Ambo Intern

AMBO INSTITUTE OF TECHNOLOGY
AMBO UNIVERSITY INDUSTRIAL ENGINEERING
INTERNSHIP REPORT
Project Title: Motor Driven Roller Conveyor
Hosting Company: Gonder MOHA soft drink s.c
By: Betelhem Melkie...............RIOT
Mentor:Ahemd kemer&
Company Supervisor: Yakob Legesse
June, 2, 2018
Declaration
We would like to declare that we have successfully completed the four month internship program
at the company called Gondar MOHA Soft Drink Share Company. We have been stayed from
February to May. During that time we have improved our theoretical and practical knowledge.
We declare that this report should be submitted to Bahir Dar University School of Mechanical
and Industrial Engineering.
All relevant resources of information used in this paper have been duly acknowledged.
Name of Student Signature Date
Alikadir Abera
Biniam Natan
This is to certify that the above statement made by the candidate is correct to the best of
my knowledge and belief. This report has been submitted for presentation with my
approval.
Name of Mentor Signature Date

Ahemed kemer
Abebe Genetu
Acknowledgement
First and for most we want to thank GONDAR institute of technology university for arranging
this internship program. We also would like to forward our acknowledgement for our host
company’s mentor Mr. Tegegne A. for their continuous courage and advice all the way to
accomplish practical services and also for our project. Finally our special thanks go to MOHA
soft drinks s.c with its entire worker for they have played a vital role during our internship period
in providing such a wonderful guidance and for their patience. They all have shared their own
remarkable and important knowledge to our eye opening experience during the four month stay
of our internship program.
Executive Summery
In all factory, not all machines and instruments perform a task in available and in wise ways.
This is because of that some emit problems on the type of machines during design or after design
at the time of assembling components and during the layout of the company reduces the
company profits as well as the quality and quantity of end products of the company. This project
has been done to solve different problems that can be faced during conveying a bottle boxes
through a roller conveyor.
These problems can cause the loss of the company’s product directly and decrease the annual
income indirectly. Therefore, these problems require a solution to establish sustainable profit by
replacing the manual system to automatic and relay out the departments. This project solves
these defects of work by making the conveying process of the bottle boxes easier by the aid of
roller chain rotating around sprockets fitted on the rollers. The shaft extended from the roller is
connected to the chain by means of sprocket. The extended shaft of roller is further connected to
an electric motor which is the source of input power.
Table of Contents
Acknowle....................................................................................................................................................................... ii
Executive Summery............................................................................................................................................... v
CHAPTER ONE
1. INTRODUCTION................................................................................................................................................ 1
1.1 History of Pepsi Cola..........................................................................................................................1
1.2 The Emerging of Pepsi Cola Plant in Ethiopia.....................................................................................1
1.3 History of Gondar Pepsi Cola Plant....................................................................................................2
1.4 Main Products of the Company.........................................................................................................3
1.5 Main Customers of the Organization.................................................................................................4
1.6 Organizational Structure....................................................................................................................4
CHAPTER TWO................................................................................................................................... 5
2. Internship Experience.................................................................................................................... 5
2.1 The Section That We Have Been Interred..........................................................................................5
2.1.1 Bottle Washer.........................................................................................................8
2.1.1.1 Sections of bottle washer....................................................................................8
2.1.2 Bottle Filler and Crowner..….....…………………………………………………………………….......…….8
2.1..2 A) Filler Machin ....................................................................................................8
2.1.2 B) Crowner ............................................................................................................9
2.1.3 Date Coder ……………………………………………………………………………………………………………..11
2.1.4 Boiler Room ……………………………………………………………………………………………………………..11
2.1.5 Syrup room ……………………………………………………………………………………………………………..13
2.1.6 Water treatment …………………………………………………………………………………………………13
2.1.6.1 Selection of Water Treatment Technology ………..……………...……………………………….14
2.1.7 Air compressor .......…………………………………………………………………………………………14
2.1.7.1 Parts of Compressor machine ............................................................................14
2.1.7.2 Use of Air Compressor In Gonder MOHA Soft Drink S.C.......................................14
2.1.8 Ammonia Compressor ……………………………………………………………………………………17
2.2 The Work Task that Executing......................................................................................18
2.3 Types of Engineering Methods, Tools and Techniques we have been using while
performing our Work Task................................................................................................18
2.4 The challenges that have been faced...........................................................................18
2.5 The measure that have been taken..............................................................................18
2.6 Over all Benefits Gained from Internship.....................................................................18
2.7 In terms of improving practical skill.............................................................................18
2.8 In terms of improving theoretical knowledge..............................................................20
2.9 In terms of improving team playing skill......................................................................20
2.10 In terms of Improving Leadership Skill.......................................................................20
2.11 In terms of Understanding about Work Ethics Related Issues.....................................19
2.12 In terms of Improving Inter-Personal communication Skill........................................20
2.13 OVER ALL CONCULUSION AND RECOMANDATION......................................................20
2.13 A) Conciusion...........................................................................................................21
2.13 B) Recommendations.................................................................................................21
PART TWO PROJECT

Introduction...................................................................................................................25
1.1 Historical Back ground of Chain and Sprocket...............................................................25
1.2 DEFINITION OF CHAIN AND SPROKET..........................................................................25
1.3 Application of Chain and Sprocket...............................................................................27
1.4 Working Principle........................................................................................................27
1.5 Problem Statement.....................................................................................................28
1.6 Objective of the Project ..............................................................................................27
1.6.1 Main objective: …………………………………………………......................………………….....27
1.6.2 Specific objective.: ……………………………………………………………………………………..........…27
1.7 Methodology ..........................................................................................................28
1 8 Design of roller chain ..............................................................................................28
1.9 Design of sprocket...................................................................................................28
1.10 Design of key ........................................................................................................29
CHAPTER THREE..................................................................................................................................32
Literature Review............................................................................................................................................30
1.1 Historical Back ground of Chain and Sprocket.......................................................
3. Methodology......................................................................................................................................................32
3.1 Design of roller chain..................................................................................................32
3.2 Design of sprocket.......................................................................................................32
3.3. Design of key.............................................................................................................33
CHAPTER FOUR..........................................................................................................35
4. Material Selection...........................................................................................................................................35
4.1 Basic Properties of Steel..............................................................................................35
4.1.1 Properties of alloy steel ................................................................................35
5. Design Analysis................................................................................................................................................38
5.1 Component of Roller Chain.........................................................................................38
5.1.2 Pin ………………………………………………………………………………………………………………………….39
5.1.3 Bushing …………………………………………………………………………………………………………….39
5.1.4 Roller ….....……………………………………………………………………………………………………..40
5.2 Design of Roller Chain.................................................................................................41
5.3 Sprocket Design..........................................................................................................42
5.3.1 Principal Dimensions of Tooth Profile The standard profiles for the teeth of a sprocket are
…………………………........................................................................................44
5.4 Motor power selection................................................................................................47
5.4 Key Design..................................................................................................................48
5.4.1 For Smaller Sprocket …………………………………………………………………………………………….....48
5.4.2 For Larger sprocket ………………………………………………………………………………………………..49
6. Result and Discussion..................................................................................................................................51
6.1 Result.........................................................................................................................51
6.2 Discussion...................................................................................................................52
7. Manufacturing and Fabrication.............................................................................................................53
7.1 Manufacturing and Fabrication of Roller Chain............................................................53
7.2 Manufacturing and Fabrication of Sprocket..................................................................53
8 Assembly and Maintenance.......................................................................................................................54
8.1 Assembly....................................................................................................................54
8.2 Maintenance...............................................................................................................54
8.2.1 Preventive Method …………………………………………………………………………………………………54
8.2.2 Curative Method …………………………………………………………………………………………………56
Cost Analysis...........................................................................................................................................................57
Conclusion & Recommendation..................................................................................................................58
REFERENCE.............................................................................................................................................................59
APPENDIX I..............................................................................................................................................................61
Table of Figures
Figure 1 Brands producing under Gondar MOHA soft drink...............................................................14
Figure 2 Bottle washer machine..........................................................................................................18
Figure 3 filler machine........................................................................................................................22
Figure 4 Boiler machine......................................................................................................................24
Figure 5 Air compressor......................................................................................................................20
Figure 6 Ammonia compressor............................................................................................................30
Figure 7 Chain with sprocket...............................................................................................................40
Figure 8 Layout of roller chain ...........................................................................................................49
Figure 9 Plate.......................................................................................................................................49
Figure 10 Pin.......................................................................................................................................50
Figure 11 Bushing...............................................................................................................................51
Figure 12 Roller...................................................................................................................................52
Figure 13 Terms used in roller chain...................................................................................................69
Figure 14 Terms used in sprocket........................................................................................................70
Figure 15 Principal tooth profiles of a sprocket...................................................................................72
Table of Table
Table 1 faults on filler and possible causes..........................................................................................21
Table 2 recommended lubricant viscosity for ambient temperatures...................................................57
Table 3 Some lubrication types...........................................................................................................58
Table 4 standard series for roller chain................................................................................................67
Table 5 standard series for sprocket.....................................................................................................68
Table 6 number of teeth on a smaller sprocket....................................................................................69
Table 7 sprocket dimensions for a given number of teeth....................................................................71
Table 8 maximum allowable speed for chains in rpm..........................................................................75
Table 9 power rating of a roller chain (in kW)....................................................................................75
Table 10 Proportions of standard parallel, tapered and gib head keys.................................................77
CHAPTER ONE
Introduction
1.1 History of Pepsi Cola
Pepsi cola traces its origins to 1898 when Caleb Brad ham, a pharmacist in New Bern, North
Carolina, created a curative drinks for dyspepsia called Pepsi Cola. Pepsi cola, later referred to
simply as Pepsi was a mixture of carbonated water, cane-sugar syrup, and an extract from topical
kola nuts. To sell this product, Brad ham formed the Pepsi Cola Company in 1903.In addition to
selling the drink at drugstore counters; Brad ham bottled Pepsi for sale on store shelves. At this
time, bottling was a new innovation in food packaging However, due to major increases in the
price of sugar, Braham began to lose money on Pepsi and in 1923 he filed for bankruptcy.
The Craven Holding Company of craven country, North Carolina, purchased the company’s
assets. In 1931 Charles Guts of the Loft Company in New York City purchased Pepsi-Cola from
the holding company. Guts had difficulty getting the business going again, but he increased sales
by selling larger bottles at an unchanged price. By 1933 Pepsi Cola was sold by 313 franchised
U.S. dealers bottled in the united states, Cuba, and England and Sold in 83 countries.
The consumption of soft drinks in their various forms has taken place for many centuries in order
to meet the body’s fundamental requirement for hydration. The most obvious source of hydration
is water, but in earlier times the consumption of water was very hazardous as it was frequently
contaminated by micro-organisms. Outbreaks of cholera, dysentery and other waterborne
illnesses were common in many European cities prior to the twentieth century.
1.2 The Emerging of Pepsi Cola Plant in Ethiopia

