PART ONE

CHAPTER ONE
DECLARATION

We hereby declare that this work, which is being presented in the report on internship at Dashen
Brewery S.C for the completion of internship program, carried out from March.01/2016 to
june.30/2016 under the supervision of Mrs. MARSHET.M is instructors in School of
Mechanical Engineering, Mechanical Engineering program of DEBERTABOR university
Institute of Technology, is an independent work of mine. All writings in this document contain
things that are done by our effort exclusively.

All relevant resources of information used in this paper have been duly acknowledged.

Name of student Signature Date

_______________ ____________ ____________

This is to certify that the above statement made by the candidate is correct to the best of my
knowledge and belief. This report has been submitted for presentation with my approval.

Name of Mentor Signature Date

--------------------------- ----------- ---------------------

Name of Supervisor Signature Date

--------------------------------- ------------------- -----------------

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ACKNOWLEDGMENT

We very appreciatively grateful to all those who lent me their generous hands for the success of
my internship period. It is your help that make me to stay awake. For the ministry of education,
the institute, the bottle section and all the members and all the company members, I would like to
say thank you for your invaluable support.

Before all we would like to express our deepest gratitude to thank our campus advisor, Mrs.
Marshet for her valuable advice, And we would also like thank to Mr. Ismael Abdi packaging
engineer of Dasheen brewery S.C no word to say our pleasure to spend our internship
program and all the workshop members, it is the very kind of you help me even when you
are very busy.

Lastly, we offer our regards and thanks to all of those who supported us in any respect during the
completion of the internship program.

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 EXCUTIVE SUMMARY

The report presents the following tasks completed during internship at Dashen Brewery S.C,
which is listed below:-
1. The overall background of the company.
2. The overall benefit from the internship program.
3. Project work on specific area to crush and reuse beer bottles.
4. Project work on the blow down heat recovery

The overall background of the company focus mainly on the main structure of the company &
process flow of each room. It consists of

 Raw material room, malt feed to in feed hopper, then to the pre-cleaning room.
 Brew house room, wort production through different process .Beer processing,
wort from brew house through the process of, filtration, fermentation & yeast
propagation.
 Bottling and packaging, beer filling & labeling are starting from KEG plant,
separation of bottled beer & draft beer through different bottle & crate washing
processes to the finished product storage room.
 Utility, the backbone of the company which includes water treatment plant, CO 2
recovery plant (CO2 purified), cooling plant, boiler plant, air compressor plant,
water chilling plant and waste water treatment .

The rest of the pages contain proposed solutions to the heat loss in the boiler plant and the
manual bottle breakage in addition to the overall benefits the & whole experience that I gained
from the internship program.

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 TABLE OF CONTENTS

Contents page

PART ONE......................................................................................................................................1
DECLARATION.........................................................................................................................1
--------------------------------- -------------------
-----------------ACKNOWLEDGMENT.......................................................................................1
EXCUTIVE SUMMARY............................................................................................................3
TABLE OF CONTENTS.............................................................................................................4
LIST OF FIGURES.....................................................................................................................5
LIST OF TABLES.......................................................................................................................5
2. Background of the company....................................................................................................6
2.1. History of the company.....................................................................................................6
2.2. MAIN PRODUCTS AND SERVICES.............................................................................7
2.3. END USERS OR CUSTOMERS......................................................................................8
2.4. ORGANIZATIONAL STRUCTURE...............................................................................9
2.5. WORK FLOW................................................................................................................10
CHAPTER THREE.......................................................................................................................15
3. THE OVERALL BENEFITS GAINED FROM THE INTERNSHIP...................................15
3.1. WORKING SECTION OF THE COMPANY................................................................15
3.2. WORK TASK.................................................................................................................16
3.3. ENGINEERING METHODS, TOOLS AND TECHNIQUES.......................................16
3.4. MAJOR CHALLENGES AND PROBLEMS IDENTIFIED.........................................17
3.5. GAINS OR BENEFITS...................................................................................................17
PART TWO...................................................................................................................................45
2. PROJECT BOTTLE CRUSHER MACHINE DESIGN AND MANUFACTURING..........45
2.1 PROJECT SUMMARY...................................................................................................45
2.2. PROBLEM STATEMENT.............................................................................................46
2.3 OBJECTIVES..................................................................................................................47

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 2.4. METHODOLOGY..........................................................................................................48
2.5 RESULT AND DISCUSSION.........................................................................................55
2.6. MANUFACTURING PROCESS....................................................................................66
2.7. CONCLUSION AND RECOMMENDATION..............................................................70
PART THREE...............................................................................................................................71
3. GENERAL CONCLUSION AND RECOMMENDATION.................................................71
REFERENCES.......................................................................................................................72

LIST OF FIGURES
Figure 1 organizational structure.....................................................................................................4
Figure 2 Mill star machine...............................................................................................................6
Figure 3 Beer production process flow............................................................................................8
Figure 4 Fermentation tank and bright beer tank.............................................................................9
Figure 5 de palletizer.......................................................................................................................9
Figure 6 Un caser...........................................................................................................................10
Figure 7 Carate washer..................................................................................................................10
Figure 8 Bottle Washer Machine...................................................................................................11
Figure 9 Filler machine..................................................................................................................12
Figure 10 Pasteurizer machine.......................................................................................................13
Figure 11 Labeler machine............................................................................................................13
Figure 12 Caser..............................................................................................................................14
Figure 13 manual bottle breakage..................................................................................................52
Figure 14 breaker..........................................................................................................................59
Figure 15 roller..............................................................................................................................61
Figure 16 casing.............................................................................................................................61
Figure 17 hopper or container.......................................................................................................62
Figure 18 braker.............................................................................................................................67
Figure 19 roller..............................................................................................................................67
Figure 20 container........................................................................................................................67
Figure 21 casing.............................................................................................................................68
Figure 22 transfer...........................................................................................................................68

