IN THE PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD OF THE DEGREE OF

Mechanical Engineering

B.Tech (Batch – 2010)

Six Months Industrial Training at Nestlé India Ltd., Moga

Under the Guidance of: Submitted by:

Mr. S.Swain –Safety Manager Avinash Kumar

Mr. H.S Makkar –Safety Officer 100661132226

Mech Engg.- 4th Year

Shaheed Bhagat Singh State Technical Campus, Ferozepur

1

DECLARATION:

I hereby declare that my project work entitled “INDUSTRIAL TRAINING AT

NESTLE” is an authentic record of my own work carried at Nestle industry Moga as

requirements of Six Month Industrial Training for the award of the degree of B.E

(Mechanical Engineering) SBSSTC under the guidance of Mr. SATCHIDANANDA

SWAIN and Mr. HARPAL SINGH MAKKAR during the training in June-November

2013.

AVINASH KUMAR

100661132226.

2

PREFACE

This training report reprints the opportunity that I got to be in professional

environment for the Six Month Industrial Training program in the 7th semester of fourth year

B.Tech in Mechanical Engineering. I am really thank full to the Dr. T.S Siddhu (Campus

Director) & Mr. Tejeet Singh (H.O.D of Mechanical Department). This effort is made that

this report gives a clear picture of the technical and commercial aspects of Nestlé Moga

which may be practical guide for Thermal engineering.

Experience, no doubt, is a great teacher and a valuable asset. However the supreme

importance of sound working knowledge of principles should not be over locked with it mere

experience cannot go a long way.

I have endeavored in this training report to explain basic principles can be applied in

practical zone. it is with deepest sense gratitude that I wish acknowledge in valuable guidance

rendered to me during training time.

Project Based on “Study of Boiler”

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ACKNOWLEDGEMENT

“Out standing achievements are not possible in vacuums. It needs a lot of help and assistance

besides a healthy environment.”

With deep sense of gratitude and indebtness to these great institutions that provides

me an opportunity to fullfill the most cherished desire of reaching my goal.

I am highly obliged and express my gratitude to our teachers for their encouragement,

feedback support and suggestions. With the help of his blessings and guidance I stand here

today.

With deep sense of gratitude, I would like to take this opportunity to thank my project

guide Mr. SATCHIDANANDA SWAIN and Mr. HARPAL SINGH MAKKAR could not

have asked for a more cooperative guide. Their involvement and unstinted support always

gives me the confidence to do my work without their guidance. I would like to thank the

people who took their time to help me to complete this project.

My profound thanks to MR. UTTAM KUMAR and MR. HARI SINGH for guiding

support all through my training at industry. I would like to acknowledge the warmth,

affection and co-operation by the operators and workers of Nestle India Ltd.

Last but not the least; I would like to thank my parents who were a source of

support throughout the making of the report.

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TABLE OF CONTENTS

Declaration 2

Preface 3

Acknowledgement 4

CHAPTER 1- INTRODUCTION TO COMPANY 9

Company Profile 10

A Word About Nestle- The Nestlé

Nestle philosophy 11-12

Nestle History

Nestle Mission Statement 13

Nestle Logo 14

Nestle Today

Nestle Factories In India 15-17

Operations In India 17

Nestle Moga 18

INTRODUCTION TO PRODUCTS 19-22

Beverages

Chocolates and Confectionary

Nestle Dishes and cooking

Ghee Products Aids 23

Moga Factory

Salient Features of Nestle Moga Factory 23-25

Various Departments in the Nestle Moga Factory

The Factory Consists of Four Production Plant

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MILK OPERATIONS 25-31

Milk Operation

Fresh Milk Reception

Ghee Plant

Egrons

Powder Filling Plant

Cereals

Utility Service Department

Boiler House

Effluent Treatment Plant

Culinary

CHAPTER 2- SAFETY 32

Why Safety

Accident

Main Reasons of Accidents 33

Reason of Careful Work

Accident sequence 34

Unsafe Acts

Unsafe Condition

Accident Prevention 35

Near Miss

Important Note 36-37

CHAPTER 3- UTILITY SERVICE DEPARTMENT 38-39

Refrigeration and Air Conditioning

Refrigeration Plant

Principle of Refrigeration Plant 40

Component of Refrigeration System

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A Typical Vapour Compression Cycle

Description of Vapour Compression Cycle 41

Refrigerant Used 42

Oil Separation 43

Cooling Towers 44

Introduction

Types of Cooling Towers 45

Natural Draft Cooling Tower

Mechanical Draft Cooling Tower 46

Forced Draft Cooling Tower 47

Induced Draft Counter Flow Cooling Tower 48-49

Induced Draft Cross Flow Cooling Tower

Factors Affecting Cooling of Water in a Cooling Tower

Heat Exchangers 50

Types of Heat Exchangers

Plate Heat Exchanger

Shell and Tube Heat Exchanger 51

Selection of the Tube Material

Heat Exchanger in Industry 52-53

Air Handing Unit 54-59

Air Handing Components

Heating and Cooling Elements

Filters

Humidifiers

Mixing Chamber

Heat Recovery Device

Controls

7

Vibration Analysis 60

CHAPTER 4- PROJECT BASED ON BOILER HOUSE 61

Boiler House

Boiler Basic

Shell Boiler 62-63

Package Boiler 64

Water Tube Boiler 65-66

SUGGESTION FOR IMPROVEMENT 67

REFERENCES 68

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CHAPTER 1

INTRODUCTION TO COMPANY

(HENRI NESTLE)

9

COMPANY PROFILE

A WORD ABOUT NESTLÉ - THE NEST

Nestle India is a multinational company with its worldwide operations in over 70

countries .The founder of Nestle was Henry Nestle who from a modest beginning founded the

company in 1866 at Switzerland for manufacturing milk powders for babies. At that time

Switzerland faced one of the highest infant mortality rates and the milk formula saved the

lives of many infants whose mothers were unable to breast feed successfully.

At present Nestle is the world’s largest food company with its international headquarters at

Vevey, Switzerland, with almost 500 factories world wide it employs almost 2 30,000 people.

Nestle is often quoted by most as “multinational of multinationals.” There is a good reason,

as less than 2% of the turnover comes from the domestic market in Switzerland.

Nestle is much decentralized in its operations and most of the markets are given considerable

autonomy in its operation. It is more of a people and products oriented company rather than

systems oriented company there are “unwritten guidelines” which are to be followed, based

on common senses and a strong set of moral principals emphasizing a lot of respect for fellow

beings.

Nestle has always adapted to the local conditions and at the same time integrates its Swiss

heritage. It has always taken a long-term view in the countries in which it operates.

There is a great emphasis placed on training by the company. It believes in rewarding

and promoting people from within. The Company’s transparent business practices, pioneering

environment policy and respect for the fundamental values of different cultures have earned it

an enviable place in the countries it operates in. Nestlé’s activities contribute to and nurture

the sustainable economic development of people, communities and nations.

Today its product brand name ‘Nestlé’ is associated with ‘quality products’ in

worldwide consumer market. Above all, Nestlé is dedicated to bringing the joy of ‘Good

Food, Good Life’ to people throughout their lives, throughout the world.

