Group 11- Essay Automation

Propose an automatic bottle filling and capping system into the production process of Hai Nam's one-member limited liability company...9 2.4.1.. The operation process of automation of fi

Ho Chi Minh City of Technology

and Education

SOCIALIST REPUBLIC OF

VIETNAM Facility of High Quality Training Independence - Freedom - Happiness

AUTOMATING BOTTLE FILLING AND CAPPING PROCESS AT HAI NAM COMPANY

Instructor: Assoc.Prof.Dr Pham Huy Tuan

Student Implement: Group 11

Pham Tuan Hung 19124001

Nguyen Thi Tuyet Mai 19124049

Le Thi Ngoc Bich 19124045

Nguyen Hoang Thuy Dung 19124062

Ho Chi Minh City, November 22 nd , 2021

Contents

CHAPTER 1: GENERAL INTRODUCTION OF HAI NAM COMPANY 3

1.1 Overview of Hai Nam Co., Ltd 3

CHAPTER 2: ANALYSIS OF THE COMPANY'S PRODUCTION PROCESS 5

2.1 Production process 5

2.1.1 Process of water purification - water treatment 5

2.1.2 Filling and Capping Process Bottled Drinking Water (500ml) 7

2.1.3 Standard Good Manufacturing Practice (Gmp) 7

2.1.4 Industrial Hygiene Process 7

2.2 Pose the problem 8

2.3 Goals 9

2.4 Propose an automatic bottle filling and capping system into the production process of Hai Nam's one-member limited liability company 9

2.4.1 Process Information 9

2.4.2 The operation process of automation of filling and capping bottle systems in Hai Nam company 11

2.4.3 Structure of automatic bottle filling and capping line 14

2.5 Advantages and disadvantages 18

2.5.1 Advantages 18

2.5.2 Disadvantages 19

CHAPTER 3: CONCLUSION 20

3.1 Comment 20

3.2 Conclusion 20

REFERENCE 21

CHAPTER 1: GENERAL INTRODUCTION OF HAI NAM COMPANY

1.1 Overview of Hai Nam Co., Ltd

Company name: Hai nam Co., Ltd

Company type: Manufacturer

Tax code: 3702469912

Year of establishment: 2019

Number of employees: From 100-300 people

Address: 994/1C Nguyen Thi Minh Khai, Tan Thang Ward, Tan Binh Ward, Di An City,Binh Duong Province

Phone: 0274 3800118

Hotline: 1900 633 874

Established history

 August 15, 2019 was established with 1 factory

 December 5, 2020 opened more facilities for production and officially established thecompany

With the ambition of “Becoming one of the well-known companies in Vietnam in thefield of beverage”, Hai Nam has continuously invested in developing the production linesystem, modernizing the technology, as well as we aim to provide our customers with thebest quality products

Producing, trading, and distributing pure beverage products that are good for Vietnameseconsumers’ health with appropriate taste and product quality according to internationalstandards, while satisfying the needs of consumers existing and potential customer needs

to become the preferred partner in business

Core values

 Satisfying customer needs

 Responsible to the community and society

 Always improve the product

 Mastery at work

 Integrity

Target

 Brand positioning is the pride of Vietnamese people

 Bringing products closer to consumers

 Building new values of Hai Nam company embodying life

 Constantly developing the scale and stature, implementing the standard of coveringgoods to communes and wards across the country

 Access to the most demanding markets such as foreign markets

CHAPTER 2: ANALYSIS OF THE COMPANY'S PRODUCTION PROCESS 2.1 Production process

Bottled drinking water production includes 3 main stages: standard water filtration

- filling, capping - preservation of finished products We would like to share the mostbasic information for customers to refer to before making investment decisions

2.1.1 Process of water purification - water treatment

 Source of water used: Water from a borehole or local water supply provided by the

central water treatment plant for people to use for daily living or normal drinking ormixed in a percentage to reduce input costs Upstream water before being put throughtreatment must be re-tested according to the "domestic water" criteria issued by thecountry

 Removal of iron and manganese alum: Upstream water will flow through a filter

with materials that are strong oxidizing agents to convert iron II into iron III, precipitate,and be discharged This process also treats manganese and the odor of H2S gas (if any).After that, water is added to continue to the next treatment step

 Pre-filter, deodorize, and deodorize: Use a dynamic filter with multiple layers of

materials to remove coarse particles above 5 microns, eliminating odors and colors

 Softening, demineralization: Raw water is filtered through an ion exchange system

(Cation–Anion), which has the effect of filtering positive ions (Cations): Mg2+, Ca2+,Fe3+, Fe2+, And negative ions (Anions) such as Cl-, NO3-, NO2- The water treatedthrough this system will be put into a tank or continue to be treated

 Deodorizing deodorization: Using an automatic filter flushing with multiple layers

of material to remove coarse residues above 5 microns, deodorizing and coloring

 pH balance: The latest regulation on bottled drinking water no longer mentions

the requirement for pH However, to make water treatment more convenient, the pH should

be adjusted to neutral (6.5-7.5)

The above stages are essential to protect and increase the life of the RO membrane system in the following main production stages.

