GONDER UNIVESITY

MECHANICAL ENGINEERING DEPARTMENT

STREAM-TERMAL ENGINEERING
INTERSHIP REPORT AND PROJECT
TITTLE OF CHAIN CONVEYOR DESIGN
HOSTING OF COMPANY: GONDER MOHA SOFT DRINKS
FACTORY
DURATION OF INTERN: MARCH

SUMITED BY:SALEAMLAK TAMRAT

ID.NO-0051/08

DURATION OF SUBMISSION REPORT: JUNE

ADVISOR:SOLOMON

THIS PROJECT DONE BY SALEAMLAK TAMRAT

I|P a g e
 DECLARATION

“I hereby declare that the internship practice has been done from MARCH/10/2017
down to JULY/07/2017 and summer free serves. I have been looker crisis of
Conveyor to get Bottle silo and to give depositary. And due to a research on the
influence of current Conveyor performance in the production and due to a project
on chain Conveyor design.”

Approved by

Company supervisor and University mentor name, signature and date

Company supervisor name……………………………………………………...

………

Signature…………………. date…………................

University mentor
name………………………………………………………………..

Signature……………………. date……………………….

III | P a g e
 ACKNOWLEDGEMENT

Thank you God for his blessings because with His permission and divine guidance, I
have successfully completed this Conveyor design project and this report. First of all
I would like to thank supervisor, Instructor Solomon For him through this project.
I also like to thank GONDER UNIVERSITY for providing enough equipment’s and
source of idea. Lastly, I would like to thank all who are involved either directly or
indirectly in this design project and provides support until I complete this report.
Thank you for all that was cooperating in this Conveyor design project at
Gonder,Moha Soft Drink Factory.

IV | P a g e
 ABSTRACT

Simple chain conveyor is the transportation of material from one location to another.
Simple chain conveyor has simple load carrying capacity, short length of conveying
path, simple design, easy maintenance and high reliability of operation. Chain
Conveyor system is also used in material transport in foundry shop like supply and
distribution of, soft drinks bottle and removal of waste. This paper provides to
design the conveyor system used for which includes motor speed, chain width,
motor selection, specification, shaft diameter, sprockets, gear box selection, with the
help of standard model calculation.

V|P a g e
 List of tables
Table 1.1 the raw materials usage and suppliers of the company
Table 2.1 temperature during bottle washing
Table 6.1 2material selection
Table 6.2 Mechanical property of shaft material

VI | P a g e
 List of figures
Figure 2.1 workshops

Figure 2.2 TIG, oxy acetyl, arc welding machine

Figure 2.3 drilling machines

Figure 2.4 bottle washer

Figure 2.5 Bottle loading washer

Figure 2.6 example of a device for discharging bottle from a washer

Figure 2.7 rinsing with rotating jet shafts

Figure 2.8 Water treatment room

Figure 2.9 atypical borehole constructions

Figure 2.10 filer machine

Figure 2.11 filling phase sequence

Figure 2.12 boiler machine

Figure 2.13 boiler room schematic

Figure 2.14 sample photo in performing our work task

Figure 5.1 cries of conveyor

Figure 6.1 supporter

Figure 6.2 plate

Figure 6.3 pin

Figure 6.4 roller

Figure 6.5 sprocket

VII | P a g e
 List of chart
Chart 1.1 Organizational structure of company

Chart 2.1 the work flow of the bottling section

Chart 2.2 Water Treatment System Process Flow Chart

Chart 2.3 work flow in Montanans department

VIII | P a g e
 Table of Contents
DECLARATION....................................................................................................................................................................III
ABSTRACT...........................................................................................................................................................................V
INTERNSHIP REPORT..........................................................................................................................................................1
chapter ONE.......................................................................................................................................................................1
1 Introduction................................................................................................................................................................1
1.2 History of Pepsi cola................................................................................................................................................1
1.3 pepsi start in ethiopia..............................................................................................................................................1
1.4 Moha soft drink industry Gonder plant...................................................................................................................2
1.5 Objectives of the company......................................................................................................................................2
1.6 The main products of the company.........................................................................................................................3
1.7 Main customers of the company.............................................................................................................................3
1.8 Vision of the company.............................................................................................................................................3
1.9 Mission of the company..........................................................................................................................................3
1.10 The raw materials usage and suppliers of the company.......................................................................................3
1.11 Organizational structure of MOHA soft drink factory...........................................................................................4
CHAPTER TWO....................................................................................................................................................................6
2 Overall Internship Experience.........................................................................................................................................6
2.1 The way to the company.........................................................................................................................................6
2.2 The work flow of the bottling section......................................................................................................................6
2.3 Sections of company were our worked...................................................................................................................7
2.3.1 W ORKSHOP ....................................................................................................................................................7
2.3.2 BOTTLE WASHER............................................................................................................................................11
2.3.3 WATER TREATMENT ROOM...........................................................................................................................15
2.3.4 Filer machine..................................................................................................................................................18
2.3.5 Boiler machine................................................................................................................................................20
2.4 Our Work tasks in the company............................................................................................................................21
2.5 Work flow in maintenances department..............................................................................................................22
2.6 Procedures we have been using while performing our work tasks......................................................................22
2.7 How good we had been in performing our work tasks.........................................................................................23
IX | P a g e
CHAPTER three 3. Over all benefit we gained from the internship program..................................................................24
3.1 Over all benefit we gained from this internship program.....................................................................................24
3.3 What we gained intermesh of improving industrial problem solving...................................................................24
3.4 What we Gain in terms of improving our team playing skills...............................................................................24
CHAPTER FOUR.................................................................................................................................................................27
4. DESIGNS OF SIMPLE CHAIN CONVEYOR.......................................................................................................................27
4.1 INTRODUCTION......................................................................................................................................................27
4.2 PROBLEM IDENTIFICATION....................................................................................................................................27
4.3 STATEMENT OF THE PROBLEM..............................................................................................................................27
4.4 Simple chain conveyor uses...................................................................................................................................28
4.5 OBJECTIVE OF THE PROJECT..................................................................................................................................28
4.5.1 THE MAIN OBJECTIVE OF THE PROJECT.........................................................................................................28
4.5.2 SPECIFIC OBJECTIVE OF THE PROJECT............................................................................................................28
4.6 LETRETURE RIVEW.................................................................................................................................................29
4.7 METHODOLOGY.....................................................................................................................................................29
CHAPTER FIVE...................................................................................................................................................................30
5. DESIGN ANALAYS & SPESIFICATION.............................................................................................................................30
5.1 TYPES OF CHAIN BASED ON ITS MATERIAL............................................................................................................30
5.2 COMPONENT OF STEEL CHAIN CONVEYOR...........................................................................................................30
5.3 SPECIFCTION OF THE PROJICT...............................................................................................................................30
5.4 MATERIAL SELECTION............................................................................................................................................31
5.4.1 DESIGN OF SUPPORTER..................................................................................................................................32
5.4.2 PLATE..............................................................................................................................................................32
5.4.3 PIN..................................................................................................................................................................33
5.4.4 ROLLER............................................................................................................................................................34
5.4.5 SPROCKET.......................................................................................................................................................34
5.4.6 DC MOTOR......................................................................................................................................................35
5.4.7 GEAR BOX.......................................................................................................................................................36
5.4.8 Shaft................................................................................................................................................................36
5.5 Assembly drawing..................................................................................................................................................42
5.6 CONCLUSTION........................................................................................................................................................43
5.7 RECOMMENDATION..............................................................................................................................................44
I recommend that The company should have establish a project design, development and expansion board that
able to modify activities and create new ideas and strategies to improve customer satisfaction based on current
needs.......................................................................................................................................................................44

