RAYA UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

PROJECT TITLE: DESIGN OF Hydro Power Based Roller Conveyer
HOSTING COMPANY: RAYA BEER S.C

PREPARED BY:

NO NAME ID STREAM

HAGOS GODIFAY 05193/12 THERMAL

2 GEBRE ARAYA 05134/12 THERMAL

3 ABDUSHUKUR WABELLA 04791/12 THERMAL

4 ZEMICHEAL TADIWOS 05733/12 THERMAL

COMPANY SUPERVISOR: MS. YALEM

ADVISER: INS. MULU TESFAY

MAY 2024

MAICHEW, TIGRAY, ETHIOPIA

 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.
 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.
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.
Table of content
List of figure
List of table
List of symbol notation and abbreviation
UVR ............................................ultraviolet radiation

E…………………………modules of elasticity
ρ………………………….density
T………………………….torque
V.R……………………….velocity ratio
d.p…………………………design power
r.p…………………………rated power
p……………………………pitch
P……………………………power
w……………………………width
h…………………………….height
t…………………………….thickness
A…………………………….area
K…………………………….radius of gyration
s.f……………………………..safety factor
L………………………………..length
I…………………………………inertia
T1………………………………..number of teeth in small sprockets
T2………………………………..number of teeth in large sprockets
N1………………………………..speed of small sprockets
N2………………………………..speed of large sprockets
𝐵……………………………….breaking loa

.
 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
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.

 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.
3. Pre-mashing

It is used to mix the grist with hot water & cold water. The objective of pre-masher are pre

Figure -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.

6. Wort collector

Wort collector is used to store the wort and its total capacity to store 31 m 3.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.

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
 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

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.

Deration tank: the condenser tank can be used as degassed water tank due to avoiding of
oxygen from 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. But currently they work at
temperature of 140°C-150°C and 10.5bar maximum 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. Therefore, this plant uses air dryer to remove moisture from the
atmospheric air. Main areas that need compressed air include Wort aeration, transporting spent
grain in mash filter, conveying of grist to the mash tun, for pneumatic valves.
 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. The water treatment plant at Raya brewery is
designed for treatment of water. The main substances or chemicals that used for WTP are:
Ferric chloride, Anti scale, Sodium hydro oxide, Sand, biocide, Chlorine and Active carbon
filter.

In Raya brewery water comes from May Muk through the help of centrifugal pumps in to
water treatment plant using four wall. Then its turbidity is checked online by amplifier, and if
turbidity less than normal Turbidity Unit it enters in to well water tank otherwise drain.

6. Waste Water Treatment Plant

Waste water is the dirty (contaminated) water collected from all the processing units and from
the production environment. The source of waste water is from Brew house, Production,
Bottling, Utility and working environment.

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 2. 1 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 2. 2 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 2. 3 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 2. 4 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 2. 5 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 2. 6 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 2. 7 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 2. 8 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 2. 9 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 2. 10 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 2. 11 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 2. 12 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
 Asking supervisor for help to integrate theoretical knowledge to tactual knowledge.
Taking some actual considerations between theoretical and actual variations
 Recommending the workshop workers to maintain failed device.
 We shift the time to inter the company to decrease the over load.
 Obeying carefully the rule and regulations of the company
 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.
Although we were unable to implement a completely novel set of ideas during the program, we
gained a diverse range of entrepreneurial skills, encompassing personal attributes and
management capabilities. These include effective time and people management, the ability to
work both collaboratively and independently, as well as proficient planning, coordination, and
organization skills.
 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.
PART TWO

CHAPTER ONE

1. Design of hydro power based roller conveyor

1.1. Introduction
A roller conveyor system is a common machine of mechanical handling equipment that
moves materials from one location to another. They are actually a series of rollers supported
within a frame where objects can be moved either manually, by gravity, or by power [4]
Conveyors are especially useful in applications involving the transportation of heavy or
bulky materials. Conveyor systems allow quick and efficient transportation for a wide
variety of materials, which make them very popular in the material handling and packaging
industries. Many kinds of conveying systems are available in the market, and are adapted
according to the various needs of different manufacturing industries. There are chain
conveyors (floor and overhead) as well. Chain conveyors consist of enclosed tracks, I-Beam,
towline, power & free, and hand pushed trolleys. Conveyor systems are used widespread
across a range of industries due to the numerous benefits they provide. Roller conveyors are
classified into two groups according to the principle of conveying action. These are:
Unpowered or Idle Roller Conveyor: In an unpowered roller conveyor, the rollers are not
driven or powered from an external source. The material or heavy boxes, etc. roll over the
series of rollers either by manual push or push from rods or clamps. Generally these
conveyors operate at horizontal plane, but at times a gentle slope is given to these conveyors
to aid motion of the loads. An inclination of 1.5% to 3% ensures that the load will roll by
gravity. Such conveyors are termed “gravity roller conveyor [2] Powered or Live Roller
Conveyor: In a live roller conveyor, all or a selected number of rollers are driven by one or a
number of motors (if necessary) depending on the selected drive arrangement. The driven
roller transfers the motion to the loads by friction. The live roller conveyors may be installed
at a slightly tilted position, up to 10° up or up to 17° down. The load can be moved in either
 directions by changing the direction of rotation of the rollers, where these are called
reversing conveyors [1]

1.2. Statement of the problem

Burie cool water and soft drink follows the oldest technology to produce and distribute soft
drinks. Due to the oldest materials they use it have some material handling equipment
problem which affects the rate of production at the given time. One of these problems is the
company uses manually operated roller conveyor to move bottle packets from storage class
to arranging part of the chain conveyor to furtherly feeding for washer. This manually
operated conveyor has its own problem on the rate of production of the company. Such as
tiredness of the labor, it delays the bottle for washing, crash of packets and bottles occurred
due to tiredness of labor at the feeding time. Major problems of the use of manually operated
roller conveyor are crashing or out use of bottles for arranging and feeding.
Problem 1
Averagely crashing 10 bottles per a day.
Price of one bottle in company market =20 Birr
20 × 10 = 200 Birr per day
There for the company loss 200 Birr per day due to this problem.
Problem 2
The second major problem is manual operated roller conveyer to move bottle packet from
storage class to arranging parts of the chain conveyer it required man labor.
Man labor per a day=6
The salary of one man labor per a day=150 Birr.
6 × 150 = 900 Birr per day.
There for the company loss approximately 900 Birr due to this problem.
Totally 900 + 200=1100
Annually 1100×365=401500
So our project reject this problem permanently.
1.3. Objective of the project

1.3.1. General objective

The main objective of this project is to design hydropower based roller conveyorl.

