CHAPTER ONE 1.0 INTRODUCTION Students industrial work experience scheme (SIWES) generally referred to I.

T (industrial training) is an initiative of the Industrial Training Fund (ITF). It is a skilltraining programme which exposes students to real-life working situations in the industry. It is mandatory to bridge the gap in the academic curriculum and in the industry. This will help the students develop skills and competencies they require to become employable. It provides an opportunity for students to apply theoretical knowledge acquired in the classroom with practical application of knowledge required to perform a task. It also gives the students exposure to tools used in the industry. It will also enhance students personal skills including presentation skills.

1.1

HISTORY OF COMPANY Kambic resources limited is located at 16 Divine Mercy Avenue

Pipeline, Rumukrushi, Port Harcourt, River state. Kambic resources limited are the producers of Kambic table water which has other divisions of different establishment in parts of Rivers state. The company has existed for over seven years and is owned by Engr. Mba Kalu. The company has staff strength of about 40 young men and women of different hierarchy.

THE COMPANYS ORGANIZATIONAL CHART

1.2
EXECUTIVE DIRECTOR

MANAGING DIRECTOR

A DMI NISTRATIO N M ANA GE R

QU ALITY CO NTRO L MA NAG ER

P RO DUCTIO N MA NAG E R ACCO UNT MAN AG ER

MA RKE TING MA NA GE R

CHI EF ENG INE ER

CHIE F DRIVE R

CHIEF S ECUR ITY

SECRETARY

QUA LITY CONTROL OFFICERS

FACTORY WORKER

ACCOUNTANT

MARKETING PERSONNEL

DRIVING PERSONNEL

SECURITY PERSONNEL

1.3

DEPARTMENTS AND THEIR FUNCTIONS

Executive director: He owns the company and has power to select, evaluate and make decision in the company. Managing director: He is in charge of the day to day activities of the company. Administrative manager: He is in charge of making the organisation operate smoothly and run the business affairs. Quality control manager: He is in charge of laboratory, supervises all the analysis carried out in the laboratory making sure that the finished product is of good quality. Production manager: He is in charge of all the production that takes place in the industry. Account manager: He keeps record of all the financial account of the company giving detail account of its expenditure and profit. Marketing manager: He is in charge of advertising and selling the product. Chief engineer: He makes sure that the machines and equipments are kept in good condition by servicing and checking them regularly.

Chief driver: Ensures that the drivers take the product to their place of marketing and delivery. Chief security: He is the head of security officers in the company. Secretary: She keeps record and documents of the affair in the company. Quality control personnel: They work with the quality control manager in the laboratory. Factory workers: They ensure that the products are produced; without them there will be no production. Marketing personnel: They work together with the marketing manager in advertising and selling of the product. Driving personnel: They ensure that the products are delivered to the buyers and drive the marketers. Security officers: They are in charge of security in the company, monitoring the people going in and out of the company and their business with the company.

CHAPTER TWO 2.0 WHAT IS WATER Water is a colourless, transparent, odourless, tasteless liquid. It is a chemical compound with the chemical formula H2O. A water molecule contains one oxygen and two hydrogen atoms connected by covalent bond in the ratio of 2:1. Water is a liquid at standard ambient temperature and pressure (00c). Water is a universal solvent. It forms the basic part of consumption (digestion) in humans and animals and the basic components of food formation (photosynthesis) in plants. Water is used for both industrial and domestic use. It is important to produce pure water for both domestic and industrial use. 2.1 IMPORTANCE OF WATER Next to air (oxygen), water is the most essential element to human life; the body usually cannot survive longer than several days without water (a maximum of 1 week). Water is essential to the functioning of every single cell and organ system in the human body.

Water makes up greater than 2/3 of the weight of the human body; the brain is 75% water, blood is 83% water, bones are 22% water, muscles are 75% water, and the lungs are 90% water.

Water is essential for the efficient elimination of waste products through the kidneys.

Water regulates body temperature (through perspiration). Water serves as a lubricant, water forms the fluids surrounding joints and bones, providing cushioning for the joints.

Water prevents and alleviates constipation (by moving food through the intestines and eliminating waste products).

Water helps the body to absorb nutrients in the intestines. Water plays a role in regulating metabolism. Water forms the base for saliva (necessary for consuming and digesting food).

