AQUIFER FOOD PRODUCTS: Packaged Drinking Water Project

Showing posts with label Packaged Drinking Water Project. Show all posts

Wednesday, November 2, 2011

Process Mineral Water Treatment Plant

Process Mineral Water Treatment Plant:
Though BIS has set a wide range of parameters to confirm to BIS-13428: 2004, and BIS : 14543:2004, a palatable and safe water poses a big challenge for water treatment professionals due to varied parameters of bore-well across India, since these are the major source of raw water for the industry.
There is various equipment / filters like sand bed filter, Activated carbon Filters, micron filtration, Reverse Osmosis, Ozonation, Ultra Violet, water testing labs and bottle , filling and pet Blowing Machine these are generally used in combination to process the water.

The water treatment plant focuses on the removal of microbial contaminants that cause typhoid, dysentery, and cholera epidemics. The treatment results in offering the consumer with absolutely safe ad pure drinking water.

TECHNICAL DATA

TECHNICAL DATA:
RAW WATER STORAGE TANK: (RWST)
Raw water is required in for storage of chlorinated water having appropriate capacity. The tank is fitted with PVC pipe work & isolation valves and suitable type of level indicator.
RAW WATER SUPPLY PUMP: (RWP)
A Horizontal Centrifugal type of pump in Stainless Steel construction has been provided for supplying Raw Water to Pressure Sand Filter Unit. Necessary Suction / discharge pipe work in SS construction with isolation valves are also provided up to PSF Unit.
PRESSURE SAND FILTER: (PSF)
Raw Water is first filtered by filtration unit in series prior feeding R.O. Plant. Pressure Sand Filter Unit is provided for removal of suspended matters & turbidity from raw water. PSF Unit is a SS vertical Pressure Vessel. Internally, it is fitted with bottom collecting system. Uniform grades silica quartz sand is charged on the supporting media of pebbles and gravels. This unit is fitted with SS frontal pipe work and Multiport Valve externally. During service cycle water is passed in down ward direction through sand bed, thus entrapping suspended matter & turbid particles. Over a period of time, sand bed gets chocked due to suspended matters resulting higher pressure drop and lesser floe. At this stage filter bed need to be backwashed.
When pressure drop across the sand bed increases beyond the specified limit (0.5 kg/cm^2) or quality of filtered water determinates, whichever is earlier. Regeneration involves backwash & rinsing of Sand Bed as below. For backwashing service water is passed in reverse direction of service cycle to loosen the filtering media bed. Due to this, entrapped suspended matters get free and come out along with effluent water. Backwashing is continued for about 10- 15 minutes or till the effluent coming out is clear.
For Rinsing of Sand Bed: Service water is passed in down ward direction to settle down the sand bed. The effluent water is drained for about 5 minutes time to ensure all unclear water is drained down.
ACTIVATED CARBON FILTER: (ACF)
Natural water may contain Colour, Odour, and Chlorine & Organics in different proportion, which is undesirable for potable application, and hence, it is necessary to remove the same from water. If raw water is chlorinated for die-infection, it is necessary to remove the free Chlorine feeding to R.O System. Chlorine being a strong oxidizing agent, it damages R.O. Membranes. Activated Carbon can remove Chlorine, Odour, & Colour while passing the water through carbon bed along with Odour & colour. These Carbon granules having larger surface area and specific property to absorb organics. ACF Unit is a FRP vertical pressure vessel. Internally it is fitted with strainer on bottom collecting system. The unit is fitted with SS frontal pipe work & MPV externally. A granular activated carbon is charged on the supporting media of Coarse & Fine Silex. During service cycle water is passed in down ward direction through Carbon Bed, which removes Chlorine & Odour from water.
When pressure drop across the Carbon Bed increased beyond the specified limit of (0.8 kg/cm^2) or quality of filter water deteriorates, whichever is earlier the unit is isolated for regeneration. The regeneration involves backwashing & rinsing of Carbon Bed. Over a period of time, life of carbon gets exhausted which can be checked during laboratory testing. Particularly iodine value is most important for this application. Generally carbon is replaced once in a year.
SMBS DOSING SYSTEM: (SMBS)
The Chlorinated water may oxidize the membrane and to avoid the same precautionary we have provided Sodium Meta Bisulphate dosing system Dosage rate is 4-5 mg/liter. A HDPE chemical preparation tank with an electronics diaphragm type dosing pump is provided for this.
ANTI SCALENT DOSING: (ANTI SCALENT)
The hardness salts of calcium & magnesium are likely to be precipitated if concentration exceeds its solubility limit & it may faults the membranes resulting into scaling which ultimately leads to poor treated water quality from R.O. System. To prevent this a anti Scalent dosing (scale inhibitor) dosing system is provided. Normally a scale inhabitation like Perma care 191 or equivalent chemical is dosed in feed water. Dosage rate is 4-5 mg/liter. A HDPE chemical preparation tank with an electronics diaphragm type dosing pump is provided for this.
