BAHIR DAR UNIVERSITY

Bahir Dar Institute of Technology

Faculty of Mechanical and Industrial Engineering
Mechanical Engineering Program
Internship Report

Project Title: Design of bottle cork belt conveyor

Hosting Company: MOHA Soft Drinks Industry S.C Gondar Plant

Internship Duration: 45 Days (Oct24-Dec9 2013E.C)

Mentors: Abiyu M.
Yeshineh J.
Company Supervisor: Mr. Yaqob
Date: 24/02/2021 GC
 BDU-FMIE-INTERNSHIP REPORT HOSTING COMPANY: Gondar MOHA soft drinks (2021 GC)

Declaration
We would like to declare that we have successfully completed 45 days of internship program
at Gondar MOHA soft drinks factory. We have been stayed from October 24 to December 9
2013 E.C. During that time we have improved our theoretical and practical knowledge. We
have done project during the internship program and included as part of this report. We want
to assure that this report and project exactly belongs to us. Here by state that this final
internship report has been submitted to Bahir Dar Institute of technology, Faculty of
Mechanical and industrial Engineering in partial fulfillment of the requirements of an
internship report.
Name of Student Signature
1. Fikad Mare Ferede .................................
2. Siraj Esleman Muhammed .................................
3. Natnael Gebregziabher .................................
Certified that the above statement made by the students is correct to the best of our knowledge
and belief. This is to confirm that we have read this Internship Report and that the information
enclosed is correct, satisfactory, and acceptable. Therefore, we approve this report is good in
scope and quality, as internship report.
Name of academic advisor Signature
1. Abiyu M. ................................
2. Yeshineh J. ................................

Name of Company supervisor Signature

1. Mr. Yaqob Legesse ................................

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Acknowledgment
First of all thanks to God for keeping all things to be happened in a good manner. We would
like to thank Bahir Dar University for giving us this opportunity to get practical skills and to
have some important and essential knowledge about soft-drink processing from raw materials
to finished product from this company. Indeed we would like to express our gratitude to Mr.
Yaqob, supervisor of production for his incredible level of advice, many suggestions and
constant support at every step of this internship program. Also we would like to gratefully
acknowledge our mentors Abiyu M. and Yeshineh J. who are Mechanical engineering
department instructors for their provision of necessary idea. Finally, we would like to thank
all those whom we did not mentioned their name and who helped us directly or indirectly in
the internship period and this report.

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Executive Summery
The international Pepsi Cola plant has more than hundred types of food and beverage
products. But there are only few products are producing in our country and these products
became well known brands of Pepsi in Ethiopia. These products are Pepsi, Miranda, 7UP,
Miranda Tonic and Mirinda Apple in their discovering order and later cool water (mineral
water) is added. Specifically when we come to Gondar moha plant Pepsi, Miranda and
sometimes 7UP are produced.

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Table of Contents
CHAPTER ONE ...................................................................................................................................... 1
1. COMPANY BACKGROUND......................................................................................................... 1
1.1 Brief history of the company.................................................................................................... 1
1.2 Objectives of the company ....................................................................................................... 1
1.2.1 Vision of the company ..................................................................................................... 2
1.2.2 Mission of the company ................................................................................................... 2
1.2.3 Core values of the company ............................................................................................. 2
1.3 Main Products of the Company................................................................................................ 2
1.4 Main Customers of the Company ............................................................................................ 3
1.5 Organizational structure of the company ................................................................................. 3
CHAPTER TWO ............................................................................................................................. 4
2 OVERALL INTERNSHIP EXPERIENCE ..................................................................................... 4
2.1 Reason for selecting the company............................................................................................ 4
2.2 The Sections We Have Been Working..................................................................................... 4
2.2.1 Water Treatment Room .................................................................................................... 4
2.2.2 Boiler room ...................................................................................................................... 7
2.2.3 Syrup preparation Room .................................................................................................. 7
2.2.4 Bottle Washer machine .................................................................................................... 9
2.2.5 Filler room...................................................................................................................... 12
2.2.6 Air compressor room...................................................................................................... 15
2.3 Work tasks we have been executing ...................................................................................... 15
2.4 Engineering methods, tools and techniques used ................................................................... 16
2.5 Challenges We Have Been Facing While Performing Our Work Tasks ............................... 16
2.6 Measures We Have Been Taking in Order to Overcome the Challenge .............................. 17
CHAPTER THREE................................................................................................................................ 18
3 BENEFITS GAINED FROM INTERNSHIP ................................................................................ 18
3.1 Improving practical skills....................................................................................................... 18
3.2 Improving theoretical knowledge .......................................................................................... 18
3.3 Improving team playing skills................................................................................................ 18
3.4 Improving leadership skills .................................................................................................... 18
3.5 Improving work ethics and related skill ................................................................................. 18
3.6 Entrepreneurship skill ............................................................................................................ 19

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3.7 Improving inter personal communication skill ...................................................................... 19

CHAPTER FOUR .................................................................................................................................. 20
4. PROJECT WORK.......................................................................................................................... 20
4.1 Short summary of the project ................................................................................................. 20
4.2 Problem statement .................................................................................................................. 20
4.3 Objective of the project .......................................................................................................... 20
4.4 Methodology .......................................................................................................................... 20
4.5 Literature review .................................................................................................................... 21
4.6 Design of belt conveyor ......................................................................................................... 22
4.6.1 Determination of belt characteristics ............................................................................. 22
4.6.1.1 Angle of inclination........................................................................................................ 23
4.6.1.2 Belt Width ...................................................................................................................... 24
4.6.1.3 Belt speed ....................................................................................................................... 24
4.6.1.4 Belt length ...................................................................................................................... 25
4.6.2 Conveying Length .......................................................................................................... 25
4.6.3 Conveying Capacity ....................................................................................................... 25
4.6.4 Power Requirements ...................................................................................................... 26
4.6.5 Idler dimensions ............................................................................................................. 28
4.6.6 Belt breaking strength .................................................................................................... 30
4.6.7 Determination of forces.................................................................................................. 32
4.6.8 Belt Tension ................................................................................................................... 35
4.6.9 Pulley Diameters ............................................................................................................ 37
CHAPTER 5 .......................................................................................................................................... 45
GENERAL CONCLUSION AND RECOMMENDATION ............................................................. 45
5.1 General conclusion ………………………………………….........................................45
5.2 General recommendation ............................................................................................... 45
REFERENCES............................................................................................................... 46
APPENDICE .................................................................................................................. 47

