INTERNSHIP REPORT

(DAIRY & JUICES)

SUBMITTED BY: SUBMITTED TO:

ALI RAZA FARHAN CH.

(alirazayousaf99791@gmail.com)
ACNOWLEDGEMENT
I have successfully completed project in dairy & juices department under the supervision of Farhan CH.
He has assisted me throughout my internship and helped me to learn and analyze process as possible as
I can. I have learnt a lot of new things during my internship especially safety precautions and culture of
Nestle SKP Plant.
1.0 INTRODUCTION
Nestle is the largest food company in the world. This company based in Switzerland-Europe. Nestle was
first created in Angelo-Swiss. In the 1860’s, Henri Nestle, a pharmacist, launched world’s first prepared
infant cereals “Farine Lactee” in Vevey Switzerland. In early 1906, the company was operating factories in
the United States, Britain, Germany and Spain. In 1905, nestle merged with the Angelo-Swiss condensed
milk company. Six world-wide corporate brands, Nestle, Nescafe, Nesvita, Maggie, Buitoni, Friskies. In
2006 Nestlé's sales, at $80billion, accounted for 1.5% of the total global food market.
1.1 VISION
To be a leading, competitive, Nutrition, Health and Wellness Company delivering improved shareholder
value by being a preferred corporate citizen preferred employer preferred supplier selling preferred
products.

"Nestlé is the largest food company in the world. But, more important to them is to be the world's
leading food company”.
1.2 CULTURE OF NESTLE
Energetic and collaborative working environment. People influence the business through their skills and
knowledge. Nestle want from its employees to bring your dedication, determination and great ideas to
the table. There is enthusiastic team behind ideas. Accept challenges.

A high performance culture supported by differentiated rewards. Key to the delivery of individual and
business objectives. Challenging responsibilities and priorities. Ensuring that employees are aware of how
their work impacts Nestlé. Most important factor in determining your opportunities within Nestlé. If
you’re keen to take on new and bigger responsibilities, you have to show that you’re able to do so. We
should stress the words 'strongly' and 'consistently ‘. At Nestlé, the end and means are equally important.
2.0 JUICE PROCESSING

 Pulp
 Sugar
 Ingredients

P+S+I(MIX)

BARMETIC TANK

( 25®C)

PRE-HEATING IN HEAT
EXCHANGER (1)

DEARETION CHAMBER
(REMOVING GASES)

PASTURIZATION

( 98®C)

ASEPTIC TANK

( 25®C)

9
2.1 FILLING SECTION

MACHINE CAPACITY

A3 Speed 200ml(L,N,G,O,D,Z) ( 24000/hr)

A3 Speed 1000ml(K,W,V,R) ( 12-15000/hr)

ABA22 180-200ml(L,N,G,O,D,Z) ( 20000/hr)

A3 Flex 500-1000ml(V,R,W) ( 7000/hr)

ABA19 125ml(A) ( 3000/hr)

ELPO 3-18 liters (190-400/hr)

2.2 LAMINATED REEL

1) Poly
2) Poly
3) Al foil
4) Board
5) Board
6) Printing Layer
7) Poly
2.3 WORKING IN TETRA FILLING MACHINE

2.4 PACKAGING
 Cap Applicator or Inserting straw
 Shrinkage Machine
 Oven (150˚C)
 Distribution Cell
3.0 PIPING & INSTRUMENTATION DIAGRAM
A piping and instrumentation diagram (P&ID) is defined by the Institute of Instrumentation and Control
as follows:

1) A diagram which shows the interconnection of process equipment and the instrumentation used
to control the process. In the process industry, a standard set of symbols is used to prepare
drawings of processes. The instrument symbols used in these drawings are generally based
on International Society of Automation (ISA) Standard S5.1
2) The primary schematic drawing used for laying out a process control installation.

-Process piping, sizes and identification, including:

 Pipe classes or piping line numbers
 Flow directions
 Interconnections references
 Permanent start-up, flush and bypass lines

-Mechanical equipment and process control instrumentation and

designation (names, numbers, unique tag identifiers), including:
 Valves and their identifications (e.g. isolation, shutoff, relief and safety valves)
 Control inputs and outputs (sensors and final elements, interlocks)
 Miscellaneous - vents, drains, flanges, special fittings, sampling lines, reducers and increasers

P&IDs also play a significant role in the maintenance and modification of the process after initial build.
Modifications are red-penned onto the diagrams and are vital records of the current plant design.

