Internship Report

ARBA MINCH UNIVERSITY
SAWLA CAMPUS
COLLEGE OF ENGINEERING AND AGRO-INDUSTRIAL

TECHNOLOGY
DEPARTMENT OF ELECTROMECHANICAL ENGINEERING

(B.Sc.)
INDUSTRIAL INTERNSHIP REPORT
HOSTING COMPANY: AQUA ADDIS BOTTLED WATER

COMPANY - ASKU Plc.
FROM JULY 01, 2022 - OCTOBER 30, 2022 (FOUR MONTHS)
BY: MILKESA TEREFE BANGO
ID No: RAMIT/1314/11
ACADEMIC MENTOR: Mr. UMAR RESHID
COMPANY SUPERVISOR: Mr. GUDETA BARI
NOVEMBER 2022
SAWLA, ETHIOPIA
BACHELOR OF SCIENCE DEGREE IN ELECTROMECHANICAL ENGINEERING, ARBA MINCH UNIVERSITY
DECLARATION
I, Milkesa Terefe a student of Arba Minch University, Electromechanical Engineering
department hereby declare that this Internship Report is submitted to the partial fulfillment of
the internship program during the last four months in Aqua Addis bottled water company-Asku
plc, carried out from July 01, 2022 - October 30, 2022, for four months under the supervision
of instructor Mr. Umar Reshid, Department of Electro-Mechanical Engineering, Arba Minch
University Sawla Campus, Ethiopia.
I also declare this report is my original and individual work and the content of this document
has never been presented or submitted to any other institution. However, citations, quotations,
and references to other people’s work or sources of information used have been given. All
relevant resources of information used in this paper have been duly acknowledged and believed.
Any part of this report has not been reported or copied from any report, or project of the
university or others.
Milkesa Terefe Bango RAMIT/1314/11

Name of student ID Number Signature
Approval of the Academic Mentor:
This is to certify that the above statement made by the students is correct to the best of my
knowledge and belief. This report has been submitted for presentation with my approval.
Internship Report for Arba Minch university Sawla campus Electromechanical engineering
department.
Mr. Umar Reshid ______________ ______________

Name of mentor Signature Date
Members of the Examining Board:

Name of examiners Signature Date
1. Rajkuamr Jonnakuti ________ ___________

2. Ashenafi Belihu ________ ___________
FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

I
ACKNOWLEDGEMENTS
First and foremost, praises and thanks to God, the Almighty, for His showers of blessings
throughout my internship work to complete the report successfully. Secondly, I would like to
express my genuine thank to my advisor, Mr. Umar Reshid, for his invaluable comments,
insights, and advice on my internship program. My special thanks also go to my dad, Pastor
Terefe Bango, and mom Obse Kebeba not only for this study but also for the motivation and
commitment in my entire life. Also would like to say thank you to my brothers, Structural
Engineer Marsimoyi Terefe, and Mr. Olani Terefe for those tremendous helping me. Finally, I
would like to thank the participants or the operational employees of Asku plc, especially my
company supervisors, Production Supervisor Mr. Gudeta Bari, Electrical Engineer Fikir Mihret,
Electromechanical Engineer Tesahaleni Yalew, Electrician Lema Diriba, Mechanic Dejene,
Mechanic Abebe Asmamew, Electrician Tadese, and Operator Hailu in my survey who have
willingly shared their precious time during the internship program.

II
EXECUTIVE SUMMARY
This report is about to explain what I did and learned during my internship period at Asku plc.
As the main purpose of the internship is to learn by working in a practical environment and to
apply the knowledge acquired during the studies in a real-world scenario to tackle the problems
using the knowledge and skill learned during the academic process. In my hosting company I
have tried to see how machines operate, why lose their function and what their functions are,
maintenance of machines, practices in the electrical workshop, practice in the mechanical
workshop, practice in control sections, and other work has been done. This internship report
has an introduction and background of the company, my overall internship experience, my
specific work, the overall benefits I gained from the internship, and an overall conclusion and
recommendations for the company. The internship was very interesting and a good opportunity
to test my selves. It helps me to predict and prepare my selves for the future about what is going
to be doing at the workplace, how to work and collaborate with people what should be the
interaction between leader and worker look like. Furthermore, I have done my project on the
design, simulation, and implementation of an automatic FG production counter using an
Arduino Uno microcontroller. It provides me to have confidence and confirms that things are
possibly done by trying to do with my best efforts. In general, the most important in an
internship program is that the student should truly spend their time with the spirit to learn the
practical orientation of the theoretical study frame.

III
TABLE OF CONTENTS
DECLARATION ..................................................................................................................................... I
ACKNOWLEDGEMENTS .................................................................................................................... II
EXECUTIVE SUMMARY ................................................................................................................... III
TABLE OF CONTENTS ....................................................................................................................... IV
LIST OF FIGURES ............................................................................................................................... VI
LIST OF TABLES ................................................................................................................................ VII
LIST OF ACRONYMS ....................................................................................................................... VIII
CHAPTER ONE ..................................................................................................................................... 1
INTRODUCTION .................................................................................................................................. 1
1.1. Company Background and Overviews ........................................................................................ 1
1.1.1 Background of the organization ............................................................................................. 1
1.1.2 Description of the organization .............................................................................................. 2
1.1.3 Quality and food safety policy of Asku plc ......................................................................... 3
1.1.4 Vision of the Company .......................................................................................................... 4
1.1.5 Mission of the Company ........................................................................................................ 4
1.1.6 Core value of the Company ................................................................................................... 4
1.2 The main product, service, and management of the Asku plc ...................................................... 5
1.2.1 Industries under ABIG (Asku and Berhane Investment Groups) managements .................... 5
1.2.2 Main products of the organization ......................................................................................... 6
1.3 Main customers ............................................................................................................................. 7
1.4. Organizational structure ............................................................................................................... 8
1.5 Over all Organization Workflow .................................................................................................. 9
1.5 .1 Process flow chart ................................................................................................................. 9
1.5.2 Process step description ....................................................................................................... 12
CHAPTER TWO .................................................................................................................................. 14
MY OVERALL INTERNSHIP EXPERIENCE AND MY SPECIFIC WORK................................... 14
2.1 The way I got into the company.................................................................................................. 14
2.2 Why do I select this company’s .................................................................................................. 14
2.3 Working section of the company ................................................................................................ 14
2.4 Section of the company I have been working In ......................................................................... 15
2.4.1 Nitrogen plant room ............................................................................................................. 15
2.4.2 Mechanical workshop .......................................................................................................... 17
2.4.3 Electrical workshop.............................................................................................................. 22
2.4.4 Air Compressor room (AC room) ........................................................................................ 27
2.4.5 Powerhouse room (Utility)................................................................................................... 29