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List of Figures
FIGURE ‎1.1 MAIN PRODUCT OF GONDAR MOHA SOFT DRINKS ................................................... 2
FIGURE‎1.2 ORGANIZATIONAL STRUCTURE OF GONDAR MOHA SOFT DRINKS ............................ 3
FIGURE ‎2.1 COAGULATION TANK ................................................................................................ 5
FIGURE‎2.2 SAND FILTER TANK .................................................................................................... 5
FIGURE‎2.3 CARBON FILTER TANK ............................................................................................... 6
FIGURE‎2.4 CARTRIDGE FILTER TANK........................................................................................... 6
FIGURE‎2.5 ULTRA VIOLET (UV) UNIT ........................................................................................ 6
FIGURE‎2.6 BOILER MACHINE ....................................................................................................... 7
FIGURE‎2.7 SUGAR DISSOLVING TANK .......................................................................................... 8
FIGURE‎2.8 CANDLE FILTER TANK ................................................................................................ 8
FIGURE‎2.9 HEAT EXCHANGER FOR SIMPLE SYRUP ....................................................................... 8
FIGURE‎2.10 SIMPLE SYRUP COOLING TOWER............................................................................... 9
FIGURE‎2.11 BOTTLE WASHING MACHINE .................................................................................. 10
FIGURE‎2.12 SLIDER CRANK MECHANISM ................................................................................... 10
FIGURE‎2.13 FOUR-BAR LINKAGE ............................................................................................... 10
FIGURE‎2.14 BOTTLE WASHER MACHINE WASHING STEPS .......................................................... 11
FIGURE‎2.15 EMPTY BOTTLE INSPECTION (EBI) ......................................................................... 12
FIGURE‎2.16 WATER AND SYRUP RESERVOIRS ........................................................................... 12
FIGURE‎2.17 COOLING TOWER FOR AMMONIA COMPRESSOR ....................................................... 13
FIGURE‎2.18 FILLER MACHINE.................................................................................................... 13
FIGURE‎2.19 FILLING PHASE SEQUENCE ..................................................................................... 13
FIGURE‎2.20 CAPPING MACHINE ................................................................................................. 14
FIGURE‎2.21 FULL BOTTLE INSPECTION ..................................................................................... 14
FIGURE‎2.22 DATE CODER MACHINE .......................................................................................... 14
FIGURE‎2.23 MECHANICAL BOTTLE COUNTER ............................................................................ 15
FIGURE‎2.24 AIR COMPRESSOR ROOM ........................................................................................ 15
FIGURE ‎4.1 COVER THICKNESS GAUGES(DUNLOP ENERKA) ................................................ 22
FIGURE ‎4.2 GRADIENT VALUES OF COVER SURFACE(DUNLOP ENERKA) .............................. 23
FIGURE ‎4.3 STANDARD DIMENSION OF CLEATS(DUNLOP ENERKA) ...................................... 24
FIGURE ‎4.4 STANDARD BELT WIDTHS(DUNLOP ENERKA) ................................................... 24
FIGURE ‎4.5 RECOMMENDED BELT SPEED BASED ON DUTY TYPE(DUNLOP ENERKA) ............ 25
FIGURE ‎4.6 STANDARD VALUES OF BELT SPEED(DUNLOP ENERKA) .................................... 25
FIGURE ‎4.7 WIDTH FACTOR(DUNLOP ENERKA) ................................................................... 26
FIGURE ‎4.8 LENGTH FACTOR(DUNLOP ENERKA) ................................................................. 27
FIGURE ‎4.9 WORKING CONDITION FACTOR (DUNLOP ENERKA) ..................................... 27
FIGURE ‎4.10 DEGREE OF EFFICIENCY VALUE(DUNLOP ENERKA) ......................................... 28
FIGURE ‎4.11 STANDARD ELECTRIC MOTOR POWER(DUNLOP ENERKA) ................................ 28
FIGURE‎4.12 TYPES TROUGHING IDLER ...................................................................................... 28

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List of Tables
TABLE ‎2.1 MANUFACTURING TECHNIQUE ................................................................................. 16
TABLE ‎2.2 MAINTENANCE TECHNIQUE....................................................................................... 16

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CHAPTER ONE
1. COMPANY BACKGROUND
1.1 Brief history of the company
Gondar soft drink industry is one of the soft drink company in north Gondar, Amhara region
of Ethiopia. It is about 727 km far from Addis Ababa to the north of the country. MOHA soft
drink S.C was established by Emperor Haile Selassie May 4, 1954 (GC). In that time the
company employed 62 employers and produced 5000 bottle/day and the products were Pepsi
Cola and Mirinda. The employer’s‎salary had been below 50 birr.
Gondar soft drink industry (MOHA) is a member of Mohammad International Development
Research Organization Companies (MIDROC). It is Ethiopian technology group companies
which are engaged in manufacturing and selling of different types of soft drink in Ethiopia.
The overall activates of the company are managed and administrated by Sheik Mohammed
Hussein Ali Al-Amoudi also he is the chairperson and the owner.
MOHA soft drink S.C. holds 52% of the market share in soft drink industry in the country
with an expansion and replacement of absolute machinery production capacity of the plant has
increase substantially. In addition, it is a corporate company, which is located in Amhara
national regional state, North Gondar, Gondar town and 727 km away from Addis Ababa and
with a total land holding area of 10,780-meter square. The company supplies different soft
drinks such as Pepsi cola and Mirinda orange to the society. Other products will be provided
due to a new company is being in construction which is located at Azezo However; the
products are available from other same company.
1.2 Objectives of the company
MOHA Soft Drinks Industry S.C was acquired from the Ethiopian Privatization Agency and
established on May 15, 1996 with the following purposes:
 To manufacture, buy, sell bottle, distribute and otherwise deal in non-alcoholic
beverages mineral and treated waters.
 To manufacture, sell and distribute bottles, corks, corkscrews and all types of crates.
 To manufacture sell and distribute carbon dioxide.
 And generally to carry on and engage in other activities which the company may
deem necessary incidental or related to the attainment of any of the above purposes.

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1.2.1 Vision of the company

MOHA’s vision is to make each of Pepsi products to be a drink of first choice among
consumer and obtainable throughout the Ethiopian market and also creating superior value for
shareholders, customers and employees.
1.2.2 Mission of the company
The mission is to be the best beverage industry in the country and will continuously improve
responsiveness to the needs and concerns of customers, employees, partners and communities
in which served. This will be accomplished through the development of employees, an
emphasis on cost efficiency, market expansion and profitability. Expanding marketing areas
to both protect and improve their positions by placing emphasis on innovation and
technological improvement to keep always ahead of competition.
1.2.3 Core values of the company
 Customer satisfaction
 Enhancement of positive corporate identity and image
 Ensure employees empowerment
 Be committed to social responsibilities, sustainability of quality and
 Excellence in work and build a winning team
1.3 Main Products of the Company
In Gondar plant, MOHA Soft Drinks Industry S.C. produces Pepsi, Mirinda and 7-UP as
shown in the figure below. The rest of the products are not available due to the old technology
of the machines. These all products are 300ml (0.3L). To produce the above-mentioned
products, MOHA Soft Drinks Industry S.C got an authorized license from international Pepsi
Cola Company. This company controls the quality and safety of the products in the market.

Figure ‎1.1 Main product of Gondar MOHA soft drinks

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1.4 Main Customers of the Company

The products always uses in local market from main distributor up to the whole seller. The
main customers/end users are:
 Individual peoples
 Different Factories
 Café, Restaurants and Hotels
 School compounds (high schools, universities, junior school etc.)
1.5 Organizational structure of the company
The plant has their own organization structure to perform their task. The following
diagram shows the overall organizational structure of Gondar MOHA soft drink industry.

Figure‎1.2 Organizational structure of Gondar MOHA soft drinks

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CHAPTER TWO
2. OVERALL INTERNSHIP EXPERIENCE
2.1 Reason for selecting the company
We chose this company because MOHA soft drink S.C. holds 52% of the market share in soft
drink industry in the country. MOHA Won four awards in 2010 from Pepsi Cola international,
as per the accomplishment of standard required by AIBI – an internationally recognized third
party audit firm. Besides it has different wide plant sites across the country. MOHA plant sites
include Teklehaimanot plant, Summit partners plant, Dessie plant, Bure-Baguna plant,
Hawassa Millennium plant and Mekelle plant.
2.2 The Sections We Have Been Working
In Gondar MOHA soft drink plant we have been working on the filler section. there are also
different sections. These sections were very essential for the manufacturing of soft drink and
they have their own procedure and safety majors to be ready for the final production. Those
sections are Boiler room, Syrup room, Bottle Washer, Filler room and Air compressor room.
The more critical unit operation in Gondar MOHA soft drink is bottle washer machine.