They are also vital in enabling development of;

 Control and shutdown schemes

 Safety and regulatory requirements
 Start-up sequences
 Operational understanding
3.1 INSTRUMENT ABBREVIATIONS & SYMBOLS
SYMBOLS
3.2 PIPE MARKING GUIDELINES
3.3 COLOR CODING FOR TAGGING OF DUFFIRENT PIPES ( TAD1 & TAD2)
4.0 PUMPS
4.1 Centrifugal or Kinetic Pumps
-Pressure creating device
-Converts velocity energy (Kinetic Energy) to Pressure Energy (Flow Work)
-Flow depends upon system characteristics

4.2 PARRALLEL COMBINATION OF CENTRIFUGAL PUMPS

The total system flow divides into two parallel paths. The check valves prevent any flow short-circuiting,
especially if only one pump runs. Since almost all installations of parallel pumps are with identical pumps,
each pump will pump exactly one half of the total flow rate. Each pump will produce the same pressure
head. Each pump will operate at the same point on its pump curve. In short, when both pumps are
running, each pump supplies one-half of the total flow rate at the total system head.
 FIG.1

4.3 SERIES COMBINATION OF CENTRIFUGAL PUMPS

When series pumping a system, each pump will pump the entire flow of the system. Each pump
supplies the full design flow rate at one-half the required head.
4.4 POSITIVE DISPLACEMENT PUMPS

 ROTARY PUMPS
 PROGRESSING CAVITY
 SLIDE VANE
 LOBE
 GEAR
 SCREW
 PERISTALTIC
 4.5 COMPARISION BETWEEN CENTRIFUGAL & PD PUMPS

CENTRIFUGAL PUMPS PD PUMPS

 -Centrifugal pumps don’t have any leakage issue. -Self-Priming/Suction Lift

 -They are able to pump hazardous as well as -Ability to Vary Capacity

sensitive fluids.

 -There is also no problem of heat transfer as the -Abrasive Fluids

space between the motor and chamber is
sufficiently large.

 -There is no loss of power due to friction and they -Handles High Viscosity Applications
are very simple in structure and easy in handling.

 -Magnetic resonance in centrifugal pump results -Handles Shear Sensitive Fluids

in small loss of energy.

-The risk of cavitation is always there. -Accurate Repeatable Flow

 -Vibrations due to surrounding atmosphere can -Can’t Run Dry
damage these pumps.
5.0 HEAT EXCHANGERS (HOLDING TIME CALCULATION)

The appropriate required holding time can be calculated when length of tube, hourly capacity and the
inner diameter of the holding tube are known. As the velocity profile in the holding tube is not uniform,
some juice molecules will move faster than the average. To ensure that even the fastest molecule is
sufficiently pasteurized, an efficiency factor must be used. This factor depends on the design of the
holding tube, but is often in the range of 0.8 – 0.9 if the flow is turbulent. For more viscous fluids, the flow
might be laminar and then the efficiency factor is lower.

Data required for calculation:

Q = flow rate at pasteurization, l/h
L = length of holding tube in dm, corresponding to Q and HT
D = inner diameter of holding tube in dm, to be known or adapted to the other pipework
V = volume of juice in l or dm3 corresponding to Q and HT
η = efficiency factor

L= 37128mm or 37.128dm

Q= 15300 l/hr

D= 63.5mm or=0.63dm

L= V×4/π×D2
V = L×π×D2 /4
V= 37.128 × 3.14 × .632 /4
V= 1165.81dm3
V = Q× HT /3600*Ƞ
HT= V* 3600* Ƞ/Q
HT= 1165.81* 3600* .80/1165.81
HT= 22.19sec

STEAM CONSUMPTION OF HEAT EXCHANGER

 The problem here we are faced with is to calculate the steam consumption in cases of both old
and new tubular.
 First we will calculate steam consumption for old tubular.
 And after that steam consumption for new tubular will be find.
 After it both of the values will be compared.

Calculations
FOR (DELTA ) T=10*c (old tubular)

Q=3400/3600 kg/sec * 4.19 (kj/kg*c) * 10*c

Q=395.53 k

m= Q/h(fg)
m= 395.53 /2773
m= 0.142 kg/sec
m= 511.2 kg/hr
m= 0.511 tons/hr
FOR (DELTA ) T=4*c (new tubler):

Q=3400/3600 kg/sec * 4.19(kj/kg*c) * 4c

Q=158.21 kw

m= Q/h(fg)
m= 158.21/2773
m= 0.05kg/s
 m=205.39 kg/hr
m= 0.20 tons/hr

COST CALCULATIONS

We know that per ton cost of steam =2880 rps/ton

So by multiplying mass flowrate of steam by in tons/hr by rps/ton ,we can calculate the cost of steam in
rps /hr.

COST WHEN (DELTA) T=10*c:

cost= 0.511*2880 rps/ton
cost= 1471.86 rps

COST WHEN (DELTA) T =4*c:

cost= 0.20* 2880 rps/ton
cost= 576 rps
Tagging of Pipes with different color codes
Heat Exchangers
Holding time calculations
Pumps