Nifas Silk Pepsi Cola is the first Pepsi Cola plant in Ethiopia and was established in 1966 as a
share company with an initial capital of 1 million Birr. The capacity of the bottling line at that
time was 20,000 bottles per hour (bph). In 1986, the plant was renovated and expanded to a
capacity of 50,000 bph with twin fillers.
Total renovation and expansion investment cost was Birr 6,647,944.00. Then Teklehaymanot
Pepsi Cola Plant was established in 1961 as ‘Saba Tej’ Share Company, but nationalized in 1975
replacing the old line as stated predicating Pepsi cola, Miranda and Team brands in January
1978. Gondar Pepsi Cola Plant, before nationalization was owned by private individual produced
wilk-fite water.
The Ethiopian beverage corporation made a new feasibility study on Pepsi cola product which
got the blessing of the government to erect the currently operating plant in 1986. Dessie Plant,
Dessie soda industry was established in 1952 by and individual owner. In1979. The plant
discontinued other soda products and started producing Pepsi Cola, Miranda brand and
carbonated Tosa Water.
• History of Gondar Pepsi Cola Plant
MOHA soft drinks s.c was formed and registered under the commercial code of Ethiopia on the
15th of May 1996.this company was formed after the acquisition of Pepsi cola plants in Ethiopia ,
namely Nifas silk , Teklehaymanot, Gondar and Dessie which were owned by government.
Moreover Bure and Hawassa Millinium plants have additionally established plants under the
company the vision of the company is to ensure the competitiveness of the company through
sustained innovation of its infrastructure and work towards IT (information technology ) focused
well managed and led organization for achieving best quality ,huge volume products based on
customers demand and be recognized as a profitable and growth oriented company and mission
is thus strive to reach , maintain and expand our national market leader ship through optimal
customer service and exceed the expectations of customer/stakeholders for our existing and new
products both in quantity and quality .
1.4 Main Products of the Company
The international Pepsi-Cola Company have more than hundreds of types of food and beverage
products. But there are only few products of PepsiCo are producing in our country and these
products became well known brands of Pepsi in Ethiopia. These products are Pepsi, Mirinda-
Orange, 7UP, Mirinda-Tonic, Mirinda-pineapple and Mirinda-Apple in their discovering order and
later cool water (mineral water) is added. Specifically when we come to Gondar MOHA Pepsi cola
plant, except cool water all six brands are producing
Figure 1.1 Brands producing under Gondar MOHA soft drink
These all products are 300ml (0.3L) and machin es fills 6000 bottles per hour. In addition to these,
the plant also produces carbon dioxide gas for the beverage purpose. According to the efficiency
of producing carbon dioxide, the plant could sell it for home consumption and supply for
consumers who need it for food preservation purpose. To produce the above mentioned products,
MOHA Soft Drinks Industry S.C got a franchised license from International Pepsi Cola
Company. This company controls the quality and safety of the products in the market.
1.5 Main Customers of the Organization
The end user of Gondar MOHA soft drinks are mainly the south region part of the country,
specifically they are listed as follow.
• Individual peoples
• Different Factories
• Café, Restaurants, canteen and Hotels
• School compounds (high schools, universities, junior school etc.)
• Employers of the company
1.6 Organizational Structure
Figure 1.2 chart showing organizational structure of the company
CHAPTER TWO
Internship Experience
2.1 The Section That We Have Been Interred
The first place that we had interred was in the maintenance department to practice in the
Internship program. But for the observation staff we had to inter in the production area. The
production room of the company held different production section where different operational
procedure is made by each section. The company has several sections; the major sections are as
follows:
• Washer room
• Filler& crowner room
• Boiler room
• Syrup room
• Water treatment room
• Air compressor room (1&2)
• Cold room
2.1.1 Bottle Washer

Bottle washer is a machine that is used to remove the dirty or otot so as to make the bottle free
from micro-organisms, there are six steps that a single needs to have to be used in the next step,
the machine is somewhat bigger and complicated relative to other machineries. Its can wash
6000 bottles per hour, the bucket holds 15 bottles at once.
Figure 2.1 bottle washer machine
This machine is very important and usable to be effective for bottle washing and it’s suitable to
wash that bottle with a little (minimum) amount of time and labor. The bottle is waiting for 30
minute in the washer machine until in late up to final out, and it pass different stages.
Those stages are: -
• Pre spray (pre rinse)
• Caustic 1
• Caustic 2
• Warm water
• Cold water
• Final rinse
Those stages are a removal agent for the bottle washing machine. As we know the bottle is
comes from different places that means the bottle is highly carried different microorganisms and
highly unmasked for bacteria’s, in order to remove those undesired things we use this machine
with different chemicals and water.
Chemical Used by Bottle Washer Machine are;
• CAUSTIC 1 AND 2: -Is used for removing of the bacteria and microorganisms inside and
outside of the bottle.
• DIVO BRITE: -This chemical is useful to be humid the undesired thing that adhere or stake
in the bottle.
• DIVO AI: -DIVO AI is used to neutral the caustic of PH ( the acidity)also it used to remove
the magnesium scale in the jet spray hole and remove heavy metal in the bottle and spray jet.
• DIVO LE: -We used this chemical in order to delete the date decoder on the bottle and the
corrosion.
2.1.1.1 Sections of bottle washer

• Pre-rinse: -This is the first stage for bottle washing and the bottle is wash internally and
externally with soft water by using spray jet.
• Caustic 1: -After pre rinse the bottle is going to caustic 1, this is a kind of bath and in this
bath there is 7000 L of caustic soda solution, also the caustic strength is must be 2 – 2.5 in
scale and the chemists is cheek this scale in every 4 hour, and the amount of caustic is 170
kg.in this section the temperature of caustic soda is must be 65 ®c.
• Caustic 2: -The difference between caustic one and caustic two: -the strength of caustic in
caustic 2 is less than caustic 1(or it measure 1 - 1.5 in caustic 2) and also the temperature is
decrease by sum amount like 25 -280c from caustic 1.
• Warm water: -The temperature of this warm water is 45 -48®c and the bottle is washed
internally and externally by using spray jet hole, those spray jets have 15 holes.
• Cold water: -Also wash the bottle with cold water.
• Final rinse: -This is the final stage for bottle washing process and the water is comes from
water treatment room, so the water is clearly treated in order to protect the bottle from
microorganism and other un-desire things.
The machine has two big gear boxes with having sprocket in the inside which is used to wrap the
bucket conveyors. The end (washed bottle ) is finally move to the filler room (using chain
conveyor) but in its way using manually it will be inspected incase caustic chemical particles are
in the bottle.
Factors that affect bottle washer
• Temperature
• Concentration of caustic soda
• Contact time
Fig 2.2 inner parts of washer
2.1.2 Bottle Filler and Crowner

