INTERNSHIP REPORT ON RAYA BREWERY S.

C
 OUTLINES
 Background of the hosting company  Specific objective
 Main products of the company  Benefits of the project
 Overall workflow of beer production  Beneficiary of the project
 Brew house  Limitation of the project
 Fermentation and filtration  Literature review
 Utility section  Methods and detail design
 Packaging (bottling) area  Methodology
 Bottled beer  Material selection
 Kegging (drought Beer)  Components of design
 Overall benefits gained from our  Working principle
internship  Result and discussions
 Design of bottle crusher machine  Conclusion and recommendation
 Introduction
 Problem statement
 Background of the Hosting Company
 Raya Brewery S.C is established in 2013 G.C and (Commercial production in Feb. 2015 G.C).
 Founders: 58 founding shareholders.
 Current status: it is owned by BGI.
 Formerly it was established for Raya beer production only but now it is producing Castel and
St. George.
 Location: Southern Tigray, Maichew 668 km from Addis Ababa.
Main Products Of Company
 Pasteurized Drought beer
 Castle Beer
 St, George Beer
 Raya Beer
 Overall Work flow Of Beer Production
 The main raw materials are:

1, malt

2, water

3, hop and

4, yeast

Fig: Simplified diagram of Beer production

Raya beer has four main sections
those are:-
 Brew house
 Fermentation and filtration
 Utility section and
 Packaging.

Brew house
The most important processes in beer
production carried out in brew house
operation are
 Malt reception and handling,
 milling section,
 Pre-mashing, mashing,
 mash filter and whirl pool.
Malt reception and handling,
Malts from malt store are put in to the malt
reception by the labor workers or chain
conveyer, and transported to the silos through
screw conveyers and bucket elevators Figure Drum sieve:

Milling section
This section is used to crush malt in to smaller
size (to extractable section) using hammer mill.
Its capacity to crush 8 tons of malt per hours

Mashing in (mash kettle)

Figure Milling
Is the mashing process that used to starch
hydrolysis and protein degrade to simple sugars
and amino acids by the help of increasing T°
using steam and adding additives with time
intervals
Fermentation and Filtration
Fermentation is the process of converting sugar into ethanol and carbon dioxide using
microorganism which is known as yeast.
Filtration is the final process to be considered in beer treatment prior to packaging and the
process involves removal of any remaining yeast cells

Utility
In Raya brewery sc. utility is the widest section. It is mainly concerned with supplying the
demands to its customers. There are five subsections under utility. These are

 water treatment, carbon dioxide recovery

 steam generation waste water treatment,

 cooling plant,,
 carbon dioxide recovery

 CO2 is very important in beer making

companies in order to prevent direct contact
between air and beer as well as draft by creating
pressure. But raw CO2 has odor test and
impurities so co2 recovery plant is necessary

Boosters

 To compress the CO2 gas from a lower pressure

to a higher pressure Figure Boosters
Gas washer
Remove water dissolvable impurities
from the incoming CO2 gas
Gas washer
Boiler

In this plant the evaporation of water in

to steam is carried out due to the
requirement of steam for different
Boiler
purpose.
 PACKAGING (BOTTLING) AREA
 In packaging area there are two types of packaging place.

A, Bottled Beer

B, Kegging (Drought Beer)

Fig: Overall Process of Bottled Beer

 A, BOTTLED BEER
1,De-palletizer: It is used to pick up layers of 4, Bottle washer: Bottle washer machine is the
crates with empty bottles and then places them most important machine which is used to
on a chain conveyor. disinfect and wash dirty bottles.

2,Unpacker: It separates empty bottle from

crate by using pneumatic system and effectors 5, Visual bottle inspection: It is done manually
(grippers). with human eye using light. If the bottles are
3, Crate washer: The crate washer inverts the broken, unclean, labeler contain, they are
crate then the inverted inters to the crate rejected.
washer
for the purpose of cleaning by using spray
mechanism with in warm water and caustic
soda.
 6, Empty bottle inspection (EBI): this machine 9, Pasteurizer: is ensuring to increase its shelf
also used to inspect the empty bottles before it life by means of destroying or reduce the
goes to filler by using inspection parameters. number of harm full microorganisms in a
7, Filler and Crowning: The objectives of product in order to increase its biological
bottle filling are to preserve the quality of the stability.
beer and get the right volume of liquid into the
bottle and Closed the bottle by cork.