IV
2.4.6 Power distribution and motor starting method Section ........................................................ 31

2.4.7 Water treatment room .......................................................................................................... 34
2.4.8 Production room................................................................................................................... 35
2.4.9 Control room ........................................................................................................................ 38
2.5 Workflow in the section of the company .................................................................................... 46
2.6 Work tasks that I have been executing........................................................................................ 47
2.7 Work pieces ................................................................................................................................ 47
2.8 Electromechanical Engineering Methods, Tools and Techniques I Have Been Using While
Performing my Work Tasks .............................................................................................................. 47
2.8.1 Electromechanical devices and components ........................................................................ 47
2.9 The challenge I have faced during my Internship Program ........................................................ 62
2.9.1 Challenges ............................................................................................................................ 62
2.9.2 Solutions .............................................................................................................................. 62
CHAPTER THREE .............................................................................................................................. 63
THE OVERALL BENEFITS I GAINED FROM THE INTERNSHIP ................................................ 63
3.1 Knowledge and Acquaintances Acquired ................................................................................... 63
3.1.1 Technical Skill I Gained ...................................................................................................... 63
3.1.2 Management skill I gained ................................................................................................... 63
3.1.3 Acquaintances I Acquired .................................................................................................... 64
3.2 In terms of Improving Practical Skill .......................................................................................... 64
3.3 In terms of upgrading my theoretical knowledge ....................................................................... 65
3.4 In terms of improving my team playing skills ............................................................................ 65
3.5 In terms of improving my leadership skills ................................................................................ 66
3.6 In terms of understanding about work ethic, industrial psychology, and related issues ............. 67
3.6.1 Personal Ethics ..................................................................................................................... 67
3.6.2 Professional Ethics ............................................................................................................... 67
3.7 In terms of entrepreneurship skills .............................................................................................. 68
3.8 In terms of improving my interpersonal communication ............................................................ 69
CHAPTER FOUR ................................................................................................................................. 70
OVERALL CONCLUSION AND RECOMMENDATIONS FOR THE COMPANY ........................ 70
4.1 Conclusion of internship program............................................................................................... 70
4.2 Recommendation ........................................................................................................................ 71
4.2.1 Recommendation for the university ..................................................................................... 71
4.2.2 Recommendation for my internship hosting company ........................................................ 71
REFERENCES ..................................................................................................................................... 74
APPENDIX: Certification of Completion ............................................................................................ 75

V
LIST OF FIGURES
Figure 1. 1 Asku Plc Actually and Map view ......................................................................................... 2
Figure 1. 2 Different size bottle finished good product at Asku plant two ............................................. 7
Figure 1. 3 Different size bottle finished good product at Asku plant one ............................................. 7
Figure 1. 4 Process of customer supply line of the company.................................................................. 8
Figure 1. 5 Organizational structure of Asku plc in block diagram (I have used Wondershare
EdrawMax Software) .............................................................................................................................. 8
Figure 2. 1 Overview of Nitrogen Plant room of Asku Plc .................................................................. 16
Figure 2. 2 Practically controlling nitrogen plant at standardized parameter ....................................... 17
Figure 2. 3 Practically working by Lathe Machine in Mechanical Workshop ..................................... 18
Figure 2. 4 Practically working by Milling Machine in Mechanical Workshop................................... 19
Figure 2. 5 Practically working by Drilling Machine in Mechanical Workshop .................................. 21
Figure 2. 6 Commands and Controls of Computer Numerical Control (CNC) Machine .................... 21
Figure 2. 7 Practically Rewinding of Induction motor in Electrical Workshop ................................... 22
Figure 2. 8 Motor Winding Diagram [8]............................................................................................... 24
Figure 2. 9 Induction motor tag reading for rewinding ......................................................................... 25
Figure 2. 10 Overview of air compressor room .................................................................................... 28
Figure 2. 11 Overview of utility room .................................................................................................. 30
Figure 2. 12 Practically working of motor starting method in control room ........................................ 31
Figure 2. 13 Power and Control circuit of DOL .................................................................................. 32
Figure 2. 14 Power and Control circuit of star-delta starter .................................................................. 34
Figure 2. 15 Blow Molding Machine .................................................................................................... 36
Figure 2. 16 Workflow and control system of Blower Machine........................................................... 36
Figure 2. 17 Palletizer ........................................................................................................................... 38
Figure 2. 18 Control Devices of Asku Plc ............................................................................................ 38
Figure 2. 19 Programmable logic controller structure and functioning ................................................ 39
Figure 2. 20 Practically control training on Human Machine Interface................................................ 40
Figure 2. 21 Programmable logic controller (PLC) software controlling system ................................. 48
Figure 2. 22 Practically control training on Programmable logic Controller........................................ 53
Figure 2. 23 Practically control training on HMI of Filler Machine ..................................................... 57
Figure 2. 24 Coupled star-wheels ......................................................................................................... 58
Figure 2. 25 Transfer star wheel ........................................................................................................... 59
Figure 2. 26 Pneumatic system of filling machine................................................................................ 61
Figure 2. 27 Capper chute machine ...................................................................................................... 61

