This technical presentation given to ISBT Global Issues Committee as a Resource Conservation and Recovery tool for Recovery Systems in the beverage Industry in addition to CIP for Profit for a complete program

1. Sustainability Makes $ en $ e Haselden Recovery Systems Alan Sheppard

5. This is a diagram of a conventional bottling line. We note the order of equipment as follows: Bulk Syrup Tank through the divert panel into our syrup recovery system supplying the blender then Carbo-Cooler then to the filler. Notice on the conveyor the bottle supply from the Depalletizer. Please note that during startup and changeovers during the bowl sweetening process, often the first and second bowls of product are dumped due to being out of spec, for either water content, mechanical failures, high or low Brix counts, or CO2 issues.

6. This is the actual screen in which we start the process of Product Recovery. Here on the main menu we indicate that we want to initiate the recovery process by selecting “Go to recovery”.

7. The Recovery Screen illustrates the selection of either a blender or filler recovery. In this slide we choose “Filler Recovery”, simulating a start-up filler bowl recovery due to out of spec product.

8. Please note the 3 actuators between the Carbo-Cooler, Filler, and the Product Recovery System (PRS). This flow diagram shows where the valve actuator stopped the flow from the Carbo-Cooler and via head pressure we push the out of spec product from filler into the PRS. Pneumatic Valve Cluster

9. This slide goes back to the PRS select screen and now selects “Blender Recovery”. We do this to recover all product in the blender and Carbo-Cooler that is out of spec due incorrect batching, high or low brix counts from bulk syrup tank changes, or bad CO2

10. This shows the flow diagram of the blender recovery. Noting the actuators and the product flow into the PRS from carbo cooler via head pressure. To eliminate product loss during the sweetening of the filler bowl, we fill the carbo cooler then send that first full carbo cooler to the PRS. While the carbo cooler is being filled the second time to operating capacity, the filler is finishing final rinse and a final blow to remove all residual water preparing for in spec product in route to filler able to run at full speed after a purge of 100% product to the filler valves Pneumatic Valve Cluster

11. This slide illustrates the options of the PRS main menu while in “Idle” mode (note: 0 Volume Gals.). This screen gives us the option of recovery, C.I.P., drain or to recover data. Here we select the “Go to Run Screen” , to review our in operation options.

12. This screen is showing our standard flow rate of 3 gallons a minute for reintroducing the recovered product into the Carbo-Cooler. At this point we can adjust the reintroduction flow either up or down depending on the need of introduction during very short runs. We also can help you during short runs to automatically adjust flow rates using our “Calculate Flow Rate” program. Once the Proper Selection has been made, select enter, then start. Once the blender starts we begin reintroduction. If the blender stops due to any in line mechanical problems the PRS reintroduction stops

13. This slide illustrates the beginning of the run once the out of spec product has been recovered and the normal run mode has begun. We again follow the flow diagram from the bulk tank through to the filler, however, paying particular attention to the fact, that when the blender is in operation and supplying the Carbo-Cooler, our PRS is also reintroducing the recovered product. When and if the blender stops the supply our PRS stops as well. Pneumatic Valve Cluster

14. Filler Start-up Sequence

15. This shows the flow diagram of the blender recovery. Noting the actuators and the product flow into the PRS from carbo cooler via head pressure. To eliminate product loss during the sweetening of the filler bowl, we fill the carbo cooler then send that first full carbo cooler to the PRS. While the carbo cooler is being filled the second time to operating capacity, the filler is finishing final rinse and a final blow to remove all residual water preparing for in spec product in route to filler able to run at full speed after a purge of 100% product to the filler valves Pneumatic Valve Cluster

16. Pneumatic Valve Cluster

17. Initiation of the PRS at 4 gpm started at 11:18am and finished at 12:07pm Last line was run out. PRS brix was at 9.71 92%

19. Again we return to the illustration of our bottling line and take note of the positioning of our Syrup Recovery System (SRS). At this point we identify that we are in current full operation mode and we are coming up to the end of a run. Please note that in the SRS we are currently holding between 170 and 180 gallons of syrup to supply the blender for two Main reasons. 1st. This level is to allow plenty of syrup to supply the blender with syrup during tank changes and the CO2 push. During tank changes we often incur either high or low Brix counts while changing syrup tanks due to the agitation of the syrup causing our Brix levels to fluctuate. Due to the fact our SRS is pressure less, the air and co2 can escape from the top of the SRS, while we draw pure syrup from the bottom while in full production thus providing a seamless transition. 2nd. To allow plenty of time to prepare for an accurate container cut off, and or changeover

20. 180 This slide shows the main selection screen for the SRS where every action is initiated, calling attention to all of the options. Here we note as before that we are holding our syrup level between 170 and 180 gallons and we are opting for a syrup cutoff, however we have to modify our cutoff to select the container size and flavor so we choose “Modify Cutoff Point”.