MICRON CARTRIDGE FILTER: (MCF)
This kind of Micron Cartridge Filter having Series of filtration with the 20 Micron , 10 Micron , 5 Micron , 1 Micron , 0.45 Micron & 0.2 Micron Nominal & Absolute Micron Cartridge. This is a Consumable Cartridge and should replace it after Days of operation. This for Extra Safety of your Product water as it comes through the followed filtration and there are some chances to slippages for any particles which can be stop through the Cartridge also 1 , 0.45 , 0.2 micron cartridge filter will also take care of Bacteriological growth up to 0.2 micron.
HIGH PRESSURE PUMP: (HPP)
For Reverse Osmosis Process to take place feed pressure of water need to be raised. For this purpose a Vertical Multistage Centrifugal High Pressure Pump in S.S construction is provided R.O. System requires operating pressure of about 14-16 kg/cm^2 . High-pressure pump is fitted with S.S. discharge pipe work with necessary control valves. Necessary instruments like a High Pressure Switch, Pressure Gauge and recirculation valves are provided for safer operation of system
REVERSE OSMOSIS SYSTEM: (ROM)
Reverse Osmosis System rejects 97 – 99% of total dissolved solids by the principle of `Osmosis’. This system consists of a R.O. Module assembly mounted on S.S. Skid. High pressure rating FRP Pressure Vessel is fitted on the skid which houses spirally wound membrane elements in series.
In RO System feed soften water is divided into two streams viz Product & Reject water. Product water is treated water having lesser TDS. Reject water is highly concentrated water, which is not to be used for any purpose but drained. Feed water at elevated pressure is first fed to first Pressure Vessel; treated water is collected in center core tube. Treated water from each membrane is collected jointly in a common product water storage tank and reject is drained.
For safe operation of system following instruments are provide on Panel.
· Feed & Reject Pressure Gauge to indicate respective pressure of R.O. System.
· Feed & Reject Flow Indicator to indicate respective flow of R.O. System.
· T.D.S Meter to measure TDS of Raw & Treated water.
· High Pressure Switch for tripping high pressure pump in case of excessive feed pressure of R.O. System.
· Time Totaliser for counting working hours of H.P Pump/ R.O. System
PRODUCT WATER STORAGE TANK: (PWST)
One No. of Treated water from R.O. System is stored in a supplied S.S. constructed storage tank of appropriate capacity. The tank is fitted with S.S. pipe work & isolation valves and suitable type of level indicator. One no. of transfer pump is provided in S.S. material of construction to feed the water in MCF.
MICRON CARTRIDGE FILTER – II & III: (MCF)
During storage, atmospheric or any other contamination may take place in treated water. Hence, after passing water from R.O. System, water is once again passed through a micron cartridge filter. This is a S.S.316 Vessel fitted internally with P.P spun micron cartridge elements having absolute ratings of 1.0 micron & 0.2 microns which removes all bacterial impurities present in the water and make the water free of particulates.
ULTRA VIOLET STERILIZER: (UVS)
Through R.O. treated water is free from all the micro-biological impurities like Bacteria, Virus, etc. it may redevelop again in water during prolonged storage. For disinfection of water is essential for Reverse Osmosis Application before Filling & Sealing in bottle. Hence, a online Ultra Violet Sterilizer is provided for disinfection of R.O. treated water before filling in pre-cleaned PET Bottles. The water to be disinfected is passed through U.V. System, which consists of U.V. Tubes which radiates high intensity Ultra Violet Rays, which in turn kills the micro organisms. This system consists of a S.S finished surface housing with Ultraviolet Lamps fitted in it. The water to be treated is surroundings this tubes during treatment. An electrical systems is provided for production of high voltage required for U.V. Rays generation
OZONE GENERATOR: (OZONE)
Though R.O. System rejects all the micro – organisms like bacterial & virus and even after passing through U.V. System it may redevelop in packed bottles over a period of time. Hence, it is necessary to disinfect R.O. Product water prior to bottling filling. This is very much essential to ensure good Mineral Water Quality as per the standards. This Ozone Generator will give your water Oxygen Rich water and remove the Bacteriological growth and also provide you the Shelf Life of your Packed Bottle water unless it opens for some period of time. Also this Ozonation of water can add some taste in to your treated water.
OZONE RE-CIRCULATING TANK: (ORT)
For required PPM Ozone gas mix up in finish product water. In ozone re-circulating tank water re-circulating by required flow rate pump. Ventury of ozone install out let of Pump it suction ozone and mix-up help with static mixer. This tank is provided with one no. of re-circulating pump and one no. of product water transfer pump to the filling section.

