A Training Report Submitted To

College Of Engineering Roorkee,Roorkee

B.Tech. in Applied Electronics and Instrumentation

And to

NESTLE INDIA LIMITEDPANTNAGAR FACTORY

SUBMITTED BY:

NISHANT GUPTA

Applied Electronics and Instrumentation

B.Tech. 2011-2012

C ERTIFICATE

This is to certify that project work in NESTLE INDIA LIMITED, PANTNAGAR is a

bonafide record of work done by Mr. Nishant Gupta under my Guidance in partial

fulfillment of the requirements for the training program in 45 days in-plant

training as required in 4 years course of B.Tech(Applied Electronics and

Instrumentation).

Mr. Pankaj Kapoor(Factory Engg.)

C ERTIFICATE

This is to certify that project work in NESTLE INDIA LIMITED, PANTNAGAR is a

bonafide record of work done by Mr. Nishant Gupta under my Guidance in partial

fulfillment of the requirements for the training program in 1 month.

Mr. Sumant Tyagi(Electrical & Automation Engg.)

D ECLARATION

I, Nishant Gupta, Student of B.Tech(Applied Electronics and Instrumentation)

hereby declare that the project report submitted here is a original piece of work

done by me and has not been submitted to any other organization in any means

possible. The work was done under the guidance and instruction of mentors in

different departments.

The projects are the result of my summer training at NESTLE INDIA LIMITED,

PANTNAGAR Factory.

NishantGupta

A CKNOWLEDGEMENT

A work is never a work of an individual. It is more a combination of ideas, suggestions, reviews & contribution that cannot be completed without the help of guidance & demonstration.

I want to take this opportunity to convey heartfelt gratitude towards all those whose contribution made this training report a reality. Firstly, I would like to thank ‘THE ALMIGHTY GOD’ for giving me such good luck to get trained in as esteemed plant of NESTLE.

Mr. …………., The Factory Manager lend me the permission to undergo 6 months training in the prestigious & dignified plant like Nestle, Pantnagar. Thank you Sir.

This is to express my gratitude to Mr. Pankaj Kapoor, Factory Engg., who gave me this opportunity, interacted with me from time to time and guided me ahead.

I would like to take the privilege to express my gratitude to Mr. Sumant Tyagi (Electrical & Automation Engg.) who shared his tremendous knowledge & experience and guided me at every stage of my training. It gives me immense pleasure in stating that a man of his stature, knowledge and experience is humble enough in making my experience as a fresher full of learning and knowledge at every step.

Lastly my special thanks to all my NESTLE INDIA LIMITED, PANTNAGAR team members who have extended their cooperation in making my training at Pantnagar Factory a significant success.

I am indebted to many of my friends Apoorv, Sapna, Gaurav, Garima, Tarun, Champa, Nishta, Naina, Sujata, Amita to support me and always being their when I need their help and company.

Nishant Gupta

C ONTENTS:

Acknowledgement

Introduction

Components of Noodle Line

Projects Done -:

PLC

Working of Motors and Process.

Study of Transformers & Techniques to remove losses

Study in DG(Diesel Generators).

INTRODUCTION OF NESTLE -:

The company dates to 1867, when two separate Swiss enterprises were found that would later form the core of Nestle. In August of that year, Charles A and George Page, brothers from Lee Country II, in the United States, established the Anglo-Swiss condensed Milk Company in Cham.

In September, in Vevey, Henri Nestle developed a milk-based baby food and soon began marketing it. In the succeeding decades both enterprises aggressively expanded their business throughout Europe and the United States.

Henry Nestle retired in 1875, but the company, under new ownership, retained his name as Farina Lactee Henry Nestle. In 1877, Anglo-Swiss added milk-based baby foods to its products, and in the following year the Nestle Company added condensed milk, so that the firms became direct and fierce rivals.

HISTORY OF NESTLE -:

Nestle is the world’s leading Nutrition, Health and Wellness Company. We are committed to increasing the nutritional value of our products while improving the taste.

Since Henri Nestle developed the first milk food for infants in 1867, and saved the life of a neighbor’s child, the Nestle Company has aimed to build a business as the world’s leading nutrition, health & Wellness Company based on sound human values and principles.

