PACKAGED DRINKING WATER PLANT

What is packaged drinking water?

Packaged drinking water uses water from any source which has to be treated and disinfected, a process that could involve filtration, UV or ozone treatment or reverse osmosis (RO) before it is fit for human consumption.

Basic requirements for setting up a packaged drinking water plant.

Here are mainly 4 sections in a packaged drinking water plant: water treatment, bottling, quality control (lab) and overall utility.

Generally, a standard 2000 LPH packaged drinking water plant needs:

• Total space: 5000 Sq. Ft built up area with 3500 Sq. Ft of covered area

• Power: 65 HP • Raw water: Approximately 3000 LPH of raw water of which 70 % will be used and 30 % will be rejected. This is, however, an indicative quantity as it will depend on the TDS (Total Dissolved Solids) of the raw water.

• Project cost : Rs. 1 cr approximately which includes the cost of machinery, utilities, furniture etc (Note – the cost was approximated in 2021). licenses/approvals are required The following licenses/ approvals are to be obtained for setting up a packaged drinking water plant in India:

• Small scale industries registration

• ISI certification from Bureau of Indian Standards (BIS)

• Pollution control certificate

• Water test report from an authorized laboratory of raw water

• Pest control certification

• Certificates from chemist, microbiologist

• Medical certificates for workers

• No objection certificate (NOC) from Gram Panchayat, if applicable

• Registration of trademark

• Documents related to ownership of land/lease of land for setting up the plant

• Memorandum of association of companies/partnership deed, if applicable.

• Electrical load sanction • Sanction layout plan

TREATMENT PROCESS

1. Chlorine/Hypochlorite Dosing System Chlorine/Hypo chlorite dosing system is done in the raw water for disinfection / oxidation of iron and manganese (if present) in the water before filtration. About 3-4 ppm of sodium hypo chlorite solution is dosed in raw water storage tank, which reacts with water to form hypo chlorite acids which acts as disinfecting agent. A LDPE chemical preparation tank with an electronic diaphragm type dosing pump is provided for this.

2. Raw Water Storage Tank Raw water, after chlorination is required to be stored to achieve a detention time as per process

(A) Pressure Sand Filter

(B) Activated Carbon Filter

3. Anti-scalene Dosing System The hardness salts of calcium & magnesium are likely to be precipitated if concentration exceeds its solubility limit & it may scale the membranes resulting in poor treated water quality from RO System. To prevent this Antiscalant dosing (scale inhibitor) system is provided. The dosage rate is 4-5 ppm. A LDPE chemical preparation tank with an electronic diaphragm type dosing pump is provided for this

4. Micron Filters Micron Filtration is achieved by a series of filtration with the 20/10 Micron, 5 Micron, and 1 Micron Cartridge Filters. This is a Consumable item and should replaced periodically

(a) Reverse Osmosis System

(b) Ultra Violet Sterilizer

5. OZONE GENERATOR Though RO System rejects all the micro – organisms like bacteria & virus; it may redevelop in packed bottles over a period of time. Hence, it is necessary to disinfect RO Product water prior to bottling. In the Ozone Generator, Ozone is formed by energetic excitation of molecular oxygen, causing some of it to disassociate into oxygen atoms, which can recombine with oxygen. The most practical way to do this in an ozone generator is via a method called "silent-arc" or "corona" or "brush" discharge. The discharge occurs when charged electrons flow through a gas containing oxygen. Ozone is used in water treatment for its oxidative qualities. Ozone oxidizes both organic and inorganic substances; removes unwanted taste, odor and color; and provide effective disinfection.

Ozone is extremely efficient as a bactericide, fungicide and virucide, killing even chlorine-resistant Cryptosporidium. Another benefit is that ozone does not lead to the formation of trihalomethanes (THMs), which are formed when chlorine is added to raw water containing humic materials. Once a THM is formed, it is difficult to oxidize, even with ozone.

6. Ozone Contact/ Re-circulating Tank By industry standards, tall-tower diffusion is the most widely used contacting method. It introduces the ozone into the bottom of a column of water, or contact tank. The incoming (raw) water enters the top of the contact tank and leaves by the bottom. The gas is mixed in the incoming water by Venturi injection process, which uses an ejector where the Water is channeled through a short tube with a constriction in the middle which causes an increase in the velocity of the water flow and a corresponding decrease in the fluid pressure. The resulting suction draws ozone into the flow stream.

The Packaging unit consists of One or All of the below mentioned process:

1. Bottle Manufacturing by PET Blowing Machine: - For manufacturing of PET Bottles for Different sizes and available in Semi and Automatic Operation up to 3600 Bottles per hour.

2. Rinsing - Filling – Capping – Sealing Machine:- The bottles are fed into the machine which automatically rinses, fills and screws the cap on it. Caps are stamped with the date of manufacture and expiry before being put into the hopper for screwing on to the bottle.

3. Labeling: In this section the labels and the neck sleeve are to be manually put on the bottles which will then pass through the shrink tunnels and onto packing conveyer.

4. Final Packing: This could be in cartons - done manually - and no machines have been provided for it.

These Packing Machines come in both versions: Fully Automatic as well as Semi Automatic.

Fully Automatic Machines are with in feed Air Conveyor which gives higher production rate with no change parts for different sizes of bottles. Such machines are Mechanical operated with Cam Drive and pneumatic operation for accuracy of Washing and Filling.

Semi Automatic Machines are with Manual washing with Turn Tables and rest activity of Filling and Capping are fully automatic operation. Both options have Shrink Tunnel for labeling application.

JB ASSOCIATES offers Complete Turnkey Plants as per the Customer's Requirements. We have Affiliations with leading Machinery manufacturers and have executed such Projects worldwide