LIST OF TABLES

Table 1 Shaft power and diameter estimation...............................................................................56

Table 2 Manufacturing process bottle crusher...............................................................................66

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Table 3 cost analysis of bottle crusher...........................................................................................69
CHAPTER TWO

2. Background of the company

2.1. History of the company
The name Dashen is taken from the famous mount Dashen, which is located 100km from the
brewery; Ethiopia’s highest mountain (Elevation 4523 meters) and a home for rare endemic
found and flora. Dashen brewery share company (DBS.C) is located in historical town of
Gondar, which is 180km far from Bahirdar and annually visited by about 95.000 tourists. The
brewery is situated on the area of 85,000 square meters with building area of 12,000sqm DBS.C
is established in September 2000, with an initial capital of over 340 million birr. It is owned by
Amhara regional state rehabilitation development organization and KRONES. Dashen brewery
utilizes state of the art technology and highly qualified exports that will enable it to compete on
the exports market with the leading international beer producing and marketing companies.

Dashen brewery S.C is the first brewery to be ISO 14001, 2004 EMS (Environmental
management system) and ISO 9001, 2008 QMS (Quality management system) certified which
enables the company to focus on customer satisfaction measurement, formulate policy and
objective by taking in to account regulatory requirement and information on activities with
significant environmental impact. Before expansion Dashen brewery had annual production
capacity 300.000 hectoliter, by expanding its capacity in to three fold the brewery has now
annual production capacity 769000 hectoliter.

Currently, the total work force in the Dashen brewery S.C is more 700 employees of which 580
permanent and 120 are contract employees. Dashen brewery S.C participates in different
development activities such as education, health, sports art and environmental conservation and
job opportunities.

2.1.1 VISION
 To make central venue for quality beer .it is endowment fund established to contribute for
the development of Amhara region by producing and selling quality beer at competitive
price and generate reasonable income.

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  To be leader in countries beer industries with respect to quality, competitive price,
prospect to high technology and international orients as well as sample for the overall
industrial sector in the country.
 To make Dashen the central venue for quality beer celebrities.

2.1.2 MISSON
 To support socio-economic development of Amhara region in particular and to the
overall development of the country in general. It is an endowment fund established to
contribute for the development of a region by producing and selling customer preferred
quality beer at competition reasonable price and generate a reasonable price.
 To by generated profit to improve the socio-economic wellbeing of the Amhara region.
 To product and seek quality beer at reasonable profit.

2.2. MAIN PRODUCTS AND SERVICES

The company produces

 Pasteurized (Dashen, royal and drought) beer

 cellar and
 Co2 as main product.

It also produces

 spent grain and

 De watered sludge as a byproduct.

It grants job for more than 700 employees and labor workers. Dashen also serves as intern
destiny for more than 200 students from many local universities. It supports many huge projects
in the country. The company has football club, being participated in Ethiopian premier league, in
its own name fully sponsored by itself. So it actively participates in different development
activities such as education, health, sports, art and environmental conservation and job
opportunities.

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 2.3. END USERS OR CUSTOMERS
The main products of Dashen Brewery are Dashen beer, Royal beer, Draught beer (locally called
draft beer) and Cellar. The end users/customers are every person above 18 years old. There is no
any limit or boundary in order to be a customer for Dashen beer other than specified above.

The products are distributed across the country in four regions and three warehouses. The
regions are:

Region 1: covers Amhara, Benishangul and Afar region.

Region 2: this covers the whole Tigray region.

Region 3: covers Central and Western part of Ethiopia.

Region 4: East and South parts of Ethiopia.

The three warehouses are:

• Gondar,
• Woldia and
• Addis Ababa

Dashen brewery exports its products to the following foreign countries:

i. California, Chicago in America.

ii. Australia.

iii. Israel.

iv. Southern Sudan.

Agents distribute 90% of the product and 10% distribution done by direct distribution to
retailers.

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2.4. ORGANIZATIONAL STRUCTURE

Figure 1 organizational structure

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 2.5. WORK FLOW

2.5.1. BASIC RAW MATERIAL

Four basic raw materials are required for beer production:

 Malt  Water and

 Hops  yeast

The quality of these raw materials has a decisive influence on the quality of the final product.

MALT: is the main raw material for beer production. Its use depends on the fact that barley has
high starch content and the husk still adheres to the gain, even after threshing and processing to
malt. Consequently it is able to form the wort filtration layer required in a later production stage.
Before use in the brewery the barley must first be converted in to malt.

HOPS give beer its bitter taste and have an effect on the aroma. The quality of the beer depends
on greatly on the quality of the hops.

Quantitatively the most important raw material is WATER. This affects the beer character and
quality at several processing stages. In addition water is used for many other processes in the
brewery and in malting.

YEAST is depends the alcoholic fermentation to form beer. This consequently is essential for
beer production. The yeast has a great effect on beer quality because of the effect of its metabolic
by-products.

Physical treatment of malt

The malt is imported from Belgium without purification. Like addition of metal, stone, other
gain straw and other objects, so to need purifications:
Intake Hooper -The purpose of this is to discharge the malt into pre cleaner by bucket
conveyors (elevators)
Pre cleaner -Pre clean ear is installed with inclination, because easily remove straw, sack
binders, piece of wood etc.