 Reverse osmosis filtration

Water is pumped (high pressure) through a reverse osmosis membrane system (ReverseOsmosis) Depending on the adjustment mode, the RO membrane will let about 25-75%

of the pure water pass through the extremely small filter holes, up to 0.001 micron Theremaining water, containing impurities, metal ions will be discharged The purifiedwater that is free of bacteria, viruses and minerals meeting the standards of bottleddrinking water will be stored in a closed tank

 Ozone sterilization:

Pure drinking water after filtration is stored in a closed tank with ozone aeration to killbacteria remaining in the water after filtration

 Re-sterilizing with ultraviolet rays

During storage, purified water is likely to be contaminated with bacteria from the air, sobefore bottling, it is necessary to re-sterilize with UV light (Ultra-violet light) to killbacteria Then put through a 0.2µm fine filtration system to remove dead bacteria (ifany)

 Final stage: Bottling or Bottling

After going through all the above processes, water is pumped to the filling system forbottling and bottling.

2.1.2 Filling and Capping Process Bottled Drinking Water (500ml)

- Stage 1: Cap preparation: The cap is washed from the cap washing area then put

into the storage compartment for production

- Stage 2: Prepare bottles: New bottles, rinse with finished water.

- Stage 3: Extraction and capping:

 Consists of 3 stages: rinsing the bottle, filling, and closing the lid

QT prepares jars and caps: Rinse -> Sterilize -> Transfer to filling and capping machine

- Stage 4: Labeling, packing

 Final inspection quality assurance department

 Quality products will be labeled and boxed to produce finished products

 This is the finishing step

- Stage 5: Preservation and storage

 The finished product boxes are transferred to the transshipment warehouse Carryout procedures for storage or distribution to the market

 End of bottled drinking water production process

2.1.3 Standard Good Manufacturing Practice (Gmp)

The production area is designed according to GMP (Good Manufacturing Practice)standards

The production area has a separate entrance for the operator, a separate entrance and exitused to transfer production materials and finished goods

Entrance and exit for authorized personnel, equipped with insecticidal lights Theproduction area is ventilated and sterile The air conditioning system (if necessary) must

be able to kill bacteria If conditions permit, a risk warning system should be equipped

2.1.4 Industrial Hygiene Process

Before entering the production area to work, workers are required to undergo thefollowing operations:

 Step 1: Dressing room

There is a separate room for employees to change into workwear before entering theproduction area

 Step 2: Sterilization room

Persons in charge when entering the production area must go through a room with adisinfection system.

 Step 3: Sanitize your hands

Perform hand washing according to the required standards Dry hands with a dryer, wear

a mask and sterile medical gloves

 Step 4: Sterilize the boots

Dip the boots in a pool of disinfecting water before entering the production room

(Note: only allow people of the authorities to check in when they are assigned to perform

their duties, have an industry card and are also required to go through the sterilizationstages as above Absolutely do not let strangers, people who are not with division intoproduction area)

2.2 Pose the problem

Currently, at the filling and packaging stage in the production of bottled water of theCompany, there is a problem that causes the company to lose more costs for labor andlabor, the use of this manual filling machine can cause problems can bring the followingadvantages and disadvantages:

- Because the machine is operated completely manually, it does not consumeelectricity, does not cost maintenance, and is cheap and easy to clean

 Disadvantages:

- The machine cannot fill solutions that contain solids or are too dense

- The design of the machine is fixed and independent, so it cannot be combined withother production lines Cannot be combined with labeling machine and bottle cappingmachine products

- The water capacity in the bottles has a difference, uneven between the bottles.Employees have to measure and measure, the quality of the product is not guaranteed andthe output is poor, which takes time and effort, making the output quality of the productnot up to the customer's requirements

2.3 Goals

With the current situation of the company that wants to develop and go up, want tohave many orders in large quantities to make a profit, it is not possible to use manualfilling system because it will cause waste of time Waste of time and money on hiringworkers With the goal of improving and optimizing, the bottled water productionprocess The authors have proposed a solution by automating the filling and packagingstages to optimize waste of time and labor, optimize human resources, and improveproduct quality

2.4 Propose an automatic bottle filling and capping system into the production process of Hai Nam's one-member limited liability company.

