Bahir Dar Instutute Of Technology

Faculty of Electrical Engineerig

Host company Dashen Brewery Share Company
Internship Final Report

Prepared:- by

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 Name and ID Number
Abebe Molla…………0500060
Submitted to Mr Atnafu

Table of Contents

. Brief History……………………………………

Main Customers (End users)……………………………

Vision, Mission , Objective of the Company and value………………….

Main Products and Service of the Company………………………………
Organizational Structure………………………………………………
Key Stakeholders of Dashen Brewery Factory…………………..
Production Process of the Company……………………………………..
4.Overall system component and opration……………………………………

Terminologies Used………………………………………………………………………………….
Programmable logic controller (PLC) …………………………………………………….
Operations and Functions of PLC…………………………………………………
.Input Device…………………………………………………………………………….

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Drive motors....................................................................................................................

Synchronous motor............................................................................................

Induction motor ..........................................................................

pump motor.....................................................................................................................

Servo motor .........................................................................................................................

Work flow of the brew and bottling section……………………………………………………………

.Beer filling and packing ……………………………………………………………………….

Full bottle inspection,priter and caser…………………………………………………………………

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Background of Dashen Brewery Share Company
1.1. Brief History

Dashen brewery was established at the historical town of Gondar and started to supply its products on June2000GC
with the total out lay of birr 350 million at theearly start-up time, it is owned by the amhara national region
rehabilitation or development organization. It's named after Mount Dashen, (Ethiopia's highest mountain elevation
4620 meters), and a home to rare endemic fauna and flora and renewed for its breath taking scenery .
unique two-raw The beer has achieved very high quality standards which earned it a number of certificates
including ISO 9001-2000 and 2008 for Quality Management System Standards and ISO: 14001-2004 for
environmental management system (EMS), in 2011 also awarded Diamond Eye Award for Quality Commitment
and Excellence by Other ways International, and Ethiopian Quality Management awards. Dashen‟s modern plant,
occupying an area of 8.5 hectares, with building area of 12000 square meters was established in the historical town
called Gondar, Ethiopian with an initial capital investment of over 340 million birr. It has a production capacity of
300,000Hl per annum, which expands to 750,000Hl per annum with additional investment of birr 110 million
which sums up its total investment cost of over birr 460 million birr. It is owned by the Amhara National Regional
state Rehabilitation/Development organization. The beer has achieved very high quality standards which earned it
a number of certificates including ISO 9001-2000 and 2008 for Quality Management System Standards and ISO:
14001-2004 for environmental management system (EMS), in 2011 also awarded Diamond Eye Award for Quality
Commitment and Excellence by Other ways International, and Ethiopian Quality Management awards. Dashen‟s
modern plant, occupying an area of 8.5 hectares, with building area of 12000 square meters was established in the
historical town called Gondar, Ethiopian with an initial capital investment of over 340 million birr. It has a
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production capacity of 300,000Hl per annum, which expands to 750,000Hl per annum with additional investment
of birr 110 million which sums up its total investment cost of over birr 460 million birr. It is owned by the Amhara
National Regional state Rehabilitation/Development organization.
The brewery has now 510 permanent &contract employees, out of which 406 &104 are permanent and contract
employees respectively with sexual ratio of 73%male and 27%female. In addition the brewery also creates job
opportunities for 350 daily labor workers. At the pre- expansion period the brewery created job opportunities for
266 permanent &contract employees, without considering temporary employees. In line with this, modern
technology diffusion and vital human resource capacity development work is under taken at all levels.
The Brewery is currently undertaking projects of malt factory to supply the Brewery and other Brewery's With a
sustainable supply of quality malt produced in the unique two-raw barely grown in the high Of the region Amhara.
The project aims to benefit the farmers of the area by integrating them as supplier the Barely for the factory.
Dashen Brewery, the youngest beer factory in the country, is going to plant the second brewery in the central part
of Ethiopia around DebreBirhan town, North Shoa Zone of Amhara Region, 130Km northeast of Addis Ababa.
The ten year old brewery, located in the historical Gondar town, 738 kms north of Addis Ababa, has submitted a
request for 20 hectares of land with a project proposal sent to the DebreBirhan City Administration in December
2011. Dashen‟s administrators plan to build their second beer production canter because they believe the area has a
huge potential in the beer market. It will be the second brewery in DebreBirhan, joining Habesha Brewery Share
Company which has already sent a similar proposal to the city administration. The brewery was established
through an endowment from Tiret. When they begin production from DebreBirhan, it will be easy for them to
reach major market places in the central part of the country because they won‟t have to transport the beer from
Gondar. Currently the brewery has been affected by having to transport its beer long distances. DebreBirhan and its
surrounding area are popular because of their enormous barley supply, which is the major ingredient of beer and
there is an abundant supply of water.

The main products of Dashen Brewery are

Dashen beer
Royal beer
Drought beer (locally called draft beer and cellar).
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1.2 Main Customers (End users)

The end users (customers are every person aged above 18 years old. There is no any limit or boundary in order to
be a customer for Dashen beer. The products are distributed across the country in four regions and three ware
house.The regions are:-
Region 1: covers Amhara, Benishangul and Afar region
Region 2: covers the whole Tigray region
Region 3: covers central and west part of Ethiopia
Region 4: east and south part of Ethiopia
There are three ware houses those are:-
1. Gondar
2. Woldia
3. Addis Ababa
Dashen brewery exports its products to the following countries:
1. California
2. Chicago
3. Australia
4. Israel
5. South Sudan
WEEK TWO

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2 Vision, Mission ,Objective of the Company and Value

2.1 Mission

1. It is an endowment (gift) fund established to contribute for the development of Amhara region by producing
and selling costumer proffered or contribute quality beer at competitive price and generate responsibility
2. To be best Ethiopian beer lead drinks company with sustained revenue growthand consistently improving
returns on invested capital.
3. Employees of the brewery have a fair commitment ownership feeling or especiallythe technical team their
commitment is increasing.