Nestle SA, Switzerland is amongst the world’s largest food and beverages companies. The Company is progressively evolving from a respected, trustworthy food and beverage company to a respected, trustworthy food, beverage, nutrition, health and wellness company. This objective is encapsulated in “Good Food Good Life”. The Principle activities of the group encompass: beverages, milk products, nutrition and ice cream; prepared dishes and cooking aids; chocolate, confectionery and biscuit; water; and pet care. It has 511 factories in 86 countries around the world.

While our Nestle Corporate Business Principles will continue to evolve and adapt to a changing world, our basic foundation is unchanged from this time of the origins of our company, and reflects the basic ideas of fairness, honesty, and a general concern for people.

BACKGROUND – NESTLE INDIA LIMITED -:

Nestle India Limited was the established in India in 1961, in an effort to upgrade the existing standards of the Indian milk industry at that period. The first production unit was launched in Punjab.

Nestle India Limited has grown over the years into the most desired brand in the food and beverage sector in India. The company has succeeded in meeting the expectations of the Indian government in bringing a marked change in the milk industry through its suggestion on the latest dairy farming techniques and upkeep of cows to improve the milk yield. Nestle India Ltd. gave directions to the farmers in incorporating the advanced technological methods with regard to crop maintenance and irrigation. The company proposed the set up of centers that not only catered to the storing and selling of milk, but also maintained contacts with the farmers.

With an Employee- strength of over 3000 and turnover of US$ 497 million in 2003, Nestle India is one of the leading companies in the FMCG space in India. The Company is acknowledged amongst India’s ‘Most Respected Companies’ and amongst the ‘Top Wealth Creators of India’.

During the first half 2004, the company registered a total income of US$ 257.8 million and net profit of US$ 23.73 million. Nestle India is a 61.85 percent subsidiary of Nestle S.A Switzerland and was incorporated as a limited company in 1959. It produces a wide range of products including beverages, prepared dishes in 1959. It produces a wide range of products including beverages, prepared dishes and cooking aids, milk products and nutrition, chocolate and confectionary.

Milk Products and nutrition account for around 45% of Nestle India’s total revenues. The Company’s beverage products generate 22% of the company’s

total revenues, while prepared dishes and cooking aids generate 18%, and chocolates and confectionery 15%.

MANUFACTURING UNITS OF NESTLE INDIA -:

Nestle India Limited initiated its workings its workings in India with the Moga unit in Punjab in 1961; succeeded by the Choladi unit located in the state of Tamil Nadu. The Moga unit dealt entirely with the proper management of dairy products whereas the Chodali unit diverted its interest to the tea industry. The main purpose behind the set up of Chodali unit was to treat the tea crop to produce soluble tea. Nestle India Limited is also the proud of owner of Nanjangud unit in Karnataka; Samalkha unit in Haryana; Ponda and Bicholim units in Goa; and Pantnagar unit in Uttarakhnad.

NESTLE INDIA LIMITED, PANTNAGAR FACTORY -:

Nestle India Limited, Pantnagar unit was establish on 26 October 2006 in the area of approximately 20 acre. Nestle Pantnagar factory manufactures Noodles, Pazzta and vending mixes. Different products produced in Pantnagar unit are Masala noodle, Pazzta Masala & Cheese and tomato, Masala-ae-Magic, Nestea Lemon & Peach, Lemonade, Orange, Frappe, Sunrise and NCVM.

The Factory has 3 Phases -:

Phase I: Includes 4 lines for Maggi Production.

Phase II: Includes 3 Lines for Maggi and 1 for Pasta Manufacturing.

Phase III: Includes Tastemaker (KANBAN), Vending Mix and HPP.

COMPONENTS OF NOODLE LINE -:

The major components of Maggi noodle are summarized as follows: Silo – Silo is the first component of noodle processing. Here the refined wheat flour is tipped into the big storage structure called silo. There are different silos for different lines and from there the flour is passed to the mixer through pipes which have pressure to deliver the flour to the mixer.

MIXER: Mixer mixes wheat flour, kansui calcium carbonate and gluten. There are fixed proportions of these ingredients. There are two mixers for each line. The mixer passes the mixture to the rollers.

ROLLERS: There are ten rollers. Each passes the sheet to the next one. After roller 1 we get two sheets but after roller 2 we get a single sheet and by the time the sheet is passed by the tenth roller the thickness is reduced further.

STEAMER: Pre-cooking of noodles takes place here with the help of steam. The noodles pass three times inside it and the moisture is preset.