2.1.2 A) Filler Machine
It is a machine used to fill the product into empty bottle. The machine that sucks the bottles and
fills the product is called a bowl. This machine has 6 sequences from receiving the empty bottles
to filling the product. These sequences are stated as follows:
• Evacuation: - When coming to filling the bottles may hold strange gases for
the product. Therefore this step used to remove those gases.
• Flushing: - Then the bottles will be flushed with CO2.
• Pressurization: - This step used to remove the CO2 that was applied for
flushing. It is carried out after the container is sealed to the sealing valve.
Removing the CO2 is required to prevent contact between product and CO2,
unless otherwise it may result exceeding the CO2 amount in the product.
• Filling: - Is a step of which the product is filled into the bottles.
• Correction: - If the fill height becomes greater than the range then it will be
corrected or sacked. This is done under correction step.
• Snifting: - Is a step used to balance the pressure between the container and the
surrounding.
It has 16 rotated filler in the device and the main drive of filling machine is by three phase AC
motor.
Figure 3.1 filler machine
Table 2.1 faults on filler and possible causes
Faults on filler Possible causes

Bottle not properly filled • Bottle mouth damage
• Lifting cylinder pressure to low

• Filling speed to high
Bottle fobbing over when with • Dirty bottle

drawn
• Filling pressure to low
• Temperature of the beverage is to high
2.1.2 B) Crowner
It is a device used to crown (cork the bottle) it holds 4 bottles at a single instant It has the
following parts;
• plungers [4 in number]
• crowner head
• Hooper
• Slider
• Small hose which contain compressed air
• Motor
The speed of the crowner is same with that of filler machine which is adjusted using the
calculated gear to gear mesh. The cork is added at the hopper which contains motor which
facilitate agitation or order {in the concave side} which then move to the slider and press by the
plunger. In case the cork is passing along the slider in the convex side due to adjustment errors it
will fall down to the spacer. The main thing is the crowner head structure which guides the
plunger between TDC and BDC.
When the main axle is driven by the meshing -gear. The main axle also contains the plunge
which rotates along with the axle during tis rotation the plunger moves through the stationary
crowner head slot. The plunger has return spring and rod which presses the cork at the BDC
(bottom bead center) When the rod pushes the cork inside the cylinder like structure the process
is successful. Finally when the process is finished it will be checked by the device (gauge)
{mostly around 1.30 in the device} as per the chemists order so as to prevent gas leakage.
2.1.3 Date Coder

It is a machine used to label the best before date and the factory’s abbreviation name with the
time of production. It has an ink and a makeup used to mix the ink which is used for the labeling
in it. A product without a label of best before date will not be available for market. In other
words there will be no production if this machine does not work.
2.1.4 Boiler Room
This section of the plant is where steam is produced and used for different machines like washer
and syrup room. There are two boilers in this room the one is new boiler and which is use to
generate steam is a fire tube type of boiler with a capacity of 3200 kg/hr. And an air intake
directly from the atmosphere with the help of air fun connected with an electric motor, air fuel
ratio manually controlled using mechanical valves, exhaust gas realized directly to the
atmosphere. The boiler room is so hot due to the loss in radiation and convection,
It is controlled with a manually adjusted servo motor that control the pre entered air fuel ratio
and an electromechanical timer for ignition and it has a light sensor for checking if combustion is
taking place to prevent unwanted fuel storing inside the boiler which may cause explosion if
ignited.
Boilers are pressure vessels that are designed to heat water or produce steam. Which is then use
for many purposes like space heating, service water heating in a building, steam jet cleaning.
There are many types of heating sources in a boiler like natural gas fired burner, oil fired burner
and electrical resistance heaters.
Figure 4.1 boiler machine

The boiler has 3 regulators;
For maximum pressure (7.5 bar) for minimum pressure (5.5 bar) for fuel control
If the pressure of the steam is 7.5 bar signal is sent to the fuel control to reduce the fuel spray. If
the pressure of steam is min (5.5 bar) signal is sent to the fuel control to increase fuel and satisfy
the needed amount of steam pressure. The vessel will burst if the pressure is above 8 bar. The
indicator has Green and Red lights if the amount of water in the vessel is less it may melt the
vessel since temperature is high.
The pump moves he water from the reservoir to the boiler. The pump helps to have adequate
water and it is automatic if the amount of water is low and steam is high signal is sent to the
pump starts automatically and pumps the water to the boiler.
The gear pump is driven by the outré motor which also derives the fan. The thin pipe (now blind)
moves to the water reservoir if it makes snow (there is no such problem in our country).
The furnace fuel is used due to its availability; it is pumped from the out door to this room the
furnace fuel is melt (heat from 50-60 oc ) to decrease its viscosity then it is pumped to the
boiler(using screw pump due to its viscosity) then it will be reheat since it should be fine spray,
if there are more viscous ruminants it will then be pumped to the main tanker for reheating
purpose . Then the fine spray will be ignited using igniter (commonly known as “candela”) then
flame is created and it will be blowed through the heat chamber using fan.
The steam generated is used for the following purposes;
• Sugar dissolving
• For bottle washing
• For hot sanitation
2.1.5 Syrup room
During the production process of soft drinks, the components of the drinks are mixed before
bottling. Many soft drinks contain the basic ingredient and components such as liquid sugar,
flavor or citric acid or syrup made from these ingredients. The components
areareprocessedprocessed in a mixing procedure in the required ratio of water to the finished
drink.
Here in the syrup room preparing standard acceptable syrup and mixing the other main necessary
ingredients to make ready for the filling room is the main objective. In this room syrup making,
filtration, mixing ingredients with syrup, cleaning and sanitizing processed. These all processes
are done by the room operators.
2.1.6 Water treatment

Water is comes from many different sources like municipal surface water, ground water, rain
water. Those are a source of usable water. Weather the bottling plant has its own well or the
water supply comes from a modern municipal treatment plant, each individual water supply
presents its own particular problem. However they are affected by weather condition,
microorganism and more easily contaminated or polluted. So in order to be ready for the
production it must be treated. Water treatment is any process that makes water more acceptable
for a specific end use. The end use may be drinking, industrial water supply or many other uses.
Water treatment remove contaminated and undesirable component or reduce their concentration
so that the water become fit for its desired end use. Treatment for soft drinking production
involve the removal of contaminated from raw water to produce water that is pure enough for
human consumption without any short term or long term risk of any adverse health effect. This
water treatment process involved in removing contaminate including physical process such as
settling and filtration ,chemical process such as deification and coagulation and biological
process such as slow sand filtration. GONDAR MOHA soft drink plant is used municipal water.
2.1.6.1 Selection of Water Treatment Technology

Selection of the correct water treatment technology for specific plant depends to a great deal on
the water source, i.e. the surface & ground water source. Raw water supplies are contaminated
by different things. In our plant (GONDAR Pepsi cola plant) the source of water is from
municipal. Surface waters are low minerals; usually contain more natural organics this organic
loading varies from season to season. Surface waters are extensively treated by municipal
Internship Report on Gondar MOHA Soft Drink S.C Treating plants; they can contain organic
material, which will interfere with the operation of a bottling or canning plant water treating
system.
2.1.7 Air compressor
An air compressor is a device that convert power (using an electric motor, diesel or gasoline
engine, etc.) in to potential energy stored in pressurized air, (compressed air) By one or several
method an air compressor force more and more air in to a storage tank, increasing the pressure.
When tank pressure reaches its upper limit the air compressor shuts off, the compressed air can
be used for a variety of applications like: - utilizing the kinetic energy of the air as it’s released
and the tank depressurizes. When the tank pressure reaches its lower limit, the air compressor
turn on again and pressurizes the tank.
Figure 5.1 air compressor
2.1.7.1 Parts of Air Compressor Machine
• In take air filter: - prevent dust from entering a compressor, if the dust is gate in to the air
compressor machine, there will be un masked for sticking valves, scoured cylinders,
excessive wear etc.
• Inter stage cooler : - reduce the temperature of the air before it enter the next stage to reduce
the work of compression and increase efficiency they are normally water cooled.
• After cooler: - is used to remove the moisture in the air by reducing the temperature in a
water cold heat exchanger.
• Air dryer: -the remaining trace of moisture after cooler are removed using air dryers. So by
using this machine (Air dryer) the moisture content will be removed.
• Moisture drain trap: -is used for removal of moisture in the compressed air.
• Air reservoir tank: - is serving as storage of compressed air.
2.1.7.2 Use of Air Compressor in Gondar MOHA Soft Drink S .C
• Cleaning of the bottle
• Push the piston of the bottle on filling beverage
• Dry the moisture on the bottle by using video jet
• Cooling the beverage
2.1.8 Ammonia Compressor
Ammonia compressor is used to compress the ammonia gas in order to cool the beverage by
using water and wind pipe. On cooling tower of ammonia compressor cooling the ammonia to
cool the beverage. Then the ammonia compressor contains cooling gas and water, the water turn
to the cooling tower of ammonia compressor again and recycles.
Figure 6.1 ammonia compressor
2.2 The Work Task that Executing