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NESTLE PHILOSOPHY

When Henry Nestle introduced the first commercial infant formula in 1867, he also created a

symbol of the Bird’s nest, graphic translation of his name, which personifies the company’s

business. The symbol, which is universally understood, evokes security, motherhood and

affection, nature and nourishment, family and tradition. Today it is the central element of

Nestle corporate identity and closely parallels the company’s corporate values and culture.

NESTLE HISTORY

The Nestlé Company was Henri Nestlé's search for a healthy, economical alternative to

breastfeeding for mothers who could not feed their infants at the breast.

The Company formed by the 1905 merger was called the Nestlé and Anglo- Swiss Milk

Company. The close of World War II marked the beginning of the most dynamic phase of

Nestlé's history.

In 1947, Nestlé merged with Alimentana S.A., the manufacturer of Maggi seasonings and

soups, becoming Nestlé Alimentana Company. After the agreement with L’Oreal in 1974,

Nestlé's overall position changed rapidly.

Between 1975 and 1977, the price of coffee beans quadrupled, and the price of cocoa

tripled.

Nestlé approached the 1980s with a renewed flexibility and determination to evolve. Thus,

between 1980 and 1984, the Company divested a number of non-strategic or unprofitable

businesses. Nestlé managed to put an end to a serious controversy over its marketing of

infant formula.

Nestlé opened the 20th century by merging with the Anglo-Swiss Condensed Milk

Company to broaden its product range and widen its geographical scope. In the new

millennium, Nestlé is the undisputed leader in the food industry, with more than 470

factories around the world. Nestlé's existing products will grow through innovation and

renovation.

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S.No Year Achievements

1 1866 Company's foundation

2 1905 Merger between Nestlé and Anglo-Swiss Condensed Milk

Company

3 1929 Merger with Peter-Cailler-Kohler Chocolates Suisses S.A.

4 1947 Merger with Alimentana S.A. (Maggi)

5 1971 Merger with Ursina-Franck (Switzerland)

6 1985 Acquisition of Carnation (USA)

7 1988 Acquisition of Buitoni-Perugina (Italy)

8 1988 Acquisition of Rowntree (GB)

9 1992 Acquisition of Perrier (France)

10 1995 Nestlé acquires Victor Schmidt & Söhne, Austria's oldest producer

of confectionery, including the famous 'Mozartkugeln'.

11 1997 Nestlé, through the Perrier Vittel Group, expands its mineral water

activities with the outright acquisition of San Pellegrino.

12 1998 Nestlé acquires Spillers Pet foods of the UK and strengthens

position in the pet food business which began in 1985 with the

acquisition of the Carnation Friskies brand.

13 1999 Divestiture of Findus brand (except in Switzerland and Italy) and

parts of Nestlé's frozen food business in Europe.

14 1999 Divestiture of Hills Bros, MJB and Chase & Sanborn roast and ground

coffee brands (USA).

15 2000 Acquisition of Power Bar.

16 2001 Nestlé acquires Ralston Purina - Nestlé Purina Pet Care Company

established.

17 2002 Perrier Vittel Group re-named as Nestlé Waters.

18 2006 Pantnagar plant starts manufacturing noodles.

19 2008 Cup noodle starts at Moga plant

NESTLE MISSION STATEMENT

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At Nestle, we believe that research can help us make better food so that people live a

better life. 

Good Food is the primary source of Good Health throughout life. We strive to bring

consumers foods that are safe, of high quality and provide optimal nutrition to meet

physiological needs. In addition to nutrition, health and wellness, Nestle products bring

consumers the vital ingredients of taste and pleasure.

As consumers continue to make choices regarding foods and beverages they

consume, Nestle helps provide selections for all individual taste and lifestyle preferences.

Research is a key part of our heritage at Nestlé and an essential element our future.

We know there is still much to discover about health, wellness and the role of food in our

lives, and we continue to search for answers to bring consumers Good Food for Good Life.

NESTLE LOGO

The Nestlé logo was launched by Henri Nestlé in 1868 on the basis of the meaning of

his name in German, i.e. little nest, and of his family emblem (that you can see here).

Henri obtained a 15-year French patent for his logo in 1868.

After he retired, it was registered in Vevey in 1875 by the new owners of his

company.

In 1938, the traditional nest design was combined with the "Nestlé" name to form

what is called the combined mark.

In 1966 the design was simplified.

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Beverages28%

%

Milk Products Nutrition Ice Cream

27%

Chocolate Confectionery Biscuits

14%

Pharmaceuticals6%

In 1988, the worm in the mother bird's beak was removed and the fledglings became

two instead of three. It is said that it was meant to better illustrate the activities of the

company, no longer active only in utrition, and to reflect the average modern family

of two children.

The logo we know now has just been simplified.

NESTLÉ -TODAY

Some names seem to belong to legend and Nestlé now synonymous with a prestigious trademark

and world’s foremost food group originally consisted of two companies Henry Nestle of Vevey

Switzerland & Anglo Swiss Condensed Milk Company in Cham. Both companies competed

vigorously from 1866- 1905. These groups merged in 1905 and become the starting point of the

recent food group.

Nestlé is now the No. 1 Food Company. It is present on all five continents has an annual turnover

of nearly 89.2 Billion Swiss Francs is present on all five continents. At present there are around

508 factories spread over 80 countries with around 260 operating companies One basic research

center and 17 technological development groups and has in excess of 2,30,000 employees.

Nestlé operations worldwide are divides into 3 zones:-

ZONE EUR : Europe

ZONE AOA : Asia and Oceanic

ZONE AMS : Americas

India comes under zone AOA which includes South- East Asian trading giants of the likes of

Thailand, Indonesia, Malaysia, Singapore, China etc. besides Australia. Mr. Nandu

Nandkishorecurrently heads ZONE AOA.

Currently Mr. Peter Brabeck heads the Nestle group worldwide and Mr. Paul Bulcke is COE

NESTLE S.A.

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Nestle India have 8 Factories in Our Country:

MOGA Factory:- Moga factory started production

in1962. Today, Moga contributing almost 75% of Nestle

India’s total production volume and manufacturing

109671 tons of food products. It employs around 1600

people. Dairy creamers, IMF, SCM, Cereals, Vending

Mixes, Noodles, Ketchups, Bouillon are manufactured in Moga

Choladi Factory:-

The factory ion Choladi started production in

1967, Situated in South Asia, about 275

kilometers from Bangalore. The factory today

has around 80 employees. It processes about 725 tons of soluble tea, which is all exported.

Nanjangud Factory :- Production

in Nanjangud Factory started in 1989 with

the manufacturing of Nescafe and Sunrise

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Milo manufacture at Nanjangud begun in

1996. It situated 160 kilometers south of

Bangalore; the factory has around 245 employees. It manufactures 15500 tons of Nescafe

mixes, Milo.

Bicholim Factory:-A satellite factory of

Ponda at Bicholim for manufacturing of Noodles and

Cold Sauces, It started their operational activity in

1997.

Ponda Factory:-Ponds Factory started

production of KitKat in 1995. It is located 40

kilometers from Panji ‘the capital of Goa’. It

manufactures Chocolates. Ponda currently

employed around 250 people.

Samalkha factory:-Samalkha Factory started

production in 1993 situated 70 kilometers from Delhi.

It has 260 employees and manufactures about 35000 tons of food products

Pant Nagar Factory:-This is the one of the

newly situated and the 7th factory of the Nestle in

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the India. Pantnagar Factory began production of

Noodles in 2006

Tahliwal Factory:- The 8th Factory was set

up at Tahliwal, Himachal Pradesh, in 2012. It will

manufacture confectionery and chocolates.