Water carries nutrients and oxygen to all cells in the body and facilitates all of the chemical processes which occur in the body.

Water plays a role in the prevention of disease. Drinking adequate amounts of water can reduce the risk of colon and bladder cancer significantly and some studies have suggested that water may also decrease the risk of breast cancer.

2.2

SOURCES OF RAW MATERIAL

The source of raw material plays a key role in water because it determines the quality of water. Soil is rich in microorganisms but decreases with increased depth. Kambic resources limited source of raw material is borehole with depth of 180ft. 2.3 TREATMENT OF RAW WATER

Clean, safe water is vital for everyday life. Water treatment process to be carried out depends on the water to be processed due to its source. Ground water is water located underground and typically requires less treatment than water from lakes, rivers and streams because microorganisms decreases with increases depth. The goal of all water treatment process is to remove existing contaminants so the water becomes fit for its desired end use. The processes involved in treating water for drinking purpose may be solids separation using physical process such as sedimentation, filtration; biological process such as sand filter, activated carbon filter; chemical processes such as coagulation and electromagnetic radiation such as ultra - violet light.

2.4

WATER PURIFICATION

Water purification is the removal of contaminants from untreated water. Substances that are removed during the process of drinking water treatment include suspended solids, bacteria, algae, viruses, fungi, minerals and chemicals. A well designed purification system uses a combination of purification technologies to achieve the final quality of water. Each of the purification technologies must be used on an appropriate order to optimize their particular removal capabilities. The combined purification technologies used in the treatment of water in Kambic resources limited is as follows; 2.4.1 MULTIMEDIA/SAND FILTER Sand filter is relatively coarse sand and other media arranged in order of their sizes. Water flows through the filter medium under gravity or under pumped pressure and the flocculated material is trapped in the sand matrix. Sand filter has very little effect on taste and smell and dissolved impurities of drinking water unless activated carbon is included. It is also used to normalize water pH.
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2.4.2 GRANULAR ACTIVATED CARBON FILTER Granular activated carbon is made from raw organic materials (such as coconut shells or coal) that are high carbon. The activated carbon removes certain chemicals that are dissolved in water passing through a filter containing granular activated carbon by trapping (adsorbing) the chemical in the granular activated carbon. A filter with granular activated carbon (GAC) is a proven option to remove certain chemicals, particularly organic chemicals from water. Granular activated carbon filters also can be used to remove chemicals that give objectionable odour or taste to water such as hydrogen sulphide (rotten egg odour) or chlorine. 2.4.3 PERMANENT SEDIMENT FILTER It acts as a sieve to remove particulate matter that can be transported by fluid flow and which eventually is deposited as a layer of solid particle on the bed or bottom of a body of water. 2.4.4 MICRO FILTERS (5, 1, 0.5 MICRON) A micro filter has pore sizes of a ranging from 0.5 5 microns. They have;

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Very high effectiveness in removing protozoa (for example,

Cryptosporidium, Giardea)
Moderate effectiveness in removing bacteria (for example,

Escherichia coli, Salmonella, Shigella).

They remove tiny particles that escape granular activated carbon filter. 2.4.5 ULTRA VIOLET LIGHT STERILIZATION Ultraviolet (UV) sterilizers consist of a long life ultra-violet lamp inside a quartz glass sleeve that is suspended in the centre of a black plastic pipe. It is used as a treatment step to kill or inhibit growth of microorganisms, remove ozone, chlorine and trace organics and reduce total organic carbon (TOC). During UV sterilization, the water is exposed to a controlled rate to ultraviolet light waves. The microorganisms absorb the UV radiation energy, which destroys or inactivates their DNA, thus preventing the microorganisms from reproducing. It removes any foreign taste odour, corrosive irritating or allergic property from the water. The water flows from the UV sterilizer to the filling machine ready for production.
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2.5

BACKWASHING It refers to pumping water backwards through the filter media to

remove trapped particles. It is a sanitary exercise that is carried out on the sand and carbon filter daily lasting 30 - 45 minutes or till the water is clear. 2.6 1. 2. OPERATING PROCEDURES FOR PRODUCTION Water from borehole is pumped to raw water tanks. Water from raw water tanks is processed through the industrial filters; sand multimedia and the granular activated carbon filter. 3. The processed water from the industrial filters is pumped into a semi-treated water holding tanks. 4. The semi-treated water is filtered via three micro filters of size 5, 1 and 0.5 micron and then through an ultraviolet water sterilizer. 5. The filtered water is sterilized by an ultraviolet light sterilizer and the sterilized water are packaged by form, fill and seal machine. 6. The filled sachets are subjected to pressure test to confirm proper sealing then packed in twenties. 7. All bags of finished products are packed on pallets in the products storage room.