2.2.1 Water Treatment Room

Water treatment is the process of removing undesirable chemicals, biological contaminant,
suspended solids and gases from raw water and that makes the water more clean and
acceptable for specific end use. The source of the water for Gondar MOHA soft drink is
usually ground water. There are two types of water treatment process Hard water treatment
and soft water treatment.
2.2.1.1 Hard water treatment
Hard water usually the ground water and the final treated hard water is used for the syrup
preparation and filling section. It is treated through the following treatment tanks.
I. Coagulation tank
Coagulation (Reaction) tank is the first tank in the water treatment room. The desired
chemical reaction takes place and water is sanitized. It is a chemical water treatment process
by changing smaller particles in to heavier so that they can quickly settle out. The coagulant,
usually Aluminum sulfate with the assistance of the chlorine and lime, forms heavy flock

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which entraps particles of debris, dirty organic matter and other undesirable material in the
water, and settles slowly toward the bottom of the tank. The flock because of its own weight is
left behind continuously trapping particles of debris as it settles.

Figure ‎2.1 Coagulation Tank

II. Sand filter tank

The purpose of sand filter tank is to remove physical matters and unwanted materials from the
raw water like floating dirts present in the ground water except chlorine from water. The sand
tanks (filter) has three layers, at the bottom there are sands (gravel) and relatively large in size
followed by medium size sand filter that covers a few height above the gravel . Fine sand
filters are filled above the medium sized sand filter followed by anthracite top up which
enhances effective filtration of foreign matter or suspended particles coming with raw water
that may occur during storage at the concrete tank (reservoir).

Figure‎2.2 Sand filter tank

III. Carbon filter tank
The water that comes from the sand filter tank is entered in to the carbon purifier. This is used
to remove chlorine by using activated carbon that present in the water. If the color is changed
then the water has chlorine, therefore the water can be corrected by removing chlorine before
it enters in to the polisher because the presence of chlorine can change the color and test of the
final product. Regeneration of activated carbon takes place by the incoming steam from boiler
room once in a week.

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Figure‎2.3 Carbon filter tank

IV. Cartridge Filter (Polisher, 1micro Sized)
This is used to remove suspended activated carbon that comes from the carbon purifier and
other unwanted particle that may be passed through the carbon purifier before transferred to
Ultraviolet (UV) Radiation. The filter bag used for filtration is called polisher. Cartridge filter
contains five polishers inside and can be used for one month. A new white polisher replaced
by the old one that is used for one month.

Figure‎2.4 Cartridge filter tank

V. Ultra Violet (UV) Radiation
It is the final treatment for the product water. It is used for destroying any microorganisms
present in‎ water.‎ It’s‎ known‎ as‎ the‎ critical‎ control‎ point‎ for‎ the‎ quality of the water. After
passing through UV, now the water can be used for production purpose, such as syrup
preparation and filling room.

Figure‎2.5 Ultra Violet (UV) Unit

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2.2.1.2 Soft water treatment

There are two softener tanks which are similar size and application but at a time only one of
them will work while the other one will be regenerated using brine tank that holds sodium
chloride. Generally, its application is to change the hard water into soft water that is used in
the washer machine and boiler room. Its mechanism is to remove calcium and magnesium in
their carbonate form which could increase the hardness of the water.
2.2.2 Boiler room
A boiler or steam generator is a device which is used to create steam by applying heat energy
to water. The boiler is made up of stainless steel, because it is less corrosive. This generated
steam has different functions in different sections of the company. Such as:
 Washing bottles in washing section
 Dissolving sugar in syrup room.
 cleaning and sterilizing internal parts of machines

Figure‎2.6 Boiler machine

2.2.3 Syrup preparation Room
The syrup preparation is the initial step in the making of soft drinks and provides the final
product with its distinct flavor and color, the process of syrup preparation is starting from
sugar treatment. For the treatment process Hyflo or diatomite and activated carbon is used.
The process begins by adding of sugar in the sugar dissolving in tank. the tank have 700L of
water with c of temperature, then 1,128 kg of sugar is added in to the tank, in addition 4
kg of activated carbon and 2 kg of sylatom is added then agitate in order to mix and wait until
the temperature rise to c.

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Figure‎2.7 Sugar dissolving tank

The activated carbon is important for the odor and removing un-wanted thing in the sugar.
Sylatom or diatomaceous earth is useful to catch up the activated carbon. In the other tank
Hyflo will mix with water in order to catch up or separate the activated carbon from sugar in
the candle filter tank.

Figure‎2.8 Candle filter tank

Through circulation the mixture of dissolved sugar and Hyflo will be contact in the candle
filter tank then the activated carbon will be absorbed by Hyflo, then the pure sugar will be
passing through the heat exchanger in order to lose its temperature and entering to the syrup
mixing tank.

Figure‎2.9 Heat exchanger for simple syrup

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The heat exchanger is connected to cooling tower of syrup outside the syrup preparation
room. The simple syrup (heated sugar) will be transferred to this cooling tank. Its purpose is
to cool down the temperature of simple syrup below c before getting to syrup mixing tank.
Decreasing the temperature is important because if the simple syrup gets into syrup mixing
tank with high temperature it may damage the flavor in syrup mixing tank besides high
temperature may be suitable for microorganisms.

Figure‎2.10 Simple syrup cooling tower

After all this process the final syrup will be produced by mixing this simple syrup with the
standard ingredients of Pepsi or mirinda in the syrup mixing tank. There are four huge tankers
and they are used to store and convert the simple syrup in to the final syrup. The simple syrup
which has less than C transferred in to these tankers from heat exchanger .Then flavors
and dry component will be mixed with simple syrup in order to give final syrup.
Standard ingredients of Pepsi: Carbonated Water , Sugar , Color (Caramel E150d) , Acid
(Phosphoric Acid) and Flavorings (including Caffeine)
Standard ingredients of Mirinda: Carbonated water , potassium benzoate (preserves
freshness) , Sodium chloride ( better taste and long shelf life ) and sodium citrate.
2.2.4 Bottle Washer machine
Bottle washing is one of the main important steps in the production of soft drinks. The shelf-
life of soft drinks depends very greatly on the state of the cleaned bottle. Empty bottle are
returned from different customers must be cleaned to a hygienically perfect condition.

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Figure‎2.11 Bottle washing machine

2.2.4.1 Mechanisms of bottle washer machine
I. Slider-crank mechanism
A slider-crank mechanism is basically a four-bar mechanism with three revolute joints,
or turning pairs and a prismatic joint or a sliding pair.

Figure‎2.12 Slider crank mechanism

II. Four-bar linkage
The kinematic linkage shown in Fig. 2.13 is known as the four-bar linkage. The conventional
numbering system is to label the ground frame as link I, and then to number links clockwise
around the mechanism "loop" as shown in Fig. 2.13

Figure‎2.13 Four-bar linkage

Cleaned bottles are transferred to the conveyor, and then to the filler machine. The bottles are
transported in rows through the bottle washer. During passage through the machine the bottles
pass different washing steps.
A. Pre and intermediate spraying
This is the first stage for bottle washing and presoaked in one or more baths at increasing
temperature the bottle is washed internally and externally with soft water by using spray jet

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B. Caustic I
In this step the bottles sink in a chemical called caustic soda and boiled with temperature of
72- C. This is controlled by diaphragm valve which senses the temperature from the boiler
in the form of steam. Thus, the diaphragm monitors the temperature range to be in between
72- C where if it goes out of the range it opens and closes the valve by a pressure that
comes from the compressor.
C. Caustic II
The difference from the former step is there is no caustic soda to be added here or the strength
of caustic II is less than caustic I and also the temperature is decreased by some amount
25- C from caustic I but it is assumed to be not free from this chemical due to carry over in
it and the most important thing in this step is more water is used to clean the bottles.
D. Warm water
The bottles are washed by hot water (the water heated by steam). This is temperate water
which is not very hot but moderate one which is heated by conduction system via steam
comes from boiler.
E. Cold water
The bottles are cleaned by cold water. In this part the bottles get more cold water to be washed
before it gets to the next step.
F. Fresh water
This is the final stage for bottle washing process the bottles washed by fresh and treated water
that comes from water treatment section in order to protect the bottle from microorganism and
other unwanted materials and the water is comes from. Finally, they are ready to go to the
filling room.

