Description of the technological process of production of the bottling line. Selection, justification and description of the technological scheme for bottling beer. Inventory standards for raw materials, basic and auxiliary materials and containers

Technological diagram of bottling beer.

The line begins with the delivery of boxes with bottles to the packaging machine by a stacker. From the packaging machine, the boxes go to an automatic machine for removing bottles from the boxes. The extracted bottles go to a bottle washing machine, where the bottles are washed and extruded. The bottles then pass through a light screen for final inspection of the washed bottles. Bottles that have undergone water treatment are sent to a filling and capping machine. To increase the stability of beer, after bottling, the bottles are sent for pasteurization. Pasteurization is carried out in a tunnel pasteurizer. After pasteurization, the bottles go through a rejecting machine to check the products for defects. Products that have been rejected are sent to the labeling machine. The bottles are then transferred to a machine for placing bottles into boxes. When bottling beer with a capacity of 12,000 bottles/hour, after placing bottles in boxes, packaging in shrink film follows.

Technological diagram for filling PET bottles.

PET bottles arrive at the plant in the form of performs. Next, the performances are manually fed into an automatic blow molding machine. Then the heated performs are transported via a plate conveyor to a rinsing machine where the performs are rinsed. The bottles arrive from the rinsing machine in a chaotic order; to arrange them in a row, the bottles pass through a packaging machine. PET bottles lined up in a row are supplied for capping; a cap feeding conveyor is connected to the machine. The finished products are sent to the labeling machine. Finished PET bottles are sent to the packaging line. And then the packaged PET bottles are sent by stacker to finished product warehouses.

Technological diagram of beer bottling into kegs.

From the container warehouse, empty kegs are transported via a conveyor to an external keg washing machine to remove dirt. Then, from the external washing apparatus, the kegs enter the internal washing and filling unit. Ready kegs are sent to automatic scales for filling control.

2 Calculation of brewing products

Table 1 – Product range

Table 2 – Distribution of beer by variety and type of container

	Into bottles

Berezina
Slutsk esp.

Zhigulevskoe special
Bobruisk dark

We calculate the products per 100 kg of grain products consumed for each type of beer with subsequent conversion to 1 dal and annual production.

The production of non-carbonated soft drinks includes the following main technological stages:

Preparation of sugar syrup;

Dealcoholization of alcohol-containing raw materials included in the drink;

Preparation of blended syrup or drink;

Bottling the drink into bottles or large containers (barrels, flasks, containers, tank trucks, thermal tank trucks);

Pasteurization of the drink;

Braquerage;

Gluing labels and transferring finished products to the warehouse;

Storage and transportation of finished products.

The organization of production of non-carbonated drinks, hot drinks and non-carbonated cocktails is carried out in accordance with the technological diagram shown in Fig. 3.

Rice. 1. Hardware and technological scheme for the production of non-carbonated soft drinks.

Blended syrup for non-carbonated drinks with infusions, essences and other flavorings is prepared using a cold method. To do this, granulated sugar from bags 1, delivered on pallets 2, is weighed on scales 3 and poured into the receiving booker of a elevator 4, which delivers it to the intermediate bunker 5. As needed, the sugar, while stirring, is added to the syrup boiler 6, where corrected water from the collection-measurement 17.

After the sugar has dissolved, the solution is brought to a boil and boiled to kill mucus-forming bacteria. Then the syrup is sent through a mesh trap 7 and a heat exchanger 9 by a pump 8 to a collection 10 for inversion of sucrose (inversion is carried out at the request of the beverage manufacturer). The inverted syrup is pumped by pump 8 into the blending apparatus 13, where, with stirring, all the components of the drinks are added from measuring containers 11, 12, 14, 15, 16, including the preservative (when making a drink with a preservative). The mixture is thoroughly mixed for 15 - 25 minutes and left alone for 2 hours to destroy microflora. After this, the calculated amount of water at a temperature not exceeding 20 ° C is added to the blending apparatus, the solution is thoroughly mixed for 15 - 20 minutes, physicochemical and organoleptic indicators are determined and pump 21 is supplied to filter press 20 for filtration. The clarified drink then enters the measuring container 18, and from it is transferred to bottling into bottles or large containers.

When bottling a drink prepared without a preservative, the drink, after sealing the bottles, can be sent to a tunnel pasteurizer or, before retail bottling, to a pasteurization unit 19, or bottled hot.

Blended syrups for hot drinks, cocktails and cruchons are prepared using a hot method, after distilling alcohol from alcohol-containing raw materials in a syrup boiler or other equipment.

Then, calculated amounts of sugar and other components are added to the dealcoholized wine material, wine or alcoholized juice when making hot drinks, the mixture is thoroughly mixed and boiled to destroy mucus-forming bacteria. After this, the mixture is brought with corrected water to a given volume, flavorings are added, thoroughly mixed, filtered and transferred to a measuring container 18, and from it to a pasteurization unit 19 or to a collection equipped with a heating jacket, and then poured into consumer containers. Bottles of the drink are hermetically sealed, subjected to visual inspection, low-quality products are rejected and transferred to a labeling machine.

When making cocktails and cruchons, the calculated amount of sugar is added to the dealcoholized raw material, the mixture is boiled, after which it is passed through a mesh trap 7 and pumped 8 to the heat exchanger 9 for cooling. Then the cooled syrup is sent to the blending apparatus 13, where all the components of the drink, including the preservative, are added while stirring. The mixture is thoroughly mixed to suppress the growth of microorganisms, filtered, adjusted with corrected water to the specified volume of the drink and transferred for bottling into bottles or large containers. Before bottling, the cocktail or cruchon can be pasteurized in a flow and bottled hot or sent for pasteurization in bottles in pasteurizers.