Generally employees in production quality maintenance department are highly committed energetic with fair a
composing
2.2. Vision
To be leader in countries beer industries with respect to quality, competitive price, prospect to high technology
and international orients as well as sample for the overall industrial sector in the country,

To make Dashen the central venue for quality beer celebrities.

2.3 Objective of the Company

To support the socio-economic development of the Amhara Region.

in particular and the overall development wellbeing of the countryin general.
Dashen brewery has customer focused orientation.

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 Dashen brewery has prevalence of accountability.
Dashen brewery has well trained and committed work force.
It gives value for the eco-environment friendly manner.
Economic use of resources.

2.4. Values

This factory supports the socio-economic development of the Amhara Region in particular and the overall
development wellbeing of the country in general.
Dashen brewery has customer focused orientation, prevalence of accountability, well trained and committed work
force. It also gives value for the eco-environment friendly manner and Economic use of resources.

WEEK 3
3.Main Products and Service of the Company
The main products of dashen brewery are dashen beer, royal beer, draught beer (locally called draft beer) and
cellar.
Table 1: The basic difference of draft and bottled beer

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 3.1 OrganizationalStructure

The new organizational structure of DashenBrewery Company looks as shown below in block diagram.

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 Figure 1:

Organizational structure

3.2 Key Stakeholders of Dashen Brewery Factory

Dashen brewer Share Company is owned by the Amhara National Region Rehabilitation /Development
organization and German’s share (recently shared 49% of it).

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3.3 Production Process of the Company

Figure 2: Production process

Main Raw materials for Dashen beer production:
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 - Malt mainly from Belgium
- Hop- for bitterly taste
- yeast
- Water
- Caramel –for flavor and aroma
1. Cleaning refers to
- Removal of dust and other impurities by screening and using dust sucker
- Removal of iron and steel by magnetic separation
- Destining and sorting according to grain size by sifting
2. Mill-star- a tank where wet milling is done.
3. Mash kettle- mashing the malt with boiled water.
4. Lautertun tank –to separate the husk (spent grain) from wort (juice) where water is addedeight times periodically
to get more valuable content of malt juice. The husk is removed to wet strains silo.
5.Weak wort tank-temporary storage of wort for recycling for mashing.
6.Pre-run tank- is used for temporary storage of wort after separation/filtration from lautertun tank.
7.Hop dosing- refers to the addition of hop into wort boiler kettle for another milling to get utilizable hop for the
bitter taste of the beer.
8.External boiler – here boiling is used to stabilize composition of the wort and to extract thevaluable substance in
the hops, in order to give the beer its character flavor and aroma.

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9.Whirlpool tank – the boiled juice is tangentially fed to this tank which cases the wort to beginrotating. Here
injection or sedimentation occurs and the sedimentedtrub is transferred to trubtank before fermentation.
10.External boiler – using glycol, the temperature of the juice (wort), which is about 90 degreecent, is reduced to
about 11 degree cent to make it suitable for the addition of propagated yeast.
11.Fermentation tanks – after cooling oxygen is added and the wort is then pump to this tank,where the yeast is
pitched in.

Week 4
4.Overall system component and opration

The company power supply is 15 kV gained directly from high transmission power lines of EEPCO
substation. This high voltage is transmitted to the two parallel connected three-phase transformers
by copper cable.

The two transformers share the 15 kV load, their working principle is based on the principle of parallel connection
of transformer. The transformers primary winding is star connection and the secondary winding is delta
connection. These transformers step down the supply 15 kV voltage in to the required voltage which is 380V, each
of the transformers have switch gear and also have Change over switch which uses to isolate the transformer when
maintenance is required.

When there is power fluctuation there is reserved diesel A.C generator which generates about 1.8MW and couples
to the transformers by bus coupler. The AC emergency generator is standby and it‟s on/off controlled by timer.
Dashen brewery factory gets electric power from EEPCO as shown below in fig 2.1

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Fig 3 Electric power distribution block diagram

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4.1Terminologies Used

1. Main station or generating station refers to an industrial facility for the generation of electric power. Here the
generator, rotating machine, converts mechanical power to electrical power by creating a relative motion between a
magnetic field and a conductor.

2. Sub-station (with step-up transformers)-refers to a sub-station of ELPA where the transmission voltage is
converted to higher voltage by transformers which is appropriate for transmission over the stretched wire.

3. Transmission lines are used to transfer electric power from main stations to sub-stations and from sub-stations
to distribution areas.
4. Distribution sub-station transfers power from the transmission to the distribution system of Dashen brewery
factory.
5. Dashen brewery power house refers to the main electric power station for the company which comprises two
big step-down transformers, emergency generator, bus coupler, power factor corrector, and other electrical control
elements.
6. Switchgear is the combinations of electrical disconnect switches, fuses, circuit breakers used to control, protect
and isolate electrical equipment‟s in an electrical power system (in Dashen at power house).
Power factor corrector-Power factor correction units consist of capacitors which act as reactive current
generators. By providing the reactive power, they reduce the total amount of power you must draw from the
network. For the same working power (kW) they can reduce the reactive power (kVAr) and the apparent power
(kVA) so that the company will then provide with improved/increased power factor. By this method the power
factor and then the electric power can be stabilized.