Figure‎2.14 Bottle washer machine washing steps

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2.2.5 Filler room

It is one of the production sections whose purpose is to verify that containers are consistently
filled to the correct level as established by correct volume or weight for the brand and package
type. There are a series of processes under filling section these are Empty Bottle inspection
(EBI), Mixer Machine, Filler Machine, Capping machine, Full Bottle Inspection (FBI) Date
coder and mechanical bottle counter.
I. Empty Bottle Inspection (EBI)
The purpose of inspection is to insure the safety of the work in the processes. Inspect empty
bottle that comes from the bottle washer manually by peoples and electrically through light
screening.

Figure‎2.15 Empty bottle inspection (EBI)

II. Mixer Machine
The basic purpose of this machine is to mix the three main contents of the product,
which are water, finished syrup and carbon dioxide. This process is called Carbonation. The
water comes from water treatment room and it is well treated water and the finished syrup
comes from syrup room whereas the carbon dioxide comes from CO2 tank.

Figure‎2.16 Water and syrup reservoirs

As the beverage is chilled, it absorbs carbonation. Most beverage operation use cooling to
20°C for cold filling. The finished beverage is cooled by ammonia gas the cooling tower for
ammonia compressor is available in the company.

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Figure‎2.17 cooling tower for ammonia compressor

III. Filler Machine
Filler machine is used to fill the bottles with the drink that has been prepared in the mixing
machine. It is also connected with the capping machine.

Figure‎2.18 Filler machine

The machine works by lubrication system automatically. There are also 16 filling valves
called vents and expanding tubes where these tubes have small holes that are used to transport
the gas as well as the drinks respectively.
The Filling phase sequences of filler machine are described below
Evacuation: this step used to remove those strange gases.
Flushing: Then the bottles will be flushed with CO2.
Pressurization: this step used to remove the CO2 that was applied for flushing.
Filling: is a step of which the product is filled into the bottles.
Correction: if the fill height becomes greater than the range then it will be corrected.
Snifting: used to balance the pressure between the container and the surrounding.

Figure‎2.19 Filling phase sequence

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IV. Capping Machine

Capping machine is device used to pack or seal the bottle with crown corks. It has cork feeder
on top part and is added manually. The cork drop by the action of gravity to seal the
incoming full bottle Inverted corks will not be dropped down because a simple horizontal bar
prevents them.

Figure‎2.20 Capping machine

V. Full Bottle Inspection (FBI)
Like EBI, this inspection area also inspects the status of a full bottle. There are parameters
used to check the full bottle. This inspection method is also done manually by people.

Figure‎2.21 Full bottle inspection

VI. Date Coder Machine
It‎ is‎ a‎ machine‎ used‎ to‎ label‎ the‎ best‎ before‎ date‎ and‎ the‎ factory’s‎ abbreviation‎ name
with the time of production. It has no contact area with the bottle it only prints the date by
spraying the ink through the print head. A product without a label of best before date will not
be available for market.

Figure‎2.22 Date coder machine

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VII. Mechanical bottle counter

Counts the number of filled bottles so that the total number of final products is known

Figure‎2.23 Mechanical bottle counter

2.2.6 Air compressor room
Atmospheric air is sucked and filtered by dust filter to avoid undesired particles. Then the
filtered gas is then transferred to vacuum suction to form pressure difference which enables to
transfer the sucked air to the desired location. Then this air is transferred to the compressor in
order to develop pressure in parallel with temperature and then cooled in two stages in both
cases. After air is stored in storage tank, it is used for different applications. Such as:
 To clean the bottle
 To operate the piston of the bottle on filler machine
 To dry the moisture on the bottle
 To cool the soft drink
 To operate pneumatic valve

Figure‎2.24 Air compressor room

2.3 Work tasks we have been executing
 Observe every section of the company when the machines are functioning.
 Save bottles from breakage

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 Pick up under fill bottles from conveyer belt and put in to cases,
 Arranging some cases & bottles when come improper position on the conveyer belt,
 Helping the operators and workers if they need
 Quality checking at FBI and EBI
2.4 Engineering methods, tools and techniques used
I. Manufacturing techniques
Manufacturing techniques are discribed in the following table

Engineering methods and techniques Tools /machines used

 grinder machine
 welding technique  bench vise
 grinding  spanner
 loosening and tightening nuts  electrodes
 welding machine
Figure ‎2.25 manufacturing technique
Activated in different maintenance activities during this time we follow engineering methods
and techniques that are presented in the following table

Engineering methods and techniques Tools /machines used

 monkey wrench
 inspection
 Allen key
 lubrication
 ball hammer
 cleaning
 lubrication can
 spare part replacement
 clean, dry clothes
 predictive and corrective maintenance
 Pipe wrench
Figure ‎2.26 maintenance technique

1.5 Challenges We Have Been Facing While Performing Our Work Tasks
 Most of manuals on the company are written by foreign language.
 Since MOHA Gondar plant is an old plant: There is no enough data of the company.
 Almost‎all‎operators‎don’t‎have‎sufficient‎idea‎about machines.
 Noises of production machineries

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1.6 Measures We Have Been Taking in Order to Overcome the Challenge

Here are some of the measures we have been taking
 Revise our previous knowledge that would support the our internship time
 Use the available manuals and time effectively
 By using internet access to support our internship program
 Make close relationship with each of workers & operator of the company

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CHAPTER THREE
BENEFITS GAINED FROM INTERNSHIP
3.1 Improving practical skills
We have gained multidimensional practical skills such as
 How to operate boiler and bottle washer machines.
 Fulfilling safety requirements(wearing glass, leather shoes and gloves).
 How to identify the problem of filler machine.
 Solving the problem of filler machine by tightening the bolts around the piston.
3.2 Improving theoretical knowledge
We have improved theoretical knowledge such as understanding the process of soft drink
preparation from raw materials.
3.3 Improving team playing skills
We have learned a lot on how to improve interactions with our team members. When
activities are done in group the acceptability, reasonability and accuracy were found to be
always better than those done by individually.
3.4 Improving leadership skills
We gain the following skills in terms of leadership
 Ability to encourage and motivate workers to do their best.
 The ability to accept problems and focus on its solution.
 Commitment and dedication
 Learned how to find solutions for any problems developed.
3.5 Improving work ethics and related skill
We gain different skills related to work ethics and related skills such as:
 Accept and follow rules and regulations of the company
 Being punctual
 Being tolerant and patient
 Change the style of dressing and wear over coat and helmets
 Smooth relation with colleagues
 Have a positive work attitude

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3.6 Entrepreneurship skill

We gained the following abilities or skills:
 Risk management
 Self-confidence
 Creativity skill
3.7 Improving inter personal communication skill
We have improved the following interpersonal communication skills.
 How to ask a question to our co-workers in a polite way
 How can we develop a friendly relationship with our co-workers
 How can we communicate with my managers and supervisors

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CHAPTER FOUR
4. PROJECT WORK
4.1 Short summary of the project
This project work emphasizes on the design of light duty belt conveyor system which is used
to transport corks for the capping machine. Under this title stated problems, general and
specific objectives are present that shows a list of work tasks. The other part of this project is
methodology which is the system of methods used in this particular study and literature
review. The later part is designing each part of the conveyor system based on standard
procedure. Finally the results are discussed and recommendation is given.
4.2 Problem statement
Nowadays, most successful manufacturing industries focuses on the possible and effective
ways of decreasing labors effort. Therefore, belt conveyor system is a way to reduce these
labors effort.
The problem we have seen in MOHA soft drink was too much load on the operators who
works on the filler and capping machine. So, we intend to solve this problem and reduce the
operator’s effort by making a belt conveyor which helps them to add corks from the cork
storage to the top of the capping machine.
4.3 Objective of the project
I. General objective
The general objective of this project work is to design an inclined belt conveying system for
transporting cork to the top the capping machine.
II. Specific objective
 Design of belt
 Design of idler rollers
 Design of pulley
 Selection of motor
4.4 Methodology
A. Sampling method
 Direct observation (position of hopper)