X|P a g e
5.7 REFERANCES..........................................................................................................................................................45

XI | P a g e
 INTERNSHIP REPORT
chapter ONE
1 Introduction
1.1 Overview of the project
During the project design stage for the transport of raw materials or finished products, the
choice of the method must favor the most cost effective solution for the volume of material
moved; the plant and its maintenance; its flexibility for adaptation and its ability to carry a
variety of loads and even be overloaded at times.

1.2 History of Pepsi cola

Pepsi cola traces its origins to 1898 when Caleb Bradham, a pharmacist in New Bern, North
Carolina, created a curative drinks for dyspepsia called Pepsi Coal. Pepsi cola, later referred to
simply as Pepsi was a mixture of carbonated water, cane-sugar syrup, and an extract from topical
kola nuts, to sell this product, Bradham formed the Pepsi Cola Company in 1903.In addition to
selling the drink at drugstore counters; Bradham bottled Pepsi for sale on store shelves. At this
time, bottling was a new innovation in food packaging However, due to major increases in the
price of sugar, Braham began to lose money on Pepsi and in 1923 he filed for bankruptcy. The
Craven Holding Company of craven country, North Carolina, purchased the company’s assets. In
1931 Charles G.Guth of the Loft Company in New York City purchased Pepsi-Cola from the
holding company. Guth had difficulty getting the business going again, but he increased sales by
selling larger bottles at an unchanged price. By 1933 Pepsi Cola was sold by 313 franchised U.S.
dealers bottled in the united states, Cuba, and England and Sold in 83 countries.

1.3 pepsi start in ethiopia

Nefas Silk Pepsi Cola is the first Pepsi Cola plant in Ethiopia and was established in 1966 as a
share company with an initial capital of 1 million Birr. The capacity of the bottling line at that time
was 20,000 bottles per hour (phi). In 1986, the plant was renovated and expanded to a capacity of
50,000 bph with twin fillers. Total renovation and expansion investment cost was
Birr 6,647,944.00 T/Haimanot Pepsi Cola Plant was established in 1961 as ‘Saba Tej’ share
company, but nationalized in 1975 replacing the old line an stated predicating Pepsi cola, Miranda
and Team brands in January 1978. Gondar Pepsi Cola Plant, before nationalization was owned by
private individual. The Ethiopian beverage corporation made a new feasibility study on Pepsi cola
product which got the blessing of the government to erect the currently operating plant in 1986.

Gonder Plant, Gonder soda industry was established in 1954(GC) by and individual owner.
In1979. The plant discontinued other soda products and started producing Pepsi Cola, Miranda
brand and carbonated Tosa Water.

1|P a g e
 1.4 Moha soft drink industry Gonder plant
Gondar soft drink industry is one of the most soft drink company In Ethiopia. moha soft
drink Sc. Was established in Emperor Haile slassie May 4, 1954(GC). In that time the company
has 62 employer and produce 5000 bottle/day and the products are Snagn Tonic, Snagn orange,
Snagn cola, Arenchata and Skish. The employer salary had been blow 50 birr.
Gondar soft drink industry (MOHA) is a member of MIDROC, Ethiopia technology group
companies of engaged in manufacturing and selling of different types of soft drink in Ethiopia.
MIDROC means Mohammad International Development Research Organization Companies. The
overall activates of the company are managed and administrated by the sheik Mohammed Hussein
Ali al Amoudin is the chairperson and owner. Dr. AregaYirdaw is the chief executive officer and
Mr. Tesfaye is the general manager.
MOHA soft drink sc. is 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 Amharanational regional
state, North Gonder, Goder town and 725 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, Miranda orange, Miranda tonic, Miranda apple, 7-up and carbonated water products to the
society. In addition, the company was setup with the modern technology in soft drink. Now the
factory produces only KOOL natural water. Due to a new company has not finishing.
Nevertheless, other products produce from other same company.

1.5 Objectives of the company

The business purposes of the MOHA soft drinks industry S.C as stipulated in the memorandum of
association are:-

1. to manufacture, buy, sell, bottle, distribute and other wise deal in non-alcoholic beverages,
mineral and aerated waters and the ingredients there of Ethiopia and elsewhere.

2. To manufacture, sell, and distribute carbon dioxide.

3. To invest in the other business enterprises, to establish and manage in Ethiopia or abroad, such
subsidiaries, branches or agencies as may be deemed desirable.

4. 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 purposes.

1.6 The main products of the company

2|P a g e
As it’s applying its machinery and technology it is producing 9000 – 12000 bottles per hour of
300ml soft drink are produced by the plant. In addition to these the company plan to install plant
for producing CO2 for the beverage purpose and according to the efficiency of producing CO2 the
plant could sale CO2 gas for customers who need it for food preservation purpose. And the
company is on process to produce 300ml soft drink like Pepsi cola, Miranda orange, Miranda
apple, Miranda tonic and 7u.To produce the mentioned products of MOHA soft drinks industry got
a franchised from International Pepsi cola company. This company, International Pepsi cola
controls the quality of the products in the market.