OPERATIONS IN INDIA:

Nestlé set up its operations in India, as a trading company in 1912 and began

manufacturing at the Moga factory in 1962. The production started with the manufacture

of Milkmaid and other product was gradually brought into the fold. Nestlé India Limited

was formally incorporated in 1978 prior to which the manufacturing license was issued in

the name of the Food Specialties Limited. The corporate office is located at Gurgaon and

the registered office at M-5A, Connaught Circus, and New Delhi At present Nestlé have

7 manufacturing units countrywide which are successfully engaged in meeting the

domestic as well as the exports demand. In addition there are several co packing units.

NestléMoga

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MOGA PLANT

In the Malwa region of Punjab State, there is a small town, which is popularly known among

the famous grain markets of the world. However the credit of bringing this town on the

industrial map of the world goes to Nestle – a Swiss Multinational company engaged in the

largest food processing operation in the world. When in 1959 Nestlé took decision to

establish a milk processing factory, a very little could the people of Moga town and the

farmers in the surrounding villages realize that the company now as Nestlé India Ltd would

play such an important role in economic & social development of the area .Company started

milk collection in Moga area on 15 Nov 1961 and on the first day 510 kg of milk was

collected from four villages. The total procurement in 1962 was 2,054 million kg from 4,660

milk suppliers of 66 villages and in 1962 fresh milk reception are 102, 33 Million kg from

46,308 farmers delivering milk at 650 collection centers in 574 villages and 10 milk chilling

centers. By 1998 the milk chilling centers had increased from 10 to 186.

INTRODUCTION TO PRODUCTS:-

Beverages:

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NESCAFE CLASSIC is a 100% pure coffee and is made from carefully

selected coffee beans picked from the finest plantations, blended and roasted

to perfection to create the unique rich and smooth NESCAFE taste.

NESCAFE SUNRISE is an Instant Coffee-Chicory blend, popular for its

robust body and a flavor akin to fresh roast-and-ground coffee. The secret

lies in the right blend of flavorful coffee and roasted chicory to give you an

incomparable experience.

NESTEA Tea Bags are made from the finest blend of Assam Teas, which

give a refreshing cup of bright, colour tea of fair strength and superior taste.

They are available both in individually enveloped and non-enveloped formats.

The improved new NESTLÈ MILO gives children the energy they need to

enjoy their active lifestyle. Packed with Actigen - E, a unique mix of B-

vitamins and other key micro nutrients which help optimize energy release

effectively.  In addition its extra cocoa and rich malt makes it so chocolaty

and irresistible that they will always be asking for more.

A wide range of premixes for the vending machines. The basket of products

include NESCAFÈ Classic, NESCAFÈ Frappe, Tea Premix (Plain,

Cardamom), Hot Chocolate, Iced Tea (Lemon, Peach, Apple), and Badam

(Almond) Milk vending mixes.

We manufacture high quality Hot & Cold Water Soluble Black and Green Tea

Powders at our state-of-the-art factory in Choladi, located in the midst of tea

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plantations which ensure availability of fresh green leaves

Chocolates and Confectionary:-

NESTLÉ KIT KAT is delicious crisp wafer fingers covered with Chocó

layer. Our special tropical zed recipe ensures that NESTLÉ KIT KAT is

preserved even in warmer climates.

NESTLÉ MILKY BAR is a delicious milky treat which kids love. With its

Calcium Rich recipe, NESTLÉ MILKY BAR is a favorite with parents to

treat their kids with.

Extremely popular in India, NESTLÉ MUNCH is wafer layer covered

with delicious Chocó layer. A crispy light irresistible snack!

NESTLÉ Milk Chocolate is a milk chocolate with a delicious taste

for you to savors.

NESTLÉ BAR-ONE is a luscious nougat and caramel core covered

with a delicious Chocó layer.

NESTLÉ offers a bouquet of three exciting éclair variants: NESTLÉ

Éclairs are rich milky caramel Éclairs with a soft center. NESTLÉ

Chocolate Éclairs are a delicious delight with luscious creamy chocolate inside.

NESTLÉ MILKY BAR, Éclairs are delightful Éclairs with a creamy milky chocolate

center.

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POLO is a mint roll popularly described as ‘The Mint with the hole’.

Now also in the new extra strong singles format as POLO Power mint.

Nestle Dishes & Cooking Aids:-

MAGGI 2-MINUTE Noodles is one of the most popular brand of

instant noodles in India. Available for export in 5 authentic Indian

flavors (spicy Masala, tangy Chatpata, Chicken, Tomato and Curry), it

is a delicious anytime snack that’s ready in just 2 minutes.

MAGGI Vegetable Atta Noodles is a unique innovative product with the

goodness of whole wheat and real vegetables. Available in the popular

Masala flavor.

MAGGI Chinese Noodles makes it so simple to prepare delicious

‘Indian Style’ Chinese Noodles at home in a jiffy! Offered in two exciting flavors,

Veg Chowmein and Lemon Chicken. These packs are for export

In addition to the nutrition from whole wheat, MAGGI Dal Atta Noodles

offers the goodness of Dal (lentils) in the deliciously ethnic Samber

Tastemaker.

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MAGGI offers a wide range of specialty Indian Sauces which are

relished for their unique taste. Available in the following delightful

variants: Tomato Ketchup, Tomato Sauce, Tomato Chilly, Masala

Chilly, Chilly Garlic, Tamarina, Tomato Chatpata, Tomato Pudina

and the all-time-favorite MAGGI Hot & Sweet Sauce.

MAGGI ‘Taste of India’ Pastes are a delicate blend of traditional

spices and freshly ground pastes, offering the convenience of

preparing authentic Indian recipes at home, in no time at all! The range

includes Biryani Paste, Curry Paste, Korma Paste, Tandoori Paste and

Tikka Masala Paste.

New MAGGI Healthy Soups are even more delicious, quick to

prepare, convenient and healthy. They contain real vegetables, are low

fat and cholesterol free. They also do not have added MSG,

preservatives or artificial colours.

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GHEE PRODUCTS

MOGA FACTORY

SALIENT FEATURE OF NESTLE MOGA FACTORY

In the Malwa region of Punjab State, there is a small town, which is popularly

known among the famous grain markets of the world. However the credit of bringing this

town on the industrial map of the world goes to Nestle – a Swiss Multinational company

engaged in the largest food now

23

NESTLÉ EVERYDAY Ghee is 100% pure Clarified Butter hygienically

packed to preserve its rich aroma and granular texture. As a cooking

medium, NESTLÉ EVERYDAY Ghee helps you add that authentic ethnic

aroma and flavor to Indian preparations every time, everyday.

A Partly Skimmed Sweetened Condensed Milk, NESTLÉ MILKMAID is

a versatile product and excellent as a dessert ingredient. With

MILKMAID, you can whip up lip-smacking desserts for your family the

shortest possible time.

NESTLÉ EVERYDAY Dairy Whitener is a creamy Dairy Whitener

specially made to add a rich, smooth taste to your tea. Every time, every

day.

Moga Factory

Processing operation in the world. When in 1959, Nestle took decision to stablish a milk

processing factory, a very little could the people of Moga town and the farmers in the

surrounding villages realize that the company now as Nestlé India Ltd. would play such an

important role in economic and social development of the area.

