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DESIGN OF BOTTLE CRUSHER MACHINE
RAYA UNIVERSITY
COLLEGE OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
PROJECT TITLE: DESIGN OF BOTTLE CRUSHER MACHINE
HOSTING COMPANY: RAYA BEER S.C
PREPARED BY:
NO NAME ID STREAM
1 ABDUSHUKUR WABELLA 04791/12 THERMAL
2 GEBRE ARAYA 05134/12 THERMAL
3 HAGOS GODIFAY 05193/12 THERMAL
4 ZEMICHEAL TADIWOS 05733/12 THERMAL
COMPANY SUPERVISOR: MS. YALEM
ADVISER: INS. MULU TESFA
MAY 2024
MAICHEW, ETHIOPIA
RAYA UNIVERSITY
DECLARATION
This internship program offers us a valuable opportunity to gain experience in both academic and
social domains. Over the course of the last 79 days, we have been actively engaged in practical
training at Raya Brewery Share Company, the hosting company. We hereby affirm that the
internship report, titled "Internship Report," along with the project work, is solely our own work,
derived from our experience at the hosting company.
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ACKNOWLEDGEMENTS
Firstly, we would like to express our gratitude to the Almighty GOD for His assistance
throughout the entire process. Secondly, we extend our thanks to Raya brewery Share Company,
our host organization, for granting us the opportunity to participate in this internship program.
Additionally, we would like to acknowledge and appreciate the invaluable guidance and support
provided by Ms. Mulu who is our academic advisor and lecturer. Without her, this internship
report would not have been possible. Furthermore, we are grateful to everyone in the technical
and maintenance department, including our field advisor, for sharing the essential insights into
the construction of each section. Lastly, we would like to extend our special thanks to Eng.
Yalem for his wise counsel and helpful supervision.
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Executive summery
The first part of this report tries to present the company background, the main product of the
company, the overall work flow, overall benefit from internship program we gain and work flow
of the section we work. The overall work flow of the company focus on the main structure of the
company. It consists pure water treatment, raw material, malt handling, wort production
processing, the processing of filtration and fermentation, packaging and waste water treatment.
In term of getting benefit, improving leadership skills, understanding about work and ethics,
practical skill and upgrading theoretical knowledge skills are shown clearly.
Each section has machines, like de-stoning, drum sieve, hammer milling, pre-mashing, mash
kettle, mash filter, wort pan, whirlpool, boiler, bottle washer, filler, crater and other machine.
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Table of Contents
DECLARATION..........................................................................................................................................I
ACKNOWLEDGEMENTS.........................................................................................................................II
Executive summery....................................................................................................................................III
LIST OF FIGURE.....................................................................................................................................VII
LIST OF TABLE........................................................................................................................................IX
ABBREVIATION.......................................................................................................................................X
CHAPTER ONE..............................................................................................................................................1
BACKGROUND OF HOSTING COMPANY............................................................................................1
1.1 INTRODUCTION.............................................................................................................................1
1.2 Objective of the company..................................................................................................................2
1.3 Vision of the company.......................................................................................................................2
1.4 Values................................................................................................................................................2
1.5 Main product and service of Raya brewery S.C.................................................................................3
The primary offerings of Raya brewery include-......................................................................................3
1.6 Main customers (end users of) Raya brewery S.C.............................................................................3
1.7 Organization structure of Raya brewery S.C.....................................................................................3
CHAPTER TWO.........................................................................................................................................5
Internship Experience Overview.................................................................................................................5
2. 1 what is the process for gaining entry into the company?..................................................................5
2.2 In which section of company you have been working?......................................................................5
2.3 How does the work flow in section look like?...................................................................................5
2.3.1 Brew house.................................................................................................................................6
2.3.2 Fermentation and Filtration.......................................................................................................10
2.3.3 Utility........................................................................................................................................11
2.3.4 Packaging Room.......................................................................................................................18
2.4 Which work piece or work task you have been executing?..............................................................31
2.5 Procedures and methods while performing task...............................................................................32
2.6 How good you have been in performing your work task?................................................................32
2.7 What challenge you have been facing while performing your tasks?...............................................32
2.8 What measures you have taken in order to overcome these challenges?..........................................33
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CHAPTER -THREE..................................................................................................................................33
OVERALL BENEFIT GAINED FROM THE INTERNSHIP..................................................................33
3.1 In terms of improving practical skills..............................................................................................33
3.2 In terms of upgrading Theoretical Knowledge.................................................................................34
3.4 In terms of improving team playing skills.......................................................................................35
3.5 In terms of improving leadership skills............................................................................................35
3.6 In terms of understanding about work ethics...................................................................................36
3.7 In terms of entrepreneurship skills...................................................................................................37
CHAPTER FOUR.....................................................................................................................................38
CONCLUSION AND RECOMMENDATION.........................................................................................38
4.1 Conclusion.......................................................................................................................................38
4.2 Recommendations...........................................................................................................................38
CHAPTER ONE........................................................................................................................................40
DESIGN OF BOTTLE CRUSHER MACHINE........................................................................................40
INTRODUCTION.....................................................................................................................................40
1.1 General idea of bottle crusher machine............................................................................................40
1.2 Problem statement...................................................................................................................40
1.3 Objective...................................................................................................................................41
1.3.1 General objective..............................................................................................................41
1.3.2 Specific objectives.............................................................................................................41
1.4 Scope and limitation the project..............................................................................................41
1.4.1 Scope of the project..........................................................................................................41
1.4.2 Limitation of the project...................................................................................................41
1.5 Significance of the project........................................................................................................41
1.5.1 Benefits of the project......................................................................................................41
1.5.2 Beneficiary of the project..................................................................................................41
CHAPTER TWO..........................................................................................................................................42
LITERATURE REVIEW.................................................................................................................................42
CHAPTER TRHEE........................................................................................................................................44
METHODS AND DETAIL DESIGN............................................................................................................44
3.1 Methodology...................................................................................................................................44
3.2 material selection.....................................................................................................................45
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3.3 Components of design..............................................................................................................45

3.3.1 Consideration for designing the machine..................................................................................45
3.3.2 Design parameter.....................................................................................................................45
3.4 Design of hammer.....................................................................................................................46
3.5 Design of connecting rod..........................................................................................................47
3.6 Design of crank..........................................................................................................................48
3.7 Pin Design..................................................................................................................................49
3.8 Key design.................................................................................................................................51
3.9 Design of crushing chamber............................................................................................................53
3.9 Cost Analysis.............................................................................................................................55
3.11 Working principle......................................................................................................................55
CHAPTER FOUR.........................................................................................................................................57
RESULT AND DISCUSSIONS.......................................................................................................................57
4.1 Result..............................................................................................................................................57
4.2 Discussion........................................................................................................................................57
CHAPTER FIVE...........................................................................................................................................58
CONCLUSION AND RECOMMENDATION..................................................................................................58
5.1. Conclusion......................................................................................................................................58
5.2 Recommendation............................................................................................................................58
Reference..................................................................................................................................................59
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LIST OF FIGURE
Figure 1 Drum sieve:................................................................................................................................................. 7
Figure 2 Milling section............................................................................................................................................ 7
Figure 3 mush-in tank............................................................................................................................................... 8
Figure 4 Mash filter................................................................................................................................................... 9
Figure 5 Boosters..................................................................................................................................................... 14
Figure 6 Gas washer............................................................................................................................................... 14
Figure 7 ACF/Drier................................................................................................................................................. 15
Figure 8 over view of De-palletizer machine...................................................................................................... 20
Figure 9 over view of Unpacker............................................................................................................................ 21
Figure 10 over view of Crate washer................................................................................................................... 22
Figure 11 over view of Bottle washer................................................................................................................... 25
Figure 12 over view of EBI.................................................................................................................................... 25
Figure 13 over view of filler................................................................................................................................... 26
Figure 14 Bottle decorations (labeling)............................................................................................................... 28
Figure 15 Packer...................................................................................................................................................... 28
Figure 16 Palletizer................................................................................................................................................. 29
Figure 17 Empty turning machine....................................................................................................................... 30
Figure 18 Rating system......................................................................................................................................... 31
Figure 19 Full turning machines......................................................................................................................... 31
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Figure 20 vertical crushing machine................................................................................................................... 42
Figure 21 methodology........................................................................................................................................... 44
Figure 22 : hammer................................................................................................................................................ 46
Figure 23 connecting rod....................................................................................................................................... 47
Figure 24 crank........................................................................................................................................................ 48
Figure 25 : pin......................................................................................................................................................... 49
Figure 26 key............................................................................................................................................................ 51
Figure 27 crushing chamber................................................................................................................................. 53
Figure 28 Assembly drawing of bottle crusher machine.................................................................................. 56
Figure 29 work flow of bottle crusher machine................................................................................................. 56
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LIST OF TABLE
Table 1 Cost analysis of the design....................................................................................................................... 56
Table 2 Result and discussions......................................................................................................................... 58
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ABBREVIATION
BBT bright beer tank
btls bottles
CCT conical cylinder tank
EBI empty bottle inspection
FBI full bottle inspection
HPI high pressure injection
Hr hour
SC Share Company
F force
l length
d diameter
m mass
n revolution
r radius
P power
t thickness
w width
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CHAPTER ONE
BACKGROUND OF HOSTING COMPANY
1.1 INTRODUCTION
Raya Brewery S.C is established in 2013 G.C and (Commercial production in Feb. 2015 G.C)
being the pre-eminent Brewery in the region producing standard strong beer. The Brewery is
equipped with the state art technology imported from Germany: Kroners, Czech Republic: DIO,
Belgium: Maura, Netherland: Hoffman, America: Cole palmer. The company has more than 500
employees, many with decades of experience in food and beverage industry. The Brewery is
located in the historical town Maichew 660 Km from Addis Ababa to the North. Raya Brewery
has an initial annual total capacity of 600,000 hectoliters current production output stand at
300,000 hectoliters (90 million bottles).Despite its young age the bottle line fill 36.000*33cl
bottles every hour (or more than quarter million bottles in an 8hr shift .the kegging line will also
fill 120*30 litter kegs per hour (or more than 25.000 litters in a single shift. The plant has been
allocated 18.5 hectares of land.
The site is located along Maichew - Korem asphalt road, on the western side at about 10 meters
off the asphalt road and 1.9km from Maichew town. It is easily accessible with vehicle both in
wet and dry seasons. The project site is generally a gently sloping terrain found just at the foot
slope of Bokhara Mountain. The site was selected mainly due to the availability of soft spring
water which has been tested and found to exceed the minimum brewing water requirements in all
respects. Besides, the yield of the spring being 55.0175 liters per second is sufficient enough to
meet the requirement of four breweries of this size. Water source of Raya Brewery S.C is natural
spring water called “Mai-muk” found at about 7KMs distance from the factory site. It is also
believed that its establishment at Maichew is strategically advantageous, since there is no other
brewery in Tigray region. The site of the plant is accessible through all-weather roads. A plot of
land measuring or an area 150,000 m2 has been given by the regional administration free of
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charge. The basic infrastructural support required for a brewery namely water, land and electric
power are reported to be available sufficiently.
The company was officially launched on May 08, 2010 at Maichew town. Presently it has more
than 400 shareholders and its head office is setup in Bole Sub City, Keble 03/05, Robel Plaza-
building. The capacity of the Raya brewery to be established shall be based on the following
production program. Total output is 300,000hl sales beer per annum. Out of this: 85% is
produced as bottled beer, 15% is produced as draft beer and total production loss is taken to be
10%.
1.2 Objective of the company