4.2. Programmable logic controller (PLC)

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 Definition
Programmable logic controller-is a special form of microprocessor-based controller that uses a programmable
memory to store instructions and to implement functions such as logic, sequencing, timing, counting, and
arithmetic to control machines and processes and is designed to be operated by engineers with perhaps a limited
knowledge of computers and computing languages. PLCs:
I. Are rugged and designed to withstand vibrations, temperature, humidity, and noise
II. Have interfacing for inputs and outputs already inside the controller.
III. Are easily programmed and have an easily understood programming language that is primarily concerned with
logic and switching operations.

Fig 4 Programmable logic controller arregment

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Typically a PLC system has five basic functional components in Siemens‟ automation which is used by Dashen
brewery. These are central processing unit, power supply unit, input-output module, interface module, and
communications interface. The Figure below shows the basic arrangement.

Fig 5 Programmable logic controller arregment

1. The power supply unit: The system power supply plays a major role in the total system operation. It is needed
to convert the mains AC voltage to the low DC voltage (5 V) necessary for the processor and the circuits in the
input and output interface modules. Its responsibility is not only to provide internal DC voltages to the system
components (i.e., processor, memory, and input/output interface modules), but also to monitor and regulate the
supplied voltages and warn the CPU if something is wrong. The power supply, then, has the function of supplying
well-regulated power and protection for other system components.
Generally PLC Power Supply
1. Supplies DC power (mostly 24V) to other modules that plug into the rack.
2. In large PLC systems, this power supply does not normally supply power to the field devices.
3. In small and micro PLC systems, the power supply is also used to power field devices.

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2. The processor unit or central processing unit (CPU): is the unit containing the microprocessor. This unit
interprets the input signals and carries out the control actions according to the program stored in its memory,
communicating the decisions as action signals to the outputs.

The voltage coming from the sensor signals is switched to the pin board of the input device. In the CPU (central
processing unit), the processor works on the program in the memory and queries whether the individual inputs of
the equipment voltage have voltage or not. Dependent on this condition at the inputs and on the program in the
memory, the processor instructs the output device to switch the voltage on the appropriate terminals of the terminal
strip. Depending on the tensile state at the terminals of the output modules, the attached actuators and/or
warninglight are switched on or off. The address counter successively (serially) queries the program memory
instruction for instructions and causes the program-dependent information to transfer from the program memory to
the instruction register. All memory of a process is made up of registers. The control mechanism receives its
instructions from the instruction register. While the control mechanism works on the current instruction, the
address counter pushes the next instruction into the instruction register.
Generally It
i. Is the “brain” of the PLC
ii. Consists of a microprocessor for implementing the logic, and controlling the communications among the
modules.
iii. Designed so the desired circuit can be entered in relay ladder logic form.

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iv. Accepts input data from various sensing devices, executes the stored user program, and ends appropriate output
commands to control devices.
3. Communications interface module: is used to receive and transmit data on communication networks from or
to other remote PLCs which includes internet protocol communication. It is concerned with such actions as device
verification, data acquisition, synchronization between user applications, and connection management.
4. Input and output module: sections are where the processor receives information from external devices and
communicates information to external devices.

Fig 6 the modularized PLC system

The inputs might thus be from switches, or other sensors such as photoelectric cells, as in the counter mechanism
temperature sensors, flow sensors, level sensors, pressure sensors, or the like. The outputs might be to motor starter
coils, solenoid valves, or similar things. Input and output devices can be classified as giving signals that are disc
rete, digital or analog.
Devices giving discrete or digital signals are ones where the signals are either off or on. Thus a switch is a device
giving a discrete signal, either no voltage or a voltage. Digital devices can be considered essentially as discrete
devices that give a sequence of on/off signals. Analog devices give signals of which the size is proportional to the
size of the variable being monitored. For example, a temperature sensor may give a voltage proportional to the
temperature ranges.
5. Interface module: which is used to connect and understand CPU of the incoming input signals and the outgoing
output signals by converting into CPU language. It is of two types:
I. Mounting rack-This is usually a metal framework with a printed circuit board backplane which provides means
for mounting the PLC input/output (I/O) modules and processor. Mounting racks are specified according to the
number of modules required to implement the system. The mounting rack provides data and power connections to
the processor and modules via the backplane.

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II. The bus system- is a collecting line for the transmission of signals. Thus the signal exchange is made in the
automation equipment between the processor and the input and output by a process of the bus system.
The bus consists of three parallel signal lines:
1. Address bus
2. Control
3. Data bus
The addresses on the individual modules are addressed with the address bus.
Data will transfer e.g. from input to output devices with the data bus.
Signals are conveyed with the control bus for the control and monitoring of the execution of functions within the
automation equipment.
4.3 Operations and Functions of PLC
The principal function of the processor is to command and govern the activities of the entire system. It performs
this function by interpreting and executing a collection of system programs known as the executive. By executing
the executive, the processor can perform all of its control, processing, communication, and other housekeeping
functions.
The executive performs: -the communication between the PLC system and the user via the programming device.
It also supports other peripheral communication, such as monitoring field devices; reading diagnostic data from the
power supply, I/O modules, and memory; and communicating with an operator interface.
The main applications of PLCs in Dashen Brewery S.C are industrial automation and control of industrial
equipment‟s.
4.3.1 Basic Principle of operation of PLC
Programmable logic controllers function by interpreting data coming through their inputs and depending upon their
state, turning on/off their outputs. They are programmable via software interfaced standard computer interfaces,
proprietary languages and network options. PLCs function using relay ladder logic programming. Ladder logic
allows programmable logic controllers to perform any command within the loop at any time without executing
previous commands. This allows PLCs to carry on their three basic functions: Control, Input, and Output - as
needed. In addition to controlling output functions, programmable logic controllers are good for compiling data
from many sources and uploading this data into a computer network.