The company is not only an industrial and a commercial house but has make sustained

efforts to improve economic and social environment of the people in the area of its operation

– be it farmers or residents of Moga. In the initial stages company faced many problems

including procurements of milk sales of which was considered a sin at that time. But the team

that surveyed that area found that it is quite suitable for development of milk and it has been

proved to be right decision.

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The company started its operation in 1962 with a capacity of 40,000 Kgs of milk per

day kept on expanding on regular intervals and at present handling capacity of 11,00,000 Kg

of milk per day. Many more products are being developed.

Company started milk collection in Moga area on 15 Nov, 1961 and on first day 510

Kgs of milk was collected from four villages. From that day onwards company is collecting

milk continuously both morning and evening without break. The total procurement in 1962

was to 2054 million Kgs from 46308 farmers delivering milk at 650 collection centers in 574

villages and 10 milk chilling centers. In 1998 the milk chilling centers have increased from

10 to 186. Nestle India Ltd. Moga factory is the oldest factory in India with the layout spread

57 Acres and have 3 plants within the factory and it is also largest factory in India

Various departments in the Nestle Moga factory

Supply Chain

NQAC

IP( Industrial performance)

FMR

Cereals

PFP

Culinary

QA

Engineering

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FMPDD

HR

The factory consists of four production plants:

MILK OPERATIONS

CEREALS

CULINARY

POWDER FILLING AND PACKAGING

MILK OPERATIONS

This plant as the name suggests is engaged in the processing of milk and all

the related activities that take place in Moga Factory. This plant can be categorized

into a number of sub- plants, which are discussed below in brief:

MILKEGRON

MILKSILO-STD

EVAPORATOR

MILK-TANKER

Packo-cooler

Milk -churnTemp.30 - 400c

PFP TEMP.40C

MILK RECEPTION AND PROCESSING

CEREALS

FRESH MILKRECEPTION

LP

TEMP.40C - 80c

HUMAN RESOURCE DEPTT. , MOGA FACTORY

Milk Reception

This plant as name suggested is engaged in the processing of milk and all related

activities that take place in Moga factory. This plant can be categorized in to number of sub-

plants:

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Fresh Milk Reception

The fresh milk, which is fundamental constituent of various products, which are

manufactured in this factory, is received in this area in tankers and churns. The fresh milk is

received in two ways namely churn milk and tanker milk. There are two reception lines both

for churn and tanker milk. There are 1100 agencies, which supply fresh milk in churns. The

fresh milk is supplied by various chilling centers.

Nestle has four own milk chilling centers. Testing of fresh milk is done in fresh milk lab

churn is tested for flat and SNF only. The supplier are paid only for fat according to %age. In

buffalo and cow milk fat varies from 4.5% to 5.5% and upto 4% respectively. While a

number of tests are performed on tanker milk. If any one of the test is found to be positive

then the tanker is rejected. The received milk is received in silos after passing through PHEs.

The pasteurized milk is stored in 6 namely A, B, C, D, E & F. The pasteurized milk is packed

in 15,000 polypacks per day. The fat and SNF in it is 4.6% and 8.6%. The milk stores in silos

used in production of various products in Ghee plant and Liquid plant.

Ghee Plant

The milk stored in silo D, E & F is used for manufacturing Ghee, which is marked

under the brand name Everyday. In this plant milk is passed through two separators. A phase

inversion from 40-50% cream in the first and 70-80% fat in the second is obtained. The final

concentration become 97% crude fat.

LIQUID PLANT

This plant is engaged in the processing of milk in the liquid form, prior to the

drying operations done in the Egron that converts it into milk powder. However

27

various products such as SCM & Desert Mixes are produced in the plant, besides the

base liquid for drying in Egrons

The general process-taking place in the plant can be summarized as follows:

The fresh milk received from the silos is first standardized. I.e. the

ingredients are added on the basis of the report send by FM lab and the product they

are going to manufacture. This is needed, as there are always variations in the

conditions at each different batch of milk. After this the milk is boiled with steam

under vacuum in evaporators in order to manufacture SCM.

No other industry has been able to make this product in all over India. A part

of the milk is sent to Egrons in order to get the milk powder. This milk powder is

then blended with certain ingredients in order to manufacture the recently launched

products namely dessert mixes.

EGRONS

Egron is a spray drier used to dry the milk, coffee liquid into powder form by

using hot air. While drying, the skimmed milk

at lesspressureand the hot air at the higher pressure are passed to the cone

through the nozzles.

The high pressure hot air breaks the milk into the very tiny particles. Because

of the vertical length of the cone these particles gets converted into the dry milk.

The dry milk falls over the shaker which does not allow the hot particles to

collaborate with each other again.

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After this the dry milk is collected in the tote bins in the bin room. The bins

are then tilted over the hopers and from which they are subsequently sent to powder

filling and packing machines.

For all this, there are four Egrons in Moga factory Egrons 2, 3, 4, are used for

drying milk powder and No.1 is used for drying coffee which is closed right now.

POWDER FILLING PLANT

The filling and the packing of milk like Everyday, Lactogen and Nestogen is

done in this plant. There are four filling and packing lines for this purpose. Two of

these are used in filling of tins & the other two are used for filling polypacks or bag-

n-boxes required by the production program.

CEREALS

This plant is engaged in the production of cereal-based baby foods and infant

formula. The production process consists of the addition of various Enzymes,

Vitamins, Minerals & fruit extracts to the cereal base. There are two filling and

packing lines in the cereal plant. One is for filling of 400 gm. sachets and other for

filling of 400gm tins. Now a 5gm every day creamer filling line machinery is also

installed in the filling section. The manufacturing of products is a continuous three-

shift operation. The Tin filling line is generally run for the export packing and

accounts for the manufactured products. The major product of the Cereal plant is

Cerelac. (Wheat, Apple, Orange)

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UTILITY SERVICES DEPARTMENT

BOILER HOUSE

Boiler House provides the Steam to whole factory. And it also looks after water

generation, de-alkanization of water to feed to boiler, soft water generation, power generators

and air heaters.

EFFLUENT TREATEMNT PLANT:

This department looks after the waste water treatemnt before draining

out of plant. In this plant, the polluted water from the factory is passed through the sieves and

collected in the aerator tank. In this tank the fan which is having the four blades at right

angle to the water is allowed to rotate . The rotation of the vertical blades or vanes

splashes the effulent. This process of splashing continous until the water gets oxidised.

“ Basically the effluent water lacks in the oxygen so it is aerated in the open air and

again gets oxidised in the open air.” By this stirring operation the sludge comes towrds the

corners of the aerator water tank and gets collected by the sludge collector and gets collected

in the sludge tank through the pipes. This sludge is allowed to dry in the sludge bath in the

open air and which is further used as the manure after the drying.

The submersible pumps are used to maintain the level of the aerator tank. After this

the water is passed to the clarifier where the further clarification of the water is done by

moving the pan containing the sieves.And after this the water is passed to the mixing tank,

from this tank the water is pumped to the chimney. The chimney is provided to maintain the

30

head. The water from this chimney is used for gardening in the factory and the rest of the

water is dumped in to the MC pipe.

CULINARY

This plant is engaged in the production of Noodles, Taste markers, Soups sauces &

the like. The plant is divided into three sections: -

NOODLES

SEASONING

COLD SAUCES

The Operation of the seasoning is inter- related with both the noodle and cold

sauce section as the spice mix base for both is manufactured in the seasoning section.