Raya brewery S.C has set forth its primary goals as follows:
 To invigorate the nation by manufacturing top-notch beer.

 To enhance the yearly beer production in Ethiopia.
 To generate value and employment prospects for individuals.
1.3 Vision of the company

 In order to contribute to the socio-economic progress of the Tigray region specifically,
and to the overall development of the country as a whole, our aim is to provide
support.
 to prioritize the preservation of the eco-environment in a sustainable and friendly
manner, while also adding value
 to enhance the socio-economic well-being of the Tigray region By generating profits,
1.4 Values
1. Upholding integrity, accountability, and transparency.
2. Striving for complete customer satisfaction and exceeding their expectations.
3. Adding value consistently, handling properties with care, and ensuring efficient resource
utilization.
4. Striving to be the best in class and setting the standard for quality.
5. Focusing on organizational and individual growth.
6. Ensuring safe working conditions for all employees.

7. Establishing sustainable, close, and enduring relationships with customers and partners.
8. Offering essential support to our employees to the fullest extent possible.
1.5 Main product and service of Raya brewery S.C
The primary offerings of Raya brewery include-
 Raya beer
 St. George beer
 Castel beer
 Drought beer
1.6 Main customers (end users of) Raya brewery S.C

Raya Brewery Share Company produces and delivers top-notch beer to ensure utmost customer
contentment. There are no restrictions or limitations on who can be a customer of the company.
The products are distributed throughout the country in three different regions. These regions
include:
Region 1: covers Desie, Addis Ababa and Mekelle.
Region 2: this covers the whole Tigray region.
Region 3: east and south parts of Ethiopia
1.7 Organization structure of Raya brewery S.C

The existing organizational setup at raya brewery S.C consists of four departments under the
supervision of the CEO: Production and Technical, Commercial, Procurement and Sourcing,
Finance and Administration, with Maichew Office serving as the company's headquarters.
Various theoretical frameworks of organizational design and the organization's feasibility study
have been taken into account.


CHAPTER TWO
Internship Experience Overview.
2. 1 what is the process for gaining entry into the company?

Upon entering Raya Brewery S.C with a referral from our campus, we received a warm welcome
and acceptance from the company. The joy of being accepted motivated us to begin our work
diligently. We chose this company based on its reputation, proximity, and the positive feedback
we received regarding its modern and efficient machinery.
2.2 In which section of company you have been working?

Throughout our 79-day internship program, we had the opportunity to gain hands-on experience
in various aspects of the company's workflow. Specifically, we were assigned to the packaging
section where we collaborated closely with the main operators to ensure seamless integration.
2.3 How does the work flow in section look like?

Beer is a manufactured commodity. It is one of the oldest and most intricate beverages to
produce. In order to craft the end result, brewers employ cutting-edge technology and costly
machinery. However, the fundamental elements of beer remain unchanged. These include Malt,
Water, Yeast, Hop, and additional additives.
1. Malt serves as the primary raw material in beer production, with barley being the raw material
for malt. Barley's high starch content and the husk's ability to adhere to the grain post-threshing
and processing are key factors in its utilization.
2. Water is a crucial component in brewing beer, constituting approximately 90% of beer

composition. The quality of water significantly impacts the overall quality of beer.
3. Hops, an essential ingredient in beer, contribute to aroma, bitterness (due to alpha-acids), and
foam head formation.
4. Yeasts, as microorganisms, play a vital role in the fermentation process by converting sugar
into alcohol and carbon dioxide.

Raya beer has four main sections those are:-
Brew house
Fermentation and filtration
Utility section and
Packaging.
2.3.1 Brew house

The most important processes in beer production carried out in brew house operation are Malt
reception and handling, milling section, Pre-mashing, mashing, mash filter, wort collector and
whirl pool.
1. Malt reception and handling
Malts from malt store are put in to the malt reception by the labor workers or chain conveyer,
and transported to the silos through screw conveyers and bucket elevators. Raya brewery S.C.
has six silos. Four of which, are with ability of storing 300 tons. The remaining two silos can
store 30 tons each. After storing the malt in the silos, the malt needs to be cleaned before it enters
the next step which is milling. The malt should be free from stones, oversized particles and
metals.

Equipment used for cleaning of malt is:
Aspiration: used to suck off dusty air.
Drum sieve: remove materials which are over size such as grass, malt and others based on sieve
size. This separates 5 tones per hour’s malts.
Figure 1 Drum sieve:
De-stoner: removes high density materials and stones by settling whereas malt pick up on space
and passed to sieves.
Magnets: separates materials which have magnetic behavioral starting next to aspiration up to
de-stoner last.
2. Milling section
This section is used to crush malt in to smaller size (to extractable section) using hammer mill.
Its capacity to crush 8 tons of malt per hours. Purpose of milling to get efficient extraction, fast
mixing & mashing, total conversion of starch, rapid &complete separation of wort.
Figure 2 Milling section
3. Pre-mashing

It is used to mix the grist with hot water & cold water. The objective of pre-masher are pre
Figure 3 mush-in tank
Venting protein coagulation and to activate protease enzyme for protein degradation.
4. Mashing in (mash kettle)
Is the mashing process that used to starch hydrolysis and protein degrade to simple sugars and
amino acids by the help of increasing T° using steam and adding additives with time intervals.
5. Mash filter
Mash filter is the separation of wort from spent grain. This mash filter separates wort through
sparking and compression. Sparking is washing the extraction of wort with hot water while
compression is separating wort by pressing the mash under pressurized air. Finally using positive
displacement pump discharge the spent grain to its temporary storage called silo.