VI
LIST OF TABLES
Table 1.1 Process of production flow chart .............................................................................. 9
Table 1.2 Process of production step description ................................................................... 12
Table 2.1 Auto run system of Blower machine data ............................................................... 53
Table 2.2 Details of Air Pressure Alarm Setting .................................................................... 54
Table 2.3 Oven data ................................................................................................................ 54
Table 2.4 Heater data .............................................................................................................. 55
Table 2.5 Details of Angle setting .......................................................................................... 55
Table 2.6 Options data ............................................................................................................ 55
Table 2.7 Filling machine technical data ................................................................................ 57

VII
LIST OF ACRONYMS
ABIG Asku and Berhane Investment Groups
AC room Air Compressor room
AC Alternating current
CIP Cleaning Internal part
Cl2 Chlorine
CSD Carbonated soft drink
DC Direct current
DOL Direct On-Line Starter
EEPCO Ethiopian electric power corporation
FG Finished Good
HACCP Hazard analytical critical control point
ISO International Standards Organization
N2 Nitrogen
NC Normally closed
NO Normally open
O3 Ozone
PET Poly Ethyl Terephthalate
Plc Private limited company
PLC Programmable logic control
QA Quality Analyst
RM Raw material
RO Reverse osmosis
TDS Total Dissolved solid

VIII
CHAPTER ONE
INTRODUCTION
1.1. Company Background and Overviews
Asku plc is one of the industries under ABIG (Asku and Berhane Investment Groups) engaged
in the manufacturing sector headquartered in Addis Ababa Ethiopia.
Asku plc, mainly focused on the food and beverages line of business strives to become the
leading food and beverages company in Ethiopia by making food and beverages that are
people's preferred choice and at the same time build a high performing organization which will
play a key role in making Ethiopia food and beverages exporting nation. Asku plc belongs to
the set of companies being managed through ABIG Management Services plc. Asku's
leadership made the strategic choice to continually invest in ensuring the company's long-term
future and market dominance, most notably evident in its vertical integration to its sister
companies providing its main production inputs [1]. This has propelled the company in to
becoming the market leader in the bottled water segment with a dominant position in a highly
competitive market and continuing to innovate and shape market conditions. Asku produces
Aqua addis, the most popular bottled water brand in Ethiopia, known for its quality and purity,
loved by many and available nationwide. Asku is also the exclusive franchise bottler for all RC
brands of RC Cola International, a division of Cott beverage USA, within the east African
region. It also bottles and manufactures the famous Ethiopicana juice in different flavors.
1.1.1 Background of the organization

Asku plc is established in the year 1999 G.C in Addis Ababa, Ethiopia by Ethiopian
shareholders (ABIG). Now, both our carbonated soft drink and juice are produced using USA
concentrate imported through our franchise agreement with cott Beverage Inc, which is a
company based in Columbus, Georgia, USA. Asku plc is the exclusive bottler of Cott product
which is the world largest supplier of private label CSD for retailers with approximately 4,000
employees. Cott operates soft drink, Juice, water, and other beverage bottling facilities in the
United States, Canada, the United Kingdom, and Mexico and sells beverage concentrates in
over 50 countries around the world [2].
Asku plc has two separate facilities in Saris and Burayu under construction for edible oil
refining and dairy product processing.

1
Figure 1. 1 Asku Plc Actually and Map view
Asku plc is an industry engaged in the manufacturing sector with the aim of becoming the
largest food and beverage company in the country.
1.1.2 Description of the organization
Asku plc is a manufacturer of bottled Natural Spring Water, bottled carbonated Spring
Water, Fruit Juice, and Carbonated Soft Drink Products and includes product packing and

2
manufacturing, product storage, the processing of sales orders from Yehule Gebeya, as well
as vehicle loading and shipment.
1.1.3 Quality and food safety policy of Asku plc
Asku plc Management Team is committed to providing its Customers & Consumers with
products that consistently meet their Quality & Food Safety expectations by developing,
implementing, and maintaining a Quality and Food Safety Management System which
complies to international standards.
It is also coming with environmentally friendly packaging, reducing its carbon footprint
for a more sustainable environment.
With an ISO Certification ISO 22000:2005, Aquaddis meets local and international
standards of quality.
It is the only bottled water brand in Ethiopia that consistently meets rigorous annual quality
and taste inspections by the United States Army.
Asku plc is committed to the following Principles.
To ensure the Top Management demonstrates Leadership and commitment
with respect to Quality and Food Safety Management System
To ensure the appointment of Multifunctional Quality and Food safety Team
who will foster communication with regards to any quality issues and who
will implement and maintain Quality and Food Safety Management System at
all levels.
To ensure Customer Focus in that I consistently meet the requirements and
expectations of our customers, as well as Customer satisfaction and statutory /
Regulatory compliance are measured and communicated throughout Organization.
To effectively display Leadership of the Top Management System by defining and
communicating its policy, which is supported by measurable objectives and
provides the resources required to meet them.
To ensure development of people through training and participation of people to
improve performance, ownership and understanding of customer requirements.
To ensure that an effective Traceability System is established throughout the
Supply Chain.
To ensure that all Hazards are controlled, analyzed, and assessed effectively based
on the HACCP plan.

3
To ensure that all potentially Unsafe products will be evaluated prior to any
release decision being made.
To ensure Externally Provided Service through identifying and selecting suppliers
who will assist them to achieve common objectives.
To strive for Continuous Improvement by developing and maintaining a culture of
Executional Excellence.
1.1.4 Vision of the Company
❖ To become the leading food and Beverage Company which will play a key role in
making Ethiopia food and beverage exporting nation.
❖ To adequate supply of high quality and quantity products to the country`s all
regions and pleasing its customers, creating jobs that benefit the local community
and to grow with the community.
❖ To become a leading producer.
1.1.5 Mission of the Company
✓ To Supply Products with Portfolio that are leaders in quality, cost, and
customer satisfaction through the integration of people technology and
process.
✓ To produce favored brand by focusing on food safety and meeting the highest
standard of quality and trashiness cost effectively.
✓ To continuously build on our knowledge and experience coupled with
technology and innovation to provide premium quality food and beverage
which are preferred by all generations.
✓ To adhere to the highest standards of corporate social responsibility and the
preservation of the environment.
✓ To continuously work with our associates and provide them with
opportunities for learning, professional growth, and a better quality of life.
✓ To produce favored brand by focusing on food safety meeting the highest standard
of quality and freshness cost effectively.
✓ To continuously build on its knowledge and experience coupled with technology
and innovation.
✓ To provide food and beverages which are preferred by all generations.
1.1.6 Core value of the Company
➢ Our success is based on our people.