10, Bottle decoration (labeler):Labeling is

decoration of the bottle that uses for market
share and used to differentiate the factory
product from the others.
8, Full bottle inspection(FBI 1):This is used to
inspect weather the bottles, which has not
crowned and under filled or over filled are
rejected.
 11, Full bottle inspection (FBI 2): Full Bottle 13, Packer: Packer is used to put bottles with
Inspection (FBI): also Called Checkmate. It is a in crates.
machine which contains a light dependent
sensor. This sensor is used to select:
 Under fill and over fill bottles.

 Uncrown/unsealed bottles.

 Miss labeled bottles.

 Identifies production bottle or not.

14,Palletizer: Palletizer is used to put crate
12, Video jet: This device used print, containing full bottles to pallet.
Expiration date, Production date, Batch number
and hour’s works by radio frequency.
 B, KEGGING (DROUGHT BEER)

1, Empty turning machine: Also it is called 4,Rating system: This is called weight sensor
inverter machine. Used to invert the kegs used to check weight of full keg. If the full keg
where came from the input and this passed to is under fill or over fill, it is pushed using
external washer machine. pusher.
2, External washer: External washer is a
machine used to wash external part of the keg
at temperature of 40°C-50°C for 7 seconds.
5, Full turning machine: It is called full
inverter machine used to invert the full kegs
sent to the output.
6, Videojet: It used to write the shelf life of the
3, Internal washer and filler: The process of draught beer on the keg.
internal keg cleaning filling has three stages. 7, Labeling: carries important and effective
imprints used to decorate the kegs glues are
used to stamp the papers with the kegs.
 OVERALL BENEFITS GAINED FROM OUR INTERNSHIP
1, Improving our practical skills: we gain practical experience of applying our engineering judgment and working
successfully with others.
2, Improving our theoretical knowledge: Internship program gave us the opportunity to apply our theoretical
knowledge in real world environments, in addition to the practical skill.
3, Improving our interpersonal communication: skills In the company, we were working with all the technicians and
operators peacefully with good communication.
4, Improving our team playing skills: the most important point in team playing skill is just reaching an agreement
from different points on the work to be done. Therefore it’s very important to work together in order to achieve
higher productivity and save time.
5, Improving our leadership skills: What we gain from the internship regarding improving leadership are:
 Seek responsibility and take responsibility for actions.
 Know peoples and look out for their well-being.
6, Understanding about work ethic related issues: we develop proper relationships with coworkers and it helps us to
create good working environment.
7, Improving our entrepreneurship skills: We had a wide range of entrepreneur skills from above skills including
personal traits and management skills.
 DESIGN OF BOTTLE CRUSHER MACHINE
Introduction
Bottle crasher is a mechanical device that can crash a bottle at high speed operated by AC motor.
This machine is designed with the aim of pulverizing bottles to aid in the recycling process.
Broken bottles come from customer and factory due to improper handling of bottles, this bottle
should be crushed with the help this machine in order to protect the worker safety and reduce the
time and cost of manual crushing mechanism. The use of a glass crusher is a crucial part of the
process for recycling this waste.
 Problem statement
As we have observed and done some research on Raya Brewery Share Company, we found that
the company dispose 1000-1300 broken bottles every day and this disposal of waste or broken
bottles were unsafe, unhealthy and costly in transportation and processing, so we come up with
the idea of designing a machine that dispose waste bottles safely and helpful in minimizing cost
and time spending, despite the maintenance cost is less and have simple working principal.

General objective
 The main objective of this project is to design bottle crusher machine .
 Specific objectives
The specific objectives of the project is to design each component of the machine by using solid
work software and other mechanisms that helps to design the project.

Benefits of the project

 To save on valuable space.
 To save human energy and time.

Beneficiary of the project

 Raya brewery
 Bottle factory
 Other disposed glasses from the environment.

