"summer Internship 2016"

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SUMMER INTERNSHIP REPORT
Submitted To:
Engineer Muhammad Ishfaq
Submitted By:
Muhammad Younus
Registration# (2013-ME-440)
Mechanical Engineering (VI Semester)
Session (2013-2017)
University of Engineering & Technology Lahore

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PREFACE
The Mechanical Engineering curriculum is designed in such a way that students can grasp
maximum knowledge and can get practical exposure to the corporate world in minimum
possible time. The Summer Internship Program provides an opportunity to the students in
understanding the industry with special emphasis on the development of skills in analyzing and
interpreting practical problems through the application of theories and techniques. It is a new
platform of learning through practical experience, it gives the student an opportunity to relate
the theory with the practice, to test the validity and applicability of his classroom learning
against real life Technical situations.

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ACKNOWLEDGEMENT
I am thankful to the ALMIGHTY ALLAH, by the assistance of HIM, I have accomplished my
Task. I would like to thank all of the people who directly or indirectly helped me to achieve
this Target. I take this opportunity to express my profound gratitude and deep regards to my
guide for exemplary guidance, monitoring and constant encouragement throughout the
training.
I am thankful to staff of CCBPL (Coca-Cola Beverages Pakistan Limited) for answering my
each query regarding the process of the company. I am obliged to staff members of CCBPL,
Gujranwala for the valuable information provided by them in their respective fields. I am
grateful for their cooperation during the period of my assignment. I am making this project to
increase my knowledge.
THANKS AGAIN TO ALL WHO HELPED ME.

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INTRODUCTION
 I Joined the CCBPL (Coca-Cola Beverages Pakistan Limited) – Gujranwala, as an
Internee on 20-06-2016 after successfully clearing the HR recruitment protocols of the
company.
 CCBPL (Coca-Cola Beverages Pakistan Limited) is a fully owned subsidiary of The
Coca-Cola Company.
 For the 6 weeks internship period I was placed at the Supply chain Department PET
Bottle Production Line#06 of the company, where I learned about the complete process
of making the Beverage Bottle.
 After the experience of two extraordinary weeks, my incharge given me an assignment
so that I can get the experience of the life at plant of the Coca-Cola Beverages Pakistan
Limited.
 The Coca-Cola plant of Gujranwala is situated at the khayali bypass G.T Road in
Gujranwala – 70 km away from Lahore.
 The plant consists of 6 production lines in which 3 are RGB (regular Glass Bottles) and
other 3 lines are PET (Polyethylene Terephthalate) Bottling lines.
 The plant is completely owned by the company and giving employment to the local
public.
 The production process of this plant is totally automated and the combination of the
raw materials is done on the basis of the formula which is pre-defined in the programs
of the machines.

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HISTORY OF THE COCA-COLA
[MIRACLE BY DR. JOHN PEMBERTON]
The first Coca-Cola recipe was invented in Columbus, Georgia, by John Stith Pemberton,
originally in 1885 coca wine was called as a ‘Pemberton’s French wine coca’. As miracle was
made by John Stith, it is assumed that he may have been inspired by the formidable success of
European Angelo Mariana’s, coca wine. John Pemberton concentrated the Coca-Cola formula
in a three legged brass kettle in his backyard. The name was a suggestion given by John
Pemberton’s book keeper Frank Robinson.
The first sales were at Jacob’s pharmacy in Atlanta, Georgia, on May 8 1886. It was initially
sold as a patent medicine’s for five cents a glass at soda fountains, which were popular in the
united states at the time due to the belief that carbonated water was good for
the health. Pemberton claimed Coca-Cola cured many diseases, including
morphine addiction, dyspepsia, neurasthenia, headache, and impotence.
Pemberton ran the first advertisement for the beverage on May 29 of the same
year in the Atlanta journal. For the first eight months only nine drinks were
sold each day.
Coca-Cola was sold in bottles for the first time on March 12, 1894. Cans of
coke first appeared in 1955. The first bottling of Coca-Cola occurred in
Vicksburg, Mississippi, at the biedenharn candy company in 1891. Its
proprietor was Joseph a biedenharn. The original bottles were biedenharn
bottles, very different from the much later hobble-skirt design that is now so
familiar. As a Candler was tentative about bottling the drink, but the two
entrepreneurs who proposed the idea were so persuasive. However that
Candler signed a contract proved to be problematic for the company for
decades to come, legal matters were not helped by the decision of the bottlers
to subcontract to other companies- in effect, becoming parent bottlers.