GENERAL REQUIREMENTS FOR PACKAGED DRINKING WATER

REQUIREMENTS TO BE COMPLIED WITH BY THE APPLICANT OF PACKAGED DRINKING WATER FOR GRANT OF BIS LICENCE ACCORDING TO IS 14543:2004
A. GENERAL REQUIREMENTS (FOR PACKAGED DRINKING WATER)

General requirements for grant of BIS Licence,

please see BIS website http://q63.linkybank.com
B. PRODUCT SPECIFIC REQUIREMENTS

1. List of Test Equipments, Glass wares & Chemicals --- See Annex A

2. List of BIS approved outside lab for the Product Water, --- See Annex B
Containers (including lids/caps)
3. Details of samples of the product/containers to be drawn during --- See Annex C
4. Acceptance of Marking Fee --- See Annex D
5. Acceptance of Scheme of Testing and Inspection (STI) --- See Annex E
6. Guidelines for assessment of Hygienic conditions with --- See Annex F
Explanatory notes for guidance
7. List of Indian Standards which a Packaged Drinking Water Industry --- See Annex G
must have in original
8. Undertaking for getting the samples tested as per STI frequency from BIS approved/NABL accredited outside lab.
9. Consent letter from concerned outside lab for testing of sample (Ref. Sr. No. 8).
10. Copy of the appointment letter, qualification certificates for Chemist and Microbiologist
11. No Objection Certificate (NOC) from the concerned office of Central Ground Water Authority (if applicable in the state).
12. Detailed Manufacturing process indicating treatment for disinfection along with Process Flow Chart. Clause 3.2 of IS 14543:2004 specifies various processes for manufacturing Packaged Drinking Water for guidance only
13. Copies of Medical Examination Reports of the employees engaged in washing/filling of the product for any communicable/skin diseases and fitness to work in a food industry.
14. Details about the arrangements of pest control treatment such as an agreement/contract with the agency. Also details of Cleaning in Place (CIP)
15. Declaration of Shelf-life of the product separately for each type of container (e.g. 1littre, 2 litre, 20 litre etc.).
16. Undertaking Regarding clause 6 (Packing) of IS 14543:2004 and clause 7.2 of IS 14543:2004 (Labelling Prohibitions)
17. Obtain request letter from BIS for getting the sample tested for Radio Active Residues, from BARC before submitting the application and test report received from BARC is to be submitted along with the application form....{.Read More } ......

Packaged Drinking Water Project

General considerations and principles for Drinking-water Quality.

The primary purpose of the Guidelines for Drinking-water Quality is the protection

of public health.Water is essential to sustain life, and a satisfactory (adequate, safe and accessible) supply must be available to all.Improving access to safe drinking-water

can result in tangible beneﬁts to health.Every effort should be made to achieve

a drinking-water quality as safe as practicable.