31

CHAPTER 2

SAFETY

Safety is the freedom from risk of injuries or the prevention of the accidents.

Safety is a thought which makes us proactive and helps us to prevent the accidents.

Why safety

It is a basic human need

Concerns all of us

Safety has to be on our mind always

At home, at work and in our community

Accidents happen when we don’t pay attention

Accident

It is a sudden and unforeseen occurrence which results in damage to

material,building,environment and above all to human beings.

Status of accidents.

Unsafe actions --------------88%

Unsafe conditions------------10%

Natural calamities-----------02%

32

98%accidents are caused by human errors.

I.E. unsafe acts or conditions.

2%accidents are beyond human’s control.

I.E. Earthquake etc.

Main reasons of the accidents:

I did not see.

I did not ask.

I did not listen.

Reasons to be careful at the work

Responsibility to ourself.

Responsibility to co-worker & company.

Do not work at time if you are not feel good.

If any unsafe placed you are seen than ask your supervisor.

33

Accident sequence

Lack of knowledge, skill, mental condition

Fault of person

Unsafe act/condition

Accident

Injury

Unsafe acts

Operating without authority.

Operating at unsafe speed.

Making safety devices inoperative.

Unsafe position or posture.

Distracting,teasing,abusing & startling.

Unsafe condition

Defective condition,rough,Sharp,slippery,cracked,corroded etc.

Unsafe illumination,ventilation,dress.

Unsafe method,process planning etc.

Hazardous arrangement, process layout.

34

Accident prevention

Illuminate the hazard

Control the hazard

Train personnel

Prescribe personnel protective equipments.

Motivate people and safety participations.

Behavioral safety

Enforcement of safety rules.

Near miss:

When any miss happening occurs suddenly to a person and does not get any injury

due to that miss occurrence is called as the near miss.

While handling the chemicals, the following PPE must be used:

1. Apron

2. Face shield or safety goggles

3. Rubber gloves

4. Safety Gum Boot

5. Nose mask

35

Important note:

Always use safety belt while working at height above 1.8m height.

Also use the helmet tight with chin strip while working at the height.

Always wear the helmet if any work in progress above your working place or at

construction sight.

Always use the nose mask where the danger of the chemicals fumes,toxic gases is

present. It avoids the inhalation of these toxic and harmful fumes.

Always wear the goggles & gloves while cutting,grinding,drilling, hammering and

chiseling.

Always wear the safety shoes while working in the factory premises.

Always use the rubber gloves while handling the chemicals.

Always use the leather gloves while handling the glass.

Always use the both side handrailing while moving over the stairs.

In case of the leakage of the harmful gases in the plant always follow the opposite

direction of the wind socks and move across the direction of wind.

Always wear the ear plug or ear muff where the noise level above 85dB (A).

Never use the mobile phone while working in factory premises.

Always walk in a walk way.

Always wear high reflective apron while driving.

Move the hand lift in proper body posture not play horse riding.

36

Personal protective equipments

ABOUT SAFETY

CHAPTER 3

37

Utility Services Department

1. Refrigeration and air-conditioning

2. Effluent Treatment plant

3. Boiler house

4. Compressor room

Refrigeration and air-conditioning

This department looks after the Chiller Water Plants which supply the chilled water

to factory and the AHU’s of factory, Air Conditioners of factory and the Air

Compressor of the factory.

Refrigeration plant

A Refrigeration plant uses gas,liquid and mechanical energy to move heat from one

place to another.A liquid,such as ammonia,which has a low boiling temperature, is allowed to

pass into a space via tubing.As the pressure in the ammonia drops,the liquid begins to boil

and enter a phase change from liquid to gas.In doing so, there is a great absorption of heat

energy by the liquid in the tubing to create this phase change.

38

REFRIGERATION PLANT

The heat energy is absorber from the space and as the liquid boils off, it forms a gas. The gas

is pulled through the tubing in the space into a suction header outside the space to the suction

of a compressor. The compressor depressurizes the gas and discharge the liquid through cold

water heat exchanges or cooling fans, exhausting the heat exchangers or cooling fans,

exhausting the heat absorbed from the space, into the outside atmosphere. By pressurizing

and cooling the gas, the gas returns to a liquid stage, where it is stored and reintroduced to the

space to be cooled.

39

Principle of refrigeration system

It is based on vapor compression refrigeration cycle. The vapor-compression uses a

circulating liquid refrigerant as the medium which absorbs and removes heat from the space

to be cooled and subsequently rejects that heat elsewhere. Figure depicts a typical, single-

stage vapor-compression system.

Components of a refrigeration System

1. Compressor

2. Condenser

3. Expansion valve

4. Evaporator

A Typical vapour compression cycle

SINGLE STAGE VAPOUR COMP. CYCLE

40

Description of vapour compression cycle

The vapor-compression uses a circulating liquid refrigerant as the medium which absorbs and

removes heat from the space to be cooled and subsequently rejects that heat elsewhere.

Depicts a typical ,single-stage vapour-compression system.

All such systems have four components: A compressor, a condenser, a thermal expansion

valve (also called a throttle valve), and an evaporator .Circulating refrigerant enters the

compressor in the thermodynamic state known as a saturated vapour and is compressed to a

higher pressure, resulting in a higher temperature as well.

The hot, compressed vapor and it is at a temperature and pressure at which it can be

condensed with typically available cooling water or cooling air. That hot vapor is routed

through a condenser where it is cooled and condensed into a liquid by flowing through a coil

or tubes with cool water or cool air flowing across the coil or tubes. this is where the

circulating refrigerant rejects heat from the system and the rejected heat is carried away by

either the water or the air(whichever may be the case).

The condensed liquid refrigerant, in the thermodynamics state known as a saturated liquid, is

next routed through an expansion valve where it undergoes an abrupt reduction in pressure.

That pressure reduction results in the adiabatic flash evaporation of a part of the liquid

refrigerant. The auto refrigerant of the liquid and vapor refrigerant mixture to where it is

colder than the temperature of the enclosed space to be refrigerated. The cold mixture is then

routed through the coil or tubes in the evaporator. A fan circulates the warm air in the

enclosed space across the coil or tubes carrying the cold refrigerant liquid and vapor mixture.

That warm air evaporates the liquid part of the cold refrigerant mixture. At the same time, the

circulating air is cooled and thus lowers the temperature of the enclosed space to the desired

temperature. The evaporator is where the circulating refrigerant absorbs and removes heat

41

which is subsequently rejected in the condenser and transferred elsewhere by the water or air

used in the condenser.

To complete the refrigeration cycle, the refrigerant vapor from the evaporator is again a

saturated vapor and is routed back into the compressor.

Refrigerant used:

Ammonia is the main refrigerant used in the refrigeration cycle.

Ammonia(NH3) is the most widely used refrigerant .It is a chemical compound of

Nitrogen and Hydrogen.

Properties of Ammonia

Refrigerant

No.