4
➢ We treat each other with respect and dignity and expect everyone to promote a sense
of personal responsibility.
➢ Food safety, Quality, and freshness
➢ Cost effectiveness
➢ Teamwork
➢ Integrity and trust
➢ Commitment to society and the environment
1.2 The main product, service, and management of the Asku plc
1.2.1 Industries under ABIG (Asku and Berhane Investment Groups) managements
I. Amenti Food Processing plc

Amenti [3] is the food processing wing for ABIG, specializing in manufacturing, packaging,
and marketing standardized food and culinary ingredients for domestic as well as export
markets.
II. Bees General Trading plc
Bees general trading [3] is the first of two companies under ABIG specializing in the
production, distribution, and marketing of Edible Oils, exclusively producing, and distributing
“Dukem Pure Niger seed oil” from the highest-grade indigenous Niger seeds in Ethiopia.
III. YID Organic Edible oil plc
YID [3] is the second company specializing in edible oil extraction. YID has the capacity to
manufacture edible oils from many different sources, both for the local and export markets.
IV. Kechenamba Trading plc
Committed to delivering outstanding Customer service while providing different commodities
to international customers, Kechenamba [3], the trading wing of ABIG, specializes in all
commodities Ethiopia has to offer to the world. It is one of the leading commodity exporters in
the country including oil seeds, coffee, pulses, and spices.
V. Yehule Gebeya plc
The distribution wing under ABIG, Yehule Gebeya [3] operates with the philosophy of
reducing logistics costs for better availability throughout the country with its mega-depots in
regional towns, it also distributes products from other manufacturers and importers.
VI. Berbero Petrochemical industry
World class packaging is a core value addition for all companies. Berbero Provides [3] this
critical solution for our companies as well as different local customers, making it one of the
biggest petrochemical companies in Ethiopia.

5
VII. Asku plc

Asku plc [2] is the beverage wing under the investment group ABlG.
Asku plc producing bottled water under the brand Aquaddis in five different sizes and
carbonated soft drink (CSD) in five different flavors: RC Edge, RC Cola, RC Orange, Royal
Tonic, and RC lemonade. In addition, in the process of introducing Orange, Fruit punch and
Mango juice in two different sizes.
Both carbonated soft drink and juice are produced using USA concentrate imported through
our franchise agreement with cott Beverage Inc, which is a company based in Columbus,
Georgia, USA.
VIII. Berossa Sa’aa Dairy plc
From our farms and herd, their feed and well-being, milk processing, product testing, to
packaging and delivery, quality defines what we do! [3]
We [3] take extra care in meeting our high TQM Standards, but we do not stop there, we
consistently strive to exceed them.
Sustainability is also very important in everything we do. Our belief in partnering with nature
is rooted in giving back more than we take out.
IX. Astu Enjera plc
Astu Enjera [3] is testament to our legacy and excellence. Astu prides itself for being the
pioneer in large scale Enjera production, the staple food for all Ethiopians. Astu provides the
local and export markets with its trademark brand, Astu 100% Teff Enjera.
Teff's unique health benefits are increasingly making it popular amongst the rest of the World,
thanks to recent celebrity endorsements for its gluten free characteristics.
1.2.2 Main products of the organization
During my practice time the company in the plant two produces only Aqua Addis bottled
drinking water in six different sizes:
0.3L, 0.6L, 1L, 1.5L, 2L and 20L (jar).
Aquaddis is one of the earliest bottled water brands in Ethiopia and has been refreshing
consumers with the taste they love and quality they trust.

6
Figure 1. 2 Different size bottle finished good product at Asku plant two
Figure 1. 3 Different size bottle finished good product at Asku plant one
1.3 Main customers
Aqua addis bottled water company is based on manufacturing and selling of bottled water
productions. Therefore, it has many customers end users in my society. The factory Sells its
products as dozen to distributers.

7
Manufactuer Costumer
Distributor
(Asku plc) (Hotels, Super
(Yehule Gabeya)
Markets,and etc.)
Figure 1. 4 Process of customer supply line of the company
The main customers end users are:

➢ Hotels
➢ Restaurants
➢ Supermarkets
➢ Cafeterias
➢ Tourist’s destination places (Historical places) and etc.
1.4. Organizational structure
The new organizational structure of Asku plc looks as shown below in block diagram [4].
Figure 1. 5 Organizational structure of Asku plc in block diagram (I have used Wondershare
EdrawMax Software)

8
1.5 Over all Organization Workflow

1.5 .1 Process flow chart
Table 1.1 Process of production flow chart
Input Process Output Responsibility
Purchase Raw material receiving Raw material storekeeper

request
Raw
Material
No Return
Quality check
to the
based on
parameter supplier Quality Control
Officer
RM Quality
Yes Inspection Test
Report
Test Report Raw Material

Transfer to warehouse
Received Warehouse
Head
Sales Order Production

and stock Prepare Production Plan Based on Plan
level the Sales order & stock level Planner
Production
Plan Infor
Evaluate the
production m to
Plan No
Sales
PM, PD
Manager
Yes Approved
Production
Plan
Production
order Pump water from Bore well
Well water Utility
Chlorinated
Well water Transfer to 200 K tanker and water Treatment
add cl2 operator
Chlorinated Treated from

water Sand filter suspended
mater

9
Treated QA analyst
from TOA
Carbon filter
suspended
Water free
from Cl2
No Regulat QA analyst &

TOA Check Cl2 Treatment
concentration e the
dozing operator
Yes
Water Free Treated from Treatment

from Softener fine particle operator
chlorine
Treated Free from fine Treatment

from fine 5 micro filter particle operator
particle
Free from Free from fine

fine particle 1 micro filter particle Treatment
operator
Free from
fine particle RO Treatment Reduced TDS QA analyst
Reduced QA analyst
TDS Check TDs based DO RO
on parameter
CIP
No
Standard
Yes TDS
Standard Ozone Tower Ozonized Treatment