MOHA soft drink company has many machineries that are used for production process which
need lubrication as per the time given in the manual , we had been lubricating the parts as per
the manual of the machinery ,not only this but also we had prepared some easy spare parts which
can be made in the machine shop.
2.3 Types of Engineering Methods, Tools and Techniques we have been using while
performing our Work Task
• We had tried to understand what does it mean maintenance performance and how it will be
improved.
• Try to see how it looks like the international one or the benchmark maintenance
performance.
• Identify the best maintenance performance parameters.
• Evaluate the current MOHA’s maintenance performance.
• Compere the current states with the benchmark.
• Identify it’s reason
• Finding solution
2.4 The challenges that have been faced

• The company have no any formal maintenance history
• Shortage of data
• Anyone in the organization won’t to accept there negative side
• Have no internet access, have no any information disk, and the machines manual are oldest.
• The organization have a very long burocracy for the silly things
2.5 The measure that have been taken

• Make close relationship with each of workers & operator of the company
• being patient to get something what I want
• taking a data relative to the current situation
• create frank communication with my minter
• Follow the company’s official rule to gate something
2.6 Over all Benefits Gained from Internship
Internship program is a method of letting the students to assume themselves as potentially

responsible workman for a particular work by assigning them to actively participating in
production control as well as maintenance in industrial company. And such trends help us to
have valuable work experience. Internship programs are also potentially valuable to the
company. In this internship, we could observe what the outside industrial world look like more
than we know when we were at the school. When we were at school, we learned or took many
theoretically lessen even difficult to understand theoretically. So in this internship, we get good
opportunity to solve these difficulties. Because those things which were theoretically difficult to
understand, were not hard to understand when we learned practically.
The overall benefits of internship are not limited to the practical skill only. We would like to
group the overall benefits that we have been gained in terms of different categories. Such as:
• Improving practical skill
• Upgrading theoretical knowledge
• Improving inter-personal communication skill
• Improving leadership skill
• Understanding about work ethics related issue
• Entrepreneurship skill
2.7 In terms of improving practical skill
The several courses that we were taken in the class dealt with the theoretical side of engineering.
Some lectures took the initiative and try to illustrate the practical part of this field by displaying
graphic images in their lecture. That was more or less illustrative or even took us to the company
to show what the actual engineering looks like. But these trials were fruitless and failed to give
us the clear picture.
This internship program was exactly what we needed to nurture the lack of practical skills we
had. Generally, as an internship student, we were responsible to handle the following piece of
works:
• Replacing electrical protective devices when they failed, for instance, circuit
breaker, lamps etc.
• Making simple installation like electrical light installation

• Seeing how to read tag number from electrical material and relate it with the
wiring diagram.
• Identifying causes of motor failure
• Trouble shooting and maintenance
• Electronics/electrical, control/automation system
• Variable frequency drives(VFDs)
2.8 In terms of improving theoretical knowledge
This internship program provided us building our intellectual knowledge and practical skills. The
works we did were mostly related to most courses that we have taken in the class room; specially
electrical machine, power system industrial control system etc. during class time, before the
internship, we mainly discussed PLC, control system, motor winding etc. we covered here
application of electronics and digital logic design like convertor/rectifier and inverter, PLC and
motor winding in electrical machine.
2.9 In terms of improving team playing skill
When different individuals come together to work for common goals of the company for
increasing productivity, the most important point is just reaching an agreement on different
points on the work to be done at a time.
A person with good team playing skill will upgrade the following:
• To help and co-operate with others
• To share ideas with colleagues to openly and willingly
• To give comment the team
• To demonstrate reliability
• To treat others in respectful and supportive manner
• To increase the ability of active participant

• To become a problem solver on time
2.10 In terms of Improving Leadership Skill
There is no much place of responsibility given to us to lead any tank. So that we have not we
have not got full benefits from leadership skills during our start at the company; but from the
observation of the leader of the company leading the workers , we understand from the internship
to give relevant and important solutions to the problems. In terms of improving leadership skills,
we offered the following:
• To plan, prepare and schedule all necessary materials
• To become more reasons because in action
• To know ourselves and to make self-important
• To become accurate and more skill on our judgment
• To give technical support
• To increase our work status
2.11 In terms of Understanding about Work Ethics Related Issues
Work ethics includes both how one feels about their job, career or vocation and how one does his
/her job or responsibilities. It demonstrates many things about whom and how a person is. It also
involves such characteristics as honesty and accountability. Essentially, it breaks down to what
does or would do in particular situation.
In our period of internship, we understand what work ethics, one of ethics is punctuality. To be
punctual is duties of every worker that they could achieve their task with the time given. Some of
work ethics are listed as follows:
• Reliability
• Punctuality
• Office disciplines
• Honesty
• Avoiding potential or apparent conflicts of interest
• Co-operation
2.13 In terms of improving inter-personal communication skill
Inter-personal communication is communication scholar in which numerous ways, always