Name Molecula

r mass

Specific

gravity

Vapou

r

density

Boiling

point at

atmospheric

pressure

Freezing

point at

atmospheric

pressure

Auto

ignition

point

R-717 Ammonia 17.02 .61 0.6 -33.3o C -76.6 o C 650 oC

TABLE 3.1 PROPERTIES OF AMMONIA

42

Advantages of using Ammonia (NH3)

1. Power consumption is less than CFC.

2. Less operational problem of oil return.

3. Better heat transfer.

4. Due to low power consumption high heat transfer capacity.

5. NH3 has no effect on Ozone layer.

Oil Separation

Refrigeration compressors are lubricated by refrigeration oil that circulates from the

compressor crankcase or housing. As refrigerant gas is discharged by the compressor, it will

leave with a fine oil mist that will be circulated throughout the entire system.

Small amounts of oil circulating through the system will not affect the system performance.

Too much refrigeration oil circulating in the system will have adverse effects on the

components in the system. Circulating oil reduces the ability of the system to effectively

remove the heat. Condensers, evaporators and other heat exchangers loose the efficiency

when coated internally with an oil film. Refrigeration oil not returning to the compressor

causes improper lubrication and eventual compressor failure. At low temperature application,

refrigeration oil thickness becomes difficult to move, causing oil to be trapped in the system.

Refrigerant gas leaving the compressor through the discharge lines contains refrigeration oil

in a vapour ousmist. As this mixture enters the oil separator, the velocity is reduced to allow

oil separation to begin. This refrigerant gas and oil mixture enters the oil separator and passes

43

through an inlet screen, causing the fine particles to combine. Larger oil particles are formed

and drop to the bottom of the oil separator.

The refrigerant gas then passes through an outlet screen to remove residual oil

particles. The oil gathers in the bottom of the oil separator until a float operated needle valve

opens to allow the return of the oil to the compressor. Oil returns quickly to the compressor,

because of the higher pressure in the oil separator than in the compressor crankcase. When

the oil level has lowered, the needle valve closes to prevent refrigerant gas from returning

back to the compressor. The refrigerant gas leaves through the outlet of the oil separator and

goes to the condenser

Cooling Towers

In the plants, the hot water from the condenser is cooled in the cooling tower, so that

it can be reused in the condenser for the condensation of the steam. In a cooling tower water

is made to trickle down drop by drop so that it comes in contact with air moving in the

opposite direction. As a result of this some water is evaporated and is taken away with air. In

evaporation, the heat is taken away from bulk of water, which is thus cooled.

Introduction

A cooling tower is equipment used to reduce the temperature of a water stream by

extracting heat from water and emitting it to the atmosphere.

44

Cooling towers

Types of cooling towers:

1. Natural draft

2. Mechanical draft

Natural Draft cooling tower

The natural draft or hyperbolic cooling tower makes use of the difference in

temperature between the ambient air and hotter air inside the tower.it works as

follows

Hot air moves upwards through the tower(because hot air rises).

45

FORCED DRAFT

INDUCED DRAFT COUNTER FLOW

INDUCED DRAFT CROSS FLOW

Fresh cool air is drawn into the tower through an air inlet at the bottom.

COOLING TOWER

Mechanical draft cooling tower

Mechanical draft towers have large fan to force or draw air through circulated

water. The water falls down words over fill surfaces.

46

Cooling rates of mechanical draft towers depend upon various parameters such as fan

diameter and speed of operation, fills for system resistance etc.

Forced draft cooling tower:

Air is blown through tower by centrifugal fan at air inlet

Forced draft cooling tower

Advantages: suited for high air resistance & fans are relatively quiet

Disadvantages: recirculation due to high air entry and low air exit velocities.

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Induced draft counter flow cooling tower:

In a counter flow design the air flow is directly opposite to the water flow. Air flow first

enters an open area beneath the fill media and is then drawn up vertically. The water is

sprayed through pressurized nozzles and flows downward through the fill, opposite to the air

flow.

Induced draft counter flow cooling tower

Induced draft cross flow cooling tower:

Cross flow is a design in which the air flow is directed to perpendicular to the water

flow. Air flow enters one or more vertical faces of the cooling tower to meet the fill material.

Water flows (perpendicular to the air) through the fill by gravity. The air continuous through

48

the fill and thus past the water flow into an open plenum area. A distribution or hot water

basin

49

consisting of a deep pan with holes or nozzles in the bottom is utilized in a cross flow tower.

Gravity distributes the water through the nozzles uniformly across the fill material.

Induced draft cross flow cooling tower

Factors affecting cooling of water on a cooling tower are:

1. Temperature of air

2. Humidity of air.

3. Temperature of hot air

4. Size and height of tower

5. Velocity of air entering tower

6. Degree of uniformity in descending water Arrangement of plants in tower

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Heat exchangers

A heat exchanger is a device built for efficient heat transfer from one medium to another,

whether the media are separated by a solid wall so that they never mix, or the media are in

direct contact. They are widely used in space heating, refrigeration, air conditioning ,power

plants, chemical plants, electrochemical plants, petroleum refineries and natural gas

processing. One common example of a heat exchanger is the radiator in the car, in which a

hot engine-cooling fluid, like antifreeze transfers heat to air flowing through the radiator.

Types of heat exchangers:

Acc. To flow arrangement the heat exchangers may be classified into three types.

1. Cross-flow In a cross-flow heat exchanger, the fluids travel roughly perpendicular to

one another through exchanger.

2. Counter-flow In a counter flow heat exchangers the fluids enter the exchanger from

the opposite end. The counter current design is most efficient, in that it can transfer

the most heat.

3. Parallel-flow In parallel-flow heat exchangers, the two fluids enter the exchanger at

the same end, and travel in parallel to one another to the other side.

Plate heat exchanger

A plate heat exchanger is a type of heat exchanger that uses metal plate to transfer heat between two fluids. This has a major advantage over a conventional heat exchanger in that the

51

fluids are exposed to a much large surface area because the fluids spread out over the plates.

This facilities the transfer of heat, and greatly increases the speed of the temperature change.

The concept behind a heat exchanger is the use of pipes or other containment vessels to heat

or cool one fluid by transferring heat between it and another fluid. In most cases, the

exchanger consists of a coiled pipe containing one fluid that passes through a chamber

containing another fluid. The walls of the pipe are usually made of metal or another substance

with a high thermal conductivity, to facilitate the interchange, whereas the outer casing of the

large chamber is made of a plastic or coated with thermal insulation, to discourage heat from

escaping from the exchanger.

Plate type heat exchanger

SHELL AND TUBE HEAT EXCHANGER

A shell and tube that heat exchanger is a class of heat exchanger designs. It is the most

common type of heat exchanger in oil refineries and other large chemical process, and is

52

suited for higher-pressure applications. As its name implies, this type of heat exchanger

consists of a shell (a large pressure vessel) with a bundle of tubes insides it. One fluid runs

though the tubes, and another fluid flows over the tubes (through the shell) to transfer heat

between the two fluids.

The set of tubes is called a tube bundle, and may be composed by several types of tubes:

plain, longitudinally finned, etc.

Shell and tube heat exchanger

Selection of the tube material:

To be able to transfer heat well, the tube material should have good thermal

conductivity. Because heat from a hot to a cold side through the tubes, there is a

temperature difference through the width of the tubes. Because of the tendency of the

tube material to thermal expand differently at various temperatures, thermal stresses

occur during operation. This is in addition to any stress from high pressure from the

fluids themselves. The tube material also should be compatible with both the shell and

tube side fluids for long periods under the operating conditions (temperature,

53

pressure, pH, etc.) to minimize deterioration such as corrosion. All of these

requirements call for careful selection of strong, thermally-conductive, corrosion-

resistant, high quality tube materials, typically metals, including copper alloy,

stainless steel, and carb steel. Non-ferrous copper alloy, in conel, nickel, hastelloy

and titanium..Poor choice of tube material could result in a leak through a tube

between the shell and tube sides causing fluid cross-contamination and loss of

pressure.