Send your good work in the knowledge base is simple. Use the form below

Students, graduate students, young scientists who use the knowledge base in their studies and work will be very grateful to you.

Posted on http://www.allbest.ru/

Introduction

Liquor production is one of the branches of the food industry that produces alcoholic beverages and alcoholic beverages. Modern production of vodka and liqueurs is based on the use of high-tech and sophisticated equipment, new materials and reagents. For the qualified use of new technologies and materials, a deep understanding of the physical and chemical processes of dissolution, adsorption, diffusion and other important processes that occur during the transformation of raw materials and semi-finished products into finished products is required.

In recent years, there have been major changes in water treatment technologies. Reverse osmosis water conditioning units have become widespread, but their use requires a different approach to the organization of the entire production as a whole, knowledge of the essence of the processes underlying reverse osmosis and the ability to manage this process.

Washing bottles is a necessary condition for ensuring product quality, since when using returnable containers, bottles may bear old labels or have persistent contamination. Before washing dishes, they are sorted depending on the degree of contamination. Normally soiled bottles are sent directly to the bottle washing machine. Over-normally soiled bottles are pre-washed (soaked).

Bottles with excess contamination are sent to the pre-wash, which is divided into alkaline and acid-base washing.

Alkaline washing is a dishwashing that requires the use of an alkaline solution of high concentration, carried out on bottle washing machines in the following mode:

The alkali concentration in the baths is 3%;

The machine's productivity is halved;

If there is a second bath, the temperature in it is maintained at 70-80°C;

Injection and external washing of bottles is carried out with water at a temperature of 40-45°C;

Pre-washed contaminated dishes are sent to the machine for a regular wash.

Acid-alkaline washing. For heavily soiled dishes (salt deposits, rings on the walls, etc.), which must be pre-treated with acid, as well as for contaminants that require treatment with a high concentration of alkali (residues of grease, etc.), manual pre-acid-base treatment is used. processing in special washing troughs or other devices. Heavily soiled dishes are washed in a separate room, isolated from the washing and filling shop. In this case, it is necessary to follow the safety rules provided for when working with acids and alkalis.

Depending on the type of contamination, bottles are treated with solutions of soda ash or hydrochloric acid using a brush.

1. Technological part

Selection, justification and description of the technological scheme.

Vodka and other alcoholic beverages are bottled in glass bottles. This course project presents a good scheme for purifying water for washing bottles with the possibility of its reuse. Water is a very expensive commodity for businesses, so the ability to reuse it will significantly reduce financial costs. Another advantage is the complete automation of the washing process, water purification and detergent regeneration.

Water from the water supply is directed to the sand filter (1), then to the AQUA-Electronics microfilter (2). With the help of these filters, water is freed from suspended matter and iron salts. After pre-treatment, the water flows into the water collector (16). If necessary, stabilizing additives are supplied to it using metering pumps (15) - dilute solutions of sulfuric acid from the tank (13) and polyphosphates from the tank (14). For ease of use, reagent solutions are prepared once a day. Next, the water is processed in a bactericidal installation (17) and sent to a storage tank (18), from where it is pumped into a cascade of reverse osmosis devices (21) through a hydraulic accumulator system (19) using a three high-pressure plunger pump (20).

The quality of purified water is controlled by a salinity meter (23), and the quantity is controlled by a flow meter (22). Using the pump (6), the softened water is directed to the pressure tank (7). Water obtained by the method described above has the following indicators: total hardness 0.02-0.22 mg*eq/dm³, alkalinity 0.16-0.3 mol/dm³, oxidability 0.2-1.5 mg O2/dm³, low content of microelements.

The reverse osmosis unit operates on water with a salt content of up to 0.5 g/dm3. When using the installation, no pre-treatment of water is required. When the salt content is from 0.5 to 30 g/m3 and above, as well as when the water turbidity is more than 1.5 mg/dm3, microfiltration, ultrafiltration and Na-cationization must be introduced before reverse osmosis treatment of water.

A simpler method for preliminary water preparation is Na-cationization. If the total hardness of the water is high, it is treated by passing it through filters (1), (2) and a Na-cation exchange filter (4). Regeneration of the Na-cation exchange filter is carried out with a salt solution supplied from a salt solvent (3). Softened water is collected in a collector (5), after which it is sent to a pressure tank (7), and then treated according to the previously described method. This water is needed to rinse bottles in a bottle washing machine.

Boxes with dirty bottles come from the warehouse to a machine that removes bottles from boxes (24). Boxes with bottles are fed to the machine and stop under the head with grippers. The head then lowers into the drawer and grabs the necks of the bottles, lifts up and carries the bottles to the table. The empty box moves further along the conveyor, and the next box takes its place.

The bottles are sent by a plate conveyor (25) to a bottle washing machine (26) with an alkaline solution coming from the tank (10). In a bottle washing machine, new bottles are only rinsed, while return bottles are pre-cleaned, and then they are washed in the machine with cold and warm water and an alkaline solution. Sodium hydroxide, sodium carbonate, trisodium phosphate, sulfosalts, etc. are used as detergents. The concentration of the alkali solution for manual and semi-automatic washing machines is 1.0-3.0%, for automatic ones - 1.8-2.0%, the solution temperature must be at least 80°C.