TDS water operator
Ozonized QA analyst
water Check O3 on
Drain
concentration
No
Ozonized
water based on
the standard

10
Bottle Blower Machine

blower
Bottle filler Filled bottled Filler Operator

bottle filler
water
Filled Treated water Filler Operator

N2 dosing
Water
Treated Bottled water Filler Operator

Capping
water
Bottled
water
Bottle inspection
Reject
trough No
inspection light
Tested bottled Bottle inspector
Yes water
Bottled labeled Bottled labeler operator

Labeling the bottle
water water
labeled Bottled water

Date coding
Bottled
water
packed packer operator
Packing
Bottled
water packed Bottled
water
Bottled Final Product QA analyst

water Product Release to
FG Store

11
1.5.2 Process step description

Table 1.2 Process of production step description
No Process steps Description
receiving of purchased materials shall be for the right quality,

Raw material quantity and other specifications and purchased and received
1. receiving materials shall be handled and opened with utmost care in a
designated receiving area.
Quality check During inspection, each delivery shall be physically counted,
based on weighed, measured, tested, or checked upon receipt at the
parameter receiving area.
2.
The inspection of a delivery shall include determining and
verifying information found on containers and any attached or
enclosed packing lists and invoices.
Transfer to The receiving activity shall be completed as soon as the
warehouse materials received arrive at the warehouse and immediately after
3.
the necessary goods receiving note in relation to the relevant
documents is prepared.
Prepare
Production Plan
Based on the Prepare sufficient amount of raw and packing material for the
4.
Sales order & received order and allocate the employee
stock level
Evaluate the shall evaluate the production order receiving form Sales or stock
production Plan level by comparing with: -
1. Company product specification
2. Time frame of the delivery
5. 3. Availability of raw and packing materials
4. Company capability in term of manpower and
machinery
5. Regulatory requirements
Pump water Bore pumps deliver water from an underground source. Bore
from Bore well pumps are submersible double drop jet pumps designed to
6.
draw water from surface. The pump uses centrifugal force to
deliver water to an above ground storage tank.
Transfer to 200
K tanker and carry water into next position /200 K tanker after being
7.
add cl2 pumped
Sand filter Sand filtration is used for the removal of suspended matter, as
well as floating and sinkable particles. The wastewater flows
8. vertically through a fine bed of sand and/or gravel. Particles are
removed by way of absorption or physical encapsulation. If
there is excessive pressure loss on the filter, it must be rinsed.
Carbon filter A filter with granular activated carbon (GAC) is a proven
option to remove certain chemicals, particularly organic
9. chemicals, from water. GAC filters also can be used to remove
chemicals that give objectionable odors or tastes to water such
as chlorine
Check Cl2 Check the chlorine dosing tank for the availability of chlorine
10. concentration and add the required amount of chlorine if the level in the tank

12
below the standard. The standard for chlorine concentration is

<0.5ppm.
Softener Water softening is a process in which the ions of calcium,
11.
magnesium and sometimes iron are removed
12. 5 micro filter 5 micron - Will remove most particles visible to the naked eye
1 micro filter A 1 micro filter has a pore size around 0.1 micron, so when
13. water undergoes microfiltration, many microorganisms are
removed,
Ro treatment Reverse osmosis (RO) is a water purification process
that removes ions, unwanted molecules and larger particles
14. from drinking water using a partially permeable membrane. As
a result, the solute is kept on the membrane's pressurized side
and the pure solvent is allowed to pass to the other side.
Check TDS
15. based on
parameter
Ozone tower The oxygen (purified air) will enter the oxygen generating unit
after having passed through the filter, the flow meter, and the
pressure adjustment valve. The cooling water will pass through
the inter layer of the shell of the ozone generating unit and the
16. inner part of the enamel discharging tube for cooling. High
frequency and high voltage power supply will join the two
electrodes of the ozone generating unit to generate ozone
through high pressure discharging.
Take sample from the ozone tower tank and check the ozone
concentration hourly. If the concentration is not with the spec,
17. Check O3 on
communicate operator for adjustments.
concentration
The standard for ozone concentration is 0.2-0.6ppm.
18. Bottle blower
19. Bottle filler
20. N2 dosing
21. Capping
Bottle Process inspection should be conducted from the start of
inspection production and in between with appropriate time interval to
22. trough prevent the occurrence of non-conformity. In case
inspection light nonconformity detected during inspection, remedial action
should be taken.
Labeling the Product labelling should be carried out which indicates the
23. bottle logo of the company, specification of the product, chemical
composition, storing instruction.
24. Date coding
Packing Final product should be packed for physical safety, to control
25.
contamination and easy to handle and palletized
Product Release
26. to FG Store

13
CHAPTER TWO
MY OVERALL INTERNSHIP EXPERIENCE AND MY SPECIFIC
WORK
2.1 The way I got into the company
Electromechanical engineering department curriculum in Arba Minch University has an

internship program for the fourth year second semester students. Since I am a
Electromechanical engineering student here in Arba Minch University and after I assigned and
qualified by the my department, I applied an internship program with my application paper
which given for me from my department request to different industries. In my locality Ethio
Leather Industry Corporation and Aqua Addis Bottled water Asku Plc both are those industries
who accepted my request. I decided to work in Asku plc due to my choice because of this
company is more facilitated and definitely related with my field than Ethio Leather Industry
Corporation. So I got into the company, then I start internship practice on the July 01,2022 G.C.
2.2 Why do I select this company’s
As an electromechanical engineering student, I have been planning to do something new,

creative and society problem solvable project in future; in order to success my plan, I have to
gain full of knowledge of electromechanical engineering. So that I would have join the
facilitated company like Asku plc to reach my future plan. Moreover, this Company is
definitely related with my field, and I hope it will be helpful for my next field of study.
2.3 Working section of the company
Workshop may be a room or building which provides the area, tools and machinery that may
be required for manufacture machines or repair of manufactured goods. They are major
working sections in the company:
❖ Nitrogen plant room

