cleaned, and then they are washed in the machine with cold and warm water and an alkaline solution. Sodium hydroxide, sodium carbonate, trisodium phosphate, sulfosalts, etc. are used as detergents. The concentration of the alkali solution for manual and semi-automatic washing machines is 1.0-3.0%, for automatic ones - 1.8-2.0%, the solution temperature must be at least 80°C.

The alkali solution is prepared in a mixing tank (10), where alkali and water from the collection tank (8) flow through the measuring tank (9) directly from the tanker through the pump (6). You can also use the used solution for washing. To do this, from the bottle washing machine through the pump (6), the alkali solution flows first into the ceramic filter (12), and then into the regeneration column (11). After the column, the alkali through the pump (6) enters the mixing tank (10).

The wastewater from the bottle washing machine is used for treatment. First, the waste flows by gravity into the collection Wastewater(27). After this, the pump (6) goes to the settling tank (28), where it is settled from suspended particles. From there, the settled water is passed through the pump (6) to the sand filter (29), where final purification occurs, after which the purified water is supplied to the purified water tank (8) by the pump (6).

Requirements for raw materials, auxiliary materials and finished products

Drinking water GOST 51232-98

Requirements for water quality according to SaNPiN 2.1.4.1074-01

Finished products:

Glass bottles GOST 10117-91

Crown plug GOST 10167-88

Carbon dioxide GOST 8050-85

Labels GOST 16 353

Dextrin glue GOST 7699

Detergents and disinfectants GOST 5100

Ethyl alcohol GOST R52522-2006

Vodka GOST R51355-1999

1. Vodkas and special vodkas must be prepared in accordance with the requirements of this standard according to technological regulations, instructions for the production of vodkas and special vodkas and recipes in compliance with sanitary standards and rules approved in the prescribed manner.

2. Depending on the taste and aromatic properties, the content of ingredients, vodka is divided into vodka and special vodka.

3. In terms of organoleptic characteristics, vodka and special vodkas must meet the following requirements:

Characteristics: transparent liquid without foreign matter and sediment

Color: colorless liquid

Taste and aroma: characteristic of vodkas of this type, without any foreign taste or aroma. Vodkas should have a mild, characteristic vodka taste and a characteristic vodka aroma; special vodkas - soft taste and emphatically specific aroma.

Table 1.

Table 2.

Technochemical and microbiological production control

Technochemical control is very important in the liquor industry, which produces high-quality liqueurs, liqueurs, tinctures and vodka in a wide range from valuable raw materials - ethyl alcohol, plant materials and food products (sugar, essential oils, etc.). Technochemical control is aimed at improving product quality, introducing rational technologies, complying with consumption standards for raw materials and materials, and reducing their losses.

Technochemical control is a set of indicators characterizing the chemical composition and physical and chemical characteristics of raw materials, intermediate products, auxiliary materials used in the production of finished products, as well as establishing the identity of the results obtained with the values of the relevant standards. Technochemical control involves the determination of a set of indicators that provide complete information about the quality of the product based on the analyzes performed and data from control measuring instruments. One of the main tasks facing the technical and chemical control service is monitoring the progress of the technological process, the quality of raw materials and finished products. High quality products can only be obtained by using raw materials whose quality meets the necessary requirements, and by observing optimal technological conditions for the production of the final product. Even the most minor deviations in the quality of raw materials and violations in the technological regime lead to the release of finished products Low quality or to marriage. These deviations are detected only with the help of technochemical control. Technochemical control at enterprises must ensure compliance with technological regimes of recipes, checking the quality of raw materials, intermediate products and finished products in accordance with standards and specifications.

An important link in carrying out technochemical control is the analysis methods themselves, which must give accurate and reliable results. Based on such results, it is possible to develop and refine the technological regime, outline ways to eliminate shortcomings and losses in production, and prevent the release of low-quality products. Such control can be the most effective, since technochemical control serves not only to identify defects in finished products, but also to prevent them, as well as to eliminate situations leading to defects at all stages of the production process.

Table 3. Technochemical control

Table 4. Microbiological control

Production accounting

During the production of vodka, liqueurs and low-alcohol carbonated drinks, records are kept of basic and auxiliary materials and finished products.

