Declaration

I hereby declare that this internship report is an authentic record of my own works as requirements of
Industrial Training during the period from March 25 to May 14 for the award of degree of B.Sc. in
Electrical and computer Engineering, Jimma institute of technology,oromia, under the guidance of Mr.
Hawoltu Afework.

Date Name of student

Haymanot Legesse

Signature of student

Approved by

Tadelea Tegegne

Signature

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Acknowledgement

I would first like to thank God for allowing me to able to go through this exciting journey and giving
me the strength to work harder and be better than I was before.

Secondly I would like to thank the East Africa bottling Share Company for implement such a structured
and tuned internship program. This company dedication to help Ethiopia in various fields including
providing endless services for interns during this period is a testament to its character which should be
appreciated.

Great thanks goes out to our internship supervisor Mr. Hawoltu who has been a constant voice of good
advice not only on matters of our training but also important issues that will affect our lives in a
meaningful way. He has been a constant source of motivation for interns and for that deserves
appreciation for his dedication in making sure interns get as much as they can from their experience at
EABSC.

I would like to thank my internship advisor Mr. Tadele.t for guiding me through this internship period
and allowing me to make a more professional report.

I would also like to thank Jimma Institute of Technology for giving its students the opportunity to
explore the outside environment and get practical knowledge that is crucial for any engineering
discipline.

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Table of Contents
Declaration..................................................................................................................................................i
Acknowledgement..................................................................................................................................... ii
List of figure...............................................................................................................................................v
List of table............................................................................................................................................... vi
Abbreviations...........................................................................................................................................vii
Executive Summary................................................................................................................................viii
Chapter One............................................................................................................................................... 1
Introduction...............................................................................................................................................1
1. Background/profile of the company.......................................................................................................1
1.1 Brief History of the Company..........................................................................................................1
1.2 Vision and Mission of the company.................................................................................................2
1.2.1 Vision of the company.............................................................................................................. 2
1.2.2 Mission of the company............................................................................................................2
1.3 Product and service of the company................................................................................................ 3
1.4 Customer or end user of the company..............................................................................................3
1.5 Goal of the company........................................................................................................................3
1.6 Structural organization and work flow of EABSC.......................................................................... 4
Chapter Two...............................................................................................................................................6
Overall internship experience.................................................................................................................... 6
2.1 How I get in to the EABSC..............................................................................................................6
2.2 Summary of duties........................................................................................................................... 6
2.3 Working Experience.........................................................................................................................7
2.3.1 Utility department..................................................................................................................... 7
2.3.2 Production process department.................................................................................................8
2.3.3 Packaging department...............................................................................................................9
2.4 work task I have been executing....................................................................................................32
2.5 work ethics.....................................................................................................................................32
2.6 Challenges I Have Been Facing.....................................................................................................32
2.7 Measures i have taken to overcome the challenges....................................................................... 33
Chapter Three..........................................................................................................................................34
3.Overall benefit that I gained from the internship.................................................................................34
3.1 In terms of Improving Practical Skills...........................................................................................34
3.2 In terms of Upgrading Theoretical Knowledge............................................................................. 34
3.3 In terms of Improving Inter -Communication Skill.......................................................................34
3.4 In terms of Improving Team Playing Skills................................................................................... 35

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 3.5 In terms of Understanding Work Ethics Related Issues.................................................................36
Chapter four............................................................................................................................................ 38
Designing of automatic syrup level controller using Arduino microcontroller....................................... 38
4.1 Abstract.......................................................................................................................................... 38
4.2 Introduction....................................................................................................................................38
4.3 Literature review............................................................................................................................39
4.4 Objectives.......................................................................................................................................39
4.4.1 General Objective....................................................................................................................39
4.4.2 Specific Objective...................................................................................................................39
4.5 Significance and scope of project.................................................................................................. 40
Chapter Five.............................................................................................................................................41
Methodology............................................................................................................................................41
5.1 Methodology of project..................................................................................................................41
5.1.1 System flowchart.....................................................................................................................41
5.1.2 Arduino Uno microcontroller..................................................................................................42
5.1.3. Design of a relay controlling switch...................................................................................... 43
5.1.4 Float Switch............................................................................................................................ 44
Chapter Six..............................................................................................................................................45
Result and Discussion.............................................................................................................................45
6.1 The complete circuit.......................................................................................................................45
Chapter Seven.......................................................................................................................................... 47
Conclusion and Recommendation............................................................................................................47
7.1 Conclusion..................................................................................................................................... 47
7.1.1 Conclusion of project..............................................................................................................47
7.2 Recommendation........................................................................................................................... 47
7.2.1 Recommendation to EABSC.................................................................................................. 48
7.2.2 Recommendation to the university..........................................................................................49
7.2.3 Recommendation of project....................................................................................................49
Reference................................................................................................................................................. 50
Appendices 01 code of the project.......................................................................................................... 51

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List of figure
Figure 1.1 Work flow of EABSC...............................................................................................................5

Figure 2.1Process layout of RGB............................................................................................................ 10

Figure 2.2 RGB packer............................................................................................................................ 11
Figure 2.3 Bottle washer machine........................................................................................................... 16
Figure 2.4 EBI machine........................................................................................................................... 17
Figure 2.5 Blender/mixer.........................................................................................................................19
Figure 2.6 Filler machine.........................................................................................................................21
Figure 2.7 Checkmat................................................................................................................................25
Figure 2.8 Feed rail containing ionizer....................................................................................................28
Figure 2.9 Infrared radiators....................................................................................................................29
Figure 2.10 Blow molder.........................................................................................................................30

Figure 4.1 work flow of waste water treatment....................................................................................... 43

Figure 5.1 Flow chart...............................................................................................................................46

Figure 5.2 Arduino Uno board.................................................................................................................48
Figure 5.3 A transistor switch.................................................................................................................. 48
Figure 5.4 Float Switch............................................................................................................................49
Figure 5.5 pulley......................................................................................................................................50
Figure 5.6 Belt......................................................................................................................................... 50
Figure 5.7 AC Motor with gear box.........................................................................................................51
Figure 5.8 Belt type oil skimmers............................................................................................................51

v
List of table
Table 2.1 Internship program.....................................................................................................................6

vi
Abbreviations

EABSC- East Africa Bottling Share Company

SABCO- South Africa Bottling Company
SAP-Management Information System
MDC- Manual Distribution Center
EMS- environmental management system
PET-Polyethylene terephthalate (plastic bottled soft drinks)
RGB-Returnable glass bottles (glass bottled soft drinks)
CIP- Cleaning In Place (machine is cleaned without being moved)
EP- environmental policy
ISO –International standard Organization
GIT- Graduate in training (fresh graduates who are hired at EABSC)
FMCG-Fast Moveable consumable goods
SHEQ- Safety Healthy, Environmental, Quality (an inclusive term denotes the four things)
HR-Human resource
JIT-Jimma institute of technology
JU-Jimma University

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Executive Summary

This is an internship report based on the two months long internship program that I had experienced in
the East Africa Bottling Share company form March 25 to May 14 as a requirement of my degree
program under the department of electrical and computer engineering, Jimma University.

The Coca Cola Company is one of the world’s largest non-alcoholic beverages manufacturers in the
world. This report briefly describes the structure of Coca Cola East Africa bottling Share company, and
includes the company’s back ground, production process description, material, environmental and socio
economic analysis, recommendation and conclusion concerning internship program and also project
work.

This internship gave me practical knowledge, work experience, technical skills and soft skills. It
thought me invaluable knowledge and practice of communication and working in teams.

viii
 Chapter One

Introduction

1. Background/profile of the company

East Africa Bottling Share Company (EABSC) is a joint share bottling company owned by several
shareholders and operates under the registered trade mark of the coca cola beverages Africa (CCBA)
that spans the entire continent of Africa. EABSC has several factories in different locations in Ethiopia
setting up its sites in different locations. This share company is mainly concerned with the fast pace
bottling and production of coca cola brand soft drinks in different sizes and container arrangements for
different types of soft drinks.

EABSC currently operates in several locations in Ethiopia including manufacturing plants in Addis
Ababa, Bahirdar, Dire Dawa and several plants are under way to erect new plants in Hawassa and
Sebeta.

1.1 Brief History of the Company

The first Coca-Cola bottler in Ethiopia was created in 1959 by five Ethiopians its initial capital was
750,000 Birr as the Ethiopian Bottling Share Company. As the business grown a branch was
established in Dire Dawa in 1965 again with the capital of 750,000 Birr.

In February 1975 the two factories were nationalized, re-named as Addis Ababa Soft Drinks and Dire
Dawa Soft Drinks and operated under separate management. In March 22, 1996 the two plants were
became private again by five young local entrepreneurs with a registered capital of Birr 67 million and
formed Ethiopian Bottling Share Company. In May 1999, a joint venture agreement was signed
between Ethiopian Bottling Share Company & Coca-Cola SABCO (CCS) to bring the professionalism,
knowledge and experience that was lacking in the operation.

The name of the company is changed to East Africa Bottling Share Company (EABSC). The
shareholding proportion was 51% and 49% by EABSC and CCS respectively.

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Coca- Cola SABCO (South Africa Bottling Share Company) is the franchise bottler of CocaCola,
Fanta, Sprite, Krest, Stony, Tab, Sparletta and other brands of Coca-Cola Company and bottles these
products on behalf of The Coca-Cola Company, which is situated in Atlanta, USA. In this respect they
act as the Coca- Cola Company’s Bottling arm. Coca- Cola Sabco has the task of selling Soft Drinks to
dealers, who in turn sell them to their customers. This whole process was good for development of
business such as people development, which is mandatory to grow the business. In line with this, a
fully equipped training center was established as soon as the joint venture was signed.

In September 2007, a third production line was installed in the Addis Plant, increasing the installed
capacity by 75% and after a waste water treatment plant was built a new PET line is started to be built
in 2011 and started production in late 2013. Currently EABSC has plants in Bahirdar, Addis Ababa and
Diredawa.

1.2 Vision and Mission of the company

This section will attempt to give an overview of what EABSC tries to accomplish and what its long and
short term plans goals are:-

.1.2.1 Vision of the company

 To be the best Coca-Cola bottler in the world
 To be the Best in sales volume growth; and in return on capital employed
 Coca-Cola Bottler: A consumer driven, customer orientated, manufacturer, sales & Distribution
Company that markets the products and brands of the Coca-Cola Company
 We measure ourselves against the best Coca-Cola bottlers in the world clear, uniting.

.1.2.2 Mission of the company

 “Is what we stand for and do in order to realize our vision” .
 “Continually increasing profitable, sustainable unit case sales of our products by satisfying new
and existing consumers: Through excellent service to and with our customers at an increasing
return”.
 To produce internationally recognized quality products and to satisfy and exceed customer
requirement.
 Protecting the environment to contribute our share of the growth of our country.
 Maximizing the benefits of customers’ needs attempt to must be strong competitor and
profitable.

2
1.3 Product and service of the company
The coca cola company holds majorities of the market share in the soft drink industry in the world. Its
sub branch in Africa, the coca cola east African Bottling Company, has numerous beverage products
aimed to refresh Africa. Some of its well-known products are:

 Coca-Cola

 Coca-Cola light

 Sprite

 Sprite zero

 Fanta orange

 Fanta pineapple

 Fanta red apple

 Fanta Strawberry

 Fanta Zero

 Schweppes tonic

 Noida Schweppes

1.4 Customer or end user of the company

 Major Distribution center (MDC)
 Hotels
 Restaurants
 Supermarkets
 Institutions
 Agents in Addis Ababa, North Ethiopia, West Ethiopia and East Ethiopia
 Individual customers
 Major retailers

1.5 Goal of the company

 Consumer relevance by executing a total beverage portfolio across segments and categories in
partnership with brand owners.

3
  Customer centric organization delivering sustainable and profitable revenue growth through
outstanding service.
 Community/ partner impact by making a difference in sustainability, safety, empowerment and
local sourcing.
 Employee empowerment by mobilizing to execute our plans and transform our system with
agility.
 Productivity and responsiveness enabling a continuous improvement culture to create superior
shareholders return.

1.6 Structural organization and work flow of EABSC

East Africa Bottling Share Company employs more than 2000 employees in different areas of expertise
including
- Engineers from every discipline
- Manual laborers
- Business management
- Accountants and financial
- Marketing
- Operators
- Specialists, technicians and mechanics

The structure of organization for tasks in EABSC are very complex and interrelated with varied fields
of study so for the purposes of this report structures relevant to the internship program will be listed
here.

4
Figure 1.1 Work flow of EABSC

5
 Chapter Two

Overall internship experience

2.1 How I get in to the EABSC

Firstly, Jimma University, institute of technology gave us an internship requesting paper in the early
2020 in order to take that paper to any place where an internship program is given. So by the above
process after completing the fourth year course. Then I’m communicated with the CBE coordinator to
send the company an email. Then I get the acceptance after passing the interview in the beginning of
March by HR persons. Finally, the JU let us to join an interesting and best company, which is EABSC
to use my internship period (program) for two months.

2.2 Summary of duties

Upon entering EABSC interns were given a schedule with which is intended to help us conduct our
work in a timely manner. To accomplish this, a rotation plan was drafted by EABSC’s training
supervisor. The details of my internship program schedule are shown as follows:-

Table 2.1 Internship program

Start date End date Location of work Personnel responsible
March 25 March 30 PET(line 4) Mezeker
April 1 April 7 Line 5 Kirubel Kebede
April 8 April 14 Line 3 Addis
April 15 SHEQ Feven Tewodros
April 16 April 23 Utility Yiferu
April 24 May 14 Project work

This table illustrates the deployment of interns to specific working areas where interns will be expected
to get some knowledge on the specific machinery that exists at the work site. Working hours for interns
was from 2:30 PM to 10:30 AM five days per week excluding holidays and festivities. Several groups
of interns were formed to plan the above rotation and each intern in that group was expected to
participate and seek theoretical knowledge and practical experience in the field that he/she is studying.
The internship training method is a self-driven one that involves the intern taking responsibility for
his/her training outcome through effort.
There are different sources of information used to obtain, validate and correlate theoretical knowledge
obtained from JIT with the practical hands on knowledge obtained from EABSC.
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 • Inquiry involves interns communicating with operators, team leaders, technicians, specialists,
and line managers if necessary to get valuable information about machines, mechanisms and
operating principles of mechanisms concerning the intern’s field of study.
• Another source of information is the machinery documentation provided to us by EABSC
which helps interns gets more detailed part about each component in a machine, maintenance
procedure, and working principles.
• Maintenance periods in manufacturing lines and utility are also major learning grounds for
interns as they give us the opportunity to be close up and personally to know how the process
have carried out.

The EABSC factory is divided into three parts based on the function served namely
Utility- refers to the part of the factory that is responsible for providing the energy and raw materials
necessary for the production of the soft drink product to the manufacturing line.
Production Process- refers to the part of the factory that is responsible for providing syrup (final and
simple syrup), water treatment for the production.
Packaging- mainly refers to the manufacturing line where the production of the soft drink product is
carried out.

2.3 Working Experience

This section will attempt to explain the whole of the experience gained during the internship program
and outline the main parts of my involvement with each machinery and process.

.2.3.1 Utility department

Utility is the term used to describe the facilities and machinery used to supply the necessary inputs to
the manufacturing lines including pure water, boiler, electric power, generator, UPS (uninterrupted
power supply), compressed air, and chilled water, HVAC. These facilities are collectively called utility
as they are utilized in the manufacturing lines.
Boiler
EABSC uses fire tube type boilers in which the fire will be inside the tube and the water will be boiled
around the tube. There are two boilers currently in use and they are capable of producing steam up
800bar with mass flow rate of 4 ton and 8 ton respectively.
These boilers are fueled with diesel powered. Out of the two boilers one is relatively outdate and uses a
air control system where by a fan with adjustable blade angle controls the amount of air available to
combust the diesel fuel. By varying the angle one can go from zero air (no combustion) to full capacity

7
(100% air available for combustion). The second boiler is more modern and uses fully automated
process that can be controlled by the operator through a screen interface (control panel). To improve
feed water quality, fuel oil condition, and steam purity, chemicals can be injected directly into the feed
water, steam or fuel oil, these chemicals called chemical additives. These additives also help to remove
scalant which can get accumulated inside the fire tubes and possibly block them making the boiler
useless as the fire tube is permanently fixed inside the shell.
Power Supply
Electrical power to the factory comes from two points namely from the main grid from the transformer
and from stand by diesel generators. During no power cuts power is taken from a step down
transformer (1500V/400V). On the other hand when power goes down, an automatic 13 switching
system will start the standby diesel generators.

The automatic switching system switches the generator on when the line voltage from the transformer
drops below 365V since some of the machines in EABSC cannot work properly under the voltage of
365V. The control system including the PLCs will never go off as there is a battery supply that is
designed to automatically supply the PLCs and other digital data keeping devices on whenever there is
a black out.
Compressors
Low pressure compressor: These compressors can generate up to 7 of compressed air that is used to
operate valves and pneumatic actuator, for counter pressure during blow molding of performs. For
these demands they use very advanced compressors named “Atlas cop co”. These compressors are
screw type and can produce operating pressure up to 7 bars. The major components of the compressor
are the screw compressor and motor assembly, cooling system, oil lubrication system, air filtration and
drying system.
High pressure compressor: this compressor is specially designed for the blow molder, in order to
produce high pressure that is used to blow performs by the shapes of the molds. This compressor is
piston type and can produce more than 40 bars.

.2.3.2 Production process department

The complexity of the manufacturing processes of soft drinks production may vary depending on the
manufacturer standards, but the following are the common main processes which are followed by most
carbonated soft drink manufacturers.

8
Water treatment
Water, the main component of soft drinks, must be carefully treated in order to assure the good quality
of soft drinks. Its quality must conform to rigid quality requirements and not interfere with the taste,
appearance, carbonation or other properties of the drink.

Water should be free from

 High levels of elements and mineral salts
 Objectionable tastes and odors
 Organic material
It should also be
 Clear and colorless
 Sterile, that is, free from micro-organisms.
Different manufacturers have different standards for water quality. Nonetheless, municipal and
underground water sources undergo different treatment stages to achieve their quality standards
Syrup preparation

Depending on the soft drink being made, natural sugars or artificial sweeteners are dissolved in the
treated water at a predetermined brix in order to achieve simple syrup. The granulated sugars are
dissolved in treated water at elevated temperatures to aid in the dissolution process. The sugar can also
be found in a liquid form. Usually the simple syrup has a very high brix usually around 55-70% so
elevated temperatures are required for these brix values.

After the simple syrup has been prepared, the concentrate of the drink we are making is added to the
simple syrup in order to result a mix known as final syrup. Large vessels with agitators are used for
these tasks. After the final syrup has been homogenized, it is sent to the packaging lines.

.2.3.3 Packaging department

A bottling line is a production line where an RGB (Returnable Glass Bottle) or PET (Polyethylene
Terephthalate) is filled with production on a large scale. Line-4 is a PET bottling line, where there are
many machines that work together to make the production. Line-1, line-3 and line-5 have work on the
production of beverage and the only container required is glass which had to be washed or rinsed after
use since the name RGB indicate that returnable glass bottles.

9
RGB product process overview
Production of the final product will involve the consumption of all the resources generated by the entire
utility section going inside the manufacturing lines. Two types of products are made in EABSC namely
RGB glass bottled soft drinks and PET (Poly ethylene Terephthalate) or plastic bottled soft drinks. This
section will discuss the entire production line along with the uses, operating mechanisms and control
systems of each machine along RGB and PET lines. RGB stands for returnable glass bottle and as the
name suggests RGB manufacturing lines make glass bottled soft drinks by reusing glass bottles that
return from the market.

Figure 2.1 Process layout of RGB

Unpacker and packer (caser and uncaser)

Both have the same working principle, the machine have mechanical, electrical, structural and
pneumatic system. The only difference between them are the filled bottle and unfilled bottle, unpacker
hold the bottle by gripper from case to conveyor and the packer hold the filled bottle by gripper to case.
The movement process with in the functional groups run sequence controlled.

The functional sequences of the groups are matched to each other so that smooth, uniform operation is
achieved. It has two servomotors which are synchronized by shaft it provides a movement for shaft to
up and down the machine in order to hold and release the bottles. Servomotor works on the pulse width
modulation principle, which means its angle of rotation is controlled by the duration of pulse applied to
10
its control PLC (programmable logic controller). Basically in case of packer and unpacker machine the
servomotor uses position feedback to control its motion and final position.

The machine has gripper head which used to moves down into the crates. The ring grippers are
pressurized by pneumatic air and thus the bottles necks are clamped in the ring gripper. The gripper
head lifts the container from crates and transfers them to the container table. There, it deposits the
container by depressurizing the ring gripper. The gripper head is programmed to travel on apath that
has been done on the PLC system.

Figure 2.2 RGB packer

Horizontal axis
The horizontal movement is performed through oscillating assembly which is driven by a crank
mechanism and its use a mechanical system to move side to side.
Vertical axis
The vertical movement is performed through a belt drive with a counter weight balancing system. The
drive is frequency controlled and has a distance detector to move up and down.
Control systems and sensor positioning
Photoelectric sensors are used extensively inside an RGB packer. A photoelectric sensor is a device that
that detects a difference in light level received from the light source. It is made up of a light source, an
amplifier, signal converter and an output to a controlling unit that takes decisions based on the output
of a sensor like a PLC (programmable logic controller). A PLC is a computer that receives information
from connected sensors or input devices processes the data and triggers outputs based on pre-
programmed parameters. Here are some of the sensors employed on the packer...

11
Emergency photoelectric cell sensor- This sensor is also located at the entrance of the packer and
helps operators turn the packer off by waving their hands or any object through the sensor to block the
light and stop the packer from operating.

Accumulation sensors- these sensors are placed before and after the packer in order to determine the
accumulation of the input and outputs of the packer. The first batches of sensors are metallic sensors
that detect when the bottle input conveyor line to the packer is full. They have a metallic plate that
moves and get sensed by a metallic (inductive) sensor when bottles from the conveyor push the metal
plates. These sensors are connected to a PLC that reduces the speed of the filler so that the packer can
catch up and pack the accumulated bottles.

The second batches of sensors are placed at the case (pack) in-feed conveyor. They are photoelectric
proximity sensors that detect the presence and motion of the cases passing them. These sensors stop the
packer if they sense that no empty cases are present. They also stop conveyor motors if the cases are
being accumulated beyond the first conveyor. The third batches of sensors are placed after the packer
where the finished product is conveyed to the section where workers manually arrange the crates for
the forklifts to carry out.

For several reasons full cases out of the packer might accumulate on the conveyor blocking new cases
from exiting the packer so several photoelectric proximity sensors are placed on the conveyor coming
out of the packer to detect the accumulation level of the crates. If all those sensors are blocked at once,
the PLC understands that means the conveyor 39 line is full and the PLC commands the shuts down of
the packer until one of the sensors is unblocked i.e. when there is more space for incoming cases.

Fringe sensors- these sensors are photoelectric proximity sensors that detect when a long metallic
element called fringe obstructs the light path. The fringe is attached to each sub gripper (a total of 5
fringes). These sensors are designed to sense when the fringe the i.e. sub gripper the fringe gets pushed
higher than normal. This can happen due to several reasons:
 Cases can contain a solid material which raises the bottle height pushing the gripper frame to an
abnormal height when it tries to grip the bottle.
 Cases might be damaged or misshaped due to rough handling or shipping damage.
Leading frame position sensor- as the name suggests this sensor makes sure that the leading frame is
down firmly holding the case for bottle insertion. This sensor is a metallic (inductive sensor) that sense

12
a metal extension of the leading frame when it goes down. The function of the sensor is to transfer the
signal to the PLC which recognizes that the leading frame has gone down and instructs the belt drive
motor to lower the gripper frame i.e. lower the gripper heads in to the bottle mouthpiece to grip the
bottle and lift it up. The leading frame sensor goes down only when there are five cases in the area. The
counting mechanism is discussed below.

Case counter sensors- are three photoelectric sensors that detect the entrance of exactly 10 cases .one
of the sensors is placed at the end of the five cases where it is covered by the last case. The other sensor
is placed in the middle whereas the last sensor is placed at the end of exactly 10 crates. So for the
packer to continue three of the sensors need to be blocked. If even one of the sensors are not blocked
by a case the machine understands that there are not enough crates to be packed and the case in-feed
stopper in opened allowing more cases in.

Rotary dial encoders- these devices are an old rendition of digital encoders where a rotating metal is
detected at different point on a circle with sensors placed at those specific points. These sensors are
placed at precise locations to track the movement of the rotating metal rod. In the packer and unpacker
this encoder is attached to one of the vertical adjustment motors. When the motor shaft rotates the
metal rod inside the encoder rotates as well through an interlocking gear system.
As this rod rotates through the several metallic sensors placed at the 40 periphery of the circle, they
record the movement of the rod i.e. the movement of the motor i.e. the vertical distance the gripper
frame has moved. These encoders then tell the electrical system of the packer/unpacker to stop the
motors once the gripper heads have reached the position of the bottle mouths.
Bottle washer
All containers, must be washed if it is returnable. The bottle washer is a machine that cleans dirt and
contaminants from empty bottle glasses before filling the soft drink in the RGB production line. The
machine uses caustic soda to clean the bottles. The caustic concentration must be at a strength of at
least 2-3% at a temperature of 600 c or higher. This washer machine is capable of cleaning any dirt from
the bottle except higher polymers. For this reason, pre inspection is performed manually before the
bottles are fed into the washer. The bottle washing machine washes 48,000 bottles per hour. The
cleaning process for one bottle will take 30 minutes.

The contact time must be at least 5 minute. First part of the washer is the infeed and pre rinse. This
where the bottles get aligned properly into the various pocket and also to rinse out the majority of the

13
bulk or loose dirt out of the incoming bottle. The change in temperature too much and too fast make
stress on the glass that can cause it to fracture. That’s why the glass gets gradually heat and then after
gradually cool it down while it travel the washer.

On washer there are 3 compartments which are operated by 8 drive motors, the first compartment holds
pre rinse stage, the second one is the caustic stage and the third one is the stage where we clean the
bottles with water having different temperatures.
 Bottles are transported through the machine while being washed by sprockets with bottle holder
called Pocket.
 The capacity to hold 631carrier and each carrier contain 40 pockets at each segment total it can
hold about 25000 bottles.
 Derived by eight synchronies drives with the same speed and different loads.
 Pumps for delivering process ingredients. - Infrared photocell sensors at in feed point used for
object detecting for safe operation.
 Another IR sensor at discharge point for sensing fallen bottles.
 Every machine’s operation is controlled by Siemens programmable logic Controllers (PLC).
These PLCs are used to integrate the machine with other machines while also controlling the
response of the machine in different situations (logical operations).
 Operation is aided by operator who will interact with the machine through human machine
interface touch screen panel.
 Sensors and measuring instruments aid the machine control system by informing the machine
operation state such as:
 Digital manometer to measure pressure of ingredients flow
 Thermocouple for sensing temperature of sub processes
 Level sensor for sensing the level of water / caustic solution
 Pressure gauge for measuring the pressure for pneumatic system
 Flow meters for measuring the ingredients flow
 Conductivity sensor for caustic concentration sensing
 Actuators there are Solenoids and pneumatic system valves.
The machines effectiveness and reliability are most important on the production process. The following
sequential step has to be followed during bottle washing.
1. Pre-rinse: -In this stage the bottles are inverted upside down and jetted by warm water to remove
debris. Jetting is done at two ways
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 A.High pressure jetting: - help to remove dirt’s that attached closely to the bottles using highly
pressurized water.
B. Normal jetting: - there is also flushing process for cleaning of external body of the bottles.

2. Caustic 1: -Operate at temperature of (60o c – 70o c) and the caustic concentration set between 90
and 100 Ms. the bottles after being jetted, they are soaked into caustic solution for about 30 – 40
minutes in caustic tank.

3.Caustic 2: - In this region the bottle is soak in caustic solution of 65.6°C and the same cleaning
process is done as that of caustic-1. But the bottle soaking twice/two times/.In this process there is
jetting as well as flushing. As the bottle leaves, the water jet is used to shower the bottle. Now the
bottle is cleaner than in the caustic-1.
4. Post - Caustic: - water is jetted and flushed to remove the caustic that come from caustic 1 and
caustic 2 within and outside surface of the bottles.

5. Warm water 1 and Warm water 2: - both are used for washing bottles. They differ in their
temperature value. Warm water 1 is about 30 -400c and warm water 2 is about 20 -350c.

6. Cold water: the jetting process by cold water will occur. Here chemicals like ferrosol, stablon BWA
2200 (Divo) and horilith are added. Ferrosol: anti-scalant to prevent the scale with in the machine.
Horilith: for PH adjustment, because by nature it is an acid. Stablon BWA 2200: to remove date code
from the bottles.

7. Final Rinse: Fresh water jetting at a temperature 25o c, operating at 2bar.Chlorine is added to kill
insects (micro- organism) and added as a form of sodium hydro chlorite Na2Hcl and calcium
hypochlorite. After the bottles are washed, the bottles will be inspected by both humans and machine
until it reaches to the filler.

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 Figure 2.3 Bottle washer machine

From the washer discharge till filler the conveyor system takes a certain long distance for two reasons
one is for reducing the bottle temperature the other is due to the capacity difference between the washer
(67,000 bottle/hr.) and the Filler (62,000 bottle / h). After passing the washer the bottles are inspected
by workers observing them for any remaining debris or imperfections. Some essential parameters need
to be carefully considered during bottle washing. These essential parameters are explained below.
EBI (empty bottle inspection)
Empty bottle inspection is a process where the washed glasses are checked for any imperfections as
human inspection can be faulty. This process uses a machine called an electronic bottle inspector that
measures several variables associated with the washed bottles including.

Figure 2.4 EBI machine

 Height of the bottles is measured through photocells to determine if the bottles are too short or
too long. If either is the case the deformed bottles are pushed by a pneumatic pusher at 4 bar
pressure. To do this two photocells with respective reflectors are placed in the minimum and
maximum acceptable heights respectively. When one of them is triggered it means the bottle
either too long or too short. This signal from the Photocells gets to the PLC and the PLC

16
 through logic commands the pusher to push the bottle off the conveyor belt. The distance
between the pusher and the bottle is significant so an encoder is used to synchronize the pusher
and the conveyor belt.
 Base inspection is also done on the bottle where the base surface of the bottle gets checked by
taking high speed photos and analyzing them using integrated circuitry inside the EBI itself.

The base is checked for debris and other imperfections or malformations.

 IR inspection is also done on the bottles. IR inspection specifically aims to detect residual oil
like substances that can pass through the washer.
 Diameter of the bottles is also checked using an ultrasonic sensor so that any broken or
deformed bottles with abnormal bottle mouth diameter will be discarded through the pusher.
 Caustic check is also another inspection stage that checks the bottle bases for any residual
caustic left over from the washer if any.
 Side wall inspection is another inspection done by the EBI in which every bottle is checked for
scuffs and breakage along the side surface of the bottle. This is done through high speed
cameras similar to the one in base inspection.
First, the bottles pass a blower where any liquid from the bottle mouths are removed in order to
maintain the proper working of the cameras inside the EBI. Using a cross-over conveyor, a spacing star
wheel, in feed warm, or a belt-type spacing station, the incoming containers are separated in such a way
that a minimum amount of space remains between them. Container guidance through the machine with
two pairs of opposed belts, whose distance from each other can be adjusted.
Blender/Mixer
Inputs or ingredients to blender (mixer) are:
 Water
 Final syrup and
 CO2
The blender is one of production section where the concentrated sugar syrup (final syrup), CO2 &water
are mixed properly and stored in buffer tank. The blender uses several pipe lines combined with the
mass flow meter and pneumatic valves. The first process of blender is De aeration.
De-aeration: as the names indicate it is the removal of air from the treated water. It is used to extract
undesired gases from the water e.g. oxygen, nitrogen.
Circulating pump: used to circulate the fluids through the machine.
Mixing pump: used to mix the final syrup and water.
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Product pump: used to transport the final mixture to the buffer tank.
The blender also has chiller (plate type heat exchanger), where the final non-carbonated product is get
cold by incoming cold water (ice water) at the heat exchanger.

Purpose of cooling non-carbonated product is

 To allow carbon dioxide can easily mix with the beverage at lower temperature (since the
solubility of gas increases at higher pressure but at lower temperature).
 Foaming can be a problem at higher temperature, so the beverage after de aeration is cooled
using plate heat exchanger type.

After chilling the cooled non-carbonated beverage mixes with CO 2 & store in the buffer tank or final
beverage tank.
Purpose of carbon dioxide፦
1. To give satisfaction character for the beverage.
2. To elongate expired date of beverage (to use the beverage a long period of time without
expired).
Final syrup is the mixture of simple syrup (sugar +water) and concentrate. The syrup is dosed to the
water pipe with a ratio 5.4:1 and controlled by centrifugal pump and control valve syrup tank.

Figure 2.5 Blender/mixer

To achieve this process the blender uses different components:-

1. Pressure gauges- to measure the pressure in the air, CO2, and water inside the tanks as well as
in the lines that transport each ingredient. These pressure gauges measurements are important to
maintain safe operation of the blender and are connected with the operation of the relief valves
that activate through PLC signals when the pressure gauge measurements are above safe levels.
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 2. Brix sensor- A brix sensor is an electrical sensor that measures the amount of sugar present
inside a fluid passing through a pipe. In the blender there are several brix sensors to measure the
sugar levels of the syrup and the final beverage.

3. Pneumatic valves and level sensors- level sensors are used to determine the amount of beverage
and water inside each tank. These level sensors are a type of proximity sensor that activate
when the fluid reaches the level of the sensor. The signals from these level sensors are
important to activate pneumatic valves that open and close progressively to allow each
ingredient to enter the tank.

4. PLC controlled air supply- the air supply module that controls many pneumatic lines is
controlled by the PLC that sends the air supply that close the pneumatic valves based on the
signals it receives from the pressure gauges and level sensors.

5. IP and PI converters- Current to pressure and pressure to current converters are also used in the
lines which transport the final product. These are devices used to measure and control the
pressure in the lines.
Filler
The filler machine is a machine used to fill the bottles with the product (drink) and cover them with a
metal crown cap. In EABSC there are two types of filler machines in operation namely the krones and
KHS filler. These are brand names from different manufacturers but have some minor differences in
operation and efficiency.

The filler machine (krones) has the capacity of filling 36,000 bottles per hour. The product/drink is
stored in a rotating ring bowl and kept compressed with either air or CO2 depending on availability.
There are four level probe sensors equally spaced around the ring bowl that each measures the amount
of product present. First the bottles are fed in to the filler through a single conveyor which direct the
bottles through a rotating in-feed worm gear which rotates and arranges the bottles with equal space
between them when they enter the filler. Rollers are plastic made wheels that roll on the centering cam
carrying the metal pieces that hold the bottle necks firmly for insertion. At the same time a cylindrical
piston that is powered though a combination of oil (hydraulics) and air (pneumatic) lifts the bottles
upwards and allows the filling nozzle (vent tube) to enter the bottle mouths. Guard plates separate each
bottle so that fragments don’t get in to the other bottles if a bottle bursts inside the machine. The lifting

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mechanism works through a pneumatic system that pushes a cylindrical bottle carrier upwards along
the lines on the sliding guide.

The cylinder receives air when a bottle is sensed to be present through an inductive bottle present
sensor. If there is not bottle the cylinder won’t get air and the bottle and roller won’t be lifted. There is
also a roller up and down sensor that in case a roller gets stuck and stays in an incorrect position due to
bottle burst fragments. In the krones a small metal tube called vent tube is used to insert the gas and the
product in to the bottles.

Figure 2.6 Filler machine

There are four steps in filling process:-

- Pressurizing
- Filling
- Settling
- Snifting

Pressurizing
Pressurizations are used to:
- To evacuate the air inside the bottle.
- To balance the pressure between the product ring bowl and the glass bottle.
- To check the strength of the bottle.
The process involves pressurizing the glass bottle at 2.5 bars to 4 bar pressure where the ring bowl and
glass bottle pressure is equal. A pressure spring opens the gas needle and the pressurized gas passes
through the vent tube to the bottle.
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Filling
It is the process of filling the bottle with product. The principle of filling valve is due to the pressure
balance between the bottle and ring bowl. The filling process begins when the product valve is opened.
The product flows into the bottle along the vent tube. There is small spreader mounted on the vent tube
guides the liquid to the bottle inner side wall, thus ensures smooth product flow without foaming. The
pressurization gas is forced out of the bottle during the filling process and escapes back into the ring
bowl via the vent tube.
Settling
When the product reaches the lower edges of the vent tube, the return flow of gas is interrupted, ending
the filling process.
Snifting
The snifting is the process where the bottle and surrounding pressure is balanced. This process is state
is informed to the machine controllers by sensory. There are four most important sensors
- Inductive Bottle Presence sensor for sensing the presence of a bottle. The machine uses this
signal for proceeding to the next step.
- Bottle Burst sensor The same kind of sensor having different task to do which is to detect bottle
burst if there is bottle which burst it inform the machine and the machine decide not to fill six
neighboring bottles 3 on right 3 on the left .
- The third and the fourth sensors are for safety and safe operation of the machines they detect
broken bottle pieces are on the bottle holding space and the safe movement of bottles to the
crowner respectively.
Filler cleaning in place operation
CIP (cleaning in place) is a vital process where any machine is cleaned in place to maintain hygiene
and chemical deposit build up. There are two types of CIP namely 3-step and 5-step CIP.

The Three step CIP

a) First rinse by 50OC- 60OC water for 10-15 minutes

b) Cleaning by 50OC -60OC using caustic soda for 20 minutes and the concentration of this soda
should be in between 0.5%-2%. 29
c) Rinse by 38OC -25OC water for 10-15 minutes then checking for the absence of caustic residual by
phenolphthalein.

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The five step CIP
a) First rinse by 50OC- 60OC water for 10-15 minutes
b) Cleaning by 50OC -60OC using caustic soda for 20 minutes and the concentration of this soda
should be in between 0.5%-2%.
c) Rinse by 38OC -25OC water for 10-15 minutes then checking for the absence of chemicals
d) Sanitize either by hot water at 80OC for 15 minutes or chlorine at 100ppm PH concentration for 20
minutes
e) Rinse by water for 10-15 minutes then checking the absence of chemicals.

Issues on filling and there causes

Excessive Foaming can be appear due to: Incorrect temperature of product or bottles, Dirty or damaged
bottles, Improperly treated water, Low filler bowl pressure, Over carbonation of finished product,
Improper seal, Defective or dirty snifting valve, Improperly adjusted vent tube diverter, Rough
handling, and Low/high product level in ring bowl Sluggish or No Fill occurs due to: Counter pressure
charging valve not opening, Blocked vent tube, Improper sealing of the bottle to the valve seal,
Leaking snift valve, Faulty liquid valve, Low/high product level in bowl.

Over fill occurs: due to Loose vent tube, Poor seal affecting counter pressure, Leaking snift valve,
Faulty liquid valve, Vent hole on the filler valve set too high, Filler valve not closing correctly.
Under fill occurs: due to Bent or partially blocked vent tube, Low liquid level in the filler bowl, Faulty
liquid valve, Vent hole on the filler valve set too low, Foaming, Filler valve not opening correctly,
Partially blocked filling valve screen.

Check Mat or full bottle inspection (FBI)

A check mat is a device which checks uncrowned, under fill and over fill bottles by using IR sensor
positioned in upper position, side positioned little lower than. When a bottle passes through the check
mat:
 Uncrowned bottles will give long bouncing infrared ray thus it can be determined
 Under fill bottles can be determined when lower IR sensor signal has to be received.
 Overfill bottles can be determined when the upper IR sensor signal is blocked.

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The machine proximity type inductive sensor to detect the crown cap. Over fill and under fill detection
is by using radioactive radiation. Gamma ray is used for detection together with a receiver. If there is
no bottle between the gamma beam and the reflector the transmitted ray is fully reach to the source.
Gamma beam passes through the bottle and if there is product in the bottle at the level of the gamma
beam, less of the gamma beam will reach the receiver than in a bottle without product. There are two
level of gamma beam one is to check over fill and the other is for under fill.
During over fill condition less gamma beam is reach the receivers then the PLC understand that there is
over fill and sends a signal to the reject bar and the bottle is rejected. When under fill occur the more
gamma beam is transmitted to the receiver than the over fill condition then the PLC understand that
there is under fill and send a signal to the reject bar and the bottle is rejected. After passing this the
bottle will pass through a blowing air and goes to the date coder.

Figure 2.7 Checkmat

Date coder
Date coder is a device that sprays and tags each passing bottle out of the check mat with
- Manufactured date and time
- Manufacturing Line of the bottle
- Expiry date
Components of the Date coder
Date encoder uses a mix of makeup (paint thinner) and actual paint to spray on the required
information on the bottle.

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  Mixing valves- these valves controls the mixing of the makeup and the paint so that they mix in
the right proportions.
 Viscometer- This device measures the viscosity of the mixture.
 Chopper- is a fast acting valve that turns the paint supply on and off at high speeds to achieve
tiny droplets inside the tubes which will create dots when they are sprayed on to the bottle.
 Charger – this section charges the paint dots and makes them receptive to the deflector plate’s
electric field.
 Charged deflector plates – these plates have a voltage difference of up to 4000 volts and are
used to control the trajectory of the paint molecules according to the characters we want to print
out.
 Photoelectric sensor- used to determine where the bottle is in relation to the paint spray.
 Encoder – is used to determine to the delay between the light sensor and the paint sprayer by
counting the digital pulses it takes the bottle to get to the paint sprayer
 Buffer- this is the an extension of the date coder’s body that blocks the sprays that are not
supposed to be sprayed on to the bottle to for a certain character.
 Blower- is a device that sprays air on to the area of the bottle to be printed on in order to dry the
surface and make sure the paint will stick the bottle instead of dripping down with the moisture
on the bottle.
PET or plastic bottle production
Polyethylene terephthalate (PET) is a strong, stiff synthetic fiber and resin, and a member of the
polyester family of polymers. PET is spun into fibers and blow-molded into disposable beverage
bottles. The raw material for these plastic bottles is a small PET plastic tube known as a preform.

A preform expands upon being blown inside a blow-mold at high temperatures and starts to hold the
shape of the bottle as it cools inside the blow molder. The manufacturing methods of RGB and PET
bottles are different. Highlighting these differences and describing each added machine or process will
be the aim of this section.
Syrup Production Room
This is the section where the raw materials of beverage are combined to give the final syrup that is
distributed to the blending and filling section. There are two types of syrup preparation in this section;
these are simple syrup and final syrup. The simple syrup is simple the combination of sugar and water.
But final syrup is the mixture of the simple syrup and concentrate or beverage base.

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Raw Materials Required: include raw sugar, Treated water, Activated carbon, and Concentrate or
beverage base.
Preform feed system
Preform feed system supplies perform to the blow molder. The preform feed system have the following
components: Elevator, Hopper, Feed rail, roller orienteer, and Intermediate conveyor.
Hopper: is a preform storing device for immediate use of blow molder. The hopper has level
monitoring that uses photoelectric sensors which emits red light and detect the back reflection from the
reflector. The sensor and reflector is located in such way that level of perform accumulation is detected
at maximum and minimum desired point.
Flap: is a removable cover of opening for emptying the hopper. This function is important when
changing preform type is required.
Elevator: A transport performs from the hopper to intermediate conveyor.
Intermediate conveyor: is used for bridging the line gap b/n roller orienteer and elevator.
Dump Chute: feeds preforms to the roller orienteer.
Orientation Roller: It is two counter rotating cylindrical parallel rods whose interspaces is wider than
the preform body and narrower than the preform neck-ring. Therefore, performs are oriented in upright
position and slide down due to its own weight since the orienteer is tilt down a little.

The application of photo-Electric gap sensor is used for detecting

 The upright position of preforms in the preform orienteer.
 The stick over or bunch up performs and trigger the preform blower to blow down
stuck over preform to return conveyor. Any stick over performs that escape blower will
be rejected back by kick wheel from further transportation.
Stopper: is used to stop preform and decrease high flow pressure.
Feed rail: is used to slide preforms down to the heating module In-feed section .It has the preform
neck ring guide to stabilize and transport preforms. The preform neck-ring size should kept proper size
to ensure further transportation. It has rejection units to clear any sliding preforms toward heating
module.
Preform Interior Blower: this machine cleans the preforms with ionized (positively charged) air
before they are heated in the Heating module. The positively charged air helps attract any dust or debris
from the preform and accumulate it elsewhere. This method of dust removal is called ionization
(ionizer). This machine uses a voltage booster circuit to generate up to 1-2 KV of electricity. This high

25
voltage is directed to a small metal pin where the highly excited particles are emitted in to the air which
in turn attracts dust particles which are sucked into a dust collector.

Figure 2.8 Feed rail containing ionizer

Use of Ionization helps to remove dust particles, avoid static attraction by preform body, and prevent
dust particles being attracted again.
Heating module
Heating module is machines which make the in-feed perform of blow molder malleable/changed from
elasticity to plasticity through heat. It use heat generated by standard infrared lamp arrays of 2.5KW to
3KW. Critical Parts of Heating Module:-

 Drive unit of mandrel chain: -use to move the mandrel chain. There are 258 mandrels to hold
the preform.
 Spindle Rotation device: - is used to rotate gripped performs to improve heat distribution by
rotating gearwheel of heating mandrel around its own axis.
 Preform Gripper: - pick up performs and transport through heating module. The protective
palate shields the preform thread (head of the preform where the bottle cap is screwed in) from
heat.
 Preform surface cooling and neck finish cooling:-It is Located along the entire equilibration
zone of heating module. Thread of performs is cooled by cold air from heat exchanger to
prevent deformation. The preform surface is cooled with ambient air to prevent its surface
overheating.
 Heater or Infrared Radiator and Ceramic Reflector:-Heater is the vertical array of infrared lamp
with air cooling to prevent overheat. The lamps generate infrared and heat the preforms. The

26
 infrared lamps can be ON or OFF and regulated individually and use ceramic to reflect infrared
in opposite side of array of lamps. The figure below shows the heating module lamp.

Figure 2.9 Infrared radiators

Blow molder
The Blow molder is the machine which molds heated preforms into final bottling container shape with
the of volume 0.5 or 1.5 litter in the blowing station. EABSC purchases these preforms from Nairobi,
Kenya, according to the requirements and uses the heating module along with the blow molder to make
a finished bottle. The blow molder uses Pressurized air from 7bar to 40bar to blow and preforms to
surface shape of molder. Blowing pressure is depends on the preform size, thickness and material
property.

After the preform is received from the heating module through rotating spring loaded preform grabbers,
one of the several cams located in the blow molder the one that controls the opening and closing of the
blow mold causes the mold to close once the preform is inside.

During the rotation a rod is inserted in to the preform stretching it downwards while pressurized. Air
blows it to the desired shape. After the end of the rotation the cam causes the mold to open releasing
the preform to another grabber which grabs the blown up bottle resembling a finished bottle.

A base cooling system is installed between the blow molder and filler machine. This is needed because
of the fact that the hottest part of the bottle coming out of the blow molder is the bottom part. To avoid
this bottle is properly cooled and solidified before it enters the filler. After the bottles at bottles are
filled and crowned with plastic caps they pass several machines.

27
 Figure 2.10 Blow molder

Flow liner
The flow liner is a machine assembly used to properly switch from single line conveyor to a multiple
line conveyor pathway to avoid overcrowding and bottle fall. It achieves this using a driven belt that
has grooves capable of carrying and cradling each bottle when it enters the flow liner. These belts are
driven by AC induction motors. After grabbing the bottles the belt assembly pushes the further
sideways to maintain some distance allowing for easy transfer of bottles from single line to multiple
line conveyors.
Linadry
The linadry is another machine that the bottles pass through. Its main function is to get rid of any
moisture on the surface of the bottle so that any labeling material can effectively stick to the bottles.
Electrical coils which heat up the air inside the linadry when power is applied are the main source of
heat used to evaporate any moisture from the surface of the bottles. Although the air is heated by the
coils it still needs to be blown directly on to the bottles using a blower fan designed to force hot air on
to the surface of the bottles.
Labeler
The labeler is a machine where a label consisting of Trade mark, ingredient, and various other useful
information is placed on the bottle.
The Labeler is mainly divided in to 2 parts such as:
Main station
 Container stopper: used to stop the bottle when the labeling machine is stop this container
stopper works by pneumatic system.
 In feed worm gear: used to space the bottle and feed to the in feed star wheel
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  In feed star wheel: used to feed the bottle to the carousel
 Carousel: the carousel is the largest rotating component of the labeling machine and it is driven
by an induction motor. The base of the bottle is placed on the centering plate and this centering
plate is rotate with its axis and the top of the bottle is holed by the centering bale.
 Discharge star wheel: used to transfer the bottle from the carousel to the discharge conveyor.
Labeling station
 Reel holder: hold the labeling material and unwound the label film by using a servo motor. Two
sensors are installed on reel holder for detecting the reel diameter and the end of the reel.
 Splicing unit: used for the exact transfer of the new label reel to empty reel. The leading end of
the label film is threaded manually in the device, held with vacuum and taped down with
double sided adhesive tape. The reel is changed automatically. The splicing unit cuts off the
label film of the used reel and bonds it automatically to the new reel.
 Register mark sensor: records or detect the register marks provided and send the signal to the
controller. Then the signals are processed by the controller and the label length is readjusted.
 Buffer: the buffer continuously tensions the label film to prevent it from falling down. It also
ensures a sufficient supply of label film during splicing. Electromagnetic sensor on a bottom
side monitors the current position.
 Wave guider: provided to maintain the label carrier film in the required horizontal position. The
ultrasonic sensor monitors the required label height.
 Feed roller: the calculated label length is achieved by means of servomotor on the feed roller.
The pinch roller presses the label film against the feed roller.
 Cutting unit: the label film is cut to the required length by the cutting unit. It comprises a
vacuum assisted cutter drum and a cutting rotor with separate servomotor. An encoder for
determining the exact position is provided both on rotor and the roller. The label is cut when the
cutter meets the cutting strip. The cutter inside the rotor is held by compressed air supply.
 Gluing unit: it comprises a glue bowl, a glue roller and two glue scrapers. Can be moved forth
and back by a pneumatic cylinder. Heating element and temperature sensors have been installed
in the gluing unit. Hot glue is pumped from the bowl to the roller. A glue film is provided
through the gap set between the glue scrapers and the rollers.
 Vacuum grip cylinder: takes the label from the cutting drum by a vacuum bars on it. Through
the contact with the glue roller, a strip of glue is applied to the leading and trailing edge of label.
Afterwards, the label is transferred to the container.
 Monitoring sensor 2: used to detect the presence of label on the vacuum grip cylinder.

29
  Monitoring sensor 3: used to detect the absence of label on the vacuum grip cylinder.
 Servo motor: there are 6 servo motors in the labeling machine each motors are for the following
component:
 Glue roller, Vacuum cylinder, Cutting unit, Feed roller, Reel holder 1, Reel holder 2
Vario-Pack
The vario-pack is a machine assembly that is mainly used to sort the bottles coming through the
conveyor and arrange them in to the required rectangular pack and wrap them with a packaging plastic
sheet introducing them to the shrinking tunnel in the process. The vario-pack has the following
components…
Lane guides- used to sort the bottles in to single lines. They are adjustable metallic frames used that
vibrate to sort the bottles in to the appropriate lines. These lanes are manually adjusted so that bottles of
different sizes can be made i.e. 0.5 and 1.5 liters need different pack arrangements hence different lane
guides with larger dimensions.
Gap-less Plastic conveyor assembly- used to transport the bottles through the vario-pack. Four
servomotors are used to drive each gap-less plastic conveyor belt. Each belt is driven by a separate
servomotor constituting a total of four conveyors for each line of bottles passing through the vario-
pack.
One retro- reflective photoelectric sensor and 4 plastic flaps- these plastic flaps touch the heads of the
bottle and collapse if there is no bottle present. These flaps allow the light to pass from the sensor to the
reflection if there are bottles present in the conveyor. But if there are no bottles present the flaps
collapse and the light is blocked which means the machine will stop until the bottles accumulate and
turn the flaps again allowing light to pass to the reflector.
Four photoelectric sensors- used to sense the gap between bottles after passing the lane guides. If
there is large gap between the bottles no pack will be formed so the machine will wait stop until bottles
arrive to that area.
Rotating Metal fingers- these fingers are attached to a cam and gear mechanism that rotates the
fingers in variable speed so as to separate packs of bottles from the conveyor. For 0.5 Liter bottles one
pack consists of a 3 by 4 arrangement constituting a total of 12 bottles. For other sizes such as 1.5 liter
bottles the fingers are replaced by larger ones. The cam and gear mechanism driving the fingers has
shafts driven by two servo motors.
Chain and pusher rod arrangement- used for pushing each pack from the fingers and arranging them
correctly. The pusher rod is a metal rod that is attached to a rotating chain driven by a several gears.

30
Plastic present sensor- This sensor is located in the chain and rod arrangement of the machine. It
shines light on to the plastic rods to detect the presence of plastic over the rods. If there is no plastic it
means that at least one pack won’t get wrapped so the machine stops.
Two Plastic reels- is a cylindrical shell with the plastic sheet rolled on it. This reel provides the source
of the plastic packaging to the wrapping section of the vario-pack. It has two motors attached to a shaft
which rotates the reel un-wrapping it from the reel and sending it to the buffer.
Buffers - buffers are two sets of rolling cylinders which are pushed together or apart depending on the
desired tension of the plastic sheets. These sets of buffers are pushed using a pneumatic actuator that
keeps the tension of the plastic sheets constant. After the buffers the plastic sheets are fed in to the
pneumatic plate.
Magnetic sensors- used to sense the speed of the plastic. It instructs the actuator to adjust the buffer
tension so that the speed and tension of the plastic can be maintained at the required value.
Pneumatic plate- this section of the machine is intended to hold the plastic sheet on to the plate firmly
using negative pressure air (vacuum). The plastic sheets are then cut in to the required size needed for
each pack depending on the bottle type. In the final stages of the pneumatic plate the positive air
pressure releases the sheets from the plate and pushes it on to chain rod arrangement which drapes the
plastic on to the packs.
Solenoid Pneumatic valves- control the pressure of the air used in the pneumatic plates. The solenoid
pneumatic valve is electrically controlled.
Photoelectric reel sensors- these are located on the two plastic reels and are used to indicate the reel
size. It basically detect whether the reel is running out or not. If one of these sensors are activated it
means the plastic reel is being depleted which prompts the operator to insert a new reel in to the shaft.
Compensation belt- is a conveyor belt between the conveyors of the vario-pack and the conveyor of
the shrink tunnel. This conveyor is used to slow down the pack speed to the conveyor speed of the
shrink tunnel. The compensation conveyor has the ability to move sideways and this sideways
movement is controlled by two pneumatic actuators inside the conveyor.
Compensation belt sensors- are photoelectric sensors used to sense whether the compensation belt has
moved too fat to the left or to the right. These sensors point light downwards through the holes in the
conveyor. If this light is blocked it means the compensation belt has moved too much to one side and
the sensors command the two actuators to adjust the compensation belt to the required position. After
passing all these sections the packs enter in to the shrink tunnel …

31
2.4 work task I have been executing
Actually, our time does not let us to work on the production line so there is no specific task given to us.
Our basic tasks are to understand the operation, working principle and controlling system of machines
by asking Forman, reading books and manuals regarding to work with the operator. My work
experience based on the flow of asking, understanding the machines.

2.5 work ethics

In my internship program I have developed the understanding of work ethics which is employer’s value
employers who understand and possess a willing to work hard. In addition work it is important to work
smart this means learning the most efficient way to complete tasks and finding ways to save time while
completing daily assignments. Working in a place you are ordered to work, be honest to do your work,
give attention to the working times.

Generally the work ethics I have developed are expressed as;

 Punctuality
 Reliability
 Responsible.
Develop strong work ethics you should:
 Good communication skill and cooperation with colleagues
 Focus primarily on work related issues
 Bring a fresh perspective to problems at work.
 Respect what others contribute to the work environment
 Committed for his/her work
 Being confident and self-motivated to do the tasks responsibly
 Commitment

2.6 Challenges I Have Been Facing

I have not faced very serious challenges during the time of being in that company due to cooperation of
the management and worker. However, there is some problem that I have been faced. These are;
 In the first time I was afraid of to express my feelings because of shyness.
 In the first time, There were little communication problems with the supervisors, department
foreman’s and with some company workers because of misunderstanding.
 Loud voices of machines have effect on the learning process.
 Even if, I observe problems in that company, I did not have a time to solve it by the shortage of
time.
32
2.7 Measures i have taken to overcome the challenges
I will describe the measures that I have taken to overcome each of the above challenges as follows.
 To overcome problems (challenges) I have tried to ask the engineers, the operators, and any
other persons who works in that company. Then they tried to give answers for my doubts as
much as they can buy sharing my theoretical skills and knowledge’s for anything that happens
at the working line or in the office and shared my ideas with my colleagues, then through time I
eliminate My shyness, inter personal communication skill and develop team playing skill.
 I was improving my tolerance ability while those persons who were supporting us were busy.
Generally, I was developing a smooth relationship with office workers and others to overcome
my challenges.

33
 Chapter Three

3.Overall benefit that I gained from the internship

The internship program has its own aims intended to be satisfied by the students in terms of improving
different skills. The aspect in terms of improving different skills, theories and knowledge’s are
illustrated below.

3.1 In terms of Improving Practical Skills

Practical skill is connected with real situations rather than ideas and theories. The main aim of
internship is developing practical skill, so the following points are mentioned in terms of improving
practical skill.

 It enables me to improve my practical skill in the maintenance and how to repair different
machine.

 I have been learnt to live together and work in team with worker.

 I get elaborated experience that will be useful in my future profession.

 I have already understood the meaning of what is interpriniership by doing together with those
of more experienced workers and Engineers.

3.2 In terms of Upgrading Theoretical Knowledge

Theoretical knowledge is the information, understanding guide and skill concerned with ideas and
principles on which a particular subject is based in order to carry out one task. Because before doing
one thing practically theoretical knowledge is the base or the pre-request. So the internship upgrades
theoretical knowledge through;

 Working mechanism of different machineries.

 Knowing the general safety rules of each operation.

 Referring different manuals of machines and vehicles.

3.3 In terms of Improving Inter -Communication Skill

Inter-communication is usually describing participants who are dependent upon one another. It can
involve one on one conversations or individuals interacting with many people. It helps us to understand

34
how and why people behave and communicate in different ways to construct and negotiate a social
reality. Electrical engineering profession is one of those disciplines, which highly depend on existence
of well-disciplined interpersonal communication skill.

Therefore, from the internship I have got the following in terms of improving inter-communication
skill.

 Communication is a two-way process; getting your message across depends on understanding

the other person. I do hear explanation of our assistance mean while I put forward some doubts
if I have.

 I was interested in the supervisors of every departments of the company when they gave us
clarifications, since they had much better experience and practical knowledge’s than us. People
are more attracted to those who are interested in them, and will pay more attention to what they
are saying. They had an amazing way of explanation during communication by smiling their
faces and use eye contact which is the most positive signal for best communicating skill. So
from here I get a good communication experience.

 Asking questions which are a best way to show people that you are really interested in them. I
have been asking some questions after the explanation have ended.

 It makes me to be assertive for others idea and view from communication habit.

3.4 In terms of Improving Team Playing Skills

Team playing skill means the activity of working well together as a team to solve or share the ideas and
challenges encountered. Team playing skill is crucial skill in electrical engineering discipline. As the
decisions made cost too much, deep exploration of ideas through team playing is required. Excellent
consequence of the decisions made through team playing. Hence I where the only student that enter the
company from JU I had communication with others student that come from other universities and that’s
improves my skill to work with others.

 As a team player tried to modify and give solution for some technical challenges that exposed in
the company.

 When we’re with in team playing, anyone can raise his opinion.

 During team playing, our concept may be varied. At this moment respect others idea.

 Ideal disputes were solved through peaceful communication.

35
3.5 In terms of Understanding Work Ethics Related Issues
Work ethics are standards or values that generally are based around conscientiousness. Mostly, work
ethics are thought to benefit a person morally, thereby improving their character. These ethics can
include preserving social skills, being reliable, and being resourceful wherever needed in a work
setting. Work ethics is the core idea when I’m in some staff. So understanding of Work ethics is crucial.
The internship gives the following advantages.

 Respecting the entrance and out time of work in the company (Being punctual), that gives good
experience for my future life.

 Giving respect for others in work place.

 Giving a special respect for my work.

 Respecting the rights and obligations of other workers until they do not stand on my ways.

 An internship is an opportunity to learn the skills and behaviors along with the work values that
are required for success in the workplace.

36
 Part 2

Designing of automatic syrup level controller

using Arduino microcontroller

37
 Chapter four

Designing of automatic syrup level controller using Arduino microcontroller

4.1 Abstract
The paper explains utilization of Arduino Microcontroller to automatically control level of syrup in a
tank. From a well spelt out algorithms, flowchart was drawn, from which Codes were written and
compiled on Arduino IDE. If statements were contionusly used. Proteus was used to simulate the
design while the project was implemented on breadboard. Liquid Crystal Display function displays the
level of water on the 16 × 2 LCD thus Very Low, Low, High and Very High. The design recommends
improvements in the area of sump control so that its low water level could disable pump thus
preventing it from running dry. Protection devices like circuit breaker overload and phase failure relays
are recommended in order to prolong the life of the syrup pump. It is believed that the design will go in
long way in educating power electronic engineers in the arts of design using Arduino; also, a mass
production of the device will accentuate Small and Medium Enterprises SMEs in developing countries
with its concomitant economic advantages.

4.2 Introduction
One of the results of modern age is the increase in devices that work in automatic fashion. Daily man
tends to find a way to simplify his activities thereby solving problems. Many times are wasted
operating systems manually; also cost of employing operators can eat deep into the company finance.
The design, apart from solving this problem, also delves into trending Arduino design methodology.
Appliance or equipment manufacturers and designers alike have key into this in order to remain
relevant. Automatic systems reduce number of workers to attend to industrial process; the resultant is
the drastic reduction in wages and losses which will undoubtedly dovetail into more profits. Thus
automatic system supports lean manufacturing where customers are satisfied at low and affordable cost
[1]. The aforementioned is made possible by continuous improvement in design techniques and
ingenuous usage of electronics components and building blocks. Microcontrollers offer better solution,
being computers on single chips enable production of embedded smart systems which are prevalent
everywhere today [2].

Water is important for Beverage Company in order to mix the syrup and it shouldn’t be wasted. In East
Africa Bottling Share Company there is a syrup room which has syrup tank that are filled for regular
and daily use of syrup. The operators switch the syrup motor on and keep track of the 30 to 90 minutes
38
for the tank to fill up in manually. Sometimes, the syrup will fill the tank too fast or too slow,
depending on the amount of syrup in the tank. The rest of the storage tank syrup will be wasted. In
order to resolve the issue, there is the automatic water level, controller.

4.3 Literature review

[1] This paper has an implemented Automatic water level control system consisted of Arduino to
automate the process of syrup pumping in a tank and has the ability to detect the level of syrup in a
tank and switches ON or OFF the pump accordingly and displays the status on the LCD screen. The
system also monitors the level of syrup in the sump tank (source tank). If the level inside the sump tank
is low, the pump will not be switched ON and this protects the motor from dry running. A beep sound is
generated when the level in the sump tank is low or if there is any fault with the sensors. [2] This paper
has developed a system which initially tests the availability of syrup in the tank with the help of a level
detector and then adjusts the state of the syrup pump according to the information collected through the
level detector. This design makes use of LCD display and a motor pump. The proposed system consists
of float switch and a digital logic processor circuit. [3] This paper introduced a system which proposes
a simple syrup level monitoring system with different levels indicated. It also signifies when the syrup
level is below and above than the requirement. [4] This paper introduced a system which measures
syrup level by using float switch. The system makes use of syrup level indicator, syrup level sensor,
syrup pump controlling system and Arduino Uno microcontroller. [5] The system used Arduino Uno
microcontroller to automate the process of syrup pumping in an over-head tank storage system and has
the ability to detect the level of syrup in a tank, switch on/off the pump accordingly and display the
status on an LCD screen. This research has successfully provided an improvement on the existing syrup
level controllers by its use of calibrated circuit to indicate the syrup level and use of DC instead of AC
power thereby eliminating risk of electrocution.

4.4 Objectives

.4.4.1 General Objective

 The objective of this work is constructing an automatic device that will control the flow and
pumping of syrup in the tank.

.4.4.2 Specific Objective

 To design an automatic syrup level control system.

39
  To avoid wastage of syrup.

 Reduced manual tasks.

 Enhancement of product quality.

 To reduced manufacturing lead time.

4.5 Significance and scope of project

This syrup level controller will give a head up the instant overhead tank and underground tank is full or
goes below the required level, hopefully giving the time to operate. The system draws virtually no
current when the sensors are dry and the current consumption is low when the buzzer is activated.

40
 Chapter Five

Methodology

5.1 Methodology of project

The tasks to be performed were listed while flowchart for the design was drawn. Input pins hosting
three float switches were connected to Arduino pins 1 to 3 using pull down 10k resistors. Four LEDs
level indicators indicating “Water Level Very High, High, Low, and Very Low” were connected to
Arduino pins 9, 8,7and 6 respectively. IF statements were in the codes. An LCD displaying water levels
was included using six Arduino pins.

.5.1.1 System flowchart

Algorithms that explain the sequence of operations and steps for the design were written thus enabling
the diagrammatical representation of flow of process through the agency of flowcharting [4]. This
approach simplifies the writing of system’s codes (Figure 5.1).

Start

Read kpinF, kpinM,

kpinL

If
valf =LOW
True &valm=LOW
& vall=LOW
LEDvl =ON,LEDl=OFF False
LEDh=OFF, LEDvh=OFF,PUMP=ON
Print Water Level,VERY LOW
PUMP ON

If
True valf =LOW
&valm=LOW
& vall= HIGH
LEDvl =ON,LEDl=ON
LEDh=OFF, LEDvh=OFF, PUMP=ON False
Print Water Level: LOW

If
True valf =LOW
&valm=HIGH
& vall=HIGH
LEDvl =ON,LEDl=ON False
LEDh=ON, LEDvh=OFF, PUMP=ON
Print Water Level: HIGH

True If
valf =HIGH
&valm=HIGH
& vall= HIGH
LEDvl =ON,LEDl=ON
LEDh=ON, LEDvh=ON, PUMP=OFF False
Print Water Level: VERY HIGH
PUMP OFF

Stop

Figure 5.1 Flow chart

41
Step 1: Read the digital values (HIGH, +5V or LOW, 0V) at microcontroller pins kpinF, kpinM and
kpinL and store their values at valf, valM and vall respectively. (F, M and L represent Full, Medium and
Low respectively).

Step 2: If valf, valM and vall have LOW (0V) values, Light Emitting Diodes LEDs LEDvl ON (lit),
LEDl OFF, LEDh OFF, LEDvh OFF; Water Pump Switched ON, Print on LCD “Water Level: VERY
LOW PUMP ON” else go to step 3. (vl, l, h, vh represent very low, low, high and very high
respectively).

Step 3: If valf and valm are LOW (0V) values and vall HIGH, Light Emitting Diodes LEDs LEDvl ON
(lit), LEDl ON, LEDh OFF, LEDvh OFF; Water Pump ON, Print on LCD “Water Level: LOW PUMP
ON” else go to step 4.

Step 4: If valf LOW while valm and vall HIGH (+5V), Light Emitting Diodes LEDs LEDvl ON (lit),
LEDl ON, LEDh ON, LEDvh OFF; Water Pump ON, Print on LCD “Water Level: HIGH PUMP ON”
else go to step 5.

Step 5: If valf, valm and vall are HIGH (+5V), Light Emitting Diodes LEDs LEDvl ON (lit), LEDl
ON, LEDh ON, LEDvh ON; Water Pump switch OFF, Print on LCD “Water Level: VERY HIGH
PUMP OFF”.

.5.1.2 Arduino Uno microcontroller

A Microcontroller can be referred to as a computer on a chip. It parades input and output pins. Unlike a
Microprocessor, it includes processor with memory location for storing programs written in C language
[5]. Arduino Uno board, Figure 5.2, has an Atmega 328 on it as the main Microcontroller. Using this
unit does not require extra money for a Programmer. Codes or sketches and compilations are done on
its Integrated Development Environment IDE This advantage makes prototyping of embedded system
easier by engineers and electronic systems enthusiasts. The board has six (A0 to A5) analog inputs to
handle analog signals and fourteen I/O pins for input and output functions [4].

Figure 5.2 Arduino Uno board

42
.5.1.3. Design of a relay controlling switch
Transistor works as a switch when it is operated at its extreme regions, that is, at cut-off and saturation
[6] at saturation, Common-Emitter Voltage, VCE =0; and Collector Current IC =𝑽𝑪𝑪/ 𝑹𝑪 as shown in
Figure 5.3.

Figure 5.3 A transistor switch

While at cut-off, Collector Supply VCC is equal to Collector Emitter Voltage VCE (VCE = VCC) and
IC = 0. Using Kirchhoff’s Voltage Law in the collector circuit (1),

𝑉𝐶𝐶 = 𝐼𝐶𝑅𝑟𝑒𝑙𝑎𝑦 + 𝑉𝐶𝐸 (1)

Using a switching and linear amplification transistor 2N2222,

IC max = 800mA at IC= 150mA, VCE = 10V while hFE min =100 and hFEmax = 300 [7]

VHIGH = VCC = 9V, Rrelay = 400 Ω, hFE= 100, Relay operating voltage = 9V

By using 300Ω, IC = 𝑽𝑪𝑪/ 𝑹𝒓𝒆𝒍𝒂𝒚 = 9 400 = 22.5mA

Base current, 𝐼𝐵 = 𝐼𝐶/ ℎ𝐹𝐸 = 22.5𝑚𝐴 100 = 0.23mA

For saturation, IB> 0.23mA.

Let IB = 2.5mA.

Arduino VHIGH = 5V, VBE = 0.7V

RB = (𝑉𝐻𝐼𝐺𝐻−𝑉𝐵𝐸)/ 𝐼𝐵 = (5−0.7)/ 2.5𝑚𝐴 *4.3/ 3𝑚𝐴 = 1720Ω

Preferred Value = 1.5kΩ

43
.5.1.4 Float Switch
A float switch is a mechanical switch that floats on top of a liquid surface. As the liquid level goes up
or down, it moves vertically with the liquid level. This is a type of level sensor and this device is used
to detect the level of liquid within a tank. And also float switch may be used to control a pump, as an
indicator, an alarm, or to control other devices.

Figure 5.4 Float Switch

44
 Chapter Six

Result and Discussion

The project was wired in Proteus [8] for simulation, (Figure 6.1). Proteus is a simulation and design
software developed by labcenter electronics [9]. Single pole single throw switch was employed to
represent float switches sensing low, medium and full syrup levels. They drive kpinL, kpinM and kpinF
respectively. The pins are pulling down using three 10kΩ resistors. A closed switch applies +5V across
its respective pin.

Figure 6.1 Simulation in proteus

6.1 The complete circuit

Syrup sensors sensing Low, Medium and Full levels of syrup tank are connected to Arduino pins 1, 2
and 3 respectively. Pin 0 drives the syrup pump and buzzer while Light Emitting Diodes indicating
Very Low (vl), Low (l), High (h) and Very High (vh) are connected to pins 6, 7, 8, and 9 respectively.
Current flowing in the LEDs are minimized by connecting 220Ω resistors in series with them; As their
cathodes are grounded (0V), the arrangement is active High, that is, when the conditions for any of the
LED to be illuminated is met, its anode terminal connected to an Arduino pin goes High, thereby
allowing current to flow through it. Input Pins (Sensors) are tied down using 10KΩ resistors, so
+5VDC is connected through the float switches to each input pin. When the syrup level is below any
switch, its contacts becomes opened, its Arduino pin sees 0V but as syrup reaches that float device the
switch closes thus presenting +5V to its Arduino pin. The values in the pins are stored in valf (full),
valm (medium) and vall (low) memory location. Digital Read functions are used to read the values, if
all the values are LOW, it means the water level is Very Low, Pin 0 that drives the water pump goes

45
HIGH (+5V) The HIGH level drives a transistor switch [10] using a switching transistor 2N2222, Its
Vcc is connected to the output terminal of a +9V fixed voltage regulator, LM7809. The base resistor
4.7Ω provides a potential difference in the base circuit which allows current to flow into the transistor.
A transistor connected in common emitter configuration act as an Inverter [11], that is, +5V at the base
produces 0V at the collector. Since a 9V relay with operating coil having ohmic (DC) resistance of
400Ω is the load, a 9V is effectively across the coil thus cause it to operate thereby closing its normally
open contact which is wired in series with Electric pump control circuit. A piezoelectric device wired
across the relay produces sound. Power diode 1N4001 acting as a suppression diode [11] connected
across the relay protects the transistor against the back emf. As the level of the water in the tank rises
with Val, valm and valf become HIGH, all the LEDs are lit, Arduino pin 0 becomes 0V, the transistor
switch cuts off, relay de-energizes, hitherto closed relay contact becomes opened thereby disengaging
power into the syrup pump control circuit. The buzzer goes off. The syrup Pump is automatically
switched off.

RESULTS

The result has helped to solve problems of manual operations of syrup pumping system. It has also
deviated from usage of PIC microcontrollers into trending Arduino platform. Float switches were
realized by manual closing of a set of four contacts. At Very Low syrup level, one LED was lit, at Low
syrup level, two LEDs were ON, at High tank level, three LEDs were lit and at Very High tank level all
the four LEDs were in ON positions at this juncture the syrup pump went off.

46
 Chapter Seven

Conclusion and Recommendation

7.1 Conclusion
All the information and has led up to this point which allows me to draw conclusions based on the
entire internship experience. This 2 month internship period has helped me greatly as an engineer by
allowing me to practically work with materials and principles that were taught in the classroom but not
quite practiced. Collaborating with people in EABSC with more experience and knowledge than me in
certain aspect has really helped me grasp new concepts about teamwork, work ethics and good working
relationships. Although the engineering side of the internship was the main aim my experience at
EABSC has taught something more valuable that allows the technical knowledge of any person be
applied such as team building skills, effective communication with co-workers, and networking.

The project prototype has been the greatest source of learning for me as it required me to step outside
the comfortable world of theoretical and allowed to me face on the challenges of the actual world and
turn theoretical ideas in to reality by pivoting, maneuvering and compromising when problems are
faced. The internship program has done a very good job of letting students like me get out of the
theoretical world of engineering and allowed us to experience the reality on the ground which we will
be faced with after we graduate.

.7.1.1 Conclusion of project

The paper has succeeded in highlighting the simplicity of using Arduino Microcontroller in the designs
of Power Electronic systems. In order to prolong the life of the pump, a Direct- on-Line starter could be
engaged in starting it. In this arrangement, an overload relay would be wired into the motor main
circuit thus preventing overloads from burning its stator windings. To further protect the syrup pump,
an overload relay and a phase failure relay can be included in the starter unit to protect it from single
phasing, wrong phase sequence and power supply imbalance.

7.2 Recommendation
I would like to recommend both the EABSC and JIT on several aspects of the interhip program as well
as other engineering solutions that might be of help to EABSC.

47
.7.2.1 Recommendation to EABSC
On the filler

 Deformed crowns are stuck often which leads to the entire fill process being interrupted. To
solve this I recommend better crown quality and a buffer system for the separation of deformed
crowns before they can cause interruption.

 Height adjustment is often a problem when changing the drink type from coca to sprite and
Schweppes. Although this problem is a problem of the height sensor. Replacement and
recalibration is recommended.

 Friction on the crowns motion also causes a dust problem. There is no dust removal mechanism
in the filler. We recommend an ionizer or a small suction fan to remove the dust caused in the
crowner agitator and the cap chute.

On washer

 Each carrier of the washer contains multiple pockets but due to the bottle fall, all of the pockets
are not fully occupied. This means the washer is not working at full capacity. To solve this I
recommend a better accumulation conveyor equipped with bottle fall sensors.

 Crowned bottles sometimes enter the washer because of the error of the manual bottle openers
causing sprayer damage and decrease in efficiency of the washer. To decrease this incidence I
recommend an automatic bottle opener or an inductive bottle sensor to alert the operator
whenever a crowned bottle is about to enter the washer.

On packer/unpacker

 In line 5, the packer unpacker is outdated in technology and uses chain drives to lift and lower
the grippers. This chain system is lubricant intensive and breaks down frequently causing the
whole line to cease. To avoid this I recommend that the chain system of the packer be replace
with a belt drive to lower down time and breakdowns. Another option is to replace the entire
packer with the new packer as in line 3.

On the Blow molder

 This is the most important in terms of financial feasibility as It could avoid great loss. Every
preform that stays in the heating stage slightly longer due to the stoppage of the filler or the
blow molder is discarded. As each heating stage can contain more than 200 preforms this loss is
huge in terms of preform loss. There is no easy fix for this problem but a suggestion would be
48
 to look in to rapid heating and cooling to instantly turn the heat on and off so that whenever the
machine stops the heating module will be turned off instantly and cooled to room temperature
until the machine starts working again. Rapid heating and cooling systems do exist but the
problem with this approach is that the whole heating station would have to be redesigned to
allow such rapid heating and cooling.

.7.2.2 Recommendation to the university

This section will try to highlight the aspect in which the internship program can be better implemented
through better university effort.

 Internship should not be a onetime effort that students should do to get their degree. This kind
of exposure is crucial for anybody who considers themselves to be engineers so I recommend
that university’s do more with the internship programs during summers so that students will get
practical experience through their 5 years of summer breaks and allow them to be adjusted to
the climate of reality when they face the job market after graduation

 Presentations are no treated with the stature they deserve and are often neglected as secondary
requirements that matter little. I beg to differ in recommending that presentations of report and
project and possibly prototype are essential in making the internship program taken seriously
among students and teachers and administration.

.7.2.3 Recommendation of project

The following recommendations are made:

1. The design can be improved by having means of sensing low syrup level in the sump to prevent
the pump from running dry.

2. An inclusion of a well selected circuit breaker will protect the motor main circuit from short
circuit.

 To further protect the syrup pump, an overload relay and a phase failure relay can be included in
the starter unit to protect it from single phasing, wrong phase sequence and power supply
imbalance.

 I recommend EABSC to install this automatic syrup level controller for production use.

49
Reference
[1] Reliable Plant, “Benefits of automation in lean manufacturing,” Retrieved from:
fromwww.reliableplant.com/leanmanufacturing-automation, Accessed online 2019.

[2] Bates, M.P., “Programming 8-bit PIC microcontrollers in C with interactive hardware simulation,”
NewnessUSA, 2008.

[3] Adafruit Learning System. I2C/SPI LCD Backpack. Retrieved online 2018 from
www.learnadafruit.com/i2c-spi-lcd-backpack .

[4] Akinwole, OO, Oladimeji, TT. “Design and implementation of Arduino microcontroller based
automatic lighting control with I2C LCD Display,” J. Electr Electron Syst, vol. 7, pp. 258, 2018.

[5] Arduino Tutorialpoint, pp. 24-35, 2016, Retrieved online from www.tutorialpont.com, 2018.

[6] Electronics Hub., “Transistor as Switch,” Retrieved from: www.electronicshub.org/transistor-as-

switch/, Sep 2018.

[7] Philips Semiconductors Datasheet on 2N2222 Switching Transistor, Retrieved from:

www.semiconductors.philips.com, 2017.

[8] Labcenter Electronics, Proteus User manual, Intelligent Schematic Input System, www.ele.uva.es,
2002.

[9] Narasimha, R. “Proteus PCB Design and Simulation Software-Introduction”,

www.circuittoday.com,2017.

[10] Akinwole, OO, “Design and implementation of an electric cooker control as a means of preventing
domestic fire incidence” Journal of Engineering Reaearch and Reports, vol. 4, no. 3, pp. 1-9, 2019.

[11] Horowitz, P., Hill, W., The Art of Electroni.cs, Cambridge University Press, 1989.

Krones manual 2010

Monthly reports from EABSC

50
 Appendices 01 code of the project

#include <LiquidCrystal.h>

#include <Wire.h>

LiquidCrystallcd (4,5,10,11,12,13);

int kpinF=1; // pin 1 is set as water full sensor pin

int kpinM=2;// pin 2 is set as water medium level sensor pin

int kpinL=3;// pin 3 is set as water low level sensor pin

int MotorBuzzer=0; // pin 0 is set as water pump and buzzer drive pin

int LEDvh=9; // pin 9 is set as Very High water level indicator pin

int LEDh=8; // pin 8 is set as High water level indicator pin

int LEDl=7; // pin 7 is set as Low water level indicator pin.

int LEDvl=6;//pin 6 is set as Very Low water level indicator pin.

int valf=0;//The value of the memory location sensing Full water level initialized to zero

int valm=0;// The value of the memory location sensing Medium water level initialized to zero

int vall=0;// The value of the memory location sensing Low water level initialized to zero

void setup()

lcd.begin(16,2); // for 16 X 2 LCD module

lcd.setCursor(0,0);

lcd.print("AUTO Syrup LEVEL");

lcd.setCursor(0,1);

lcd.print(" CONTROLLER");

delay(1000);

pinMode(kpinF, INPUT);//kpinF set as Input pin

pinMode(kpinM, INPUT);//kpinM set as input pin

51
pinMode(kpinL, INPUT);// kpinL set as input pin

pinMode(LEDvh, OUTPUT);//LEDvh set as output pin

pinMode(LEDh, OUTPUT);// LEDh set as output pin

pinMode(LEDl, OUTPUT);// LEDl set as output pin

pinMode(LEDvl, OUTPUT);// LEDvl set as output pin

pinMode(MotorBuzzer, OUTPUT);// MotorBuzzer set as output pin

void loop()

valf=digitalRead(kpinF);// Read kpinF and store the digital value in valf

valm=digitalRead(kpinM); // Read kpinM and store the digital value in valm

vall=digitalRead(kpinL);// Read kpinL and store the digital value in vall

if((valf==LOW)&&(valm==LOW)&&(vall==LOW))

digitalWrite(LEDvl, HIGH);

digitalWrite(LEDl, LOW);

digitalWrite(LEDh, LOW);

digitalWrite(LEDvh, LOW);

digitalWrite(MotorBuzzer, HIGH);

lcd.clear();

lcd.setCursor(0,0);

lcd.print("Syrup LEVEL");

lcd.setCursor(0,1);

lcd.print("VERY LOW PUMP ON");

delay(500);

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}

if((valf==LOW)&&(valm==LOW)&&(vall==HIGH))

digitalWrite(LEDvl, HIGH);

digitalWrite(LEDl, HIGH);

digitalWrite(LEDh, LOW);

digitalWrite(LEDvh, LOW);

lcd.clear();

lcd.setCursor(0,0);

lcd.print("Syrup LEVEL");

lcd.setCursor(0,1);

lcd.print("LOW");

delay(500);

if((valf==LOW)&&(valm==HIGH)&&(vall==HIGH))

digitalWrite(LEDvl, HIGH);

digitalWrite(LEDl, HIGH);

digitalWrite(LEDh, HIGH);

digitalWrite(LEDvh, LOW);

lcd.clear();

lcd.setCursor(0,0);

lcd.print("Syrup LEVEL");

lcd.setCursor(0,1);

lcd.print("HIGH");

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delay(500);

if((valf==HIGH)&&(valm==HIGH)&&(vall==HIGH))

digitalWrite(LEDvl, HIGH);

digitalWrite(LEDl, HIGH);

digitalWrite(LEDh, HIGH);

digitalWrite(LEDvh, HIGH);

digitalWrite(MotorBuzzer, LOW);

lcd.clear();

lcd.setCursor(0,0);

lcd.print("Syrup LEVEL");

lcd.setCursor(0,1);

lcd.print("VHIGH PUMP OFF");

delay(500);

54