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FLOW CHART OF WATER TREATMENT

BOREHOLE (RAW WATER)

RAW WATER TANK (4000L CAPACITY)

MULTIMEDIA/SAND FILTER

GRANULAR ACTIVATED CARBON FILTER

PERMANENT SEDIMENT FILTER

SEMI-TREATED WATER TANK (4000LCAPACITY)

MICRO FILTER (5, 1 AND 0.5 MICRONS)

UV LIGHT STERILIZER

FORM, FILL, SEAL MACHINE (DINGLI)

SACHET WATER

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DIAGRAM OF WATER TREATMENT

2 2
6

4 3 3
T O DR A IN

7 7

8 8 8

10

1. 2. 3. 4. 5.

B o re h o le c o m p le te p u m p R a w w a te r ta n k T ra n s fe r p u m p M u ltim e d ia /s a n d filte r G r a n u la r a c tiv a te d c a rb o n filte r

6 . P e rm a n e n t s e d im e n t filte r 7 . S e m i-t re a te d w a te r ta n k 8 . M ic ro filte rs ( 5 , 1 a n d 0 .5 ) 9 . U ltra vio le t lig h t s te riliz e r 1 0 . F o rm , fill, s e a l m a c h i n e

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CHAPTER THREE 3.0 QUALITY CONTROL Quality control is a process that is used to ensure a certain level of quality in a product. It involves thoroughly examining and testing the quality of product. The basic goal of this process is to ensure that the products that are provided meet specific requirements and characteristics, such as being dependable, satisfactory, safe and fiscally sound. In Kambic resources limited, there is a team of workers headed by quality control manager who focus on testing the water. The water examined are chosen at random (raw water, semi-treated water and treated water) for parameters such as pH, colour, odour, taste. 3.1 WHO STANDARD FOR TABLE WATER

The result of the physiochemical and microbiological analysis of the water sample are within the world health organisation (WHO) specification for all the parameters analysed and they are as follows;

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3.1.1 PHYSIOCHEMICAL QUALITY S/NO PARAMETER ANALYSIS RESULT WHO REMARK SPECIFICATION (HIGHEST DESIRABLE LEVEL) Clear WS Colourless Unobjectionable 6.5 - 8.5 5NTU 1000uS/cm 500mg/l 500mg/l 0.05mg/l 0.01mg/l 0.2 0.05mg/l 100mg/l 100mg/l 200mg/l 10mg/l 0.1mg/l 0.001mg/l WS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

General appearance Clear Colour Taste Odour pH Turbidity (NTU) Conductivity(uS/cm) Total solids (mg/l) Total dissolved solid (mg/l) H2S (mg/l) Mineral oil Total organic carbon (mg/l) Alkalinity (mg/l) Total hardness (mg/l) Chloride (mg/l) Nitrate (mg/l) Nitrite (mg/l) Phenolic compounds (as phenols) (mg/l) Sulphate (mg/l) Calcium (mg/l) Iron (mg/l) Zinc (mg/l) colourless unobjectionable 6.83 0.04 42.0 20.0 20.0 Nil 71.0 60.06 4.0 0.6 Nil

19 20 21 22

0.57 22.4 <0.001 0.029

200mg/l 75mg/l 0.3mg/l 5.0mg/l

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23 24 25 26

Magnesium (mg/l) Copper (mg/l) Lead (mg/l) Chromium (mg/l)

0.985 <0.001 <0.001 <0.001

50mg/l 1.0mg/l 0.05mg/l 0.05mg/l

WS

3.1.2 MICROBIOLOGICAL QUALITY S/NO PARAMETER ANALYSIS RESULT WHO REMARK SPECIFICATION (HIGHEST DESIRABLE LEVEL) 100cfu/ml WS