1.7 Main customers of the company

The products always uses in local market from main distributor up to the whole seller
everywhere can get products of the cafeteria company.
The most customers/end users are: -main distributor, hotels, restaurants, bars, cafeterias,
shops, tourist’s destination places (historical places), different entertainment place, institutes, non-
governmental organization (NGO) and individuals.

1.8 Vision of the company

To see Pepsi cola company the biggest soft drinks industry in the country and remain the dominant
in the market.

1.9 Mission of the company

The company is committed to marketing its products to all groups, treating all costumers with
respect, sensitivity and fairness, while providing some of the greatest products on the earth.

1.10 The raw materials usage and suppliers of the company

Table 1.1: - The raw materials usage and suppliers of the company

Raw Material Description Suppliers of the company UNIT

Water A.A water and sewerage Authority Lt
Sugar Sugar corporation (Wangi) Qt
Pepsi concentrate Pepsi cola International Unit
M- orange concentrate Pepsi cola International Unit
7-up concentrate Pepsi cola International Unit

3|P a g e
 1.11Organizational structure of MOHA soft drink factory

Chart: 1.1Organizational structure of company

MOHA operates with attend office located at A.A led by a chief executive office (C.E.O)
appointed by the chairman of the ward. The C.E.O is empowered to direct, plan, coordinate,
4|P a g e
organize, control and administer the overall operation of the company.Hire and file personal
directly or through this delegated management team. Represent the company in all fields of the
company activities.To approve annual budget and justify to the board chairman or MIDROC–
Ethiopia, keep and maintain the proper booking of the company accounts.Hierarchically the C.E.O
is accountable to the chairman of the board currently the activities of the company reporting to
C.E.O are grouped in to the following functions.

1. Finance division

2. Human resource division

3. Marketing division

4. Technical division

5. Procurement &stores /supplies division

6. Quality control &production division

CHAPTER TWO
2 Overall Internship Experience

5|P a g e
 2.1 The way to the company
Before i get into the company things came in my mind; how one goes about getting a place in
company, I thought it’s important that I do have a bit of concept. After I joined that company I
were practice as an intern for four month. Beginning from that day I were tried to see the whole
process and workflow of the company& also I have seen how the company did there production.

2.2 The work flow of the bottling section

Chart: 2.1the work flow of the bottling section

2.3 Sections of company were our worked.

The plant has several sections which help to produce its product. So I tried to describe
all of them that our worked in. These are:-

6|P a g e
  Workshop
 Bottle washer machine
 Water treatment room
 Filer machine
 Boiler machine

2.3.1 W ORKSHOP

Figure 2.1workshops

The infrastructure of the Workshops could provide the following listed services for the industry

i. Fitting

ii. Welding

iii. Drilling

iv. Cold working

2.3.1.1 Fitting
7|P a g e
These days small, medium and heavy industries are using automatic machines. But
Bench and fitting work also plays a significant role for completing and finishing a
job to the desired accuracy. Most of semi-finished works can be accomplished with
fairly good degree of accuracy in a reasonable time through various kinds of quick
machining operations. They still require some minor operations to be performed to
finish the job by hand. The term bench work denotes the production of an article by
hand on the bench. Whereas fitting is the assembling of parts together and removing
metals to secure the necessary fit, and may or may not be carried out at the bench.
These two types of work require the use of a large number of hand tools and other
devices or equipment’s that involve a number of operations for accomplishing the
work to the desired shape and size. Some of the commonly used tools are discussed
as under.
2.3.1.1.1 Tools used in fitting

Tools used in bench and fitting are classified as under.

1. Measuring instruments

2. Supporting tools

3. Holding tools

4. Striking tools

5. Cutting tools

6. Tightening tools,

2.3.1.2 WELDING
Welding is a process for joining two similar or dissimilar metals by fusion. It joins different
Metals/alloys, with or without the application of pressure and with or without the use of filler
Metal. The fusion of metal takes place by means of heat. The heat may be generated either from
combustion of gases, electric arc, electric resistance or by chemical reaction. During Some type of
welding processes, pressure may also be employed, but this is not an essential requirement for all
welding processes. Welding provides a permanent joint but it normally affects the metallurgy of
the components. It is therefore usually accompanied by post weld heat treatment for most of the
critical components. The welding is widely used as a fabrication and repairing process in
industries.
Sam of Welding machines in the industry

8|P a g e
Figure 2.2 TIG, oxy acetyl, arc welding machine

2.3.1.3 DRILLING
Drilling is an operation of making a circular hole by removing a volume of metal from the job by
cutting tool called drill. A drill is a rotary end-cutting tool with one or more cutting lips and
usually one or more flutes for the passage of chips and the admission of cutting fluid. A drilling
machine is a machine tool designed for drilling holes in metals. It is one of the most important and
versatile machine tools in a workshop. Besides drilling round holes, many other operations can
also be performed on the drilling machine such as counter- boring and countersinking etc.

Types of drilling machine in the industry:-

9|P a g e
Figure 2.3 drilling machines

2.3.1.4 COLD WORKING

Cold working of a metal is carried out below its re crystallization temperature. Although normal
room temperatures are ordinarily used for cold working of various types of steel, temperatures up
to the re crystallization range are sometimes used. In cold working, recovery processes are not
effective.

There is some increase and some decrease in properties of the cold worked part, which are given
as under.

Cold working process increases

• Ultimate tensile strength

• Yield strength

• Hardness

• Fatigue strength

• Residual stresses

Cold working processes decreases

• Percentage elongation

• Reduction of area

• Impact strength

• Resistance to corrosion

• Ductility

10 | P a g e
 Cold working processes

Commonly employed cold working processes are:

1. Rolling

2. Extrusion

3. Wire drawing

4. Forging

5. Sheet metal operations

Bet now a day in the industry mostly used cold working is sheet metal operations.

2.3.2 BOTTLE WASHER

Figure 2.4 bottle washer

2.3.2.1 Basic principles of bottle washer

The shelf-life of SOFT DRINK depends very greatly on the state of the cleaned bottle. Empty
bottle are returned soiled to very different extents from customers, but all bottle, even the very
dirty ones, must be cleaned to a hygienically perfect condition. In all cases there are two tasks to
be accomplished:
 The bottles must be cleaned mechanically and
All soft drink spoilage microorganisms must be removed and killed

11 | P a g e
 2.3.2.2 Influencing factor
To obtain this cleaning effect use is made of the following factor.