The consumption of basic materials is determined taking into account recipes, technological instructions, as well as taking into account inevitable production losses.

The production loss rates depend on the technology, the equipment used, its condition, production discipline and other factors. The loss rate is established at various stages of production and is rechecked at least once every 5 years.

Vodka accounting.

Water-alcohol solutions in the purification department and finished vodka are taken into account by volume and anhydrous alcohol content in them. Finished products, i.e. packaged in bottles, decorated and placed in corrugated boxes, are taken into account quantitatively and expressed in deciliters.

Finished products transferred to the expedition, as well as sold to the distribution network, are taken into account by the number of boxes, the number of bottles and finally in deciliters.

To count bottles and boxes, the plant uses counting devices, mainly of the electric contact type.

Alcohol_inventory.

When taking inventory of alcohol in industrial premises, the volume of alcohol in measuring tanks and other tanks is determined by readings from level meters. In this case, each container must have a State verification certificate in the prescribed manner. At the same time, measure the strength and temperature of the alcohol in each tank.

The amount of semi-finished products (alcoholized juices, fruit drinks, infusions, aromatic alcohols), aqueous-alcoholic solutions, vodka, alcoholic beverages and low-alcohol carbonated drinks in tanks, correctable and irreparable defects is determined by the readings of measuring glasses in deciliters and at the same time the temperature of the liquids is measured, samples are taken for determination of strength from each container.

In the vodka department, the amount of water-alcohol solution in the filters is taken into account, and the amount of alcohol-containing liquids in the communications is indicated. Accounting for alcohol in communications and the filtration battery is carried out according to reports of the presence of alcohol in the equipment.

In exceptional cases, the aqueous-alcoholic liquid is drained from the equipment and measured.

When determining anhydrous alcohol in semi-finished or finished products with a significant content of extractive substances at temperatures above or below 20°C, the volume of the product is reduced to 20°C. Bringing the volume to 20°C is carried out according to special tables, which take into account the volumetric expansion of products depending on the content of extractive substances and alcohol in them. The amount of anhydrous alcohol is found by multiplying the strength at 20°C by the volume of the product reduced to 20°C.

Accounting for alcohol and sugar is carried out in order to control the technological process, in order to save material resources and for the purpose of_full_reporting.

2. Calculation part

vodka raw microbiological recipe

Product calculation

Recipe for vodka "Michurinskaya":

rectified alcohol "Extra",

softened water,

apples 3 kg,

carrots - 0.82 kg,

sugar - 6 kg.

The calculation is carried out per 1000 decalitres of the product.

Table 5

According to the standards confirmed by the Ministry of Food Industry, losses are accepted:

Alcohol 0.94%,

Correctable defects 1.7%,

Uncorrectable defects 0.7%.

Calculation of the amount of alcohol

To determine a given amount of alcohol consumed for the preparation of vodka, it is necessary to take into account its irretrievable losses during the preparation of sorting, processing it activated carbon, filtration, and bottling. These losses are calculated as a percentage of the amount of alcohol entering production. We accept the following values of alcohol loss.

Table 6

To prepare this type of vodka, we use rectified alcohol produced from grain potato raw materials, with a strength of 96.4%. The consumption of anhydrous alcohol for the preparation of 1000 dal of sorting, taking into account the strength and losses in production, will be

V = =403.76 dal

Consumption of rectified alcohol "Extra" with a strength of 96.4% vol.

V = = 418.84 dal

Calculation of the amount of corrected water.

Taking into account the contraction of the alcohol - water mixture to obtain 40% vol. sorting to 100 dal of alcohol with a strength of 96.4% vol. water consumption will be 142.2 dal. For 1000 dal of product, the water consumption will be:

V water = 595.59 dal

Calculation of sorting quantity.