❖ Mechanical workshop
❖ Electrical workshop
❖ Control Room
❖ Air Compressor room (AC room)
❖ Powerhouse room (Utility)
❖ Water treatment room
❖ Production room

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2.4 Section of the company I have been working In
In Asku plc there are many sections. During period of my internship program, I am
participating and work in manufacture machines in mechanical Workshops, rewind motor in
electrical workshops, Maintenance and Utility. Those all operations have the vital roles to get
different Electromechanically engineering methods and principle. As it is an electromechanical
shop it has both mechanical and electrical works.
2.4.1 Nitrogen plant room
Asku Plc Nitrogen plant [5] is produced nitrogen gas which is purified and dried. In Ethiopia
Nitrogen Plant there only Bole International airport and Asku plc.
At the Bole international airport those are using for the strengthening wheel of airplane and in
the Asku plc those are using for the strengthening of PET bottle. Asku plc Nitrogen generation
plant based on the process consist of two adsorbers filled with carbon molecular sieves, which
has the property to absorb Oxygen from compressed air. Compressed and purified air is passed
through the absorbers in this process. Mainly oxygen is absorbed on the carbon molecular
sieves as it has preferential properties for adsorption of moisture first and nitrogen enriched gas
is leaving the absorber. The oxygen concentration can be reduced to almost all required levels.
During adsorption in one adsorber, the second adsorber is totally regenerated just by
depressurization to ambient pressure. The oxygen enriched off gas is vented. After about one
minute adsorption in one adsorber, the process controller is switching over to the second
adsorber to produce nitrogen on a continuous basis.
Process
The adsorption separation is accomplished in the following process steps:
1. Feed Air Compression and Conditioning
The ambient (inlet) air is compressed by an air compressor, subsequently dried by an air dryer,
and filtered before entering the process vessels.
2. Pressurization and Adsorption
The pre-treated air is passes into a vessel filled with Carbon Molecular Sieve (CMS) where the
oxygen is adsorbed
preferentially in the CMS pores so that nitrogen with an adjustable purity (down to a residual
O2 content of 50 ppm) remains in the gas stream. Before the adsorption capacity of the CMS
is fully utilized, the nitrogen separation process is interrupted, and the switching of the adsorber
vessels is initiated.

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3. Desorption
The saturated CMS is regenerated (i.e. the adsorbed gases are released) by means of pressure
reduction below that of the adsorption step. This is achieved by a simple pressure release
system. The resultant waste stream is vented into atmosphere. The regenerated adsorbent can
now be used again for the generation of nitrogen.
4. Nitrogen Receiver
Adsorption and desorption take place alternately at equal time intervals. This means that the
continuous generation of nitrogen can be achieved with two adsorbers, one being switched at
adsorption and the other at regeneration.
Constant product flow and purity is ensured by a connected product buffer vessel that stores
the nitrogen at purities up to 99.995% and pressures up to 8.3 bar (g) / 120 PSIG.
5. Nitrogen Product
The result is a constant stream of on-site produced high purity nitrogen at cost significantly
below that of liquid or bottled gases.
Figure 2. 1 Overview of Nitrogen Plant room of Asku Plc

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Figure 2. 2 Practically controlling nitrogen plant at standardized parameter
2.4.2 Mechanical workshop
Asku plc mechanical workshop [6] is a place where acquire knowledge on the operation of
various processes involved in manufacturing and production. Mechanical workshop is also
involved in different maintenance/repair works for Asku plc. Mechanical workshop is a place
in which metal parts are cut to the required size, Welding, drilling, Turning, and put together
to form mechanical units or machines. The machines so made are to be used directly or
indirectly in the production of necessities and luxuries of civilization.
A. Lathe machine
Lathe machine is one of the most important machine tools which is used in the mechanical
workshop of Asku plc.
It operates on the principle of a rotating work piece and a fixed cutting tool.
The cutting tool is feed into the work piece which rotates about its own axis causing the
workpiece to form the desired shape.
Functions of lathe Machine: -
• The main function of Lathe machine is to remove excess material in the form of chips
by rotating the work piece against a stationary cutting tool.

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• This is accomplished by holding the work securely and rigidly on the machine and then
turning it against cutting tool which will remove metal from the work.
• To cut the material properly the tool should be harder than the material of the work
piece, should be rigidly held on the machine and should be fed or progress in a definite
way relative to the work.
Operation of Lathe Machine: -
Turning (Tapers and Taper Turning, Straight turning, Profiling, External grooving, etc.),
Facing, Drilling, Boring (Counter Boring, Taper Boring), Reaming, Knurling, Chamfering,
Filling, Parting, Threading, Grooving, Forming, and Polishing.
Figure 2. 3 Practically working by Lathe Machine in Mechanical Workshop
B. Milling Machine

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A milling machine is a machine tool that removes metal as the work is fed against a rotating
multipoint cutter. The milling cutter rotates at high speed, and it removes metal at a very fast
rate with the help of multiple cutting edges.
Working Principle of Milling Machine: -
Milling is a metal removal process by means of using a rotating cutter having one or more
cutting teeth as illustrated in figure Cutting action is carried out by feeding the workpiece
against the rotating cutter. Thus, the spindle speed, the table feed, the depth of cut, and the
rotating direction of the cutter become the main parameters of the process. Good results can
only be achieved with well-balanced settings of these parameters.
Figure 2. 4 Practically working by Milling Machine in Mechanical Workshop
Milling machine operations:
A. Plain milling: - For producing a plain, flat, horizontal surface parallel to the axis of
rotation of plain milling cutter.