Figure 4 Mash filter
6. Wort collector
Wort collector is used to store the wort and its total capacity to store 31 m3.Wort collectors is
temporary storage of wort and no chemicals are added. The presence of wort collector saves time
by allowing the next process to take place until the wort is fully collected.
7. Wort pan (wort Boiler)
Wort pan is conical cylindrical tank used to mix the wort with hop to change color of the wort
and to increase its alcoholic content by the rotating agitator at a temperature about 96 0C.
Boiling of wort is carried out in wort pan via steam for different purpose. Mainly the aim of wort
boiling is to stabilize the wort compassions, Removal of undesirable volatile compounds, to
remove water in the form of vapor and extract the desirable material from hops which gives to
beer its characteristics aroma and flavor. The wort entered with a temperature of 78°C is
increased to 91°C by steam addition and pressurizing.
Objective of wort boiling are:-
Removal of undesirable volatile compounds
Concentration of wort
Sterilization of the wort to prevent wort spoilage
Stopping enigmatic action

Evaporation of some water
Isomerization of bitter substances
Precipitation of protein polyphenol complexes
8. Whirl pool
Whirl pool is used to separate trub from the hopped wort and then the hopped wort is transferred
in to fermentation tank but trub is stored in trub tank.
2.3.2 Fermentation and Filtration
1. Fermentation
Fermentation can be preceded by respiration is performed by wort sedimentation in kettles,

flotation, centrifugation or filtration. Aeration is used to ensure that the yeast is supplied with an
adequate amount of oxygen in order to support cell multiplication. Later on, the metabolism of
the yeast changes from respiration to alcoholic fermentation; then processes the carbohydrate
molecules contained in the wort to produce ethanol and carbon dioxide. Other ingredients of the
wort are also converted. The resulting fermentation products significantly influence the character
of the beer produced. The duration and course of the fermentation are determined by the yeast
strain and by controlling the process of parameters are pressure and temperature. Fermentation
takes place in cylindroid-conical tanks (CCTs). CCTs are installed outdoors. The CO2 produced
during the fermentation process can be collected by a CO2 recovery system. Fermentation is the
process of converting sugar into ethanol and carbon dioxide using microorganism which is
known as yeast.
2. Filtration
This is the final process to be considered in beer treatment prior to packaging and the process
involves removal of any remaining yeast cells and the removal of precipitated protein and
polyphenol haze materials. This is the clarification of beer to a standard that is acceptable for
sale. It should be done after the Beer has been laagered. The process involves the removal of any
remaining yeast cell and Removal of precipitated protein and polyphone haze material. The beer

must be rendered stable So that visible changes don’t occur on its commercial or shelf life. The
filtered beer is pumped into the bright beer tank and stored for 2 – 3 days. Bright beer tank are
buffer vessel between the filter and they are mostly constructed as vertical stainless steel tanks
without internal fitting. Before filtered beer is stored in bright beer tank carbonation (CO2) will
dose on line for the purpose of beer stabilization & extend the shelf life of the beer.
2.3.3 Utility
In Raya brewery s.c utility is the widest section. It is mainly concerned with supplying the
demands to its customers. The customers of utility are brew house, fermentation, filtration, water
treatment, waste water treatment, packaging etc. Utility section provides steam, treated water, ice
water, cold degassed water and pure CO2 for its customers. There are five subsections under
utility. These are water treatment, cooling plant, steam generation, waste water treatment, and
carbon dioxide recovery.
1. Cooling plant
Cooling plant is one of the subsections of utility which provides ice water to cool the wort where
came from brew house, cold degassed water used for dilution of beer and glycol used for cooling
CCTS, wort used for propagation etc. Under this cooling plant, there are two main cooling
processes.
First, ammonia in liquid form at a temperature of 40°C under 10bar pressure is stored in a
permanent closed tank. But this must be transported in to storage tank 02 and storage tank 01.
Glycol is brought from its source at -2°C but glycol for cooling must be -4°C. Liquid ammonia
converts to temperature and pressure to -7°C and to 2bar respectively by expansion valves. Then
glycol is cooled by transported to storage 02 is used to cool glycol but before it enters to that
tank, it is better to reduce the tem ammonia in plate heat exchanger to -4°C temperature and
returns to its storage whereas ammonia is passed to compressors as it is. Then after reaches its
temperature to 120°C. This also passed to condenser in order to cool down to temperature of
40°C by fan and cold water.
Secondly: cooling of water by glycol: water used for cooling purpose and the degassed water
used for dilution of beer is cooled by glycol after being cooled by ammonia. Ammonia that was

storing at T° of 40°C and under pressure of 10bar is transferred to storage 01 to reduce its
temperature of 3°C and pressure of 3bar by expansion valve. Brew water and degassed water are
brought at a temperature of 27°C. Then cooled by ammonia in plate heat exchanger to 5°C
temperature but ammonia changed from liquid to gas return to storage 01 and after sent to
compressors that reached to temperature of 120°C then passed to condenser to cool down to
temperature of 40°C whereas brew water and degassed water are cooled by glycol at a
temperature of -4°C to 1.5°C and 2°C respectively in plate heat exchanger.
2. Carbon dioxide Recovery
Co2 is very important in beer making companies in order to prevent direct contact between air
and beer as well as draft by creating pressure. But raw co2 has odor test and impurities so co2
recovery plant is necessary.
 CO2Rawgas contains a lot of odors, tastes and in purities.
 The gas needs to be cleaned and purified by a CO2 system according the latest technology
 Afterwards it can be used in the rest of the brewery or soft drink industry
Steps in the process
 Cleaning of possible foam remains
 Washing to take out solid parts and alcohols
 Compression in 2 stages
 Taste and odors removal
 Drying
 Cooling down to liquefaction of the CO2
 Storage in liquid form
 Evaporation
 Reduction of pressure and temperature for factory usage
Why this special treatment
 Cleaning of the gas (foam separator / gas washer)
o Dissolving foam, alcohol and other dissolvable components
 Deodorizing (ACF)
o Absorbs the smell containing compounds
 Liquefying (Condenser)

o Turn gas into liquid (most economic point at 17,5 Bar @ -24 °C) and removing
non-condensable gasses
o Drying (Driers)
o To remove the moisture from the gas before it is liquefied (else the pipes in the
condenser get blocked
Why Liquefaction of the CO2
 The total volume of CO2 storage decreases
o In case CO2 is stored in gas phase the storage volume would be 500 x bigger!
 The purity of the CO2 will improve
o Only CO2 is turned into liquid at 17,5 Bar @ -24°C
o Air and other non-condensable gases are still present
o These gases can easily be blown off from the CO2 condenser
o With stripping technology the separation is even better
Parts of CO2 recovery process
 Foam Separator
 CO2 gas balloon
 Booster (option)
 CO2 gas washer (High Pressure)
 CO2 Compressor
 ACF / Driers
 CO2Reboiler
 CO2 condenser + Cooling system
 CO2 Pump
 CO2 Tank
 CO2 Evaporator
 CO2 Reducing station
A. foam trap
Main Function
 To avoid that foam that can come along with CO 2 from the CCT’s enters the CO2
recovery plant

B. Boosters
Main Function
 To compress the CO2 gas from a lower pressure to a higher pressure
 Provides positive pressure necessary to overcome distances line losses and Gas washer
resistance.
1ste
 Increases the suction pressure on the stage of the CO2 compressor which increases the
capacity.
Figure 5 Boosters
C. Gas balloon
Main Function
 Equalize the difference between the CO2 supply from fermentation and the capacity of
the CO2 compressor.
 To create a gas buffer to avoid excessive starts and stopping of the CO2 compressor.
 Balloon size always depending on plant / fermentation capacity.
D. Gas washer
 Remove water dissolvable impurities from the incoming CO2 gas

Figure 6 Gas washer
E. CO2 Compressor
 A Compressor is a mechanical device that increases the pressure of a gas and can
transport the gas through a pipe by reducing its volume. Co2 compressor is a specific
type of gas compressor. Pump pressurizes and transport liquid. Reciprocating piston
compressor is appositive displacement type of compressor. It uses piston driven by
crankshaft.
Main Function
 To compress the fermentation gas (P approx. 1 bar abs) from the gas washer to approx.
17, 5 Bar before it enters the ACF/Driers.
 The compression is done in 2 stages
 After each compression stage the warm CO 2 needs to be cooled down by coolers (Inter-
After cooler) Different cooling media can be used.
 Additional cooling of the cylinder head is required.
F. ACF/Drier
Main Function
 Remove the impurities from the CO 2 gas that are not already been removed in the gas
washer by means of Active Carbon
Figure 7 ACF/Drier
G. CO2 Storage
Main function
 To store the produced liquid CO2 of the recovery system
H. CO2Evaporater
Main Function

 To evaporate liquid CO2 form the Tank into gas to be used in the brewery (brewery
consumption
I. CO2 reducing valve
Main function Back Pressure station
 To hold minimum pressure in the CO2 storage tank
3. Boiler
In this plant the evaporation of water in to steam is carried out due to the requirement of steam
for different purpose. For example steam used for sterilization of yeast in yeast propagation step,
for preparing degassed water in filtration, in water treatment for killing of micro-organisms,
pasteurization for beer. In boiler there are steps to boil water.
Softener unit: water coming from water treatment is 60% softened. It is using two softener units
which have volume of (380-400) m³ and work one after the other to soften the water to 100%.
Condenser: this tank has many functions but mainly used as storage of condensed steam
returned.
Economizer tank: because of the steam returned boil water that is at normal temperature to
above 85°C, it saves energy consumed by heating water.
Boiler: there are two boiler units which exchanged weekly to perform their function. These
boilers are standardized to load up to 240°C and 15bar pressure.
. It has different components of material to boil the water:-

 Water softener tank
 Economizer tank

 Boiler tank
 Drainage tank
 Oil tank
 Valves; -boll valve
 -needle valve
 -safety valve
 Centrifugal pup
 Gear pump
 Servo meter
 Pressure gage
4. Air compression plant
Air compressor is a device that converts power (usually from an electric motor, a diesel engine
or a gasoline engine) into kinetic energy by compressing and pressurizing of air. The main
objective of this plant is to change low pressure atmospheric air into high pressurized air by the
process of compression. In case of this company the type of compressor used is the screw type
compressor. The quality parameters that we check for air compression plant is the moisture
content of the atmospheric air..
5. Water Treatment Plant (WTP)
Water is the major raw material for beer processing. It must be free from impurities and
microorganisms. Water in Raya brewery is taken from a place called May Muk which natural
ground water and treated to the desired quality. The main aim of WTP is to treat untreated
water to get clear water. In order to be suitable for use in brewing, water must be
microbiologically pure, Clear and colorless (turbidity and color can be caused by suspended
solids), Tasteless and odorless (chlorinated water can affect beer flavor), pH neutral (pH 7, or
slightly acidic), Free from heavy metal ions.