HEAT EXCHANGER IN INDUSTRY

Heat exchangers are widely used in industry both for cooling and heating large scale

industrial processes. The type and size of heat exchanger used can be tailored to suit a

process depending on type of fluid, its phase, temperature, density, viscosity,

pressures, chemical composition and various other thermodynamic properties.

In much industrial process there is waste of energy or a heat stream that is being

exhausted, heat exchangers can be used to recover this heat and put it to use by

heating a different stream in the process. This practice saves a lot of money in

industry as the heat supplied to other streams from the heat exchangers would

otherwise come from an external source which is more expensive and more harmful

to the environment.

Heat exchangers are used in many industries, some of which include:

Waste water treatment

Refrigeration systems

Wine bravery industry

Petroleum industry

54

In this waste water treatment industry, heat exchangers play a vital role in maintaining

optimal temperature within anaerobic digesters so as to promote the growth of microbes

which remove pollutants from the waste water. The common types of heat exchangers used in

these applications are the double pipe heat exchangers as well as the plate and frame heat

exchanger.

Effluent treatment plant

AIR HANDLING UNIT

Air handling unit (often abbreviated to AHU), is a device used to condition and circulate air

part of a heating, ventilating, and air-conditioning (HVAC) system. An air handler is usually

a large metal box containing a bowler, heating or cooling elements, filter racks or chambers,

sounds attenuators, and dampers. Air handlers usually connect to duck work that distributes

the conditioned air through the building and returns it to the AHU. Sometimes AHUs

discharge (supply) and admit (return) air directly to and from the space served without duck

work.

55

Some AHU components shown are:

1) Supply duck

2) Fan compartment

3) Vibration isolator (‘flex joint’

4) Heating and/or cooling coil

5) Filter compartment

6) Mixed (recalculated + outside) air duct

AHU SYSTEM

Air handling components:

Air handlers typically employ a large squirrel cage blower divan by an AC induction electric

motor to move the air. The blower may operate at a single speed, offer a variety of set speeds,

or be driven by a Variable frequency drive to allow a wide range of air flow rates. Flow rate

may also be controlled by inlet vanes or outlet dam person on the fan. Some residential air

56

handlers (central ‘furnaces’ or ‘air conditioners’) use a brushless DC electric motor that has

variable speed capabilities.

Multiple blowers may be ore sent in large commercial air handling units, typically placed at

the end of the AHU and the beginning of the supply ductwork (therefore also called “supply

fans”). They are often augmented by fans in the return air duct (“return fans”) pushing the air

into the AHU.

Heating and/or cooling elements

Air handlers may need to provide heating, cooling, or both to change the supply air

temperature depending on the location and the application.

Smaller air handlers may contain a fuel-burning heater or a refrigeration evaporator, placed

directly in the air stream. Electric resistance and heat pumps can be used as well. Evaporative

cooling is possible in dry climates.

Large commercial air handling units contain coils that circulate hot water or steam for

heating, and chilled water for cooling. Coils are typically manufactured from copper for the

tubes, with copper or aluminum fins to aid heat transfer. Cooling coils will also employ

delimiters plates to remove and drain condensate. The hot water or stream is provided by a

central boiler, and the chilled water is provided by a central chiller. Downstream temperature

sensors are typically used to monitor and control ‘off coil’ temperatures, in conjunction with

an appropriate motorized control valve prior to the coil.

57

Filters

Air filtration is almost always present in order to provide clean dust-free air to the

building occupants. It may be via simple low-MERV pleated media, HEPA, electrostatics, or

a combination of techniques. Gas-phase and ultraviolet air treatments may be employed as

well.

It is typically placed first in the AHU in order to keep all its components clean. Depending

upon the grade of filtration required, typically filters will be arranged in two (or more) banks

with a coarse-grade panel filter provided in front of a fine-grade bag filter, or other ‘final’

filtration medium. The panel filter is cheaper to replace and maintain, and thus protects the

more expensive bag filters.

The life of a filter may be assessed by monitoring the pressure drop through the filter medium

at design air volume flow rate. This may be done by means of a visual display, using a

pressuregauge, or by a pressure switch linked to an alarm point on the building control

system. Failure to replace a filter may overcome its inherent strength, resulting in collapse

and thus contamination of the air handler and downstream ductwork.

Humidifier

Humidification is often necessary in colder climates where continuous heating will

make the air drier, resulting in uncomfortable air quality and increased static electricity.

Various types of humidification may be used:

Evaporative: dry air blown over a reservoir will evaporative some of the water. The rate

of evaporation can be increased by spraying the water onto baffles in the air stream.

Vaporizer: scream or vapor from a boiler is blown directly into the air stream.

58

Spray mist: water is diffused either by a nozzle or other mechanical means into fine

droplets and carried by the air.

Ultrasonic: A tray of fresh water in the airstream is excited by an ultrasonic device

forming a fog or water mist.

Wetted medium: A fine fibrous medium in the airstream is kept moist with fresh water

from a header pipe with a series of small outlets. As the air passes through the medium it

entrains the water in fine droplets. This type of humidifier can quickly clog if the primary

air filtration is not maintained in good order.

Mixing chamber

In order to maintain indoor air quality, air handlers commonly have provisions to

allow the introduction of outside air into, and the exhausting of air from the building. In

temperature climates, mixing the right amount of cooler outside air with warmer return air

can be used to approach the desired supply air temperature. A mixing chamber is therefore

used which has dampers controlling the ratio between the return, outside, and exhaust air.

Heat recovery device

Heat recovery device heat exchangers of many types, may be fitted to the air handler

between supply and extract airstreams for energy savings and increasing capacity. These

types more commonly include for:

Recuperate, or plate heat exchanger: A sandwich of plastic or metal plates with interlaced

air paths. Heat is transferred between airstreams from one side of the plate to the other.

59

The plates are typically spaced at 4 to 6mm apart. Can also be used to recover colt. Heat

recovery efficiency up to 70%.

Thermal Wheel or Rotary heat exchangers: A slowly rotating matrix of finely corrugated

motel, operating in both opposing airstreams. When the air handling unit is in heating

mode, heat is absorbed as air passes through the matrix in the exhaust airstream, during

one half rotations, and released during the second half rotation into the supply airstream

in a continuous process. When the air handling units is in cooling mode, heat is released

as air passes through the matrix in the exhaust airstream, during one half rotations, and

absorbed during the second half rotation into the supply airstream. Heat recovery

efficiency up to 85%. Wheels are also available with a hydroscope coating to provide

latent heat transfer and also the drying or humidification of airstream.

Run around coil: Two airs to liquid heat coils, in opposing airstream, piped together with

a circulating pump and using water or a brine as the heat transfer medium. This device,

although not very efficient, allows heat recovery between remote and sometimes multiple

supply and exhaust airstream. Heat recovery efficient up to 50%.

Heat pipe: Operating in both opposing air paths, using a confined refrigerant as a heat

transfer medium. The ‘pipe’ is multiple sealed pipes mounted in a coil configuration with

fins to increase heat transfer. Heat is absorbed on one side of pipe, by evaporation of the

refrigerant, and released flows by gravity to the first side of the pipe to repeat the process.