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B. Face milling: - To produce flat surface face milling cutter rotated about an axis
perpendicular to work surface
C. Side milling: - Producing flat vertical surface on the side of the workpiece
D. Form milling: - Operation of producing irregular contours by using form cutters.
E. Profile milling: - Operation of reproduction of an outline of a template or complex
shape of a master die on a workpiece.
F. End milling: - producing a flat surface which may be vertical, horizontal, or at an angle
in reference to the table surface.
G. Saw milling: - Producing narrow slots or grooves on the workpiece.
H. Gear cutting: - To produce gears
C. Drilling Machine
It is a machine which is used to drill the holes on the components or workpiece with the
help of drill bits.
Working Principle of Drilling Machine:
When the power is given to the motor, the spindle rotates, and thereby the stepped pulley
attached to it also rotates. On the other end, one more stepped pulley is attached and that is
inverted to increase or decrease the speed of the rotational motion.

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Figure 2. 5 Practically working by Drilling Machine in Mechanical Workshop
The applications of Drilling Machine are Surface mining, Counter boring, Countersinking,
Underground mining, Tapping etc.
D. Welding
It is the process of permanent fastening where two metals are fused at the temperature of
3200°C (when metals are melted). The most common types of welding are:
• Electric Arc Welding

• Gas Welding (Oxy Acetylene Welding)
E. CNC Machine
Numerical control (NC) is the automation of machine tools that are operated by abstractly
programmed commands encoded on a storage medium, as opposed to controlled manually via
hand wheels or levers, or mechanically automated via cams alone. NC is computer numerical
control (CNC), in which computers play an integral part of the control.
CNC Machine used for drills, saws, etc.
Figure 2. 6 Commands and Controls of Computer Numerical Control (CNC) Machine

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2.4.3 Electrical workshop
Asku plc Electrical workshop [5] is the center for the modifying, repairing, rewinding motor,
troubleshooting the programmable logic controller, and testing other control panels (Gearbox,
contactors, Circuit braker, Relays, Variable frequency driver, and etc.).
Motor Rewinding
Electric motor [7] needs rewinding, that means the coils are shorted, grounded, or otherwise
damaged. There here can be a wide variety of issues behind motor failures that necessitate
rewinding. Mostly motor failures occur due to Insulation failures can take several different
forms, including windings that have shorted turn-to-turn or phase-to-phase, coil-to coil, or
grounding at the edge of the slot. These particular issues can usually be traced back to
contamination, abrasion, voltage surges, overall age of the machine, or vibration.
Figure 2. 7 Practically Rewinding of Induction motor in Electrical Workshop
Calculation I have calculated before going to rewind motor: -
60* f 60*50
1. Calculate Number of pole pairs: p = = =1
ns 3000

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Where is:
p-Number of pole pairs
f- Nominal frequency (Hz)
ns-Rotation speed of magnetic field (deg/min)
 *D 3.14*75.5
2. Calculate Pole step:  = = = 118.53mm
2* p 2*1
Where is:
 - Pole step
D - Inner diameter of stators package (mm)
P - Number of pole pairs
Z 24
3. Calculate Number of slots per pole and phase: q = = =4
2* p * m 2*1*3
Where is:
q - Number of slots per pole and phase
Z - Number of slots
p - Number of pole pairs
m - Number of phases in winding
Z 24
4. Calculate Pole step in slot:  = = = 12
2* p 2*1
Where is:
 - Pole step
Z - Number of slots
P - Number of pole pairs
6* w ' 6*247
5. Calculate number of turns in slot: S ' = = = 61.75 ; 62
Z 24
Where is:
S' - Calculation number of turns in slot
w' - Calculation number of turns in pole and phase
Z - Number of slots

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Figure 2. 8 Motor Winding Diagram [8]
Motor rewinding involves the following basic steps:
i. Gathering Winding Data

ii. Burnout and Stripping
iii. Making the Coils
iv. Winding Insertion and Connecting
v. Testing the Coil Windings
vi. Insulating a New Winding in a Motor
vii. Vacuum Pressure Impregnation
I. Gathering Winding Data
Before starting to rewind I need to gather winding data as most motors have significant
differences in their windings even if they are the same horsepower, speed, and voltage. This
data includes: the number of slots, wire size, number of coils, number of turns per coil, critical
dimensions, bracing, and insulation parameters.

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Figure 2. 9 Induction motor tag reading for rewinding
This data is used to replicate the original motor as well as suggest design improvements to
improve performance and extend the mean time to failure. This data should be checked to other
programs that are available to confirm the winding arrangement meets or exceeds the
nameplate data and performance of the motor.
II. Burnout and Stripping
After all the key information has been gathered, the existing motor windings are stripped out
of the motor core. This starts with putting the stator of the motor into a high temperature oven
typically referred to as a burnout or burn off oven. Need to make sure the oven is recording
oven temperature and part temperature to ensure the motor doesn't get too hot and damage the
core insulation. The oven should also have a water suppression system to help keep the heat
from getting too far out of line. This burnout step can take up to multiple days for larger units
and results in the insulation essentially being reduced to ash. The next step, once its cooled
down, is to physically remove the windings from the stator core, typically referred to as
stripping. Most times you are gathering winding data before and after the stripping process. A
core loss test should be performed prior to the oven process as well as afterwards to ensure the
integrity of the core iron insulation.
III. Making the Coils

