Br igh t B lue 50GCoca Cola Specification

This is the most advanced

ozone system for mineral water disinfection currently on the market.

The Bright Blue CCS system w a s d e s i g n e d a n d

developed specifically for the bottling of “Bon Aqua” brand water. It conforms to Coca Cola standards for Ozonation and electrical

equipment.

Designed for Bon Aqua

This system is designed to meet Coca Cola specifications for the bottling of Bon Aqua.

There are three main components consisting of a large contacting vessel for Product (Syrup) ozonation, a small contacting vessel for rinse water ozonation and a double door control panel.

The large contacting vessel is sized to allow for an ozone/product contact time of 4 minutes at peak bottling flow. The ozone level in this tank is electronically controlled so as to give an ozone residual in the bottle after filling of 0.2 to 0.4 ppm.

A 30 litre ozone contactor works on the same principle as the larger contactor but supplies water with an ozone residual of 0.8 ppm to the bottle rinser. Enough to disinfect the bottles & caps prior to filling.

A centralised ozone generator control panel with two compartments. One compartment for the product ozonation and the other for the rinse water.

Each compartment contains a PLC controlled ozone system operated by a colour touch screen. The systems are fully independent of each other.

The unique user interface features large easy to read dials and icons. Operation is easy and intuitive with varying access levels:

• One touch On/Off for the operator• Access to ozone set-point & diagnostics

for the line manager• Fu l l access to a l l leve l s fo r the

administrator

Continuous Ozone measurement is done using a Dr. Reiss GMBH ozone probe and measuring cell. This is coupled to a dedicated P.i.D controller which enables “Auto-tuning” of the ozone dosage.

This allows for accurate control of the desired dissolved ozone level to within as little as 1% of the set-point.

An optional Ethernet connection allows the entire system to be monitored & controlled from a Computer workstation.

Product Ozone Contactor

Rinsing Ozone Contactor

Easy to Use, Easy to Maintain

The Bright Blue system has been constantly improved and refined since the first unit was produced in 2001.

Our focus has always been on quality and reliability, so much so that many of our customers regard our systems as amongst the most reliable in their plant.

The systems are extremely easy to operate. On a day to day basis the operator simply pushes the start/stop button. The PLC does the rest.

Only occasional interventions are required to calibrate the system against an ozone test kit.

Maintenance is very straightforward with all major components being easy to access. Wassertec hold a full spares inventory at all times.

Wassertec Oxygen GeneratorThe built-in oxygen generator converts compressed air to oxygen at up to 95% purity. Unlike some other models, it is fully serviceable and can be easily & inexpensively re-sieved in the event of water ingress.

Wassertec Ozone ModulesD e s i g n e d t o p r o d u c e h i g h concentrations of ozone without the need for water cooling the ozone modules each have a max. output of 10gr/hr. Ozone output is regulated from 0-100% via a 4-20mA input signal from the PLC. Ozone cells have a 10,000 service interval.

Power & ControlThe upper rail contains all the circuit breakers and switchgear for the system.The lower rail holds the PLC and PID controllers. Components are all Coca Cola approved.

De-Gassing & Ozone Sampling.The top of the contacting systems feature a special ozone resistant de-gas valve. This allows undissolved ozone to be vented safely away from the production area whilst maintaining tank pressure.The ozone sampling probe and flow cell are fitted to the side of the contactor. Sample flow is controlled by a solenoid valve and ball valve combination.

Sterile Sampling Tap.The contacting systems are fitted with Guth Q-Fit sampling taps as per Coca Cola requirements.T h e s e c a n b e f l u s h e d w i t h a disinfecting solution after samples have been taken.

Ozone Leak Detectors.Ozone & Oxygen sensors are mounted in the bottling hall and in the ozone plant room. They are interlocked to the PLC. In the event of ambient ozone levels exceeding the SABS limit the ozone system will be shut down and a warning displayed.

Component Details

The History of Controlling Dissolved Ozone

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Ozone with On/O! Control

Risk of Product Oxidation

Risk of Product Infection

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Ozone with Rosemount Controller

Risk of Product Oxidation

Risk of Product Infection

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Ozone with PID Control

Risk of Product Oxidation

Risk of Product Infection

Ozone is a very powerful oxidising agent created from

Oxygen. When dissolved in water it is ideally suited to packaging disinfection because:

• Ozone reacts extremely quickly, allowing a bottle to be disinfected in seconds.

• Ozone reverts to Oxygen after use, leaving no

chemical residual or taint.