21. This slide shows where we have an option of either a syrup or Depal cut, and the options of container size. Here we opt for the syrup cutoff and select the 8 Oz. Container and continue by then selecting “Next”.

22. 35 On this screen we the select the flavor. Please note, that once we select this flavor, in the top of the left hand screen, the preprogrammed number of gallons of syrup needed for the even syrup and container run-out appears. We select “Main Menu” to continue.

23. 180 Once Back to the Main Menu and the cutoff is set by the QA Mgr the selections will appear in the Status Menu. Then the QA Mgr. will activate the alarms for both the CO2 and the Communication System to the Syrup room and Depalletizer operator.

24. This slide shows our alarm menu and here we turn on our “Low-Level” (SRS syrup cutoff point) and “Communication Lights” alarm to notify the depalletizer operator and the syrup room operator when the cutoff is taking place and their instructions. Then select “Main Menu” to finish

25. Here we go back to the line layout and call attention to the fact the line is still in full production and the SRS is still holding 170 to 180 gallons, however the communication alarms are on and ready for the cutoff.

26. In this slide we show that the bulk syrup tank has run out, the CO2 push has been concluded, and the SRS has dropped down to the cutoff point of 35 gallons. At this point, the low-level alarm has been sounded and the filler gate has been automatically closed. At this time two things simultaneously occur. 1)Our system takes an automatic inventory of the amount of syrup we have in the SRS, the amount of finished product in the Carbo-Cooler and the number of containers needed on the conveyor between the depal and the filler to provide an exact run-out of product and containers. 2) The depal operator has been notify via communication lights that the filler gate has stopped and their only task is to fill the conveyor with containers and hit the “Depal Acknowledgement Button”. Depal Alarm Filler gate closes

27. This slide illustrates the Depal operator has hit the “Depal Acknowledgement Button” and the filler gate in response has opened initiating the final run-out. Depal Acknowledge Button has been pushed Filler Gate Opens

28. In this slide we can see where all of the syrup and finished product have been processed without waste and the final bottles will be running through the filler in conjunction with the amount of product left in the filler, thus providing an even run-out. With all the benefits the Syrup Recovery System (SRS) offers, we guarantee the SRS will increase yields, eliminate waste, and provide consistent changeovers every time

29. Projected yield savings can be calculated by the following measures: Number of Flavor Changes Filler Bowl Size 96 Valve/Gallon x 2/3rds (The operational Level) Start and Stop Dumps 72 Gallons per dump Number of dumps per Changeover One and a half Blend Ratio 5 to 1 5 Gallons Treated H20 1 Gallon Raw Syrup Est. Loss of Finished Product, Raw Syrup and Treated H2O per changeover 108 Gallons Finished product 18 Gallons raw syrup 90 Gallons treated H2O Syrup Line distance 170 feet Syrup line diameter 1.5 inch Est. Loss per changeover 5 gallons Raw Syrup Carbo-Cooler/ProductHoldingTank Losses to Drain ie; Hi/ Lo Brix, or CO2 issues Average 2 a week 355 Gals Finished Product loss 59 Gals Raw Syrup Loss 296 Gallons Treated H2O Loss Recovery Potential per Week Recovery Potential per Year Recovery potential based on 15 change-overs per week: 2,333 Gallons Finished Product 388 Gallons Raw Syrup 1,945 Gallons Treated H2O 116,650 Gals. Fin. Prod. loss per yr 19,400 Gals. Raw Syrup loss per yr 97,250 Gals Treated H2O loss per yr (Calculated @ 50 Weeks)

30. Haselden Recovery Systems Alan Sheppard Global Director Sales, Marketing and Distribution Phone 843-224-9169 E-Mail <alshep2000@yahoo.com>