4 5 6

Aerobic mesophilic bacteria (cfu/ml) Total coliform (MPN/100ml) Faecal coliform (MPN/100ml) Escherichia (cfu/ml) Mould (cfu/ml) Yeast (cfu/ml)

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0MPN/100ml

0MPN/100ml

0 0 0

0cfu/ml 0cfu/ml 0cfu/ml

WS - Within WHO specification mg/l milligram per litre

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uS/cm - microSiemens per centimetre NTU - Nephelometric turbidity units MPN/100ml Most probable number of viable cells in 100 millilitres CFU - coliform forming unit 3.2 METHOD OF SAMPLE

Samples are selected using bottles from different points of treatment unit and from the final product. The analysis is then carried out on the samples immediately after collection to avoid biological and chemical reactions which will take place with long storage at normal temperature. 3.3 DETERMINATION OF TOTAL ACIDITY

Acidity is the capacity of a system to neutralize base. The more acid a solution, the more base that must be added to raise the pH to an acceptable level. The concept of acidity is opposite that of alkalinity. In determination of total acidity, the sample is titrated against standard hydroxide solution using phenolphthalein for total acidity and methyl orange for mineral acidity.

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Calculation Total acidity of CaCO3 = Titre value 0.02 50,000 Sample volume = Titre value 50,000 0.02 100 = Titre value 10 Note: The volume of sample used in 100ml. 3.4 DETERMINATION OF TOTAL HARDNESS

Cations in calcium and magnesium are principally responsible for water hardness. Apparatus: conical flask, pipette, burette, clamp stand and measuring cylinder. Reagent: distilled water, EDTA (ethylene diaminetetra acetic acid) solution, total hardness buffer and total hardness indicator. Procedure: 1. 2. 3. Wash and rinse the glass apparatus with distilled water. Fill the burette with EDTA solution and clamp in a retort stand. Shake the water sample thoroughly and collect 100ml of the sample into a conical flask using a measuring cylinder.
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4.

Add 2ml of total hardness buffer solution to sample in the conical flask.

5. 6.

Add 0.5ml total hardness indicators. If the colour of the sample and other solution turns pink before titrating then after titrating with EDTA, it turns blue; it indicates the end point of titration.

Calculation: A 1 1000 ml of sample Where: A = Average value 1 = 1mg of CaCO3 equivalent to 1ml EDTA 1000 = Conversion factor. 3.5 DETERMINATION OF pH pH is a measure of the molar concentration of hydrogen ions (H+) of a solution and as such is a measure of the acidity or basicity of the solution. The pH scale range from 0 14 on which 7 is neutral, lower values are acidic while higher values are basic or alkaline. A pH meter is used to determine the pH of water. A pH meter contains a buffer solution. A buffer pH solution is composed of either a
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weak acid and the conjugated base or a weak base and conjugated acid. The main characteristic of a buffer pH calibration solution is that the pH value of the solution will not alter when a small amount of acid or a base is added whereas pH value of a calibration solution does not only alter with its composition but with temperature changes. Water with low pH (<6.5) could be acidic, soft and corrosive which could leach metals such as copper, lead, manganese, zinc and iron from plumbing fixtures and pipings. Water with low pH has metallic or sour taste. Water with high pH (>8.5) could indicate that the water is hard. It does not pose a health risk but can give an alkali taste to water and formation of scale or precipitate on fixtures and pipings causing water pressure and interior diameter of piping to decrease. Control To maintain a balance in pH of treated water, the granular activated carbon filter is daily backwashed for 30 45 minutes before production and the water is being checked at intervals to ensure the WHO pH range (6.5 8.5) is met.