1.3.2. Specific objective

The specific objective of this project is to design all parts of the object like:-

 To design leg
 To design roller
 To design chain drive
 To design frame

1.4. Scope of the project

In this design we have involved different methods to finalize the project. First we will describe
the importance of roller conveyor design. The scope of the project is design of roller conveyor
which replaces man power with high accuracy protecting bottles from crashing and the
importance is replacing human power or decreasing man power during working. Then explain
parts and components of the conveyor, analyze force and stress, part and assembly drawing and
then finally result and discussion of each parts of the project.

1.5. Significance of the project

This project is mainly important for company by conveying packets and bottles without man

power in short period of time or by reducing working time it reduces man power. It increases
company’s product and decreases human labor.

Generally significance of this project is.

 To avoid labor tiredness

 To avoid bottle and packet from crashing
 To reduce labor salary
 To avoid time wastage
 To increase production rate
 To reduce bottle neck
 To avoid crowdedness of the room by employees
1.6. Limitations of the project
It is used for objects with flat surfaces and for movement to relatively short distances and the
water comes from the washer machine and inter to the roller blade is dirty it Couse to
corrosionand failure.

CHAPTER TWO

2. Literature review

2.1. Related work

Alspaugh M.A, (2007) presents latest development in belt conveyor technology and the
application of traditional components in non-traditional applications requiring horizontal curves
and intermediate drives have changed and expanded belt conveyor possibility.for examples of
complex conveying applications along with the numerical tools required to insure reliability and
availability will be reviewed. This paper referenced Henderson Pc2 which is one of the longest
single flight convectional conveyors in the world at 16.2611 km. Nazzal et al., (2007) conducted
the study on Survey of Research In Modeling Conveyor Based Automated Material Handling
Systems In Wafer Fabs. This paper discusses literature related to models of conveyor systems in
semiconductor fabs. A comprehensive overview of Simulationbased models is provided. We also
identify and discuss specific research problems and needs in the design and control of closed-
loop conveyors. It is concluded that new analytical and simulation models of conveyor systems
need to be developed to understand the behavior of such systems and bridge the gap between
theoretical research and industry problems. Taylor et al, (2009) Studies the availability modeling
of powered roller conveyors. This paper provides an analysis of the reliability and availability of
two common designs of the line-shaft roller conveyor. The first is a standard design in which
each roller is belted directly to a spinning line shaft under the conveyor. The second is a new
design in which only one top roller is belted to the line shaft, and all other rollers are belted to
the one powered roller in a series arrangement. The main reason for this design is that the upper
belts are faster to replace than belts connected to the line shaft, thus increasing system
availability. However, the latter design is less reliable in that the failure of a single belt may lead
to multiple roller failures.

Abbas et al., (2004) studied the Investigation into design and Manufacturing of Mechanical
Conveyors Systems for Food Processing. This paper presents application of concept of
concurrent engineering and the principles of design for manufacturing and design for assembly,
several critical conveyor parts were investigated for their functionality, material suitability,
strength criterion, cost and ease of assembly in the overall conveyor system. The critical parts
were modified and redesigned with new shape and geometry, and some with new materials. The
improved design methods and the functionality of new conveyor parts were verified and tested
on a new test conveyor system designed, manufactured and assembled using the new improved
parts. The improved methodology for design and production of conveyor components is based on
the minimization of materials, parts and costs, using the rules of design for manufacture and
design for assembly. Results obtained on a test conveyor system verify the benefits of using the
improved techniques.

Sekimoto et al (2004) conducted the study on Development of Concept Design CAD System. In
order to shorten the product development time and improve the product quality, 3 dimensions at
CAD/CAE system is essential. It is necessary to develop a system which utilizes the concept
design data at the early stage for the whole process of the product development. The purpose of
this project is to improve the product quality by the sufficient design study iteration at the early
stage of design. A CAD system which can be used for the concept design and an appropriate
CAD environment should be developed. And another Purpose is to shorten the product
development time at the late stage of design.

Ogedengbe, T. I. (2010) Lecture Note on Applied Techniques of Production Management.

Handling of materials which is an important factor in manufacturing is an integral part of
facilities design and the efficiency of material handling equipment add to the performance level
of a firm. A roller conveyor has series of rollers, mounted on bearings, at fixed spacing on two
side frames which are fixed or mobile. The spacing of rollers depends on the size of the unit
loads to be carried, such that the load is carried at least by two rollers at any point of time. Roller
conveyors are used for conveying almost any unit load with rigid riding surface that can move on
two or more rollers.
Alspaugh M.A,(2005), MIN Conveyor systems allow quick and efficient transportation for a
wide variety of materials, which make them very popular in the material handling and packaging
industries. Many kinds of conveying systems are available, and are used according to the various
needs of different industries. There are chain conveyors (floor and overhead) as well. Chain
conveyors consist of enclosed tracks, I-Beam, towline, power & free, and hand pushed trolleys.
Conveyor systems are used widespread across a range of industries due to the numerous benefits
they provide.

