System Overview
The Bottle Cooling System is made up of a cooling tower and basin and several pumps, which distribute cooling water to the various stages of the cooling system. Cooled water from the basin is pumped into Stage 5 of the cooling system and is distributed with spray nozzles over the bottles. The water then collects in a sump and is pumped into Stage 4. This is done repeatedly, down through Stage1 where the hot incoming bottles first come in contact with the warmest cooling water. This process allows a slow cooling process to take place, preventing a drastic temperature change, which could fracture the bottles. This area of the cooling system is the most difficult to treat because the atomization of warm water speeds the reduction of chlorine levels.

Control of the free residual chlorine levels in the cooling system ensures that plate counts remain very low, preferably zero, and that there are no coliform or e.coli counts. Since the bottles are relatively hot when they come into the cooling system, there is a possibility that a vacuum could be formed as the bottles cool, which could pull the cooling water into the bottles. Many beverage makers require that chlorine residual be maintained and all monitor for bacteria counts, some more stringently than others. This particular client relies on contracts from major beverage companies for their bottling business — companies who audit and follow the results of the bottler?s control of bacteria counts in the cooling systems.

Previous Program
The initial program at the facility involved two separate feed systems for each of the two bottle cooling lines. The plant was feeding two chemicals at each location, bromine and chlorine (4 drums for each cooling line). One system per line was setup as the Baseline System, and was always running. The purpose of Baseline System was to establish and maintain a baseline free residual chlorine level in the cooling system. The second system on each line was an automated system, whose intent was to measure chlorine levels in the last stage of the cooling system and feed chemicals to maintain a predetermined residual in that stage.

Problem
The primary problem with the program was the frequent degradation of the tubing used to feed the liquid products. The lines became brittle over a short period of time and broke. The chemicals then sprayed on adjacent equipment and/or personnel. The pumps continued to pump, typically until the drums were empty. Also, because of the difficulty in getting and maintaining a prime when pumping liquid chlorine and bromine, the pumps frequently lost prime. Control of chlorine levels was very sporadic and high bacteria counts became a problem.

RMC Program Solution
RMC implemented a dry feed system eliminating the need for two products and eliminating the need for 4 drums per system. The automated control systems were removed and currently we are feeding product into the system at the tower basins. We replaced their previous program, which included 8 pumps, 2 very expensive automated controllers and a lot of headaches with 2 less expensive bromine feeders. We trained the operators, getting them more involved with the monitoring and adjusting of feed rates. With a measured free residual chlorine level of greater than or equal to .5 ppm, no high bacteria counts have been recorded.

Benefits
Several benefits have been realized by the implementation of our program. Our customer now has improved production rates with improved control of bacteria providing more consistent results -- which makes their customers happy. We reduced the complexity of the system, making it easier and safer for the operators to use.

Improved quality, safer employees, reduced costs -- an Integrated Solution from RMC.