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Calibration of pH To calibrate the pH meter, a buffer solution is poured into a beaker and the pH meter is inserted into it. Press CAL button and wait for the reading to stabilize. The pH meter is calibrated when a solution high in concentration with the memorized pH is used in pH meter. Significance of test Measurement of pH meter provides a means of controlling hardness, softening and coagulation in water treatment. It is used to determine the measure of acidity and alkalinity in water. World health organization standard for treated water going into distribution is 6.5 8.5. 3.6 DETERMINATION OF TOTAL ALKALINITY Alkalinity is a measure of the basic constituents in natural water. It also measures the acid neutralizing capacity of the water sample. Alkalinity has an aggregate property of the water sample and can be interpreted in terms of specific substances only when a complete chemical composition of the sample is also performed. The alkalinity of surface water is primarily due to the carbonate, bicarbonate and hydroxide content and is often interpreted in terms of concentration of these CaCO3. The higher the alkalinity, the greater the
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capacity of the water to neutralize capacity. To detect the different types of alkalinity, the water is tested for phenolphthalein and total alkalinity. Significance of the test Generally, alkalinity has no effect but it is important in connection with coagulation, softening and corrosion control. Soda ash (Na2CO3) is a natural salt and when added to the water, tends to be maintaining a balance of pH. It is therefore necessary to maintain sufficient alkalinity to prevent coagulated water from being corrosive. For this reason, it is essential that the parameter in both raw and treated water is maintained. Method: titrimetric method employing sulphuric acid as titrant. Apparatus: burette, pipette, conical flask. Procedure: phenolphthalein in alkalinity. 1. 2. 3. Pipette 50ml of sample into the conical flask. Add 0.1ml of phenolphthalein indicator solution. If the sample remains colourless, there is no phenolphthalein alkalinity, then move to procedure 2.

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4.

If the sample turns pink, titrate with sulphuric acid solution, drop wise until the pink solution disappears. Record the volume of the acid used.

Calculation: Phenolphthalein alkalinity = ml of 0.1 H2SO4 100,000 ml of sample used

Procedure 2 Methyl orange total alkalinity 1. Add 0.1ml (2 drops) of methyl orange indicator into 50ml of fresh water. 2. Titrate with the H2SO4 (0.01m) solution, mixing gently until sample first turns orange. Calculation: Total alkalinity as mg/l CaCO3 Titre alkalinity m 100,000 ml of sample Where m = the molarity of the titre value of H2SO4. Alkalinity to both methyl orange and phenolphthalein indicator is obtained in order to disclose the chemical nature of the alkaline compound and the relationship to hardness producing compound.
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3.7

EXAMINATION OF PHYSICAL PARAMETER

3.7.1 ODOUR Odour in water is caused by extremely small concentrations of volatile compounds. It may originate from industrial waste such as

decomposition of vegetable matter or from microbiological activities. The human nose is the ultimate odour testing device because it is usually impractical and often impossible to isolate and identify the odour producing chemical. Significance of test Odour check is useful to know the quality of water distributed to the consumer. 3.7.2 TASTE Taste is caused by volatile compounds which may originate from industrial waste and microbial activities. Taste and odour are closely related but odourless water may have a distinct taste. Treated water is tested with the back of the tongue to know if there is taste.

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Significance of test Treated water meant for consumption should be tested and controlled in order to determine the effectiveness of treatment and also meet consumers acceptance based on palatability according to the world health organization. 3.8 MICROBIOLOGICAL EXAMINATION OF WATER Microbiological examination offers the most sensitive test for the detection of recent and potentially dangerous faecal populations thereby providing a hygiene assessment of water quality with high sensitivity and specificity. The most common and wide spread danger associated with drinking water is contamination either directly or indirectly by sewage, human and animal. Water samples should be examined regularly for faecal pollution to ensure that treated water is free from pathogenic organism. An indicator for bacteria is the coliform group of organisms. As a group, they are not excessively of faecal origin since they are present in large numbers not only in faecal human and other warm blooded

26

animals. However, the detection of faecal coliform, Streptococci in absence of Escherichia coli is a definite faecal pollution. Significance of test Microorganism examination of water is one of the key elements in the quality control of drinking water. Potable water that is to be distributed must undergo deterioration before it gets to the consumer. 3.9 SANITARY PRACTICES

A clean environment is directly proportional to the well being of its inhabitants and any consumable products from such an environment. Kambic resources limited strive to maintain a high level of cleanliness to ensure the product is of good quality. 3.9.1 SURROUNDING The general appearance of the water packaging factory is clean, hygienic and inviting. 1. The surrounding of the factory is daily cleaned and all dirt and waste adequately disposed in a well - covered waste bin. 2. The personnel are routinely trained and retrained in the practice of hygiene and maintenance of clean and safe working environment.