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There are three states of operation of PLC
1. Detect incoming signals
2. Process it
3. Generate outputs to control various devices, it achieves machine control as a result of;
a. Program written in to its memory
b. The power of its CPU

PLC uses binary number system for digital signaling; binary signals can take the value of two possible states.
-Signal state “1”= voltage available = e.g. switch on
-Signal state “0” voltage not available = e.g. switch off
In control engineering, a frequent DC voltage of 24v is used as “control supply voltage”. A voltage level of +24v at
an input clamp means that the signal status is “1” for this input accordingly OV means that the signal status is “0”
In addition to a signal state another logical assignment of the sensor is important. It is a matter of whether the
transmitter is “normally closed” contact or a “normally open” contact.
Contrary to a binary signal that can accept only signal statuses “voltage available = 24v” and “voltage available =
0V”, there are similar signals that can take many values within a certain range when desired. A typical example of
an analog encoder is a potentiometer, which depends on the position of the rotary button (wiper).
Method of representation
There are fewer methods of representation to write the program language among these the first two are commonly
used in the Dashen brewery share company.
a. Statement list (STL) - represents the program as sequence of operation mnemonic abbreviations in the form
of a list. The STL has being written using words which has the following format.
A I 12.0
When A is the operation it means AND operand
I 12.0 is the operand & I is operand ID
12.0 is the parameter of the operand.

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The operation tells programmable controls what to do with the operand .The operand is what a PLC should use to
complicate its task. The parameters indicate the operand adder‟s s5-90u PLC only uses this method of
representation.
b. Ladder diagram (LAD)-Ladder diagram graphically represents control functions with symbols to circuit
diagram. The symbol is basically no (normally open) & normally closed contacts. The s5-90u PLC caries out
instruction of the sty but if we have programmer with display scream. The table shows STL&LAD
simultaneously.

4.4.Input Device

One type of feedback frequently needed by industrial-control systems is the position of one or more components of
the operation being controlled. Sensors are devices used to provide information on the presence or absence of an
object. The term sensor is used for an input device that provides a usable output in response to a specified physical
input. Sensor is a convertor that measures a physical quantity and converts it into a signal which can be read by an
observer or by an (today mostly electronic) instrument. It is a device which receives and responds to a signal. An
electronic sensoris any device that uses electricity to sense a change in something, and then through a voltage
change, send a signal to a device that captures this information. There are input devices which convert one type of

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energy or quantity into electrical analog signal. Sensors that give digital or discrete, that is, on/off, outputs can be
easily connected to the input ports of PLCs. An analog sensor gives an output proportional to the measured
variable. Such analog signals have to be converted to digital signals before they can be input to PLC ports. The
following are examples of some of the commonly used PLC input devices and their sensors.

4.5 Types of Sensors found in Dashen Brewery Control System

Electrical devices

There are many electrical devices that are found in bottling section, utility section and brewery sections of the
company. From those devices backups, photocells, encoders, sensors, and drive motors.

Backup switch

Is an inductive sensor which is used to detect an over load. It is mainly found at the side of bottle conveyor. It
works by using comparator, solenoid and copper conductor. There is a set a current value, when there is an
overload the bottle pushes the conductor and the current is produced through the conductor due to this current loss
the current value at the solenoid deviates from preset current value. This digital current value reaches to PLC based
on this value gives appropriate response to the system.

Photo cell

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It is advices used to detect the presence and absence of bottles or crates. Some photo cells have two different
operational types, light operate and dark operate. Light operate photo eyes become operational when the receiver
"receives" the transmitter signal. Dark operate photo eyes become operational when the receiver "does not receive"
the transmitter signal. It has sender (LED) and receiver (photodiode) parts. These two parts may or may not be
placed at the same place, if sender receiver are at the same place it uses reflectors. The LED emits light and the
photo diode receives this light and change to current signal to input the PLC. Based on this digital signal value
PLC gives the appropriate response through output devices.

Encoder

It is an electrical input device used for synchronization and position control purpose. It operates by pulse counting
that an object moves.

Sensors

Are an electrical input device used to sense different status of a system. There are many sensors in production
system.

Level sensor

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It is a capacitive sensor used to check the status of a container. It is located at the bottom and top of the container
for empty and full inspection. It operates by sensing the change capacitance and Frequency value. When the
dielectric changes, the capacitance value changes this leads to change in frequency.

Temperature sensor

It is a device used to detect the temperature of liquid, gas, etc. It commonly used in motor control applications are
thermostats and thermocouples. A thermostat relies on the thermal expansion/contraction of a bimetal, while a
thermocouple relies on a principle known as the See beck effect. Two dissimilar metal wires are joined together in
a loop with one end being the hot junction; the other being the cold junction. A difference of potential is generated
in the loop in response to temperature change. Each of these devices sense temperature change and then presents a
contact closure for use in a control circuit. Principle and operation of temperature sensor RTD (resistance
temperature detector) works on the correlation between metals and temperature. As the temperature of the metal
increase the metal resistance to flow of electricity increase .similarly, as the temperature RTD resistance element
increase the electrical resistance element increase, the electrical resistance measured in ohm increase.RTD element
are commonly specified according to the resistance in ohm at zero degree Celsius (0℃).the most common RTD
specification is 100ohm at 0℃.platinium the most commonly used metal for RTD element. Theywork by the
combination ofR= Ro (1+∝ (Δ𝑇)) when R↑ 𝑇 ↑ and when R↓ 𝑇 ↓

Pressure sensor

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It is used to detect the pressure level of typically gases and liquids. A pressure sensor usually acts as a transducer it
generates signal as a function of the pressure imposed. When a pressure applied to pressure sensor, the sensor acts
to complete electrical circuit. These types of sensors are also known as pressure switch.