describing participants who are dependent upon one another and have the shared history. It can
involve one on one conversations or individuals interacting with many people within a society.
It also helps us understand how and why people behave and communicate in different ways to
construct and negotiate a social reality. While interpersonal communication can be defined as its
own area of study, it also occurs within other contexts like groups and organizations.
Company that we have been involved has different people with various background came
together. They are varying in educational level, economic situations, cultural backgrounds, life
standards and etc. since the aim of the company is to accomplish the work in good way, we need
to have good communicative skills.
During our internship, we have improved our communication skill by communicating starting
from daily labor to project manager learning different type of production terms.
2.14 OVER ALL CONCULUSION AND RECOMANDATION
2.14 A) Conclusion
From internship practicing period we conclude that those months are very important to gate
experience and to know work habit, this is very important for future of student. The other
important part of this program is we learn about saving money and increase inter personal
relationship. Gondar MOHA soft drink company is limited to produce a good product, legal, by
decreasing the cost to produce good quality product that are acceptable by customer, wait the
company from un wanted debris is individual worker responsibility.
2.14 B) Recommendations
Finally we recommended to the company, there is a problem of:
• Waste treatment
• It’s not updated with the technology
• All inspection are performed manually
• It’s not comfort to the employers
• There is a shortage of laboratory equipment etc.
So we would like to recommend that:
• The waste must treated at least physically
• Must be updated with technology
• Must use automatic machines like fbi, ebi to decrease the problems and improve
productivity
Part 2
Project
CHAPTER ONE
Introduction
1.1 Historical Back ground of Chain and Sprocket
The word meaning” chain” can be traced back to ancient word in the Indo-European language
family. As early as 225Bc, chain was used in the 16 th century, Leonardo da Vinci made sketches
of what appears to be the first steel chain. These chains where probably designed to transmit
pulling , not wrapping, power because they consist only of plates and pins and have metal
fittings .However, da Vince’s s sketch does show a roller bearing. It took some time for the
technology to catch up with the concept. Problems in the manufacturing and processing of steel
prevented chain growth until the 19th century, when new technologies made steel chain and
bearings realities. In the 1800s’ a Frenchman named Gull obtained a patent for similar a chain
for use on a bicycle. This chain, called “Gull chain,” is still used today in h Stellanging
applications. When molded chain was invented in the 19th century, things begin to move rather
than quickly. First the cast detachable chain came, which is composed of identical cast links.
Next, the pintle chain, which has a separate pin, appeared. The cast detachable chain and the
pintle chain have been improved over the years, and they are still in use today in some special
applications. They are being re placed –gradually – by large pitch steel conveyor chain. In the
late of 1800s’ a new development – the bushing-revolutionized steel chain. Chains with
bushings had greater wear resistance than Gull chain because the bushing acted as a bearing,
protecting the pin. At This point, the chain story moves in to super speed. , Steel bushing chain
was used on bicycles, in the rear wheel drive of early automobiles, and, in 1903, as the propeller
drive in the wright brothers, airplane to draw a bucket of water up from a well. This very early
bucket chain was composed of connected metal rings
1.2 DEFINITION OF CHAIN AND SPROKET
A sprocket is a toothed wheel that is used to transmit motion and torque from one shaft to
another. Chains that are used to transmit motion and force from one sprocket to another are
called power transmission Chains. Unlike gears that have to mesh to transmit motion and torque
from one gear to another, sprockets May be positioned far apart. Sprockets are connected by a
chain. A sprocket with a hole that matches the diameter of the shaft is chosen and slid onto the
shaft. The sprockets then rotated until the keyways in the sprocket and shaft line up. A
rectangular piece of steel bar called a Key is slid into the keyways to prevent the sprocket from
spinning on the shaft. Chain and sprocket mechanisms perform the same task as a belt and pulley
system, i.e. they transfer motion and force from one shaft to another. A belt can slip on a pulley
but the teeth on the sprocket prevent the Chain from slipping. A chain and sprocket is used
wherever a positive, non-slip drive is required, e.g. Bicycles, motorcycles, forklift mechanisms,
and the camshaft drives in car petrol engines. In an automotive vehicle, engine produces the
power which is transferred to the drive shaft. Chain drive is one of the commonly used drive
train to transfer this power. Chain assembly consists of chain, driving sprocket and driven
sprocket. The driving sprocket is connected to engine output shaft, which transfer power to
driven sprocket by chain. Further this driven sprocket transfer power to drive shaft. Therefore in
chain assembly driving sprocket has a Chance for design and optimization for weight reduction.
Due to high power transfer and high speed of rotation, high stress induces in sprocket teeth, also
high speed leads to the vibrations. Hence it is important to design and manufacture sprocket
properly, also mounting of sprocket is important.
While transferring power from driving to driven sprocket, chain exerts high load on sprocket
teeth. So, maximum loads acting on teeth are calculated. Stress induced due to load should be
less than the Yield stress of the material. If stress becomes more than yield stress of material then
there is a possibility of failure. Hence static analysis was performed to ensure that the proposed
design has factor of safety greater than one. Also due to cyclic load acting on the sprocket from
chain, it is important to test the sprocket for fatigue loading. In fatigue analysis fatigue life of
sprocket is calculated and it is ensured that the minimum fatigue life is higher for safe use of
sprocket for sufficient time period. After the minimum fatigue life, crack in the component
initiated, which further increases with time and leads to failure of component. Therefore it is
important for any component to have sufficient fatigue life. Chain and sprocket mechanisms
perform the same task as a belt and pulley system, i.e. they transfer motion and force from one
shaft to another. A belt can slip on a pulley but the teeth on the sprocket prevent the Chain from
slipping. A chain and sprocket is used wherever a positive, non-slip drive is required, e.g.
Bicycles, motorcycles, forklift mechanisms, and the camshaft drives in car petrol engines.
Figure 7.1 chain with sprocket
1.3 Application of Chain and Sprocket
In an industrial facility, motors and turbines use energy to produce rotational mechanical motion.
In order to harness this motion to perform useful work, there must be a way to transmit it to other
components and machines. One method of power transmission is through the use of chain drives
and sprockets. Chain drives consist of an endless series of chain links, which mesh with toothed
sprockets. Chain drives are used to perform three basic functions: transmitting power, conveying
materials, and for timing purposes.
• Transmitting Power
• Conveying Materials
• Timing Purposes
1.4 Working Principle
The sprockets, which are fitted with the conveyor roller, are connected using chain and when the
motor is connected to the smaller sprocket end (since we need to reduce motor speed) and when
power input is given the system starts its motion and during this period the box which carries
empty bottle starts to move to its final destination.
1.5 Problem Statement
These problems include:
• It usually crush a bottle boxes and even crush bottles
• It forces the work to be done slowly
• It wastes man power/it needs human force
• It doesn’t allow the boxes to move safely
• It has high friction
• It is stacking time to time
1.6 Objective of the project

1.6.1 Main objective:
The main objective of the project is to design a chain convey the bottle boxes away from the
store and even from the production of soft drinks instead of roller conveyor alone. The bottle
boxes are conveyed through roller conveyor driven by a chain which is connected by a motor.
The boxes are moved from the store to the washer machine and then from the production to the
soft drink store.
1.6.2 Specific objective:
Specific objectives of the project include:
• To reduce labor force
• To do the overall work fast
• To provide safe movement of the bottle boxes through the conveyor
• To reduce payment required by the company due to many labor force
• To increase life time of boxes and bottles.

1.7 Methodology
In the design of roller chain, the following procedures should be taken
• Introduction about roller chain and sprocket
• Definition
• Classification
• Type
• Mechanism and operating principle of roller chain with sprocket
• Problem statement
• Main and specific objective
• Material selection of each component
• Design of each component in this section we have ;
1.8 Design of roller chain
Determine chain size which meets the required criteria
Using chain size read pitch, pin diameter, roller width, and plate thickness
1.9 Design of sprocket

Take velocity ratio which best fit our requirement.
Read the number of teeth based on velocity ratio using standard table.
Using the number of teeth read other sprocket terms like diametrical pitch, and outer diameter,
from the standard table.
Determine principal tooth profile dimensions.
Formulas used
1. Tooth flank radius (re)
= 0.008 d1 (T 2 + 180) ... (Maximum)
= 0.12 d1 (T2 + 2) ………... (Minimum)
Where d1 = Roller diameter, and T = Number of teeth
2. Roller seating radius (ri)
= 0.505 d1 + 0.069 d1...... (Maximum)
= 0.505 d1 ... ………………… (Minimum)
3. Roller seating angle )
= 140º – 90º/T ... (Maximum)
= 120º – 90º/T ... (Minimum)
4. Tooth height above the pitch polygon (ha)
= 0.625 p – 0.5 d1 + 0.8 T /p ... (Maximum)
= 0.5 (p — d1) ... (Minimum)
5. Pitch circle diameter (D)
==pcosec
6. Top diameter (Da)
= D + 1.25 p – d1…... (Maximum)
= D + p (1-... (Minimum)
7. Root diameter (DF)
= D – 2ri
8. Tooth width (bf1)
= 0.93 b1 when p ≤12.7mm
4.3. Design of key

Using inner diameter of the sprocket (hub diameter) determine the width and thickness of the
rectangular key
Calculate length using both torsional and crushing stress and take the bigger of the two values
Formulas used
T=l*w*
T=
• Result and discussion
• Method of Manufacturing
• Cost analysis
Formulas used
Total cost = material cost + manufacturing cost + labor cost
CHAPTER TWO
Literature Review
Thomas Robins began a series of inventions which led to the development of a roller conveyor
used for carrying coal, ores and other products.
Sandvik invented and started the production of steel conveyor belts.
Richard Sutcliffe invented the first conveyor belts for use in coal mines which revolutionized
the mining industry.
Henry Ford introduced conveyor-belt assembly lines at Ford Motor Company's Highland Park,
Michigan factory.
Robert Batan created in New Caledonia the longest straight-belt conveyor in the world, at a
length of 13.8 km.
B. F. Goodrich patented a conveyor belt that it went on to produce as the Turnover Conveyor
Belt System. Incorporating a half-twist, it had the advantage over conventional belts of a longer
life because it could expose all of its surface area to wear and tear.
Nile E. Sawmilled, Craig S. saw miller. The invention relates to an improved roller drive
mechanism for a con eyorThe mechanism provides horizontally oval path which provides an
improvement in the thrust imparted to the driving bottle box during the downward movement of
the bottle box. These paths are defined by two sets of sprockets disposed in parallel planes
connected by a set of single strand chains. This mechanism is connected to the drive wheel by a
conventional sprocket-chain linkage.
James S. Busby, Costa Mesa, Calif. A direct drive roller conveyor comprising a main frame of
the roller conveyor. Rotatable mounted within the mainframe is a variable rate transmission unit
having rotatable input and output shaft. Rotatable connected to the main frame is a roller.
The roller is mechanically coupled to the input shaft of the transmission unit in a
mannerwhereirotationofthechainconveyorcofacilitatestherotationofinputshaft.
Patrick E. Turner; Lawrence O’Dell, A drive mechanism is disclosed that is select ably
engage able to provide a conveyor has normally driven and no driven wheels with either single
or dual wheel drive. The drive mechanism includes a power take off means that has: a first power
transmission mechanism mounted on said frame; a second power transmission mechanism
mounted on the roller in positive drive power transmitting engagement with a normally non-
driven wheel of the chain conveyor; and a power transfer apparatus connected to receive power
from the first power transmission mechanism and transmit it to the second power transmission
mechanism. A coupling mechanism is operatively connected with the power take off and is
selectively actuatable to place the first power transmission mechanism either in a drive position
receiving power from the normally driven wheel or a disengaged non-power transmitting
position.
William Brahma, a direct drive roller conveyor comprising a main frame of the roller
conveyor. Rotatable mounted within the mainframe is a variable rate transmission unit having
rotatable input and output shaft. Rotatable connected to the main frame is a roller.
The roller is mechanically coupled to the input shaft of the transmission unit in a
mannerwhereirotationofthechainconveyorcofacilitatestherotationofinputshaft.ca
Califf O’Dell, The invention relates to an improved roller drive mechanism for a con eyorThe
mechanism provides horizontally oval path which provides an improvement in the thrust
imparted to the driving bottle box during the downward movement of the bottle box. These paths
are defined by two sets of sprockets disposed in parallel planes connected by a set of single
strand chains. This mechanism is connected to the drive wheel by a conventional sprocket-chain
linkage.
CHAPTER FOUR
Material Selection
We need a material having the following properties;
• Strength
• Corrosion resistance
• Easily availability
The material that satisfies our requirement is alloy steel, so alloy steel is our material.
4.1 Basic Properties of Steel