2.3.4 Packaging Room

In packaging section the work flow looks like as follows
BBT Keg
Filer & Visual Bottle

crown inspection washer
machine EBI
Unpacked
FBI Crate washer
Pasteuriz
ation
Labeler Packer Palletizer De-palletizer
Empty bottle
Packed beer for from customer
customer customer
Packaging is the final process in beer production factory.
There are two main lines in packaging process:
1. Bottling line
2. Kegging line
Bottling line
This section is mainly concerned about packing bottles containing beer and delivering this
product to customers. Averagically it packed about 36000 bottles per hour. It ensures the product
that can be supply to customers being free from micro-organisms. Bottling line is described as
follows step: -
1. De-palletizer
It receives customer bottles from the forklift. Each pallet has a capacity of holding 48 crates. The
transfer carriage picks the first layer (8 crates) with the help of gripper at a time and put it to the
discharge table by moving horizontally for further transfer moment can be performed. The first
row of crate of the layer is conveyed to the stop plate. The stop plate moves down and the
separating fingers move the row of the crates on the pack discharge. Then the dischar.ge
conveyer starts and takes the crates to the un-packer.
Full pallets in feed as: - fork lift put pallet on in feed roller the roller starts role and pushes the
pallet in to proper position for De-palletizer.
Empty pallet discharge ፦ when the in feed pallets completely discharge by the de palletizer the
roller discharge the empty pallet to palletizer.

Figure 8 over view of De-palletizer machine
This is the process of separating pallet from crate containing unclean bottles. De palletizer is a
robotic system which is used to separate pallet and empty bottles with their crates. It has some
components such as base, belt conveyor, controller sensor, actuator and effecters (gripper).
 Base: - the base of de palletizer is fixed to ground for the purpose of every activities stand
with balanced.
 Belt: - is a mechanical part of de palletizer which is used degree of freedom for the
purpose of moment with in the direction of up and down and also sliding mechanism
motion.
 Controller: - it is a device with hard and soft ware support for giving commands to the
drive.
 Sensor: - it is used to give feedback information for subsequent action of arm

(mechanical gripper) as well us to interact with the environment which the de palletizer is
working.
 Actuator: - it is a device which is used to causing the manipulated arm to move.
 Gripper: - is a part of de palletizer which is used to holding .This mechanism is done by

the pneumatic presser system.

2. Unpacker
The crates those are discharged from de palletizer are conveyed to the unpacker. Unpacker
machine is fully automatic machine. And it helps to discharge the empty bottles from the crate
by pneumatic (air) system. After that the empty bottles convey to the bottle washer and the
empty crate convey to the crate washer. It has two motion mechanisms. One is oscillating
mechanism and the other is up and down motion. They up and down motion takes place by the
belt driver associated with in host motor but the oscillating mechanism is oriented by gear box to
hinged pillar push rod, crank, cross transport drive and function tube to perform their functions.
Figure 9 over view of Unpacker
3. Crate washer
Crate washer machine is a machine which is used to wash the crate that are dirty which comes
from the customer. First the dirty create enter in to pre wash stage after completing this stage it
washes with steam and water and rinse with water and convey to the packer machine.

Figure 10 over view of Crate washer
4. Bottle washer
Bottle washer machine is the most important machine which is used to disinfect and wash dirty
bottles. Bottle washer machine can wash 40,000 bottles per hour and this machine has washing
cycle and consists of four distinct phases
 Pre-wash
The pre-soaking stage takes place in one or two stages; after leaving the presoaking area, the
bottles are overturned and emptied; the dripping water fall onto a collection pan and is filtered
before returning into the presoaking area itself. The presoaking area is maintained at a constant
temperature and continuously renewed by hot water coming partly from the first rinsing area and
partly from the detergent sprayer’s tank, without any additional energy consumption. An internal
sprayer and an external shower perform a double step heat recovery process to increase bottles
and carriers temperature before immersion in the main detergent tank.
 Caustic spraying
The washing stage takes place in the main detergent bath where also three label extraction
(caustic1, caustic2, caustic3) stations are located those caustic chemicals have basic property.
The time of immersion (water jet), caustic (chemical NaOH) and the temperature can be set
according to the specific characteristics of the bottles being cleaned. After the soaking in the hot
caustic solution the bottles are turned upside down until they are completely emptied. A final
washing stage is then performed by a set of sprayers directing a jet of detergent solution inside
the bottle.

 Rinsing(post jet)
This process is performed after the complete process of caustic. At rinsing stage the bottle is
washed internally and externally to clean the caustic (since the chemical is base). Therefore at
this stage acidic properties chemical are used since basic properties are deactivate by acidic
property chemical.
 Hot water
In this stage the bottle is washed by the hot water to clean and deactivate completely the
chemical properties in the exterior and interior part of bottle in the earlier processes.
 Cold water
After the hot water washing process is performed since the bottle is very hot so to decrease the
temperature we use fresh water that is came from water treatment room. And although before
discharging we use fan to dry the water and caustic foam.
Types of pumps installed in the bottle washer with their function are: -
 Recirculation pump: - is used to control the viscosity of caustic.
 Jetting pump: - is used for the cleaning interior and exterior parts of the bottles.
 Dosing pump: - is used to control the entrances
 Extraction of hydrogen (H2): -container (bottle) with in thin Aluminum foil feeds in to
the machine in the form of label stick to the bottle and the aluminum foil decomposes in
the caustic solution as result hydrogen is released in to the space of bottle washer.
Therefore hydrogen reacts with oxygen to form an oxy hydrogen explosive mixture
which can be easily ignited. Because of the ignition it can destroy the containers and
other parts of machines. Then to protect this explosive we must extract before hydrogen
react with oxygen from the bottle washer by using extractor pump (from production area)
The main mechanical components of bottle washer are: -
 In feed :- is the process of trans partition of bottle in to the bottle washer and the main
components of in feed bottle are ,bump ,s. shapes ,agitator, plastic profile, bottle pusher
shaft with bearing, arm (push rod), piston and gears (bevel and spur) with their
Mechanisms. The in feed activity is performed by the mechanism of gear, shaft, piston,

pusher rod, bearings system. The main purpose of in feed is to reduce the over loads and
the power transmission is controlled by bevel gear system.
 Agitator:-is a component of in feed system and it works only with back pressure and
easily replaced. Agitator itself moved by eccentric shaft.
 Bottle slide:-is used for smooth transmission bottles on the discharge easily to access and
it has a plastic profile with exchangeable.
 Chain conveyor: -it is very important for the purpose of transmission of bottles at the
whole bottling process.
 Spray nozzles: -are used to spraying water and caustic for the purpose of cleaning internal
and external
 Gears:-it used for power transmission and for easily moment mechanism. The main
preferable gears in the bottle washer are warm and bevel gears.
 Bevel gear:-is used for power transmission in the place of in feed and discharge position
only. Worm gear:-is founds at every gear boxes for the purpose of the rotational motion
change in to linear motion from each gear box placed position.
 Rip pan:-is a very important for removable droplets and mixture from the bottle.
 Discharge:-used for good treatment of the empty bottles. It works by synchronous drive
Smooth and silent setting down of the bottles a good transfer on to the discharge
conveyor. In bottle washer used to only one motor for all activities by synchronies
operation system within the universal joint arrangement force and torque transmission as
required process. After the bottles remove, the crates will travel to the crate washer which
washes the crates through the conveyor with water by consecutive levels

Figure 11 over view of Bottle washer
5. Visual bottle inspection
It is done manually with human eye using light. If the bottles are broken, unclean, labeler
contain, they are rejected.
6. Empty bottle inspection (EBI)
In Raya brewery s.c there are three different sensors used for empty bottle inspection. The first
sensor removes bottles other than St. George, Raya, and castle bottles, the second sensor remove
bottles that are too high and the last sensor bottles too low in height. Using camera checked in
order not to present like suspended caustic, oil, residual liquid etc. in bottles to reject.
Figure 12 over view of EBI