Effect of soaking
Removal of dirt requires a dissolving and soaking time which is affected by various factors. This
also applies to the removal of labels. The soaking time is 10 to 30 min.

Mechanical effect of jetting

Cleaning is reinforced by the mechanical effect of rinsing the flasks in the upper part of the bottle
washer. Bottle washing machine nowadays always employs combined soaking with subsequent jet
rinsing.

Washing temperature
Higher temperature always speeds up the removal of dirt. Temperature of 60 to 85C

Cleaning agent
Cleaning agent is caustic soda and hot water also kills micro-organism, particularly at high
temperature. They release and dissolve dirt; dirt removed depends on this.

The effectiveness of cleaning agents depends on the temperature. The higher the temperature the
lower concentration of cleaning agent needed. The following rule of thumb applies:
 An increasing a concentration by 50% of the cleaning agent or
An increasing of temperature of 5.5 0c has the same cleaning effect.

2.3.2.3 Basic designs of bottle washing machines

The bottles are transported in rows through the bottle washer. During passage through the machine
the bottles are
 presoaked in one or more baths at increasing temperature,
 Passed through several hot caustic baths,
 Rinsed with hot caustic,
 Rinsed with hot water,
Rinsed with cold water and finally
 Rinsed with fresh water.

12 | P a g e
If the basic requirements are associated with bottle rinsing:
 The internal diameter of the bottle mouth must be only 17 mm.
 If a satisfactory internal cleaning is to be obtained, the relative movement of the bottle and
spray jet must be matched exactly.
 The volume of the stream entering the bottle must be calculated so that there is no gurgling in
the mouth region of the bottle when more liquid is sprayed in than can out.

This is achieved by arranging that a rotating jetting shaft moves synchronously with each bottle
carrier row. The jet shaft contains holes, for the spray streams to flow through, which are moved,
precisely, close to the bottle mouth and consequently spray the bottle wall and bottom from
different directions and impact angles. This leads to internal cleaning of the bottles.

Figure 2.5 Bottle loading washer

Figure 2.6 example of a device for discharging bottle from a washer

13 | P a g e
 2.3.2.4 Temperature during bottle washing
During cleaning the bottles are heated up to the caustic bath temperature and then cooled again to a
temperature of 10 to 15 0c. In the process approximately the following temperatures are reached.
Table 2.1 temperature during bottle washing

Figure 2.7 rinsing with rotating jet shafts

2.3.2.5 Inspection of cleaned bottles

Basically, all bottles should be clean and fit to use after cleaning. For this to apply, the bottles
which are not fit to use, for various reasons, must be separated and removed before filling.

These include:-

 Bottles containing foreign bodies, dried on insect larvae, pigment or adhesive residues or other
contaminations,
 Bottles containing foreign bodies, residual caustic from the washer.
 External, interior side wall inspection

14 | P a g e
 Bottom inspection
 Bottle mouth inspection

2.3.3 WATER TREATMENT ROOM

Figure 2.8 Water treatment room

2.3.3.1 How to achieve the desired water quality?

Whether the water comes from a borehole or from the town mains, it must comply with current
national legislation as well as meet the company water standard. This generally implies some form
of water treatment. In the simplest form of treatment, the water would just be passed through a
sand filter to remove any particulates and a carbon filter to remove any organic
material and possible taints and odors. Finally a polishing filter down to 2μm absolute would be
used. At this level cryptosporidium is removed. Chlorination of the water is frequently used to
ensure it is free from harmful micro-organisms. The carbon filter would then remove any residual
chlorine. Finally the water should be passed under an ultraviolet (UV) lamp to ensure final
disinfection.

2.3.3.2 Product and Process Water Treatment Procedures

Boreholes: - A borehole with natural mineral water status and sufficient quantity and quality of
water to meet current and future demands is every manufacturer’s dream. Often, in fact, the supply
has to be treated in some way to ensure that the taste of the soft drinks
produced meets customers’ requirements at all times. In this case it is often better just to obtain for
spring water status, where some treatment is allowable. Most boreholes provide very consistent
water quality from the aquifer at a constant temperature. Deep Simple exploratory borehole is
often drilled first, and if water in sufficient quantity and quality is found Atypical borehole

15 | P a g e
construction is shown in Figure D. Such boreholes are often in excess of 100m, a full borehole is
then constructed.

The company uses its own ground water from 110 m deep well. The submersible pump inserted in
the well deliver the water to the tanker that has a capacity of 100,000 liters. The water is then
passes through sand filter, carbon filter and Ultra Violet Treatment.

In water treatment, there are two types of water treatment process

1. Hard water treatment

2. Soft water treatment (rain)

2.3.3.3 Hard water treatment

In MOHA soft, drink plc. There is a main water (hard water) tanker. This water is interning to the
Cognition Tanker. The Cognition Tanker use to filter small duct material. This water is transfer to
the intermediate tank to be stored the water that transfers from the Intermediate Tanker pumped to
Sand Filler Tanker to filter small duct materials. This tanker has contained six m3 waters after this
process the water that outs from sand filter tanker into the Buffer Tanker and transfer to Carbon
Filter Tanker. After this to kill small insects that found in the treated water passes through the
Polishers, after this water inter to the Ultraviolet Disaffection Treatment to kill microorganism m
by ray. After all this process, the water treated is ready to the production process.

2.3.3.4 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 one and its mechanism is that to
remove calcium which could increase the harness of the water and plus to this those minerals
could have effect on boiler and bottle washer machines by forming scales on the machine body .

There for removing those minerals made the water soft and safe.

Water Treatment System Process Flow Chart

16 | P a g e
Chart: 2.2Water Treatment System Process Flow Chart

2.3.4 Filer machine

17 | P a g e
Figure 2.10 filer machine

2.3.4.1 Working principle of filer machine

The filling machine is filling already prepared product to the bottles to the required level and
covering the bottle with a metal cap. In this factory, rotary filler machine is used. This rotary filler
recognized by its clear arrangement and clean appearance. Stainless steel covers for the front; ring
bowl and crowner are detachable in sections. The ring tank covers with rollers can move
telescopically around the filler circumference. Bottle guide parts positioned on studs and fastened
with hand nut for easy change over without tools.
Rotary filling machine commonly used to fill bottle, such as soft drink, beer, milk, oil…etc. with
fill liquid. In the conventional filling machine, empty bottles delivered on a linear conveyor then
fed by feed star-wheel conveyor to the rotary table or turret of the filling machine. The turret is
equipped with bottle support or platforms that individually lift the bottles against filling valves
mounted on the upper portion of the machine. Depending on the capacity of the filling machine,
the diameter may vary from 2 to 6 meters.