The alkali solution is prepared in a mixing tank (10), where alkali and water from the collection tank (8) flow through the measuring tank (9) directly from the tanker through the pump (6). You can also use the used solution for washing. To do this, from the bottle washing machine through the pump (6), the alkali solution flows first into the ceramic filter (12), and then into the regeneration column (11). After the column, the alkali through the pump (6) enters the mixing tank (10).

The wastewater from the bottle washing machine is used for treatment. First, the effluent flows by gravity into the wastewater collection tank (27). After this, the pump (6) goes to the settling tank (28), where it is settled from suspended particles. From there, the settled water is passed through the pump (6) to the sand filter (29), where final purification occurs, after which the purified water is supplied to the purified water tank (8) by the pump (6).

Requirements for raw materials, auxiliary materials and finished products

Drinking water GOST 51232-98

Requirements for water quality according to SaNPiN 2.1.4.1074-01

Finished products:

Glass bottles GOST 10117-91

Crown plug GOST 10167-88

Carbon dioxide GOST 8050-85

Labels GOST 16 353

Dextrin glue GOST 7699

Detergents and disinfectants GOST 5100

Ethyl alcohol GOST R52522-2006

Vodka GOST R51355-1999

1. Vodkas and special vodkas must be prepared in accordance with the requirements of this standard according to technological regulations, instructions for the production of vodkas and special vodkas and recipes in compliance with sanitary standards and rules approved in the prescribed manner.

2. Depending on the taste and aromatic properties, the content of ingredients, vodka is divided into vodka and special vodka.

3. In terms of organoleptic characteristics, vodka and special vodkas must meet the following requirements:

Characteristics: transparent liquid without foreign matter and sediment

Color: colorless liquid

Taste and aroma: characteristic of vodkas of this type, without any foreign taste or aroma. Vodkas should have a mild, characteristic vodka taste and a characteristic vodka aroma; special vodkas - soft taste and emphatically specific aroma.

Table 1.

Table 2.

Technochemical and microbiological production control

Technochemical control is very important in the liquor industry, which produces high-quality liqueurs, liqueurs, tinctures and vodka in a wide range from valuable raw materials - ethyl alcohol, plant materials and food products (sugar, essential oils, etc.). Technochemical control is aimed at improving product quality, introducing rational technologies, complying with consumption standards for raw materials and materials, and reducing their losses.

Technochemical control is a set of indicators characterizing the chemical composition and physical and chemical characteristics of raw materials, intermediate products, auxiliary materials used in the production of finished products, as well as establishing the identity of the results obtained with the values of the relevant standards. Technochemical control involves the determination of a set of indicators that provide complete information about the quality of the product based on the analyzes performed and data from control measuring instruments. One of the main tasks facing the technical and chemical control service is monitoring the progress of the technological process, the quality of raw materials and finished products. High quality products can only be obtained by using raw materials whose quality meets the necessary requirements, and by observing optimal technological conditions for the production of the final product. Even the most minor deviations in the quality of raw materials and violations in the technological regime lead to the release of finished products of low quality or to defects. These deviations are detected only with the help of technochemical control. Technochemical control at enterprises must ensure compliance with technological regimes of recipes, checking the quality of raw materials, intermediate products and finished products in accordance with standards and specifications.

An important link in carrying out technochemical control is the analysis methods themselves, which must give accurate and reliable results. Based on such results, it is possible to develop and refine the technological regime, outline ways to eliminate shortcomings and losses in production, and prevent the release of low-quality products. Such control can be the most effective, since technochemical control serves not only to identify defects in finished products, but also to prevent them, as well as to eliminate situations leading to defects at all stages of the production process.

Table 3. Technochemical control

Table 4. Microbiological control

Production accounting

During the production of vodka, liqueurs and low-alcohol carbonated drinks, records are kept of basic and auxiliary materials and finished products.

The consumption of basic materials is determined taking into account recipes, technological instructions, as well as taking into account inevitable production losses.

The production loss rates depend on the technology, the equipment used, its condition, production discipline and other factors. The loss rate is established at various stages of production and is rechecked at least once every 5 years.

Vodka accounting.

Water-alcohol solutions in the purification department and finished vodka are taken into account by volume and anhydrous alcohol content in them. Finished products, i.e. packaged in bottles, decorated and placed in corrugated boxes, are taken into account quantitatively and expressed in deciliters.

Finished products transferred to the expedition, as well as sold to the distribution network, are taken into account by the number of boxes, the number of bottles and finally in deciliters.

To count bottles and boxes, the plant uses counting devices, mainly of the electric contact type.

Alcohol_inventory.

When taking inventory of alcohol in industrial premises, the volume of alcohol in measuring tanks and other tanks is determined by readings from level meters. In this case, each container must have a State verification certificate in the prescribed manner. At the same time, measure the strength and temperature of the alcohol in each tank.

The amount of semi-finished products (alcoholized juices, fruit drinks, infusions, aromatic alcohols), aqueous-alcoholic solutions, vodka, alcoholic beverages and low-alcohol carbonated drinks in tanks, correctable and irreparable defects is determined by the readings of measuring glasses in deciliters and at the same time the temperature of the liquids is measured, samples are taken for determination of strength from each container.

In the vodka department, the amount of water-alcohol solution in the filters is taken into account, and the amount of alcohol-containing liquids in the communications is indicated. Accounting for alcohol in communications and the filtration battery is carried out according to reports of the presence of alcohol in the equipment.

In exceptional cases, the aqueous-alcoholic liquid is drained from the equipment and measured.

