Acknowledgement

We would want to thank God first and foremost for his unending support during
our academic careers and our family, without whom we would not be here. We
appreciate Dashen Beer Factory for allowing us to observe and learn about the
company's current technology, as well as Debre Derhan University for providing
this internship program opportunity to transform our theoretical knowledge into
practical knowledge. We also appreciate the packaging department operator for
sharing their time with us to explain the working principle of robotic machine and
the technology they use. We also went to thank our company advisor,Mr. Bekure,
Mr. Fikermariam and their friends for the brilliant suggestions, careful and
encouragement of fruitful ideas.
Executive summery
 CHAPTER ONE
Introduction to host company

1.1 Introduction

The process of making beer is known as brewing. Beer production is one of the industrial
processes. Dashen brewery is one of the different beer industry found in our country Ethiopia.
Dashen beer factory is the most popular one and this beer factory used sophisticated technology
for the production Dashen and Balageru beer and draft. Dashen beer and drought beer are same
in alcoholic content. Both are alcoholic content of 4.8% by volume. The only difference between
them is the pasteurization temperature and the way of packaging process. Balageru beer and
drought beer, this beer is the second brand of Dashen brewery it is purely 100% barely. This
means that there is no adding of malt. Its alcoholic content is 5.2% by volume. Dashen brewery
has four main sections these are brew house, packaging (production), and utility and quality.
Beer is alcoholic beverage that produces from malt, hop, yeast, barely and water are main raw
material to produce cold wort that is ready for fermentation. Dashen brewery could be said as
having a capacity of production of 3 line and two each line having capacity 45,000bottle/hr and
line 3 is 60,000bottle/hr, per a day more than 3 million bottle of beer is produced

1.1.1 Background of the company

Debre Berhan Dashen Brewery Share Company was established in November 2008 E.C. The
name Dashen is taken from the famous mountain of RasDashen. Dashen Brewery Share
Company is located at the city of Debre Berhan, which is 130km far from our capital city Addis
Abeba. It is owned by the Amhara National Regional State Rehabilitation/Development
organization. It has invigorated on November 15, 2015 by our Prime Minister Haile Mariam
Desalegn, which is the first of its kind in Africa with a total production capacity of 4.2 million
HL per annually, Since its establishment. It is the art of technology and has qualified
professionally work force that will enable it to complete on the export market with leading
international beer producing and marketing company. Dashen breweries has already been a beer
tycoon and a pioneer in customer satisfaction, which is confirmed by being awarded two
internationally recognized certifications, ISO 9001and ISO 14001and national quality awards
and recently Debre Berhan plant awarded ISO 9001-2015

. 1.1.2. Vision of the company

 To be best brewer in Ethiopia in terms of quality products, customer service and the
employer of choice.

1.1.3. Mission of the company

 Delighting consumers
 Enriching communities
 Enhancing Ethiopian progress

1.1.4. Values of the company Principles

Ownership, Trust, Leadership development, Passion for Edge & Winning

 To estimate and understand basic environmental issues regarding with the industry.
 To develop professional skill.
 To solve the factories problem as much as possible.
 To know working ethics briefly

1.1.5. Services and products of the company

The raw materials used for beer production are malt, barley, hop, water and yeast. The main
products of Dashen Brewery S.C Debre Brehan plant are: - Dashen beer (100% malt), Balageru
beer (100% barely), Dashen and Balageru draught.
Table 1: product of the company

Alcohol
Product Brand Raw material Expiration date
content
Bottled
Dashen 4.8 Malt, hop, water One year
beer
Bottled
Barely, hop,
Balageru 5.2 Six months
water
Beer
Only two
Draught Dashen 4.8 Malt, hop, water
months
Barely, hop, Only two
Draught Balageru 5.2
water months
 Chapter Two
Understanding workflows and production process

1.3 PACKAGING DEPARTMENT

Packaging department is the vital places in Dashen brewer. This department has two different sorts: a
bottle seal and a KEG seal. Three lines are on the bottle seal and one line is on the KEG seal. Line 1 and 2
are krone's Germany made, produce 45000 bottles per hour. Line 3 is KHS made, produce 60,000 bottles
per hour. Line 4 is krone's made, produce 240 per hour. De palletizer, un packer, crate washer, bottle
washer, filler, EBI, FBI, Packer, and palletizer are just a few of the machine types found in bottle seals. The
primary raw material used in the packing process is glue, pallets, conveyors, crates, crown caps, and so
forth.
Figure 5. packaging process

1.3.1 Bottle beer

A beer bottle is a bottle designed as a container for beer. Such designs vary greatly in size and
shape, but the glass commonly is brown or green to reduce spoilage from light, especially
ultraviolet. The most widely established alternatives to glass containers for beer in retail sales are
beverage cans and aluminum bottles; for larger volumes kegs are in common use.