18 | P a g e
 Filling

Figure 2.11 filling phase sequence

2.3.4.2 Description of the Filling Phases

Evacuation = the air is evacuated from the containers.

Rinsing = the containers are flushed with protective gas (e.g., CO2).

Pressurization = the pressure between the container and product bowl/container is balanced

(Container pressure = operating pressure in the product bowl/container).

Filling = the containers are filled with product.

Correction = the fill level in the container is optimized (excess product removed from

Container).

Snifting = the pressure between the container and surroundings is balanced (container

Pressure = atmospheric pressure).

19 | P a g e
 2.3.5 Boiler machine

Figure 2.12boiler machine

A boiler is an enclosed vessel that provides a means for combustion heat to be transferred into
water until it becomes heated water or steam. The hot water or steam under pressure is then usable
for transferring the heat to a process. Water is a useful and cheap medium for transferring heat to a
process. When water is boiled into steam its volume increases about 1,600 times, producing a
force that is almost as explosive as gunpowder. This causes the boiler to be extremely dangerous
equipment that must be treated with utmost care .The process of heating a liquid until it reaches its
gaseous state is called evaporation.

2.3.5.1 Boiler Systems

The boiler system comprises: - feed water system, steam system and fuel system
Feed water system: - The feed water system provides water to the boiler and regulates it
automatically to meet the steam demand. Various valves provide access for maintenance and
repair.
Steam system: - The steam system collects and controls the steam produced in the boiler. Steam is
directed through a piping system to the point of use. Throughout the system, steam pressure is
regulated using valves and checked with steam pressure gauges.
Fuel system: - The fuel system includes all equipment used to provide fuel to generate the
necessary heat. The equipment required in the fuel system depends on the type of fuel used in the
system.

20 | P a g e
Figure 2.13boiler room schematic

2.4 Our Work tasks in the company

After we join moha soft drink Gonder plant for internship we was pleased in the Montanans
department .this department play the vital role in the company it haze two brood category the
workshop grope (fitters and welders ) and technical mechanics and also machine operators are
work in both gropes .

After we join the department our tasks is helping the mechanic in every job what they are doing
after a while we was show them our garage experience in the arc welding and mechanical works
by practice and they let me work as a mechanic in every problem.

In all maintenance poses and operation of the machine we use several machine tulles same of them
are listed billow,

 Measuring instruments

 supporting tools

 holding tools

 Striking tools

 Cutting tools

 Tightening tools,

 Welding machine …

21 | P a g e
 2.5 Work flow in maintenances department

Chart: 2.3 work flow in Montanans department

 The manager maintenance plan to the supervisor or work shop Forman, Then they maintain
according to the plan with mechanists.

 Report from operators to mechanists and engineers and then together maintain.

2.6 Procedures we have been using while performing our work tasks
Procedures while maintaining are:-

 Inspection by sense organs including visual inspection of machines that may lead to determining
the root cause.
 Dismantling if necessary.
 If dismantling is the course action that is to be taken, then dismantle properly as per
maintenance procedure manual.
 Inspecting all machine parts whether the frailer is due to wearing, aging, shortage of lubricant
etc.

22 | P a g e
 Depending on the inspection criteria that determine the root cause, taking the respective
corrective solution.

 Assembling after the corrective action is taken.

2.7 How good i have been in performing my work tasks

I was good enough while performing my work tasks. It is to mean i read the manuals; i
consult patiently the mechanics and operators without prolonging the maintenance and
productive time and also follow up mechanics.

Figure 2.14sample photo in performing my work task

23 | P a g e
 CHAPTERthree
3. Over all benefit I gained from the internship program

3.1 Over all benefit we gained from this internship program

In the company i was tried to perform my task or duty by acting like responsible and as a real
mechanic. This helps me to improve my practical knowledge. In Moha soft drink factory i have
been observing understanding, application and operation of the machine.

I was gained much more multidimensional practical skills. Such us: -

 How to soft drink manufacturing working system and I will see its mechanical parts.
 I also gain benefits on the company how to working flow organize.
 How to identify the problem of certain machine.
 How to solve the problem in recommended ways.
 How to operate a machine safely.
 How to service different machines.
Especially:-
 I also gain benefit how to the machines plant layout in the company.
 And also fitting and welding of pipes with arc and TIG (tungsten inert gas welding).
 How to operate different machines such as: - boiler, mixer machine, filer machine, bottle
washing machine.
3.2 What i was gained in terms of upgrading my theoretical knowledge
Because i was in the company which is technologically developed, i was improved the theoretical
knowledge. The practical skill makes me ready to realize, understand and grasp theoretical
knowledge. This is due to visible and practically done activities are unforgettable in nature.

3.3 What I was gained intermesh of improving industrial problem solving

capacity In moha soft drink i face several problems such as shortage of material or faller of
machine in the production tame .such types of problems are mostly occurred in the company bet
all problems are their Owen solution not all solution are rile solution i am consider the cost and
efficiency of that solution according to this problem are solved in the company this all are help to
improve our industrial problem solving capacity.

3.4 What I Gain in terms of improving our team playing skills

We learn a lot how to improve interactions with our team members. When activities are done in
group the acceptability, reasonability and accuracy find to be always better than those done

24 | P a g e
individually. Here being patient ability to listen carefully are the mandatory tasks.
3.5 What i gain in terms of improving our leadership skill
Leadership is a mechanism of influencing others to accomplish a certain task. We can realize that
to be a good leader. We get the opportunity to compare our leadership principles with the
leaders/managers in the company. Our leadership principles are: firstly thinking globally not
personally then respect, listen and work with all concerned bodies of the company. In moha soft
drink there are managers who follow the principles similar to mine. These managers lead honestly
as per rules and regulations of the company. There are also managers, small in number, thinking
narrowly.
3.6 What we gain in terms of understanding about work ethics related issues
These statements of intended conduct are expected of every member (permanent members,
associate members, contract members and student members) of the moha soft drink.
General moral imperatives: - (as a moha soft drink member we will …)
 Contribute to society and human well-being.
 Avoid harm to others.
 Be honest and trustworthy.
 Be fair and take action not to discriminate.
 Respect property rights (Honor copyrights and patents; give proper credit; not steal, damage, or
copy without permission).
 Respect the privacy of others.
 Honor confidentiality.
Additional Professional Obligations: - (as a moha soft drink entrant we will ...)
 Strive to achieve the highest quality in the processes and products of our work.
 Acquire and maintain professional competence.
 Know and respect existing law pertaining to our professional work.

