ABSTRACT

This report is based on the knowledge acquired during a full month of training. This report summarizes our
training in Shamlan industry and contains the theoretical and practical knowledge gained during training
involving the construction and operation of machines and other components. We have accumulated
experience in solving engineering problems, which is the result of applying a large amount of information
obtained during five years of hard work in the Faculty of Engineering. This report represents the problems
that have been solved by us as mechatronics engineers. Some of such problems are listed inside this report.
Now, we have more confidence to work in any company or any industrial that related to our field of
mechatronics.
Always remember, the safety first! We have a background about safety from the mechatronics course,
so when we have observed industrial safety signs at Shamlan factory, we have understood them correctly.
INTRODUCTION

 About Shamlan
Shamlan Company, also known as Arwa Mineral Water Company, is considered as the best and well-
known water company in Yemen. It was established in 1978. As the water of Shamlan is the best water
in Yemen that have high quality, we have chosen Shamlan industry including some reasons. The quality
control unit in the industry is very organized and continuation as the samples are taken to the lab at
specific precision. Shamlan has applied a certificate attesting to its high quality and purity. The
company has won the European Quality Award twice. One from Madrid in 1988 and the other from
Geneva in 1988. The company now has second facility in Hodeida with higher production capacity.
The company has a workforce of about 400 employees and 100 contractors.

 The vision of Shamlan Factory

To be the leader in producing pure natural water at the highest quality and international standards in
Yemen and the region.

 The mission of Shamlan Factory

Producing clean, healthy, bottled water in line with international quality standards through the use of
the latest technologies in water purification and preparation in order to meet the needs of customers and
the market. Full commitment to the standards of occupational safety, quality, teamwork, continuous
development, matching everything new in our field and a sense of social responsibility.

 Aims
1. Produce the healthiest and purest water that conforms to international quality and safety
standards.
2. Commitment to professional safety and social responsibility.
3. Team work.
4. Transparency.
5. Technical competence.

 Shamlan Products Overview

Unlike other water companies Shamlan has a natural resource for its water due to its area where it is
located and surrounded by mountains of Wadi -Dhaer which gives the best quality of pure natural
Water.
Shamlan has three production lines (A, B, C) to produce water in two different size of bottles: two lines
of small bottle with 750 mL size and one line of large bottle with 1.5 L size. The average capacity of
each production line is 20000 bottles per hour, as the production lines are run 24 hours a day.
Table 1.1 Packing Standards

 Quality and water supply

Pure natural water

Arwa Mineral Water Company (Shamlan) is pure,
natural water and is guaranteed to be the highest quality
and purity water. Arwa Mineral Water Company has
been the leader in water extraction from wells in Yemen
for more than 30 years.

Modern techniques
Over the past years, Arwa has continuously used new
ways to improve and upgrade the equipment used in its
factories. The company has always been interested and
still interested in acquiring the latest technologies.
 Professional staff
Qualified and qualified staff monitors the quality of drinking water that
meets WHO standards regularly.

Awards obtained by the company

Company of the year 2013

Arwa Mineral Water Company was rated as the company of the year
2013 and one of the best investment companies in Yemen and its
product Shamlan water as the best water in Yemen.

Investment Award 2012

Arwa Mineral Water Company won the Investment Award for 2012
as one of the best investment companies in Yemen.
 European Grand Prize for Quality
Arwa Mineral Water received the European Grand Prize for
Quality for its Shamlan water product twice. The first was from
Madrid in 1988, and the other from Geneva in 1998.

 Constructions/Operation of Shamlan Factory

All production lines are manufactured from the German company Krones. Krones was founded in
1951. Krones provides its customers with all the machines and production lines, as well as the
components, internal logistics and IT solutions that customers need for their production.
Besides Krones, there is another Italian machine for ordering and moving the packages (4 packages
up each other).