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In 1915 first contour bottle is produced. The Coca-Cola contour bottle prototype is designed
by Alexander Samuelson.
Coca-Cola Cane (1955)

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The Coca-Cola Company is a 120 years old company with its origin from Atlanta,
Georgia. Coke was at first used as a refreshment drink.
The drink was discovered by Dr. John Pemberton on May 8, 1886. The soft drink was
given the name Coca-Cola by Frank Robinson.
The Coca Cola Company was bought over and incorporated by Asa Griggs Candler, an
entrepreneur.
The company was then patented in the year 1887 and final was registered in 1893.
Coke sells 1.7 billion drinks a day and it is the most recognized brand in the world.
Coca-Cola currently offers more than 500 brands in over 200 countries or territories.
The formula of manufacturing Coke lies in Downtown Atlanta on a piece of a paper.
The Coca-Cola Company was founded by Mr. Asa Griggs Candler after he bought the
brand in 1889 and incorporated the company in 1892. Muhtar Kent is the current
chairman & chief executive of the company.
The Coca-Cola Company is a beverage company which has several competitors
throughout the world. But the leading competitors of the company globally are PepsiCo,
Nestle etc.
Coca-Cola in Pakistan
Introduction
The Coca-Cola Company is a global company with some of the world's most widely recognized
brands, the Coca-Cola business in Pakistan has completed its 50 years of operation. The
beverages are produced locally, employing Pakistani citizens. And their product range and
marketing reflects Pakistani tastes and lifestyles, and they are deeply involved in the life of the
local communities in which they operate.
History
After the country’s independence in 1947, Coca-Cola came to Pakistan in 1953. Like in every
other country where it operates, the Coca-Cola business in Pakistan is a local business. The
beverages are produced locally, providing employment to Pakistani citizens, and the product
range and marketing reflects Pakistani tastes and lifestyle.
After the introduction of Coca-Cola, Fanta was introduced in 1965, Sprite was introduced in
1972, and after a gap of 30 years, Diet Coke and Fanta Lemon were introduced in 2001.
Currently, Coca-Cola beverages are produced and sold in Pakistan via the company’s own

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bottling plants which operate under Coca-Cola Beverages Pakistan Ltd. (CCBPL). A local
service office, Coca-Cola Pakistan, focuses on marketing the Company’s brands locally.
Brands
Products
Bottling Information
The Coca-Cola System in Pakistan operates through twelve bottlers, 10 of which are owned by
Coca-Cola Beverages Pakistan Limited, out of these twelve plants now eight are operating. The
CCBPL plants are in Karachi, Hyderabad, Lahore, Gujranwala, Faisalabad, Rahimyar Khan,
Multan and Sialkot. The remaining two plants, independently owned, are in Rawalpindi and
Peshawar. The Coca-Cola in Pakistan serves over 100,000 customer’s retail outlets.
Employment/Economic Impact In Pakistan it employs 1,800 people. In Pakistan it has invested
over $130 million (U.S.).

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Safety & Health
By: The Coca-Cola Company
At The Coca-Cola Company, long-term success depends upon ensuring the safety of
workers, visitors to its operations, and the public.
The company believes that a safe and healthy workplace is a fundamental right of every person
and also a business imperative. Its Workplace Rights Policy requires that it takes responsibility
for maintaining a productive workplace in every part of Company by minimizing the risk of
accidents, injury and exposure to health hazards for all of associates and contractors. In
addition, the company is working with their bottling partners to ensure health and safety risks
are minimized for their employees and contract workers.
Company provides safety jackets, Hair Net and Ear plugs to everyone who enters in the
plant.
In the Plant these safety posters (Cautions) are sticks to the wall for aware to worker.

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Coca-Cola Gujranwala Plant
The Coca-Cola plant of Gujranwala is situated at the Khayaali Bypass G.T Road in
Gujranwala – 70 km away from Lahore. The plant consists of 6 production lines in which
3 are RGB (Regular Glass Bottles) and other 3 lines are PET (Polyethylene Terephthalate)
Bottling lines. The plant is completely owned by the company and giving employment to
the local public. The production process of this plant is totally automated and the
combination of the raw materials is done on the basis of the formula which is pre-defined
in the programs of the machines. Production Lines detail is as under:
Line# Description Average Speed
Line 1 KRONES PET bottling Line 26000 BPH
Line 2 KRONES RGB (Regular Glass Bottle) 36000 BPH
Line 3 KHS PET bottling Line 36000 BPH
Line 4 PAKTOOL RGB (Regular Glass Bottle) 18000 BPH
Line 5 KRONES RGB (Regular Glass Bottle) 60000 BPH
Line 6 KHS PET bottling Line 36000 BPH
Other than production Lines, Water Treatment Plant, Syrup Room, Generator Room (for
Power Supply) and waste water treatment plant are the part of Gujranwala plant.
KHS PET LINE#06:
Machines Sequence and their infeed of raw materials and other inputs are shown in
next page:

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KHS Line#06:
SYRUP ROOM
Sugar
Concentrate
Treated Water
Carbon Powder
Steam from
Boiler
MIXER
Water
Heat
Exchanger
Glycol for
Cooling
Filler
Preform
Hopper
Blow
Fill
CO2
GesnerCaps
Dryer
LABLER
Krones
KISTER
Innopac
PALATIZER
Label + Glue
Shrink Film
Stretch Film Production
BLOCKM/C
Date Code Print
P1= 10 bar
P2= 40 bar
P1= 10 bar
P1= 10 bar
Preform
conveyer
Bottle
conveyer
Packet
conveyer

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Complete Process/Operation
In syrup room sugar dissolves with treated water using Miteco Sugar Dissolving System.
Than this Mixture transfer in final syrup room where Concentrate of different products
(Coke, Sprite, 3-G and Fanta) according to requirement added with this mixture. Then this
syrup is transferred to the Mixer of production line for fill of the bottles.
In Mixer treated water receives from water treatment plant, CO2 from CO2 Tanks and glycol
(used for cooling purposes) mixed with syrup comes from final syrup room. After that this
Beverage is sends to the Filler machine for filling of bottles.
Preform made by venders are collect in hopper and receive in Blow max machine by the
Preform Roller conveyer. Here it will be heated up in the oven (electric heaters) at 110-
120O
C.then these heated preform sends in molds (a hollow container used to give shape to
hot material when it cools and hardens) where the two pressures applied P1 and P2, after that
preform change into bottle.
PET bottle filler:
The machine is designed to fill carbonated and non-carbonated beverages into PET bottles
only. This machine is high speed for 1.5 liter bottles its maximum speed is 36000 bottles/hour
and for 1 liter bottles its speed is 39600 bottles/hour.
The computer on the filler turret controls the filling process. The fill level (volume) in the
bottle is determined via a flow meter.
The machine consists of the main assemblies
1 Filler turret
2 Filler base
3 Outfeed conveyor
4 Filling valve
5 Capper
6 Star wheels for bottle transport and capping
7 Outfeed conveyor
153 valves installed on ring bowl it means that 153 bottles fills with beverage in one cycle of
this bowl.
The filling operation is controlled electro-pneumatically by computer. The amount of product
to be added to the bottle is determined by a volume meter. When the preset filling volume is
reached, the filling process is terminated by the computer. The media is supplied to the filler
turret from the valve manifold via the supply lines and rotary distributor and discharged from
there. The add-on bottle guide takes the bottles from the upstream machine and channels
them to the filler turret.
The bottle detector positioned in front of the filler senses whether a bottle is present. The
filling valves pick up the bottles and fill them while the filler turns. If a bottle is not present,
the corresponding filling valve remains closed. The add-on bottle guide receives the bottles
from the filling valves and feeds them to the capper.
After filling, the transfer star takes receipt of the bottles. The transfer star pushes the bottles

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into the central capper star. The central capper star guides the bottles beneath the capper
elements.
Capper/Gasner Machine
This machine consists of different parts.
1 Cap feed
2 Drive
3 Capper turret
4 Capping elements
5 Bottle guide
6 Frame on which the capper is mounted
The filled bottles coming from the filler are fed to the capper guided by format parts.
The screw caps are rotated from the on-site supply into the processing position and fed to the
capping channel. In the capping channel, the screw caps slide to the cap feed. The cap feed
transfers the screw caps to the capping elements.
The screw cap is screwed onto the bottle by the rotating capping spindle while the capper is
rotating.
The torque with which the screw cap is screwed on can be adjusted on the capping spindle.
The format parts convey the capped bottles to the outfeed conveyor.
After capping, the central capper star guides pushes them into the outfeed star. The outfeed
star pushes the bottles onto the outfeed conveyor. The outfeed conveyor brings the bottles out
of the machine and transfers them to the container conveyor.
Labeler Machine
The bottles coming from the filler receives in labeler machine. Where the machine stick the
labels with the bottle by using special glue. After labeling data code printer Prints the data
code top of the bottle.
Packer/Kister Machine
This machine make the Packet of 6 bottles, collects the bottles from the labeler machine
arrange them and wrap it with shrink film. After that this packet will send in the heating oven
also called the heating Tunnel where the shrink film is squeezed over the bottles and packet is
strengthened.