When determining anhydrous alcohol in semi-finished or finished products with a significant content of extractive substances at temperatures above or below 20°C, the volume of the product is reduced to 20°C. Bringing the volume to 20°C is carried out according to special tables, which take into account the volumetric expansion of products depending on the content of extractive substances and alcohol in them. The amount of anhydrous alcohol is found by multiplying the strength at 20°C by the volume of the product reduced to 20°C.

Accounting for alcohol and sugar is carried out in order to control the technological process, in order to save material resources and for the purpose of_full_reporting.

2. Calculation part

vodka raw microbiological recipe

Product calculation

Recipe for vodka "Michurinskaya":

rectified alcohol "Extra",

softened water,

apples 3 kg,

carrots - 0.82 kg,

sugar - 6 kg.

The calculation is carried out per 1000 decalitres of the product.

Table 5

According to the standards confirmed by the Ministry of Food Industry, losses are accepted:

Alcohol 0.94%,

Correctable defects 1.7%,

Uncorrectable defects 0.7%.

Calculation of the amount of alcohol

To determine the given amount of alcohol consumed for the preparation of vodka, it is necessary to take into account its irretrievable losses during the preparation of sorting, its processing with activated carbon, filtration, and its bottling. These losses are calculated as a percentage of the amount of alcohol entering production. We accept the following values of alcohol loss.

Table 6

To prepare this type of vodka, we use rectified alcohol produced from grain potato raw materials, with a strength of 96.4%. The consumption of anhydrous alcohol for the preparation of 1000 dal of sorting, taking into account the strength and losses in production, will be

V = =403.76 dal

Consumption of rectified alcohol "Extra" with a strength of 96.4% vol.

V = = 418.84 dal

Calculation of the amount of corrected water.

Taking into account the contraction of the alcohol - water mixture to obtain 40% vol. sorting to 100 dal of alcohol with a strength of 96.4% vol. water consumption will be 142.2 dal. For 1000 dal of product, the water consumption will be:

V water = 595.59 dal

Calculation of sorting quantity.

The amount of prepared sorting is greater than the amount of vodka received, because part of it is returned to prepare the next sorting, part is lost when washing filters and coal columns and during regeneration is returned in the form of irreparable waste. We take the amount of losses equal to 1.7% of the total amount of production. In addition, sorting losses occur with faulty scrap, which cannot be reused. Taking into account these losses, the sorting volume will be:

V grade. = = 1033.4 dal,

where: 1.7 - the amount of correctable defects%,

0.7 - the amount of irreparable defects%,

Volume of correctable defects

V isp.br. = = 17 gave

V unused br. = = 7 gave

If we take into account the losses of vodka in the purification shop and assume that in the bottling shop all irreparable defects are obtained in the amount of 0.5% of the volume of all products, then the volume of vodka in the finished vats will be:

V = = 1015 dal

Table 7. Summary table of raw material consumption per 1000 dal of product

Products	Units	Product quantity
Rectified alcohol
Corrected water
Sorting
Repaired marriage
Unrepaired marriage
Vodka in finishing vat

Table 8 Summary table products

Products	Unit	Product size

Rectified alcohol
Corrected water
Sorting
Repaired marriage
Unrepaired marriage
Vodka in finishing vat

Calculation and selection of equipment

In order to select equipment for this technological scheme, you need to calculate the number of bottles produced per hour, that is:

a=10*1900000*1.02*0.3/21*3*8*2*0.9*0.5=12817 bottles/h

We select 2 lines with a capacity of 6,000 bottles per hour

Energy calculations

Table 9. Calculation of electricity consumption

Table 10 Calculation of steam consumption

Table 11 Calculation of water consumption.

Table 12 Calculation of compressed air consumption

Table 13 Summary table of energy calculations

3. Occupational safety

The main harmful and dangerous substances in alcohol and liquor production are bulk raw materials, carbon dioxide, alcohol and alkali, and hazardous areas are technological equipment operating under pressure.

To create healthy and safe working conditions in production, it is necessary that all technological equipment and technological processes meet safety requirements.

In the china shop, it is necessary to comply with the requirements of the Rules when storing boxes.

When stacking by hand, boxes with dishes should be stacked in stacks of no more than 2 m. The main passage between stacks must be at least 2 m wide.

The temperature of bottles entering the bottle washing machine must be at least 10°C.

Bottle washing machines should be located on the lower floor. If bottle washing machines are located on the 2nd floor, it is necessary to provide waterproofing measures against possible leakage of washing liquid through the ceilings.

Storing concentrated acids and alkalis in the washing area is prohibited.

The bottle washing machine must have a locking device to disable the drive in the following cases:

When the bottle transporter is loaded or jammed;

When the working bodies for loading and unloading bottles become jammed;

If the bottles do not fall out completely from the bottle carrier nest;

When the outlet conveyor is overfilled with bottles;

When the pressure in the water supply network at the entrance to the machine drops and the temperature of the washing liquids changes.

Filling the baths of a bottle-washing machine with cleaning solution and loading cassettes with bottles must be mechanized. Cleaning solutions should be prepared in a separate room. Broken bottles can only be removed from the working parts of the machine using special devices (hooks, tongs, etc.)

Glass debris generated during machine operation should be removed only after the machines have stopped and should not accumulate near the equipment.

4. Industrial sanitation

The main task of industrial sanitation is to prevent the adverse effects of harmful production factors in order to ensure safe working conditions, eliminate the causes of occupational and work-related morbidity, as well as premature fatigue.

In food enterprises, harmful factors primarily include factors affecting the functioning of the respiratory system, circulatory system, nervous system, organs of vision and hearing.