PRE-DRYER: Here the cakes pass three times and the moisture content is reduced by drying the cakes.

FRYER: Now after removing the moisture to a good extent, frying is done. RBDO (Refined Bleached Deodorized Palm Oil) is used to fry the noodles. Three temperatures are set here and all three are around 130 degrees Celsius with slight variation in each of them.

COOLING CONVEYER: This conveyer runs through a cooler and noodle cakes are cooled here and are further passed to ADS.

ADS: This is Automatic Distribution System. This consists of receiving conveyers, hinge conveyers, transfer conveyers, aligners, evacuators and belts and wrappers). The noodle cakes after cooling conveyer through these hinge and transfer conveyers are distributed to the wrappers and packing take place ultimately.

WRAPPER: There are wrappers in line and each wrapper contains metal detector, gap fill sensor, 1 metering sensor, 2 index sensor and their individual conveyers dispenser, horizontal flow wrap machine, sachet detector, check weigher and overhead conveyer which leads to the packing area.

PACKING: Packing of packed packets in cartons is done manually. This is the last step or before storing and transportation. Automatic case packer (Pick, Place Robot) is also installed at Line 7 and there are further plans to have the same on other lines in the near future.

M ANUFACTURING -:

Tipping:-

Tipping is the fast step in the Noodle manufacturing process. Here Flour from the begs is tipping or emptied into the hoper. After tipping, foreign body (FB) removal is done and flour free of any FB is conveyed to the mixers.

Mixing:-

In the step, thorough mixing and uniform dispersion of various Ingredients (Flour + kansui: solution of sales) is done to from a homogeneous mixture. This homogeneous mixture is essential for uniform Sheet formation at the rollers.

Sheet formation:-

The dough formed at the mixers is rolled into a sheet by a set of rollers. This Step is similar to a domestic kitchen operation, of rolling the dough into a Sheet for marking chapati/Indian bread. After the last roller, the continuous Sheet is passed through a kiriha/slitter, which slits the sheet into uniform Strands.

Steaming:-

Process of looking the raw noodles by subjecting in to pressurized Saturated steam.

Cutting & folding :-

In this step, steamed noodle is cut and folded to form noodle Cake of prescribed weight and dimension.

Pre – Drying:

In this step, noodle cakes are dried by application of heated air. The main purpose of the step is to reduce the moisture content of the noodle cakes which further helps in.

Reduction in oil uptake in the noodle cake Reduction in frying time & temperature

Frying:-

During frying, noodle cakes are fried in an oil bath. In this step, oil penetrates into the product giving it a flavor and also adds Crispiness to the product.

Cooling:-

The cakes coming out of the fryer are at very high temperature. At this high temperature filling the cakes into packets is not advisable. So to bring back temperature of cakes to ambient temperature, a cooler is used.

Filling & Packing:-

In this step, filling machine is used to pack the cake and tastemaker sachet into a pouch.

The main functions of packaging are:

Protect the nutritional and sensory properties of the product.

Contain to allow ease of handling, transport and distribution.

Creating sales appeal and brand identity on the shelf.

Provide convenience and added value to consumer.

WHAT IS CALIBRATION?

There are as many definitions of calibration as there are methods.

According to ISA’s The Automation, Systems, and Instrumentation the word

calibration is defined as “a test during which known values of measurand are

applied to the transducer and corresponding output readings are recorded under

specified conditions.” The definition includes the capability to adjust the

instrument to zero and to set the desired span.

An interpretation of the definition would say that a calibration is a Comparison of

measuring equipment against a standard instrument of higher accuracy to detect,

correlate, adjust, rectify and document the accuracy of the instrument being

compared.

Typically, calibration of an instrument is checked at several points throughout the

calibration range of the instrument. The calibration range is defined as “the

region between the limits within which a quantity is measured, received or

transmitted, expressed by stating the lower and 2 Calibration Principles upper

range values.” The limits are defined by the zero and span values.

The zero value is the lower end of the range. Span is defined as the algebraic

difference between the upper and lower range values. The calibration range may

differ from the instrument range, which refers to the capability of the instrument.

WHAT ARE THE CHARACTERISTICS OF ACALIBRATION?