Steel is an alloy, a combination metal made of iron and carbon. The carbon content of steel
reaches a maximum of 1.5 percent. Because of its hardness and strength, steel is used in the
construction of buildings, bridges, automobiles, and a host of other manufacturing and
engineering applications. Most steel produced today is plain carbon steel or simply carbon steel.
The carbon in steel exists in the iron carbide state. Other elements, among them sulfur,
phosphorus, manganese and silicon, are present as well different types of steel are produced
according to the mechanical and physical properties required for their application. Various
grading systems are used to distinguish steels based on these properties, which include density,
elasticity, melting point, thermal conductivity, strength, and hardness (among others). To make
different steels, manufacturers vary the type and quantity of alloy metals, the production process,
and the manner in which the steels are worked to produce particular products.
Steel has a density of 7,850 kg/m 3, making it 7.85 times as dense as water. Its melting point of
1,510 C is higher than that of most metals. In comparison, the melting point of bronze is 1,040 C,
that of copper is 1,083 C, that of cast iron is 1,300 C, and that of nickel is 1,453 C. Tungsten,
however, melts at a searing 3,410 C, which is not surprising since this element is used in light
bulb filaments. Steel’s coefficient of linear expansion at 20 C, in µm per meter per degree
Celsius, is 11.1, which makes is more resistant to changing size with changes in temperature
than, for example, copper (16.7), tin (21.4) and lead (29.1).According to the American Iron and
Steel Institute (AISI), steels can be broadly categorized into four groups based on their chemical
compositions.
• Stainless Steels
• Tool Steels
• Carbon Steels
• Alloy Steels
4.1.1 Properties of alloy steel

Alloy steels are so named because they are made with a small percentage of one or more metals
besides iron. The addition of alloys changes the properties of steels. For example, steel made
from iron, chromium, and nickel produces stainless steel. The addition of aluminum can make
steel more uniform in appearance. Steel with added manganese becomes exceptionally hard and
strong. We select alloy steel material due to cost, strength and availability. Let’s see the
properties of alloy steel, AISI Type 303 See alloy Steel, cold drawn, bars.
Chemical properties
Composition Content %
Carbon(C) Max 0.15
Cr 18
Fe 69
Mn Max 2
Ni 9
P Max 0.2
S Max 0.06
Se Max 0.15
Physical properties
Properties Metric English
Density 8 g/cm3 0.289 lb/in³
Mechanical properties
Properties Metric English
Hardness, Brinell 228 228
Hardness, Knoop 251 251
Rockwell B 96 96
Rockwell C 19 19
Hardness, Vickers 240 240
Tensile Strength, 690 MPa 100000 psi
Ultimate
Tensile Strength, Yield 415 MPa 60200 psi
Elongation at Break 40% 40%
Modulus of Elasticity 193 GPa 28000 ksi
Poisson's Ratio 0.25 0.25
CHAPTER FIVE
Design Analysis
5.1 Component Description

The project has 6 main components and other additional components.
• Outer plate
• Inner plate
• Pin
• Bush
• Roller
• sprockets
Figure 8.1 Layout of roller chain
Where, ❶ outer plate❷ inner plate ❸ pin ❹ bush ❺ roller
5.1.1 Plate
The plate is the component that bears the tension placed on the chain. Usually this is a repeated
loading, sometimes accompanied by shock. Therefore, the plate must have not only great static
tensile strength, but also must hold up to the dynamic forces of load and shock. Furthermore, the
plate must meet environmental resistance requirements (for instance corrosion, abrasion etc.)
Figure 9.1 plate
5.1.2 Pin
The first component is the pin. Typically these are manufactured out of carbon steel and
depending on the quality level, the pin can be thru-hardened, case hardened, or heat-treated. We
can also supply roller chain pins as stainless steel or nickel plated. The pin is subject to shearing
and bending forces transmitted by the plate. At the same time, it forms a load-bearing part,
together with the bushing, when the chain flexes during sprocket engagement. Therefore, the pin
needs high tensile and shear strength, resistance to bending, and also must have sufficient
endurance against shock and wear.
Figure 10.1 pin
• Bushing
The bushing is subject to shearing and bending stresses transmitted by the plate and roller, and
also gets shock loads when the chain engages the sprocket. In addition, when the chain
articulates, the inner surface forms a load-bearing part together with the pin. The outer surface
also forms a load-bearing part with the roller's inner surface when the roller rotates on the rail or
engages the sprocket. Therefore, it must have great tensile strength against shearing and be
resistant to dynamic shock and wear Bushings are a crucial component for performance and wear
life and are available as solid or split configurations for both ANSI and ISO standard roller
chains.
Figure 11.1 bushing
5.1.4 Roller
The roller is subject to impact load as it strikes the sprocket teeth during the chain engagement
with the sprocket. After engagement, the roller changes its point of contact and balance. It is held
between the sprocket teeth and bushing, and moves on the tooth face while receiving a
compression load. Furthermore, the roller's inner surface constitutes a bearing part together with
the bushing's outer surface when the roller rotates on the rail. Therefore, it must be resistant to
wear and still have strength against shock, fatigue, and compression.
Figure 12.1 roller
• Relevance of the Project

• It reduces labor force.
• It does the overall work fast.
• It provides safe movement of the bottle boxes through the conveyor.
• It also reduces payment required by the company due to many labor

force.
• It increase life time of boxes and bottles.
• The way that the existing bottle work

The conveyors are placed at some angle and when some force is applied the box carrying the
bottles move by the help of gravitational force.
• The way to convert manual conveyor to automatic conveyor
This is done by using motor which is fitted on to the roller conveyor, and also it needs limit
switch since there is jamming of the box.
5.5 Design of Roller Chain
Data that we have taken (using primary data collection);
Distance between the targeted points = 3m
Optimal speed needed for the box = 3m/s
From the standard chart of roller chain we have selected roller chain having chain size of 35
(they are arbitrary numbers given by ANSI).
Factors to consider when choosing size of roller chain would include:
• Less cost
• High strength
• Easy to maintain
Benefits of 35 pitch chain
• Adjustable length / Breakable. Because 35 pitch chain is relatively strong, it can afford to
compromise its strength and offer removable links. One of the biggest advantages of 35 pitch
chain is the ability to lengthen or shorten it with a removable link. This also proves an
enormous advantage where rear axles are driven ‘in- board’ with a sprocket between the
bearings.
• Higher Strength a. Because 35 pitch chain has marginally larger components, it has increased
strength.
• Lower Price a. Due to the ability to manufacture 35 pitch chain at good strength at a lower
quality of manufacture, prices can be lower.
Disadvantages of 35 pitch chain
• Larger Sprocket Diameter: Because 35 pitch chain has a larger pitch (9. 525mm), less links
occupy a given diameter of sprocket. That means a 35 sprocket with the same number of
teeth as a 219 pitch sprocket will be larger in diameter. This means a lower number of teeth
can be used compared to 219 pitch before the sprocket fouls the ground or chassis. This
reduces the gearing options.
• Less- smooth power transmission / reduced sprocket life: Because of the larger pitch, teeth
are further apart so a less even drive force is transmitted per square mm of sprocket tooth.
This increases the amount of stress on each tooth and provides a marginally reduced sprocket
lifespan.
From the table 5.1 (appendix) we can have the following values for chain size 35.
Size Pitch Max. roller Min.ult. Tensile Measuring load
diameter strength
35 9.53mm 5.08mm 800kg 8.2kg
From table 5.2 (appendix) we can determine pin diameter, width, thickness of link plate.
Pin diam. =3.58mm
Width=4.7625mm
Thickness of link plate=1.27mm
Chain width=4.7625+2.54=7.30mm
Figure 13.1 terms used in roller chain
5.6 Sprocket Design