 Encourage review by peers and all affected parties.

 Honor contracts, agreements, and acknowledged responsibilities.
3.7 In terms of entrepreneurship skills
Entrepreneurship needs a skill of creativity. So we realize that how can we pick out weakens on
certain mechanisms on given company and change them to a job. This makes us to understand we
should be a good solution seeker for problems instead of keeping them alive. This will make the
company managers to revise their working mechanism and it will give us a chance to work on
thatimprovement. To be an entrepreneur one has to work hard and think deeply the way how to
become entrepreneur according to the time and his country.
3.8 Interpersonal Communication Skills
The purpose of communication is to get our message across to others clearly and unambiguously.
The interpersonal communication skill has a vital role in the world of job. Because it helps to get a
25 | P a g e
better relationship with our co-workers, this will result a best work flow, motivation to work and a
good managerial environment between the managers and the workers. Especially this helps
students to get knowledge and experience from the workers.
This internship helps we much to improve our interpersonal communication skill
intermesh of: -
 How to ask a question our co-workers in a polite way.
 How can we communicate with our managers?
 How can we give comments?
 How can we develop a friendly relationship with our co-workers, even they got older than we?
 How we can make others to understand a complex concepts.
 How to solve problems with negotiation.
 Understand written and spoken information has and produce our technical report...

26 | P a g e
 CHAPTER FOUR
4. DESIGNS OF SIMPLE CHAIN CONVEYOR
4.1 INTRODUCTION
A simple chain conveyor system is a common piece of mechanical handling equipment that moves
materials from one location to another. Conveyor systems allow quick and efficient transportation
for a wide variety of materials, which make them very popular in the material handling and
packaging industries.

A chain is a reliable machine component which transmits power by means of tensile force and
used primarily for power transmition and convince system. The function and uses of chain are
similar to a belt. There are many kinds of chains it is convent to sort types of chains by either
material of composition or method of construction.

4.2 PROBLEM IDENTIFICATION

We have selected simple chain conveyor in our project in our internship host company there are a
lot of problems that hinders from achieving its objective.

 Problem of boiler machine

 Problem of old material used
 Problem of filer machine
 Problem of compressor
 The problem of conveyor(simple chain conveyor)

Figure 4.1 cries of conveyor

So that we are select simple chain conveyor in our project

4.3 STATEMENT OF THE PROBLEM

In all factory, not all machines and instruments perform a task in available and in wise ways.
This is because of that some emit problems on the type of machines during design or after design
at the time of assembling components and during the layout of the company reduces the company
profits as well as the quality and quantity of end products of the company. We are need to design

27 | P a g e
chain conveyor because of the factories are uses roller conveyor, this conveyors have a great
problems;

• It has low speed

• It needs high human force

• It uses for short period of time(short life time)

• It is stacking time to time

• It has high friction

These above problems can case the loss of the company’s product directly and decrease the
annual income indirectly. Therefore, these problems require a solution to establish sustainable
profit by replacing the manual system to automatic and relay out the departments. According to
this problem we are assume to solve by changing it by simple chain conveyor.

4.4 Simp le chain conveyor uses

• To conveyed the material fastly

• Transporting materials without human force

• It has long life time

• It reduces cost of the factory

• It reduces friction between the chain and the conveyed object

4.5 OBJECTIVE OF THE PROJECT

4.5.1 THE MAIN OBJECTIVE OF THE PROJECT
• To design use of simple chain conveyor instead of roller conveyor.

4.5.2 SPECIFIC OBJECTIVE OF THE PROJECT

• To reduce labor force

• To produce products within a short period of time

• To reduce the cost of the materials

• To increase life time

28 | P a g e
 4.6 LETRETURE RIVEW
Conveyors are devices which helps to transport materials from the starting to the discharging
point.

There are different types of conveyors, roller conveyor, and chain conveyor, belt conveyor; apron
conveyor

But we are tray to design chain conveyor because of the following problem

The labors pushing the bottle box to transport to from the store to the washer by applying force
manually. And many bottles are damaged when the boxes are down fail.

4.7 METHODOLOGY
To achieve the objective of our project the following methodology are used.

1. primary data collection

The primary data collection will be collected by

 Interview of the operators

 By observing of the machines

 By asking production manager

2. Secondary data collection

The secondary data source will be collected by

 Redding books

 The company present and past manual

After the data are collected we analyzed using appropriate tools and procedures in order to
solve problems.

29 | P a g e
 CHAPTERFIVE
5.DESIGN ANALAYS & SPESIFICATION
5.1 TYPES OF CHAIN BASED ON ITS MATERIAL
We can sort chains into five types

1 cast iron chain

2 cast steel chain

3 forged chain

4 steel chain

5 plastic chain

Demand for the first three chain types is now decreasing they are only used in some
special situation. For example cast iron chain is part of water treatment equipment, forged chain is
used in over load conveyors for automotive factories. The main use of steel chain (simple chain
conveyor) is to move conveyance the materials.

I have selected steel chain conveyor in MY project.

5.2 COMPONENT OF STEEL CHAIN CONVEYOR

 Motor
 Sprocket
 Supporter
 Roller
 Plate
 Pin
 Gear box

5.3 SPECIFCTION OF THE PROJICT

I specified some parameters in design the maximum distance of the conveyor, the width of
the chain and the load of the conveyed object that applied on the tension.
 That is maximum distance (L=10m), the width of the chain (W=40cm) and the
height (H=1m)
 All parts are made of austenitic 304 stainless steel.
The material composition is: -
Carbon (C): less than 0.08%
Chromium (Cr): 18.00 to 20.00%
Nickel (Ni): 8.00 to 10.50%

30 | P a g e
 SS Roller Chains are the most commonly used environmentally resistant
Application Example
Chains for the manufacture of foods, chemicals, medicines, or transmission in water. They
are also used in indoor conditions where rust is a problem.