Heat recovery efficiency up to 65%.

Controls

Controls are necessary to regulate every aspect of an air handler, such as: flow rate of

air, supply air temperature, mixed air temperature, humidity, air quality. They may be as

60

simple as an off/on thermostat or as complex as a building automatic system using BAC net

or Lon Works, for examples.

Vibration isolators

The blowers in air handlers can create substances vibration and the large area of the

duct system would transmit this noise and vibration to the occupants of the building. To avoid

this, vibration isolators (flexible sections) are normally inserted into the duct immediately

before and after the air handler and often also between the fan compartment and the rest of

the AHU. The rubberized canvas-like material of these sections allows the air handler to

vibrate without transmitting much vibration to the attached ducts.

61

CHAPTER 4

MY PROJECT BASED ON BOILER HOUSE

BOILER HOUSE

Boiler House provides the steam to whole factory. And it also looks after water

generation, de-alkalization of water to feed to boiler, soft water generation, power

generators and air heaters. There are four boilers in the Nestle Moga factory. The two

are coal fired and the two are the oil fired boilers.

BOILER BASIC

Boilers are the most important part of the steam circuit, after all, this is where the

steam is initially created. A boiler can be defined as a vessel in which the heat

energy from a fuel is transferred to a liquid. In the case of saturated steam, the boiler

also provides heat energy to produce a phase change from liquid to vapour.

Historically, steam boiler plant has always required a high level of

manual supervision to provide the necessary degree of plant safety. Contemporary thinking

demands such plant to be run efficiently, and this may often be attempted by matching supply

to demand as much as possible. This can mean boilers running continuously in some

instances, or being shutdown for long or short intervals in others. Either way, modern

technology enables the plant engineer to confidently choose the boiler regime to best suit his

application, with control systems able to provide the required degree of efficiency, integrity

and safety.

A boiler is often the largest piece of equipment to be found in a steam circuit.

They can range In size depending upon the application on which they are used. Often several

boilers may be used on a large site, where varying steam loads exist.

62

A Typical Diagram of boiler

Shell boilers

Shell boilers operate by passing heat through tubes in the boiler, which in turn transfer heat to

the surrounding boiler water. There are several different combinations of tube layout for

shell boilers, involving the number of 'passes' the heat from the boiler furnace will usefully

make before being discharged. A typical arrangement can be seen in Figure A which shows a

two pass boiler configuration.

Figure A and Figure B also shows the two methods where the heat from the furnace is

reversed to flow along the second pass. Figure A shows a dry back boiler where the

heat flow is reversed by a refractory lined chamber on the outer plating of the boiler.

A more efficient method of reversing the heat flow is through a wet back boiler configuration

as shown in Figure B. The reversal chamber is contained entirely within the boiler which

allows for a greater heat transfer area, as well as allowing the boiler water to be heated at the

point where the heat from the furnace will be hottest - on the end of the chamber wall.

63

It is important to note that the combustion gases should be cooled to at least 420°C for

plain steel boilers and 470°C for alloy steel boilers before the reversal chamber.

Temperatures in excess of this will cause overheating and cracking of the tube end plates.

These limitations will be observed by the boiler manufacturer within his design criteria.

There are several different types of shell boilers that have been developed, which will

now be looked at in more detail.

(a) Dry Back Boiler

(b) Wet Back Boiler

64

Package boiler:

The improvement of materials and manufacturing processes meant that more tubes

could be accommodated within the boiler. Early in its development the basic boiler was long and required a large boiler house area. By forcing the hot gases to go

backwards and forwards through a series of tubes, the boilers were designed to

be shorter, and heat transfer rates were improved. The modern multi-tubular packaged boiler is the present state of this evolutionary process.

The packaged boiler is so called because it comes as a complete package. Once

Delivered to site it requires only the steam, water and blow down pipework, fuel

supply and electrical connections to be made for it to become operational.

These boilers are classified by the number of passes - the number of times the hot

combustion gases pass through the boiler. The combustion chamber is taken as the

first pass. The most common boiler is a three pass unit as shown in Figure 6 with two

sets of fire-tubes and the exhaust gases exiting from the back end of the boiler.

A Typical Package Boiler

65

Package Boiler

Water Tube Boiler:

Water tube boilers differ from shell type boilers in that the water is circulated inside the tubes

with the heat source surrounding them. This means that much higher pressures can be used

because the tube diameter is significantly smaller than the shell on the fire tube boiler, and

therefore the circumferential stress is also significantly less. Water tube boilers tend to be

considered for large steam outputs, for high pressure, or for superheated steam. For most

industrial and commercial applications, a multi-tubular shell boiler is often appropriate. Only

if the requirement is for an individual output above 27 000 kg/h or at pressures above 27 bar,

or steam temperatures above 340°C is it necessary to use a water tube boiler. The reason for

this is that water tube boilers cost more to build for a given output than multi-tubular shell

boilers.

However, throughout the world, water tube boilers compete with shell boilers size for size

below 270 bar g. To give an idea of the diversity of water tube boilers on land, units start

from about 2 000 kg/h and rise to power station sized units rated at 3 500 000 kg/h and above.

The smaller sized units can be manufactured and then delivered to the site in one piece. The

larger sized units are generally manufactured in sections, to be transported to site for final

assembly. Water tube boilers operate on the principle of water circulation. This is a subject

which is worth covering before looking at the different types of water tube boilers which are

available. Use of the following diagram best helps to explain this theory.

66

Riser – Down comer configuration of water tube boiler

Cold feed water is introduced into the steam drum where it falls in the down comer to the

lower or mud drum, due to it having a greater density than that of hot water. Its density

decreases as it passes up the riser, where it is heated, eventually creating steam bubbles. The

hot water and steam bubbles pass into the steam drum once again, where the steam naturally

separates from the water, and is then taken off. However, when the pressure in the water tube

boiler is increased, the difference between the density of the water and saturated steam

reduces, therefore less circulation occurs. To keep the same level of steam output as design

pressure increases, the distance between the lower drum and the steam drum must be

increased.

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SUGGESTIONS FOR IMPROVEMENT

Safety is very important for all those who works in the industry even all those who works

outside the industry. Because, accident happens only when the human being not take interest

to perform the job. Some of employees follow the safety rules and regulations but most of

employees not follow. Some of workers use the personal protective equipment. But most of

workers not used. They fill the behavior based safety sheets only for formalities & only for

completing the targets.

My project report is based on boilers. So, I should give suggestion about

to improvement of boiler. Water tube boiler give higher efficiency than the fire tube boiler or

shell tube boiler. So, my suggestion is that most of time use water tube boiler than fire tube

boiler. The water from soft water plant or RO plant used by boiler is only 25% and reject by

boiler is 75%. So such type of these wastage of water will have to be stopped by reused this

water in boiler.

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REFERENCES

1. Guidance from Mr. Sachidananda Swain(Manager Of Safety) and Mr. Harpal Singh

Makkar (Sr. Executive).

2. Manuals of Every Plant.

3. WWW.NESTLE.IN

4. Actual Captured Snaps at site.

5. Google search engine.

6. http://www.bluegrasskesco.com/Boiler%20System.html

7. http://en.wikipedia.org/wiki/Package_boiler

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