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Dry De stoner-The pre cleaned malt is intake to the DE stoner the main purpose of this they are
used to separate granular material according to specific weights, Less than malt size , Equal to
malt size and Greater than malt size like coffee and other grain
Pipe magnet -Magnet devices are built into operate near the start of processing, so that iron parts
flowing with the product cannot cause any damage. Simply remove metal part from the malt.
Mechanical weigher-Pure malt is before it release into malt mill weighed records the weighed
release 50 kg in one time they it moves by chain convey to malt mill

2.5.2 WORT PRODUCTION (BREW HOUSE)

2.5.2.1 MILL STAR

This machine comprises of four parts
 Hooper- Pure weighed malt is feed in to hoper
 Stepping -Malt steeping before filling pure malt step with hot water a temperature of
58oc b/c of do not produce powder
 Crushing zone -The stepping malt enters into the crushing roller by control of feed
roller.

Figure 2 Mill star machine

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 2.5.2.2 MASHING TUN
The milled malt was mixed with water in a mashing tun kettle (MTK), mashing is the most
important process in wort production. The process of mashing refers to the conversion of
brewing materials in the presence of enzymes into fermentable extract suitable for yeast growth
and beer production. Mashing involves increasing the temperature of mash to optimum
temperature for enzyme that one allows to act, and maintaining a rest at that temperature. Protein
rest (62℃), maltose rest (63℃), Saccharification rest (72℃), mashed off (78℃).

 Objective of mashing
 To form an extract with desired level of sugar that can yeast utilize.
 To dissolve soluble extract immediately
 To convert extracted substance in to fermentable extract through enzymatic action

2.5.2.3 WORT KETTLE

Wort kettle is an optimum tank for boiling wort which simple design a variety of combination
option like external boil and hoper adding the external boil wort 1-2 hour about 98℃ in this tank
hopes are added according to the brewery specification. There are two different hopes added on
the wort kettle, for bitterness and for color, extract flavor and aroma compound from hope, the
main purpose of wort boil is to remove water. Once the wort boiling process is complete, the
wort is pumped in to the whirl pool. At wort kettle, have different valves like safety valve (relief
valve) protects the heat from over pressure from the wort.

2.5.2.4 WORT COOLER

Wort which can be produced in the whirl pool is very hot with high temperature this need to
minimize to the lower temperature as it needed this is performed using plate heat exchanger
which is ready for this purpose inside the brow house heat exchange minimize the hot wort
temperature.

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 2.5.3. BEER PRODUCTION PROCESS FLOW

Figure 3 Beer production process flow

2.5.4 BEER PRODUCTION

 Yeast propagation
There are three distinct stages in pure yeast propagation.
 Isolation of suitable yeast cell
 Multiplication of the yeast in the laboratory

 Yeast multiplication in the plant until an amount sufficient pitching is obtained.

 Fermentation tank
 During fermentation the sugar in the wort are fermented in to ethanol and carbon
dioxide by yeast sugars are fermented
 In Dashen brewery fermentation takes 19-21 days in this day the wort is cooling
by glycol with- 6oc to rotates the fermentation tank

 Fermentation tanks are cylindrical council vessel, which is built with cylindrical
upper part and conical shaped lower part.
 Beer filtration tanks

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Filtration is separation process in which the yeast cell and other turbidity cause in material still
present in the beer are removed from the beer. The purpose of filtration is to make beer so stable
that no visible changes occur for a long time and so these beers looks the same as when it was
made. Filter aid are powdery substance diatom ate which are used in the brewery for the
filtration of beer then filtered beer transferred to bright beer tank.
 Bright beer tank (BBT)
The only purpose is to store the filtered beer Dashen brewery has 6 BBT, then filtered beer
transferred to bottle filler or draught filler.

Figure 4 Fermentation tank and bright beer tank.

2.5.5 BOTTLING AND PACKAGING PROCESS

De Paletizer

The carates are unloaded from the palette by the pneumatic and mechanical operated robot. This
is the newly installed machine

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 Figure 5 de palletizer

Uncaser (unloading)
During this process of this the bottle and the carate are separated by using pneumatic valve the
equipment has an efficiency to separate the bottle from the crate at a time.

Figure 6 Un caser

Crate washer
The crate can become dirty during transportation and in store after emptying they pass through a
create washer and turner are stacked in crate store until used after a filler
It’s used to wash the crate, then washed bottle crate moved to caser machine to put down
finished bottled beer.

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 Figure 7 Carate washer

Bottle washer
The shelf life of depends very greatly on the stage of the cleaned bottle empty bottles are returns
solid to very different extent from customers but all bottles, even the very dirty ones must be
cleaned to hygienically perfect condition.
In all case there are two tasks to be accomplished
 The bottle must be cleaned mechanically

 All beer spoilage microorganisms must be removed and killed

The mechanical or optical cleaning effect is regarded as achieved when no visible soiling can be
detected in or on the bottle. Mechanical cleaning is considered to have been achieving if the
bottles are covered by continuous film of water.

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 Figure 8 Bottle Washer Machine

Visual inspection
Visual inspector is used to inspect of all cleaned bottles from out bottle washer.