Richardson, J. F., Harker, J. H. and Buckhurst, (2003), Conveyor systems are durable and
reliable in materials transportation and warehousing. Based on different principles of
operation,there are different conveyor systems namely: powered, gravity, belt, screw, bucket,
vibrating, and pneumatic/hydraulic John R. English, University of Arkansas, John Usher, (2001),
University of Louisville Availability modeling of powered roller conveyers. This paper provides
an analysis of the reliability and availability of two common designs of the line-shaft roller
conveyor. The first is a standard design in which each roller is belted directly to a spinning line
shaft under the conveyor. The second is a new design in which only one top roller is belted to the
line shaft, and all other rollers are belted to the one powered roller in a series arrangement. The
main reason for this design is that the upper belts are faster to replace than belts connected to the
line shaft, thus increasing system availability. However, the latter design is less reliable in that
the failure of a single belt may lead to multiple roller failure.

2.2. The gap we observed from related work

In the first inventor each roller requires their own spinner and belt. The second inventer used
manual and then electrical power for rolling source ,even the roller rolls at a time with each other
by using belt.So,to avoide manual power and to reduce electric source we use water as a power
source for our design
. CHAPTER THREE

3. Design of Hydro Power Based Roller Conveyer

3.1. Methodology of the Project

The method to do the project and for design is based on stress analysis such as bending stress,
shear stress, torque, bending moment and yield stress and this is done based on standards. The
conveyor used at the beginning and end of the production room and the design is depends on
Filled bottles and packets. After designing and calculations based on the dimension of parts
AutoCAD and solid work software is used to get the shape and general feature of the machine.
 Identification of the problem

Statement of problem

Data collection

Data analysis

Numerical
Theoretical

Part and assemble drawing

Result

No Yes

3.1.1.Primary data collection

Primary data collection methods are used collect data directly from the source. That uses by
interview making (i.e. asking a factory manager, workers, and technical assistant to identify
problems.

3.2.1. Secondary data collection

Secondary data collection methods are used to collect data indirectly from the source. Thus are:
Different magazines; books; internets.

The current conveyor that the company uses is manually operated and that is not much safe for
the production system. Due to this problem the conveyor must be modified and redesign
Working principle

Figure 3.2 working principle of the conveyor

Water comes from the washer machine after washing the botte directly enters to the roller blades
through the nozzle and touch the blade. Then the blade start to rotate so the roller start to rotate
roller. At the end of the roller there is sprockets used to connect roller conveyor in to the power
by chain drive.There for the power produce from roller blade transmitted to the roller and easily
to transmitted roller conveyor then starts to role.

3.2. Material Selection

The knowledge of materials and their properties is great significance for a design analysis. The
following factors should be considered while selecting the material.

 Availability of the materials

 Suitability of the materials for the working conditions in service
 The cost of the materials
 Corrosion resistance materials
 Acid resistance (during washing and accidents)
 Strength, durability, Machinability
The material to to be selected to desiagn the part is mild steel,carbon steel,chrome
steel,and alloy steel.
3.3. Properties of the material
3.3.1. Basic physical properties of steel
Steel is an alloy, a combination metal made of iron and carbon. The carbon content of
steel reaches a maximum of 1.5 percent. Because of its hardness and strength, steel is
used in the construction of buildings, bridges, automobiles, and a host of other
manufacturing and engineering applications. Most steel produced today is plain carbon
steel or simply carbon steel. The carbon in steel exists in the iron carbide state. Other
elements, among them sulphur, phosphorus, manganese and silicon, are present as well
different types of steels are produced according to the mechanical and physical properties
required for their application. Various grading systems are used to distinguish steels
based on these properties, which include density, elasticity, melting point, thermal
conductivity, strength, and hardness (among others). To make different steels,
manufacturers vary the type and quantity of alloy metals, the production process, and the
manner in which the steels are worked to produce particular products. Steel has a density
of 7,850 kg/m3, making it 7.85 times as dense as water; its melting point of 1,510 C is
higher than that of most metals. In comparison, the melting point of bronze is 1,040 C,
that of copper is 1,083 C, that of cast iron is 1,300 C, and that of nickel is 1,453 C.
Tungsten, however, melts at a searing 3,410 C, which is not surprising since this element
is used in light bul Celsius, is 11.1, which makes is more resistant to changing size with
changes in temperature than, for example, copper (16.7), tin (21.4) and lead
(29.1).According to the American Iron and Steel Institute(AISI), steels can be broadly
categorized into four groups based on their chemical compositions: Carbon Steels Alloy
Steels Stainless Steels Tool Steel.

3.3.2.Properties of mild steel

Mild steel is one of many different grades of steel which are produced internationally. In
fact, the World Steel Association claims there are more than 3500 grades of steel when
you consider all of the unique physical, chemical and environmental properties. These
different properties are brought about by varying the different alloying elements mixed
with iron in the production of steel. Alloying elements even carbon act as hardening
agents, preventing dislocations from occurring inside the iron crystals which allow the
 lattice layers to slide past each other. This is the reason why steel is harder than iron, and
why mild steel which contains a lower amount of carbon than other steels is a more
ductile variety of the material. Strength Although all varieties of steel are harder and
display higher strength than pure iron, the structural strength of mild steel is not sufficient
for it to be used in structural applications or wherever high levels of stress will be placed
on it. This is due to the low carbon content which makes the steel more malleable,
however this fact affords mild steel a greater degree of flex which can be advantageous
particularly in applications where flexibility is required and where stronger steels would
be too brittle. Mild steel is suitable for mechanical engineering and general purpose
fabrication. Its strength makes it a terrific choice of material for the construction of cages,
frames, fencing and in other applications where it will not be subjected to high stress.
Bright mild steel, which is cold finished for an enhanced aesthetic appearance, has tighter
sectional tolerances and increased straightness. It has a marked increase in physical
strength over standard mild steel which makes it a better choice for more demanding
projects. Malleability The reduced carbon content of mild steel makes it easier to shape,
drill, weld and cut than other, more brittle varieties of steel. It is this reputation for
versatility which has led to its remarkable popularity in many industries from the
manufacture of household items to structural applications such as fencing, roll cages and
semi-permanent structures. A high level of demand leads to reduced costs, and mild steel
is the most widely produced material in the world thanks to the range of projects which
can be completed with this material. Corrosion Mild steel has a high proportion of iron to
carbon, which means that it is very susceptible to corrosion. Corrosion is brought on by
exposure to oxygen, moisture or salt and manifests in brownish red deposits on the
surface of the material wh surface of the metal, exposing more of the material to that
which is causing it to corrode. Therefore, if left untreated, corrosion in mild steel will
eventually lead to the total decay of the material. It is therefore not suitable for use in
marine environments or in other demanding applications, and wherever mild steel is used
outside it is recommended that it is protected with paint or by galvanizing it.