7. Filler
After EBI bottles are sent to filler and the air inside bottles was sucked out by vacuum chamber,
then CO2 is charged to bottles to remove O2 from bottles after slightly difference beer is filled
by taking from BBT. Filling beer is operated at high pressure even sterile with hot water
continuously the bottles in order to remove air from head space with foam and crowned with
carbon dioxide. Filler has the following steps:-
First evacuation: used to remove O2 from bottles.
Carbon dioxide flashing: rinsing carbon dioxide in bottles
Second evacuation: allows the displacement of CO2.
Pressurization: helps to add CO2 in bottles.
Filling: beer displaces CO2 from bottles.
Sniffing: used to control pressure releasing.
Figure 13 over view of filler
8. Closing the bottles with crown
After filling the bottles are closed faster in order to prevent the beer from contaminants and
entering gases. To prevent the oxygen intake during the time of closing the bottle with a cork a
continuous fine stream of water is sprayed in to the still open bottles so that some of the content
immediately foam out and prevent entry of oxygen. The bottles are closed with a crown cork

which has Thickness - 0.235mm thick stainless steel plate, Number of teethes – 21 and Outer
diameter -32mm.
9. High pressure inspection (HPI)
It is used to control air before bottle is entered to capper.
10. Full bottle inspection 1
Filled bottles were checked for under fill and proper crowning by full bottle inspection machine
then bottles are transported to pasteurization.
11. Pasteurization
Pasteurization is ensuring to increase its shelf life by means of destroying or reduce the number
of harm full microorganisms in a product in order to increase its biological stability. The
objective is the effective kill of harmful organisms with the minimum use of energy that can
grow and cause beer spoilage in the bottle. The tunnel pasteurizer in Raya Brewery has
pasteurization capacity of 36,000btls/h and one bottle at least 45 minutes to be pasteurized. In the
pasteurizer there are 10 Induction motors. The pasteurizer operates as put in a three series zones.
 The first three zones (1, 2&3) are called heating zones and temperature set point is 25°C-
45°C.
 The next four zones (4, 5&6, 7) are called pasteurized zones at maximum temperature of
65°C.
 The last three zone (8, 9&10) are called cooling zones at temperature range of (45°C-
25°C).
12 .Bottle decoration (labeling)
Labeler is used to label the brand name and kind of beer on the body and neck of bottles using
glue. In the unending struggle for market share, the appearance of the bottle is very important.
The number and size of labels, their color and design, their arrangement and the overall effect
should be showing for the customer that is producer’s beer but not only the best it also the most

attractive. In Raya brewery S.C every bottle labels with Body label, Neck label and Labeling is
also describe expire date of the beer, chemical content, gradient and place of product.
Figure 14 Bottle decorations (labeling)
13. Full bottle inspection-2
This is used to check whether the bottles are packed and label properly.
14. Packer
Packer is used to put bottles with in crates. It is the same as unpacker but the difference is packer
is bottle loading or inserting in the crate & unpacker is removing the bottle in the crate, so that
same structure, working principle, but different in work.
Figure 15 Packer

15. Palletizer
Palletizer is used to put crate containing full bottles to pallet. It is similar to de palletizer in their
construction, but different in their function and degree of freedom. In palletizer number of
sensors are much amount than de palletizer even crate pusher machine is present in palletizer but
in de palletizer. The moment of palletizer is up and down sliding and also rotational motion is
presence but not in de palletizer. Other components are the same to the one.
Figure 16 Palletizer
2 Keg line
Draught beer is filled by keg. A keg is a standardized cylindrical metal barrel chrome nickel
steel. Steps in the draught beer
1. Flash pasteurization
In this case before filling the beer should be pasteurize by flashing method. Flash pasteurization
occurs before the beer put to its final container but the pasteurization is carried out on line using
heat exchanger at temperature of 74°C for 15 seconds. The difference between bottled beer and
draught beer are pasteurization way, pasteurization temperature and time, shelf life. The shelf life
of draught beer stays for one month.
2. Empty turning machine
Also it is called inverter machine. Used to invert the kegs where came from the input and this
passed to external washer machine.

Figure 17 Empty turning machine
3. External washer
External washer is a machine used to wash external part of the keg at temperature of 40°C-50°C
for 7 seconds.
4. Internal washer and filler
In Raya brewery S.C there are two internal washers and fillers each. The process of internal keg
cleaning filling has three stages at temperature of 80°C-82°C for 40 seconds using 90%
concentration of caustic and acid concentration is 16 % for cleaning case.
Stage-1: first pressurizing the keg to remove the residual materials from the keg and rinsing by
water.
Stage-2: blowing out of water, rinse by caustic, blowing out of caustic and rinsing by hot water.
Stage-3: blowing out of hot water with steam at temperature of 85°C, steaming, venting and CO2
pressurizing and filling of draught beer.
5. Rating system
This is called weight sensor used to check weight of full keg. If the full keg is under fill or over
fill, it is pushed using pusher. Then the weight of full keg 39kg. But 9kg is the weight of the keg
whereas 30kg is equal to volume of kegging i.e. 30 liters of draught beer.

Figure 18 Rating system
6. Videojet
It used to write the shelf life of the draught beer on the keg.
7. Full turning machine
It is called full inverter machine used to invert the full kegs sent to the output.
Figure 19 Full turning machines
2.4 Which work piece or work task you have been executing?
In Raya brewery Sc. the overall process is done automatically even if there is done manually
they do by the operators only. This is told when we enter the company as rule of the company by
our company adviser. The only we have the task we work are to see properly and listing and to
do simple tasks which are done manually by the operators those are:-
 Put the unclean bottles and labeler contains in to the crate and put the barked bottle to
the storage tank which is rejected by visual bottle inspection.

 Adjust the dilapidated bottles and open the closed bottles by using stick at the intern
of bottle washer.
 Adjust the crate when miss the line of motion.
 Closing the keg.
 Put the keg to the roller chain before entering the empty turning machine.
2.5 Procedures and methods while performing task

 By see when the operators are work
 Integrating with the operators

 To help the operators as they are work by labor
2.6 How good you have been in performing your work task?
In the first month we were that much good in performing the works .After the first month we
work by ourselves means student to student as there is happening of coved 19 operators are not
work as the first month beside this we have the chains to learn by student to student. Then
through practice we became good persons in understanding different type works in the company
process sections. Experience will be obtained from involvement therefore; we have involved in
different work of the company and have gain a good experience. We have learned from our
mistakes and developed our strong sides. So we believe that we have performed our work in
accordance with the scope of the intern ship.
2.7 What challenge you have been facing while performing your tasks?
 In the first month we were confused with everything because we are new for the
environment and also for work.
 In the first month as coved 19 enters to Ethiopia there is misgiving to work properly.
Every operator are care there selves as they have not more information about the
coved 19.
 After coved 19 there also happen regional problem which give the chance to enter
more students to this company, besides this we miss so much chances as the company
is over load students are accepted.

 Have not internet access to follow up the work task, the manuals are not clear to
understanding and there was also shortage of translated manual in English language.
 We have not freedom to work properly.
 Failures of some devices in process and misgiving between the theoretical and
operational of the machines.
 Lack of library access to read manual and some reference are the main.
2.8 What measures you have taken in order to overcome these challenges?
 After the time we were familiar with everything especially with work.
 To know the whole information and the operation of the machines we ask the
operators.
 By using one student to other student as the internet accesses means that by sheering
idea with other intern students and the operators
CHAPTER -THREE
OVERALL BENEFIT GAINED FROM THE INTERNSHIP
The internship provided us with the chance to utilize our knowledge and abilities in a
professional environment while still being in school. The internship provides a meticulously
designed and supervised work experience with the aim of acquiring further knowledge through
job exposure. Additionally, the internship is an integral part of an educational program through
which we can earn academic credit from our university. It is important to note that the internship
is organized separately from the curriculum, allowing us to solely focus on gaining work
experience.
3.1 In terms of improving practical skills

Throughout this internship program, we have had a valuable opportunity to significantly enhance
our practical skills. It is evident that we have been able to grasp theoretical concepts more
effectively through the use of various visual aids. Some instructors have taken the lead in
demonstrating the practical aspects of the field by incorporating graphic images into their
lectures or providing illustrative materials, and even arranging site visits to showcase real-life
engineering scenarios. However, these efforts have fallen short in comparison to the hands-on

experience gained through practical skill development. This internship program has proven to be
instrumental in addressing the deficiencies in our practical skills. We have made significant
progress in various areas such as malt storage, raw material handling, brew house operations,
beer processing, bottling, keg plant management, utility systems, and final product storage,
thereby optimizing the overall process flow and ensuring cohesion among different departments.
Additionally, we have honed our ability to carry out active preventive maintenance on
machinery, thereby extending their service life and reducing downtime and costs associated with
maintenance. In cases where corrective maintenance is necessary to maintain normal operations,
we have also gained valuable experience. Overall, we have made strides in enhancing our
practical skills, including fostering creativity and innovative problem-solving approaches,
analyzing and interpreting complex information, critical thinking, and evaluating designs, plans,
and projects.
3.2 In terms of upgrading Theoretical Knowledge