DE palletizer

DE palletizer is robotics machine that unload (De palletizer) packages or products from the
pallet. The De palletizer allows the transfer of product and materials from pallets without the use
of human personnel, saving thus time, money and effort. It uses an elector pneumatic technology
to operate, which separates the crate from the pallets. The pallets and 6 layers of crates are
brought by a forklift and loaded to the in feed of the conveyor (roller). De palletizer staked packs
from the pallet and placed them on discharge table. It works by pneumatic system by comprised
air at pressure of 5.5-6 bar working capacity of 64500 crates per hours. from pallet, pallet
transfer to the pallet store with help of synchronized roller conveyor (turn over motor). The crate
moves toward the create rainser. The rinser shower hot water on the empty bottles. Rinsed water
used to remove stacked dirt and dusts from the bottle. Rinsing water to the dirty bottle is very
important for the ease of washing. Crate should arrange in width side. Crate turner is used to turn
the crate on the width side by using sensor signal. Then the crate with empty bottle heads to un
packer.

Un packer machine

The unpacking machine is suitable to take bottles from plastic crates or cardboard-boxes and
automatically feed the bottling line. The packing machines are instead suitable, within the
packaging lines as a completion of the bottling systems, to insert bottles inside plastic crates.
Glass bottle gripper heads are used by the machine in the Dashen brewery sector to pack and
unpack bottles into or out of the crate. Un packer machine is used to remove empty removal
bottles from the plastic create. Thus this un packer machine runs from 5 to 6 bars pressure and
there are two un packer machine line with a working capacity of 54,000 bottles/ hours each of
them. The crate with the empty bottle feed to the nu-packer machine and then gripper head grips
the neck of bottles with the help pneumatic system gripper cups and discharge on the table
conveyor and create goes to create washer and bottle transfer to bottle washer machine.

Bottle washer machine

Bottle Washer machine is a machine used to clean a bottle using chemicals, water and other
additives to get germ free, and clean bottles are free of contaminated and residue. so that they . It
insures the healthy condition of the customers. The quality of beer very much depends on bottle
washing conditions. The krone's lavatec KD and KHS innoclean in Dashen were designed in
accordance with the “double-end” principle: the bottle are fed and discharge at different location,
ensuring the best hygienic condition.

Chemical used for bottle washer:

 ü Caustic additives like Divo-bright is added to the caustic soda

- To give shiny look for bottle

- To increase the concentration of caustic

- To remove organic and inorganic matter

- To remove the labeler

- Prevent from foam.

- To increase their shelf life

Anti-salient like Divo-ps is added to the warm water to prevent from scale.

There are 3 compartments in this bottle washer. Each of them has their own optimum
temperature, namely:

Pre-cleaning: Presoaking, high-pressure Pre-jetting, and high pressure jetting are three
categories under which it is categorized. Everyone has a private bath with a temperature range of
30 to 55 ℃. The figure transfer the bottle is bumped on to the machine’s feed belt. The dust and
soluble particle are first removed from the bottle during pretreatment.

Main cleaning: It has two primary caustic path, caustic one and two, each of which has a
concentration of 90ms and a temperature of about 80 ℃. Labels, oil residues, and other materials
on the outside and inside of the bottle will be removed during this process. The caustic bath is
dosed with additional additives like polix and stabllion. The bottle is made shiny by the stabllion
and the polix give the carrier anti-rusting properties. Following a caustic bath, the bottles residual
caustic was rinsed with water.

Post cleaning: It is the last cleaning procedure before the bottle goes in to the filler. Water is
being used to clean. There are different temperature water baths. The baths themselves are
specifically post- caustic, warm water 1, warm water 2, and cold water. To disinfect the water,
add CLO2 to the cold water

Filler machine

Beer and CO2 from the brew house and CO2 recovery plant, respectively, are poured into
washed-out bottles using a filler machine. It is sort of module filler than can fill 60,000 bottles
per hour for KHS and 45,000 bottles per hour for each krone's line. However, the bottles are
produced by the bottle washer. Phenolphthalein indicator is used to verify the presence of base in
bottles before they enter the filler machine; if base is present, the color changes to pink;
otherwise, the hue is less intense.

Component of filler machine

1. In feed worm: it’s main and fundamental purpose is to create similar gap between the
bottles and the bottles to in feed star wheel.

2. In feed star wheel: Empty bottles are sent there to be filled by the set filler.

3. Middle star wheel: it serves as a feeder and discharge for the in feed and discharge star
wheels respectively.

4. Lifting slender: - Used to lift or carry bottle

5. Vent tube: beer is poured into empty bottles using a particular sort of tube is Called a vent
tube.

The machine drive is servomotor with absolute encoder and PLC main control for all machines
of filler.

Steps on filling process

1) First evaluation: the centering bell presses the bottle tightly against the filler head,and a
fixed stop opens the vacuum valve. The bottles are evacuated to 90% of their capacity in
relatively short period of time. The centering bell raises a vacuum protection device to stop
collapse.

2) Purging CO2: when the roller lever is actuated, the gas valve quickly opens, allowing CO 2
to enter the bottles from the filler bowl and purge them.

3) Second evaluation: a vacuum of about 90% is created by repeating the procedure describes
for phase 1. The air that is still there is removed along with the CO2 from the bottle by this
vacuum.

