Mineral Water Plant (project)

INTRODUCTION

The demand for mineral water is increasing at a rapid rate, as people become more health conscious and take precautions
against water borne diseases.
Bottled mineral water provides easy transportability and assured water quality.

THE PROJECT INVOLVES MACHINERY FOR
PURIFYING WATER
BOTTLE MANUFACTURING.
BOTTLING PURIFIED WATER.
LABELLING

CAPACITY

The plant is being designed for minimumeconomically viable capacity, such that the capital outlay is optimized.
The capacity of the various units are as under:
- Purification: 1000 litrers / hour i.e. 8000 litres / 8 hour shift
- Bottle Manufacturing: 550 Bottles per hour per machine. 2 nos. machines will give 1100 bottles per hour i.e. 8800 bottles
per 8 hour shift.
- Bottling : 24 Bottles per minute of 1000 ml. i.e. 1440 Bottles / hour i.e. 11520 Bottles per 8 hour shift.
- Labelling : Heat Shrink Tunnel would handle 1000 Bottles per hour.
All the 4 capacities have been nearly matched - for any adjustments some of the machines can be run for longer duration.

PROCESS FLOW

The plant has 6 components :
1] Purification: Water received fromthe external source is passed through the purification plant and stored in a stainless steel
tank. Thereafter it is fed to the bottling section - and continuos operation achieved.
2] Bottle Manufacturing: Pet preforms are blown into bottles and a sufficient number of bottles, say 1000 nos., kept ready while
the machine continues to produce more during the shift , when the bottling has been started.
3] Rinsing - Filling - Capping: 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.
4] Labeling: We are proposing use of heat shrink labels and tamper evident heat shrink sleeve on the neck of each bottle.
The label and the neck sleeve are to be manually put on the bottles which will then pass through the shrink tunnels and onto
packing conveyer.
Expiry date and batch number could be printed on labels or caps prior to their being put on the bottles.
5] Heat Shrinking: The bottles are passed through heat shrink tunnel so that the label and neck sleeve, shrink and stick to the
bottles.
6] Final Packing: This could be in cartons - done manually - and no machines have been provided for it.

MACHINES / EQUIPMENT OFFERED

The various machines and equipment being offered by us is explicitly listed here. This does not include miscellaneous items
like pipes, electricals etc., which are specific to the site and each project.

Purification Section:
Flow rate : 1000 lit / hour
Raw water quality (assumed) : 1000 ppmas TDS
Description Quantity
Alumdoser 3 lit/hr dosage 1
2 nos. pump (1W+1S) (SS) 1
Activated Carbon Filter
Flow Rate : 2000 lit/hr.
MOC : SS 304
1
Pressure Sand Filter
Flow Rate : 2000 lit/hr.
MOC : SS 304
1
Softener 1
Reverse Osmosis System
Permeate Flow : 500 lit/hr.
Consist of :
5 Micron Filter SS-304 PP
H.P. Pump with 3 HP Motor
Membrane - 4 nos.
Pressure Vessel (SS-316) - 4 nos.
1
Instruments & panel
Ozone Generator
Capacity - 1 gm/hr.
Ozone Dissolution Col.
MOC : SS-316
Flow Rate : 1000 lit/hr.
1
UV Disinfectant
Flow Rate : 1000 lit/hr.
1
Storage tank for Pure Water
Capacity : 1000 ltr. SS-316
1
Total Cost USD 34,300/-
If the quality of the raw water is good it may not be necessary to use some of the above equipment and consequently the cost
can come down. Tanks for Raw water, and alumdosing are to be provided by the client. The output water purification would be
in line with WHO specifications - however final results depend on input water quality.
Bottle Manufacturing Section:
To achieve 1100 nos. bottles per hour production.
Description Quantity
Stretch Blowing Machine:
upto 2 ltr. Capacity
(PreformManual Loading Machine fromConveyor to Stretch Blowing Machine)
- 2 cavity bottle upto 2 ltr. (Neck dia upto 46 mm)
- Hydro-pneumatic locking system
- With Infrared heating systemconveyor and separate Control Panel with
2
Microprocessor.
- Production : 550 Bottle / Hour
- Model No. TPD 2000
Refrigeration Unit : (Chiller)
Cooling Capacity : 1 Ton;
(Standard Make)
2
Air Compressor :
with after cooler and moisture separator
2
Mould sets :
Double Cavity 1.5 ltr. Round shape mould in aluminium
Double Cavity 1 ltr. Round shape mould in aluminium
Double Cavity 500 ml. Round shape mould in aluminium
2
Approx. Spares for 1 Year 2
Total Cost USD 48500/-

It is possible that the air compressor be bought locally.
We are in a position to offer automatic moulding machines also.
However that would result in higher investment hence is not recommended at the initial stages.