Safe drinking-water, as deﬁned by the Guidelines, does not represent any signiﬁ-

cant risk to health over a lifetime of consumption, including different sensitivities that

may occur between life stages. Those at greatest risk of waterborne disease are infants

and young children, people who are debilitated or living under unsanitary conditions

and the elderly. Safe drinking-water is suitable for all usual domestic purposes, including personal hygiene. The Guidelines are applicable to packaged water and ice

intended for human consumption. However, water of higher quality may be required

for some special purposes, such as renal dialysis and cleaning of contact lenses, or for

certain purposes in food production and pharmaceutical use. Those who are severely

immunocompromised may need to take additional steps, such as boiling drinkingwater, due to their susceptibility to organisms that would not normally be of concern through drinking-water. The Guidelines may not be suitable for the protection of aquatic life or for some industries.

The Guidelines are intended to support the development and implementation of

risk management strategies that will ensure the safety of drinking-water supplies

through the control of hazardous constituents of water. These strategies may include

national or regional standards developed from the scientiﬁc basis provided in the

Guidelines. The Guidelines describe reasonable minimum requirements of safe practice to protect the health of consumers and/or derive numerical “guideline values” for...{ Read More }...

Tuesday, November 1, 2011

Processing of Water for Bottling

Processing of Water for Bottling.

I n I n d i a , t h e q u a l i t y o f drinking water is very poor i n

c omp a r i s o n t o o t h e r c o u n t r i e s . T r e a tme n t o f

wa t e r i s r e q u i r e d f o r pur i f i c a t ion. To produc e h i g h

q u a l i t y d r i n k i n g wa t e r a s p r e s c r i b e d b y t h e Wo r l d

He a l t h Or g a n i s a t i o n (WHO) ,c o n v e n t i o n a l

p r o c e s s i n g methods like coagulation, flocculation,

sedimentation, ion exchange, filtration and o x i d a t i o n e t c . a r e n o t

s u f f i c i e n t . Memb r a n e processes have advantages

over other treatment processes. Micro-filtration and ultra-filtration are said to

be very useful inremoving micro-organisms. Reverse osmosis membranes

are used to remove various contaminants found in drinking water.

A combination of reverse osmosis and de-ionisation can be used to

produce high quality water.

Bottle Filling

Before filling, freshly manufactured plastic bottles are rinsed and inverted

from where they go for filling on a rotary bottle filler. The water flows from

the filler bowl into the bottles via ventra flow valves. These valves use

an airlock method for accurate filling. The variation is no more than

5mm. When liquid reaches the end of the valve sleeve, air cannot escape.

Pressure is created at the top of the bottle, and no more liquid can enter.

The airlock method provides consistent, repetitive filling and reduced

product loss. The fillers are available in a wide range of configurations and

are adaptable to a variety of capping systems. IS : 14543 - 1998

(Specification for Packaged Drinking Water) prescribes the hygienic practices

to be followed in respect of collecting water, its treatment, bottling,

storage, packaging,transport, distribution and sale for direct consumption ,

so as to guarantee a safe, hygienic and wholesome product.The

bottles are generally capped using roll-on type plastic caps,with pilfer

proof rings. PET Bottles in the Indian Market.

Bottle Labeling

The last step is the labeling of bottles. In the earlier days, gummed paper labels

were used which satisfied only the legal requirements of declaration. When

these labels came in contact with moist surface, they lost their identity. Later

shrink film plastic labels came into use for this a p p l i c a t i o n . Au t o –

s l e e v e s y s t em f o r l a b e l i n g t h e n b e came a c omme r c i a l

s u c c e s s .Auto-sleeve labels are used both for one way and refillable-multi-

trip plastic bottles. It is a stretchable label made of low density polyethylene of special grade.

The Department of Health, Ministry of Health and Family Welfare has notified to carry the

following declaration on the label of the disposable bottle of mineral water or

packaged drinking water.

[“Crush the bottle after use” ]

The notification will be published in the Gazette of India and the rule will come into force from

01/04/2004.Other labeling requirements should be as per PFA Rules and

Packaged Commodities Rules as prescribed in IS: 14543 – 1998 (Specification for

Packaged Drinking Water).