3-in-1 automatic bottling system, modern fully automatic pure water bottle filling, andcapping line

Model Number: YX-12-12-3

Capacity: 500ml - 4000ml

Error: <= ± 5mm

Bottle size: (mm) diameter φ100 100 height  150-320 mm

Mounting type: Vortex mounting

Water pressure of washing bottle: 0.18 Mpa

Bottle washing water: 2500 (Kg/h)

Gas pressure: 0.4 Mpa

Compressed air consumption: 0.4m3/min

Total power: 6.57KW

Total weight: 550Kg

Dimensions: 3200 × 2100 × 2250 mm

Structure Diagram The Automatic Bottle Filling and Capping Process

The model includes the main components and the function of each component:

- Conveyor 1: transport empty bottles from bottle supply to filling and cappingsystem

- Conveyor 2: transport the cap into the system for the bottle to take the cap

 Sensor 1: detects empty bottles for filling

 Sensor 2: detects that the bottle is full

 Sensor 3: detects the bottle to close the cap

There is a machine used in the process of washing bottles Empty bottles are

transferred along conveyor rails There are two washing times inside and out, the bottle washing efficiency is extremely high

Magnetic torque is used to close the vortex bottle cap The bottle cap is closedsecurely, quickly, and without any errors.

The whole operation of the machine is controlled by the PLC system with a class touch screen The number of bottled drinks can be controlled automatically, themachine will stop automatically when there is no bottle When the bottle is full withoutthe cap the machine will stop automatically Frequency change technology has enablednon-stop operation speed adjustment This automatic bottle filling and capping system iscompletely suitable for the beverage production process of Hai Nam company

high-2.4.2 The operation process of automation of filling and capping bottle systems in Hai Nam company

The system works according to the following steps:

First, the plastic bottles (PET) are put on the conveyor system and go through therinsing system to clean the dirt

Pure water from the tank is connected to the RFC system

The conveyor belt will automatically transport PET bottles into the washing system.The bottles move around and into the correct position of the rinsing faucet Note that thewashing water has quite strong pressure to wash PET bottles due to the built-in pump inthe sprayer

After washing, the PET bottle will be put into the filling position, the lever armswill hold the neck of the bottle to prevent double-overflow during the filling process Thebottles are conveyed by the conveyor belt to the filling system, into the filling position toensure that mechanical mechanisms can be arranged to hold the bottles The bottles arerotated continuously on the filling conveyor The built-in water pump will automaticallyfill the bottle Here, the liquid is extracted into the bottle by different methods, isostaticextraction, is volumetric extraction, quantitative extraction When the extraction iscompleted, the bottle is frozen transport load to the buttoning or capping position

Filling methods

Normal pressure filling

Accordingly, this principle is based on the principle that the liquid flows into thebottle by itself thanks to the difference in height of the extraction nozzle and the bottle.This method is very suitable for pouring less greasy solutions such as cooking oil orshampoo

Vacuum Filling

The bottles will be connected to a vacuum system This creates a difference inpressure between the bottle and the container for the solutions to flow inside Because ofits characteristics, this principle is used when it is not possible to keep the container at aheight to use the normal pressure filling principle.

Isometric filling

This is the principle used to fill carbonated solutions such as carbonated drinks…With this filling method, CO2 is charged inside the bottle until the pressure in the bottleequals the pressure of the container Then, take advantage of the height to let thesolution flow inside the bottle

When the tank is full of water, it will be moved to a closed position The containercap is filled in the container and inserted right into the top of the PET bottle Then theswingarms will tighten the cap The closing mechanism can be a pneumatic cylinder(with a stamping button) or a motor (with a knob) Then the PET bottle is transferred onthe conveyor to the outside

Flowchart of automatic bottle filling and capping process

The machine is used to fill liquid into the vial and is operated on the principle of line filling

straight-The circuit board system is protected in a sealed box, ensuring that the circuit is notbroken by environmental factors and human impact, helping the machine to operateefficiently The device has outstanding advantages such as:

+ Beautiful design, stable operation, and high durability, saving maintenance and repaircosts

+ Following safety standards, do not worry about staining or containing impurities, toxicmetals for the body

+ Precise dosing thanks to the servo system, ensuring the piston can reach the specifiedposition

+ Variable speed of filling: During the filling process, when the filling amount is close tothe specified level, the filling speed will be changed slowly, avoiding the material leakingout of the bottle mouth and causing pollution

+ Convenient adjustment: To change the bottle size, you just need to change theparameters on the screen

Moved to Closed Lid

Close Lid

Finishing water extraction and

close Lid process