5.4MATERIAL SELECTION
It is essential that we should be used during design through a knowledge of
the properties of the materials and their behavior under working conditions.
Table 5.1 material selection

Part name Material Property of material

type
Supporter Iron  low cost
 ductility
 malleable

Roller Stainless steel  high resistance

 low friction
 high stiffness and ductility
 light in weight
 high wear resistance
 High corrosion resistance

Plate Stainless steel  high wear resistance

 High corrosion resistance

Pin Stainless steel  low friction

 high stiffness and ductility

 light in weight

Motor Dc motor  Easily construction

31 | P a g e
  Low cost
 It has more torque
 It has more speed
Sprocket Stainless steel  light in weight
 high wear resistance
 High corrosion resistance
 low friction

Shaft Carbon steel  High efficiency

 Good machinability
 Good heat treatment
 High wear resistance

5.4.1DESIGN OF SUPPORTER
The material selection is the same with connecting rod.

The base part is fixed with ground.

To determine diameter of support weight of gear and weight of shaft is considered.

So we select carbon steel material. Since it is support we select solid carbon steel
material definitely. Length=10m and plate thickness= 2cm and width=40cm
height=1m

Figure 5.1 supporter

32 | P a g e
 5.4.2 PLATE
The plate is the component that bears the tension placed on the chain. usually this is a repeated
loading, sometime a combined by shock therefore the plate must have not only great static tensile
strength but also must hold up to the dynamics force of load and shock. Furthermore the plate must
meet environmental resistance requirement for example corrosion and abrasion.

Figure 5.2 plate

5.4.3 PIN
The pin is subject to shearing and bending force transmitted by the plate. At the same time it forms
a load bearing part together with the pushing, when the chain flexes during sprocket engagement.
Therefore the pin needs high tensile and shear strength resistance to bending and also must have
sufficient endurance against shock and wear.BUSHING: the bushing is subjected to shearing and
bending stress transmitted by the plate and roller and also gets shock loads when the chain engages
the sprocket.

In addition when the chain articulates the inner surface forms a load bearing part together with
the pin.The outer surface forms aloud bearing part with the rollers inner surface. When the roller
rotates on the rail or engages the sprocket therefore it must have great tensile strength against
shearing and be resistant to dynamic shock and wear.

33 | P a g e
Figure 5.3pin
5.4.4 ROLLER
The roller is subjected to impact load as it strikes the sprocket teeth during the chain engagement
with the sprocket .after engagement the roller changes its point of contact and balance.it is hold
between the sprocket teeth and pushing, and moves on the teeth face while receiving a
compressionload. For the more the rollers inner surface constitutes a bearing part together with the
pushing outer surface when the roller

Rotates on the rail.The belt conveyor is composed of the belt, the idlers, the pulleys, the drive
equipment, the take-up and the supporting structure.

Therefore it resistant to wear and still have strength against shock, fatigue and compression.

Figure 5.4 roller

5.4.5 SPROCKET
The chain converts rotational power to pulling power, or pulling power to rotational power, by
engaging with the sprocket.

The sprocket looks like a gear but differs in three important ways:

34 | P a g e
1. Sprockets have many engaging teeth; gears usually have only one or two.

2. The teeth of a gear touch and slip against each other; there is basically no slippage in a sprocket.

3. The shape of the teeth are different in gears and sprockets.

Figure 5.5sprocket
5.4.6 DC MOTOR
An Electric motor is a machine which converts electric energy into mechanical energy. Its action is
based on the principle that when a current-carrying conductor is placed in a magnetic field, it
experiences a mechanical force whose direction is given by Fleming’s Left-hand Rule and whose
magnitude is given by F = BIlNewton.

5.4.6.1 ABSORBED POWER

PA = Absorbed power i.e., power required for drive
pulley after taking drive pulleys loss into account.

Where,

Rwd = Wrap resistance for drive pulley (230 N)

Rbd = Pulley bearing resistance for drive pulley (100 N)
Therefore,

5.4.6.2 MOTOR POWER

The motor output power (shaft) is given by PM = PA/η

35 | P a g e
Where
η = Overall efficiency by taking the power losses of gear-box and couplings into account. = 0.94
Therefore,

5.4.6.3 MOTOR SELECTION

At present, all the motors are of 1500 rpm. By referring the catalogue, the selected motor is of 37
kW/1500 rpm (Nominal power). The shaft diameter of the motor is 60mm.

5.4.7 GEAR BOX

5.4.7.1 GEAR BOX SELECTION:
For gear box selection, we need to calculate the reduction ratio.

The output rpm is calculated using the formula

Where,
D = Diameter of driving pulley = 630 + 12 + 12 = 654 mm [According to IS, 630
mm diameter of driving pulley is suitable for the motor of power which is less than
50 kW & 24 mm (12 + 12) extra diameter is provided due to lagging of the pulley]

5.4.8 Shaft
A shaft is a rotating member, usually of circular cross section, used to transmit power or motion. It
provides the axis of rotation, or oscillation, of elements such as gears, pulleys, flywheels, cranks,
sprockets, and the like and controls the geometry of their motion. We use with the pulley system.

36 | P a g e
Table 5.2 Mechanical property of shaft material

Designation Tensile strength, N / mm

2
Yield strength, N / mm
2

40 C8 569-667 324
45 C8 618-696 353
50 C8 647-765 373
50 C12 206 min 392
5.4.8.1 Analysis of shaft

The shaft carries at the end pulley and spinning blanket. Pulley and tension created by the
belt is set at the right end FA and WP respectively. Show in the below Fig.

Warped blanket and tension create by blanket also set at the left end WB and FC respectively. Show
in the following Fig

Moreover, there is reaction force at the center used to support the applied load by the shaft show
the Fig. in the following

FCZ and WB FAZ and WP

FD
maximum weight of the warped blanket on the shaft let, take WB  100 N

To find reaction force at point D and the tension created by the spinning blanket at the point C.