Over the past three years, we have immersed ourselves in the field of mechanical engineering,
undertaking numerous courses to enhance our theoretical understanding. While we may have
grasped the scientific principles behind how things work on paper, we struggled to envision the
practical workings and operational methods of machines. However, this internship program has
provided us with the opportunity to solidify our previous knowledge and comprehend the
previously elusive concepts. Through this program, we can gain a comprehensive and lucid
understanding of the application of equipment, machines, chemicals, and instruments in beer
production. Additionally, we can discern the various chemical processes employed and the
specific chemicals utilized in each process. By delving into the working principles of machines,
we can further augment our theoretical knowledge.
3.3 In term of improving Interpersonal communication skills
Initially, when we started this program, we were completely unfamiliar with everything on the
site. It was challenging to seek clarification or gather information through asking questions.
Nevertheless, as time passed, we found it easier to communicate with the operators. In our daily
interactions, we would reach out to individuals and enhance our communication abilities by
inquiring about things we didn't comprehend. Overall, we realized the importance of fostering

harmonious relationships among colleagues to cultivate a social life and enhance both theoretical
and practical knowledge.
3.4 In terms of improving team playing skills

Despite being campus students and honing our team playing skills on campus, we have also
strived to enhance our abilities in the following ways:
1. Enhancing our listening skills.
2. Cultivating strong relationships with guests at all times.
3. Mastering problem-solving techniques and effectively identifying issues.
When activities are conducted in a group setting, the acceptability, reasonability, accuracy, and
precision are consistently higher compared to those performed individually. Respecting one
another during discussions and actively listening are essential responsibilities. The majority of
the tasks we accomplished were assigned as group responsibilities. However, we also had to
work independently simultaneously. While engaging in these diverse tasks, various ideas
emerged, leading to occasional arguments among us. Nevertheless, we ultimately reached a
consensus on acceptable terms, which, we believe, facilitated the sharing of our thoughts. This
aspect contributes to the development of our teamwork skills to a certain degree.
3.5 In terms of improving leadership skills

During our internship program, we have gained valuable insights into the principles of effective
leadership. One key aspect we have learned is the importance of thinking globally rather than
personally, and the significance of respecting, listening to, and collaborating with all
stakeholders within the company. At Raya Brewery, we have witnessed managers who possess
strong leadership abilities, as they adhere to both the company's regulations and the country's
constitution. These managers lead with integrity, ensuring that each worker is supervised and
organized in their day-to-day tasks. Among various management functions, we have recognized
that human resource management holds the utmost importance. We have observed firsthand how
the control of working hours and the allocation of tasks to each worker contribute to the smooth
execution of the work plan. In essence, leadership is a skill that entails guiding, overseeing, and

monitoring individuals. Effective leaders must possess excellent communication skills,

confidence, and a willingness to share their experiences and dedication.
3.6 In terms of understanding about work ethics

In our comprehension, work ethics encompasses a set of principles centered around hard work
and diligence. It also recognizes the inherent benefits of work and its capacity to bring about
improvement. It is essential for individuals to uphold ethics not only in the workplace but also in
their social lives. We have consistently adhered to the rules and regulations set forth by the
company. Some key work ethics include:
1. Punctuality: Adhering to the designated start and end times of work and completing assigned
tasks within the given timeframe.
2. Office discipline: Maintaining a conducive working environment by refraining from

disruptive behaviors such as speaking loudly or engaging in activities that disturb fellow
colleagues.
3. Reliability: Ensuring that workers possess the necessary qualifications, skills, and knowledge
required for their assigned roles.
4. Honesty: Upholding integrity and refraining from engaging in unethical behaviors such as
cheating, bias, or corruption.
5. Cooperation: Encouraging collaboration and teamwork among workers, as it facilitates

problem-solving and enhances productivity.
From our perspective, we have learned the importance of transparency and attentiveness as
crucial work ethics to abide by. These principles of conduct are expected from all members of
the Raya brewery, including permanent members, associate members, contract members, and
student members. Furthermore, as Raya members, we are committed to upholding general moral
imperatives. This includes contributing to society and the well-being of humanity, avoiding harm
to others, practicing honesty and trustworthiness, promoting fairness and non-discrimination,
respecting property rights, and valuing the privacy of others. Additionally, we recognize our

professional obligations as Raya brewery entrants, striving for excellence in our work processes
and products, and continuously acquiring and maintaining professional competence.
3.7 In terms of entrepreneurship skills
promoting the growth of entrepreneurship not only fosters the development of a thriving
industry, but also serves as a foundation for enhancing the social and economic capacity of the
nation. Throughout this internship program, we acquired the necessary skills and knowledge to
embark on small business ventures, equipping us to become effective entrepreneurs. The essence
of entrepreneurship lies in taking calculated risks that yield profitable outcomes and creating
something of value. These skills enable individuals to generate innovative ideas that contribute
not only to the construction sector, but also to any other field that yields tangible results.

CHAPTER FOUR
CONCLUSION AND RECOMMENDATION
4.1 Conclusion
Generally it is concluded that this internship program is very useful to know the practical work
in relation with the theoretically knowledge of four years in the university. It also helps us to
understand and get ready for the work that expects us after graduation. We were taking our
internship program in Raya Brewery S.C and it was very successful and gave us so many
advantages. Some of them are:
 Allow us to both make and develop professional contacts, for our future job
search
 Assist us in developing greater understanding of our own strength and

weakness
 To understand the company’s Work flow
 Upgrade our theoretical knowledge at school
 Industrial automation system
 Leadership skill
 Knowing the industrial always used terms
 Knowing working standards
 Work ethics
 Team playing skills
4.2 Recommendations
During the three months of internship experience period some positive and negative things
have seen in the hosting company. In this part some points are suggested to hosting company.

 Safety shoe should be given for trainee students because they are members of the
workers so they need safety for the duration of their internship.
 Give freedom to the intern students after learn to practice.

 We recommend using material handling equipment to save human tired or from
safety purpose.
 Helmet should be given for all workers for the protection of their safety
 Spur parts for all machines should be available as much as possible in spur part
store for maintenance and changing of damaged parts.
Therefore, it is recommended that, the company should host more intern students in the future
for the common good of the student and its company.
Finally, raya brewery Share Company palletize 40 kg filled keg manually by operators. This
company uses above 5 operators per shift. Actually the maximum operating capacity of these
operators is 100 number of keg per hour (0.6 minute per keg). But the production capacity of the
company is 120 number of keg per hour (0.5 minute per keg). Thus there is loss of time.
Indirectly there is also lost of operator’s energy. As a result the labor cost of the company will be
high and the production speed of the company will be decrease.
When we calculate the loose
 There is 20 number of keg per hour, implies that 160 number of keg per one operating
shift which gives that 480 number of keg loose per day.
 There is 0.1 minute loose when they lift one keg due to they spent 0.6 min to lift one keg
which implies that 96 minute loose per one operating shift this gives 288 minute (4.8
hour) loose per day.
During all these times we also was thinking to submit a project for the company to increase the
production capacity of packaging department but we could not done any project in case of
internet access, instability and in the cause of time. Finally we recommended that, to solve
those problems the company should be given as a project to the next intern students.

CHAPTER ONE
INTRODUCTION
1.1 General idea of bottle crusher machine

Bottle crasher is a mechanical device that can crash a bottle at high speed operated by AC motor.
This machine is designed with the aim of pulverizing bottles to aid in the recycling process.
Broken bottles come from customer and factory due to improper handling of bottles, this bottle
should be crushed with the help this machine in order to protect the worker safety and reduce the
time and cost of manual crushing mechanism. The use of a glass crusher is a crucial part of the
process for recycling this waste.
1.2Problem statement
As we have observed and done some research on Raya Brewery Share Company, we found that
the company dispose 1000-1300 broken bottles every day and this disposal of waste or broken
bottles were unsafe, unhealthy and costly in transportation and processing, so we come up with
the idea of designing a machine that dispose waste bottles safely and helpful in minimizing cost
and time spending, despite the maintenance cost is less and have simple working principal.
Figure 35: broken bottles

1.3Objective
1.3.1 General objective
The main objective of this project is to design of bottle crusher machine.
1.3.2 Specific objectives

The specific objectives of the project to design each component of the machine by using solid
work software and other mechanisms that helps to design the project.
1.4Scope and limitation the project

1.4.1 Scope of the project
The scope of the project is to design and modify bottle crusher machine in Raya Brewery Share
Company by using of reciprocating mechanism to crush the bottle. This design is done from
gathering data up to final design by using theoretical calculations, Solid work for 3D modeling,
part drawing and assemble drawing.
1.4.2 Limitation of the project

Design of bottle crusher machine have the following limitations:-
 It cannot crush more than six bottles.
 Shortage of time.
 Since the speed of motor is directly rotate to the connecting rod this leads for failure, so it
inserts gear to vary the speed.
1.5Significance of the project

1.5.1 Benefits of the project
The significant of this project
 To save on valuable space
 To minimize noise pollution of environment
1.5.2 Beneficiary of the project