Bottling Section :
This section receives the empty bottles, rinses them, fills and caps them.
Description Quantity
Stainless Steel Conveyor:
Made of S.S, 8 meter long for conveying of empty washed bottles onto the filling
1
machine.
The different operations like rinsing, filling, capping are done on the conveyor.
Electrical Details: 0.5 H.P. with variable speed drive..
Rinsing, Filling, Capping:
This machine is designed to fill 24 bottles per minute for 1 ltr bottle & is capable to
fill 500 ml, 1000 ml, 1500 ml bottles. Machine speed is depended on the volume to
be filled.
The bottles are holded in groups of 6 & moved on the conveyor together.
These grouped bottles are rinsed by means of spraying pressurized water inside the
bottle.
After Rincing the bottles are again placed on the conveyor & are loaded on the filling
& capping machine one by one.
Filling & capping takes place by indexing mechanism. There are total 8 indexes.
1
Change parts for 500 ml and 1500 ml 1 set each 1 set each
Spare for item2 for 2 years

Total cost USD 33,300/-

LABELLING & PACKING SECTION :
Description Quantity
Shrink Tunnel:
This is fitted on the online conveyor to shrink labels and neck sleeves. The
1
labels & neck sleeves are to be manually inserted on the bottle.
Machine will be provided with suitable capacity Heaters, Blower,
Reduction Gear Box and Electric Motor, complete in all respects ready to
use.
Printing Machine ( for mfg. Date & batch nos.)
Semiautomatic machine is proposed.
This is a table top coding machine with a printing area of 35 mmx 25 mm
& capable of printing 3 variable line message on labels or caps.
OR
Direct online inkjet printers can be provided at additional cost of
approximately USD 10000/-
1
Total cost USD 4500/-


TOTAL COST OF THE MACHINERY OFFERED

1. Purification section: USD 34,300.00

2. Bottle Manufacturing section: USD 48,500.00

3. Bottling section: USD 33,300.00

4. Labeling & packaging section: USD 4500.00

Total FOB USD -- USD 1,20,600.00


RAW MATERIAL

The water source is of critical importance and the continuity of the plant would depend upon it. Apart fromwater following
items are required and can be supplied by us.
1] Preform- for blowing into bottles
2] Caps for the bottles
3] Labels
4] Neck sleeves
5] Cartons for final packing.


The budgetary prices for the above material is as follows -
1] Preforms
a) 1000 ml - 25 gms USD 50.00/1000
b) 500 ml - 20 gms USD 35.00/1000
c) 1500 ml - 31 gms USD 55.00/1000
2] Caps - 28 mmUSD 8.00/1000

3] Labels
a) 2 colour USD 4.00/1000
b) colour USD 4.85/1000

4] Neck Sleeves Plain USD 1.15/1000

5] Cartons USD 15.00/1000

Final rates prevailing at supply time would be quoted on knowing design, quantity, sizes etc.

COSTS

The various cost elements involved are :
1] Raw material
2] Packing cost
3] Operating cost - Electricity
4] Manpower


ELECTRICAL LOAD

The total Electricity load would be about 2.0 KW

MANPOWER
Number of people required to operate various machines is
1] Bottling - 1 nos.
2] Labeling - 2 nos.
3] Bottle making - 2 nos.
4] Printing - 1 no.
5] Packing - 2 nos.
6] Miscellaneous - 2 nos.

Total - 10 nos.


PRODUCT COSTING :

We are presenting hereunder costs for 1000 bottles of 1000 ml

Cost per 1000 in USD
Preformcost 50.00
Cap cost 8.00
Label cost 4.00
Carton cost 15.00
Water cost 1.00
Electricity, Wages et 2.00
Transportation 2.00

USD 82.00/1000
The above costs are based on our selling price, you would have to add import duty and other charges which are levied in your
country.

COMMERCIAL TERMS & CONDITIONS :

Total Price FOB USD 1,20,600.00
(TOTAL USD One hundred Twenty Thousand and Six Hundred only )

Erection and Commissioning
We can send our Engineers for commissioning. Per person a charge of USD 100/- per day would be payable along with, to and
fro Air Fare and accomodation

Price Basis
Prices quoted are FOB and subject to Design, engineering, fabrication and supply of plant and equipment as per details
submitted.
Following are excluded :
I] Sea freight and marine insurance fromIndian port to the port of destination in your country.
Ii] Customs / Port clearance and handling at the port of destination, unloading, loading, inland transportation and insurance for
the transportation of equipment fromthe port to the site.
Iii] Bank charges towards L/C confirmation, negotiation and remittance.