Empty bottle inspection

 To reject this machine like Foreign bottles, Faulty bottles and Contaminated bottles
 And to detect
 Caustic detection , Side wall inspection, Lateral neck finish inspect and

 Bottle height detection

Filler machine
 Bottle filling machines are always built as rotating machines with up to 120 filling values
 During rotation of the filler the bottle are
 Pressed against the filling element
 Evacuated and counter pressurized once or twice
 Filled
 The filling height in them is corrected
 The pressure is released and

The bottle are lowered again and mixed away.

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 Figure 9 Filler machine

Crowner cork
The crown cork pass and magnetic conveyor band a slide or other conveying device into the
storage hopper of the bottle closer and there is brought in to the correct orientation by a sorting
devices.
Pasteurizer
No viable microorganism is to treat at the last possible movement that is the beer is treated
various water circulation paths in order to utilize recovered heat. It takes about an hour to pass
through.

There are ten sections in which one bottle stays the pasteurization unit 6 minutes.

Figure 10 Pasteurizer machine

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Labeler
The main function of labeler is labeling on neck and body of the beer bottle. The appearance of
the bottle is extremely depending on the quality of the labeling to be able to do this label paper
must have the following properties are contained
 Amount (volume)
 Expired date
 Production data

 Ingredients (food grades)

Generally for labeling process glue and air are the two important materials to coat the label.

Figure 11 Labeler machine

Full bottle inspection (FBI)

The full bottle inspector defects
 Neck label , Body label , Missed label , Proper closing of crown cork and Under fill and
overfill
The presence and arrangement of the labels are checked by using photoelectric sensor if there is
a problem or error it sends a signal to a rejection.
Caser (loading)
It’s pneumatic operated machine, which can put down the bottle with in the crate.
Note: caser and UN caser machine.

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The bottle in a crate are fitted from the create by a gripper head and set down at a predetermined
position. The sequences of operation are performed continuously.

Figure 12 Caser

Paletizer

The one which loads the carate to the palette so that it is ready to be stored transported by the
fork lift.

Figure 13 Paletizer

CHAPTER THREE
3. THE OVERALL BENEFITS GAINED FROM THE
INTERNSHIP
Internship is one method of making opportunity for undergraduate students potentially valuable
and explores general career avenues as well as specific companies. Such arrangement can
provide us with valuable work experience and an opportunity to line up job before graduation, in
addition to securing good work experience. Internship programs are also potentially valuable to

20
company. Unfortunately, some companies continue to regard interns as a little more than free
source of labor to catch up on filling and other tedious office work. However, many business
owners and managers realize the internship programs can provide them with an early opportunity
to gauge the talents of a new generation of workers and, in many cases, sell themselves as a
quality place for students to begin their careers after they graduated.

While we participate in this internship, we expect that only practical and theoretical knowledge
will be gained in the internship but after completing of the internship, we were able to realize
that we get so many benefits some of them are described above from intern perspective view and
company perspective view. The major benefits that we get from the internship are classified and
stated as below briefly.

3.1. WORKING SECTION OF THE COMPANY

Since we are mechanical engineering student, we directly involved into the maintenance and
production activities. We were always there wherever maintenance of production equipment’s
and machineries is being done. But mainly we were allocated to the following areas
 Packaging and bottling, where beer bottle is washed, filled with beer, labeled
etc. and where drought beer is pasteurized and filled.
 Workshop and garage, where required tools are made and tools and machines
are maintained
 Utility, where all the required raw materials except the malt and hop are
produced, recycled and recovered

3.2. WORK TASK

The major tasks that we were involved are

 Bottle crusher machine designing and manufacturing

 Design of boiler blow down heat recovery system design
 Boiler efficiency test
 Bourdon tube pressure gauge maintenance
 Screw conveyor manufacturing
 Conveyer maintenance

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  Labeler disassembly, cleaning , servicing and assembly
 Pasteurizer overhauling
 Filler overhauling including sun gear replacement
 Caser and uncaser overhauling
 Gear box disassembly and assembly

 Air compressor plant disassembly and replacement of screw compressor

 boiler plant overhauling including boiler burner disassembly servicing and assembly,
furnace oil pump maintenance, blow down discharge maintenance, boiler fire tube
cleaning
 co2 recovery plant overhauling including ammonia condenser descaling, co2 intercooler
and after cooler descaling, activated carbon replacement,co2 evaporator replacement,
micro cooler descaling,
 cooling plant overhauling including evaporative condenser descaling

3.3. ENGINEERING METHODS, TOOLS AND TECHNIQUES

I have tried to apply the methods that I acquire and tools that are available to the subject as well
as the techniques I can discover to be applied. Among them

METHODS

 problem solving
 data collection
 data analyzing
 maintenance

TOOLS

 extractor to extract bearings, gears and gearbox assembly

 welding machines
 grinders
 pipe wrench
 Allen key set

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 3.4. MAJOR CHALLENGES AND PROBLEMS IDENTIFIED
Since we were theoretical students, it was difficult for us to know even the mechanical
equipment’s. We were confused to understand the working principles of machines when they are
working because we were not properly introduced to the practical world. The other difficulty was
there some areas that are not allowed for students to enter.

In order to be familiar with the mechanical devices, we first tried to observe them when they are
not working by asking anyone in the room about them repeatedly to enable us to know the
internal deriving mechanisms

3.5. GAINS OR BENEFITS

3.5.1 INTERMS OF IMPROVING OUR PRACTICAL SKILL

In Dashen brewery S.C., the internship program I will get much more experiences from
maintenance staffs. So I will improve practical skills like:
 Thinking and the highly developed disassemble and assemble of the machine.
 Effective assessment and management risk, resource and time.
 Creativity and innovative approach to solving problem
 The ability to analyze and interpret diverse, complexes data

 Critical ability to evaluate designs, plans and projects

And I can develop my skill by participating myself into different part. As I had learned
theoretically in my department courses

3.5.2 INTERMS OF UPGRADING THEOROTICAL KNOWLEDGE

For working practically it also improve the theoretical skills by any means like, when working
time to asks the maintenance staff, to read the manuals, also read references books when working
projects and we will improve theoretical skills like.
 Capacity of all machine in the company
 Mechanisms of machine in the company
 Type of machine

 About the projects of how it can improve capacity in brew house technique

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 3.5.3 INTERMS OF IMPROVING TEAM PLAYING SKILL
Team playing skills are one of the basic requirements for the proper working of a good company
regardless of its size and service and to improve like:
 To increase self confidence
 Easily control the environment
 Easily solve problems

 To share knowledge’s
 To give fast decision making
 To interpret the problems and solve the problems
 Giving respect for other
 To narrow differences

3.5.4 IMPROVING OUR LEADERSHIP SKILL

A leader is a person who has strong principles, courage and dedication of a clear vision, and
improving:
 Creating and managing the vision  Motivating and developing others
 Making good decision  Resolving conflicts and issues
 Communicating effective  Creating positive culture and climate
 Using appropriate style and power  Conducting meaningful evaluation
 Leading change

3.5.5 UNDERSTANDING ABOUT WORK ETHICS

 Solve the problem by discussion
 Carefully understand the procedure
 Being effective in performance
 Being punctual and motivated
 Be fast to understand changes
 Share experienced knowledge
 Be honest to all
 Being transparent and operative

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 3.5.6 INTERMS OF ENTERPREANURSHIP SKILL
The basic entrepreneur skills that these people have and I noted is

 Business planning
 Risk assessment
 Team building

A wide range of skill is seen as entrepreneurial and useful to entrepreneurs, these includes

 The ability to tell ideas and persuade others

 The ability to work both as parts of a team and independently
 Able to research effectively for example
 Available markets
 Suppliers
 Customers and
 The competition
 To be self-motivated and disciplined
 To be adaptable
 To have innovative thinking and to be creative
 To take responsibility and make decision
 The ability to work under pressure
 To be willing to take risks
 The ability to network and make contact
 Being visionary and goal oriented

3.5.7 INTERMS OF IMPROVING INTERPERSONAL COMUNICATION

Developing interpersonal communication skill is vitally important in today’s work place. In the
company of Dashen brewery have different professional persons so that to the knowledge from
those persons have interpersonal internship skills and also improve good playing skills to
internship friends and get from mentors about everything what we have to need.
Generally, we get it by the help of good communication skills like:
 To increase practical skill

25
  To increase the theoretical knowledge of each machine
 And create smooth relation to other staff members
In addition, for working projects require communicating with our partners.

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 PART TWO
2. PROJECT BOTTLE CRUSHER MACHINE DESIGN AND
MANUFACTURING
2.1 PROJECT SUMMARY
Beer bottles can be broken and useless in the normal bottling and packaging process due to
different reasons. The most frequent one is one bottles are broken during its way through out
from the de palletizer to palletizer. It can be broken due to thermal crack in the washer and
pasteurizer or it can be broken in filling and labeling machines etc. So these broken bottles are
waste to the bottling process but the waste bottles is a resource out of its place. They have to be
recycled or crushed to be used in making concrete. But in Dashen brewery these broken pieces of
bottles are hammered manually in to smaller pieces and then transported to Addis to be crushed.
Obviously this hammering process has to be mechanized.

Beer bottles are hard but not tough so they can be broken easily with a single collision. The only
requirement is to collide it with something harder than the bottle with high speed just to create
higher impact. Someone who wants to break bottles must exert a higher impact and someone
who wants to crush it needs a higher compressive force. Relatively crushing small pieces of
bottles is easier than crushing full round bottles because the roundness itself contributes to the
compression strength of the bottle. So before the bottles goes to the crusher it is better to break
them in two pieces with a mechanism which will apply a greater impact.

Kicking the bottles and throwing to collide it with roughened wall is the best way to break them
in to pieces. This done by a high speed rotating profiled blade in a roughened casing. The bottle
after being kicked are thrown to the rough surface in front of the kicking blade, thus it creates
two chances to break bottles. After breaking the bottles are dropped to the crusher which is a
rotating roller with rough surface in this rough surface the clearance between the casing and the
roller depends on the crushed output. The corks are to be separated by a magnetic system at the
discharge. The magnet attracts the cork and make them out of the way of the crushed bottles then
we can collect the cork easily

27
 2.2. PROBLEM STATEMENT

The laborers who manually break the bottles by hammering each have to apply a force larger
than the weight of an 80kg man. Applying this force throughout the day is very tiresome and
overloading. The manual breaking of corks is risky because sharp bottle pieces hurtful and the
process is time consuming which makes it labor wasting. The cork is separated by manually
picking it after hammering this is difficult for glove worn fingers. Again the manually breaking
couldn’t bring the bottle in to uniform sized pieces.

 Risky
 Tiresome
 Time consuming
 It is not good transportation

Figure 14 manual bottle breakage

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 2.3 OBJECTIVES
MAIN OBJECTIVE

Our main objective is to design a bottle crusher machine and manufacture it to avoid the manual
breakage of bottles.

SPECIFIC OBJECTIVE

 To design breaker
 To design roller
 To design casing
 To design stand
 To design magnetic cork separating system

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 2.4. METHODOLOGY
 Contact with the company supervisor and talk about the gaps in the company
 Brain storm to solve the proposed problem
 Collect data primarily by asking the authorized individuals and secondarily by
surveying different literatures and searching on the web.
 Selecting materials for each component by studying the working conditions of
all the components
 Select the shaft diameter and power from table then select the motor and gear
box assembly that will provide the required power for the shaft
 Analyze the stress of the shafts
 Design the rest of the components in relation to the breaker and roller
specification
 Design the magnetic cork separation system
 Design the stand based on the total weight of the machine and the wind load
 Draw both the part and assembly drawing as per the dimensions designed
 Manufacture all the machine components using the available materials in the
shop
 Assemble, install, test the machine
 Analyze the cost of the machine using the cost standards that the company is in
market contact
 Conclude the project

30
 2.5 RESULT AND DISCUSSION
Design of components

 Breaker  In let container

 Shafts  Out let (discharge)
 Roller  Casing
 Bearings  Magnet

Design of breaker

The breaker plays two rolls or if breaks the bottles in two ways:-

1. It kicks the incoming bottles there by it breaks the bottles.

2. It also throws and make the broken bottles collide to the roughened wall in front of the
breaker kicking direction. So to perform its intended functions the breaker has to be:-
 Strong enough to overcome the impact strength of the bottles.
 Rotate fast enough throw a highest speed in this time the collision between the
bottle and the roughened wall will result breaking of the broken bottles.

REQUIRED DATA

 The maximum impact strength of the bottles is 22 pound Inch

or 2.5 joule
 Material selection ASI - 10 18
HB - 126
UTs - 440Mpa
VTs - 370Mpa
Density - 7.85kg/cm3
Good weldablity to all conventional welding. The material has to be harder than the glass, it has
to be checked for buckling and bending etc.

Shaft design

55
 Operating speed must be20% lower than the critical speed?

W = √kg∕mg = √k/m where k = force constant

The kinetic energy of broken bottles must be greater than the impact strength of bottles so that it
will be broken again when collide with the roughened wall. The broken bottles are required to go
with the speed

1
mbVb 2 = 2.5j
2

5
Vb 2= = 4.117m/s
0.295

Let the distance between the bottle inlet and roughened wall be 0.5mm. Then, the bottle
to cover this distance it requires 0.1 second.
2.5 j
The power required to throw the bottle with this speed is = 25w
0.1 sec
The power required to break the bottle is almost similar that means the power given to the bottle
both when kicked and thrown must be by far more than 50w. The shaft also requires power to
drive the mass of the blades and the shaft itself and to overcome the friction.
To estimate the shaft parameters from the table:-

Table 1 Shaft power and diameter estimation

Power kw 0.75 1.5 2.25 3 3.75 6 7.5 11.3

Speed rpm Shaft diameter mm

60 45 55 60 65 65 75 80 85
80 45 50 55 60 60 70 75 80
100 40 50 50 55 60 65 70 75
120 40 45 50 55 55 65 65 75
140 35 45 50 50 55 60 65 70
160 35 40 45 50 55 60 60 70
180 35 40 45 50 50 55 60 65
200 35 40 45 50 50 55 60 65
250 35 40 40 45 50 55 55 60
300 30 35 40 45 45 50 55 60
400 30 35 40 40 45 50 50 55

56
 Let the shaft diameter - 40mm
Power - 2.25kw
N -250rpm
3
60 p
T= = 60× 225 ×10 = 85.9N.m
2 πn 2 π ×250
Then we can calculate the shear stress, let factor of safety (ns) = 6
∂ y 16 T
>
ns π d 3
370 16∗85.9∗103
6
>
π ¿ 403
61.67 > 6.93
So we have selected a strong shaft and our design is safe.

Now we can estimate the length of our shaft = Length of two bottles + length of gear box
+ width of belt + thickness of casing in two sides + some clearances. By the above
calculation we have to gain 500mm or 0.5m is the length of our shaft.

The width of the blades be more than half of the diameter of the bottles and less than the
diameter of the bottles. So that it can kick on half of its circumference if the bottle enters
horizontally then it will apply the force all over the bottles entire length.
1
db> wb> db
2
Let the length be 40mm because the bottle’s maximum diameter is 80 mm
Let thickness be 6mm minimum (plate)
The number of blades must be in such a way that no round bottle goes down without being
kicked by the blades. The total diameter of the breaker is 40mm+40mm+40mm = 120mm.
The number of blades equals to =
120
=3
40
Then calculating the mass of the breaker:-

57
 m=ρ ν
¿ 7 . 85 g /cm 3(Volume of Shafts + volume of blades)
ν=4 ( 450× 60× 40) = 4.32×10−4 m3
m=3 . 39 kg
Then the shaft is subjected to bending due to its mass and mass of blades and also the mass of
bottles assume two bottles have at a time 3.39kg + 2(0.295)
= 3.98kg or 39.8N

Weight of bottles and blade

Converting it in to concentrated load

w=39.8∗0.45= 17.9N/m

Assuming counter clock wise to be positive

Ma=0=Rb∗500−17.9∗225

Rb=8. 06 N

Mb=0=Ra∗500−17.9∗275

Ra=9 . 85 N

At C, the maximum bending moment is:-

Mc=0.225∗9.85=2 .22 N.m

Then checking for both bending and torsion is:-

58
∂ y 32 √ M 2 +T 2
=
ns π d3

(2.22 ¿ ¿ 2 ¿ +85.92 )∗10002

370
6
=32
√ π 40 3
¿¿

61.61>13.68Mpa

So, our design is safe

Figure 15 breaker

Design of roller

The roller has a rough surface and also the casing is rough with the same direction and they have
a small clearance less than 1cm so the roller crushed the bottle in a small size. The roller is a
back bone of this machine because the crushed bottles come from the breaker with in a large size
the roller is crush with in a final size.

REQUIRED DATA

 The material must be somewhat harder because the compressive strength of

the bottle is higher.
 It also needs stronger shaft because the shaft is the backbone of the work
mean up to 180lb or 81.5kg man can stand on a bottle this due to its
compressive strength.

59
  The roller shaft must run at least with the same speed of the breaker shaft,
the minimum speed of the roller shaft and also the breaker shaft is not more
than 250rpm.
 Minimum force required to crush the bottle is 815N. So, obviously this
shaft requires larger power motor to select from the standard table.
 Material selection us=570 Mpa−700 Mpa
Diameter = 50mm
Length = 500mm
Power = 3.75kw
N = 250rpm
 Good weldablity for all conversional welding.
 The material has to be harder than the glass, it has to be checked for
buckling and bending .
We can finding the torque (T) with the given data’s.

60 p 60∗3.75∗103
T= = = 143.24N.m
2π n 2∗π∗250

Yield strength
 ∂ y=0.8∗570=456 mpa

∂ y 16 p
=
ns π d3

456 16∗143.24∗103
=
6 2∗π∗503

76Mpa > 5.83Mpa

From this our design is safe.

Bending strength
Total volume of the roller is:-
V =π r 2∗L =¿ π × 702 × 450=3.53× 10−3 m3

60
The net mass of the roller would be:-
m=ρ∗V =7870∗3.53∗10−3=27 kg
This implies 270N weight. Using the principle of bending moment theory
∂ y 32
= √ M 2+ T 2
ns π d 3
570 32
> √¿ ¿+¿ ¿
6 π ×100 3
95>11.931 Mpa
So, our design is safe.

Figure 16 roller

CASING DESIGN

MATERIAL SELECTION

The material for the casing is stainless steel for the parts the bottle is in contact at high speed and
compressive force. Particularly the front side of the breaker casing and circumference side of the
roller casing is recommended to be stainless steel. The rest is to be black iron. The surfaces of
the casing which are in contact with bottles at high speed and at high compressive force must be
roughened. Especially the stainless steel part in both casings must be roughened for it to be good
enough to crush effectively.

Again the thickness varies depending on the interaction of the bottle with the casing. The
stainless part is to be 4mm and the black part is 2.5mm.

61
 Figure 17 casing

Design of transfer and hopper or container

The container is as big as the plastic bottle storage used in the bottling to store broken bottles
until the fork brings it to the crusher. The crusher can crush a full hopper of bottles in the period
of the fork takes to bring another full plastic vessel of broken bottles. So the shape is to be
frustum for allowing smaller number of bottles to drop into the transfer at a time.

The transfer is just to allow quantified number of bottles to be dropped in to the rotating breaker.
The breaker can break maximum of two bottles at a time. So that the transfer has to allow a
maximum of two bottles at a time.

62
 Figure 18 hopper or container

Design of cork separator

The cork is sold to metal factories to be re melt and used. It is also bad for the crushed bottle
purchaser of the company to send the crushed bottle without picking it. The cork is magnetic in
nature so the simplest method to separate it from the crushed bottle route is using strong bar
magnet at the discharge of the bottle crusher. Since the crusher discharge is somewhat elevated,
it is possible for the magnet to attract the corks out of the dropped crushed bottle.

Once being attracted the corks are either dropped out of the route of the crushed discharge or
trapped to the surface of the magnet. It must be frequently cleaned from the bar magnet so that
the attraction of the next cork will not be blocked. Cleaning the bar magnet is not only to remove
the trapped corks but also the dusty crushed bottle pieces. The bar magnet is to be on the four
surfaces of the discharge but at least one must be with flexible joint to open and close for
frequent cleaning.

The recommended dimensions of this system is based on compromising the

 Effect of dust particles and

 Effect of distance on magnetic strength

63
The strength of the bar magnet is not that much affected up to it is 10 to 40mm far from the
attracted metal especially if the magnet is strong. Based on this the magnetic separator is
490mm by 60mm rectangular box with minimum clearance 10mm clearance because the bottles
are not finely crushed. So no fear of dusts.

Design of stand

The stand must support

 Weight of all components

 Bending load due to wind
 And other loads

From the weather condition of our town Gondar in recent year the maximum sustained wind
speed has reached 96Km/h, (26.667m/s). (BBC weather forcast 2016 report)
MATERIAL SELECTION – The requirement to be full filled are:-

 Ductility
 Hardness
 Strength

Standing from the view of working condition mild steel is best fit. The support is subjected to
both axial and bending force. The axial load is due to weight from bottles and the machine itself
the bending load is due to wind.
 Wind (bending load)
W x2
Mx=
2
1
Pw= cdPa Um2=0.05Um 2
2
Where Pw = wind pressure
Uw = wind velocity
Pa = density of air

64
 Cd = drag coefficient
1
But cdPa is constant mostly 0.05
2
Then Pw=0.05Uw 2=0.05(26.67¿¿ 2)=35.56 N /m2 ¿
Then the wind load w=Pw∗A
A=800*1400 = 1.12m 2
w=Pw∗A=1.12*35.56=39.82N
So the bending moment due to wind is

W x 3 39.82∗1. 4 2
Mx= =
2 2
= 39.0236N.m
1
The axial load is equal to total weight of the machine and the bottles. The mass of the
4
bottles a container can hold at a time is:-
Mbottles= ρbottles∗volume of acontainer
Mbottles
From this 𝝆bottles =
Vbottles
Mbottles=0.293 kg
Vbottles=πdtl=0 .0001382 m3
0.293
𝝆bottles= =2120.73kg/m3
0.0001382
Mbottles= 𝝆bottles×Vcontiner = 2120.73×0.24 = 508.8kg

This mass is reduced due to arrangement of bottles in the container. Which means the
arrangement must be compact to say the container is filled with bottles. But it is good to design a
higher load for it to be safe for smaller loads.

The weight of the machine is:-

Weight of all sheet metals + weight of roller + weight of breaker + weight of motor + weight
of gear box etc. = 1903kg

The total mass of the stand support is

65
 508 kg+1903 kg=2411 . 8 kg

Total weight = mg = 2411.8 ×9.81 = 23659.76N

23649.76
The weight of a single support is =¿ 5912.44N then the support is subjected to
4
combined bending and axial load.

P Mc
∂= +
A I

The cross-sectional area of the support as to be

A2
A1

A1

A=A 1− A 2=1002 −902 = 1900mm2

1
C= b=50 mm
2

b 14 b 24 1004 90 4 6 4
I= - = − =2.83∗10 mm
12 12 12 12

5912.44 N 39.0236∗103∗50
Then,∂= + = 3.112 + 0.6 = 3.802N/mm2
1900 mm2 2.83∗106

∂y
The yield strength is 456 Mpa >∂
ns

76>3.802

So, our design is safe.

66
 2.6. MANUFACTURING PROCESS
All the parts are to be manufactured as per the design. The process is listed in the following
figure with time it takes.
Table 2 Manufacturing process bottle crusher

s/no Part Manufacturing process remarks

1 Breaker  Plate metal cutting Use only stain less
 Profiling electrode
 Welding
2 Roller  Roughening
 Welding
3 Casing  Sheet metal cutting
 Welding
 Roughing
 Boring for shaft alignment
 Door making
4 Container  RHS cutting
 Frame welding
 Sheet metal cutting
 Welding
5 Transfer  sheet metal cutting
 welding
6 Stand o RHS cutting
o Boring for bolting
o Bolting
7 Alignment Our supervisor is to
8 Assembly visit the progress
9 Painting
10 Installation
11
12

The images of parts are listed as follows

67
 Figure 19 barker

Figure 20 roller

Figure 21 container

68
Figure 22 casing

Figure 23 transfer

69
 Cost analysis

As per the company’s market standard and salary scale the cost of the machine the is estimated
as follows

Table 3 cost analysis of bottle crusher

N Part name Material Specification Dimension Q Cost ETB

O

1. Breaker shaft C.s AISI1018 ꬾ40*600 1 6000

2. Roller shaft M.s AISI1045 ꬾ50*600 1 8100

3. Roller M.s AISI1045 ꬾ100*450 1 6075

4. Casing plate M.s AISI1045 6400*10800 _ 20000

S.s 316 _

5. Motor _ 50HZ,2.25KW _ 1 12976

and
1 14350
50HZ, 3.75KW

6. Gear box _ _ 2 36023

7 Bearing _ _ 4 1848

TOTAL COST 105372

70
 2.7. CONCLUSION AND RECOMMENDATION

As seen from the design and cost analysis the crusher is not that much costly as per the
advantage it brings over the manual crushing. It eases the process of crushing by far when
compared to the manual crushing. The project looks beneficiary in relation to the company
safety rules the company worries a lot about and it saves the labor force which will be allocated
to other sections in the company.

It is recommended if the company manufactures this design with the calculated dimensions and
selected materials so that it will crush the whole broken bottles. It’s also better if it collects the
scratched bottles in the Customers home all over the country and recycle it.

71
 PART THREE
3. GENERAL CONCLUSION AND RECOMMENDATION
Conclusion

Generally, this internship is a good program of improving practical skill, upgrading theoretical
knowledge, improving interpersonal communication skill, improving team playing skills,
improving leadership skills, understanding about work ethics and related issue and improving
entrepreneurship skills. It helps in understanding what the environment outside the school looks
like. It is very beneficiary semester than all other semesters I spent in the campus. It creates me
the chance to face practical problems and the challenge to solve them. It helps me to acquire
many experiences from many individuals.

Recommendation

We recommended the company is that to change its poor advertisement in media about their
works. Although the company has its own website, it is not sufficient to advertise all the works
of the company. So, we think the company should give more attention to organize commercials
and prepare posters that will attract owners towards the company.
The company should full fill the safety material for the students
or it should inform the university to do so.
The company should have establish a project design, development and expansion board that is
able to modify activities, create new ideas and strategies supervise intern projects to improve
customer satisfaction based on current needs.

72
 REFERENCES

1. Coulson & Richardson's Chemical Engineering [1]. Vol. 6, Chemical Engineering

Design, 4th Ed - Copy (2)
2. Girma Gebrewold, vertical pressure vessel design report paper, Adama University
3. Dashen brewery water chemistry data book
4. Dashen brewery boiler plant operating manual
5. Kurmi
6. Technology of brew and malt production kunze.1990GC in England
7. Company manuals

73
74