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Pelletizer Machine
This machine make the pellet of packets coming from the packet conveyer.
Machine consists of these Tables:
1. Assigning Table
2. Collecting Table
3. Preparation Table
Two Robots named as kuka track -I and kuka track -II programmed to arranges the packets
and two other arm robots sets these packets layer by layer on the wooden crate separated by
the Pads by using the Pad inserter Arms Robots.
In one Pellet,
1 liter=168 Packets, 6 Layers
1.5liter=110 Packets, 5 Layers
After that this Pellet sends into Octopus machine where the layered pellet is wrapped by the
stretched film.
Before send this pellet into market a Bar Code Inserter sticks the printed paper on the pellet
on this printed paper manufacturing date, Expiry dates and other information is printed

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Clean in Process
Clean-in-place (CIP) is a method of cleaning the interior surfaces of pipes, vessels, process
equipment, filters and associated fittings, without disassembly.
Up to the 1950s, closed systems were disassembled and cleaned manually. The advent of CIP
was a boon to industries that needed frequent internal cleaning of their processes. Industries
that rely heavily on CIP are those requiring high levels of hygiene, and
include: dairy, beverage, brewing, processed foods, pharmaceutical, and cosmetics.
The benefit to industries that use CIP is that the cleaning is faster, less labor-intensive and more
repeatable, and poses less of a chemical exposure risk to people. CIP started as a manual
practice involving a balance tank, centrifugal pump, and connection to the system being
cleaned. CIP has evolved to include fully automated systems with programmable logic
controllers, multiple balance tanks, sensors, valves, heat exchangers, data acquisition and
specially designed spray nozzle systems. Simple, manually operated CIP systems can still be
found in use today.
In Coca-Cola Plant two types of CIP
o 3-Step CIP
o 5-Step CIP
3-Step CIP
Following steps are performed in 3-Step Cleaning.
I. Cooled Water
II. Sodium hydroxide (NaOH), also known as caustic soda
III. Warm Water
5-Step CIP
I. Pre-Rinse
II. Detergent Wash Cycle (Ambient or Hot)
III. Intermediate Rinse
IV. Disinfection (Sanitation) Cycle
V. Final Rinse

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Change Over
In manufacturing, changeover is the process of converting a line or machine from running
one product to another.
A soft drink bottler may run 1 liter plastic bottles one day, perform a changeover on the line
and then run 1.5 liter plastic bottles the next day.
The 3 Ups
Changeover can be divided into the 3 Ups:
Clean-up:
Product, materials and components from the line. It may range from minor, if only
the label of a package is being changed to major, requiring complete disassembly of the
equipment, cleaning and sterilizing of the line components in the case of an injectable
product.
Set-up:
Set-up is the process of actually converting the equipment. This may be achieved by
adjusting the equipment to correspond to the next product or by changing non-adjustable
"change parts" to accommodate the product. Typically it will be a combination of both.
Start-up:
Start-up is the time spent fine tuning the equipment after it has been restarted. It is
characterized by frequent stoppages, jams, quality rejects and other problems. It is generally
caused by variability in the clean-up and set-up or by variability in the product or its
components.

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Project Report
[Project Title: Preform Yield Improvement]

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Project Summary:
To improve overall Preform Yield of KHS PET lines from 99% to 99.3%
Function: Supply Chain
Department: Production
Yield:
An amount produced of an agricultural or industrial or Beverage product.
Preform Yield Percentage?
Ratio of Total Actual produce bottles from filler to the Total infeed Prefroms for
a specified period is called Preform Yield.
Yield Percentage=
𝐴𝑐𝑡𝑢𝑎𝑙 𝑉𝑎𝑙𝑢𝑒
𝑇ℎ𝑒𝑜𝑟𝑎𝑡𝑖𝑐𝑎𝑙 𝑉𝑎𝑙𝑢𝑒
Why CCBPL Cannot Achieve Maximum Yield:
Due to some aspects Block Machine cannot achieve the Maximum Preform Yield:
1. Clouser/Caps Stucks in Gasener’s spiral conveyer.
a. Seal damaged
b. Shape difference like oval shape or D shape
2. Damaged Preform infeed to the oven.
a. Neck/collar broken.
b. Banana Shape
c. Other Product/brand’s Preform
3. Electric Power loss from Wapda or Generator room.
4. Bottle Transfer star wheel gripper broken or bottles stuck in these
grippers.
5. Preform stuck in the heating Oven/Tunnel.
6. Preform Stuck in Mold.
7. Filler discharge conveyer sensor malfunction so this wastage of bottles.
8. Treated water missing from the water treatment plant.
9. Lack of syrup from syrup room.
10.Preform material temperature variation.
11.Oven filters are choked.
12. Blow discharge sensor malfunction, Sensor dusty so bottles fall.
13.Conveyer stopped by operator mistakenly.
14.Safety doors opened by any operator or other person.

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If any of above error/situation is occur then emergency beak down on block
Machine. Due to this break on machine 245 Preforms waste. Because at a time 245
preforms are moving in Oven/heating tunnel. These 245 rejections creates a gap in
achieving the maximum yield if we make over come in all above situations then we can
achieve the maximum possible 99.3% Preform yield.
Some Previous Stats of Line#06: