INTERNSHIP REPORT

INTERNSHIP REPORT
SUMMER INTERNSHIP II – (5009)
Submitted by

SIVAPRASAD PS (2101033006)

Department of Electrical & Electronics

Engineering
MGM Polytechnic College, Pampakuda,
Ernakulam

MAY 2023
 MGM
POLYTECHNIC COLLEGE
PAMPAKUDA P.O, ERNAKULAM, KERALA- 686667

CERTIFICATE
This is an INTERNSHIP REPORT done by SIVAPRASAD P S (210103300
6) of fifth semester Diploma in Electrical & Electronics Engineering at MGM
Polytechnic college for the award of Diploma in ELECTRICAL&
ELECTRONICS ENGINEERING under the Board of Technical Education,
KERALA, during the year 2023.

Mr. REJI PAUL Mrs. JAISY MARY JOSEPH

HEAD OF THE DEPARTMENT INTERNSHIP GUIDE
Department of Electrical & Electronics Department of Electrical & Electronics
Engineering MGMPTC Pampakuda. Engineering MGMPTC Pampakuda.

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT

First and the foremost, I thank God, the Almighty who gave me the inner strength, resource
and ability to complete the work successfully without any complications.

I am grateful to our Principal, Mr. N K Rajan, for his valuable advice. I am thankful to
Mr. Reji Paul, Head of the Department of Electrical & Electronics Engineering, for his
valuable advice and motivation.

I whole heartedly thank my internship guide Mrs. Jaisy Mary Joseph, Lecturer,
Department of Electrical & Electronic Engineering for her valuable advice and support. I
express my heartfelt thanks to our internship co-ordinators Mr. Binil Baby, Mr.
Muhammed Jazeeludeen, Mrs. Aswathi Gopi for their helpful feedback and timely
assistance.

I convey my sincere thanks to all other faculties in the department for their support and
encouragement. we thank all my friends who have helped me during the work with their
inspiration and cooperation. I truly admire my parents for their constant encouragement and
enduring support, which was inevitable for the success of this venture. Once again I convey
my gratitude to all those persons who directly or indirectly influenced my work.

SIVAPRASAD P S

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 ABSTRACT

This abstract encapsulates the essence of an internship visit to Sarah’s Techno, a

distinguished Manufacturer, Exporter, and Supplier specializing in an extensive
array of Industrial Food Machines and equipment. The internship provided a
firsthand experience of the manufacturing processes, operational intricacies, and
technological innovations that define Sarah’s Techno as a leader in the industry.

During the internship, I gained insights into the diverse range of industrial
machines produced by the company, encompassing cutting-edge technology and
precision engineering. The experience included exposure to the manufacturing floor,
where I observed and actively participated in the production, assembly, and quality
control processes of various machinery.

The visit allowed me to interact closely with professionals and experts in the
field, providing valuable mentorship and fostering a deeper understanding of the
industry's best practices. Engaging discussions on market trends, global
competitiveness, and sustainable manufacturing practices enriched my perspective
on the broader implications of industrial machinery production.

Furthermore, the internship at Sarah’s Techno provided an opportunity to

witness the company's commitment to international standards and quality assurance.
I was exposed to the rigorous testing procedures and quality control measures
implemented to ensure that each product meets or exceeds customer expectations.

This report outlines the significant aspects of the internship visit, including
practical exposure to manufacturing processes, interactions with industry experts,
and an appreciation of the company's commitment to excellence. The experience at
Sarah’s Techno has not only enhanced my understanding of industrial machinery
manufacturing but has also equipped me with practical insights that will undoubtedly
contribute to my academic and professional development in the field.

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 CONTENTS

CHAPTER 1 Page No

INTRODUCTION 1

CHAPTER 2
3
SARAH’S TECHNO

CHAPTER 3

MAJOR PRODUCTION MACHINERY 5

3.1 Electric Roster 5
3.2 Grill Machine 6
3.3 FWB (Fluid Bed Drive) 6

CHAPTER 4
ANALYSIS MAJOR ELECTRICAL AND ELECTRINIC 7
INVOLVEMENT
4.1 Temperature controlling by PID System 7
4.1.1 Advantages 14
4.1.2 Applications 15
4.2 J-Type Thermocouple 15
4.2.1 Advantages 17
4.2.2 Applications 18
4.3 Contactors 19

CHAPTER 5

CONCLUSION 23

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 LIST OF FIGURES

Fig:3.1 Electric Roster. 5

Fig:3.2 Grill Machine. 6
Fig:3.3 FWB (Fluid Bed Driver ) 7
Fig:4.1 PID Controller. 8
Fig:4.2 PID Controller Graphical Understanding. 9
Fig:4.3 PID Controller with Feedback Control Loop. 9
Fig:4.4 PID Controller logic Block. 10
Fig:4.5 PID Control Parameters. 11
Fig:4.6 Proportional Block output Signal. 11
Fig:4.7 Proportional Block output Signal Offset. 12
Fig:4.8 Integral Block output Signal. 12
Fig:4.9 Integral Block output Signal P and I Together. 12
Fig:4.10 Derivative Block output Signal. 13
Fig:4.11 Controller Tuning. 13
Fig :4.12 PID Temperature Controlled System Basic Block Diagram. 14
Fig :4.13 Basic Structure of Thermocouple. 16
Fig :4.14 J- Type Thermocouple. 16
Fig :4.15 Contactor. 19
Fig :4.16 Contactor Cross Section view. 20

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 ABBREVIATIONS

PID Proportional Integral Differential.

FWB Fluid Bed Drier.
FDA Food and Drug Administration.

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CHAPTER-1

INTRODUCTION

In the heart of the contemporary food industry lies a realm of technological

sophistication and precision industrial food machines and equipment. This
introduction sets the scene for an immersive exploration into the inner workings of
this dynamic sector, as witnessed firsthand during an enlightening internship at
Sarah’s Techno. As a distinguished Manufacturer, Exporter, and Supplier, Sarah’s
Techno stands at the forefront of innovation, playing a pivotal role in shaping the
landscape of industrial food machinery.

The industrialization of food processing has transformed the way we produce and
consume food, and the machinery driving this evolution represents a fascinating
intersection of engineering, technology, and culinary science. Against this backdrop,
an internship at Sarah’s Techno becomes not only an educational venture but a
journey into the core of a specialized industry, where precision and efficiency are
paramount.

This internship experience unfolds as a narrative of discovery, unveiling the

intricate processes involved in the manufacturing of industrial food machines. From
the conceptualization of cutting-edge technologies to the fine-tuning of equipment
designed to meet the exacting standards of the food industry, Sarah’s Techno provides
an invaluable learning ground.

As we navigate through the realms of design, production, and quality control, this
exploration aims to shed light on the dynamic forces shaping the industry. Through
interactions with seasoned professionals and immersion in the day-to-day operations
at Sarah’s Techno, we endeavor to decode the secrets, challenges, and innovations
that underpin the manufacturing of industrial food machines.

This journey into the heart of industrial food machinery manufacturing at Sarah’s
Techno promises not only to broaden our understanding of the intricacies of the field
but also to inspire a new wave of insights and perspectives. Join us as we embark on

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the unraveling of the dynamics that define the captivating world of industrial food
machines and equipment manufacturing.

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CHAPTER-2

SARAH’S TECHNO

Sarah’s Techno is a major manufacturer, exporter and supplier of a wide range of

post-harvesting and food-processing machines and equipment. The range includes a
Pneumatic Piston Filler, Fruit Mill, Hammer Mill, Heating Kettle, Lemon Cutting
Machine Sautiner, and many more.

They provide our services as consultants in the pickle, sauce, and jam industry
manufacturing. Their industrial machines and equipment are in high demand by the
food processing and fruit processing industry, manufacturers of pickle, jam, juice,
curry paste, and ayurvedic medicine manufacturers alike.

They are firmly committed to fulfilling the needs of the industry and making
contributions to society by providing high-quality food, fruit, pharmaceuticals, and
packing equipment. The concept of “Continuous innovation” permeates Techno
consultancy services and has resulted in the evolution of unique technologies in the
company. We want to be a reliable partner for the food industry in providing effective
solutions and technologies for food processing and packing needs.

They have moved from an owner-driven company to a professionally run

organization with highly qualified managers and engineers. We provide excellent
support in sales and services under the leadership of Mr. Mathew Antony who has
more than 25 years of experience in food and fruit processing equipment
manufacturing. They are a “One roof solution provider” for food, fruit &
pharmaceuticals processors and packers.

2.1 MACHINERY
• Food Processing

• Spices Processing

• Fruit Processing

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• Rice flour & Health food

2.2 TRAUNKEY PROJECTS

• Automatic Rice Flour

• Plant Fruit Processing

• Plant Spices Processing

• Plant Distillation Extraction

• Plant for Spices & Herbs

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CHAPTER-3

MAJOR PRODUCTION MACHINERIE

3.1 ELECTRIC ROASTER

Fig 3.1 : Electric Roster.

An electric roaster machine is a specialized equipment used for roasting and

concentrating food items. It applies controlled heat to roast ingredients while
simultaneousy evaporating moisture, resulting in concentrated flavors and

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enhanced texture. It is commonly used in food processing and culinary

applications.

3.2 GRILL MACHINE

Fig 3.2 : Grill Machine.

Grill Machine is a state-of-the-art equipment designed for grilling a wide

range of food items. It incorporates both rotary and linear motion mechanisms,
ensuring thorough and even grilling. The machine features adjustable temperature
controls, easy-toclean surfaces, and a robust construction, making it ideal for
commercial grilling operations.

3.3 FWB (Fluid Bed Drier)

A fluid bed dryer is a drying equipment that utilizes a suspended bed of

particles in a gas stream to efficiently remove moisture from solid materials. It

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offers rapid drying, uniform heat distribution, and enhanced product quality,
making it suitable for various industries such as pharmaceuticals, chemicals, and
food processing.

Fig 3.3 : FWB (Fluid Bed Driver )

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CHAPTER-4

ANALYSING MAJOR ELECTRICAL AND ELECTRONICS

INVOLMENTS

Most of their equipment are combinations of both mechanical and electronics

including electrical parts, for reliable and automated machines with better efficiency.
The major components are

4.1 Temperature controlling by PID System

A PID controller is an instrument used in industrial control applications to
regulate temperature, flow, pressure, speed and other process variables. PID
(proportional integral derivative) controllers use a control loop feedback
mechanism to control process variables and are the most accurate and stable
controller.

Fig 4.1 : PID Controller.

PID control is a well-established way of driving a system towards a target

position or level. It's a practically ubiquitous as a means of controlling
temperature and finds application in myriad chemical and scientific processes as

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well as automation. PID control uses closed-loop control feedback to keep the
actual output from a process as close to the target or setpoint output as possible.

Fig 4.2 : PID Controller Graphical Understanding.

Because every process responds differently, the PID controller determines

how much and how quickly correction is applied. By using varying amounts of
proportional, integral, and derivative action, each block contributes a unique
signal that is added together to create the controller output signal.

Fig 4.3: PID Controller with Feedback Control Loop.

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The controller is responsible for ensuring that the process remains as close to
the desired value as possible, regardless of various disruptions the controller
compares the transmitter process variable or PV signal and the set point. Based on
that comparison, the controller produces an output signal to operate the final
control element. This PID controller output is capable of operating the final
control element over its entire 100% range.

Fig 4.4: PID Controller logic Block.

Most modern PID controllers are part of a PLC or DCs and are created in the
program control logic using block commands. Before PLCs came along, a PID
controller was a standalone device responsible for controlling one loop. A control
room would have dozens or hundreds of standalone controllers mounted on a
panel.

It’s been said that the PID controller is responsible for ensuring that the
process remains as close to the set point as possible, regardless of various
disruptions. Now referring into the difference between the process variable and
the set point as the error signal.
There are still many stand-alone PID controllers being manufactured and used
today. OK, let’s get back and talk about what each of the P, I, and D components
of the PID controller does. Remember earlier we said that the PID Controller is
responsible for ensuring that the Process remains as close to the setpoint as

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possible regardless of various disruptions. Let’s refer to the difference between the
Process Variable and the Setpoint as the Error signal.

Fig 4.5: PID Control Parameters.

The proportional block: Creates an output signal proportional to the magnitude of

the Error Signal.

Fig 4.6: Proportional Block output Signal.

Unfortunately, the closer you get to the setpoint, the less it pushes.
Eventually, the process just runs continuously close to the setpoint, but not quite
there.

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Fig 4.7: Proportional Block output Signal Offset.

That’s when Integral jumps in.

The integral block: creates an output proportional to the duration and
magnitude of the Error Signal. The longer the error and the greater the amount, the
larger the integral output.

Fig 4.8: Integral Block output Signal.

As long as an Error exists, Integral action will continue.

Fig 4.9: Integral Block output Signal P and I Together.

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The derivative block: creates an output signal proportional to the rate of

change of the error signal. The faster the error changes, the larger the derivative
output.

Fig 4.10: Derivative Block output Signal.

Derivative control looks ahead to see what the error will be in the future and
contributes to the controller output accordingly. That brings us to a term
called Controller Tuning.

Fig 4.11: Controller Tuning.

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As said earlier that every process responds differently and that the PID
controller determines how much and how quickly correction is applied by
adjusting Proportional, Integral, and Derivative action. Controller Tuning involves
correctly setting the controller P, I, and D values for specific process
requirements. Interestingly, the correct settings achieved by Controller Tuning can
differ vastly between processes because of specific requirements.

There are many different manual methods for tuning a controller that involves
observing the process response after inflicting controller setpoint changes.

Fig 4.12: PID Temperature Controlled System Basic Block Diagram.

In the context of temperature control, the PID controller continuously adjusts

a heating or cooling element to maintain the temperature close to the desired
setpoint. The controller calculates the error, applies the proportional, integral, and
derivative actions, and adjusts the output accordingly. This iterative process
continues until the system reaches a stable state with minimal deviation from the
setpoint temperature.

4.1.1. Advantages

• Accuracy and Precision

• Versatility

• Adaptability to Different Processes

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• Stability.

• Quick Response to Disturbances.

• Ease of Implementation

• Tuning Flexibility.

• Robustness.

• Suitability for Different Types of Processes.

• Cost-Effectiveness

4.1.2. Applications

Due to these advantages, Sarah's Techno uses a PID-based

temperature control system in every machine that deals with heating or
roasting purposes so that the raw materials (wheat flour, chili powder,
etc.) that are fed to the machine get an optimal temperature. Therefore,
all their top manufacturing machines are equipped with PIDs as
temperature control modules, like:
• Fluid Bed Dryer

• Grill Machine

• Box Steamer

• Electrical Dryer

• Drum Roaster

4.2 J Type Thermocouple

The basic principle behind thermocouples is the Seebeck effect, where a
voltage is generated at the junction of two dissimilar metals in response to a
temperature difference. In the case of the J-type thermocouple, as the temperature
changes along the length of the wires, it produces a voltage that can be measured
and correlated to the temperature.

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Fig 4.13: Basic Structure of Thermocouple.

A J-type thermocouple is a type of temperature sensor widely used for

measuring high-temperature environments, typically ranging from -210 to
1,200 degrees Celsius (-346 to 2,192 degrees Fahrenheit). The J-type
thermocouple is composed of two dissimilar metal wires, typically made of
iron and constantan (a copper-nickel alloy).

Fig 4.14: J- Type Thermocouple.

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Type J thermocouple is a very common and general purpose thermocouple. It

has smaller temperature range and a shorter lifespan at higher temperatures. It
consist of positive leg made of an Iron wire and negative leg made of an
Constantan ( Copper-Nickel ) alloy wire. Due to the Curie Point of the iron at 770
°C Type J has a limited temperature range of -40°C to 750°C.It should not be
used at high temperatures in an oxidizing atmosphere as iron undergoes a
molecular change and permanently loses its standard voltage output versus
temperature. It does not recover when the iron is cooled. Type J has sensitivity of
approx 50 microvolts/ degree C .The expenses and reliability of Type J is same as
Type K. For proper working of J Type thermocouple reduction atmosphere is
desired and use at low temperature is also not recommended.

4.2.1. Advantages

• Wide Temperature Range: J-type thermocouples cover a relatively

broad temperature range, typically from -210 to 1,200 degrees Celsius (-
346 to 2,192 degrees Fahrenheit). This makes them suitable for a variety
of industrial applications where moderate to high temperatures need to be
measured.

• Good Sensitivity and Accuracy: J-type thermocouples provide good

sensitivity and accuracy within their specified temperature range. They
can offer precise measurements, making them reliable for applications
that require accurate temperature monitoring.

• Cost-Effective:J-type thermocouples are generally more cost-effective

compared to some other types of thermocouples or temperature sensors.
This cost-effectiveness makes them a practical choice for various
industries.

• Durable and Resistant to Oxidation:The materials used in J-type

thermocouples, such as iron and constantan, are resistant to oxidation.
This resistance makes them suitable for use in environments with
oxidizing atmospheres without significant degradation over time.

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• Versatility in Applications: J-type thermocouples find applications in a

wide range of industries, including metallurgy, industrial heating, food
processing, and more. Their versatility makes them adaptable to various
environments and processes.

• Robustness: J-type thermocouples are known for their robustness and

durability. They can withstand harsh conditions and mechanical stress,
making them suitable for use in demanding industrial settings.

• Standardization and Availability: J-type thermocouples are widely

standardized and readily available. This standardization ensures
compatibility and ease of integration into existing systems and processes.

• Color-Coded for Easy Identification: J-type thermocouples are often

color-coded for easy identification. In the United States, the positive leg
is typically red, and the negative leg is white, simplifying installation and
maintenance.

• Easy Replacement: Due to their common use and availability, J-type

thermocouples are easy to replace when needed. This can be
advantageous in scenarios where quick maintenance or troubleshooting is
essential.

4.2.2. Applications

The combined output of the proportional, integral, and derivative

terms is used to adjust the heating or cooling element in the system. This
adjustment is based on the J-type thermocouple's feedback, aiming to
minimize the temperature error and bring the system to a stable state
around the setpoint.

Continuous Monitoring and Adjustment: The process of measuring the

temperature with the J-type thermocouple, calculating the error, and
adjusting the system output is performed continuously. The PID controller

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dynamically responds to changes in the environment to maintain the

desired temperature with accuracy and stability.

In summary, the J-type thermocouple feedback is crucial in a PID

temperature controller as it provides real-time information about the
current temperature. The PID algorithm uses this feedback to calculate the
necessary adjustments to the system output, ensuring effective and precise
temperature control in various applications.

4.3 Contactors
A contactor is an electrical device that is widely used for switching
circuits on and off. As such, electrical contactors form a subcategory of
electromagnetic switches known as relays.

A relay is an electrically operated switching device that uses an

electromagnetic coil to open and close a set of contacts. This action results in a
circuit powering either on or off (establishing or interrupting the circuit). A
contactor is a specific type of relay, although there are some important
differences between a relay and a contactor.

Fig 4.15: Contactor.

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Contactors are principally designed for use in applications where a large

amount of current needs to be switched. If you are looking for a concise
electrical contactor definition, you could say something like the following

Fig 4.16: Contactor Cross Section view.

An electromagnetic field produced when the electromagnetic coil is

energized. As we have seen in the construction, the moving contact of the
contactor is connected with the armature (metallic rod) of an electromagnet.

When an electromagnetic field produced, the armature experiences the

force and pulls towards the fixed contact. The force produced by the coil is
more than the force of the spring. Both contacts remain in this position until
the coil is not de-energized.

Once the coil is de-energized, the electromagnetic force is zero and the
armature pulls back due to the force of spring. And return in the normal

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condition (OFF position). The contactors are designed for the rapid ON-OFF
operation.

The input of the contactor coil may be AC or DC or in some cases, the

universal coil is used as an electromagnetic coil. The universal coils operate
on AC and DC both. A small amount of power loss occurs in the contacts and
an economizer circuit is used to reduce this loss.

While making and breaking of contacts, an arc is produced between the

contacts. This arc may reduce the life of contactor as it increases the
temperature of contacts. Due to arc, harmful gases are produced like mono-
oxide. Hence, there are several methods are used to control and extinction of
arcs.

The contactors are selected base on load current and voltage, the control
range of voltage, and application based on utilization category. If you want to
check the connection of contacts are open or close, you can check it with the
help of ohm-meter. Connect the ohmmeter between the input and output
contacts, if the meter shows infinite reading the contacts are open and if the
meter shows zero reading the contacts are closed.

In food machinery, electrical contactors play a crucial role in controlling

the electrical power supply to various components and ensuring the proper
functioning of the equipment. When selecting electrical contactors for use in
food machinery, several factors must be considered to comply with food safety
standards and industry regulations. The main considerations are:

• Material Selection: Contactors used in food machinery should be made

from materials that are corrosion-resistant, easy to clean, and suitable for
contact with food. Stainless steel or other food-grade materials are often
preferred.

• Sealed Design: To prevent the ingress of contaminants and facilitate easy

cleaning, electrical contactors in food machinery should have a sealed or
enclosed design. This helps maintain hygiene and reduces the risk of food
contamination.

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• Food-Grade Lubricants: Lubricants used in the contactor mechanism

should be food-grade to ensure that there is no risk of contamination.
Food-grade lubricants are specifically formulated to meet strict food
safety standards.

• IP Rating: The contactors should have an appropriate Ingress Protection

(IP) rating, indicating their resistance to dust and water. A higher IP
rating is often desirable in food processing environments where cleaning
processes involve water or other liquids.

• Easy Accessibility for Maintenance: Accessibility for maintenance and

cleaning is essential. Contactors should be designed to facilitate easy
access for inspection, cleaning, and any necessary maintenance without
compromising food safety.

• Compliance with Regulations: Ensure that the selected electrical

contactors comply with relevant industry standards and regulations, such
as those set by the Food and Drug Administration (FDA) or other local
regulatory bodies.

• Corrosion Resistance: Food processing environments may involve

exposure to acidic or alkaline substances. Contactors should be resistant
to corrosion from such substances to maintain their effectiveness and
longevity.

• High Reliability: Food processing operations often require continuous

and reliable performance. Select contactors from reputable manufacturers
known for producing reliable and durable electrical components.

• Temperature Resistance: Consider the temperature range within the food

processing environment. Contactors should be able to operate efficiently
within this range without degradation.

• Hygienic Design: Opt for contactors with a hygienic design, minimizing

areas where food particles or contaminants could accumulate. Smooth
and rounded surfaces are preferred.

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CHAPTER 5

CONCLUSION

The culmination of my internship at Sarah's Techno has been nothing short of a

transformative journey into the heart of industrial food machines and equipment
manufacturing. As the internship progressed, it became increasingly evident that
Sarah's Techno stands as a beacon of innovation and excellence in this dynamic field.

The hands-on experience within the manufacturing processes has provided

invaluable insights into the meticulous design, precision assembly, and stringent
quality control measures employed by Sarah's Techno. Witnessing the seamless
integration of cutting-edge technologies into the production of industrial food
machinery has been both enlightening and inspiring.

Interacting with industry experts and seasoned professionals at Sarah's Techno

has expanded my understanding of the broader implications of industrial food
machinery manufacturing. Engaging discussions on market trends, technological
advancements, and the ever-evolving demands of the food processing industry have
enhanced my perspective on the intricacies of this specialized field.

Sarah's Techno's commitment to excellence, as demonstrated through its

adherence to international standards and continuous innovation, has left an indelible
mark on my professional ethos. The transition from an owner-driven company to a
professionally managed organization, under the adept leadership of Mr. Mathew
Antony, speaks volumes about the company's dedication to growth and adaptability in
the face of industry challenges.

In conclusion, my time at Sarah's Techno has not only deepened my technical

understanding of industrial food machinery but has also instilled in me a profound
appreciation for the precision, innovation, and commitment required to excel in this
field. I am grateful for the opportunities for learning and growth afforded by this
internship, and I leave with newfound knowledge, insights, and a lasting respect for

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the contributions of Sarah's Techno to the realm of industrial food machines and
equipment manufacturing.

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