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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 skill–training
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
1.1 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.
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1.2
3
1.3 DEPARTMENTS AND THEIR FUNCTIONS
4
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.
5
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.
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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.
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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
8
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, 9
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;
2.4.1MULTIMEDIA/SAND FILTER
Sand filter is relatively coarse sand and other media arranged
in order of their sizes. Water flows through the filter medium
10
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.
2.4.2GRANULAR 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.
2.4.3PERMANENT SEDIMENT FILTER
11
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.
2.4.4MICRO FILTERS (5, 1, 0.5 MICRON)
A micro filter has pore sizes of a ranging from 0.5 – 5 microns.
They have;
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.
2.4.5ULTRA – VIOLET LIGHT STERILIZATION
Ultra–violet (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).
12
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.
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 OPERATING PROCEDURES FOR PRODUCTION
1. Water from borehole is pumped to raw water tanks.
2. 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.
13
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.
FLOW CHART OF WATER TREATMENT
14
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16
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;
17
3.1.1PHYSIOCHEMICAL QUALITY
S/NO PARAMETER ANALYSIS RESULT
WHO SPECIFICATION (HIGHEST DESIRABLE LEVEL)
REMARK
1 General appearance
Clear Clear WS
2 Colour colourless Colourless WS3 Taste unobjectiona
bleUnobjectionable
4 Odour 5 pH 6.83 6.5 - 8.5 6 Turbidity (NTU) 0.04 5NTU 7 Conductivity(uS/
cm)42.0 1000uS/cm
8 Total solids (mg/l)
20.0 500mg/l
9 Total dissolved solid (mg/l)
20.0 500mg/l
10 H2S (mg/l) Nil 0.05mg/l 11 Mineral oil 0.01mg/l 12 Total organic
carbon (mg/l) 0.2 –
0.05mg/l
13 Alkalinity (mg/l) 71.0 100mg/l 14 Total hardness
(mg/l)60.06 100mg/l
15 Chloride (mg/l) 4.0 200mg/l 16 Nitrate (mg/l) 0.6 10mg/l 17 Nitrite (mg/l) Nil 0.1mg/l
18
18 Phenolic compounds (as phenols) (mg/l)
0.001mg/l
19 Sulphate (mg/l) 0.57 200mg/l 20 Calcium (mg/l) 22.4 75mg/l 21 Iron (mg/l) <0.001 0.3mg/l 22 Zinc (mg/l) 0.029 5.0mg/l 23 Magnesium
(mg/l)0.985 50mg/l WS
24 Copper (mg/l) <0.001 1.0mg/l 25 Lead (mg/l) <0.001 0.05mg/l 26 Chromium (mg/l) <0.001 0.05mg/l
3.1.2MICROBIOLOGICAL QUALITY
S/NO PARAMETER
ANALYSIS RESULT
WHO SPECIFICATION (HIGHEST DESIRABLE LEVEL)
REMARK
1 Aerobic mesophilic bacteria (cfu/ml)
70 100cfu/ml WS
2 Total coliform (MPN/100ml)
0 0MPN/100ml
3 Faecal coliform (MPN/100ml)
0 0MPN/100ml
4 Escherichia (cfu/ml)
0 0cfu/ml
5 Mould 0 0cfu/ml
19
(cfu/ml)6 Yeast
(cfu/ml)0 0cfu/ml
WS - Within WHO specification
mg/l – milligram per litre
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 20
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.
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.
21
Reagent: distilled water, EDTA (ethylene diaminetetra – acetic
acid) solution, total hardness buffer and total hardness
indicator.
Procedure:
1. Wash and rinse the glass apparatus with distilled water.
2. Fill the burette with EDTA solution and clamp in a retort
stand.
3. Shake the water sample thoroughly and collect 100ml of
the sample into a conical flask using a measuring cylinder.
4. Add 2ml of total hardness buffer solution to sample in the
conical flask.
5. Add 0.5ml total hardness indicators.
6. 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
22
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 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 piping’s.
Water with low pH has metallic or sour taste.
23
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.
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
24
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 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
25
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. Pipette 50ml of sample into the conical flask.
2. Add 0.1ml of phenolphthalein indicator solution.
3. If the sample remains colourless, there is no
phenolphthalein alkalinity, then move to procedure 2.
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 × 100,00026
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 × 100,000ml 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.
3.7 EXAMINATION OF PHYSICAL PARAMETER
3.7.1ODOUR
Odour in water is caused by extremely small concentrations of
volatile compounds. It may originate from industrial waste such
27
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.
3.7.2TASTE
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.
Significance of test
Treated water meant for consumption should be tested and
controlled in order to determine the effectiveness of treatment 28
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 animals. However, the
detection of faecal coliform, Streptococci in absence of
Escherichia coli is a definite faecal pollution.
Significance of test
29
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.
3.9.1SURROUNDING
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.
3.9.2INTERIOR30
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.
3.9.3STORAGE 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.
3.9.4FORM, 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.
3.9.5MICRO FILTERS
31
The micro filters are dispensable. They are replaced every 2
weeks or when clogged earlier than the 2 weeks set time.
3.9.6UV 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.
3.9.7PVC PIPELINES
All PVC pipelines are flushed with 2ppm (mg/l) dilute solution of
chlorine followed by flushing clean with treated water every
two weeks.
3.9.8INDUSTRIAL 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 of concentration 1ppm is then used for
32
cleaning of tanks, flushing of PVC lines and UV sterilizer and
general disinfection. Dilution must be prepared fresh and
used.
33
CHAPTER FOUR
4.0 GENERAL APPRAISAL OF THE PROGRAMME
4.1 RELEVANCE OF SIWES PROGRAMME
The student’s 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.
34
I was able to complete my industrial training program and
acquired more knowledge despite all these challenges.
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.
35
Payment of allowance to participants to motivate and
encourage them to work.
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.
36
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.
37
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