Packaging Requirements

It is well known that drinking water should be packed in clean, colourless, odourless,

clear, tamperproof containers, which are hygienically safe. Much of the water is packaged

in similar bottles as carbonated soft drinks, and would, therefore, carry many of the same

requirements.Strength Unlike carbonated drinks, the bottles filled with still water need

only enough strength to hold water and to survive impact.Colour and Clarity

Clarity is one of the most important requirements and is the main reason why clear bottles of

plastics are used. A resin with higher levels of co-polymer adds to the clarity. As regards the

light blue colour in the bottles, this is permissible for one time use bottles. However in India,

the BIS (Bureau of India Standards) has prescribed colourless bottles for multi trip

/reusable containers. S i n c e c u r r e n t l y a lmo s t a l l t h e b o t t l e r s u s e

b l u e c o l o u r e d c o n t a i n e r s , s t u d i e s h a v e

commenced at IIP to establish whether blue colour helps to reduce the UV effect and the

percentage of blue colour that could be considered to be added without affecting the clarity

of the bottle.PurityBecause water is a flavourless product, using a plastic that remains

tasteless and odourless isimperative. Mandatory Certification To prevent adulteration,

the quality of the bottle and its sealing drew great attention and concern. The

standardisation of the quality of the water and the bottles was not thought of earlier. There

was a concern whether mushrooming brands in packaged drinking water would really ensure

quality and safety. The provisions of mandatory BIS certification and that of Prevention of Food

Adulteration Act (PFA) have brought in assurance to the consumers that packaged drinking

water is trustworthy.The Indian Standard IS: 14543 – 1998 prescribes the quality and

safety requirements of packaged drinking water...{ Read More }....

REJECT WATER HARVESTING
The Reverse Osmosis process has been discussed. Since it is a process based on molecular rejection, wastage of water is an inherent feature. The water thus rejected needs attention.Lately, Apart from bottled water industries, majority of the industry is switching over to RO technology, in place of conventional DM [ion exchange] process.

Though the reject water stream has more TDS than the raw water, the water which passes through RO membranes is invariably pre treated for turbidity hardness therefore it is safe to harvest it. As currently there is no limit of TDS set by pollution control board, for putting it in land or harvesting, this process COULD be carried out. BUT one should remember that SODIUM ABSORPTION RATIO has to be kept under control while such discharge and harvseting. To put in plainly, there should be an ideal level of Mg. & Ca. Vis-à-vis sodium so as to retain the fertlity of the land. It is where social and environmental factor comes into play as at this juncture, law is silent regarding the reject discharge and harvesting.
The day is not far when authorities would lay down restrictions on quality of water being drained.

Rain Water Harvesting

Rainwater harvesting refers to the collection and storage of rainwater. It also refers to other measures aimed at harvesting surface and ground water and prevention of its loss through evaporation and seepage. It includes all other hydrological studies and engineering interventions, aimed at conservation and efficient utilization of the water. It refers to collection of rainwater from roofs of the buildings to directly store it or use it to recharge the ground water aquifer. It makes optimum use of rainwater, which is the ultimate source that feeds all the secondary sources of water like rivers, lakes and ground water.

Broadly, rainwater is harvested for two purposes. The first purpose is direct storage The second purpose is recharging of ground water.

Notification

Special provision have been made by the Ministry of Urban Development and Poverty Alleviation, Govt. of India, in the Building Bye Laws 1983, in respect of rainwater harvesting. Gazette of India notification dated 28th July’ 2001 in this regard is produced as below:

‘Water harvesting through storing of water runoff including rainwater in all new buildings on plots of about 100 sq mts and the above will be mandatory. The plans submitted to the local bodies shall indicate the system of storm water drainage along with points of collection of rainwater in surface reservoirs or in recharge wells.

All buildings having a discharge of 10,000 litres and above per day shall incorporate waste water recycling system which shall be used for horticultural purposes.
{ Read More }...

Friday, October 28, 2011

General considerations and principles for Drinking-water Quality

General considerations and principles for Drinking-water Quality