Water Treatment System

It can effectively get rid of muddy organic matter, iron, manganese and oxide, filter suspended
substance, colloid, remained oxygen of microorganism and some of heavy metal ion in the water,
reduce the hardness of the water to make all specifications of the water quality fully meet the state
fresh water standard of fresh drink water.
The production line is constructed by:

 The Contifeed station

1. Preform hopper
2. Elevator
3. Intermediate conveyor
4. Roller sorter
5. Return conveyor
6. Feed rail
7. Control cabinet
8. Operator panel
 Figure 1.1 The Contifeed station

Method of operation
The Contifeed is infinitely adjustable and gently handles any preform size. A preform tipper dumps the
supplied PET preforms into the preform hopper of the preform feed system. From there, an elevator conveys
the preforms without pressure to the roller sorter via intermediate conveyors. There, they are oriented by
two rollers running in opposite directions and the feed rail transports them to the blow moulder. Any
preforms which have not been sorted are automatically rejected and conveyed back to the dump chute.
The output of preforms is nearly bout 48,000 preforms/h

 Heating and moulding station

The Contiform operates according to the two-stage process in which PET preforms (Capsules) are
blown to form bottles. To do so, the Capsules are first carried through a modular linear oven which
has been heated up to its optimum processing temperature. Capsules are taken throw a stage of high
temperature up to 3000 W (heated by 13 heaters, each heater has 9 leds).
They are then transferred to the cam-controlled blowing wheel where compressed air and a
particularly economic application of energy are used to blow-mould them into bottles.
 Filling and Capping station
o The bottles are fed to the machine via the infeed.
o In the machine, the bottles are positioned under the filling valves and filled.
o Afterward they are transferred to a capper, where they are capped.
o The bottles then exit the machine through the discharge.

1. Operator station
2. Discharge
3. Starwheels
4. Infeed
5. Guards
6. Control cabinet
7. Carrousel
8. Capper
Figure 2 Filling station

Method of operation
The machine is operated from the operator station. The bottles exit the machine through the discharge. The
transport devices are mounted on the starwheel columns. The bottles enter the machine through the infeed.
The guards protect persons against injuries while the machine is in operation. Valve manifolds and pipe
system. Processing and operating materials are supplied to the machine via the valve manifolds and pipe
system. The control cabinet contains the machine's electrical components. The filling units are located in
the top part of the carrousel. The carrousel drive is located in the bottom part of the carrousel. The capper
caps the filled bottles.
 1. Bottle discharge with conveyor
2. Bottle stop
3. Infeed worm
4. Infeed starwheel
5. Carrousel with filling units
6. Carrousel discharge starwheel
7. Capper
8. Machine discharge starwheel
9. Bottle discharge with conveyor

Bottle handling:
 When the bottle stop is released, the bottles are transported on a conveyor through the bottle infeed
to the infeed worm.
 The infeed worm increases the spacing between the bottles until it corresponds to the pitch of the
infeed starwheel and the spacing between the filling units.
 The bottle filling units are installed on the carrousel. During operation, the carrousel rotates
together with the filling units.
 The carrousel picks up one empty bottle per filling unit from the infeed starwheel and transfers it
to the discharge starwheel, once it has been filled.
 The bottles are fed via the discharge starwheel to the capper, where they are capped.
 Afterward the bottles are transferred via the discharge starwheel to the bottle discharge.

 The labelling Station

1. Infeed worm
2. Infeed and discharge star wheels
3. Curved guides
 4. Bottle plates
5. Centering heads (in case of open bottles)
6. Gluing device: pump, glue roller

Method of operation
Labels are rolled with two rolling machines (one is labeling). Labels are marked by color (where it should
be cut) so the color sensor gives signal to the knife and cut equally labels for each bottle. The glue that used
for labels needs a heat 165℃. Last stage is the packaging.

 Packaging Station
sorting bottles by specific numbers of bottles that has to be packed (20 bottles for each package). There is
a machine produces air with high pressure that helps to pull boxes and cover bottles.
  Processes
The production process passes through the sections specified below:

The nomination processes

At this stage, mixed impurities are blocked while water is pumped from the wells
through pre-filters and this process is carried out in several tanks.

Purification process
In this process, the water undergoes a more accurate cleaning process with the
help of sterilization with a fine filter. The water is sterilized as it is pumped into
sophisticated ultraviolet compartments. Then the water undergoes ozone
treatment.

Sterilization process
This stage witnesses the most advanced sterilization process using a very
advanced system according to the standards of international standards.

 Bottle and cap manufacturing

Bottles and lids are made in the process. This section is equipped with special machines and it
automatically takes us to the third and final stages of this course

Fig (8): Bottles and cap manufacturing

 Packaging
In this final stage, many automatic processes occur from filling the bottles with pure water, to covering
the bottles with lids, then pasting the stickers onto the bottles and placing them in the boxes.
Fig (9): boxes

Finally after passing through all operations that occur in each production line and understanding steps
and actions happen in each operation here the plan which summarize the all operations.