Transducer

It is electro-mechanical devices which convert physical quantities, such as pressure, to a proportional electrical
value, such as voltage or current.

Proximity sensors

It is available in modes using high frequency oscillation to detect ferrous and nonferrous metal object and in
capacitive modes to defect non-metal objects

Principle and operation of proximity sensor

A high frequency magnetic field generated by coil L in the oscillation circuit. When a target approaches the
magnetic field, an induction current (eddy current) flows in the target due to electromagnetic induction. As the
target approaches the sensor, the induction current flow increase, which cause the loud on the oscillation circuit to
increase. Then oscillation attenuates or stops. The sensor detects this change in the oscillation status with the
amplitude detecting circuit, and out puts a detection signal.

Capacitive sensors

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It is a proximity sensors that can be used to detect non-metal objects, such as liquids and plastics an inductive
sensor is a proximity sensor which detects metallic objects without touching them.

Flow sensor

It is a device for sensing the rate of fluid flow. Typically a flow sensor is the sensing element used in a flow meter
to record the flow of fluids. Pressure sensor: measures pressure, typically of gases or liquids.

Conductivity sensors

It is widely used in manufacturing applications. It senses when the conductivity of water (ionization) increases
above the setting value.

Ultrasonic sensors

It generates high frequency sound waves and evaluates the echo which is received back by the sensor. Sensors
calculate the time interval between sending the signal and receiving the echo to determine the distance to an object
(bottle). Proximity sensors are available in modes using high frequency oscillation to detect ferrous and nonferrous
metal object and in capacitive modes to defect nonmetal objects.

Solenoid valves

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It controls the flow of draft beer by closing and opening the valve, which is derived (energized

Principle and operation of solenoid valve

A solenoid valve is electromechanical operated valve. The valve is controlled by electric current through a
solenoid. A two way valve has two port if the valve is open then the two port are connected and the fluid may flow
between two port, if the valve is closed then ports are isolated, if the valve is open When the solenoid is not
energize then the valve is termed normally open (N.O) if the valve is closed when the solenoid is not energize then
the valve is termed normally closed.

Inductive proximity sensors

It is used for non-contact detection of metallic objects. Their operating principle is based on a coil and oscillator
that creates an electromagnetic field in the close surroundings of the sensingsurface. The presence of a metallic
object (actuator) in the operating area causes a dampening ofthe oscillation amplitude. The rise or fall of such
oscillation is identified by a threshold circuit that changes the output of the sensor. The operating distance of the
sensor depends on the actuator's shape and size and is strictly linked to the nature of the material. Inductive sensors
are used to detect metal objects with in specific operating ranges. This object distance is translated into analog
output signal proportional to distance, making these sensors ideally suited for measuring and controlling
applications. The objects operate under the electrical

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Principle of inductance. Inductance is a phenomenon where a fluctuating current, which by definition has a
magnetic component, induces an Emf in a target object. To amplify the devices inductance effect, a sensor wire
twisted into a tight coil and runs current through it.

Figure 7: Inductive proximity sensor

A photoelectric sensor, or photo eye, is a device used to detect the distance, absence, or presence of an object by
using a light transmitter, often infrared, and a photoelectric receiver. They areused extensively in industrial
manufacturing. There are three different functional types: opposed(through beam), retro-reflective, and proximity-
sensing (diffused).

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Figure 8: Photo sensor

Conceptual through-beam system to detect unauthorized access to a secure door, If the beam is broken, the detector
triggers some remote alerting device.

Month two

Week 1

1 Drive motors

There are many electrical motors that are used for different purpose. Such as: ac motors (synchronous and
induction motor), dc motor and servo motors.

1.1 Synchronous motor: - those motors are doubly exited fed type and have direct current in theirfield windings
and ac armature windings. This motor is mainly used at washer machine for the purpose of driving bottle chain
holders.

1.1.1Working principle of Synchronous Motor

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 When the rated-phase voltage is applied to the stator windings, a rotating magnetic field is developed. This
field travels at the synchronous speed. As stated in previous units, the synchronous speed of magnetic field
depends on the frequency of the three-phase voltage and the number of stator poles.
The magnetic field which is developed by the stator windings travel at synchronous speed andcuts across the
squirrel cage of the rotor.
Both voltage and the current are induced in the bars of the rotor winding. The resultingmagnetic field of the
short circuited winding (squirrel cage) reacts with the stator field to create atorque which causes the rotor to
run.
The rotation of the rotor will increases the speed to a point slightly below the synchronousspeed of the
magnetic field set up by the stator.
In other words, the motor is started as squirrel cage induction motor.
The field circuit is now excited from outside source of dc and fixed magnetic poles are set up inthe rotor
field cores.
The magnetic poles of the rotor are attracted unlike magnetic poles of the
magnetic field set upby the stator.
Once the field poles are locked, the with unlike poles of the stator field , the rotor
speedbecomes the same as the speed of the magnetic field set up by the stator
windings. In otherwords, the speed of the rotor is now the synchronous speed.

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 Remember that a synchronous motor must always be started as a three-phase squirrel
cageinduction motor with the dc field excitation disconnected.
The dc field circuit is added only after the rotor accelerates to a value near the synchronousspeed.
The motor will then operate as a synchronous motor.
If an attempt made to start a three-phase synchronous motor by first energized the dc fieldcircuit
and then applying the three-phase voltage to the stator windings, the motor will not startsince the
torque is zero.