Harmful substances

The main harmful substances that pollute the air at food enterprises are dust of organic and mineral origin, various gases and vapors generated during the processing of raw materials, starting materials, the creation of intermediate products, products, as well as those contained in production waste. Harmful dusts, gases and vapors that enter the human body in small quantities through the respiratory, digestive or skin organs have an adverse toxic or pathogenic effect on it, disrupting the physiological functions of internal organs, systems or causing various diseases.

The main part of harmful substances enters the human body through the respiratory organs, which perform one of the main functions of human life support - supplying the entire body with oxygen.

To prevent adverse consequences, as well as suffocation due to lack of oxygen, it is necessary that the air used for breathing meets sanitary and hygienic requirements for the content of both its main components and harmful impurities.

Of the harmful gases and vapors, the most dangerous are carbon oxide and dioxide, sulfur dioxide, nitrogen oxides, vapors of alcohols, food essences, acids, alkalis, etc.

Collective protection measures against harmful substances

At food enterprises, to prevent the impact of harmful substances on humans, a set of collective protection measures is used, which can be divided into: technological, the main task of which is to prevent the release of harmful substances into production premises; technical, which are designed to maintain maximum permissible concentrations of harmful substances in premises; medical and preventive measures consist of systematic clinical monitoring of the health status of workers; control tests include an assessment of the content of harmful vapors, gases and dust in the air.

Microclimate at work places

The microclimate of industrial premises is the meteorological conditions of the internal environment, determined by the combinations of temperature, relative humidity and air speed acting on the human body, as well as thermal radiation and temperature of the surfaces of enclosing structures and technological equipment.

Microclimate indicators: temperature (°C), relative humidity (%), air speed (m/s) and intensity of thermal radiation (W/mI) - have absolute values of optimal and permissible values.

Industrial noise and vibration

Process equipment of food enterprises is a source of noise and vibration. Noise and vibration, being biological irritants, cause general disease in the human body.

Compliance of noise and vibration levels in workplaces with safety standards is established by comparing measured parameters with sanitary standards.

Since vibration and noise are most often interrelated, it is advisable to classify collective protection measures against them as vibroacoustic protection measures. These measures are divided into: organizational, which consist of excluding active vibroacoustic equipment from the technological scheme, using equipment with minimal dynamic loads, its correct operation, etc.; technical ones are divided into two categories: eliminating noise and vibration at the source of their occurrence and reducing the intensity of vibration and noise to the level of sanitary standards; Construction and planning measures include planning the placement of equipment to reduce its impact on people.

Individual protection means

According to their purpose, personal protective equipment is divided into personal protective equipment and safety devices; sanitary protection and emergency equipment.

Personal protective equipment and safety devices are designed to prevent or reduce to the required level the impact of hazardous and harmful production factors on workers. They are used in cases where collective protective equipment does not provide complete safety, their use is technically or economically infeasible, or is impossible under these specific conditions.

In addition to PPE, employees of food enterprises who are in direct contact with food products are also provided with personal sanitary protective equipment, which is designed to protect food products from infection and contamination.

Duty personal protective equipment is designed to protect workers when performing urgent repair work, eliminating the consequences of accidents, or for working in emergency situations.

Conclusion

In this course project, a scheme of the washing department was considered, which provided for the complete purification of used water with the possibility of its reuse. Thanks to this opportunity, economic costs for water are reduced, because water for production is a very expensive product.

Literature

1. I.I. Burachevsky et al. "Production of vodka and alcoholic beverages."

2. Faradzhev “General Technology”.

3. V.E. Balashov "Diploma design of enterprises

4. Kovalevsky "Technology of fermentation production", 2004.

5. V.S. Nikitin, Yu.M. Burashnikov "Labor safety in the food industry", Moscow: "Kolos", 1996.

Posted on Allbest.ru

Reception of alcohol

Rectified alcohol is taken by volume, which is measured with conical (from 250 to 1000 dal) and cylindrical (75 dal) measuring cups. Simultaneously with measuring the volume, the alcohol strength is also measured, as in alcohol production. To receive alcohol, factories are equipped with alcohol receiving departments (workshops). Alcohol is drained from road tankers through the bottom fitting using a rubber hose. From railway tanks, alcohol is drained using a pump or by gravity. The first method is used only if the receiving gauges are located above the level of railway tanks. When the receiving measuring tanks are located below the level of railway tanks, the alcohol is drained using a siphon installation (Figure 2), consisting of a rubber corrugated hose, a hand pump and a funnel. One end of pipe 1, equipped with a tubular tip, is immersed in tank 2 to the bottom, and the other is connected to drain communication 3. Open valves 4 and 5 and, with valves 6 and 7 closed, and all valves connecting this communication with conical 8 and cylindrical 9 using measuring instruments, using pump 10 or a vacuum, suck alcohol from the tank. As soon as alcohol appears in the drain funnel 11, the pump is stopped, tap 7 and the tap in front of the conical measuring cup, into which alcohol should flow, are opened.

Using an installation of three measuring instruments makes it possible to quickly accept alcohol with the necessary measurements and calculations. While filling one of the measuring cups, alcohol is downloaded from the second through the receiving tank 12 using an alcohol pump 13 into the alcohol storage tanks.

Figure 2 - Diagram of the alcohol receiving compartment with a siphon installation for draining alcohol

Water and its preparation

The water must meet the requirements of drinking water, do not contain harmful impurities, must be colorless, transparent, odorless and taste good. Total water hardness should not exceed 1.60483 mEq/l (4.5°) and temporary hardness - 0.35663 mEq/l (1 0). If the water hardness exceeds the established limits, then it is corrected, i.e. softened using the sodium cationite or soda-lime method.