Let’s assume the velocity ratio is 2, since when the velocity ratio increases the number of teeth
on the smaller sprocket decreases and this result in noisy drive this is undesirable.
From the table5.3 (appendix) for roller chain with V.R 2 the number of teeth on the smaller
sprocket is 27. Since V.R is 2 the number of teeth on the larger sprocket is 54.
P=9.53mm (chain pitch)
Breaking strength =106P2
= 106(9.53mm) 2
=9.63KN
Fig 14.1 terms used in sprocket
The sprocket type that is needed is simplex type which is in single gearing with the roller chain.
From the standard table5.4 (appendix) below we can get outside diameters, pitch diameter, and
other sprocket dimensions.
• For small sprocket having 27 number of teeth we get the following sprocket dimensions
(for simplex),
Outside diameter=144mm
Pitch diameter=136.75mm
Dm=85mm
D1=20mm
A=35mm
• For large sprocket having 57 number of teeth we get the following sprocket dimensions
(for simplex),
Outside diameter=296mm
Pitch diameter=286.18mm
Dm=108mm
D1=25mm
A=43mm
5.6.1 Principal Dimensions of Tooth Profile
The standard profiles for the teeth of a sprocket are shown in Fig. below the principal dimensions
of the tooth profile are as follows;
Figure 15.1 principal tooth profiles of a sprocket
For smaller sprocket;

= 0.008 d1 (T 2 + 180) ... (Maximum)
=33.12mm
= 0.12 d1 (T2 + 2) ………... (Minimum)
=32.59mm
Where d1 = Roller diameter, and T = Number of teeth.
2. Roller seating radius (ri)
= 0.505 d1 + 0.069 d1...... (Maximum)
=11.48mm
= 0.505 d1 ... ………………… (Minimum)
=10.11mm
3. Roller seating angle )
= 140º – 90º/T ... (Maximum)
=136.670
= 120º – 90º/T ... (Minimum)
=116.670
= 0.625 p – 0.5 d1 + 0.8 T /p ... (Maximum)
=-1.77mm
= 0.5 (p — d1)………………..... (Minimum)
=-5.23mm
==pcosec
=82.09mm
= D + 1.25 p – d1…... (Maximum)
= 74.00mm
= D + p (1-...... (Minimum)
=71.05mm
= D – 2ri
=59.13mm
= 0.93 b1 when p ≤12.7 mm…..our p value is
9.53mm
=8.86mm
9. Tooth side radius (r x) = p=9.53mm
10. Tooth side relief (b a)
= 0.1 p to 0.15 p=0.95mm
For larger sprocket;
= 0.008 d1 (T 2 + 180) ... (Maximum)
=46.80mm
= 0.12 d1 (T + 2)............ (Minimum)
=44.89mm
where d1 = Roller diameter, and T = Number of teeth.
2. Roller seating radius (r i)
= 0.505 d1 + 0.069 d1 ………. (Maximum)
=14.35mm
= 0.505 d1 ……………... (Minimum)
=12.63mm
3. Roller seating angle ()
= 140º – 90º/T ... (Maximum)
=139.830
= 120º – 90º/T ... (Minimum)
=119.830
= 0.625 p – 0.5 d1 + 0.8 T/ p ... (Maximum)
=-2.01mm
= 0.5 (p — d1) ... (Minimum
=-7.74mm
==pcosec
=163.91mm
= D + 1.25 p – d1... (Maximum)
= 148.15mm
= D + p (1-... (Minimum)
=147.34mm
= D – 2ri
=134.85mm
= 0.93 b1 when p ≤12.7 mm……….…….our
P value is 9.53mm
=9.45mm
9. Tooth side radius (rx) = p=9.53mm
• Motor power selection
We select motor based on
• Load on conveyor (10 kg as per the data collected)
• Self-load of conveyor
From the table5.5 (appendix) maximum allowable speed for chains in rpm = 2550 rpm.
Power rating using the given speed of smaller sprocket or pinion (in rpm.) is given on the table.
In this table we also need to use iteration.
2500 =0.68 kW using interpolation we can determine the value for “x”
2550 =x
3000 =0.8 kW
The value of “x” becomes 0.75kw ~ from standard 1 H.P motor is recommended.
Therefore the power rating is 0.746 kW.
p= …=> n=
where W b = Breaking load in newton’s
v = Velocity of chain in m/s
n = Factor of safety, and
KS= Service factor = K1.K2.K3
The service factor (KS) is the product of various factors, such as load factor (K1), lubrication
factor (K2) and rating factor (K3). The values of these factors are taken as follows:
1. Load factor (K1) = 1, for constant load
= 1.25, for variable load with mild shock
= 1.5, for heavy shock loads
2. Lubrication factor (K2) = 0.8, for continuous lubrication
= 1, for drop lubrication
= 1.5, for periodic lubrication
3. Rating factor (K3) = 1, for 8 hours per day
= 1.25, for 16 hours per day
= 1.5, for continuous service
For our design we have taken, K1=1 K2=1.5 K3=1.5
Ks= K1*K2*K3
=1*1.5*1.5
=2.25
n= =9630*3/746*2.25 = 4.78 ~ 5
The distance between two sprockets is 3 m it is the targeted distance that we need , but to
accommodate sagging we reduce the this center distance by 2-5 mm (Source; R.S Khurmi and
J.K Gupta , Machine Design , 4thed.2004. )
5.8 Key Design
5.8.1 For Smaller Sprocket
From the hub inner diameter (motor shaft diameter) D1=20mm
Material properties of alloy steel
Shear stress (τ) = 42 Mpa
Crushing stress (crushing) =70 Mpa
From the table below for a shaft diameter of 20 mm we can get width= 8mm
And thickness = 7mm
Considering shearing of the key; we know that shearing strength (or torque transmitted)
of the key,
T=l*w* = 3360 (l) N.mm………………………………………………………....eq1
And torsional shearing strength (or torque transmitted) of the shaft,
T= = 65973.4
N.mm………………………………………………………………………...eq2
From equations (1) and (2), we have
l = 19.63mm
Now considering crushing of the key. We know that shearing strength (or torque
transmitted) of other key,
T =l*…………….………………………………………………….…….eq3
Equating both torques we can get length of eq3
Tshear=Tcrush
l= 26.9mm~27mm
Taking larger of the two values, we have length of key,
l = 27mm
5.8.2 For Larger sprocket

From the hub inner diameter (motor shaft diameter) D1=25mm
Material properties of alloy steel
Shear stress (τ) = 42Mpa
Crushing stress (crushing) =70Mpa
From the table below for a shaft diameter of 20 mm we can get width= 10mm
And thickness = 8mm
Considering shearing of the key; we know that shearing strength (or torque transmitted)
of they,
T=l*w* = 4200(l)N.mm……………………………....eq1
And torsional shearing strength (or torque transmitted) of the shaft,
T=
= 128854.3 N.mm……………………………..eq2
From equations (1) and (2), we have
l = 30.68mm
Now considering crushing of the key. We know that shearing strength (or torque
transmitted) of
the key,
T =l*………….…….eq3
Equating both torques we can get length of eq3
Tshear=Tcrush
l= 25.57mm
Taking larger of the two values, we have length of key,
l = 30.68mm
CHAPTER SIX
Result and Discussion
6.1 Result
Part Name Dimension

Pitch=9.53mm
Pin diam. =3.58mm

Roller Chain Width=4.7625mm
Thickness of link
plate=1.27mm
Chain width=7.30mm
Smaller sprocket Larger sprocket
Outside diameter 144mm 296mm
Diameter 136.75mm 286.18mm