Figure 9: Synchronous machine

1.2 Induction motor: - Is a singly fed type motors which carry ac current in both stator and rotor winding. It is a
type of electric motor that converts electrical energy in to mechanical energy in which alternating current from a
power source is fed through a primary winding and induces a current in a secondary winding, with the parts

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arranged so that the resulting magnetic field cause a movable rotor to rotate with respect to a fixed stator. A type of
brushless electric motor in which an alternating supply fed to the windings of the stator creates a magnetic field
that induces a current in the windings of the rotor. Rotation of the rotor results from the interaction of the magnetic
field created by the rotor current with the field of the stator. It is mainly used for the purpose of driving the
conveyer chain and compress.

1.2.1Principle Operation of induction motor

When the 3-phase stator winding are fed by a 3-phase supply then a magnetic flux of constant magnitude but
rotating at synchronous speed is set up. The flux pass through the air gap sweeps past the rotor surface and so cuts
the rotor conductors which, as yet stationery.

Due to the relative speed between the rotating flux and the stationary conductors, an emf is induced in the latter
according to Faraday’s laws of electro-magnetic induction. The frequency of the induced emf is the same as the
supply frequency. Its magnitude is proportional to the relative speed between the flux and the conductors and its
direction is given by Fleming’s Right-hand rule. Since the rotor bars or conductors form a closed circuit, rotor
current is produced direction, as given by Lenz’s law is such as to oppose the very cause producing it. In this case,
the causes which produce the rotor current is relative speed between the rotating flux of the stator and the
stationary rotor conductors. Hence to reduce the relative speed, the rotor starts running in the same direction as that
of the flux and tries to catch up with the rotating flux.

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Figure 10 : Induction motor
1.3 pump motor: it is mainly used to pump fluid and air. Pump motor is the main part of the fluid filling
system that controlled by the control circuit according to the level of the fluid in the tank and drives the fluid pump
to fill the tank, when the fluid level goes below the predeterminedlevel of fluid in the tank.

1.4 Servo motor: this motors is supplied by both ac and dc sources. It is mainly used at the two robotic machine
(caser and UN caser) to control the position of grippers. It is a motor which forms part of a servomechanism, which
is an automatic device that uses error sensing negative feedback to correct the performance of a mechanism. It is
paired with some type of encoder to provide position/speed feedback. Dashen is a brewery company which has
been producing beer for the past 12 years. The raw materials required for beer production is barley, hops, water
&yeast. The quality of these raw materials have a big influence on the quality of final product i.e. beer. Knowing
the properties of the raw material, their effects on the process &product provides the basis for their handling and
processing with such knowledge it is possible to control the whole process. Principle and operation of servo motor

As themotor shaft progresses the encoder knob also rotate as it is coupled with motor shaft with the help of gear
arrangement. As the position of the potentiometer knob changes there will be an electrical signal produced at the
encoder port. As the angular position of the knob progresses the output orfeedback signal increases. after desire

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angular position of motor shaft the encoder knob is reachat such position the electrical signal generate in the
encoder becomes same as of externalelectrical signal given to amplifier.
Week two
2 Work flow of the brew and bottling section

The bottling section is one of the many sections found in the Factory and it is the main and the biggest section in
the production process. As the name implies in this section the action of many operating machine is applied on the
bottles, means from the entry of empty bottle at the inlet up to the outlets of beer filled bottle as a final product.
The overall working process of the bottling section is facilitated by the action of different operating machines with
related to PLC system and a few man powers. The bottling section comprises different types of motors and sensors
that can receive a command from the PLC and helps to operate the different machines in the section.

Dashen is a brewery company which has been producing beer for the past 12 years. The raw materials required
for beer production is barley, hops, water &yeast. The quality of these raw materials have a big influence on the
quality of final product i.e. beer. Knowing the properties of the raw material, their effects on the process &product
provides the basis for their handling and processing with such knowledge it is possible to control the whole
process.

We could summarize the work flow (production process) in block diagram as flow

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Fig11 Block diagram of production processes

2.1 Bottling house

It is one of the biggest section of the company it comprises both mechanical and electrical maintenance
departments. The automation system is also the other parts of the company. Many electrical machines are available
in this section. Those machines are two robotic machines, bottle and crate washer machine, filler machine,
pasteurizer machine and labeler machine. The above machines are controlled by different sensors, photocells,
backups and encoders. The other essential machine that is found in bottling section is PLC (programmable logic
controller) machine this machine takes an input signal from different input devices through
In feed labors put dirty bottles within crate on the roller conveyor then it goes to un caser or the first robotic
machine.
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 2.2 UN caser machine
It is a machine which is used to lift empty bottles from the crate and the crate goes to the crate washer and the
bottle to the bottle washer. For the operation of the robot, the plc checks the states of the conveyor that means crate
overload, in front of un caser, bottle overload and the presence of crates that are ready to enter un caser by three
photocells. And the PLC checks the number of crates on centering frame by two photo cells. When the number of
crates is above and below six the robot stops their operation, but it can be restarted manually by operators. There
are also other photocells on the gripper head that are used as input devices for the PLC to position of crates. In this
robotic machine three encoders are available, that are used as input devices of PLC.

The first encoder controls horizontal movement, the second encode controls the vertical movement of the robotic
machine. The last encoder controls the mechanical pistons that blocks and discharges the crates. There are counters
in the PLC which counts how many bottles can the machine works per hour and is displayed on the screen. The
machine works with master-slave communication systems, there are two masters and many slaves. The master can
communicate with each other but the slaves can‟t. And also the machine works with interrupt driven program
execution i.e. if there are operations which it have to give priority after one program is executed it will
automatically interrupted.