Calibration Tolerance: Every calibration should be performed to a specified

tolerance. The terms tolerance and accuracy are often used incorrectly. In ISA’s

The Automation, Systems, and Instrumentation, thedefinitions for each are as

follows:

Accuracy: The ratio of the error to the full scale output or the ratio of the error

to the output, expressed in percent span or percent reading, respectively.

Tolerance: Permissible deviation from a specified value; may be expressed in

measurement units, percent of span, or percent of reading. As you can see from

the definitions, there are subtle differences between the terms. It is

recommended that the tolerance, specified in measurement units, is used for the

calibration requirements performed at your facility. By specifying an actual value,

mistakes caused by calculating percentages of span or reading are eliminated.

Also, tolerances should be specified in the units measured for the calibration.

Accuracy Ratio: This term was used in the past to describe the relationship

between the accuracy of the test standard and the accuracy of the instrument

under test.

Traceability: All calibrations should be performed traceable to a nationally or

internationally recognized standard. For example, in the United States,the

National Institute of Standards and Technology (NIST), formerly National Bureau

of Standards (NBS), maintains the nationally recognized standards. Traceability is

defined by ANSI/NCSL Z540-1-1994 (which replaced MIL-STD-45662A) as “the

property of a result of a measurement whereby it can be related to appropriate

standards, generally national or international standards, through an unbroken

chain of comparisons.”

Note this does not mean a calibration shop needs to have its standards calibrated

with a primary standard. It means that the calibrations performed are traceable

to NIST through all the standards used to calibrate the standards.

Uncertainty: Parameter, associated with the result of a measurement that

characterizes the dispersion of the values that could reasonably be attributed to

the measurand. Uncertainty analysis is required for calibration labs conforming to

ISO 17025 requirements. Uncertainty analysis is performed to evaluate and

identify factors associated with the calibration equipment and process instrument

that affect the calibration accuracy. Calibration technicians should be aware of

basic uncertainty analysis factors, such as environmental effects and how to

combine multiple calibration equipment accuracies to arrive at a single calibration

equipment accuracy.

Calibration procedure of instrumentation

1. Pressure Guage

Connect the guage to be calibrated on right side of the dead

weight tester.

Now add weight according to pressure to be appliked on the

guage.

Now roate the dead weight tester’s handle in clockwise till

weight applied is lifted freely and weight equilant pressure is

applied on the guage.

Check the reading on the guage corresponding to the

pressure applied.

Increase the pressure in steps of 1 kg/cm2 and check the zero

and span error.

2. By microprocessor based pressure calibrator

Attachguage to be calibrated to BSP hose fitting.

Switch the indicator ON.

Secure that the pressure system is pressureless by opening

the valve and zero set the indicator.

Turn needle Vent Valve of the pump clockwise until it is tight

by hand only.

Pump movable handle until the desired vacuum or pressure

reading is obtained.

Increase hand pressure on handle at the end of the stroke to

obtain higher vacuum of item being tested.

Turn vernier counter clockwise to decrease pressure reading

and clockwise to increase pressure of item being tested.

Turn vernier slowly for precise incremental pressure control.

Upon completion of testing turn vent valve counter

clockwise to release the vacuum or pressure to zero

pressure or vacuum and remove the test device from the

hose end.

Increase the pressur in step of 1 kg/cm2 and check the zero

and span errors.

3. By Pneumatic pressure pump

Take one calibrated pressure guage of desired range as

refrence.

For calibration purpose pressure/vacuum can be selected

by change over switch.

Generate pressure/vacuum by squeezing handles together

and then releasing.

Apply this pressure to guage to be calibrated and check for

results.

Take readings by applying pressure with different kg/cm2.

4. By multifunction calibrator

Connect the guage under test to MC5 calibrator.

Apply the known pressure from the MC%.

Check the reading on the guage corresponding to the

pressure applied.

Increase the pressure in steps of 1 kg/cm2 and check the

zero and span error.

Tempratue sensor : Resistance temperature detector (RTD) and

Thermocouple

Remove the sensor from application are and clean it .

Insert the sensor probe in oil bath and connect it with

temperature indicator or resistance measure device.

Set the oil bath temperature from 500c to 2500c or as per

desired range.

Compare the reading of oil bath and the temperature

indicator or resistance measurement device.

Resistance measurementdevice should variate resistance

of RTD according to standard Resistance-Temprature

chart.

Temperature transmitter

Select the required temperature range in hart

communicator.