Limitation of the project

 It cannot crush more than six bottles.
 Shortage of time.
 Literature Review
Department of Design and Technology, Loughborough University, has presented a paper
emphasizing the need for recycling the wastes particularly the metal can wastes. The paper insists
that the requirement for environment accountability has become a feature of consideration for the
engineers, especially for mechanical engineers. The various design methodologies have been
discussed in the paper for the construction of a can crusher which would be helpful in waste
management.[1]
C.M. Everts son, Department of Applied Mechanics Chalmers University Of Technology,
Sweden have presented a paper to develop a wear model for the cone crushers which are used to
crush the rocks minerals which are in the form of ores in mines. Disagreements between predicted
and measured geometry and several effects were suggested to explain the discrepancy in the
model. The model is of complex construction and it has some of the real time shortcomings which
reduces the efficiency of the machine drastically. The various drawbacks have been studied and
the measurements have been done to predict the efficiency.[2]
 Methods And Detail Design
Methodology

Data Material Design Part Assemble Recommend

Start End
gathering selection analysis drawing drawing ation

Material Selection
Materials are selected based on;
 Material cost
 Manufacturability
 Availability of the materials,

 Suitability of the materials for the working conditions in service.

The material that we select for bottle crusher machine is Mild Steel (A-36) for all components
of design.
  Characteristics for motor selection is based on;
 Efficiency
 Output power
 Speed
For this design the selected motor is AC motor.

Components of Design
1, Design of hammer: The main objective of hammer is to crush the bottles.
2, Design of connecting rod: The main objective of connecting rod is transfer reciprocating
motion from crank to the hammer.

3, Design of crank: The main objective of crank is to convert rotational motion in to reciprocating
motion. Rotational motion come from AC machine and rotate the crank then the crank convert
this motion into backward and forward motion which transfer this motion to the hammer inside
crushing chamber which lead the hammer to crush the bottles.

A=
4, Pin Design: Pins are used to connect the crank with link and link with hammer.

 Resisting area (A) = x d2

5, Key design: For this design sunk key is selected from different types of key, sunk key are provided half in the key way of the
shaft and half in the keyway of the crank. we choice a square sunk key.

6, Design of crushing chamber: From the crushing chamber or body only the front wall is subjected to normal stress and the front
wall of the chamber thickness should be the same as the thickness of the hammer in order to balance the force reaction between
the two parts.
 Power input:
 Working Principle
The operation or working principle of bottle crusher is starts from operators by starting the AC
motor. After starting the motor it will convert the electrical power of motor to rotational motion of
shaft. At the same time the rotational motion of shaft will drive to the crank, since the crank is
connected with shaft, it induce a rotational motion similar with shaft. After the rotational motion
of the crank it must be convert reciprocating motion, so for this mechanism it uses connecting
rod. Finally the hammer will crush to the bottles by collapsing (over lapping) with wall of
chamber by reciprocating mechanism. Since the hammer is connect with connecting rod. After the
bottle was crushed it discharge through the small bottom holes of chamber.
 Result and Discussions
Result
Design components Result

Hammer L= 300mm
t=32mm

Connected rod L=324.46mm

t=28.8mm

Crank d=85.65mm

Pin dp=12mm

Key t=w=3mm

Crushing chamber t=32mm

L=310mm
h=270mm
 Discussion
The crushing machine was successfully designed, since the results are so safe. The machine
crushed multiple bottles simultaneously with ease both during electrical as well as during
mechanical modes of operation. While crushing the bottles manually, the bottles got crushed with
minimal human effort operators.
Conclusion and Recommendation
Conclusion

Generally we conclude that the bottle crusher is designed in such a way that even bottle crusher
can operate it without much effort. It is designed efficient and the cost of production of this
crusher is very less. The crusher has been designed accordingly keeping in mind about the
minimum power requirements and minimum effort to the operator. This crusher upon fabrication
would serve its purpose the small scale recycling plant and does not require power for operation
and can also be operated manually without much physical effort.
 Recommendation

We recommended that, if the company uses the designed machine certainly the company will be
beneficiary, since it minimizes the time needed to process and energy required to dispose waste
bottles manually also guarantee the safety of the workers. Generally waste bottle disposal in Raya
Brewery Share Company is unsafe and costly in transportation and processing. Therefore, if this
machine is introduces to the company it will be very helpful in guaranteeing the safety of the
worker and working condition of the company.

Finally, this project is very essential and helpful in order to make the working condition of Raya
brewery Share company more effective and safe also it reduce the time and cost wastage. As
mentioned above, in Raya brewery Share company there is no bottle crasher machine, therefore,
if this project is applicable in the company the effectiveness and profitability will be achieved.
 o u !
k Y
h a n
T