The soda-lime method is rarely used due to the significant consumption of reagents and cumbersome equipment. The sodium cation exchange method makes it possible to obtain corrected water with a minimum hardness of 0.07132-0.178-30 mEq/l (0.2-0.5°). The cation exchanger installation is simple in design, compact and easy to maintain. When water with high temporary hardness is supplied, a combined method is used. Processing is first carried out using the soda-lime method, and then sodium cationization. Instead of the combined method, you can use the Na - H cationization method or, using only the sodium cation exchange method, neutralize the treated water with mineral acids (HCl or H 2 SO 4).

Preparation of a water-alcohol mixture

The sorting is prepared as follows. In a hermetically sealed vat, called a sorting vat, a calculated amount of alcohol is taken from measuring cups according to the required sorting strength, and then water is added until the specified sorting volume is obtained. After adding water to the vat, thoroughly mix it using a stirrer or pumping, or bubbling with compressed air (Figure 3).

Air for mixing is supplied from a compressor or blower through a beam bubbler with holes with a diameter of 1.5 mm. Air consumption is about 1 m 3 per 1 m 2 of the cross section of the vat per minute. Alcohol traps should be installed to capture alcohol from the air leaving the sorting tanks.

In the alcohol department, above the mixing vat, a conical and cylindrical measuring tank is installed on the platform, vats of return products, a softened water gauging tank, a vat for sodium bicarbonate (soda) solution, and slightly below there is a pump (in explosion-proof design) for pumping the sorting into the pressure vat in front of the filters.

1 - softened water meter; 2 - a jar of soda solution; 3 - collection of returnable products; 4, 5 — alcohol measuring cups; 6—mixing vat; 7 - pump
Figure 3 - Scheme for preparing sorting in a periodic manner

There is a known method for continuous preparation of sorting. To do this, use a mixer into which water and alcohol are continuously introduced through bubblers at a constant temperature and pressure, regulating the flow using taps. Below is a diagram of the installation for continuous automated sorting preparation.

Alcohol and softened water, respectively, from containers 1 and 2 enter pressure tanks 3 and 4, equipped with float level regulators (Figure 4). The flows of alcohol and water are measured by glass rotameters (type RS-2.5Zh and RS-4Zh), regulated by valves 23 and 25 and mixed in a mixer 9 equipped with a manifold 8, which serves to distribute water. The ratio of alcohol and water flows is taken such that the sorting strength after the mixer is 0.5-1.5% vol. above 40% (1:1.38-1.44). Finally, it is supplied with water coming from the pressure tank 4 through the rotameter 7 (RS-0.63Zh) and the actuator 16 into the product pipeline in front of the pump 11. The operation of the pump is monitored using a technical vacuum gauge 10, and the performance is regulated by valve 29.

To determine the strength of the sorting and process the corresponding pneumatic signal, a flow-through pneumatic sensor 14 is used. The selection of sorting to the sensor after the pump is carried out by valves 26 and 27 through the filter-gas separator 13. The speed of sorting is measured by rotameter 17. The total pneumatic signal processed by the density sensor enters the control unit and regulation 15, consisting of a secondary device and a proportional-integral regulator, and then to the actuator 16.

The secondary device is equipped with a push-button device to control the operation of the installation in manual and automatic modes.

1 — alcohol capacity; 2 — capacity of softened water; 3 — pressure tank with alcohol level regulator; 4 - pressure tank with water level regulator; 5 — alcohol flow meter; 6 - water flow meter; 7 — additional water flow meter; 8 - collector; 9 - mixer; 10 — pressure-vacuum gauge; 11 - centrifugal pump; 12, 34, 35 — pressure gauge; 13 — filter-gas separator; 14 — density sensor; 15 — density control and regulation unit; 16 — pneumatic actuator; 17 — flow meter of the solution taken to the sensor; 18, 30, 33 — shut-off and control valves; 19, 20, 21, 22 — shut-off valves; 23, 24, 25 - valves regulating the flow of components; 26-29 - valves that regulate the selection of gas from the sorting and its supply to the density sensor; 31 — remote control panel; 32 - filter for air purification.
Figure 4 — Scheme of a continuously operating installation for the preparation of sorts

If an imbalance occurs between the current density value and the set one, the controller of block 15 changes the output pneumatic signal, providing a corresponding change in the position of the valve in the actuator towards aligning the resulting strength with the set one.

The installation for continuous sorting preparation is completely sealed, which reduces alcohol losses by 0.03% compared to the batch method. Its compactness allows you to reduce production space.

Calculation of the amount of alcohol and water for preparing a water-alcohol mixture

The amount of alcohol required to prepare the sort is calculated using the formula:

V sp and V grade—volumes of alcohol and sorting, respectively;
a sp and a grade - alcohol strength and sorting

Filtration of water-alcohol mixture

To remove suspended particles, the water-alcohol mixture is filtered twice: before treatment and after treatment with active carbon.

Quartz sand is used as a filter material. Filtration is carried out under the pressure of a liquid column using sand filters, in which quartz sand is placed on a mesh partition covered with a filter fabric made of flannel or cloth.

Filtration of the water-alcohol mixture occurs under the pressure of the liquid column; the sorting is supplied to the filter by gravity from a pressure tank located above the filters. As the amount of filtered liquid increases, the height of the sediment layer on the filter material increases. Flow resistance increases and filtration rate decreases. To eliminate this, the filter is periodically cleaned. Filtration of the water-alcohol mixture through quartz sand is carried out using sand filters (Figure 5).