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 By measurement (hopper diameter, horizontal distance for the design of belt conveyor)
B. Data collection method
 Primary data collection (Observation, Interview)
 Secondary data collection (Reference books, Written documents)
C. Data analysis method
 Selection of the standard dimension for each part
 Calculation of the required dimensions

4.5 Literature review

4.5.1 Introduction of Belt conveyor system
A belt conveyor system is a common piece of mechanical handling equipment that moves
materials from one location to another. They allow quick and efficient transport for a wide
variety of materials, which make them very popular in the material handling and packaging
industries.
History of belt conveyor
Until the mid-1970’s‎ conveyor‎ belt‎ development‎ and‎ technology‎ was‎ concentrated‎ on‎ the‎
search for appropriate materials of belt and the solving of drive problems. Chronological
advancements of belt conveyor are listed below (DUNLOP ENERKA Design of belt
conveyor system Textbook)
From 1870 Trials with plain cotton belts
Up to 1914 First rubber conveyor belts developed from drive belts.
1921 Founding of the Genera factory. Manufacture of drive belts and later
1923/1924 First use of belts underground, not a success due to drive Problems
From 1933 Development of Rayon/cotton belts and pure rayon belts.
Transition from natural rubber to synthetic rubber for protection of carcase.
From 1939 Increased use of rayon and synthetic rubber.
1941/1942 Use of PVC belts above ground.
1942 Steel cord belts used for the first time for major long haul
From 1945 Further development of rayon belts.
Introduction of mixed material fabrics includes synthetic weft.
1954/1955 Development of high tensile strength belts e.g. plies from rayon, polyamide

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And polyester.
From 1955 Development and use of steel cord belting in Europe.
From 1970 Use of Aramide as reinforcing material for the carcase
From 1980 Development of new conveyor systems

4.6 Design of belt conveyor

4.6.1 Determination of belt characteristics
The selection of the belt specification depends on the application. Our application is a light
duty type so we chose the belt material to be PVC (polyvinyl chloride) because it has the
following advantages: Strong and lightweight, Easy to install, Durable ,Cost-effective, Safe
material (nontoxic) and Fire resistant.
The following items mentioned below should be considered carefully to select the proper belt
characteristics.
4.6.1.1 Belt construction
Covers
The belt is protected against outside influences by the covers which are normally made out of
either rubber or PVC. It is available in different qualities of rubber or PVC.
I. Cover thickness
Carrying side Cover thickness
The thickness of the carrying side cover depends upon the nature of the load and loading
conditions (type of load, gradient, height of fall etc.)
Figure ‎4.1 Cover thickness gauges(DUNLOP ENERKA)
Conveyor Load/Duty Cover Thickness (mm)
Carrying Side Pulley Side
Light package Conveying 2 2
Gravel, Earth, Potash etc. 2-4 2-3
Ore, Ballast, Coal 4-8 2-3

Light package conveying can be selected for our application then for the material to be
transported, cork, the carrying and pulley side cover thickness is 2mm.
Return side Cover thickness
The carrying side cover should not be more than 3 times thicker than the running side cover.

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Carrying side : Return side 3 : 1

I. Cover surface type
The carrying side surface depends on the load, the inclination of the installation or depending
on the use of the belt, smooth, profiled, cleated and with corrugated edges.
Figure ‎4.2 Gradient values of cover surface(DUNLOP ENERKA)
Cover Surface Belt Type Max. Gradient Application
Smooth Normal 18° - 20° Unit and
bulk loads
T-cleats Belts with up to 90 Piece and bulk loads
with or without Corrugated side walls
corrugated edges with or without T-
cleats

Profiled Fishbone Rufftop up to 35° Piece and bulk load

The cover surfaces of the belt have cleats and the application is conveying pieces of corks.
4.6.1.1 Angle of inclination
The maximum angle of inclination of a belt conveyor depends on the friction value between
material and belt and the form of material. For steeper inclinations up to 90°, profiled belts,
belts with cleats or elevator belts are used. Knowing angle of inclination is important to
convey the materials efficiently. (DUNLOP ENERKA)

Figure ‎4.1 Inclination angle of a belt conveyor

The‎space‎in‎the‎working‎area‎of‎the‎filling‎and‎capping‎machines‎is‎narrow‎so‎we‎don’t‎want
to take a smaller angle because the smaller the inclination angle the wider its space on the
ground therefore from table 4.2 the inclination angle is chosen

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For better material handling we chose the High incline or Bucket cleat. The dimensions of the
cleat can be determined from the table below.
Figure ‎4.3 standard dimension of cleats(DUNLOP ENERKA)
Form Type Measurements Weight
Designation (mm) (Kg/m)
H B D
Straight T 15/20 15 20 0.18
T-Cleat T 20/40 20 40 0.27
T 40/70 40 70 0.70
T 60/80 60 80 1.04
Sloping TS 50/65 50 65 7 0.88
T-Cleat TS 70/80 70 80 60 0.82

Bucket Cleat B 80 80 80 1.90

B 110 110 80 2.90

So the dimension of the bucket cleat selected as Height (H) =80mm, Width( B)=80mm and
weight of cleat ) = 1.90 kg/m
4.6.1.2 Belt Width
The type of the materials determines the minimum belt width. Wherever possible a standard
belt width should be selected.
Figure ‎4.4 Standard Belt Widths(DUNLOP ENERKA)
300 - 400 - 500 - 650 - 800 - 1000
1200 - 1400 - 1600 - 1800 - 2000 2200

The cork storage which is at the top of the bottle capping machine have a diameter of 450 mm
and this bottle capping machine works at a lower speed if the feeding rate due to larger belt
width is increased, the storage will be filled and corks will dropped down. Therefore in order
to avoid filling of the storage we have to take the minimum belt width available that is less
than 450mm from the standard belt width table. The chosen belt width is
4.6.1.3 Belt speed

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The belt or Conveying Speed (m/s) must be appropriate for the material composition and
operation conditions. The recommended belt speed can be selected from the table below.
Figure ‎4.5 Recommended belt speed based on duty type(DUNLOP ENERKA)
Duty v (m/s)
Unit Loads, Assembly Lines ≤‎1.68
Mobile Conveyors 0.52 - 1.68
Very dusty loads such as Flour, Cement ≤‎1.31
Ash and Refuse ≤‎1.68
Our duty is unit load so the belt speed can be less than or equal to 1.68 m/s selecting the
standard belt speed which is less than 1.68 from the table below.
Figure ‎4.6 Standard Values of belt speed(DUNLOP ENERKA)
Speeds V (m/s)
0.42 - 0.52 - 0.66 - 0.84 - 1.05 - 1.31 - 1.68
2.09 - 2.62 - 3.35 - 4.19 - 5.20 - 6.60 - 8.40
The capping machine works at a lower speed so we have to select the minimum speed
possible. Therefore the value of belt speed
4.6.1.4 Belt length
The purpose is to design belt conveyor which have elevation distance of . from this we
can calculate the belt length

……………………………………..………..(1)

where Elevation distance =

= Angle of inclination

4.6.2 Conveying Length

Conveying length ……………………………………..………..(2)

4.6.3 Conveying Capacity

For the calculation of the conveying capacity for unit loads the following formula applies.

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Quantity conveyed = ( ) ……………………………………….(3)

where = Belt Speed ( )

= Piece Length in direction of travel ( ) = piece length of a single cork =
= Spacing of pieces ( )
= (pieces per hour)

Load stream (capacity) = …………………………..….(4)

where = Piece Weight = piece weight of single cork =

=

Weight of load = …………………………………..(5)

4.6.4 Power Requirements

With the aid of the following formula, power requirements can be roughly assessed. The
accuracy is sufficient for normal installations with simple straight-forward running conditions.
Power at Drive Pulley ( ) …………………………………..(6)

Power for empty Conveyor and Load = ( ) ……………………..(7)

Where = width factor

= Length factor
= service factor
Figure ‎4.7 Width factor(DUNLOP ENERKA)
Belt Width B (mm)
Duty 300 400 500 650 800 1000 1200 1400 1600 1800 2000 2200

Light 31 54 67 81 108 133 194 227 29

Medium 36 59 76 92 126 187 277 320 468 554 691 745
Heavy 65 86 103 144 241 360 414 644 727 957 1033
From the above table a value of 31 for is obtained.

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Figure ‎4.8 Length Factor(DUNLOP ENERKA)

L (m) 3 4 5 6 8 10 12.5 16 20
CL 667 625 555 526 454 417 370 323 286

L (m) 25 32 40 50 63 80 90 100 150

CL 250 222 192 167 145 119 109 103 77
The conveying length is , By using interpolation we can find length factor

………………………………………..(8)

where = , = ,
= , =

Therefor the value of length factor for a coveying length of is

Figure ‎4.9 working condition factor (DUNLOP ENERKA)
Working Conditions
Favourable, good alignment, slow speed 1.17
Normal (Standard Conditions) 1
The working condition will be favorable, good alignment and slow speed so the value of the
working condition factor is
Therefore, the Power for empty Conveyor and Load ( )

= = 17.04

The Power for Lift (or fall) = )

where = conveying height =

= 0.96
Is the sum of additional power for trippers, skirtboard friction, ploughs
So =0
Total power at the drive
W

Required motor power =

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where = degree of efficiency

The degree of efficiency is obtained from the above table with respect to type of drive unit.
Figure ‎4.10 Degree of efficiency value(DUNLOP ENERKA)
Types of Drive
V-Rope drive 0.95
Pulley motor 0.96
Normal coupled drive 0.94
Hydraulic motor 0.86
Type of drive Pulley motor can be selected and the respective efficiency value is 0.96

The required motor power calculated as = ……………………….(9)

= 18.75 W
Installed Motor or Nominal motor power is selected from standard list.
Figure ‎4.11 Standard electric motor power(DUNLOP ENERKA)
1.5 2.2 3.0 4.0 5.5 7.5 11 15 18.5
22 30 37 45 55 75 90 110 132
160 200 250 315 400 500 630
can be selected because it is the least motor power and it can cover the power
consumption since the application is small and running at low speed.
4.6.5 Idler dimensions
A flat type troughing of idler is selected for the carrying and return because the belt width of
the conveyor is small

Figure‎4.12 Types troughing idler

Idler diameter
The minimum idler diameter can be calculated as

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( …………………………………..(10)

where = idler diameter

= idler revolution ( )
But, the idler rotation should not be greater than approximately
So calculating the minimum idler diameter
=
Idler diameter that is higher than is selected from the table below
Figure ‎4.13 standard diameter of idlers(DUNLOP ENERKA)

Carrying Idlers 51 63.5 88.9 108 133 159 193.7 219

Impact Idlers - - - 156 180 215 250 290
Support Discs - 120 138 150 180 215 250 290
So idler diameter is selected for the carrying and return idler roller.
Idler length
The standard idler length is obtained by the belt width from the table below
Table ‎4.13 standard idler length(DUNLOP ENERKA)

For flat troughing type and belt width of the idler length
Mass of idlers
The mass of idlers is also obtained from a standard table

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Table ‎4.14 mass of set of idlers(DUNLOP ENERKA)

Belt width B Idler Rollers Idler Roller Diameter (mm)
(mm) 51 63.5 88.9 108 133 159 193.7 219.1
300 Flat 1.6 2.2 3.2 - - - - -
2 part 2.3 3.4 4.1 - - - - -
400 Flat 2.0 2.7 3.9 5.6 - - - -
2 part 2.6 3.7 4.7 6.6 - - - -
3 part 2.9 4.4 5.4 7.3 - - - -

For flat type idler with diameter of 51 mm the mass of carrying and return idler is obtained as
Mass of one set of carrying idler roller ( ) = 1.6 kg
Mass of one set of return idler roller ( ) = 1.6 kg
The return side is also flat so the mass of the carrying and return idlers are equal.
Idler spacing
Values for Pitch of carrying idlers ( )
= , For Small installation or high impact
= App. , For Normal installation
= , For High tension installation
Selecting = to prevent belt sag conditions
Pitch of return idlers ( ) can be calculated as
= (2-3) =2 =1 ………………………….(11)

Number of carrying idlers Idlers ……………………………….(12)

Number of return idlers Idlers…………………………………….(13)

Number of revolution ………………………..……...(14)

4.6.6 Belt breaking strength

From the power calculations, the belt type can be closely determined. The actual nominal belt
weight can be used in the more precise calculation of the belt.

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This formula is to enable calculation of belt breaking strength and applies to installations with
a single pulley head drive.

Breaking strength k= ( ) ……………………..……..(15)

where = Friction value factor

= Breaking strength loss at joint factor
Table ‎4.15 Friction value factor(DUNLOP ENERKA)
Drive Friction Belt Width B (mm)
Pulley Value
Surface 300 400 500 650 800 1000 1200 1400 1600 1800 2000 2200
bare, wet 0.15 98 74 59 45 37 30 25 21 18 16 15 14
rubber 0.25 69 52 41 32 26 21 17 15 13 12 10 9
lagged, wet 0.30 62 46 37 28 23 18 15 13 12 10 9 8
and dirty
bare, dry, 0.35 57 43 34 26 21 17 14 12 11 9 8 8
lagged, wet
It will be assumed that the conveyor will operate in a bare dry situation so the value of is
then 57 also the value of friction value ( is 0.35.
Table ‎4.16 Breaking Strength Loss at Joint Factor Cv(DUNLOP ENERKA)
DUNLOP Belt Type Splice Type Ply Rating Factor Cv
DUNLOFLEX 2 ply overlap 100% 1.00
1 ply overlap 50% 0.50
FERROFLEX Zig-Zag Splice Joint 0.90
DUNLOPLAST Finger Splice Joint 0.90
The belt material is DUNLOPLAST so the factor value is 0.9
Now calculating the breaking strength

k= = 2.71

The nominal Breaking Strength is obtained by rounding up the calculated breaking

strength value (k) to the next highest belt type

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Table ‎4.17 Standard property of belt types(DUNLOP ENERKA)

Belt type Cover thickness(mm) Cover thickness(mm) Weight( )
DLP 250 PVC BLS 2 + 1 4 5.0
DLP 315 PVC BLS 3 + 1.5 6 7.5
DLP 400 PVC BLS 4 + 2 8 10.0
DLP 630 PVC BLS 5 + 3 11 13.75
From this table the rounded up value of will be , the first on the table. So the specific
belt type of the application is DLP 250 PVC BLS. the value of the belt weight is also on the
table
4.6.7 Determination of forces
I. Peripheral Force ( )
It is the steady state running peripheral force. For installations with one loading point, as a
rule the following summation applies
[ ] …………..….(16)
Where = Length factor
= Artificial friction factor
= Conveying length =
= acceleration due to gravity ( ) = 9.81
= Mass of rotating carrying and return idlers
= Mass of the belt
= Mass of load (kg/m) = 0.078 kg/m
= angle of inclination =
= conveying height
The influence of Factor C will decrease as the conveyor length increases.