The amount of prepared sorting is greater than the amount of vodka received, because part of it is returned to prepare the next sorting, part is lost when washing filters and coal columns and during regeneration is returned in the form of irreparable waste. We take the amount of losses equal to 1.7% of the total amount of production. In addition, sorting losses occur with faulty scrap, which cannot be reused. Taking into account these losses, the sorting volume will be:

V grade. = = 1033.4 dal,

where: 1.7 - the amount of correctable defects%,

0.7 - the amount of irreparable defects%,

Volume of correctable defects

V isp.br. = = 17 gave

V unused br. = = 7 gave

If we take into account the losses of vodka in the purification shop and assume that in the bottling shop all irreparable defects are obtained in the amount of 0.5% of the volume of all products, then the volume of vodka in the finished vats will be:

V = = 1015 dal

Table 7. Summary table of raw material consumption per 1000 dal of product

Products	Units	Product quantity
Rectified alcohol
Corrected water
Sorting
Repaired marriage
Unrepaired marriage
Vodka in finishing vat

Table 8 Summary table products

Products	Unit	Product size

Rectified alcohol
Corrected water
Sorting
Repaired marriage
Unrepaired marriage
Vodka in finishing vat

Calculation and selection of equipment

In order to select equipment for this technological scheme, you need to calculate the number of bottles produced per hour, that is:

a=10*1900000*1.02*0.3/21*3*8*2*0.9*0.5=12817 bottles/h

We select 2 lines with a capacity of 6,000 bottles per hour

Energy calculations

Table 9. Calculation of electricity consumption

Table 10 Calculation of steam consumption

Table 11 Calculation of water consumption.

Table 12 Calculation of compressed air consumption

Table 13 Summary table of energy calculations

3. Occupational safety

The main harmful and dangerous substances in alcohol and liquor production are bulk raw materials, carbon dioxide, alcohol and alkali, and hazardous areas are technological equipment operating under pressure.

To create healthy and safe working conditions in production, it is necessary that all technological equipment and technological processes meet safety requirements.

In the china shop, it is necessary to comply with the requirements of the Rules when storing boxes.

When stacking by hand, boxes with dishes should be stacked in stacks of no more than 2 m. The main passage between stacks must be at least 2 m wide.

The temperature of bottles entering the bottle washing machine must be at least 10°C.

Bottle washing machines should be located on the lower floor. If bottle washing machines are located on the 2nd floor, it is necessary to provide waterproofing measures against possible leakage of washing liquid through the ceilings.

Storing concentrated acids and alkalis in the washing area is prohibited.

The bottle washing machine must have a locking device to disable the drive in the following cases:

When the bottle transporter is loaded or jammed;

When the working bodies for loading and unloading bottles become jammed;

If the bottles do not fall out completely from the bottle carrier nest;

When the outlet conveyor is overfilled with bottles;

When the pressure in the water supply network at the entrance to the machine drops and the temperature of the washing liquids changes.

Filling the baths of a bottle-washing machine with cleaning solution and loading cassettes with bottles must be mechanized. Cleaning solutions should be prepared in a separate room. Broken bottles can only be removed from the working parts of the machine using special devices (hooks, tongs, etc.)

Glass debris generated during machine operation should be removed only after the machines have stopped and should not accumulate near the equipment.

4. Industrial sanitation

The main task of industrial sanitation is to prevent the adverse effects of harmful production factors in order to ensure safe working conditions, eliminate the causes of occupational and work-related morbidity, as well as premature fatigue.

In food enterprises, harmful factors primarily include factors affecting the functioning of the respiratory system, circulatory system, nervous system, organs of vision and hearing.

Harmful substances

The main harmful substances that pollute the air at food enterprises are dust of organic and mineral origin, various gases and vapors generated during the processing of raw materials, starting materials, the creation of intermediate products, products, as well as those contained in production waste. Harmful dusts, gases and vapors that enter the human body in small quantities through the respiratory, digestive or skin organs have an adverse toxic or pathogenic effect on it, disrupting the physiological functions of internal organs, systems or causing various diseases.

The main part of harmful substances enters the human body through the respiratory organs, which perform one of the main functions of human life support - supplying the entire body with oxygen.

To prevent adverse consequences, as well as suffocation due to lack of oxygen, it is necessary that the air used for breathing meets sanitary and hygienic requirements for the content of both its main components and harmful impurities.

Of the harmful gases and vapors, the most dangerous are carbon oxide and dioxide, sulfur dioxide, nitrogen oxides, vapors of alcohols, food essences, acids, alkalis, etc.