3.3.3.Properties of Carbon Steel

Carbon steels are alloys made from a combination of iron and carbon. By varying the percentage
of carbon, it is possible to produce steel with a variety of different qualities. In general, the
higher the carbon level the stronger and more brittle the steel. Low carbon steel is sometimes
called "wrought iron." It is easy to work and may be used for decorative products such as fencing
or lamp posts. Medium carbon steel is very strong and is often used for large structures such as
bridges. High carbon steel is used mainly for wires. Ultra-high carbon steel, also called "cast
iron," is used for pots and other items. While it is very hard steel, it is also quite brittle. Carbon
steel is generally regarded as an iron-carbon alloy with up to 1.7% carbon, less than
1.6%manganese and less than 0.6%,siliconandlessthan0.1%sulphur and phosphorus However,
CalQlata defines carbon steel as an iron-carbon alloy with up to 1.7% carbon the mechanical
properties of which are governed by its carbon content. CalQlata's definition therefore includes
plain, special alloy carbon steels. There is a well-defined relationship between the mechanical
properties of carbon steel and its carbon content.

3.3.4.Properties of alloy steel

Alloy steels are so named because they are made with a small percentage of one or more metals
besides iron. The addition of alloys changes the properties of steels. For example, steel made
from iron, chromium, and nickel produces stainless steel. The addition of aluminium can make
steel more uniform in appearance. Steel with added manganese becomes exceptionally hard and
strong.

sChrome steel resists warping and melting under condition of extreme heat and is ideal for high
temprature application such as jet engine components.The high strength and corrossion resistant
properties of stainless steel containing more than five percent chromium were discovered in the
early 1900s.
3.4. Design of roller

Figure 3.3 model of roller

Roller Assumptions

The roller is subjected to bending stress

The load is uniformly distributed to the roller

Full of packet with soft drink weights 18 Kg.

The packet covers 5 rollers at the time means the load acts on 5 rollers at a time.

Material for roller is mild steel with:

3
E=2.10∗105 Mpa , ρ=7860 kg /m , S yt =590 mpa , factor of safety =2

Calculation

Load per roller = 18 kg /5=3.6 kg (Load act on 5 rollers at a time)

Weight ¿ 3.6∗9.81=35 N

Do = Outer diameter of roller = 50 mm, Di = Inner diameter of roller = 42 mm w = Width of

roller = 500 mm y = Distance from neutral axis ¿ 50/2= 25mm

Considering uniformly distributed load,

Figure 3.4. Distributed load on the roller
Maximum Moment;
2
WL
M max = =35×0.52 /8=1.1Nm
8

π ( Do4 −Di4 ) 4
Moment of Inertia; I = =0.000000154 m
64

M max∗ y 0.25
Maximum bending stress; =1.1 × =1.786 MPa
I 0.000000154

60 60
Torque on the roller T=p× =2146 × × π ×584=35 Nm
2 πN 2

Since the allowable stress >> maximum bending stress the design consideration is safe and factor of
safety is greater.
4 4
5∗W ∗L 5∗W ∗L
Maximum deflection;Y max = = 5 −7
=0.88
384 EI 384∗2.1∗10 ∗3.06∗10

As compared to length 500 mm, deflection of is very negligible. Hence, selected roller can be
considered as safe.

3.5. Design of chain

Chain are made up of a number rigid links which are hinged together by pin joint in order to
provide the necessary flexibility for warping round the driving and driven wheels. The toothed
wheels are known as sprocket wheel or simply sprockets. The sprocket and the chain are thus
constrained to move together without slipping and ensures perfect velocity ratio

3.5.1 Classification of chain

On the bases of their use chain can be classified as
  Hoisting and hauling chain
 Conveyer or tractive chain
 Power transmitting chain
From the above chain we have seen in detail about power transmitting chain. This chain are used
to transmission of power, when the distance between the shafts is short. These chain have
provision for efficient lubrication. Power transmitting chain are the following three type

 Block or bush chain

 Bush roller chain
 Silent chain
From the above chain we select bush roller chain because the chain is extremely strong and
simple in construction. It gives good service under sever condition. This is a little noise with this
chain which is due to impact of the roller on the sprocket wheel teeth. This chain may be used
where there is a little lubrication. And the most useful material to construct this chain is alloy
steel

Figure 3.5. Model of power chain [8]

Assume

N1=speed of rotation of small sprocket in rpm

N1=250 rpm

N2=speed of rotation of large sprocket in rpm

N2=150 rpm

T1=number of teeth in small sprocket

T2=number of teeth in large sprocket

We know that velocity ratio of the chain

Table 3.1. Standard table number of teeth at velocity ratio [6]

From the above table we find that the roller chain the number of teeth on the smaller sprocket or
pinion (T1) for a velocity ratio of 2 are 27 Number of teeth on the large sprocket or gear

We know that the design power =rated power × service factor ( )

The service factor (K ) is the product of various factor K1,K2, K3 the values of these factors are
taken as follow

Load Factor (K1) for variable load with heavy shock is 1.5

Lubrication factor (K2) for drop lubrication is 1

Rating Factor (K3) for 16 hours per day is 1.25

Service factor ( K s )=K 1∗K 2∗K 3=1.5∗1∗1.25=1.875

Assume that rated power is 3kw

d . p=r . p∗1.875

d . p=3∗1.875=5.625 KW
Table3. 2. Standard table of speed at give power [6]

From table we find that the corresponding to a pinion speed of 300 rpm. The power transmitted
for chain no. 12 is 5.625 kw per strand. There for a chain no. 12 with to strand can be used to
transmit the required power

Table 3.3. ISO standard breaking load [6]

From table by using design power we find that;

Pitch (p) =19.5mm

Roller diameter (d) =12.7mm

Minimum width of roller (w) = 11.68mm

Breaking load (W b ) =28.9KN

We know that pitch circle diameter of smaller sprocket or pinion

 d 1= p csc ( 180
T1)
=19.5 csc (
45 )
180
=164.1mm

Pitch circle diameter of the large sprocket or gear

d 2= p csc ( 180
T2 ) =19.5 csc (
27 )
180
=273.1 mm

Pitch line velocity of smaller sprocket

πd 1 N 1 π∗0.164∗300
v 1= = =2.578 m/s
60 60

Rated power 3 kN
load on chain w= = =1.164 KN , And
Pitch line velocity 2.578

w b 28.9 kN
Factor of safety Sf = = =24.83
w 1.164 KN

The minimum center distance between the smaller and larger sprocket should be 30 to 50 times
the pitch

Let as take it as 30 times the pitch

Center distance between the sprocket ¿ 30 P=30∗19.5=585 mm

In order to accommodate initial sag in the chain the values of center distance is reduced by 2 to 5
Correct center distance x=585−5=580 mm

[ ]
2
T 2−T 1
∗P
We know that the number of chain links (k) T 1+T 2 2 x 2π
¿ + +
2 P x

[ ]
2
45−27
∗19.5
27+45 2∗580 2π
k= + + =97
2 19.5 580

Length of the chain ( L )=k∗P=97∗19.5=1.89 m

3.6. Design of frame
Frame is used as for supporting Material selection We select mild steel used as frame metal for
guiding due to its medium cost and its good Mechanical property Mechanical property of mild
steel;

 Tensile strength=580Mpa
 Yield strength=400Mpa
 Density=7900kg /m3
Assume the load uniformly distributed. The frame is both end fixed and assume the force is
concentrated at the center, so maximum bending moment is created at the center. Material; mild
steel

 Tensile strength=580Mpa
 Density=7900kg /m3
 E=2.1×105Mpa

Figure 3.6 model of frame

 Assume Geometry of the frame;

 Length=8m  Width=12mm
 Height=100mm
Analysis

To check whether our design is safe or not we must find its bending stress and its must be lower
than from materials allowable stress can be safe.
2 2
th 12∗10 3
section modulus Z= = =20,000 mm
6 6
−5 3
Z=2∗10 m

2W
The maximum bending moment M ma x =
L
But we consider 2m length for frame between two legs to check bending stress.

The load act on the frame is the load of the 7 filled crate and 80 roller

Weight W=7∗180+ ( 40∗77.6 )=4364 KN

4364∗2
Maximum bending moment M max = =4364 KN
2

M
Bending stress M b =
Z

4364 Nm
M b= −5 3
=218.2 MPa
2∗10 m

M b ≪ M max, 218.2 MPa≪580 MPa therefore the design is safe

3.7. Design of leg

The legs used for carry and support the whole working portion of the machine. The legs which
have a rectangular cross section are fixed on the ground which supports overall weight of the
conveyor. The material used for design of supporter leg must have the ability to resist buckling
force because of force acting on it. Therefore, depend on these we select mild steel.

From locally available market we select the overall dimension of the rectangular cross section
legs to be

 Height = 850mm
 Width = 40mm
 Length = 40mm
 Thickness = 3mm
Figure 3.7.model of leg
Members such as leg that are long subjected to an axial compressive force can deflect laterally or
sideways if the force exceeds a critical value. This is called buckling. The mathematical formula
that shows below is used to calculate the allowable buckling load of the leg. The column will
tend to buckle in the direction of least moment of inertia. But in our case in all
direction moment of inertia are the same. For rectangular cross section;

Cross sectional area, A=L∗W =40 mm∗40 mm=1600 mm2

Moment of inertia, I xx=¿ I yy=I =¿

lw 40mm ( 40mm )
3

12
=
12
2
4
=213,333.33mm ¿
¿

Radius of gyration;k =
√ √
I
A
=
213,333.33 mm3
1600 mm
2
=11.55mm

() ( )
2 2
h 850 h 850
Slenderness ratio; s= k = 11.55 = k = 11.55 =73.6 mm

Crippling or buckling load calculates as follow:

σ c∗A 320∗1600
w cr = = =297,283.6 N
( hk ) For each frame
2
1 2
1+ α 1+ ( 73.6 )
7500

For four number of rectangular frame then total buckling load ( w cr ¿=

8∗297.287 kN =2378.3 kN

Calculation of total dead weight

 3 2
Weight of frame ( W f ) =L∗t∗h∗ρ∗g=8 m∗0.12 m∗0.1 m∗7900 kg /m ∗10 m/s =316 N

2
πd
Weight of single roller (𝑊𝑟) ¿ ∗L∗ρ∗g=77.6 N
4

But we have 80 roller so total weight =77.6¿80 =6,208N

Weight of single filled crate (𝑊𝑐) =180N

But the total carrying capacity of the roller conveyor is 16 crates at a time.

So, the total weight is, 𝑊𝑡𝑐=16 *180 =2880N

Total dead weight act on the leg (w) =𝑊𝑓 + 𝑊𝑟 + 𝑊𝑡𝑐=9404N=9.4kN

FS=2, then the Total dead weight act on the leg= 9.4kN×2=18.8KN

Therefore, the total buckling load is greater than the total dead weight.

i.e. 2378.32 KN >>18.8KN, then our design is safe.

3.8. Design of bearing

The roller is smoothly rotated on the bearing to both sides of the roller and it is bolted to the
frame.

Assumptions:-

 Bearings have great role in the machine to carry load so, they must have longer life.
Based on this idea assume the life to the bearing to be 8 years and 9 hours per day for lifting the
load and 300 working days per year.

 Material for bearing to be chrome- steel.

 Bearing type single row arrangement.
 Bearing type radial ball bearing is selected to carry load by to avoid stress concentrations.
Figure 3.8.model of bearing

Symbols:-

 LH→ life of bearing in hours.

 L → life of bearing in n m revolutions.
 B → bore of bearing.
 DO → outer diameter of bearing.
 W → basic dynamic equivalent radial load.
 WA→ axial load
 WR→ radial load
 N → angular speed for pinion.
 R → radius of outer diameter.
LH = years x days x hours
8 * 260 * 9 = 18720 hours
L = 60 x N x LH
60 * 50 * 20800 = 561.6 105 revolutions
Since the smallest roller diameter (the diameter which is assembled with bearing) is
20mm bore of the bearing is 20mm for contact roll bearing.
From table for standard dimension of radial ball bearing with bore 15mm, we can get:-
DO = 42mm, Width = 15mm, bearing number = 302.
We know that the basic dynamic equivalent radial load
W =X∗V∗W R +Y ∗W A
W A =150N,W R=100N
Table 3.4. Bearing specification [6]

In order to determine axial load factor (Y) and radial load factor (X) we require
W A /W R𝑎𝑛𝑑 W A /CO since the values of basic static load capacity ( C O) is not known
there for let as take W A /CO =0.5 and from the table we can find that the values of X and
Y corresponding W A /W R= 150/ 100 = 1.5
Which is greater 𝑒 = 0.44
X=0.56 and Y=1
W =0.56∗1∗100+1∗150=206
Since the rotational factor (V) for most of bearing is 1

( )
5 1

( )
1
L K 561.6∗10 3
Dynamic load rating:( C )=W 6
=206 6
=3.66 KN , Where k= 3 for ball
10 10
bearing
From standard table, for the corresponding bearing number=16kN,so the design is safe by
comparing with induced dynamic rating factor.

3.9. Design of roller blades

Roller blade is the principal element that convert pressure energy of the working fluid in
to kinetic energy or it is the portion of a tool weapon or machine with an edge that is
designed to puncture, chops, slice, or scrape surface or material.
Figure 3.9.model of roller blade [8]

3.7.1. Material selection

To design roller blade we select CA6NM. This is a combination of iron, chromium, nickel, and
molybdenum which is hardened by heat treatment. This material has very high tensile strength
and impact strength. This is not corrosive and thus it is used mainly in constructing structures
formed in water. Property

Value Density =1695 kg /m3

Young’s Modulus =1.9995 ¿ 105

Poisson’s ratio =0.27

Bulk Modulus=1.4489 ¿ 1010

Shear modulus =7.872 ¿ 1010

Yield Strength =689.43Mpa

Ultimate Strength= 827.37Mpa

Assume

The flow rate of water lave from washer machine (𝑄𝑡) = 0.08 m3 /s

Clearance ratio (𝐶𝑛) =0.6

Gross head (𝐻𝑔) = 6𝑚

Speed (N) =700 rpm

Input power to move roller convers (p) =𝑔 × 𝜌 × × 𝐻𝑛 × 𝑄𝑡

𝑛𝑒𝑎𝑡 ℎ (𝐻𝑛) = 𝐻𝑔 − 𝐻𝑡1 for hydropower 𝐻𝑡1 = 0.06𝐻𝑔

𝐻𝑡1 = 0.06 × 6 = 0.36

𝐻𝑛 = 6 − 0.36 = 5.64m

Figure 3.10.velocity triangle of blades [2]

885
specific speed ( N s )= 0.25
=103.28 rpm
Hn
1.25
Hn ∗N s 5.461.25∗103.28
roller speed ( N )= = =584 rpm
√p √ 2.164
84.58∗∅∗√ Hn
Runner diameter ( Drn ) = Where ∅ =0.0242∗N s0.66=0.515
N

84.58∗0.515∗√ 5.46
Runner diameter ( Drn ) = =0.174 m
103.28

Hub diameter ( Dhu ) =outer diameter of the roller+ clearance ratio

Hub diameter ( Dhu ) =50 mm+0.6=50.6 mm

 π ( D rn −Dhu )
2 2
Q 2
speed of inlet velocity ( V f 1 ) = Where A= =0.022 m
A 4

0.08
speed of inlet velocity ( V f 1 ) = =3.63 m/ s
0.022

πDN 3.14∗0.174∗584
Average blade velocity ( U )= = =5.32 m/ s
60 60

P 2146
Whirl velocity ( C u 1 )= = =5.04 m/ s
ρqU 1000∗0.08∗5.32

−1 V f1
inlet blade angle ( β 1 )=tan =85 °
U −C u1

−1 Vf1
blade outlet angle ( β 2 ) =tan =34 °
U

Drn
Number of blade ( N b ) =6+ =7.74
2∗D hu

Force on the blades

π ( Drn2 −Dhu2)
Axial force ( F a ) =g∗ρ∗Hn∗A Where A= =0.022 m2
4

Axial fo rce ( Fa ) =1695∗9.81∗5.46∗0.022=1.97 KN

P
Tangential force ( F t ) = =5 N
2 π N b∗N
3.10. Design of nozzle Nozzle
Used to convert liquid flow in to high speed which strikes the blades or vanes mounted on the
runner which in turn rotates the runner of blades.

Figure 3.11.model nozzle [10]

3
m
The water flow through each nozzle (Q) = 0.08
s

2
π Drn 3.14∗0.1742 2
Nozzle area (A)= = =0.024 m
4 4

Drn −Dhu 0.174−0.0506

Nozzle length (( Ln ) = = =0.018 m
tan β 1 tan 85

The distance between the nozzle and runner should be 5 percent the runner circle diameter
plusan extra 3mm clearance to account for emergency deflector.

x nb=0.05∗Drn + Dhu=0.05*0.174+0.05=0.0112m

The clearance between the nozzle and blade

x nb=0.625∗Drn=0.625∗0.174=0.018 m
3.11. Design of connecting road
Road is an element used to carry load and connect both fame of the roller conveyer

Material selection

Materials used for connecting road should have the following properties:

 High strength
 Good machinability
 Good heat treatment properties
 High wear resistance properties

We select carbon steel for connecting road design.

40c8 carbon steel which has 𝜎𝑦 = 248.17𝑀𝑝𝑎 and 𝜎𝑢 = 482.55𝑀𝑝𝑎.

Assume the length of connecting road (L) = 50mm

The road is subjected to bending moment due to the weight the roller and packets

Figure 3.12.Bending moment diagram

Since F=mg where m is the weight of the packets which is 18kg and g is 9.81𝑚 / 𝑠2

F=9.81× 18 = 176.58𝑁 and we can determine RA and RB to use summation of force along y axis
and x axis

∑ 𝐹𝑦 = 0

∑ 𝐹𝑦 = R A + R B −176.58=0 but the force is applied at the middle point of the road the two
reaction forces are equal. Therefore, R A = R B= 176.58N
To determine the bending moment at different section. Then we obtain the maximum bending
moment

∑ Mx=0
∑ Mx=−0.025∗176.58+176.58∗0.050=4.41 Nm
P∗60 2164∗60
Torque ( T )= = =35 N
2 π∗N 2 π∗584

16 T
M= 3
πD

D=
√
3 16 T
πM
=34mm

3.12. Casing

Casing is strong steel pipe used to prevent the wall of wellbore from caving and other things we
use casing:-

 Prevents caving of the borehole.

 Provide a support for fractured, weak and vulnerable formations.
 Prevent contamination of fresh water zones, and to prevent water migration to producing
formation.
 Provide support for surface equipment (Blow out prevent and production tree).
 Isolate abnormal pressure zones and also lost circulation zones (To control pressures
during drilling).
 Provides a borehole of a known diameter for further operation.
 Provide passage for production fluids. In general production.
 Allow an adequate means for installing artificial lift equipment for production
CHAPTER FOUR

4. Results and discussion

4.1.Results

Table 4.1.Results of our desiagn

For roller

Load per roller 3.6kg

Weight 35N

Maximum moment 2.2Nm

Moment of inertia 3.06×10^-7m^4

Maximum bending stress 1.79Mpa

Maximum deflection 0.88m

For power chain

Velocity ratio 2

No.of teath in large sprocate 45

No. Of teath in small sprocate 27

Survice factor 1.875

Rated power 3.75KW

Pitch 19.5mm

Roller diamrter 12.7mm

Mimimum width of roller 12.68mm

Breaking load 28.9KN

Pitch circle diameter of small sprocate 52.7mm

Pitch circle diameter of large sprocate

Pitch line velocity 0.544

Load on chain 5.514KN

Factor of safty 2

Center distance between sprocate 585mm

Coract center distance 580

No.link 96

Length of chain 1.872m

For frame

Length of frame 8mm

Width of frame 12mm

Hight 100mm

Section modules 2×10^-5 m^3

Maximum benfing moment 4364N

Bending stress 218Mpa

Weight 4364N

For leg

Area 1600mm^2

Moment of inertia 213333mm^2

Radius of gyration 11.5mm

Slenderness ratio 73.6

Buckling load 297.28KN

Weight of frame 316N

Total weight 2880N

Total deid weight 18.8KN

For bearings

Life of bearing 561.6×10^5

Dynamic equivalent radial load 100N

Dynamic load rating 3.66KN

For roller blades

Input power 2.614KN

Net head 5.46m

Specific speed 103.28rpm

Roller speed 584 rpm

Runner diameter 174mm

Hub diameter 50.6mm

Speed of inlet velocity 3.63m/s

Blade velocity 5.32m/s

Inlet angle 85 degree

No. Of blade 8
 For nozzle

Area 0.024m^2

Length 0.018m

Clearance between nozzle and blade 0.018m

Distance between nozzle runner 0.0112m

For connecting road

Weight 176.58N

RA 176.68N

RB 176.68N

Maximum moment 4.41Nm

Diameter 34mm

4.2. Discussion
The roller conveyors do its task properly, when the results which determined from design
analysis must be applied. The roller conveyor is powered with hydropower which have rating
speed of 584rpm; it can drive all rollers if assembly is made perfectly. The rollers are installed
with the help of radial ball bearing end to end. Frames are needed for seating bearing properly.

The blade roller and the first roller are connected by chain to transmit the power and torque from
blade to other rollers. The rollers are seat with in an interval of 5cm between each other.
The crate covers 5 rollers at a time of motion. The hydropower must have planetary type gear
box to get Varity speed and torque for comfortable transportation of bottles and crate

4.3 Cost analysis of desiagn

The material we use in the project in each component is mild steel as we have listed the reason in
the material selection and its density,modules of elastisity,yield strength. The cost estimation
depends on the material durability,types and size.

Cost analysis of roller

The cost of one mete long, 50 millimeter outer and 42 millimeter inner diameter roller of mild
steel is 300 birr.We have used 0.5 meter long with the same diameter.So,the cost of one roller is
150 birr.