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Table ‎4.18 Length factor C(DUNLOP ENERKA)

The value of obtained from the graph for a conveying length of It is approximately
about 8.8
Artificial friction factor
The friction factor f is used for the calculations of the resistances to motion. It provides an
estimate of the resistance to rotation of the idlers, the belt resistance (flexing and idler
impressions) and material impression resistance. Values for the factor f are dependent upon
the working conditions and construction characteristics of the installation.
Table ‎4.19 Artificial friction factor(DUNLOP ENERKA)
Favourable working conditions,easily rotating idlers, material with low
internal friction and good tracking, good maintenance 0.017
Normal installation, normal material 0.020
Unfavourable conditions,low temperature, material with high internal
friction, subject to overload, poor maintenance 0.012 - 0.016

Assuming the application with normal installation and normal material so the respective value
of f is 0.020
Mass of rotating carrying and idler rollers

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The mass of rotating parts ( ) is calculated from the weight of the rotating idler
rollers on the carrying and return runs.

( ………………………………..(17)

Where = Mass of one set of carrying idler rollers

= Mass of one set of return idler rollers
= Pitch of carrying idlers
= Pitch of return idlers
Therefore =
Mass of the belt
Total mass of the belt = mass of belt + mass of cleats
= ………………………………………...(18)
Where = belt weight ( = from table for DUNLOPLAST belt =
= Belt width
= mass of cleats = from table for bucket cleat type =
Calculating the total mass of the belt
= =
Now substituting all the parameters to find the force
[ ]
[ ]

II. Peripheral Force at Start-Up

At the breakaway and start-up of a loaded installation, the inertial resistances to motion of the
masses to be moved, have to be overcome. The belt stresses during acceleration kept to a
minimum. The initial pulley peripheral force at start-up must not exceed a certain value.
Recommendations The maximum peripheral force should not be greater than approx. (1.3
to1.5 ) , the steady state running peripheral force.
So peripheral force at start up = (1.3-1.5) …………………………………….(19)
= 1.4 =

Acceleration = ……………..…..(20)

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Where
= 0.72
4.6.8 Belt Tension
First the individual resistances are calculated as follows:
Main resistance ( ) = .……....(21)
= 3.21 N
Secondary resistance ( = ………………………..…..(22)
= length factor = 8.8 = 25.04 N
Friction resistance
carrying side ( ) = …………..…..(23)
= 3.18 N
Return side ( ) = ……………..…..…..(24)
= 1.05 N
Slope resistance
carrying side ( ) = ………….…………..(25)
= 102.36 N
Return side ( ) = ……………….….………….…..(26)
= 100.06 N
Inertial resistance
carrying side ( ) = …………..……(27)
Where
=
= 17.5 N
Return side ( ) = …………………………(28)
= 17.32 N
Determination of the point tensions of single pulley head drive ( to and to with
the help of individual resistances (for peripheral force ≥‎0,‎positive).

Figure ‎4.3 single pulley head drive stress points

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I. Belt Tension at steady state

………………………………………………………(29)
where = drive factor

= …………………………………………………………..…(30)

where = Friction coefficient =

= angle of wrap
The angle of wrap of the conveyer is because no snub pulley is used in the application

Figure ‎4.4 angle of wrap

Substituting the angle of wrap value in the drive factor equation =
The value of drive factor can also be obtained from the table
Table ‎4.20 drive factor value(DUNLOP ENERKA)
Angle of wrap Friction coefficient
160 3.10 1.92 1.34 0.99 0.76 0.60 0.49 0.40
170 2.90 1.78 1.24 0.91 0.70 0.55 0.44 0.36
180 2.71 1.66 1.14 0.84 0.64 0.50 0.40 0.32
With an angle of wrap and friction coefficient 0.35 the value of drive factor is 0.5
Now we can calculate the tension on different points
………………………..……..…..(31)
N
= ……………………….....…..(32)
= N (Compression)
= = N (Compression)
= …………………………(33)
= 63.19 N
II. Belt Tension at non steady state (working)

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, = drive factor slack side at start up

= ,

= 0.4
…………………………………………(34)
N
= …………………………….…(35)
= N (Compression)
= = N (Compression)
= …………………………(36)
=

Min belt tension ……………………………………….…(37)

213.3 N

Start up time = 0.72 s……………………………………….…(38)

Start up distance = 0.1512 m……………………………….…(39)

4.6.9 Pulley Diameters

Drum Style Pulleys - the selected pulley is drum style pulley for allowing for continuous full
contact with the conveyor belt. The contact surface is constructed from a cylindrical shell,
tube or pipe.(Selection of drum pulley according to DUNLOP ENERKA )
The Pulley diameter can be selected on the table depending on the belt type
Table ‎4.21 standard pulley diameter and weight(DUNLOP ENERKA)
Belt type Cover Cover Weight( ) Pulley mnimum
thickness(mm) thickness(mm) diameter(mm)
A B C
DLP 250 PVC BLS 2 + 1 4 5.0 160 125 100
DLP 315 PVC BLS 3 + 1.5 6 7.5 250 200 160
DLP 400 PVC BLS 4 + 2 8 10.0 315 250 200
DLP 630 PVC BLS 5 + 3 11 13.75 500 400 315

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Table ‎4.22 Group and application of pulley

GROUP APPLICATION
A Pulleys in the areas of high belt stress Drive Pulleys
B Pulleys in areas of low belt stress Tail Pulleys
C Pulleys‎with‎an‎angle‎of‎wrap‎‎≤‎90°, snub Pulleys
The selected material was DLP 250 PVC BLS so the corresponding pulley diameter is
Diameter of drive pulley ( )=
Diameter of tail pulley ( )=
The angle of wrap is so‎we‎don’t‎need‎a‎snub or deflection pulley

Number of revolution (drive pulley) ………………………(40)

Number of revolution (tail pulley) ………………..…………(41)

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Result
Part Value
Installation Conveying height 3m
Conveying length 3.19 m
Angle of inclination 70
Type of drive Single head pulley drive
Type of motor Pulley motor
Belt material PVC
Belt type DLP 250 PVC BLS
Carrying side 2 mm
Cover thickness Pulley side 2 mm
Belt characteristics Return side 0.33 mm
Belt width 300 mm
Belt speed 0.42 m/s
Belt weight 5 kg/m
Cleat Cleat type Bucket cleat
Cleat dimension Width 80 mm
Height 80 mm
Cleat weight
Conveying capacity Quantity conveyed 47,25 P/h
Load stream (Capacity ) 0.118t/h
Weight of load 0.078 kg/h
Power Power for empty conveyor and load 17.04 W
over the horizontal distance
Power for lift (or fall) 0.96 W
Additional power 0W
Total power at the drive 18 W
Required motor power 18.75 W
Installed motor power 1.5 KW

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Idler Diameter 51 mm
Length 380 mm
Mass of One set of carrying idler 1.6 k/g
Mass of One set of return idler 1.6 k/g
Pitch of carrying idler 0.5 m
Pitch of return idler 1m
Number of carrying idler 6
Number of return idler 3
Number of revolution 157.28 r.p.m
Force Steady state running Peripheral force 63.23 N
Peripheral force at start up 88.52
Individual resistances Main resistance 3.21 N
Secondary resistance 25.04 N
Friction resistance Carrying side 3.18 N
Return side 1.05 N
Slope resistance Carrying side 102.36 N
Return side 100.06 N
Inertial resistance Carrying side 17.5 N
Return side 17.32 N
Belt tension At steady state start up T1 63.19 N
T2 31.62
T3 -67.39 N
T4 -67.39 N
At non steady state TA1 101.8 N
Working TA2 35.41 N
TA3 -46.28 N
TA4 -46.28 N
Pulley Head pulley diameter 160 mm
Tail pulley diameter 125 mm
Number of revolution Head pulley 50.16 r.p.m
Tail pulley 60.2 r.p.m

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DISCUSSION
The results we finally found almost have shown us some progresses and successes in our
design project. Because, as we can see from the overall design analysis, there are components
of belt conveyor system which are designed in appropriate way of dimensional analysis and
load. All of the components of belt conveyor system are designed by using appropriate
formulas for each and suitable material to avoid failures.
CONCLUSION
At the end of the result we have obtained following this analytical approach but also the
personal ideas.
 The parts are selected according to an international standard of DUNLOP ENERKA.
 The overall tension, power and force results are safe for the working condition.
 Belt speed belt width and conveying length are obtained depending on the working
condition of the company.
RECOMMENDATION
 Allowance must be taken during manufacturing in order to fulfill the desired task
 The company should follow installation of the belt conveyor with the right way
 The company should follow preventive maintenance schedule with the right way and right
persons to decrease a frequent break down of equipment and loss of production.