Collective protection measures against harmful substances

At food enterprises, to prevent the impact of harmful substances on humans, a set of collective protection measures is used, which can be divided into: technological, the main task of which is to prevent the release of harmful substances into production premises; technical, which are designed to maintain maximum permissible concentrations of harmful substances in premises; medical and preventive measures consist of systematic clinical monitoring of the health status of workers; control tests include an assessment of the content of harmful vapors, gases and dust in the air.

Microclimate at work places

The microclimate of industrial premises is the meteorological conditions of the internal environment, determined by the combinations of temperature, relative humidity and air speed acting on the human body, as well as thermal radiation and temperature of the surfaces of enclosing structures and technological equipment.

Microclimate indicators: temperature (°C), relative humidity (%), air speed (m/s) and intensity of thermal radiation (W/mI) - have absolute values of optimal and permissible values.

Industrial noise and vibration

Process equipment of food enterprises is a source of noise and vibration. Noise and vibration, being biological irritants, cause general disease in the human body.

Compliance of noise and vibration levels in workplaces with safety standards is established by comparing measured parameters with sanitary standards.

Since vibration and noise are most often interrelated, it is advisable to classify collective protection measures against them as vibroacoustic protection measures. These measures are divided into: organizational, which consist of excluding active vibroacoustic equipment from the technological scheme, using equipment with minimal dynamic loads, its correct operation, etc.; technical ones are divided into two categories: eliminating noise and vibration at the source of their occurrence and reducing the intensity of vibration and noise to the level of sanitary standards; Construction and planning measures include planning the placement of equipment to reduce its impact on people.

Individual protection means

According to their purpose, personal protective equipment is divided into personal protective equipment and safety devices; sanitary protection and emergency equipment.

Personal protective equipment and safety devices are designed to prevent or reduce to the required level the impact of hazardous and harmful production factors on workers. They are used in cases where collective protective equipment does not provide complete safety, their use is technically or economically infeasible, or is impossible under these specific conditions.

In addition to PPE, employees of food enterprises who are in direct contact with food products are also provided with personal sanitary protective equipment, which is designed to protect food products from infection and contamination.

Duty personal protective equipment is designed to protect workers when performing urgent repair work, eliminating the consequences of accidents, or for working in emergency situations.

Conclusion

In this course project, a scheme of the washing department was considered, which provided for the complete purification of used water with the possibility of its reuse. Thanks to this opportunity, economic costs for water are reduced, because water for production is a very expensive product.

Literature

1. I.I. Burachevsky et al. "Production of vodka and alcoholic beverages."

2. Faradzhev “General Technology”.

3. V.E. Balashov "Diploma design of enterprises

4. Kovalevsky "Technology of fermentation production", 2004.

5. V.S. Nikitin, Yu.M. Burashnikov "Labor safety in the food industry", Moscow: "Kolos", 1996.

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CONCLUSION

The purpose of this course work was the development of software for a programmable controller to control the technological process of bottling mineral water.

Departmental standards
technological design of bottling plants
mineral waters

Date of introduction 1986-04-01

DEVELOPED by the State Institute for Design of Food Industry Enterprises “Sevkavgipropishcheprom” of the USSR State Agroprom.

Performers: Yu.M. Zharko (topic leader), V.P. Ivakh, S.A. Antonyants, Yu.I. Rodionov, N.E. Miroshnikov, B.D. Klochkov, V.B. Labzin, S.M. Belenky - Candidate of Technical Sciences (responsible executors).

INTRODUCED by the Subdivision of Design Organizations of the USSR State Agricultural Industry.

AGREED BY: State Construction Committee of the USSR and State Committee for Science and Technology No. 45-162 dated January 31, 1986.

Scientific and Production Association of the Beer and Non-Alcoholic Industry No. 1-14/2700 dated 11/15/84.