Fig12 UN caser (unloading) machine

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 2.3 Crate washer
This machine is used to wash crates by using water to clean the crate. This is done by using water and applying
high pressure spray from different direction and finally the washed crate become inverted upside down for
removing broken glass and unwanted (dirty) things.
2.4 Bottle washer
This machine is used to wash the dirty bottles by using hot water ,caustic one ,caustic two and fresh water.
Afterwards the labels and all dirty things removed by vacuum pumps. In bottle washer 11 electrical drives are
available from those 7 motors work synchronously by using electrical encoders that used for synchronization to
move the bottle holder chain with the same speed and frequency. The other two motors big 11.5 KW motors used
to adjust two caustic levels. The last two drives used in fed and discharge the 40 bottles with a pulse. In this
machine there are three photo cells the first two photo cells which are located in the in fed part of the machine are
used to detect unwanted materials. The last photo cells used to control the discharge motor in the machine. There
are also temperature sensor and IP positioner to adjust the temperature of two caustics at 80oc.

Fig13 bottle washer machine

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 2.5 Visual inspection
It is used to identify dirty, UN washed, forging (other bottles which is not dashen beer and st.george) and broken
bottles manually.
2.6 Empty Bottle Inspect
It is used to inspect the empty bottles before it goes to filler and cause unwanted production step, the following
parameters are checked. Unfortunately it doesn‟t work properly but it was used to detect the following
Optical (mechanical) gap detection: stops the machine if there is fallen bottles or gaps in bottle flow

Optical detection of too high or short bottles. Faulty bottles are rejected by a pusher installed at the in fed

Contour detection- detection of bottle shapes and bottles whose shape is substantially different from the normal
production bottle.

Glass color detection –detection of bottles which substantially deviate from production bottle with regard to
color or color intensity. Light emitter bottle receiver evaluation color of the bottle

Base inspection, camera technology –a stroboscope lamp illuminates the bottle from below. Alight meter in the
camera sends signal to the control unit which automatically adjusts the exposure time of the camera the light
transmission ratio of the bottle material. The camera takes an image of the bottle base and converts the signal
into digital image data. The digitized image data are passed on via the control unit to the individual evaluation
unit (256 gray scale increments) and are displayed on color monitor. As soon as pre-set threshold values are
exceeded a signal is sent to the rejection unit. A clock pulse generator coordinates camera, light controller
&evaluation unit.
Neck finish inspection, camera technology-it is illuminated from above by a dome –type LED array. The camera
takes an image of the bottle neck finish and converts the signal to digital image data. The digitized image data are
passed on via the control unit to the individual evaluation unit (256 gray scale increments) and are displayed on

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color monitor. As soon as pre-set threshold values are exceeded a signal is sent to the rejection unit. A clock pulse
generator coordinates camera, light controller &evaluation unit.

HF caustic detection-the bottle passes the high frequency transmitter the antenna integrating the high frequency
receiver. Measures the electronic conductance of the various media. The signals are passed to the evaluation unit if
the value measured exceeds the set limit value a fault is registered, the rejection unit is activated.
Week three
3.Beer filling and packing

3.1Beer filler machin

This is a mechanical filling machine; in order to fill bottles.
First evacuation-control mechanism number 1 opens the vacuum valve. This forms a connection between the
container and the vacuum channel. The lift cylinder presses the container so that it is air tight. The air in the
bottle is sucked into the vacuum channel.

ntrol thCO2 flushing –control mechanism number 2 opens the gas needed to allow gas to flow from the product
bowl, through the vent tube and into the container.

Second evacuation-(only for machines containing double pre-evacuation) control mechanism number 3 for the
second evacuation opens the vacuum valve. This forms a

connection between the container and the vacuum channel, extra gas mixture in the container is sucked into the
vacuum channel.

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Pressurizing-control mechanism number 4 is made up of two parts; the first part is pre settler. This moves the
control lever from the closed to the neutral position. The second part then opens the gas needed to allow gas to
flow from the product bowl into the container. The container is completely pressurized as soon as the container
is subjected to the same amount of pressure as is present in the product bowl.

Filling-the product valve opens automatically as soon as the container is subjected to the same amount of
pressure as is present in the control product bowl. The product flows into the container and the gas in the
container escapes through the vent tube and back into the product bowl. Control mechanism returns the control
lever to the neutral position as soon as the bottle has been slightly filled. The CO2 valve would automatically close
to stop the CO2 being lost.

Packing-whenever the motor starts working the magnet turned on. The dc motor will start picking the corks and
then these corks transferred into the filling and packing machine. The packing machine is made to precisely fit
with the size of the cork if the cork is not in its proper position the machine will adjust in its proper size.
In this machine there are 3 proximity sensors. The first one checks the presence of bottles that is ready to
pressurizing one. The second proximity sensor is located on before beer filling that checks broken bottles and the
3rd one check to refuse the entry of broken bottles. In addition to this there are also in feed monitor and encoder.
The in feed monitors are photo cells that control the position of bottles at the in feed part and the encoder is used to
coe movement of the bowl.