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Cost Estimation
1. Estimated cost for Belt
Belt material = PVC
Density =
Cost per kg (APPENDICE A)
W= m,t=
Volume
Mass
Cost
2. Estimated cost for Cleats
Cleat material = PVC
Density = (APPENDICE A)
Cost per kg =
A , W =0.08 m

3. Estimated cost for Frame

material =high strength 4330.
Density = (APPENDICE A)
Cost per kg =
Total area of the frame

4. Estimated cost for hopper

material =high strength 4330.
Density =
Cost per kg =

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Total area of the hooper

5. Estimated cost for idlers

Material cast iron
Density [APPENDICE B]
Cost per kg ⁄
The volume for idler

The mass for idler

The cost for idler
6. Estimated cost for Pulley
The pulley is made from cast iron
Density= 7800 kg/m3
Cost per kg ⁄
I. Head pulley
The volume for head pulley

The mass for head pulley

The cost for head pulley
II. Tail pulley
The volume for tail pulley

The mass for idler

The cost for idler
7. Estimated cost for Stand (Legs)
The stand is made up from steel, high strength 4330.
Density = (Appendix A)
Cost per kg = Total volume of stand ,
,

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COST RESULT
No Part Name Material Quantity Estimated cost Total cost
type
1 Belt PVC 1 16.08 $ 16.08 $
2 Cleat PVC 16 0.21 $ 3.36 $
3 Frame Steel, high 1 71.9 $ 71.9 $
Strength
4330

4 Hooper Steel high 1 14.99 $ 14.99 $

strength
4330
5 Idler Carrying Cast iron 6 2.85 $ 25.65 $

return 3 2.85 $

6 pulley Head Cast iron 1 10.46 $ 18.66 $

Tail 8.2 $

7 Stand Steel 30.55 $ 30.55 $

High
Strength
4330
8 Motor 1 50-500 375 $
Total Estimated cost 484.29 $

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CHAPTER 5
GENERAL CONCLUSION AND RECOMMENDATION
5.1 General conclusion
Generally we concluded that the internship program helps to improve and develop our
Leadership skill, Team working skill, Work ethics related issues, Industrial problem-solving
capability and Practical and theoretical knowledge. Specifically we have gained practical
skills such as how to operate filler and capping machine.
5.2 General recommendation
 Take care for used working equipment, since the company is profitable they do not care
about little thing that can cost them high amount of money.
 The company must assigns the operator with their qualification level.
 Bahir dar university must assign MOHA soft drink Company to help internship students
properly.
 Enough operator instructions and manuals should be present in the worker /operators for
each section to perform appropriate activities.
 The university industry linkage should be focus on technical work for the students
during the internship rather than visualization, Therefore the university should have a
good linkage with the industry.

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REFERENCE
[1] A text book of machine design, R.S. KHURMI & J.K. GUPTA.
[2] https://mohasoftdrinksindustry.com.
[3] http:// www.wikipedia.com.
[4] Belt conveyor design dunlop textbook(DUNLOP ENERKA).
[5] Manual of Gondar MOHA Soft drinks.

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APPENDICE A
Densi Shear
Poisso Yield Fracture
Cost ty Young's Modul UTS Breaking Thermal
n's Stress Toughness
MATERIAL Type ($/kg ( , Modulus us ( f strain Expansion
Ratio ( Y, (K c ,MN m-
) Mg/ (E , GPa) (G , ,MPa) ( f, %) ( ,10-6/C)
( ) MPa) 3/2)
m3) GPa)
Alumina (Al2O3) ceramic 1.90 3.9 390 125 0.26 4800 35 0.0 4.4 8.1
Aluminum alloy
metal 1.80 2.7 70 28 0.34 500 570 12 28 33
(7075-T6)
Beryllium alloy metal 315.0 2.9 245 110 0.12 360 500 6.0 5.0 14
Bone (compact) natural 1.90 2.0 14 3.5 0.43 100 100 9.0 5.0 20
Brass (70Cu30Zn,
metal 2.20 8.4 130 39 0.33 75 325 70.0 80 20
annealed)
Cermets (Co/WC) composite 78.60 11.5 470 200 0.30 650 1200 2.5 13 5.8
CFRP Laminate
composite 110.0 1.5 1.5 53 0.28 200 550 2.0 38 12
(graphite)
Concrete ceramic 0.05 2.5 48 20 0.20 25 3.0 0.0 0.75 11
Copper alloys metal 2.25 8.3 135 50 0.35 510 720 0.3 94 18
Cork natural 9.95 0.18 0.032 0.005 0.25 1.4 1.5 80 0.074 180
Epoxy thermoset polymer 5.50 1.2 3.5 1.4 0.25 45 45 4.0 0.50 60
GFRP Laminate
composite 3.90 1.8 26 10 0.28 125 530 2.0 40 19
(glass)
Glass (soda) ceramic 1.35 2.5 65 26 0.23 3500 35 0.0 0.71 8.8
Granite ceramic 3.15 2.6 66 26 0.25 2500 60 0.1 1.5 6.5
Ice (H2O) ceramic 0.23 0.92 9.1 3.6 0.28 85 6.5 0.0 0.11 55
Lead alloys metal 1.20 11.1 16 5.5 0.45 33 42 60 40 29
Nickel alloys metal 6.10 8.5 180 70 0.31 900 1200 30 93 13
Polyamide (nylon) polymer 4.30 1.1 3.0 0.76 0.42 40 55 5.0 3.0 103
Polybutadiene
polymer 1.20 0.91 0.0016 0.0005 0.50 2.1 2.1 500 0.087 140
elastomer
Polycarbonate polymer 4.90 1.2 2.7 0.97 0.42 70 77 60 2.6 70
Polyester thermoset polymer 3.00 1.3 3.5 1.4 0.25 50 0.7 2.0 0.70 150

Polyethylene (HDPE) polymer 1.00 0.95 0.7 0.31 0.42 25 33 90 3.5 225

Polypropylene polymer 1.10 0.89 0.9 0.42 0.42 35 45 90 3.0 85

Polyurethane
polymer 4.00 1.2 0.025 0.0086 0.50 30 30 500 0.30 125
elastomer
Polyvinyl chloride
polymer 1.50 1.4 1.5 0.6 0.42 53 60 50 0.54 75
(rigid PVC)
Silicon ceramic 2.35 2.3 110 44 0.24 3200 35 0.0 1.5 6
Silicon Carbide (SiC) ceramic 36.00 2.8 450 190 0.15 9800 35 0.0 4.2 4.2
Spruce (parallel to
natural 1.00 0.60 9 0.8 0.30 48 50 10 2.5 4
grain)
Steel, high strength
metal 1.34 7.8 210 76 0.29 1240 1550 2.5 100 14
4340
Steel, mild 1020 metal 0.50 7.8 210 76 0.29 200 380 25 140 14
Steel, stainless
metal 2.70 7.8 210 76 0.28 240 590 60 50 17
austenitic 304
Titanium alloy
metal 16.25 4.5 100 39 0.36 910 950 15 85 9.4
(6Al4V)

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APPENDICE B

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