Gipropishcheprom-2 Ministry of Food Industry of the USSR No. S-101/1371 dated 02.08.85

Central Committee of the Trade Union of Food Industry Workers No. 09-M dated June 13, 1985

Main Fire Department of the USSR Ministry of Internal Affairs No. 7/6/2887 dated June 24, 1985

Ministry of Health of the USSR No. 123-12/539-6 dated June 18, 1985

PREPARED for approval by the Institute for Design of Food Industry Enterprises “Sevkavgipropishcheprom”

Mineral water bottling shop with water storage and treatment departments (filtration, cooling, disinfection, carbonation), tableware shop;

Finished product workshop (expedition), station for loading mineral water into railway and automobile tanks; station for draining mineral water from road or railway tanks.

Production laboratory;

Compressor - refrigeration and air;

Mechanical repair shop;

Transport container repair workshop;

Electric charger;

Material warehouse;

Administrative and amenity premises.

3. OPERATING MODE OF THE ENTERPRISE, DETERMINING THE PRODUCTION CAPACITY OF THE MINERAL WATER BOTTLING PLANT

Working hours in hours - 2584;

Number of working days per year - 238;

Number of work shifts per year - 1 - 2

Shift duration - 8 hours;

The work schedule of workers is shifts, with breaks;

The duration of scheduled preventive maintenance of equipment is 20 days.

The equipment operating time fund is determined taking into account its utilization factor equal to 0.75 - 0.9 (see section).

A 1,2,3 - nameplate productivity of installed bottling equipment of various brands, bottles/hour;

H 1,2,3 - number of filling machines of the same capacity;

K 1,2,3 - coefficient of technical standard for equipment use ( K 1,2,3 = 0,9);

T- number of working hours per shift.

Note: when bottling mineral waters into bottles with a capacity of 0.33 liters, it is necessary to make the appropriate recalculation for a 0.5 liter bottle. When developing new bottling lines, the machine utilization rate may be lower and is taken in accordance with the recommendations of the machine manufacturer.

4. SELECTION OF TECHNOLOGICAL SCHEME

a) transportation (supplying water from a source to storage tanks (pipeline, tank truck);

b) water storage;

c) water treatment (filtration, cooling, disinfection, carbonation);

d) bottling and capping of water;

e) rejection;

f) labeling;

g) placing finished products in boxes;

h) transportation of mineral water to the finished product workshop;

i) storage of products;

j) quality control of mineral water and finished products.

Technological scheme 2 - for carbon dioxide mineral waters is similar to scheme 1, but only transporting water under conditions that exclude degassing; storage under sealed conditions and carbonation without a deaeration stage in saturators.

Technological scheme 3 - for mineral waters containing iron (II) compounds.

a) supply of water from a source to storage tanks under conditions excluding degassing, in automobile tanks under an excess pressure of carbon dioxide of 0.02 MPa. Before filling the tank with water, the air is completely replaced by carbon dioxide.

At the drain station:

b) preparation of working solutions of stabilizing acids;

c) displacing (draining) carbon dioxide of mineral water from the tanker into a receiving sealed tank;

d) introduction of stabilizing additives of food acids into the receiving tank for storing mineral water (it is allowed to introduce stabilizing additives into automobile tanks before filling them with mineral water);

e) storage, processing of mineral water, bottling and subsequent operations similar to scheme 1.

Technological scheme 4 for mineral waters containing hydrogen sulfide or hydrosulfite ions.

The scheme is similar to scheme 1, only before storage and processing, sulfur-containing compounds must be displaced from mineral water by bubbling the water with carbon dioxide.

Process flow diagram 5 for mineral waters containing sulfate-reducing bacteria.

The scheme is similar to scheme 1, only when treating mineral water, disinfection is carried out with chlorine-containing solutions.

Note: The introduction of “active” chlorine is carried out before filtration using dispensers. The dose of active chlorine is determined by the chlorine absorption of mineral water; the residual concentration of chlorine in water should not exceed 0.3 ± 0.05 mg/l, 30 minutes after chlorination. The preparation of a chlorine-containing solution (sodium hypochlorite) is carried out in an electrolysis installation (see paragraph 9.17.20).

5. CONSUMPTION RATES FOR RAW MATERIALS AND AUXILIARY MATERIALS

Quality indicators of raw materials and auxiliary materials should be taken in accordance with the requirements of state and industry standards, technical specifications, and in their absence - according to established industry indicators.

Mineral water consumption rates per thousand 0.5 liter bottles are 550 liters.