37 | P a g e
Let do moment at point C

∑M C=45xFDZ−¿95x(FAZ+WP)=0

45xFDZ−¿95(1084.07+100) FDZ=2499.7N

SO WE CAN FIND THE TENSION CREATED BY THE SPINNING OF BLANKET BY ADDING OF THE
FORCE IN THE Z - AXIS (F CZ )
FCZ+WB-FDZ+FAZ+WP=0

FCZ100-2499.7+1094.07+100=0 FCZ=1215.6N

Analysis on the shaft in the Y-axis

FCY FAY

FDZ

To find reaction force at point D and the tension created by the spinning blanket at the point C.

Let do moment at point C.

XY-plain

∑M C=0=45xFD-95xFAY=45xFDY-95x1877.7

FDY=3963.96N

To find the tension created by the spinning blanket (FDY) adding of the force found in the Y-axis

FCY-FDY+FAY=0 FCY-3963.96+1877.7=0 FCY=2086.26N

At the speed of 1000 rpm the design life of 10000h correlates to bearing life of

The magnitude of the force or resultant force at the point D. At point C

F 2  FCY
2
 FCZ
2

 2086.26 2  1215.6 2
F  2414.57N
at point A
F 2  FAY
2
 FAZ
2

F 2  1877.7 2  1084.07 2
F  2168.17 N

5.4.8.2 Shearing force

38 | P a g e
Means where it can get break or shear

XZ-plane at point “C”

V=FCZ+WB=1215.6+100=1315.5N

At point “D” V=FCZ+WB-FDZ=1315.6-2499.7=-1184.1N

At point “A” V=FCZ+WB-FDZFAZ=-1184.1+1084.07+100=-0.03N

XY-plane

At point “C” V=FCY=2086.26N

At point “D” V=FCY-FDY=2086.26-3963.96=-1877.7N

At point “A” V=FCY-FDY+FAY=-1877.7+1877.7=0

5.4.8.3 Bending moment

Bending moment at any point we can find by singularity function formula is like the following by
varying the value of “X” assume length of shaft is 95cm

XY-plane

When X=0 or at point “C” Mx¿ (Fcz+WB) (X)-FDZ(X-45)+(FAZ+WP)(X-95)

MC=MO=(1215.5+100)(0)-2499.7(0-45)+(1084.07+100)=0

When X=45cm or at point “D”

MD=M45=91215.6+100)(45)-2499.7(45-45)+(1084.07+100)(45-95)=592Nm

When X=95cm or at point “A”

MA=M95=(1215.6+1009(95)-2499.7(95-45)+91084.07+100)(95-95)=0

XY-plane

Mx=FCY(X)-FDY(X-45)+FAY(X-95)

When X=0 or at point “C”

MC=2086.26(0)-3963.96(0-45)+1877.7(0-95)=0

When X=45cm or at point “D”

MD=2086.26(45)-3963.969(45-45)+1877.7(45-95)=89.38Nm

When X=95cm or at point “A”

39 | P a g e
MA=2086.26(95)-3963.96(95-45)+1877.7(95-95)=0

5.4.8.4 Shaft design

Resultant pull on the pulley due to belt tension

F
p=( ¿ √ K 2 +1+2 K cos ¿ ¿¿
K−1

By assuming, the weight of the pulley is 100 N. The driver situate at the below level, the drive
0
shall be inclined by 30 . Hence, the resultant pull on the other pulley becomes,

s 2  p 2  w 2  2  p  w  cos
s 2  2165.9 2  100 2  2  2165.9  100  cos 60
s  2112 .9 N
assuming the overhang of pulley to be 80 mm

Torque of shaft M=2112.9x80=169035.5N.mm

T=(F1+F2)D2/2=1158.5x300/2=173775N.mm 1

2T π 3 2 x 173775 π
= d σ= = (38)3σ
n 64 4 64

σ =32.2N/mm
2
This is less than 200 N/mm , giving factor of safety of belt s=syt/σ =200/32.2=6.1

s=6. Assuming suddenly applied loads with minor shocks from the Table.
k m  1.75 and k t  1.25

Te  (k m  M ) 2  ( k t  T) 2
 (1.75  169035.5) 2  (1.25  173775) 2
 366999.7 N.mm
2
Assuming the shaft to be 40C8 steel the tensile yield stress is 328.6 N/mm . the yield stress in
 0.5  328.6
 0.5  ys  164.3 N/mm 2
maximum shear theory is

Taking the factor of safety for design equal to two, and key way effect to be 0.75, the permissible
shear stress

τ =σ x due ¿ max shear theory x key way effect ¿

factor of safty
40 | P a g e
τ=164.3 x 0.75
=61.61N/mm2
2

In other form

π 3 π
Te= d τ 230066.44= d3x61.61
16 16

d2=28.79mm from the table standard measurement is 30mm

41 | P a g e
 5.5 Assembly drawing

Figure 5.6 Assembly drawing

42 | P a g e
 5.6CONCLUSTION

This internship program is given to me a great experience, b/c I was gained more
practical and theoretical knowledge, work experience when I was expose the work
place for the next time.

I can generally conclude that this internship program helps to improve and develop
to:-
 Team playing ability skills
 Leadership ability skills and
 Work ethics related issues, etc…

In my project I conclude that chain conveyor are a machine type which used to
convied objects in a proper manner.

But, all conveyors are not transport martials wisely, example roller conveyor .due to
this problem i was tried to design simple chain conveyor this conveyors are more
effective.

It reduces the labor force of the company. Cost of the material, reduces friction and
to increases the rate of production, etc.

43 | P a g e
 5.7RECOMMENDATION

The company should full fill the safety material for the students or it should inform
the university to do so.

The loss of steam at the kettle should be recycled to the next process.
I recommend that The company should have establish a project design, development and
expansion board that able to modify activities and create new ideas and strategies to
improve customer satisfaction based on current needs.
The lay out of the factory is very poor due to this the production rat ,the marital
storing capacity ,the follow of production and the staff co-operative working
interest were very poor. As are result the factory will have different challenges in
order to satisfy its ultimate goal and to be competitive with other factory.

Therefore I recommended that the factory will be change its layout and modify
its better working principle and apply canzone principle in order to the above
problems and archiving its mission and vision.

5.7REFERANCES
44 | P a g e
1 www.wikipedia.com

2 MOHA Soft Drinks factory module

3 A Textbook of Machine Design by R.S.KHURMI AND J.K.GUPTA

4 www.mastercar.com

45 | P a g e