1 - body; 2 - bottom; 3 - cover; 4 — supply fitting; 5 — outlet pipe; 6 — lantern; 7 - valve - air vent; 8 — release fitting
Figure 5 — Sand filter with control lamp

The sand filter is made of sheet copper in the form of a cylindrical body 1, tinned inside, with a spherical bottom 2 and a removable cover 3, bolted to the body flange. Filter height 1100 mm, diameter 700 mm. Using two removable tinned perforated disks resting on rings attached to the body, the filter is divided into three chambers: the upper and lower chambers are free, the middle one is filled with quartz sand in two layers with a total height of 700 mm. In the lower layer, the grains range in size from 1 to 3.5 mm, in the upper layer - 3.5-5 mm. Before filling with sand, a tinned copper or wooden hoop covered with flannel or overcoat cloth is placed on the lower disk. The same hoops are placed between layers of sand and above the upper disk. The gaps between the hoops and the filter housing are clogged with a cotton cord.

The sorting to be filtered comes through fitting 4 with a tap, passes through the filter chamber and is taken through pipe 5 for treatment with active carbon.

Sand filters for filtration of vodka are distinguished by the fact that they are made of stainless steel, equipped with a rotameter and a glass lantern 6 on the outlet pipe. The filtration rate is controlled using a rotameter, and the transparency of the vodka is controlled using a flashlight.

The first, cloudy portions of the filtrate are returned to the mixing vat. After obtaining a clean filtrate, filtration is carried out at a speed of 0.77 m/h (30 dal/h), regulated by smoothly turning the filling tap.

After the filter has been running for 20-30 days (the speed with the tap open becomes low), it is turned off to recharge.

There are several types of sand filters that are widely used for filtering sortings in the alcoholic beverage industry. They are divided by design into single-flow and double-flow.

In single-flow sand filters, the sorting is supplied from the top and discharged from the bottom (Figure 6). The double-flow sand filter (Figure 7) is additionally equipped with a tubular drainage device, the pipes of which are wrapped in a fine mesh with a hole of 0.2-.03 mm. The bottom layer of sand with grains of 2-3 mm has a height of 50 mm, the middle layer with grains of 1.5-2 mm has the same height, and the top layer with grains of 0.5-1 mm has a height of 400-600 mm. The drainage device is located in the middle of this layer of sand. Sorting enters the filter from below and above and is discharged through the drainage system. The sorting stream coming from below is filtered first through large, then through medium and finally through small sand grains. The upper sorting stream is filtered only through small grains.

1 - body; 2 — supply fitting with distribution device; 3 — outlet fitting; 4 - drainage device; 5 - switchgear; 6 - partition; 7 - top layer of sand; 8 - middle layer; 9 - bottom layer
Figure 6 - Single-flow sand filter

1 - body; 2 - distribution devices; 3 - partition; 4 — outlet pipe; 5 - window; 6 — drainage device; 7 - top layer; 8 - middle layer; 9 - bottom layer
Figure 7 - Double-flow sand filter

Sand regeneration in single-flow and double-flow filters is carried out by a reverse flow of water: sorting during preliminary filtration, vodka during final filtration for 10-12 minutes.

Ceramic filters are also used, in which the filtering element is ceramic tiles. Regeneration of ceramic tiles is carried out by treatment with hydrochloric acid and calcination in a muffle furnace at 500-600°C.

Treatment of a water-alcohol mixture with active carbon

To remove impurities from the sorting that give it an unpleasant taste and smell, it is treated with active carbon of the BAU brand. In addition to adsorbing some impurities, activated carbon catalyzes the oxidation reactions of alcohol and its impurities with the formation of organic acids and their subsequent esterification, i.e. formation of esters. Activated carbon is loaded into columns made of copper or stainless steel. The sorting is filtered from bottom to top through carbon columns connected in series.

Regeneration of spent activated carbon

As filtration proceeds, impurities of alcohol and water accumulate in the pores of the coal and reduce its absorption activity. Columns usually pass from 15,000 to 100,000 dal of sorting or more. It is periodically necessary to restore the adsorption and catalytic abilities of waste coal. To do this, waste coal is regenerated in a column with water vapor at 110-130°C. As a result of processing, impurities absorbed by coal are distilled off.

Vodka filtration

After treatment with active carbon, the vodka is filtered to separate the smallest impurities and obtain a transparent product with a crystal shine. Vodka is filtered using sand or ceramic filters. In the latter, the filter partition is ceramic tiles with a pore size of 40μ.

Bringing vodka to the required strength

The filtered vodka enters the finishing vats, where it is mixed and the strength is checked. If the strength of vodka deviates from the standard, it is brought to the required strength by adding alcohol or water. After this, the vodka is sent for bottling.

Mineral waters bottled, depending on the chemical and gas composition, as well as the filling method, are divided into four technological groups: 1) still waters; 2) carbonated waters; 3) carbonated waters containing iron; 4) hydrosulfite and hydrosulfide-hydrogen sulfide waters.

The first technological group includes the most stable mineral waters, which do not undergo oxidation during the bottling process and do not change their chemical composition.

The technological flow diagram for bottling still waters belonging to the first technological group is shown in Figure 1.15.

Mineral water from wells 1 under its own pressure or using a deep pump is supplied to a hermetically sealed collection 3 installed in a capture structure 2. From collection 3, mineral water is pumped by pump 4 into collection 5 for storage and, as needed, supplied by pump 4 to ceramic filters 6 , from where it enters the counterflow heat exchanger 7, and then into the intermediate collection. From this collection, water is supplied by pump 4 to the saturator 9, where carbon dioxide is supplied from the gasification station 35, delivered to the plant in specialized tanks 36. C02-saturated mineral water is sent through a disinfection installation 10 to the tank of the filling machine 22. Delivered on pallets 11 in bags 12 or boxes 13, glass containers are placed in boxes and fed along a conveyor belt 14 to automatic machines for removing bottles from boxes 15.