End users of from the project are
 Raya brewery
 Bottle factory
 Other disposed glasses from the environment

CHAPTER TWO
LITERATURE REVIEW
B.P.Numbi etl. Have presented an optimization technique for the vertical crushing machine.
The paper presents the optimal control model to improve the operation efficiency of a
vertical shaft impact crushing machine. They have proposed optimum methods to reduce the
power consumption by varying the conveyor feed flow rate, the vertical shaft impact crusher
rotor feed rate and the bi-flow or cascade flow rate.
Figure 20 vertical crushing machine

Department of Design and Technology, Lough Borough University, has presented a paper
emphasizing the need for recycling the wastes particularly the metal can wastes. The paper
insists that the requirement for environment accountability has become a feature of
consideration for the engineers, especially for mechanical engineers. The various design
methodologies have been discussed in the paper for the construction of a can crusher which
would be helpful in waste management [7].
M.L indqvist and C.M. Everts son, Department of Applied Mechanics Chalmers University
Of Technology, Sweden have presented a paper to develop a wear model for the cone
crushers which are used to crush the rocks minerals which are in the form of ores in mines.
Disagreements between predicted and measured geometry and several effects were suggested
to explain the discrepancy in the model. The model is of complex construction and it has

some of the real time shortcomings which reduce the efficiency of the machine drastically.
The various drawbacks have been studied and the measurements have been done to predict
the efficiency [8].
ZHAO La-la etli. Of China University of Mining and Technology, have presented a paper on
the Multi-object Optimization design for differential and grading toothed roll crusher using
genetic algorithm. The crusher blends the efficiencies of toothed roll crusher and also the jaw
crusher to possess great crushing ability and high breaking efficiency. Crank rocker
mechanism forms the basis of the machine. Thus the construction of the machine becomes
complicated and as a result the cost of the machine increases [9].
OLALEYE B M Department Of Mining Engineering, Federal University Of Technology,

Nigeria, has proposed a paper on Jaw Crusher performance in the granite quarry. The paper
determines the Effect of Rock Strength on Crushing Time and Grain Size Distribution of the
rocks. Investigation was conducted with five sample rocks and the performance and
drawbacks were spotted out. Various tests have been performed and the results have been
tabulated and plotted in the form of graphs [10].
Now our bottle crusher machine is fully packed with advanced features that enhance
functionality and usability keeping in minds clients different requirements, we offer the
entire range in various technical specifications. The purpose of this project is to design bottle
crusher machine in terms of its functionality. The main consideration of this machine is give
as low vibration and it has low power consumption.

CHAPTER TRHEE
METHODS AND DETAIL DESIGN
3.1 Methodology
Start
Data gathering
Material Selection
Yes No
Design
Analysis
Part
Drawin
Assemble Drawing
Recommendation
End
Figure 21 methodology

3.2 material selection

Materials are selected based on;
 Material cost
 Manufacturability
 Availability of the materials,
 Suitability of the materials for the working conditions in service
The material that we select for bottle crusher machine is Mild Steel (A-36) for all components
of design.
Characteristics for motor selection is based on;
 Efficiency
 Output power
 Speed
For this design the selected motor is AC motor.
3.3 Components of design

3.3.1 Consideration for designing the machine
 Force needed to break one glass of bottle is equal to 800 N
 The machine design to crush six bottles once
 The machine speed is 80 rpm
3.3.2 Design parameter

Parameters of low carbon steel
Take F . s=3

3.4 Design of hammer
Figure 22 : hammer
Glass has great inherent strength. It is weakened only by surface imperfections which give
everyday glass its fragile reputation. The practical tensile strength of glass is about 27Mpa to
62Mpa. However glass can withstand extremely high compressive stresses. Therefore most glass
breakage is due to tensile strength failure.
σ u=400 Mpa
σ y =150 Mpa
E=200 Gpa
Take F . s=3
From this the allowable stress will be
σy
allowable stress(σ )=
factore of safty
150 Mpa
allowable stress(σ )=
3
allowable stress ( σ )=50 Mpa
The hammer subjected to wearing and axial stress, but the wearing stress is negligible because
the material to be crushed is glass.
The axial stress will be found in this way

allowable stress ( σ )=F / A
The length of the hammer can be calculated by the number of bottles multiply by the diameter of
the bottle which is:
 № of bottles = 6
 Diameter of the bottle =50mm
L=6∗5 Omm
L=300 mm
allowable stress ( σ )=F / A
2
50 N /m m =4800 N /300 mm∗t
t=4800/(50∗300)
t=32 mm
3.5 Design of connecting rod
Figure 23 connecting rod

The main objective of connecting rod is transfer reciprocating motion from crank to the hammer.
In this work attempt is to be made for design and analyze in connecting rod with composite
material, presently connecting rod are manufactured using carbon steel and in recent days
aluminum alloys are finding its application in connecting rod. Composite connecting rod is
possessed higher potential life. The design parameters are analyzed with the objective
minimizing the weight composite connecting rod.

The main objective is to find
 Thickness
 Width
 Length
To check the stability of the connecting rod
Let: t=w
allowable stress ( σ )=F / A (By neglecting the weight of the hammer)
83.3Mpa =4800 N /t2
t2¿ 4800 N /83.3 Mpa
t=10 mm
Therefore the thickness and the width is 10mm
To find the length of the connecting rod we have to check the buckling stress by buckling theory.
2
F=π EI / L ²
3
I =bh /12
2 2 4
L =(π ×200 Gpa × ( 0.01 ) )/¿ ×12)
L= 182.5mm
3.6 Design of crank
Figure 24 crank

The main objective of crank is to convert rotational motion in to reciprocating motion. Rotational
motion come from AC machine and rotate the crank then the crank convert this motion into
backward and forward motion which transfer this motion to the hammer inside crushing chamber
which lead the hammer to crush the bottles.
To find the diameter of the crank we use the formula:
allowable stress ( σ )=F / A ;……………………..…….By neglecting the weight of

2
πd
A= connecting rod and the hammer
4
4800 N
83.3 Mpa= 2
πd
( )
4
2
d =(4∗4800)/(83.3 Mpa∗π )
d=85.65 mm
3.7 Pin Design
Figure 25 : pin
Pins are used to connect the crank with link and link with hammer.
Assumptions
 The pin only carry tensile stress
 Cannot carry compressive stress, if it buckle
 The force is uniformly distributed load
 The clearance between the pin and bore is to small so ignore bending stress
Material selection

A-steel (low carbon steel),

Yield stress(σ y )=250 MPa
Ultimate stress(σ u)=650 Mpa
Young’ s modulus(E)=200GPa
Poisons ratio(V )=0.26
Shear modulus(G)=750 GPa
Assume the des ign factor (f . s)=3
The mian objective is ¿ find diameter of the pin
The pins are failed by pure shear load. Then according to the Maximum shear stress theory
(MSS)
Yield stress(σ y )
Maximum shear stress =
2 x design factor (f . s)
σy
=
2x f .s
250
=
2x 3
¿ 41.66 Mpa
Tangential force (Wtotal)

Shear stress =
Resisting area( A)
Since, the pin supports the weight of the movable crank. Then the tangential force is the weight
of the movable crank (w).
Tangential force = weight of the movable crank (w)
W total=4800 N
Again, the shearing takes place at two cross-sections of the pin (both end), then the pin is said to
be in shear. In such a case, the area resisting the shear off the pin,

π
Resisting area (A) = x d2
4
π
A= x d2
4
A = 0.785 d2
4800 N∗4
d ²=
π x 41.66
dp=12.11mm say dp=12 mm
3.8 Key design
Figure 26 key
For this design sunk key is selected from different types of key, sunk key are provided half in the
key way of the shaft and half in the keyway of the crank. The sunk key we choice a square sunk
key.
Square key way
In the square keyway its thickness and width are equal.
d
w=t=
4
Where w=widthof the key
T =thickness
D=diameter of the shaft

12
W =t= =3 mm
4
And the torque can be calculated by:
T ( torque )=F∗r
T =4800 N∗42.825 mm
T=205.5 Nm
A key may fail due to shearing or crushing
Material selection for key
Plane carbon steel for which the allowable shear stress and crushing stress is 50Mpa and
80Mps respectively.
Diameter of the shaft d =85.65 mm
First let us consider the shearing stress of the key
We know the torque transmitted
T =l∗w∗d /2∗τc
Where T =torque transmitted=205.5 Nm
L=length of the key way=35 mm
D=diameter of the shaft =85.65 mm
τc=shear force
T =l∗w∗d /2∗τc
τc=2 T /lwd
τc=45 Mpa

45 Mpa ≤ 50 Mpa so thedesign is safe

3.9 Design of crushing chamber
Figure 27 crushing chamber

From the crushing chamber or body only the front wall is subjected to normal stress and the
front wall of the chamber thickness should be the same as the thickness of the hammer in
order to balance the force reaction between the two parts.
Therefore:
 The thickness of the chamber is 32mm.
 The length is equal to the number of bottles multiply by the diameter of the bottle
which is 50mm*6+10mm clearance =310mm.
 The height of the chamber is equal to the height of the bottle which is 250mm+20mm
clearance=270mm.
Power input:
2 πNT
P=
60
T ( torque )=F∗r Where, F=4800 N
r ( crank radius )=42.825 mm
T =4800 N∗42.825 mm
T=205.5 Nm

2 πNT
P=
60
2 π∗80 rpm∗205.5 Nm
P=
60
P=1721.59 W
P=1.7 KW
Therefore the power input must be 1.7KW to use the full efficiency of the machine.

3.9 Cost Analysis

Table 1 Cost analysis of the design
Part Material Mass Volume Unit per Total

mass birr
Hammer (MS (A-36)) low carbon 5k.g 2400c.m3 53 265.6

still
Connected rod (MS (A-36)) low carbon 2k.g 269.12c.m3 53 106

still
Crank (MS (A-36)) low carbon 3.5k.g 403.313c.m3 53 185.5

still
Pin Low carbon steel 0.75k. 39.5c.m3 53 39.75

g
Key (MS (A-36)) low carbon 0.5k.g 26.54cm3 53 26.5

still
Crushing (MS (A-36)) low carbon 14k.g 7168.9 53 742

chamber still
The total birr need to constrict the parts of the bottle crasher machine is the sum of the cost of
individual parts so: It is equal to
= 265.6+106+185.5+39.75+26.5+742=1,365.35 birr but the AC engine cost about 15000 birr
So completely construction of the machine needs a cost about 16,365.35 birr.
3.11 Working principle

The operation or working principle of bottle crusher is starts from operators by starting the AC
motor. After starting the motor it will convert the electrical power of motor to rotational motion
of shaft. At the same time the rotational motion of shaft will drive to the crank, since the crank is

connected with shaft, it induce a rotational motion similar with shaft. After the rotational motion
of the crank it must be convert reciprocating motion, so for this mechanism it uses connecting
rod. Finally the hammer will crush to the bottles by collapsing (over lapping) with wall of
chamber by reciprocating mechanism. Since the hammer is connect with connecting rod. After
the bottle was crushed it discharge through the small bottom holes of chamber.
Figure 28 Assembly drawing of bottle crusher machine
Figure 29 work flow of bottle crusher machine

CHAPTER FOUR
RESULT AND DISCUSSIONS
4.1 Result
Table 2 Result and discussions
Design components Result
Hammer L= 300mm
t=32mm
Connected rod L=324.46mm
t=28.8mm
Crank d=85.65mm
Pin dp=12mm
Key t=w=3mm
4.2 Discussion
The crushing machine was successfully designed, since the results are so safe. The machine
crushed multiple bottles simultaneously with ease both during electrical as well as during
mechanical modes of operation. While crushing the bottles manually, the bottles got crushed
with minimal human effort operators.

CHAPTER FIVE
CONCLUSION AND RECOMMENDATION
5.1. Conclusion
Generally we conclude that the bottle crusher is designed in such a way that even bottle crusher
can operate it without much effort. It is designed efficient and the cost of production of this
crusher is very less. The crusher has been designed accordingly keeping in mind about the
minimum power requirements and minimum effort to the operator. This crusher upon fabrication
would serve its purpose the small scale recycling plant and does not require power for operation
and can also be operated manually without much physical effort.
5.2 Recommendation
We recommended that, if the company uses the designed machine certainly the company will be
beneficiary, since it minimizes the time needed to process and energy required to dispose waste
bottles manually also guarantee the safety of the workers. Generally waste bottle disposal in
Raya Brewery Share Company is unsafe and costly in transportation and processing. Therefore,
if this machine is introduces to the company it will be very helpful in guaranteeing the safety of
the worker and working condition of the company.
Finally, this project is very essential and helpful in order to make the working condition of Raya
brewery Share company more effective and safe also it reduce the time and cost wastage. As
mentioned above, in Raya brewery Share company there is no bottle crasher machine, therefore,
if this project is applicable in the company the effectiveness and profitability will be achieved.

Reference
1. Operating Manual Packaging Area
2. Operating Manual Filler – Modular Design, Base-Handling System by krones 2013.
3. Operating Manual Double-End Bottle Washer by krones 2013.
4. Technology Brewing and Malting, Wolfgang Kunze, International Edition, 1999.

5. http://www.wrightwayproducts.com.au/other-products/glass-and-bottle-crushing-systems.html.
6. www.roymech.co.uk/useful_Tables/matter/Glass.html.
7. GUPTA, R. K. (2005). Textbook of machine design,first multicolour edition. EURASIA
PUBLISHING HOUSE (PVT.) LTD.
8. McGraw-Hill, s. a. shigley,s mechanical engineering design. Budynas-Nisbett, 1 © The
McGraw−Hill 1.
9. shigely. mechanical engineering design.
10. Vishal N. Kshirsagar, Dr.S.K.Choyoudhary, Prof. A.P. Ninawe (2014). An automatic
approach for can /plastic bottle crusher machine. International journal of research in
aeronautical and mechanical engineering. Vol.2 Issue.7,pp.102-113,July 2014.
11. Surve Qais, Sayed Saif, Sayed Jafar, Shaikh Nadeem (2015). Fully automatic can crusher.
International journal of mechanical and industrial technology. Vol. 2, Issue 2, pp.155-159.
12. Vishal N.kshirsagar, Dr. s..k Choudhary, Prof. A. P. ninawe (2014). An automatic can / plastic
bottle crusher machine.international journal for scientific research and development. Vol. 2,
Issue 02, 2014,pp.66-68.
13. Vishal N.Kshirsagar, Dr. s..k Choudhary, Prof. A. P. Ninawe (2014). Design consideration in
an automatic can /plastic bottle crusher machine. International Journal of engineering research
and general science. Volume 2, Issue 4, june-july, 2014, pp. 769-779.
14. Shadeb Husain, Mohammed Shadeb Sheikh (2015). Can crusher using scotch yoke
mechanism. IOSR journal of mechanical and civil and civil engineering. pp. 60-65.

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DESIGN OF BOTTLE CRUSHER MACHINE

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

PROJECT TITLE: DESIGN OF BOTTLE CRUSHER MACHINE

HOSTING COMPANY: RAYA BEER S.C

1 ABDUSHUKUR WABELLA 04791/12 THERMAL

2 GEBRE ARAYA 05134/12 THERMAL

3 HAGOS GODIFAY 05193/12 THERMAL

4 ZEMICHEAL TADIWOS 05733/12 THERMAL

COMPANY SUPERVISOR: MS. YALEM

ADVISER: INS. MULU TESFA

RAYA UNIVERSITY Page I

RAYA UNIVERSITY Page II

RAYA UNIVERSITY Page III

RAYA UNIVERSITY Page IV

RAYA UNIVERSITY Page V

3.3 Components of design..............................................................................................................45

RAYA UNIVERSITY Page VI

Figure 1 Drum sieve:................................................................................................................................................. 7

Figure 2 Milling section............................................................................................................................................ 7

Figure 3 mush-in tank............................................................................................................................................... 8

Figure 4 Mash filter................................................................................................................................................... 9

Figure 6 Gas washer............................................................................................................................................... 14

Figure 8 over view of De-palletizer machine...................................................................................................... 20

Figure 9 over view of Unpacker............................................................................................................................ 21

Figure 10 over view of Crate washer................................................................................................................... 22

Figure 11 over view of Bottle washer................................................................................................................... 25

Figure 12 over view of EBI.................................................................................................................................... 25

Figure 13 over view of filler................................................................................................................................... 26

Figure 14 Bottle decorations (labeling)............................................................................................................... 28

Figure 17 Empty turning machine....................................................................................................................... 30

Figure 18 Rating system......................................................................................................................................... 31

Figure 19 Full turning machines......................................................................................................................... 31

RAYA UNIVERSITY Page VII

Figure 20 vertical crushing machine................................................................................................................... 42

Figure 23 connecting rod....................................................................................................................................... 47

Figure 27 crushing chamber................................................................................................................................. 53

Figure 28 Assembly drawing of bottle crusher machine.................................................................................. 56

Figure 29 work flow of bottle crusher machine................................................................................................. 56

RAYA UNIVERSITY Page VIII

Table 1 Cost analysis of the design....................................................................................................................... 56

Table 2 Result and discussions......................................................................................................................... 58

RAYA UNIVERSITY Page IX

RAYA UNIVERSITY Page X

BACKGROUND OF HOSTING COMPANY

RAYA UNIVERSITY Page 1

1.2 Objective of the company

 To invigorate the nation by manufacturing top-notch beer.

1.3 Vision of the company

RAYA UNIVERSITY Page 2

1.5 Main product and service of Raya brewery S.C

The primary offerings of Raya brewery include-

1.6 Main customers (end users of) Raya brewery S.C

Region 1: covers Desie, Addis Ababa and Mekelle.

Region 2: this covers the whole Tigray region.

Region 3: east and south parts of Ethiopia

1.7 Organization structure of Raya brewery S.C

RAYA UNIVERSITY Page 3

RAYA UNIVERSITY Page 4