• Ozone is produced at the point of application from air & electricity, thus eliminating the need for handling & storage.

When using Ozone as a means of disinfection the following considerations need to be taken into account:

• If the level of dissolved ozone is too high then there is a risk of oxidation of the product. This is especially true for wine bottling.

• If the ozone level is too low then there will be insufficient oxidation. This will result in an increased

risk of product infection.

• An Ozone level between 0.7 and 0.9 ppm (parts per million) is ideal in most instances.

Before 2002Our ozone systems for bottling have always featured a high quality Rosemount Analytical ozone analyser

to measure and control ozone electronically.Our original systems were only able to use an On/Off signal to control the ozone modules. (Some of our competitors still use this method)With this system the ozone would rise to the set-point.

The ozone would switch off but the level would continue to rise. It would then peak and fall below the set-point as the ozone switched on again. And so on in a Yo-Yo pattern.

2002 to 2008In 2002 we improved our ozone power supplies to accept a 4-20mA control signal from the Rosemount

ozone analyser. We were now able to control the ozone level to within the capability of the analyser.The Rosemount allows the user to input the level at which ozone output should be 100% and where output should be 0%. As the dissolved ozone level

rises the power decreases and vise versa. This resulted in a much improved level of control.

2008 onwards - P.I.D. ControlIn 2008 we moved away from the Rosemount analyser to a fully PLC controlled system for which

we developed our own control software.Measurements from the ozone probe are fed directly into the PLC where a dedicated P.I.D (proportional integral derivative) controller continuously measures the difference between the desired and actual

levels of ozone, making adjustments all the time.As a result the user simply keys in the desired level of ozone and the controller targets and maintains the level to within 1%.

Ozone Level Set-Point

Main screenThree easily visible dials show:

• The actual ozone level in PPM (with a set-point

indicator)

• The ozone gas pressure/vacuum

• The current ozone output in %

Access buttons to other function screens:

Calibrate, Servicing, Diagnostics, Set Level, Trends & Startup.

Setting the Ozone levelTo set the desired level of dissolved ozone the operator must enter the access password.

The ozone level can then be entered as a value from 0.00 to 2.00 PPM.This will then represent the default level.

Ethernet ConnectivityThe latest 10” Touch screens have optional Ethernet Connectivity. With the system connected to a

network it becomes possible to operate the Ozone Generator by remote control from a Desktop or Laptop PC.

Control Screens Overview

DiagnosticsThe diagnostic mode is extremely useful for troubleshooting, setup or servicing.

It allows any of the major components to be run independently so that they can be verified.The systems 3 main parameters of ozone level, gas pressure and ozone output are displayed.

Contact UsIf you are interested in discussing a project with us or would like some more information please get in touch.

Our friendly team are ready to assist you

Tel! ! +27 21 705 9090

Fax ! ! +27 21 705 9092

Email Sales! info@wassertec.co.za

Email Tech! christian@wassertec.co.za

Web! ! www.wassertec.co.za

Physical Address

A1 Diep River Industrial Park

Greenville Road

Diep River

Cape Town 7800

South Africa

Specification

OZONE GENERATOR SPECIFICATION

Size 1750h x 1420w x 380d

Weight 150Kg

Enclosure material Laser cut 304 stainless steel IP42

Ozone output 5 x 0 to 10 gr/hr ozone modules

Power Requirement 380 volts, 50Hz, 4000w

PLC Delta + analogue extension + PID controller

HMI (Human/Machine Interface) 2 x Delta 10” full colour touchscreen

Oxygen generator 3 x Wassertec, max 5 lit/min @ >90% purity

Air filtration Festo MS6 5 micron and 0.01 micron

Dissolved ozone measurement Dr. Reiss GMBH Ozone probe & flow-cell

Dissolved ozone control 0.00 to 2.00 parts per million

760L / 30L WATER CONTACTOR SPECIFICATION

Size 2200h x 700dia / 1400h x 150dia

Weight Empty 120Kg / 40Kg

Material & Construction 316 stainless steel certified pressure vessel

Water pump Ebara 200/25 / Ebara 90/10

Venturi Mazzei 1584 / Mazzei 684

De-gas valve Armstrong fully ozone resistant

Water inlet connection NW50 / NW32

Water outlet connection NW50 / NW25

ON SITE REQUIREMENTS

Ambient temperature 45 Degrees C Max

Water temperature 40 Degrees C Max

Compressed air 300 lit/min @ 2 bar. MUST be clean & dry

Power 380v three phase 20A + Neutral + Earth