Bottles removed from the boxes are fed by a conveyor belt 14 to the loading device of the bottle washing machine 18, passing by the viewing screen 17. The washed bottles are sent by a plate conveyor 16 to the viewing screen 17 to check the quality of washing. Then the bottles pass sequentially through a filling machine 22, a capping machine 23, a rejecting semi-automatic machine 24, a labeling machine 25 and enter the machine for placing bottles in boxes 26, to which empty boxes are fed by a conveyor belt 14. Finished products, packed in boxes 27, are placed on pallets in stacks 28 for transportation to the finished product warehouse. The concentrated alkali solution is delivered to the plant in tank trucks 29, from which it is pumped by pump 30 into a collection tank 31 for storage.

As needed, the concentrated alkali solution is pumped from this collection by pump 30 into the measuring tank 32, from where it enters the container 33 for preparing a working alkali solution, or directly pumped into the measuring tank 21. The spent alkali solution is poured into the receiving collector 19 and after settling is supplied by pump 20 to filter 34, then into a container for preparing working solution 33.

The crown cap for capping bottles of mineral water is delivered to the plant in bags 40, laid on pallets 11. From the bags, the crown cap is poured into a hopper 39, from where it enters the receiving hopper of the magnetic lift 38 via a tray and is delivered by a conveyor belt 37 to the hopper of the capping machine. cars.

The second technological group includes mineral waters, the chemical composition of which is subject to change. Since the carbon dioxide they contain is a stabilizer of the chemical composition, bottling of such waters must be carried out under conditions of slight excess pressure created by CO 2, which will minimize the possibility of degassing.

The technological scheme for bottling mineral waters belonging to the second technological group is identical to the one given above, but all technological operations associated with their transportation, storage and bottling are carried out under slight excess pressure of CO 2.

The third technological group includes waters containing from 5 to 70 mg of iron per liter.

To avoid the formation of sediment in the bottle when bottling these mineral waters, conditions must be provided to prevent iron oxidation and degassing of the water during the bottling process. For this purpose, a solution of stabilizing acids - ascorbic or citric - is introduced into mineral water.

Mineral waters containing iron are classified as shallow circulation waters. They are most susceptible to bacterial contamination. Secondary water pollution is possible during pumping, storage, processing and bottling. The introduction of organic acids can serve as a source of nutrition for non-toxic microorganisms found in mineral waters, in particular sulfate-reducing microorganisms. Therefore, mineral waters containing iron must undergo mandatory disinfection. The C0 2 content in the finished products must be at least 0.4% in weight, and for sealing they should use only crown caps with gaskets made of polymer materials.

The bottling of ferruginous mineral waters belonging to the third technological scheme is carried out according to the generally accepted technological scheme shown in Figure 1.2

An additional process of stabilizing the chemical composition of water during bottling is carried out according to the following technological scheme. Mineral water from well 1, located in the hood structure 6, enters a hermetically sealed collector 3, equipped with a safety valve 2 and a pressure gauge. From this collection, water is pumped by pump 4 into collection 5, from where it is transferred to production. A solution of stabilizing acid is added to the supply pipeline to collector 5, a concentrated solution of which is located in collector 8. The working solution is prepared in collectors 7 equipped with stirrers.

Figure 1.2 Technological flow diagram for bottling non-carbonated mineral waters belonging to the first technological group

In the case of transporting mineral waters containing iron over a distance of up to 200 km, sealed tank trucks are used, from which the air is first displaced with carbon dioxide supplied from carbon dioxide cylinders. The stabilizing solution is introduced into a tank or intermediate container, from which the air is also previously displaced.

When using two-chamber tank trucks for transportation, the CO2 air is sequentially displaced and each chamber is filled with water separately. The completeness of air displacement from tanks and intermediate containers is checked by the turbidity of barite or lime water through which the air leaving the tanks or intermediate container is bubbled. After complete displacement of air from the tanks or intermediate container, the supply of CO 2 is stopped. Tankers are filled with mineral water to 9/10 of the volume. Mineral water is transported under slight excess pressure of C0 2.

For bottling hydrosulfide-hydrogen sulfide and hydrosulfite waters, combined into the fourth technological group, mineral waters containing hydrogen sulfide up to 20 mg/l and hydrosulfides up to 30 mg/l can be used. Since the reduced forms of sulfur contained in these waters are predisposed to oxidation with the formation of colloidal sulfur, causing opalescence of the water, and, in addition, neither hydrogen sulfide nor hydrosulfidiones are useful components of water, a technological method aimed at removing them from the composition of mineral waters.

The bottling of mineral waters, combined into the fourth technological group, is carried out according to the technological scheme shown in Figure 1.15, with additional water treatment in a scrubber. To do this, mineral water from a storage tank is pumped into the upper part of a scrubber filled with Raschig rings. At the same time, CO 2 is supplied to the lower part of the scrubber. Water flowing in a thin layer over the surface of the rings. Rashiga, intensively contacts with CO 2, and the equilibrium shifts towards the formation of hydrogen sulfide, which is removed from the mineral water by a current of carbon dioxide. The pumped desulfurization water is sent to a storage tank, and the carbon dioxide leaving the scrubber can be treated and reused.

It might be useful to read: