B.G.I, Ethiopia Internship Report: Certificate/Declaration

B.G.
I, ETHIOPIA INTERNSHIP REPORT 2020
Certificate/Declaration
My name is TSEGAYE TEKA, I am fifth year Electrical and Computer Engineering student, I
have undertaken my internship experience in BGI, ETHIOPIA it is a beer factory located at the
capital city of Ethiopia, Addis Ababa, Mexico sub-city from a period of October 2019 to January
2020 under the guidance of Mr. Nigussu (Academic advisor), Mr.Zedingle (Company Mentor)
and supervisor of electrical and computer engineering department specially Mr.Gebrie T. who is
internship program coordinator.
I certify that my work is original and compiled according to the internship report writing
guideline given by the UIL (university-Industry Linkage) office of the Institute.
This is to declare that the above statement made by the candidate is correct and true to the best of
my knowledge
Student’s Name Signature Date
Tsegaye Teka _____________ __________
As the student’s academic supervisor I certify that the internship report written by the student is
original work and compiled according to the guideline provided by the institute’s UIL office.
Name of academic Advisor Signature Date
Mr.Nigussu ______________ ____________
Mentor Name Signature Date
Mr.Zedingle ____________ ____________
UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page i

B.G.I, ETHIOPIA INTERNSHIP REPORT 2020
Approval
Student’s Name Signature Date
Tsegaye Teka ________________ ________________
Approved by Board of Examiners Signature Date
Mr.Nigussu(Advisor Name) ________________ ________________
Mr.Estifanos D (Department Head Name) ________________ ________________
Examiner name one
_________________ ___________________ ________________
Examiner name two
_________________ ___________________ ________________
UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page ii

Acknowledgement
First of all I thank the almighty God bring me up to this level and my families for their
uninterrupted help from start till now. In view of the successful completion of my report I
extremely delighted to express my deepest gratitude to B.G.I, Ethiopia brew house department
for their cooperation like Mr. Zedingle and Mr. Wedaje a good chance was modification of brew
house in that I have been executing welding, reading and interpreting technical drawing,
observing electrical installation, termination of motors, actuators and introducing with electrical
and mechanical hand tools, asking foreigner’s in Electrical board and panel how to supply power
and signals’ to the new plant and how to control frequency?
Also I would like to thank to all Method office staff of Engineer like Ato Nahome,. I wouldn’t
pass without thanking to Ato Damtew (senior Electrician) and Ato Muez (senior Electrician) for
their unlimited cooperation. More or less things have gone well, but little bit access information
has been shortened. But all the formals and labors were doing their requirement.
Finally, I fill that it is a long way with enormous ups and down to come to the end of this report.
So, generally thankful to all who have contributed their share on the process. I’m surprisingly,
appreciate to site Engineer G/kirstos & Amenti for guide us in the process.
Special thanks to my Tewodros bottling section or your special contributes.
UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page iii

Executive Summery
Internship program has a key role for us to have an experience on practical skills by interrelating
our previous theoretical knowledge and helps to apply hands on work duty in a certain
occupational field. In my duration in BGI, ETHIOPIA the first three weeks I started to look the
whole working process of the company, as well as the main raw materials that used and product
of the factories. My final internship report contains all the necessary information about my work
experience that I have gained from the St. George factory. This report consists of five chapters.
The first part describes the background of the hosting company. And it includes its brief history,
its vision, mission and objectives, main products or services, customers or the end users of its
products or services and the company’s overall organization and work flow. In the second part,
the topic that is discussed in detail is the overall internship experience. It includes details on the
process of the section that have been worked in and works that have been executed. Also
challenges that have been faced and measures that have been taken to solve the challenges. In the
third part I have included the project that solves the problem of the factory. In the fourth part, I
also discussed in detail what I have gained benefits which helped me to explore my Skills,
qualities, abilities and scope of my theoretical knowledge’s. Finally I tried to discuss the
conclusion and recommendations for the intern ship report.
UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page iv

Table of Contents
Certificate/Declaration ..................................................................................................................... i
Approval ......................................................................................................................................... ii
Acknowledgement ......................................................................................................................... iii
Executive Summery ....................................................................................................................... iv
List of Figures .............................................................................................................................. viii
List of Tables ................................................................................................................................. ix
List of Equations ............................................................................................................................ ix
List of Symbols and abbreviations .................................................................................................. x
CHAPTER ONE ............................................................................................................................. 1
GENERAL BACKGROUND OF ST.GEORGE BREWERY ....................................................... 1
1.1 Historical Background of the Company ................................................................................ 1
1.2 Main products and services ................................................................................................... 1
1.3 Main Customers (End Users) ................................................................................................ 2
1.4 BGI, Ethiopia Exports ........................................................................................................... 2
1.6 Mission .................................................................................................................................. 3
1.6.1 Value ............................................................................................................................... 3
1.7 Objective of the company ..................................................................................................... 3
1.7.1 Some of social activities of the company ....................................................................... 3
1.8 Organizational Structure of the company.............................................................................. 4
1.9 Work flow of the main section .............................................................................................. 5
CHAPTER-TWO ............................................................................................................................ 6
OVERALL INTERNSHIP EXPERIENCE .................................................................................... 6
2.1 Objectives of the internship................................................................................................... 6
2.1.1 General objective ............................................................................................................ 6
2.1.2 Specific objectives .......................................................................................................... 6
2.2 Section of the company that have been worked .................................................................... 6
2.3 Process description of these sections .................................................................................... 6
2.3.1 The raw material of beer ................................................................................................. 6
2.3.2 Silo .................................................................................................................................. 8
2.3.3 Browning house .............................................................................................................. 8
UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page v

2.3.4 Beer Packaging ............................................................................................................. 12

2.3.5 Utility Section ............................................................................................................... 16
2.4 The work pieces that have been executed ........................................................................... 19
2.5 Procedure that have been used while performing tasks ...................................................... 19
2.6 Challenges that have been faced during task work ............................................................. 19
2.7 Measures that have been taken to solve the challenges ...................................................... 19
CHAPTER THREE ...................................................................................................................... 20
THE OVERALL BENEFIT GAINED FROM THE INTERNSHIP ............................................ 20
3.1 Upgrading theoretical skills ................................................................................................ 20
3.2 Improving practical skills .................................................................................................... 20
3.3 Improving industrial problem solving capability ................................................................ 20
3.4 Improving our team playing skills ...................................................................................... 20
3.5 Improving our leadership skills ........................................................................................... 21
3.6 Understanding about work ethics issues ............................................................................. 21
3.7 In terms of entrepreneurship skills ...................................................................................... 21
CHAPTER FOUR ......................................................................................................................... 22
PROJECT TITLE: DESIGN AND SIMULATION OF AUTOMATIC BOTTLE FILLING
SYSTEM USING PLC ................................................................................................................. 22
4.1 Executive summary ............................................................................................................. 22
4.2 Introduction ......................................................................................................................... 23
4.3 Statement of the problem .................................................................................................... 23
4.4 Objective of the project ....................................................................................................... 24
4.4.1 General objective .......................................................................................................... 24
4.4.2 Specific objective ......................................................................................................... 24
4.5 Significance of the project................................................................................................... 24
4.6 Scope of the project ............................................................................................................. 24
4.7 Literature review ................................................................................................................. 25
4.8 Methodology ....................................................................................................................... 26
4.9 Method of filling bottle ....................................................................................................... 26
4.9.1 Working principle ......................................................................................................... 27
4.10 General design procedure of the bottle filler machines’ components ............................... 27
UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page vi

4.10.1 Design of co2 flushing pressure ................................................................................. 27

4.10.2 Designing of pressure relief valve spring ................................................................... 28
4.10.3 Design of vent tube ..................................................................................................... 31
4.10.4 Design of spreader ...................................................................................................... 33
4.11 Flow-chart the project ....................................................................................................... 34
4.12 System Design ................................................................................................................... 35
4.12.1 Hardware Design ........................................................................................................ 35
4.13 Software ............................................................................................................................ 38
4.14 Result and discussion ........................................................................................................ 38
4.14.1 Program discussion ..................................................................................................... 38
4.14.2 Simulation result ......................................................................................................... 39
4.15 Conclusions and recommendations ................................................................................... 40
4.15.1 Conclusions ................................................................................................................ 40
4.15.2 Recommendations ...................................................................................................... 40
CHAPTER FIVE .......................................................................................................................... 41
GENERAL CONCLUSIONS AND RECOMMENDATIONS ................................................ 41
5.1 Conclusions ......................................................................................................................... 41
5.2 Recommendations for the company .................................................................................... 41
5.3 Recommendations for the university................................................................................... 41
References ..................................................................................................................................... 42
UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page vii

List of Figures
Figure 1.1: Organizational structure of BGI, Ethiopia ................................................................... 4
Figure 1.2: Block diagram of Work flow of BGI, Ethiopia ............................................................ 5
Figure 2.1: Silo................................................................................................................................ 8

Figure 2.2: Production process in bottling section........................................................................ 15
Figure 2.3: Process in Water treatment plant ................................................................................ 17
Figure 2.4: Boiler plant flow chart ................................................................................................ 17
Figure 2.5: Process in Boiler plant ................................................................................................ 17
Figure 2.6: Process in cooling plant .............................................................................................. 18
Figure 2.7: Process in CO2 Production process ............................................................................ 18
Figure 2.8: Process in Treatment Plant ......................................................................................... 18
Figure 4.1: Structural flow of the methodology............................................................................ 26

Figure 4.2: Indicates operation of pressure relief valve ................................................................ 27
Figure 4.3: Free body diagram of pressure relief valve ................................................................ 28
Figure 4.4: Vent tube .................................................................................................................... 33
Figure 4.5: Spreader ...................................................................................................................... 33
Figure 4.6: Vent tube with spreader .............................................................................................. 33
Figure 4.7: Flow chart of the project ............................................................................................ 34
Figure 4.8: Short hand representation of design ........................................................................... 35
Figure 4.9: Programmable logic controller arrangement .............................................................. 35
Figure 4.10: Pressure sensor working process .............................................................................. 37
Figure 4.11: Temperature sensor working process ....................................................................... 37
Figure 4.12: Simulation result....................................................................................................... 39
UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page viii

List of Tables
Table 1.1: Brands of BGI ................................................................................................................ 2
Table 4.1: Design of vent tube ...................................................................................................... 32

Table 4.2: List of input and output of the simulation ................................................................... 38
List of Equations
Equation 4.1: Spring index ........................................................................................................... 29
Equation 4.2: Stiffness of spring ................................................................................................... 29
Equation 4.3: Shear stress factor ................................................................................................... 29
Equation 4.4: Wahl’s correction factor ......................................................................................... 29
Equation 4.5: Solid length............................................................................................................. 29
Equation 4.6: Free length .............................................................................................................. 29
Equation 4.7: Pitch of spring ........................................................................................................ 29
Equation 4.8: Deflection ............................................................................................................... 29
Equation 4.9: Flow rate of each filler valve .................................................................................. 32
Equation 4.10: Tangential stress ................................................................................................... 32
Equation 4.11: Radial stress” (GUPTA) ....................................................................................... 32
UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page ix

List of Symbols and abbreviations

AC Alternating current
AMWF Automated multiple water filling
BBT Bright beer tank
BGI Brasseries Et Glaciers Internationals
BSC Brewery share company
CPU Central processing unit
DC Direct current
DGM Director general manager (marketing)
EBI Empty bottle inspection
EEPCO Ethiopian electric power corporation
EIAMD Electrical instrumentation and automation maintenance division
FBI Full bottle inspection
HGB High gravity beer
HR Human resources
I/O Input output
IR Infrared
ISO International organization system
KM Kilometer
KV Kilo volt
LED Light emitting diode
MAWP Maximum allowable working pressure
NC Normally closed
NO Normally open
PB Push button
PLC Programmable logic controller
POT Potentiometer
PS Photo sensor
SCADA Supervisor control and data acquisition system
UIL University Industry Linkage
UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page x

CHAPTER ONE
GENERAL BACKGROUND OF ST.GEORGE BREWERY
1.1 Historical Background of the Company
B.G.I (Brasseries ET glaciers internationals) or brothers group international has a long history
which dated back to more than one hundred years ago in Indochina in which it was took over by
the castle group in 1990 in under impetus. B.G.I is present in around 20th century in Africa and
operates more than 50 industrial plants directly.
During the age enlightenment of technology in Ethiopia, one of the modern things that happened
was the opening of the first brewery during the reign of emperor menilik the second. The
brewery was set up with modern primacies to produce the country’s first bottled beer. 85 years
ago George beer founded by a Belgian national of Ethiopian descent named Mussie Hal .But
currently it’s owned by a France Company. The production capacity did not exceed 200 bottles
per day. But slowly St. George brewery continued to grow. The 1940s and 1950s could be taken
as the golden and remarkable years for St. George brewery, in which it exceed in every aspect of
its service, like production, working hours, number of workers, and even got its own
transportation system that transports beer through the empire.
1.2 Main products and services
Main products include:
 St. George bottle beer,(Alcoholic content: 4.5% Size: 33cl)
 St. George keg beer
 Amber beer
 Panache
 Raya beer
 Zebidar beer
 St. George castle beer at the Kombolcha branch.
 Sister company Kombolcha plant, St. George keg beer and Castel bottle beer are
produced
 Oxygen used for restaurant and hotel which provide draft
 Spent grain as a byproduct used for animal feed and they have plane to pasteurize and sell
the aged yeast for animal feed.
UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 1

BGI Ethiopia provides number of services to the society includes:

 Training beer servers on sanitation, customer service, and equipment handling.
 Giving professional consultancy for other Breweries on matters of brewing and
distribution.
 Hosting internship programs for students from educational and research institutes.
1.3 Main Customers (End Users)
The end users/customers are every person aged above 18 years old.
 Local customers
 Sub site customers
The BGI Ethiopia products are preferred in many sectors. Some of the sector includes:
 Restaurants
 Hotels
 Individual person
1.4 BGI, Ethiopia Exports
BGI, Ethiopia products are distributed by partner agents in all corner of country and exported
inter nationally:
 North America(USA and Canada)
 Europe(UK,Italy,France,Germany,Switzerland,Belgium,Netherland,etc)
 Middle-East(Israel and UAE)
 Australia
 Africa (Kenya, Tanzania, South Africa, South Sudan, Djibouti etc.)
 Asia (China, Japan etc.)
Table 1.1: Brands of BGI

1.5 Vision
To continue being the leading in the local market as well as to export quality beer to foreign
market by applying modern technologies .In addition to these controlling the local markets by
producing and distributing their own different product with reasonable price and quality to the
society.
1.6 Mission
To be profitable in sustainable manner by production and distribution of beer and other
multipurpose products with reasonable price and better quality to the local as well as export
market so to generate foreign currency to the country and to minimize import of similar product
by producing substitute products at local in order to save foreign currency.
1.6.1 Value
To satisfy its customer demand by providing convince and reliable quality product.
 The beer company profitable.
 Making Proper usage of company’s asset.
 Proper usage of working hours.
1.7 Objective of the company
 To manufacture, sell & bottle distributed, corks & all type creates
 To involve in export market.
 To produce & sell quality beer at reasonable profit.
1.7.1 Some of social activities of the company
 Repair and construction of subsidiary roads.
 Participation in changing the life street dwellers.
 It also corporate in sport club(St. George sport club)
 Financial assistance for students.

1.8 Organizational Structure of the company
Figure 1.1: Organizational structure of BGI, Ethiopia

1.9 Work flow of the main section
Figure 1.2: Block diagram of Work flow of BGI, Ethiopia

CHAPTER-TWO
OVERALL INTERNSHIP EXPERIENCE
2.1 Objectives of the internship
2.1.1 General objective
The general objective of internship is to allow students substitute their theoretical knowledge
with practical skill and raise their technical capacity also makes them productive.
2.1.2 Specific objectives
 To provide intensive field experience allowing for hands-on computer work.
 To receive an introduction to an organization within the information systems industry and
to gain a better understanding of its design and structure.
 To develop an understanding of an organization's various management and technical
skills, the communications techniques and the decision-making processes.
2.2 Section of the company that have been worked
There are four main sections of BGI, Ethiopia: brew house, utility, fermentation and filtration,
production (bottling).There are also some other sub-section cooperatively work with main
section All the section have their own controlling systems for example the other three sections
like brew house, filtrations and fermentation, and utility uses PID, SCAD, PLC and relay type
control systems because of that it tries to cover all section of the company.
2.3 Process description of these sections
2.3.1 The raw material of beer
Beer is a fermented beverage initiated by four major ingredients WATER, HOPS, BARLEY
and YEAST in which each raw material plays its role. Moreover the quality of these raw
material highly influence on the quality of the final products.
1. Barley
Beer brewery use barley malt. For the fact that it contain high starch content and it fibrous husk
still adhere to the grain even after threshing and processing to malt. It supply the starch required
for beer production.
In BGI Ethiopia there are two types of barley malts used.

 Local Malt:-it is the product of our country (Ethiopia), so it comes from Asela. It
transferred by using cars and it is used directly that means not stored in silos, simply it
passes through fro malt container to the willing house and the others are put in to room
(raw material house) at room temperature.
 Imported Malt:-it is the product of outside country (European Especially it comes from
Belgium. Its amount of flour and quality is higher than the local malt. It stored in silos.
2. Hops
The quality of beer highly depends on the hops and by far the most expensive raw material in
beer production. The hops contain bitter resins and ethereal oils which supply bittering and
aroma component to beer and the composition of beer. BGI Ethiopia import hop from the largest
hop growing countries like Germany. BGI-brewery uses three types of hop products:
 Hop extracts: - They are produced extraction, means of a suitable solvent (liquid CO2
ethanol).
 Reduced isomerized hop product: - They are produced by heating at elevated
temperature and isomerization in alkaline condition.
 Isomerized kettle extracts (IKE): - These are hop products that are produced by per
isomerization of the a-acids.
3. Water
Quantitatively the most important raw material which affect the beer character and quality at
several processing stages. Water makes 95% of beer. The source of water in BGI Ethiopia is a
ground water. Reason for preference of underground sources:-
 Natural Constituents may provide the right quality.
 More consistent quality may be achieved.
 Usually less pollution problem.
4. Yeast
Any of a number of microscopic, a unicellular fungi important for their ability to ferment
carbohydrates in various substances is called yeast. Yeast is the most unimaginably essential,
mysterious ingredient in beer production which turns wort into beer and produces more of it.
Through anaerobic respiration, it converts the malt sugar into alcohol, CO2, and other by-
products. In a brewery, the quantity of yeast required for fermentation is obtained by propagation
of a pure yeast culture. Yeasts are imported from Europe.

2.3.2 Silo
It is a humongous cylindrical sheet steel container used to store malt. Here in BGI, there are four
silos each having a capacity of 700 tons and they are only used to store imported malts. And for
proper transportation. The malt enters the silo at 35 tons/hr. Transport system for malt to be
transferred to and from the silo to milling machine and also for local malt to milling machine is
by a pneumatic conveyor with a carrying capacity of 10 tons/hr. The company uses 70% of
imported malt and 30% of local malt to produce one brew
Types pneumatic of Conveyers:
 Chain conveyer: used for horizontal transportation of malt.
 Bucket conveyer: used for vertical transportation of malt.
 Screw conveyer: used for inclined transportation of malt.
Figure 2.1: Silo
2.3.3 Browning house

Almost 70% of the production process is achieved in brew house. Processes like malt handling,
milling, pre masher, mash kettle, mash filter, wort collecting, wort pan and wort cooling.
2.3.3.1 Malt reception and handling
In this room, storing, cleaning and milling of malt are take place.
1. Equipment used for cleaning malt:
 Cyclone separators are used to remove husks and dusts from the malt.

 De stoner is used to remove stones and high-density particles from the malt.
 Drum sieve is used to separate oversized particles
 Magnetic separators are used to separate metallic materials from malt. Thus, it prevents
damage in the hammer mill as the metallic objects are retained.
 Aspiration machine: used to select the dust and pure malt then reject the dust.
2. Milling: is a mechanical process and during it the husks must be treated carefully because
they are used as a filter material during lautering. The objectives of hammer mill are to breakup
malt and adjuncts to such an extent that the greatest yield of extract is produced in the shortest
time in the mashing equipment in use. The milled malt is called the grist and the amount used in
brewing is called grist charge.
a) Milling Machines: is a power driven machine that cuts the malt by means of a multi tooth
rotating cutter. Classic mill is used for milling of the malt as required size and able to mill 5500
kg of malt in one hour. St. George brewery uses hammer mill as it uses mash filter (filter press)
to separate the wort from grain spent.
b) Grist bin (Malt hopper): used to hold and store the powder of the malt (grist) used for
temporary storage of grist and it is the final stage in the malt handling process. It is equipped
with a mass measurement system at its bottom, it not only stores the grist but also measures its
amount in mass (Kilograms). At BGI, the grist bin has a storage capacity of 9 ton.
2.3.3.2 Mashing Process
1. Mecha masher: This is where an extremely thorough mixing of grist with brewing water at a
specified mashing-in temperature occurs. In BGI, the water used is a blend of hot and cold water
from the hot water tank and cold water tank respectively, giving water at 550c and with a pH
range of 5.5-5.3 using additives such as H3PO4. Mashing-in can basically be operated at any
temperature but is influenced by the optimum temperature of the enzyme which the brewer wants
to act initially. Mashing-in is very essential because activates malt enzymes and makes pumping
to mash-tun easy. Mixing of the process water and grist must be done in such a way as to
minimize clumping and oxygen uptake. Clumping reduces extract recovery, and no segregation
of the grist components. The mecha-masher in BGI has a capacity of mixing 50tons/hr.
2. Mash-tun: The process of mashing refers to the conversion of brewing materials in the
presence of enzymes, in to a fermentable extract suitable for yeast growth and beer production.

3. Mash filters (lautering): At the end of mashing process, the mash consists of a watery
mixture of dissolved and undissolved substances. The aqueous solution of the extract is called
wort the insoluble part is referred as the spent grains. Only the wort is used for beer production
and for this purpose it must be separated as completely as possible from spent grains. This
separation process is called lautering or mash separation.
2.3.3.3 Wort Boiling
1. Wort kettle: Wort boiling is performed in the wort kettle which is equipped with everything
needed for vigorous through boiling. The end product of wort boiling is the casting wort i.e. the
hot finished wort. During wort boiling bitter and aromatic hop components are transferred into
the wort and simultaneously proteins are precipitated.
During wort boiling a number of important processes occur:
 Extraction and transformation of hop components
 Formation and precipitation of protein-polyphenol complexes
 Evaporation of water
 Wort sterilization
 Destruction of all enzymes
 Increased coloration of the wort and formation of reducing substances
 Acidification of the wort and effects on the dimethylsulphide content of wort
2. Wort separation (claisever): Whirlpool is a separation (clarification) equipment to maintain
purity of the wort.
3. Wort cooling: Because yeast can only live and ferment at low temperature, the hot wort must
be cooled. In B.G.I., this stage is achieved through a plate heat exchanger. The wort is pumped
into the heat exchanger, and goes through every other gap between the plates. A good heat
exchanger can drop wort at 80 0C to 80C, while warming the cooling medium from about 50C to
800C. At BGI, the casting temperature of wort is 80C.
4. Wort aeration: It has been pointed out that yeast needs oxygen to multiply. Fermentation of
the wort in the fermenter requires a lot of yeast. Multiplication of the yeast must therefore be
activated and the same time fermentation initiated. Using air, a wort oxygen level of 8 to 9 mg/l
is achievable and this is adequate for many fermentations.

2.3.3.4 Fermentation process

The objective of fermentation is to convert the sugar in the wort to ethanol & CO2 as the major
products, and esters, higher alcohols and some other substances as byproducts. The fermentation
tanks in BGI are cylindroconical tank (CCT/TOD) and are 18 in numbers each with a different
holding capacity, 1-12 of them is small TOD (1500-1600 hl) 13-18 TOD are large (1700-2500
hl).
Fermentation of glucose sugar to ethanol & CO2: C6H12O6 yeast 2C2H5OH +2 CO2
Fermentation stages:
1. Primary stage: When the yeast is added in to the wort fermentation start during these stage
yeast population growing festally because of the huge supply of sugar, nutrients and oxygen they
lucked into. This stage is most active and productive phase of fermentation. During this stage the
temperature is increase from 90c to (12-13) % by using heat in order to increase. The yeast break
down the Glucose worth in to alcohol and Co2.
2. Secondary stage: Secondary fermentation also known as VDK reduction, in which the
amount of diactyl is reduced up to 0.188 ppm because they disturb the flavor of beer. The
temperature of secondary fermentation is increased by using steam (energy) based on the
concentration of extract.
a) Cooling section: Now decrease the temperature from 140c to 1.50c in order to cool the
fermentation process which is used to deactivate the yeast and also enzymes, because we don’t
need further fermentation. The temperature is decreased by using glycol (Top, medium and
cone). These low temperature (1.50c) used for the preventive of autolysis.
b) Laggering section: The beer is then transferred to a chiller where it is cooled to 1.50c and for
further cooling it goes to the next step, this is called laagering. The beer is laagered to -0.50c for a
day or two
2.3.3.5 Maturation process
The customary fermenters and laagering tanks could be used only up to a certain size. The drive
for greater profitability and larger volumes led inevitably to the introduction of larger production
units for the fermentation and maturation of beer.

2.3.3.6 Filtration, carbonation and cellaring process

1. Filtration: Filtration is a separation process in which the yeast cells and other turbidity
causing materials still present in the beer are removed from the beer. It is a physical operation
very important in chemistry for the separation of materials of different chemical composition. It
is used to separate particles and fluid can be a liquid, gas or super critical fluid.
2. Carbonation: A normally treated beer keeps its CO2 content until it is in the bottle. It can
however happen that the CO2 content has decreased as a result of a process treatment at lower
pressure or increased temperature and must be renewed before filling. In this case the lost CO2
must be replaced. This process is known as carbonation. To achieve this carbonation unit is
introduced into the beer flow line.
3. Cellaring (BBT): The filtered beer is pumped into the pressure storage tank (bright beer tank)
and stored for two to three days in this pressure tank.
Bright beer tanks are buffer vessels between the filter and the filler. They are mostly constructed
as vertical chrome nickel steel tanks without internal fittings and the entire bright beer storage
cellar is cooled to 00c to 20c. There are no other safety devices after them. All safety measures
must therefore be built into them. These include:
 The tanks must be very thoroughly cleaned by CIP system
 The cleaning must be carefully controlled
 The tanks must have a smooth internal surface (little surface roughness)
2.3.4 Beer Packaging
It is one of the important sections in beer factory which uses complex, robotic mechanical
machines and plant to maintain high quality of beer and to increase the demand of customer by
excellent presentation of the product. In this section two types of packaging are takes place:
1. Bottling and
2. Kegging for drought beer
2.3.4.1 Bottling Section
In this section processed bright beer from BBT (bright beer tank) filled in washed bottles,
properly sealed, pasteurized and delivered to store after labeling. As shown below is going to
summarize a series of steps and corresponding components involved in bottling process:

1. Warehouse: Warehouse is for storing empty bottle returned from market and store full bottle
until sale for customer. Forklift truck that use for transport pallet having a packed bottle from
ware house to DE-palletizer conveyor, from palletizer to ware house and having many
application area for lifting, moving, and conveying.
2. DE-Palletizer: DE Palletizer: - In a fully automated production process a DE Palletizer is
indispensable. A fork lifts truck loads a pallet with stack of crate with used empty bottled that
arrive on pallets or coming from warehouse. The palletizer picks 28 crates (672 bottles) at once
and the crates are passing to de crater machine through conveyer a roller conveyor and then a
chain conveyor .and also a pusher with a sensor to align the crate movement.
3. Conveyor: It is a mechanized device used to move materials in relatively large quantities
between specific locations over a fixed path. There are over 400 types of conveyors.
The major types are Roller, Chain, Portable, Vibrating, Screw/Spiral and Belt. In BGI Ethiopia
the type of conveyor used is the belt type.
4. DE craters (De camatic or Un-packer): This machine is used to pick up the bottles from the
craters and put into the bottle conveyor. At one pick it picks 96 bottles from 4 crates. The empty
bottles are passing on to the bottle washer and the empty crate passing to the crate washer.
Electrical part in unpacked machine
 Photoelectric sensor
 Photo electric sensor with counter to arrange the position of the crates
 Servo motor to run the robotic machine run up and down wards
5. Crate Washer: It is used to wash the crate with warm water and high-pressure spray from
different direction. The entire system is constructed out of stainless plate s and profiles and is
placed at adjustable feet. The wash tunnel upward folding doors. When a door is opened during
operation, the washer will stop instantly. Transport of crates is conducted by a synthetic chain.
At the end of washing process, the crates are transferred to the crater machine to be filled with
full bottles.
A. By inverting the crate up and down so that any broken glass or any unwanted materials
removed from it.
B. By washing the crate by using hot water at 50oc temperature and caustic soda acid in Order to
found perfect and clean crate.

6. Bottle Washer: - Returnable bottles come back from the customer dirty and still label so, to
reuse the bottles must be cleaned and the label and
7. Empty Bottle Inspection: The empty bottle inspector is a type of sensor which has three
phases to inspect anything that can affect the filling process. The first phase of inspection: - the
sensor checks the right part of the bottle wall
The second phase of inspection: - the sensor check the left part will be checked.
The third phase of inspection has two compartments;
A. Base Inspection: - this compartment of the sensor checks if there is anything unusual on the
bottom part of the bottle.
B. Finish Inspection: - this compartment checks if there is anything on the top part of the bottle.
8. Filler Machine: Bottle filler is where the dry clean bottles get filled with the beer coming
from bright beer tank. Bottle filling machines are built as rotating machines with up to 72 filling
valves. The bottles are delivered on a conveyor belt, separated to predetermine spacing an
separating device, and positioned on a lifting platform under the filling elements by a star wheel
loading device. The bottle filler has a capacity of filling 35,000 bottles in an hour. Then the
bottles are crowned. The bottles can hold 33ml of beer.
Crowner Machine: After the bottles are filled, It is use to seal filled bottles with crown cork,
The crown cork passes on a magnetic conveyor band, a slide or other conveying device into the
storage hopper of the bottle closer and is there brought into the correct orientation by a sorting
device. The cork supply supplies with the capacity of 350000cap per hour.
9. Full Bottle Inspection (FBI-1): is also another type of sensor. This is the detection of overfill
and under fill by means of different measuring methods includes Optical sensors, Video camera,
Infrared camera, High frequency and X-ray. FBI is used for metallic containers like kegs and
transparent containers like bottles. The Overfill and the under fill is rejected using a high
frequency and pneumatic system.
Like empty bottle inspection consists four phase:
A. The first inspection sensor checks whether above the bottle loin have some unusual things
B. The second inspection sensor check whether the bottle is accurately capped
C. The third inspection sensor check whether if it is under filled or over filled bottles
D. The four inspection sensor check whether below the bottle loin have some unusual things
Other than this everything is as empty bottle inspection.

10. Pasteurizer Machine: This process Used to heat treatment on products that have already
been bottled or packaged. Which is carried out to make the beer stable both biologically and
colloid ally. The main reason of pasteurization is for sterilization, killing of microorganisms in a
solution and to have long storage life, makes the bottled beer unexpired before one year.
11. Labeler: This machine used to decorate bottles after pasteurization. Since the appearance of
the bottle is very important in competition of market share. The label of the bottle is both on the
body and neck foil with its respective brand. The labeler can label up to 40,000 bottles in an
hour. Then the bottles go to the FBI 2 which is the same as FBI 1 but with additional of sensing
labels correctly, and then pass to the Incamatic machine.
12. Domino Machine: The main function of this machine is to print the production date, the
name of the Production Company and expired date of the beer. In this, we do not have any sensor
that detects the incoming of bottles but it uses encoder of the servo drive to print these bottles by
using gamma ray.
13. Full Bottle Inspection (FBI-2): This is used to inspect weather the bottles, which has not
crowned, under filled and over filled are rejected by FBI 1 and after rejected the bottles are
removed by the operator.
14. Crater (Incamatic) Machine: After the bottle pass domino machine and the crate pass crate
washer machine they go to this machine. It is the last machine that joins the bottle and the crate
so that precise arrangement of the two parts must be clear.
15. Palletizing: Automatic machine that places crates coming from crater machine on a Pallet
which is a reverse process of de palletizer.
Figure 2.2: Production process in bottling section

2.3.4.2 Kegging (Drought Beer) Section

Drought beer is filled by keg. A keg is a standardized cylindrical metal barrel made of chrome
nickel steel. Steps in the draught beer:
1. Flash Pasteurization: Before filling the beer should be pasteurized by flash pasteurization
method. Flash pasteurization occurs before the beer put into its final container.
The filtered beer comes from bright beer tank through beer lines.
2. Empty turning machine: also called empty inverter machine. It accepts kegs from the input
and uses to invert the keg. Again passes to the external washer machine.
3. External washer: it is a machine used to wash the keg external.
4. Internal washer and filer: The process of internal keg cleaning and filling has three stations.
Stage-1: first pressurizing the keg, to remove residual product in the keg and rinsing by water.
Stage-2: Blowing out of water, rinse by caustic, blowing out of caustic and rinsing by hot water.
Stage-3: Blowing out hot water with steam, steaming, venting & CO2 pressurizing and filling of
drought beer.
5. Rating system: also called weight sensor Used to check the weight of the full keg. If the full
keg is under and over fill, they push by the pusher.
6. Labeler: The labels carry important and effective imprints used to decorate the kegs.
7. Video jet: used to write the shelf life of the drought.
8. Full turning machine: also called full inverter machine. It accepts kegs from the filler and
uses to invert the keg. Again passes to the output.
2.3.5 Utility Section
It is the back bone of the company which is the sources of steam, process and service water,
glycol and purified CO2 those have significant impact on the production process.
2.3.5.1 Water Treatment Plant
BGI used ground water to fulfill the desired amount of water in its production steps in the
company compound. Ground water is part of the water which pre calottes in to the ground.
Depending on its cleanliness water is treated in three stages:-
Stage 1: Removal of suspended matter.
Stage 2: Removal of dissolved materials.
Stage 3: Removal of microorganisms.

Figure 2.3: Process in Water treatment plant
2.3.5.2 Boiler Plant

Boilers are closed containers or arrangements of pipes which produce steam at higher than
atmospheric pressure of outside the boiler. The aim of this plant is steam generation; which is
used for different purposes like brew house, bottling, CIP and utilities. In this company, there are
two boilers Bosch the latest and loos boiler the older one.
Figure 2.4: Boiler plant flow chart
Figure 2.5: Process in Boiler plant

2.3.5.3 Cooling Plant
Cooling plant is used for heat rejection purpose. A cooling tower is a heat rejection device which
rejects waste heat to the atmosphere through the cooling of a water stream to a lower
temperature.

Figure 2.6: Process in cooling plant
2.3.5.4 CO2 Recovery Plant

Carbon dioxide is the most useful element in beer factory. CO2 is byproduct of starch in
fermentation process.
Figure 2.7: Process in CO2 Production process
2.3.5.5 Air Treatment Plant

In air treatment plant air from the surrounding environment is collected and treated.
Figure 2.8: Process in Treatment Plant
2.3.5.6 Power distribution of a company and components

Power house of the factory is the section, which has two parts, high power tension and low
power tension, which provide suitable power to the factory and residence. The transformer step-
down 15KV to 380V.

2.4 The work pieces that have been executed

 Observing
 Analyzing, and taking continues notes, working with workers and cooperating with them
use hand tools trying to repair and maintain Electrical materials like termination in the
new modification brew house and interpreting technical drawing and realizing with
Electrical installation what my mentor was doing.
 Checking the whole process in the company.
2.5 Procedure that have been used while performing tasks

 Identify the problem.
 Mark the problem area name.
 Ask about the problem to our company advisor and deal with him on the problem.
 Collect data to solve the problem using full information.
 Show day to day activities to the advisor to get basic component to correct our self-given
proposed solution to the problem.
2.6 Challenges that have been faced during task work
During my task work there were different challenges. Some of these are:
 The company government system
 Excess number of students in the group
 Less willingness of worker to show something what we want to ask.
 MY understanding of PLC was insufficient.
2.7 Measures that have been taken to solve the challenges
Some measures to overcome the challenges or problems that have been facing during internship
period. It has been tried to solve the challenge with PLC by asking other PLC technicians. Also
tried to study the course from internet, books and manuals. Also have taken measure for that
mentor was so busy and he was not will to show but making a schedule and read previous work,
asking each of workers confidentially without afraid of them, made so
many shift workers so that they helped in so many practical places

CHAPTER THREE
THE OVERALL BENEFIT GAINED FROM THE INTERNSHIP
3.1 Upgrading theoretical skills
This internship program provides us opportunity to expand intern horizon, bordering intellectual
knowledge and practical skills and also add some knowledge when on the lessons from class. In
instrumentation engineering, industrial automation, power electronics and electric drive system,
as well as how to control closed loop and open loop system, better understood from campus time.
In addition to this, the theoretical part is important that clearly understand different electronic
devices working principle and interconnection. Also had known about how much it important to
standardized a material when design.
3.2 Improving practical skills
In the internship program, there were some benefits gained accordingly.
 Understand how transport, control and distribute huge materials in industry
 Able to give maintenances for different mechanical device which are used in industrial
application.
 Able to apply our basic mechanical knowledge to the solution of more advanced
mechanical engineering problems.
 Creative and logical approach to solving problems in the industry.
3.3 Improving industrial problem solving capability
Intern has gained many things like identifying problems and possibly improves creativity. Also
had learned the basic steps how to solve problem. The steps are:
 How to finding and defining problem
 How to generating alternative ideas
 How to selecting alternative solutions
 How to implementing solution
3.4 Improving our team playing skills
 Fast decision making skill
 Self-confidence
 Good communication skill

3.5 Improving our leadership skills

For effective leadership we understood that personal values like confidence, effective
communication and devotion are very important.
 Should have Good speaking ability
 Should have the ability to listen to others
 Should be decisive
 Should have Good management skills
 We understood that Leadership is a skill to guide, control and monitor peoples.
3.6 Understanding about work ethics issues
Work Ethics and discipline is one of the major factors for the step to professionalism. Some of
the work ethics are as follows:
 Punctuality.
 The office discipline.
 Reliability.
 Honesty.
 Cooperation.
3.7 In terms of entrepreneurship skills
Entrepreneurship can be defined as the process of involving the creation of new enterprises and
that the entrepreneur is the founder. The major characteristics of entrepreneurs that we have been
observed in the company include the following.
 Self-confident multi-skilled
 Innovative skills
 Results-orientated
 A risk-taker
 Total commitment

CHAPTER FOUR
PROJECT TITLE: DESIGN AND SIMULATION OF AUTOMATIC
BOTTLE FILLING SYSTEM USING PLC
4.1 Executive summary
This project was aimed to design and simulate Automatic bottle filling and capping system using
PLC that the filling and capping operations are controlled using PLC. Filling is the task that is
carried out by a machine and this process is widely used in many industries. The set amount of
inputs to be process is received as a group, and an operation produces and finishes the product.
The objective of this project was to be applied in drinking beer industries and to automate the
bottle filling process.
The system consists of an assembly line, and when a bottle reaches the filling station, a fixed
amount of liquid is filled into the bottle, and then it moves towards the end of the assembly line
to make way for another bottle to be filled for the conveyor system. A sensor has been used to
detect the position of the bottle. Ladder logic has been used for the programming of the PLC,
which is the most widely used and accepted language for the programming of the PLC. Although
this type of PLC controlled systems already exists in the industries, but we want to improve
overfill and under fill problems on St. George Brewery Company by designing the vent tube,
pressure control valve and spreader systems. Generally, the function of the machine is to fill the
beer automatically into bottles through a vent tube and by the help of in feed worm spacing as
well as pressure valve. So in this process, the bottles that will fill with this beer are closed with
crown cork and start to transport towards pasteurizer through the chain conveyor.

4.2 Introduction
Many industrial processes are now dependent on automatic machinery. The transition from
manual systems to automatic systems was necessary to optimize the rate and capacity of
production. To control an industrial process, a special microprocessor based controller called the
PLC is used. This is a batch operation where a set amount of inputs to be process is received as a
group, and an operation produces the finish product. Generally, the function of the machine is to
fill the beer automatically into bottles through a vent tube. Therefore, in this process the bottles
that will fill with this beer are closed with crown cork and start to transport towards pasteurizer
through the chain conveyor. The PLCs read the input states of switches, sensors etc. And can
drive motors, relays, solenoids etc. One of the many uses of PLCs in industries is in assembly
lines involving packaging. Especially in beverage industries, mineral water packaging plants, it
is required to fill-up a bottle with a certain amount of liquid. In these systems, empty bottles are
put on a conveyor belt which brings these to the filling station. At the station, the bottles are
automatically filled-up and then moved along the conveyor for further stages to perform other
tasks such as cap fitting or packaging etc. (.).
4.3 Statement of the problem
The global market place has become increasingly competitive and volatile, thus resulting in the
need for the players in the beverage industry to continuously improve their processes, especially
on bottle filling and crowning operations. Overfilling is just as undesirable, since the sum of all
overfills outside of normal tolerances could have been used to fill other saleable units. In this
system there are over fill and under fill bottles and they are unnecessary, not advisable to use.
The beer is finally removed as a waste. Since those bottles are crowned and passes through
different processes and finally rejected by FBI. Under fill and overfill problems are happened:
 Due to bending of vent tube
 Due to improper material selection
 Due to flushing pressure is too high
 Due to the damage of the filler valve tube under fill and over fill are happened.

4.4 Objective of the project

4.4.1 General objective
The general objective of the project is to minimize the wastage of beer due to the under fill and
over fill of the bottle since when such cases happened the bottles beer are out of market use.
4.4.2 Specific objective
 To fill bottles one after another with the desired level.
 To design of filler vent tube that have good strength and long lifetime usage
 To design the spreader with a good material selection
 To design the pressure controlling system
4.5 Significance of the project
 It reduces unnecessary wastage of beer during filling processes.
 To avoid under and over filing process.
 It can be used to gain high production quantity in small time.
 The system has some features:
 Detection of the presence of a bottle using sensor
 Timer based automatic bottle filling
4.6 Scope of the project
This automatic bottle filler machine is reducing the wastage of beer. This project is planned to
reduce the wastage of time during maintenance period after the under fill and overfill situations
are avoided. Depending, the speed of the bottles movement and the conveyer fits with the in feed
worm or screw, the operation can be done.

4.7 Literature review

“PLC based automatic bottle filling and capping system with user defined volume selection
-8thaugust 2012: In this research paper the researchers, T.Kalaiselvi, R.Praveenaat all...have
develop an automatic bottle, filling and capping system with a mechanism using sensors.
Automatic filling process for all the bottles simultaneously with a user defined selection for
volume to be filled. Since, the filling system is user defined bottle detection; the process has its
own drawbacks. It takes so much time and they do not consider which material can be selected to
fill the bottle properly” (R.Praveen).
“PLC based automatic bottle -3rd may 2015: In this research paper the researcher Jaymin
Patel department of physics and electronics of Hemchandracharya North Gujarat University,
Patanhas develop a bottle filling system based on certain specifications. More features can be
added to this system as follows: Depending on the size, shape and weight of the bottles, filling
operations can be processed. Even though, the system was used automatic bottle filling, it should
not fill the bottle properly. Because it only depends on the bottle features" (Jaymin).
“Automated multiple water filling (AMWF) machine -April 2009: In this research paper the
researcher Ruhairi Bin Abdul Rahim from University Technical Malaysia Melaka has developed
a project to apply filling system where this system can automatically fill the liquid into their
bottle randomly by using PLC as a controller” (Rahim).

4.8 Methodology
A development method may be regarded as a path or a procedure by which the developer
proceeds from a problem of a certain class to a solution of a certain class. In trivial cases, the
method may be fully algorithmic.
Figure 4.1: Structural flow of the methodology
4.9 Method of filling bottle

One attempts to fill the beverage into the bottles as rapidly as possible and without any damage
to it. For this the following methods are used:
1. Conveyor belt: The conveyor belt mechanism consists of a belt and rollers with motor. It is
coupled with rollers and runs continuously with the support of a motor when a start button is
pressed. The conveyor belt carries the bottle along the assembly line to be filled with liquid up to
a particular level and then the conveyor belt runs again to take the filled bottle to the other end.
2. Bottle detection: The task of bottle detection is performed using a photoelectric based IR
sensor. A photoelectric sensor is placed beside the conveyor belt at the filling station to detect
the presence of a bottle. The sensor has an infrared light transmitter and a receiver. When a bottle
is brought in front of the sensor by the conveyor belt, the infrared light emitted from the emitter
gets reflected from the bottle, which is then received by the receiver of the sensor. When no
object is in front of the transmitter, the receiver does not receive any signal.
3. Liquid flow control: When the bottle is detected by the photoelectric sensor, the task of
filling the bottle with liquid starts. A solenoid valve is used to control the flow of beer from
overhead tank to the bottle.
4. Liquid level: Due to continuous filling of the bottles, the amount of liquid at the overhead
tank gets depleted. So, it is crucial to maintain a minimum level of liquid at the overhead tank to
continue the smooth operation of the bottle filling task.

4.9.1 Working principle

Bottle filling machines are built as rotating machines with 72 filling valves in St. George
brewery. The bottles are delivered on a conveyor belt, separated to predetermine spacing by in
feed worm, and positioned on lifting platform under the filling elements by a star wheel loading
device. It follows the steps to fill the bottles. These are:
A. First evacuation
B. 𝐂𝐎𝟐 flushing
C. Second evacuation
C. Second evacuation
D. Pressurizing
E. Filling:
F. Settling
4.10 General design procedure of the bottle filler machines’ components
4.10.1 Design of co2 flushing pressure
Pressure relief valve: A pressure relief valve is a safety device designed to protect a pressurized
vessel and overpressure from predetermined event. An overpressure event refers to any condition
which would cause pressure in a vessel or system to increase beyond the specified design
pressure or maximum allowable working pressure (MAWP).
…. (GUPTA)
Figure 4.2: Indicates operation of pressure relief valve
It operates when pressure is normal and less than the valve setting, the valve is closed. But if it is
greater than normal the valve opens and pressure back to the tank.
There are two types of pressure relief valve
1) Direct acting 2) Pilot operated
For the project direct acting pressure relief valve is selected because it helps to close by a direct
Force of a mechanical spring. The spring force holding the valve close is opposed by the system
Air pressure. If the air pressure increases from the normal, the valve begins to open and the
pressure will be easily removed.
4.10.2 Designing of pressure relief valve spring
Material selection
The most suitable material for springs are spring steels which can store up the maximum amount
of work or energy in a given weight or volume of spring material, without permanent
deformation. These steels should have a high elastic limit as well as high deflection value, which
is chrome-vanadium steels these steels have high elastic limit, resistance to fatigue and impact
stresses.
…. (GUPTA)
Figure 4.3: Free body diagram of pressure relief valve
“δ = 8FD3Nd4G
𝑘 = Fδ
k= Fδ = d4G8D3N
p = FA
Where, p = pressure of the fluid
𝛿 = deflection of the spring
F = spring force
d = diameter of the spring
D = mean diameter of the spring

N = number of turns of spring

G = modulus of rigidity for the material of the spring
Terminologies used in springs
Spring index (c): It is defined as the ratio of the mean diameter of the coil to the diameter of the
wire
c = Dd…………………….…………... Equation 4.1: Spring index
Where, D = mean coil diameter (mm)
d = wire diameter (mm)
Stiffness (k): It is defined as the ratio of load to deflection
k = Wδ (Nmm) ………………….….… Equation 4.2: Stiffness of spring
Shear stress factor (Ks), Ks = 1+12c……… Equation 4.3: Shear stress factor
Kw = 4c−14c−4+0.615c…………….. Equation 4.4: Wahl’s correction factor
Solid length (𝐿𝑠): It is the length of the spring in fully closed condition (𝐿𝑠)
Ls = n*d …………………...….... Equation 4.5: Solid length
Where, n = number of turns of spring
d = diameter of wire (mm)
Free length (𝐿𝑓): It is the length of the spring in unloaded condition
Lf = Ls +δmax+ 0.15δmax………... Equation 4.6: Free length
Pitch of the spring (p): is defined as the axial distance between adjacent coils in uncompressed
state
p = Lfn−1……………….………….... Equation 4.7: Pitch of spring
For squared and ground ends
Total number of coils = number of active coils + 2
Active coils are these which take part in deflection
n’ = n + 2
Deflection (δ): δ = 8∗W∗D3∗nG∗d4…………Equation 4.8: Deflection
Where, W = load on the spring. (N or KN)
D = mean coil diameter (mm)
n = number of active coils
G = modulus of rigidity (Nmm2)
d = wire diameter (mm)

Assume, D = 60mm
d = 6mm
Based on material type and property from machine design:
τmax = 60Mpa
G = 800𝑁𝑚2
Spring index (c) = Dd, c = 606 = 10
Shear stress factor (Ks) = 1+12c
𝐾𝑠=1+12∗10 = 1.05
Maximum shear stress induced in the wire (τmax), τmax = Ks*8∗W∗Dπ∗d3
60Mpa = 1.05*8∗W∗60π∗63
W = 60*π∗638∗1.05∗60 = 80.784N
Stiffness (k): It is most of the time taken as 15 percent of maximum deflection
So, k = Wδ = 15∗δ100 = 80.784δ
δ2 = 80.784∗10015 = 538.56𝑚𝑚2
δ = 538.5612 = 23 mm
We know that the deflection of the spring (𝛿) = 8∗W∗D3∗nG∗d4
n = 8∗80.784∗603800∗64∗δ
n = 8∗80.784∗603800∗64∗23 = 5.854 turns ~ 6 turns
Wahl’s correction factor (KW) :
KW = 4∗c−14∗c−4 + 0.615c = 4∗10−14∗10−4 + 0.61510 = 1.145
Solid length (Ls): Ls = n*d = 6*6 =36mm
Free length of the spring (Lf): Lf = Ls +δmax+ 0.15δmax
𝐿𝑓 = 36 + 23 + 0.15*23 = 62.45mm
Pitch of the spring (p): p = Lfn−1 = 62.456−1 = 12.49mm
Therefore, to evaluate the pressure (P): pressure is equal to the ratio of axial load on the spring to
the area of the spring
P = FA = WA = 80.784A where, A = π*𝑟2 = π∗𝑑24 = π∗624 = 28.274𝑚𝑚2
P = 80.78428.274 = 2.857Mpa
Since the designed pressure is greater than the pressure of the given system, it is safe to design
like this.

4.10.3 Design of vent tube

Material selection
The selection of a proper material, for engineering purposes, is one of the most difficult
problems for the designer. But, the best material is one which serve the desired objective at the
minimum cost. The following factors should be considered while selecting the material:
1. Availability of the materials,
2. Suitability of the materials for the working conditions in service, and
3. The cost of the materials.
Material properties
There are many different factors to consider when choosing a material including strength, wear
resistance to bending and buckling, product contamination. However, the overriding factor when
Selecting a material is generally their resistances to corrosion that can occur are discussed
below. In the brewing industries the major material of the choice is stainless steel.
Stainless steel: It is defined as steel which when correctly heat treated and finished, resists
oxidation and corrosive attack from most corrosive media.
It has designed vent tube with a good resistance to corrosion, oxidation, temperature, bending
without changing the standard dimension of material in St. George brewery factory. For these
vent tube I select stainless steel with best grades as shown below table.
The dimension of the vent tube
External diameter =5.3mm
Length =76.2mm
Thickness =1.15mm
Internal diameter =3mm
Bottle filling machines is a machine, which fill 42000 bottles per hour with 120 filling valves. So
we have change bottle per hour to per second
42000bottle 3600sec = 11.66666 bottle per second
One normal bottle contains 330ml
Then, 330ml×11.6667=1050000ml/sec
= 1050 L/sec
The flow rate of each filler tube can be calculated by:

Qi = QTno filler valve……………….… Equation 4.9: Flow rate of each filler valve
Qi = 1050L/sec120 valve = 8.75L/sec
The velocity of fluid (beer) flowing in to the bottle is:
Q = A×V where, V = velocity
A = area of the tube
A = πDi24
A= 3.14 ×5.324 = 22.051mm2
8.75×10−3m3/sec = 22.051×10−6m2×V
V = 396.814m/sec
Stresses in pipes (tube)
The stresses in pipes due to the internal fluid pressure are determined by Lame's equation.
According to Lame's equation, tangential stress at any radius x,
σt = p(ri2)ro2−ri2(1+ro2x2)………..Equation 4.10: Tangential stress
And radial stress at any radius x
σr = p(ri2)ro2−ri2(1−ro2x2)…………Equation 4.11: Radial stress” (GUPTA)
Where, p = Internal fluid pressure in the pipe,
ri = Inner radius of the pipe, and
ro = Outer radius of the pipe.
The tangential stress is maximum at the inner surface (when x=ri) of the pipe and minimum at
the outer surface (when x =ro) of the pipe. Substituting the values of x = ri and x = ro in equation
(1), we find that the maximum tangential stress at the inner surface of the pipe,
σt (max) = p(ri2+ro2)ro2−ri2
= 20000pa (1.52+2.652)2.652−1.52 = 38.85804Kpa
And minimum tangential stress at the outer surface of the pipe,
σt (min) = 2p×ri2ro2−ri2 = 2×20000pa×1.522.652−1.52=18.85804Kpa
To check the design of vent tube is safe
Table 4.1: Design of vent tube

From the above table that have selected 316H because 316H has
Higher strength at elevated temperature
Pressure containing application
Better corrosion resistant
Assume factor of safety 3 Factor of safety = yield stress working stress = 3 = 205woking stress
Working stress = 68.33Mpa
The maximum stress from above calculation for vent tube is 38.858Kpa which is less than
working stress of material. i.e. 68.33Mpa > 38.858Kpa, therefore the design is safe.
Figure 4.4: Vent tube
4.10.4 Design of spreader

To design the spreader in filler machine, the best material selection is a good achievement for
design a part. Because the main weakness of a spreader is wearing. So, to reduce this problem
the material we selected is carbon fiber reinforced plastic. Because it has
1. High tensile strength
2. Excellent wear resistance
3 .Good toughness
4. It has good softness property
Figure 4.5: Spreader

The dimension of the spreader is:
Length = 5mm Internal diameter = 5.3mm
Thickness = 3mm External diameter = 12mm Filet angle = 〖45〗^0
Figure 4.6: Vent tube with spreader

4.11 Flow-chart the project

A flowchart is the graphical or pictorial representation of an algorithm with the help of different
symbol, shapes and arrows in order to demonstrate a process or a program
Figure 4.7: Flow chart of the project

4.12 System Design

4.12.1 Hardware Design
Figure 4.8: Short hand representation of design

4.12.1.1 Description of the Components Used
4.12.1.1.1 Programmable logic controller (PLC)
“PLC-is a special form of microprocessor-based controller that uses a programmable memory to
store instructions and to implement functions such as logic, sequencing, timing, counting, and
arithmetic to control machines and processes and is designed to be operated by engineers with
perhaps a limited knowledge of computers and computing languages of PLCs” (.).
Figure 4.9: Programmable logic controller arrangement

Basic principle of operation of PLC:
1) Detect incoming signals
2) Process it
3) Generate outputs to control various devices
4.12.1.1.2 Input devices
Input devices are inputs to PLC to tell the operating condition of a certain system. Sensor is a
convertor that measures a physical quantity (e.g. temperature, pressure etc.) and converts it into
an electrical signal. Some of commonly used sensors found St. George Brewery Company are
listed below:

1. Back up sensor switch: Applications of backup switches in B.G.I, Ethiopia

 To detect an overload of bottles on the conveyor system
 To detect the presence of filled bottles in filler machine and pack them with cork
 Control the balance of the in feed and discharge gears at filler machine.
It works by using comparator, solenoid and copper conductor. There is a set current value, when
there is an overload the bottle pushes the conductor and the deviates from preset current value.
This digital current value reaches to PLC based on this value gives appropriate response to the
system. Current is produced through the conductor due to this current loss the current value at
the solenoid. Two types of back up (proximity) sensor switches are available in St. George
Brewery Company. These are inductive and capacitive back up (proximity) switches.
 Inductive proximity switch: inductive proximity sensors detect magnetic loss due to
eddy currents that are generated on a conductive surface by an external magnetic field. An
AC magnetic field is generated on the detection coil, and changes in the impedance due to
eddy currents generated on a metallic object are detected. These sensors are found at
conveyor, and filler machine.
 Capacitive proximity switch: capacitive proximity sensors detect changes in the
capacitance between the sensing object and the sensor. An ordinary capacitive proximity
sensor is similar to a capacitor with two parallel plates, where the capacities of the two
plates are detected. One of the plates is the object being measured (with an imaginary
Ground), and the other is the Sensor's sensing surface. The changes in the capacity generated
between these two poles are detected. These sensors are found in caser/ un-caser machine.
2. Photo cell: It is a devices used to detect the presence and absence of bottles or crates. Some
photo cells have two different operational types, light operate and dark operate. Light operate
photo eyes become operational when the receiver "receives" the transmitter signal. Dark operate
photo eyes become operational when the receiver "does not receive" the transmitter signal. It has
sender (LED) and receiver (photodiode) parts. The LED emits light and the photo diode receives
this light and change to current signal to input the PLC.
3. Position sensors: Position sensors report the physical position of an object with respect to a
reference point. The information can be an angle, as in how many degrees an object has turned,
or linear, as in how many inches a robot arm has extended.

 Encoder: used to control both speed and position of caser and uncaser machines as
counter.
4. Pressure sensor: It is used to detect the pressure level of typically gases and liquids. A
pressure sensor usually acts as a transducer it generates signal as a function of the pressure
imposed. When a pressure applied to pressure sensor, the sensor acts to complete electrical
circuit.
Figure 4.10: Pressure sensor working process
5. Temperature sensor: It is a device used to detect the temperature of liquid, gas etc. It
commonly used in motor control applications are thermostats and thermocouples.
Figure 4.11: Temperature sensor working process
4.12.1.1.3 Output devices

Some kinds of actuators found and used in St. George brewery factory are:
1. Drive motors
There are many electrical motors that are used for different purpose. Motors mostly used in the
company that is, induction motors, synchronous motor and servo motors.
 Synchronous motor: Those motors are doubly exited fed type and have dc field
windings and ac armature windings. This motor is mainly used at washer machine for the
purpose of driving bottle chain holders.
 Induction motor: Is a singly fed type motors which carry ac current in both stator and
rotor winding. It is a type of electric motor that converts electrical energy in to
mechanical energy in which alternating current from a power source is fed through a
primary winding and induces a current in a secondary winding.
 Servo motor: It is mainly used at the two robotic machine (caser and un caser) to control
the position of grippers at the desired place.

2. Relay
Relays are electro-mechanical devices used to turn pilot lights on/off, control mechanical
equipment, and send signals from a sensing device, such as a float switch, to another component,
such as a motor.
3. Contactor
Contactor is an electrically controlled switch used for switching an electrical power circuit,
similar to a relay except with higher current rating.
4.13 Software
Logix: PLC Logix is designed to simulate the functionality of the most popular PLCs in
industries. PLC Logix helps us to write a program, see the programs operation using a ladder
logic Simulator, and control the operation of the program. In order to properly understand the
operation of PLC systems, it is necessary to spend considerable time programming, testing, and
debugging ladder logic programs.
Table 4.2: List of input and output of the simulation
4.14 Result and discussion

4.14.1 Program discussion
Initially, the system was started as the start push button was pressed; the conveyor systems as
well as motors were activated to move. The photo sensor based infra-red sensor was activated
when main conveyor of the system went with the empty bottle. If the empty bottle sensor was
activated, it would send message to the limit switch to open the solenoid valve and then filling
the bottle until it reaches at the required level. If the time that we use to fill was achieved, the
solenoid valve would be closed and the full bottle indicator would have activated. At the end the
bottle capping the system is activated by the cap ram sensor detector.

4.14.2 Simulation result
Figure 4.12: Simulation result

4.15 Conclusions and recommendations

4.15.1 Conclusions
Finally the interns have concluded that in order to minimize the wastage of beer during filling of
the bottle, we have to design the vent tube, pressure relief valve, and the spreader of the system
to prevent over pressure and control increase of temperature in the system.
4.15.2 Recommendations
Finally the interns have to recommend that if someone who wants to improve our project, it is
better to design the in feed screw warm in addition to our design and use the latest version of the
PLC software to simulate.

CHAPTER FIVE
GENERAL CONCLUSIONS AND RECOMMENDATIONS
5.1 Conclusions
Generally, this internship period was interesting because it enables us to get knowledge, improve
our practical skill, upgrading our theoretical knowledge, improving team playing skills,
improving leadership skills and understanding about work ethics related issue. In addition to this
interns have been familiar with the following concepts how to control the overall mechanical
system of the industry and Stimulate new interest in academic course work and frequently
developed and Inter disciplinary perspective. Gain an increased awareness of skill, attributes and
personal qualities and values.
5.2 Recommendations for the company
Interns have a lot of recommendation to the company. The company should have research and
design team to improve the company production performance and other related tasks by
assessing the problem associated with the work flow.
 The company should give full information and knowledge on the implementation of
continues performance improvement
 The company should rearrange the position of fill level detection place
 The company should limit the number of intern students
 The company should be encouraging internship students in any aspects.
5.3 Recommendations for the university
This internship program offers a lot of advantages to the students. It enables the students to adapt
and look the working environment at different angle. The university industry linkage (UIL)
should work with the industries more on:
 Preparing proper projects with industries
 Discussing the way, the internship students are to be treated
 Concerning the benefits, the industries can obtain from the students
 Totally I can say that almost UIL is just for a symbol doing nothing, the curriculum must
have fundamental change unless it will continues this gap between industries and
university.

References
[1] F r a n k D. PROGRAMMABLE LOGIC CONTROLLERS,Fo u r t h E d i t i o n. New York:
McGraw-Hill, a business unit of The McGraw-Hill Companies, , 2011.
[2] BGI, Ethiopia. About Us:BGI,Ethiopia. 12 October 2018. 12 January 2019
<http://www.bgiethiopia.com>.
[3] GUPTA, R. K. A. J. A Text Book of Machine design. New Delhi, India: S Chand & Co Ltd,
2005.
[4] Jaymin, Pantel. "PLC Based AUTOmatic BOTTLE." Electrical Engineering (2004): 100-102.
[5] R.Praveen, T.Kalaiselvi and. "PLC Based Automatic Bottle Fillin and Capping System wit
User Define Volume Section." Industrial Engineering Journal (2012): 134-138.
[6] Rahim, Ruhairi Bin Abdul. "Automated multiple water filling." Electrical Engineering
(2009): 150-160.

B.G.I, Ethiopia Internship Report: Certificate/Declaration

Uploaded by

Copyright:

Available Formats

B.G.I, Ethiopia Internship Report: Certificate/Declaration

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

B.G.I, Ethiopia Internship Report: Certificate/Declaration

Uploaded by

Copyright:

Available Formats

B.G.

I, ETHIOPIA INTERNSHIP REPORT 2020

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page i

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page ii

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page iii

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page iv

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page v

2.3.4 Beer Packaging ............................................................................................................. 12

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page vi

4.10.1 Design of co2 flushing pressure ................................................................................. 27

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page vii

Figure 2.1: Silo................................................................................................................................ 8

Figure 4.1: Structural flow of the methodology............................................................................ 26

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page viii

Table 4.1: Design of vent tube ...................................................................................................... 32

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page ix

List of Symbols and abbreviations

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page x

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 1

BGI Ethiopia provides number of services to the society includes:

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 2

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 3

1.8 Organizational Structure of the company

Figure 1.1: Organizational structure of BGI, Ethiopia

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 4

1.9 Work flow of the main section

Figure 1.2: Block diagram of Work flow of BGI, Ethiopia

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 5

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 6

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 7

Figure 2.1: Silo

2.3.3 Browning house

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 8

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 9

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 10

2.3.3.4 Fermentation process

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 11

2.3.3.6 Filtration, carbonation and cellaring process

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 12

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 13

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 14

Figure 2.2: Production process in bottling section

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 15

2.3.4.2 Kegging (Drought Beer) Section

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 16

Figure 2.3: Process in Water treatment plant

2.3.5.2 Boiler Plant

Figure 2.4: Boiler plant flow chart

Figure 2.5: Process in Boiler plant

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 17

Figure 2.6: Process in cooling plant

2.3.5.4 CO2 Recovery Plant

Figure 2.7: Process in CO2 Production process

2.3.5.5 Air Treatment Plant

Figure 2.8: Process in Treatment Plant

2.3.5.6 Power distribution of a company and components

UOG, IOT, DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING Page 18

2.4 The work pieces that have been executed