Mineral water losses amount to 10%.

The consumption and loss rates of carbon dioxide, auxiliary materials and bottles should be taken according to the current temporary standards at enterprises of the USSR Ministry of Food Industry.

6. STOCK STANDARDS FOR RAW MATERIALS, BASIC, AUXILIARY MATERIALS AND CONTAINERS

Name of raw materials, waste	Stock norm	Type of storage

Mineral water (before bottling)	2 days	In metallic or reinforced concrete tanks
Bottles 0.5 l	8 days	In stacks, boxes, nuclear materials
Crown cap (area utilization factor 0.3)	2 months	Floor-standing in boxes, bags	1200 ÷ 1500
Labels	1 year	On racks in packs	1200 ÷ 1500
Dextrin	2 months	On pallets in bags	1200
Caustic soda (NaOH)	15 days	In tanks
Soda ash	1 month	On pallets in bags	1250
Carbon dioxide (CO 2)	4 days 2 months	in cylinders in tanks

7. REQUIREMENTS FOR TECHNOLOGICAL EQUIPMENT AND TECHNOLOGICAL PIPELINES

a) pipeline;

b) automobile tanks;

c) railway tanks.

tightness to preserve dissolved CO 2 and ion-salt composition of mineral water, prevent bacterial contamination from groundwater leaks and eliminate the formation of solid travertine deposits on the internal walls of pipelines;

the use of corrosion-resistant material to prevent corrosion of its internal surface;

protection of pipelines from the influence of soil corrosion and the effects of stray currents;

optimal modes of speed, pressure, temperature along the entire length of the pipeline under its rational operating conditions.

8. REQUIREMENTS FOR LOCATION OF TECHNOLOGICAL EQUIPMENT

Main passages in places of permanent residence of workers, as well as along the service front of control panels (if there are permanent workplaces) with a width of at least 2 m;

The main passages along the maintenance front of machines, pumps, devices with control valves, local instrumentation, etc. in the presence of permanent workplaces with a width of at least 1.5 m;

Passages between rows of receiving or storage tanks and the wall - 0.8 m;

The distance between tanks in a row is at least 0.4 m; between paired rows of tanks at least 0.8 m;

The main passages for maintenance between tanks are at least 1.8 m;

The distance between the top of the tank and the protruding floor structures is at least 1.0 m.

a) for water with a total mineralization of no more than 8.5 g/l on ceramic filters;

b) for water with higher mineralization on plate filters.

If possible, the first stage of cooling should be carried out at mineral water sources.

Disinfection can be carried out by ultraviolet rays, treatment with silver sulfate, or chlorination.

To use silver sulfate treatment, permission from the chief sanitary doctor of the USSR is required, which is issued individually for each composition of mineral water.

10. BASIC REQUIREMENTS FOR THE DESIGN OF A MINERAL WATER FILLING DEPARTMENT

A- hourly equipment productivity, thousand bottles;

O- production of bottled mineral water per year, pcs.;

H- number of shifts per year;

τ - hours of work of the workshop per day;

K 1 - coefficient taking into account broken and defective bottles during washing;

K 2 - equipment utilization factor 0.75 - 0.90.

Produces for bottling lines. 3 ÷ 6 thousand bottles/hour K 2 = 0,9

11. REQUIREMENTS FOR THE DESIGN OF SHOPS FOR GLASS CONTAINERS, FINISHED PRODUCTS AND AUXILIARY MATERIAL STORES

Where W- the amount of dishes required to create an 8-day supply, pcs.;

Q- quantity of products produced per year, pcs.;

nn = 8);

K 1 - coefficient taking into account the loss of tableware during all production operations, taking into account the conditions of its procurement:

K 1 = 1.0314 - when transported in batches,

K 1 = 1.0793 - when transported in bulk;

n 1 - number of working days in a year.

75 boxes should be laid per 1 m2 of area. Folding metal boxes of the YaSM type, hereinafter referred to as YaSM, for 140 bottles must be stacked on top of each other in six tiers. 12 boxes of the Yasm type are stacked per 1 m2.