Fig14 filler machine

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 3.2 Pasteurizer machine
Pasteurizer means of killing micro-organisms in an aqueous solution by heating. Thus if beer is exposed to higher
temperature the micro-organism contained in it are killed in short time. It is undesirable to use a high temperature
because the beer then envelops bread like flavor, the pasteurizer flavor if however the high temperature is
maintained for only a very short time the pasteurization flavor is not developed. The basic aim of pasteurization is
for the shelf life of beer. The beer is pasteurized at the temperature of 66oc, but this temperature is reached
progressively (i.e. 23 oc, 44 oc, 54 oc, 66 oc) and decrease gradually for the temperature adaptation of bottles. In
this machine there are many electrical devices such as IP positioner temperature sensor force transducer,
manometric switch, level transmitter and drive motors. Temperature and IP positioner is used to adjust the
showering water, force transducer used to safe operations of the conveyor. It senses the gear force and changes this
non electrical value to electrical signal for the operations of the drive motors. Level transmitter is used to control
the level of water in the pump. Manometric switch used to sense the pressure level of pumped water for the
safeopretion operation

Fig 16 pasteurizer machine

Labeler
It is an important machine which is found in bottling section that contains
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 3.3 Labeler
It is an important machine which is found in bottling section that contains label marker. The label marker
accomplishes its task with the aid of in feed and discharge worms and gears which can fit to the bottle size &
shaped to stamp the labels. Every bottle is provided with at two levels body and neck labels. The labelers are used
to differentiate the factory products among others.
This machine works with different sensors and encoders to control the overall functionality of labeling process.
There are two proximity sensors, two photocells, counter, encoder and different derive motors. The first proximity
sensor that is located at the in feed part checks the gap and positions of bottles, the second one checks the presence
of crown and the two photocells used to check body and neck label of a bottle. The counter is used to count the
normal, under fill and over fill bottles that are displayed on the control panel touch screen. The encoder that is
located on the bottom of the machine which is used to tell unwanted bottle reached to the pusher. The labeling
process is performed by the help of the glue (which is heated by glue heater at 35°C) and lubricates the worm &
gear for the sticking purpose during stamping of labels on the bottle the labels are given as an input to the bottle by
the help of high pressure. The labeler has maximum labeling capacity of 48,000 bottles per hour.

Fig17 labeller machine

Week four
4. Full bottle inspection,priter and caser

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 4.1 Full bottle inspect (FBI)
This machine located after labeler machine that controls the quantity of the beer that reaches the customer and
checks the following parameters: - crown and un crown corks, under filled and over filled bottles, whether the two
papers on the neck and body present having the trade mark (i.e. dashen beer) of the company attached to the filled
bottles or not.
The body and neck labels are checked by sensors which sense the gamma rays. If one of the above parameters is
not satisfied the bottle will be pushes by pusher i.e. it will not pass to the next stage.
4.2 Printer
It is an ink jet printer type which helps to print production date on the bottles. This machine has an interrupted
power supply to operate the machine fast.
4.3 Caser
This machine is used to load filled bottles on the crates. There are different electrical devices that are integrated for
the operations of this machine which are intended to specific task. These
Dashen Brewery are mechanical switch, sensors, photoelectric cell, encoders and proximity switches. The
applications of those electrical devices that listed above function as the same as in un caser robotic machine. The
proximity switch used to check whether the filled bottles are fully placed on the conveyor or not and the other
sensor makes sure that six crate are ready to accept the filled bottles, if the crate is less than six the caser will stop.
The other sensors check whether the filled bottles are arranged exactly to fit with the holes of the machine. There is
also another sensor which used to check other unwanted materials are present in the washed cask. If there are
unwanted materials the machine will stop.

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 Fig18 caser machine
4.3 Keg machine
In this machine two processes are accomplished sterilizing the keg and filling the sterilized keg with draught.
Sterilizing is performed by the help of the steam cylinder and it uses to kill micro-organisms in the keg. The filling
process are accomplished by the help of draught filler closes the keg by the counter pressure principle. Just after
filling the draught filler closes the keg after this it becomes ready for user. The text display on the screen of this
machine helps to operate the machine effectively and efficiently. There are different photocells and an electric
weight balance work integrated with electro-pneumatic pusher that pushes under and above weighted kegs. The set
weight of draught is 40Kg that means the beer weighs 30 kg and the keg weighs 10kg. If it is less or more than the
under filled draught beer will be pushed by electron-pneumatic pusher.

Fig19 Keg machine

Conveyor: this is mechanical equipment that is used to transport both the bottles and crates. There are many
electrical devices such as photo cells backups and gridline that is used to control the movement of crates and
bottles when there is an overload.

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Glide liner: a device which is located before EBI and labeler the applications of this devices is to guide the bottles
that comes in many lines into a single line. This is done by varying the speed of conveyors. It combines bottles
from multi-lane conveyors to a single-lane conveyor, using a straight chain conveyor, and 10° to 12 ° inclined
conveyor.
Purpose of combining: To hand over the bottles from the intermediate conveyor to the in feed worm of the parent
machine without gaps.
To minimize the pressure on the in feed worm

To minimize the noise generated during combining of the bottles

To separate glass fragments and fallen bottles from production flow of bottles.
conclution

The overall internship program is very interesting for me. I have got something including practical and theoretical
knowledge. But, there were some challenges that we personally encounter during my two month duration in the
company. I were happy and effective because I gained basic skills both in practical and theoretical aspects. On our
staying in dashen brewery during internship program has helped us to improve all my personalities just like
interpersonal communication skills and our team playing skills. Our task during this internship was to observe
electrical equipment and understand their methods of operation. Based on the major findings presented above it is
easy to understand that internship has a great significant in up grading students‟ theoretical knowledge and
improve practical skill. We can generally conclude that this internship program helped me to improve and develop
us:
Practical and theoretical knowledge

Interpersonal communication skills

Team playing ability skills

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Leadership ability skills and

Work ethics related issues, etc…

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