Therefore, the total cost of roller is 150*80=12,000birr.

since number of roller is 80.

Cost analysis of chain

Various type of chains are there in the shop.However,due to the reason we have listed in material
selection we used bush roller type.The cost of this type of chain which have 12 meter is 14,000
birr.

Cost analysis of frame

The costs of the frame which are made up of mild steel of 1 metter long and 6 up 12 millimeter
thicknesses are 100 birr.So,the cost of frame that we have used is;

24meter×100birr=2400 birr.Since, 24 meter is the length of two frames.

Cost analysis of leg

The cost of one meter long leg is 80.But,We used four legs with 850 millimeter.

Cost of one leg is 0.85×80=68 birr.So,

The Cost of four legs are 4×68=272birr.

Cost analysis of bearing

Based on durability or life time and its type we bought 160 bearings.The bearing that we have
used to the project is radial ball type and it can works 20 hours per a day.

Cost of one bearing is 120 birr.

Therefore, the tolal cost of bearing is; 160×120=19,200 birr

Cost analysis of blade

The blade must be ressist the corrossion and other failurity because the water that hits the blade
is not pure. So,due to that we bought good life time blade.

The price of blade is 5000birr.

Cost analysis of nozzle

The price of nozzle with diameter is 174.2 millimeter is 2300 birr.

Cost analysis of connecting rode

The material which used to made the connecting rode is carbon steel.The price of carbon steel of
one meter long is 4000birr.

Threfore,the price of 0.5 meter long connecting rode is given by;

0.5×4000=2000birr.

4.3.1.Material cost

Table 4.2. material cost

No Item QTY. Unit price Total price

1 Roller 80 150 12,000

2 Chain 1 14,000 14,000

3 Frame 2 12,000 24,000

4 Leg 4 68 272
5 Bearing 160 120 19,200

6 Blade 1 5000 5000

7 Nozzle 1 2300 2300

8 Connecting 1 2000 2000

rode

78,772

4.3.2.Manufacturing cost

Table 4.3. manufacturing cost

No Qualification Cost

1 Millimg machine 200

2 Drilling machine 150

3 Lathe machine 300

4 Welding machine 150

800

4.3.3. Total cost for our design

Table 4.4. Total cost for our desiagn

No Item Material cost

1 Material cost 78,772

2 Manufacturing cost 800

3 Total 79,572
REFERENCES
[1] M. A. Alspaugh. "Survey of Research In Modeling Conveyor-Based Automated Material

Handling Systems In wafer fabs" Proceedings of the Winter Simulation Conference (2007)
 [2], Shirley’s Mechanical Engineering Design, Eighth Edition Budynas−Nisbe

[3], Shirley’s Mechanical Engineering Design, 8th edition, TATA McGraw Hill publication,

(pp: 597-652, 2009)

[4], Dima Nazzal , Ahmed El-Nashar “Survey Of Research In Modeling Conveyor-Based

Automated Material Handling Systems In wafer fabs Proceedings of the 2007 Winter Simulation

Conference.

[5], John Usher, John R, G. Don Taylor “Availability modeling of powered roller conveyors”.

[6], R.S. KHURMIJ.K.GUPTA, text book of machine design

[7], Text book of engineering mechanisms of machinery.

[8], S.H. Masood · B. Abbas · E. Shayan · A. Kara, (2004) “An investigation into design and

manufacturing of mechanical conveyors Systems for food processing”, Springer-Verlag London

Limited.

[9], Vishwanath Patil, Prof. K. H. Munde, (2016) “Stress Analysis and Weight Reduction of
Roller

of Roller Conveyor”, IRJET

1. A manual Raya Brewery Sh.Co Brew House Wort Production Compiled By: Ermias Teshome,
November 2015.
2. Brewing science and practice, Dennis E. Briggs, Chris A. Bolton, Peter A. Brookes and Roger
Stevens, Woodhead Publishing Limited and CRC Press, 2004.
3. Den Skandinaviske Bryggerhøjskole Packaging Packaging Technology Abstracts Module

3, 2006.

4. Operating Manual Filler – Modular Design, Base-Handling System by krones 2013.

5. Operating Manual Double-End Bottle Washer by krones 2013.

6. Technology Brewing and Malting, Wolfgang Kunze, International Edition, 1999.

CHAPTER FIVE

5. Conclusion and Recommendation

5.1. Conclusion
The project is focused about the rate production system of the company to increase its annual
profit or income by cost minimization and by developing material handling equipment that the
company did not use currently. One of the problems of the company is improper use of material
handling in production room; the company use old type gravity roller conveyor. The problem of
this conveyor is it is drive by man power to transport crate and bottles. This leads to out of use or
crashing of bottles. Further it minimizes the income of the company. Other type of material
handling problem that the company did not use is robotic system for picking placing of bottles at
the beginning and end of the production system. To solve this project focused on powered roller
conveyor. The conveyor is modified with replacing of man power by hydropower drive. The
conveyor includes rod, rollers, chain, frame, leg, bearing and support beam. The current
conveyor that the company uses is 8m long from feeding to end of the process. The project also
focused this total length to solve the problem totally. The design for this project is based on
standard specifications and based on force, stress, torque, compressive, and rating speed of
movable parts.

5.2. Recommendation
We recommended that the company to use this conveyor to increase its income/ profit and it will
avoid labor tiredness, to follow modern production system, to reduce wastage of materials like,
bottles and crate. The user should use proper oiling and lubrication for parts of conveyor to
reduce power loss and to increase its durability and Cost of the project can be minimized by
changing material type without reduce its working performance; this is done by standard
specifications.

Therefore, manufacturers can use this machine at low cost. In addition to this we recommended
the following to improve company working condition and to reduce different wastages
APPENDIX
Assemble drowning