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3.9.2 INTERIOR Strict adherence to safety and hygiene start at the entrance into the factory. On arrival at the factory, the personnel move straight to the cloakroom where they change and put on their production coats, sterilized shoes and hand gloves. 1. The plant is cleaned twice daily and the floor scrubbed with liquid detergent. 2. The plant is well ventilated with net screen doors into the factory and out of the production rooms. 3. The factory is fumigated quarterly.

3.9.3 STORAGE TANKS The storage tanks (i.e. raw water and semi treated water tanks) are isolated every two weeks, emptied and cleaned. The tanks are washed with diluted chlorine solution of concentrated 2ppm (mg/l) and rinsed with treated water. 3.9.4 FORM, FILL AND SEAL MACHINE The form, fill and seal packaging machine is daily flushed for 5 -10mins daily before commencement of operation. The moving parts are lubricated before production.
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3.9.5 MICRO FILTERS The micro filters are dispensable. They are replaced every 2 weeks or when clogged earlier than the 2 weeks set time. 3.9.6 UV STERILIZER The UV sterilizer quartz sleeve is de-scaled every three months by cleaning the quartz sleeve with cotton wool soaked in methylented spirit. The UV lamp is replaced yearly. 3.9.7 PVC PIPELINES All PVC pipelines are flushed with 2ppm (mg/l) dilute solution of chlorine followed by flushing clean with treated water every two weeks. 3.9.8 INDUSTRIAL FILTERS The industrial filters are back-washed daily. The loaded media is replaced yearly. 3.10 DILUTE CHLORINE SOLUTION 2PPM (mg/l) 1. Dissolve 10g of chlorine in 1litre of water obtain a concentration of 5g/l. 2. To prepare your dilution of 2ppm (mg/l) solution, pipette 5ml of the concentrate and add to 50litres of treated water. The final dilution
29

of concentration 1ppm is then used for cleaning of tanks, flushing of PVC lines and UV sterilizer and general disinfection. Dilution must be prepared fresh and used.

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CHAPTER FOUR 4.0 4.1 GENERAL APPRAISAL OF THE PROGRAMME RELEVANCE OF SIWES PROGRAMME

The students industrial work experience scheme provides avenues for students in institutions of higher learning to acquire practical skills that they are likely to meet after graduation. The scheme affords students the opportunity of familiarizing and exposing themselves to the needed experience in handling equipment and machinery that are usually not available in the institutions. 4.2 CHALLENGES DURING ATTACHMENT

I was faced with the following challenges during industrial training; Inability of some of the workers to explain some technical production process. I was faced with the problem of rain due to the period I did my training (rainy season). High cost of transportation. I was able to complete my industrial training program and acquired more knowledge despite all these challenges.

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4.3

ADVICE TO FUTURE PARTICIPANTS Submission of application letter for placement early enough to companies.

Obedience to authorities of the place of attachment. Commitment to work, being punctual as to acquire the basic practical and industrial knowledge.

To be of good moral attitude to work and to those in authority. To know that the main reason for the training is to learn and never to place allowance first.

4.4

ADVICE TO SIWES MANAGERS There should be proper awareness to companies and establishment so that students will be accepted for industrial placement in the right time.

The industrial training fund (ITF) officials and the institution based supervisors should effectively carry out their assigned job.

Payment of allowance to participants to motivate and encourage them to work.

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4.5

WAYS TO IMPROVE SIWES PROGRAMME Orientation should be done for the students prior to the commencement of the programme by the institution in conjunction with the industrial training fund (ITF) and the institution making the attendance mandatory for students.

Companies and organisations should be lectured on the importance for industrial training so as to accept students.

There should be regular check on the performance of student by their institutional supervisor.

Government organisation and some private establishment should make provision of some kind of allowance to the trainee in their section as this will help to motivate students interest to work and give in their best.

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CONCLUSION Treating water adequately before consumption is important to avoid water diseases through intoxication and infestation. My six months industrial training in Kambic resources limited has enlarge my knowledge in handling equipment and machinery that are usually not available in the institution. RECOMMENDATION I recommend my fellow future industrial training participants to strive to find a good place for their industrial training.

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