Where Q days - quantity of products produced per day;

n- the number of days for which a stock of dishes is created ( n = 8);

K 1 - coefficient taking into account the loss of dishes during all operations;

K 2 - coefficient taking into account the area for travel (when working with hand trucks 0.25, when working with electric forklifts, stackers - 0.5);

W- the number of dishes stacked per 1 m2.

Finished products are shipped in packages formed and bundled from polymer, wooden boxes, cardboard boxes and in YSM-type boxes.

Where Q days - quantity of finished products produced per day (average daily for the year);

n- the number of days for which a stock of finished products is created ( n = -8);

k- coefficient taking into account the area for passages (when working with hand trolleys K= 0.25, when operating electric forklifts and stackers K = 0,5);

W- number of bottles stacked per 1 m2.

The warehouse area is specified graphically by the layout of the stacks.

12. BASIC REQUIREMENTS FOR THE DESIGN OF BASIC AND AUXILIARY MATERIAL WAREHOUSES

13. MECHANIZATION OF LOADING, UNLOADING AND TRANSPORTATION AND STORAGE (STW) WORKS

	Unit change	Mineral water bottling plant, million bottles per year
	Unit change	up to 20	up to 50	up to 100	up to 250
Main production
PRTS works

Calculation of the level of mechanization of PRTS work is carried out according to the methodology of the research laboratory of complex mechanization of the Moscow Technological Institute of the Food Industry.

14. REQUIREMENTS FOR DESIGNING A PRODUCTION LABORATORY

Name of premises	Area of premises (m2) at the plant with a capacity of million bottles. in year
Name of premises	up to 100	over 100
Chemical
Microbiological with box
Weight
Washing-autoclave
Pantry
Manager's room laboratory
TOTAL:

	Name of production unit and profession	Number of people
	Head laboratory
	Chemical engineer
	Bacteriologist
	Senior Assistant
	Laboratory assistant
	Hygienist engineer
	TOTAL:

15. REQUIREMENTS FOR MECHANICAL REPAIR WORKSHOPS AND CHARGING STATIONS

16. CONSUMPTION RATES OF WATER, STEAM, COLD, AIR

The consumption of water, steam, electricity and carbon dioxide for technological processes must be taken according to the passport data of the installed equipment.

Determination of the cold consumption for cooling mineral water before saturation is carried out according to generally accepted thermotechnical formulas.

Specific consumption of water, steam, electricity per 1000 bottles is determined by the formula:

Where Q about. - specific costs per 1000 bottles. (0.5 l);

Q g - annual expenses;

n- plant productivity bottles/year;

Q g - is defined as the product of the sums of hourly costs (water, steam, electricity) spent on technological processes, equipment washing, auxiliary and household needs by the number of hours of work per shift and the number of shifts per year.

When making aggregated calculations of energy resource needs, the specific consumption of water, steam, cold, electricity, CO 2 and compressed air should be taken according to table of unit costs.

Water consumption for washing process equipment should be 0.1 m3 per 1000 bottles. bottling, for rinsing railway tanks 9 m 3 per 1 tank, for washing the floors of industrial premises 3 liters per 1 m 2 of floors.

17. SPECIFIC COSTS FOR TECHNOLOGICAL NEEDS FOR BOTTLING MINERAL WATER, SPECIFIC AREA

Name	Unit change	Specific costs per 1000 bottles.
		For mineral water bottling plants with annual capacity in million bottles.

Water	m 3
Steam	kg
Cold (at 1° water cooling)	mJ ∙ °С	2,76	2,47	2,41
Electricity	kW/hour
Carbon dioxide	kg
Compressed air	m 3

Average specific consumption rates of steam, water, electricity, cold per 1000 bottles. mineral water bottling are compiled based on the experience of existing enterprises and projects of mineral water bottling plants developed by the Sevkavgipropishcheprom Institute.

17.1. Specific indicators of the areas of workshops for the main production of mineral water bottling plants (without warehouses for containers and finished products)

	Annual plant capacity	Specific areas, m 2 - million bottles

	20 million bottles 0.5 l
	50 -"-
	100 -"-
	250 -»-

Average specific indicators of area per 1 million bottles. mineral water bottling plans are compiled on the basis of approved designs of mineral water bottling plants.