4) Counter pressurized: phases 2’s procedure is repeated, but for a longer period of time. After
the two-fold evacuation, the pressure of the bottle is raised to the same pressure as that in the
filler bowl, resulting from the CO2 concentration in the bottle.

Filling: the valve is opened by the roller lever via the outside spring following pressure
equalization the bottle and the filling bowl. Because of the height disparity and the deflection of
the cone by the bottles, the beer can flow descending the wall. Through the air pipe, the CO 2 that
was expelled returns to the CO2.
Pressure venting, sniffing: To prevent immediate over foaming, the pressure in the bottle is
slowly decreased by opening the pressure release valve which is connected to the nozzle. The
vacuum pump produces a vacuum which sucks the air out of the containers. This causes the
pump to heat up. To get rid of the heat, water from an overflow tank is fed into the pump. The
water picks up the heat, and together with the extracted gas, it is pumped back into the overflow
tank. In the overflow tank, the water and gas are separate
Crowner: The crowner, a machine for closing bottles, is housed in the same block as the filler
And has servo motor driving to ensure synchronous operation. Crown corks are used to seal the
bottles. The crown cork descends on to the bottle via a curved track after passing a magnetic
conveyor and a slide conveying device in to the storage hopper of the elements bottles. The
crown cork then rests on the mouth of the bottle. It’s employed to seal filled bottles. It uses 18
cork heads to close the bottle, and it moves quite quickly.

Bottle spraying system: For the purpose of removing the foam created during high pressure
injection, bottle spraying systems spray water onto the topped bottles.

Labeler machine: Labeling is the process of attaching a label to a bottle so that it may be
declared and so that user can see information about the brew. The details could consist of the
product name, the alcohol content, and the input material. We’ve seen that the brewery employs
a Krones and KHS machine to show data on the body, neck, and rear of the container.

Components of labeling machine

 In feed worm
 In feed star wheel
 Labeling magazine( neck , body and back(this label is used when the beer is to be
exported))
 Container table
 Discharge star wheel
 Control cabinet
 Cold glue labeling station
 Machine table and drive( 3phase induction motor with gear box )
 Center guide
 sensor ( in feed monitoring sensor, bottle present sensor and label sensor)

Krones and KHS labeler machine uses

 Glue
 Labeler paper
 3 phase electric motor
 Packed bottle beer
Date coder: This device was used to print the beer’s production and expiration dates. With laser
jet, date coding is possible. Code must be readable in the bottle for a longer period of time.

Packer machine

Use different gripper head systems, the packer is a contemporary and adaptable packing robotics
machine that can pack a variety of containers in crates, trays, cartons e.t.c. This packer machine
was used to grip glass bottles. Glass bottles that have been filled are put in crates using a packer
machine. Since there are Krones and KHS packer machine, this packer machine operate between
5 and 6 bars of pressure at the movement.
The bottle conveyor on the packer machine comprises:

1. Bottle in feed with flat-top chains

2. Bottle table with stainless steel flat-top chains or plastic flush grid belts

3. Container table Monitoring Devices

Counter Checkmate: This counter check mate check there are 24 bottles in each crate. If not
the light sensor sense there is a gap it reject it by using pushing action of pneumatic system.
They system controlled by plc

Palletizer machine

Palletizers are robotics devices powered by an electro-pneumatic mechanism. Mostly utilized in

packed manufacturing factories to decrease down time, maintain high productivity, increase
completed product quality, and guarantee complete customer satisfaction.

Components of palletizer machine

1. In feed conveyor: This will accept the crate from packer which is going to be palletized.

2. Pusher: This will push the crate in the order of 3,3, and 4 crates at a time to the grouping
station.
3. Grouping station: In this area the crate that are pushed by the pusher is grouped together in
order to make one layer.

4. Gripper system: The gripper system is equipped with pneumatic grip bars that are arranged
on four sides, and is designed to pick up a pack layer. For palletizer, the gripper system has 10
pneumatic pistons that is because the load of the layer is high, but in the de-palletizer only two
pistons are used because the load is simple since it contains crates with empty

Chapter Three
Improving and Applying Methods and Value
Engineering Principles

 Method study is the systematic recording and critical examination of

existing and proposed ways of doing work, as a means of developing and
applying easier and more effective methods and reducing costs

Flow diagram recording

Un
packer
DE
Empty crate store palletizer

Labeler Filler Bottle

Washer
 Chapter Four
Conclusions and Recommendations

Conclusion

In Dashen brewery factory we stay three month for intern program .we are interested by what we
observe. There are many section in Dashen brewery factory .these section are divided and
observe by 16 week.at the end of the week we had a presentation .these presentation helps us to
recognize what we observe in each section. The machine in Dashen brewery factory is very latest
and high technology approach .all machine are automatic and synchronous. We tried to
understand the working principle and mechanism of those machine. And we have seen no
addition of sugar for preparation of beer.

Recommendation
he machine installed in the Dashen factory is automatic and synchronized. We tried to understand the
principle of automation and operation of different machines .we recommended to know well about the
machine and the controllers in some section of Dashen brewery s.c in debre berhan, and the manual
working principle of the machine. The other thing what we recommend is have no research manager to
initiate the student as well as the employer