Sprocket Dm 85mm 108mm
D1 20mm 25mm
A 35mm 43mm
Small sprocket Large sprocket

key Width 8mm 10mm
Thickness 7mm 8mm
Length 27mm 30.68mm`
6.2 Discussion
In the roller chain since pin diameter is equal with the bush diameter it should be force fitted
during assembly and also the roller and bush should be force fitted during assembly. All the
plates have equal dimensions (inner, outer and intermediate plates).
Since our conveyor roller diameter is more than sprocket hub diameter we need to extend
conveyor roller diameter by weld a rod having a diameter equal with sprocket inner hub
diameter. The motor is connected with the small sprocket since we need the speed reduction.
CHAPTER SEVEN
Assembly and Maintenance

7.1 Assembly
After the parts has been manufactured the next step is to assemble them in the following
sequence
Steps showing assembly of roller chain,
Steps showing assembly of sprocket

7.2 Maintenance
In this part it contains two methods of maintenance; preventive and curative approaches.
7.2.1 Preventive Method
In this method maintenance is given before the machine fractures and it is the best method that
we need .The best way is lubrication, Lubrication is essential to give a roller chain the best
chance of achieving its maximum potential service life. It acts by forming a slippery film over
the components, reducing direct metal-on-metal contact, hence minimizing friction and wear.
The barrier created by the lubricant also helps to protect the metal components against corrosion,
as well as creating a buffer against the impact of sprocket-roller engagement, to reduce noise and
provide smoother operation.
The Role of a Lubricant
The primary functions of a lubricant are to:
• Reduce friction
• Prevent wear
• Protect the equipment from corrosion
• Control temperature (dissipate heat)
• Control contamination (carry contaminants to a filter or sump)
• Transmit power (hydraulics)
Suggested Lubricants
Neither heavy oil nor grease is a suitable roller chain lubricant. Only high quality oil should be
used. Viscosity of the oil used will depend on the chain size, running speed and ambient
temperature. Recommended viscosity for temperature and size of chain can be found in the table
below. Regardless of the application and method of lubrication, the chain should be periodically
cleaned with a petroleum cleaner and inspected. Damage and/or reddish brown discoloration on
the pins and/or bushings indicate inadequate lubrication. For the majority of applications, a high-
quality, non-detergent, petroleum based or synthetic, multi grade SAE 20/50 oil will be suitable.
However, the temperature of the application needs to be considered, as low temperatures
increase the viscosity of the lubrication, whereas high temperatures may cause the lubricant to
dissipate, carbonize or deteriorate more quickly, leaving oil residues which may impact chain
performance.
Table 7.1 recommended lubricant viscosity for ambient temperatures
Ambient Lubricant SAE Rating BS4231

Temperature
-5 to 5 20 46 to 68
30 100
5 to 40
40 to 50 40 150 to 220
50 to 60 50 320
Lubricant for our purpose since our working temperature is not more than 30 centigrade and due
to its availability and easy to apply and cost and due to its non-poisonousness.
7.2.1.1 Type and methods of lubrication

Table 7.2 some lubrication types
Type Method Recommendation
Manual Lubrication
A B brush Periodically to keep chain joints from drying
B Dripping Lubrication Excess oil should be caught in a drip pan
C Oil Bath Lubrication Effective at low and medium speeds

To be submerged ¼ to ½ inch deep
• We select the first type of lubrication method since it best for the application of
this project due to its cost, availability, and ease to apply.
7.2.2 Curative Method

In this method maintenance is given after failure has happened using hammer and other tools this
may require force fit. In this way we can provide maintenance after failure.
CHAPTER EIGHT
Cost Analysis
Ite Part Material Manufacturing Labor Total Cost(ETB)
m Name Cost (ETB) Cost(ETB) Cost(ETB)
No.
Pin 16.092 18.27 16.82 51.82
1
Bush 14.02 15 13.85 42.87
2
Roller 12.02 18.20 12.50 42.72
3
Plate 22.75 12 15 49.75
4
Small 6.20 14 5 25.20
sprocket
5
Large 57.88 20 32.92 110.80
sprocket
6
Key for 1.25 0.75 0.55 2.55
small
7
sprocket
Key for 1.50 0.80 0.50 2.80
large
8
sprocket
328.51+25%(328.51)
Total added cost for all (25% cost is added for guarantee and some sudden =410.635 + motor
mishaps) cost (5000)
= 5410.635 ETB
CHAPTER NINE
Conclusion & Recommendation
Motor driven chain and sprocket uses motor to transfer power from one shaft to anther to roll the
roller used to convey the bottle box from one place to anther the motor uses around 1hp power to
transfers motion with the length of the chain 6 meter. The advantage of this motor driven chain
and sprocket is used to facilitate the speed of the conveying box, and also increase the life
expectancy of the bottle box and avoiding labor force.
Finally we recommend that proper lubrication should be employed periodically and properly and
the conveyor should not be loaded more than the design factor of safety.
REFERENCE
[1]R.Skhurmi and j.k Gupta, Text book of machine design, 14th edition, 2005.
[2]Peter R. N. Childs, Mechanical Design, 2nd edition, 2007.
[3]Robert L. Norton, Machine design of an integrated approach, 3rd edition, 2007.
[4]G.K. Vijayaraghavan S. Vishnupriyan, Design of Machine elements, 2nd edition, 2008.
[5]Robert L. Norton, ISM for machine design, 3rd edition, 2007.
[6]M.F Spotts, Design Of machine elements, 3rd edition, 2007.
[7]Grover, Basics of manufacturing, 2nd edition, 2005
[8]Gondar Pepsi cola plant industry manual volume one and two.
[9]Gondar Pepsi cola plant industry manual volume three and four
[10]PepsiCo international Quality manual and manufacturing processing V- 1 revised 2005.
[11]Quality manual PepsiCo international standards and specifications and operational practice
V-3 and V -4 revised in July 2005 .
[12]www.google.com/MOHA-soft-drink.s.c.
PART AND
ASSEMBLY
DRAWING
(APPENDIX II)
APPENDIX I
Table 5.1 standard series for roller chain
Table 5.2 standard series for sprocket
Number of teeth at the velocity ratio

Type of Chain
1 2 3 4 5 6
Roller 31 27 25 23 21 17
Silent 40 35 31 27 32 19
Table 5.3 standard series of roller chain

Table 5.5 maximum allowable speed for chains in rpm
Table 5.6 power rating of a roller chain (in kW)

Table 5.7 Proportions of standard parallel, tapered and gib head keys
Table 5.8 Standard table for sprocket design

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AMBO INSTITUTE OF TECHNOLOGY

AMBO UNIVERSITY INDUSTRIAL ENGINEERING

Project Title: Motor Driven Roller Conveyor

Hosting Company: Gonder MOHA soft drink s.c

By: Betelhem Melkie...............RIOT

Company Supervisor: Yakob Legesse

Name of Student Signature Date

Name of Mentor Signature Date

PART TWO PROJECT

1.2 The Emerging of Pepsi Cola Plant in Ethiopia

• History of Gondar Pepsi Cola Plant

Figure 1.1 Brands producing under Gondar MOHA soft drink

1.5 Main Customers of the Organization

Figure 1.2 chart showing organizational structure of the company

• Filler& crowner room

• Water treatment room

• Air compressor room (1&2)

2.1.1 Bottle Washer

Figure 2.1 bottle washer machine

2.1.1.1 Sections of bottle washer

• Cold water: -Also wash the bottle with cold water.

• Concentration of caustic soda

Fig 2.2 inner parts of washer

2.1.2 Bottle Filler and Crowner

Figure 3.1 filler machine

Table 2.1 faults on filler and possible causes

Faults on filler Possible causes

• Lifting cylinder pressure to low

Bottle fobbing over when with • Dirty bottle

• Temperature of the beverage is to high

2.1.3 Date Coder

2.1.4 Boiler Room

Figure 4.1 boiler machine

2.1.6 Water treatment

2.1.6.1 Selection of Water Treatment Technology

Figure 5.1 air compressor

2.1.7.1 Parts of Air Compressor Machine

2.1.7.2 Use of Air Compressor in Gondar MOHA Soft Drink S .C

• Cleaning of the bottle

• Push the piston of the bottle on filling beverage

• Dry the moisture on the bottle by using video jet

• Cooling the beverage

2.1.8 Ammonia Compressor

2.2 The Work Task that Executing

• Identify the best maintenance performance parameters.

• Evaluate the current MOHA’s maintenance performance.

• Compere the current states with the benchmark.

• Identify it’s reason

2.4 The challenges that have been faced

• Anyone in the organization won’t to accept there negative side

2.5 The measure that have been taken

Internship program is a method of letting the students to assume themselves as potentially

• Improving practical skill

• Upgrading theoretical knowledge

• Improving inter-personal communication skill

• Improving leadership skill

• Understanding about work ethics related issue

• Making simple installation like electrical light installation

• Identifying causes of motor failure