18. SCIENTIFIC ORGANIZATION OF LABOR

19. QUALIFICATION LIST OF WORKERS IN MAIN PRODUCTION AND SANITARY CATEGORY BY PROFESSION

Name of profession		Note

Tableware workshop
Acceptor-deliverer		Categories are accepted according to the tariff and qualification directory of works and professions, approved by the State Committee of the Council of Ministers of the USSR for Labor and Wages
Electric forklift driver
Stacker-packer
Operator of a bottle removal machine
Transporter

Finished products workshop
Loader driver
Transporter
Stacker-packer
Operator of package collectors and automatic bottle packing machines
Assistant transport worker
Storekeeper
Water treatment department
Saturator	IIv
Water Treatment	IIv

Alkali solution regenerator
Bottling shop
Washing machine operator	IIv
Filling and capping machine operator	IIv
Bottle Washed Inspector
Inspectors of finished product bottles
Water Treatment	IIv
Assistant transport worker
Machine and equipment adjuster
Gluevar
Loading station
Water Treatment	IIv
Helper worker	IIv
Mechanical repair workshops
Turner
Milling planer
Repairman
Toolmaker
Blacksmith-welder
Helper worker
Remstroygroup

Mason
Painter
Glazier
Helper worker
Box shop
Machine operator
Assembler of parts and wood products
Helper worker
Electric charger
Batteryman
Repairman

20. REQUIREMENTS FOR THE TERRITORY, INDUSTRIAL BUILDINGS AND STRUCTURES

21. WATER SUPPLY AND SEWERAGE

Water supplied to bottle washing machines must have a hardness of no more than 3.5 mEq/l. If the hardness of the source water is more than 3.5 mEq/l, water softening should be provided.

The placement of drains and funnels and their number must ensure the drainage of wastewater from the equipment, preventing it from spreading across the floor. The floor area per ladder should not exceed 150 m2.

22. HEATING AND VENTILATION

In domestic and auxiliary buildings and structures - heating using local heating devices.

Name of premises	Air temperature, °C	Air exchange rate m 3 /hour
Name of premises	Air temperature, °C	influx	hood

Bottling shop
Glass container workshop (heated)
Water treatment department		By calculation
Alkali recovery department
Finished products workshop

Note: The indoor air temperatures indicated in the table are calculated for the cold and transition periods. In the warm season, it should be taken according to SNiP “Heating, ventilation and air conditioning”. In the finished product workshop, the calculated winter temperature is given; the summer temperature is not standardized.

23. SUPPLY OF MINERAL WATER BOTTLING PLANTS WITH CARBON DIOXIDE

Creation of a gas cushion in transport and stationary containers during transportation and storage of mineral water, as well as in filling machines;

		Enter L1 level value from PA


	L1=1 Go to “Close the valve on the valve (position 1-7)”


	L1 =0.5 m. Go to “Open the valve on the valve (position 1-7)”
		Enter the L2 level value from the saturator


	L2=2 m Go to “Switch off pumps (position 2-7, 2-8)”


	L2 =0.3 m. Go to “Turn on pumps (position 2-7, 2-8)”
		Enter the value of level L3 from cooling tank H-3.


	L3=1.5 m Go to “Switch off pump (position 3-7)”


	L3 =0.2 m. Go to “Turn on pump (position 3-7)”
		Enter the T level value from PA


	T £ 4 0 C Go to “Close the valve on the valve (position 4-8)”


	T > 4 0 C Go to “Open the valve on the valve (position 4-8)”
	Is there a program termination signal?
	If there is, go to "Stop program execution"
	If not, go to the beginning of the program
	Close the slide valve (position 1-7)

	Open the gate valve (position 1-7)

	Switch off pumps (position 2-7, 2-8)

	Turn on the pumps (position 2-7, 2-8)

	Switch off the pump (position 3-7)

	Turn on the pump (position 3-7)

	Close the slide valve (position 4-8)
	Open the gate valve (position 4-8)
	Output L1 level value
	Print L2 level value
	Output L3 level value
	Display temperature T

Technological diagram of water bottling. Technological diagram of vodka production. Basic requirements for the design of a mineral water bottling department

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