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What follows is the actual making of the coils. Key parameters of this process include layering,
wire tension, and keeping count of the number of turns on the coil. Please keep in mind that
the process varies when you are making random wound coils versus form wound coils. Random
wound coils are made in a repair shop using buckets of magnet wire and winding heads to make
the correct length coil. Form coils are made by a manufacturer that specializes in form coils
and has the correct wire, tapes, press equipment, spreading equipment, testing capabilities, etc.
IV. Winding Insertion and Connecting
Once the coils are made, they are installed in the stator slots and then connected. When inserting
coils, the process varies whether you are working on a random wound winding or a form coil
winding, but it is the same basic process of inserting coils and insulation into the core of the
motor. You then must connect the coils together to form the complete winding. Blocking and
bracing of the winding is an important factor to note in this process. If a winding is not braced
properly, the mechanical movement can cause winding failure.
V. Testing the Coil Windings
Multiple tests are run during the entire rewinding process to ensure the integrity and quality of
the coil windings. After the rewinding process is complete, the insulation process, sometimes
referred to as varnishing follows.
VI. Insulating a New Winding in a Motor
Besides providing electrical insulation, the varnish used also keeps the coils from moving,
bonds the multiple coils together, and protects the windings from contamination. One of two
approaches can be used for applying the insulation to the newly wound coils: the more
traditional varnish dip and bake or the technologically advanced vacuum pressure impregnation
process (VPI). The traditional varnish dip is also used when a motor is reconditioned. However,
on new windings a simple varnish dip should be replaced by Vacuum Pressure Impregnation.
VII. Vacuum Pressure Impregnation
With VPI, highly controlled vacuum and pressure cycles are used to penetrate and coat the
windings with a 4 to 5 ml build of solventless epoxy resin. The reason why it is replacing the

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more traditional varnish approach lies in the advantages it provides: it provides superior
performance in harsh environments, it increases efficiency through better heat transfer, is less
susceptible to contamination and reduces coil vibration. Many repair shops have not made the
significant investment in the VPI systems. Unfortunately these shops cannot offer this,
advanced, solution. However, this should be the preferred method that is used.
2.4.4 Air Compressor room (AC room)
An air compressor [5] is a device that converts power (using an electric motor, diesel, or
gasoline engine, etc.) into potential energy stored in pressurized air (i.e. compressed air). By
one of several methods, an air compressor forces more and more air into a storage tank. The
energy contained in the compressed air can be used for a variety of applications. When tank
pressure reaches its lower limit, the air compressor pressure reaches its engineered upper limit,
the air compressor shuts off. The compressed air turns on again and re-pressurizes the tank. Air
compressor room supply air into production room. Elements of AC room
▪ Fun & its motor

▪ Main air tanker
▪ Air cooler
▪ Motor (main motor)
▪ Compressor: - screw type/piston type
▪ Cylinder: - for condensing purpose and reduction of pressure
▪ Air dryer: - used to filter water from air that sacked in high pressure
▪ Exhaust tube
▪ Oil tanker and separator
▪ Oil coolant: - process of cooling pressurized oil
▪ Moisture tube
▪ Pressure switch
Process: the hottest and environmental air inserted to AC room. After that this rooms air is
collected by fun since this air is the collection of pure and dust (waste) so it must be filter out
the waste once ago away into the environment. The pure cooling air is passing into the main
air tanker. The pure cooling air which has a collection of pure air and moisture, then it is
essential to isolate moisture from pure air. The collection air is filter out by using moisture
filter and removes the moisture after passing this process. The pure air gives in to the product

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room as the necessary of room. These air compressors have its own power circuit and control
circuit.
I. High Pressure Air Compressors

➢ High pressure air compressors are designed to blow the PET bottle, systems with an
operating pressure range of 35 - 40 bar. Most rotary screw compressors are designed
to operate efficiently between 38 bar and 40 bar. A rotary screw compressor designed
for operation in this range will use a smaller motor and consume less power than a
machine designed for operation at a higher pressure. Special construction is required
for satisfactory operation in this range. Some applications require compressed air at 35
bars but are constrained by space, noise, or cost considerations to use a modified rotary
screw compressor rather than a reciprocating compressor. High pressure reciprocating
compressors having 3, 4 or 5 stages capable of reaching pressures from 35 bar to 40
bar are found in industrial settings, drilling rigs, diving operations, fire stations and
more. It uses Temperature: 35 – 40 °c
II. Low Pressure Air Compressors
Low Pressure Air Compressors are designed for systems with an operating pressure range of
7- 8 bar. It used to rotate the Blower Machine by Pneumatic System and Used in all production
room and treatment room. It uses Temperature: 35 – 40 °c
High pressure rotary screw compressor
Figure 2. 10 Overview of air compressor room

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2.4.5 Powerhouse room (Utility)
Asku plc it uses the power supplies from Ethiopian Electric power corporation (EEPCO), 15
KVA and it is step down by transformer to 380-420 V.
Transformer
The transformer has one step down transformer. The passage of electric power before it enters
to three phase stabilizers.
Basic transformer parts are:
▪ Body: - for air suction and cooling purpose.

▪ Oil tank: - supply oil for cooling purpose. Transformer uses oil as coolant.
▪ Gauge: - measure oil content.
▪ Safety valve: - control oil circulation.
▪ Silica: - have moisture absorbing purpose
▪ Thermometer: - measure the temperature of the oil.
Electric power flow in Asku Plc is as the following:
Insulation circuit: Made Oil: as coolant, since

Bus bar: for
of Bakelite and used to the power is high it
continuous flow
connect the cables to bus produces heat
of power
bars and have air gap
Ceramics: Bus bar

Step Down AC
uses Ceramics for
Transformer: Reduced
support and
from 15KVA to 400V
insulation
Three phase stabilizers

Stabilizer [7] is an electrical device which is used to provide a constant voltage output to a
load at its output terminals irrespective of any change/ fluctuation in the input i.e. incoming
supply. It is also known as automatic voltage regulator. The purpose of stabilizer is to protect
the machines from the probable damage due to voltage surge/ fluctuation, over voltage and
under voltage conditions. It also used fed power supply from outside. The output voltage from
this stabilizer stays in range of 380V or 400V within given fluctuating range of input voltage.
Effects of Continuous/ Recurring over voltage to machines

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➢ It may cause permanent damage to the machine.

➢ It may lead to unnecessary disruption in the load.
➢ It may lead to over-heating of the machine.
➢ It may degrade useful life of the machine.
Effects of Continuous/ Recurring under voltage to machines
• It may lead to machine malfunction.

• It may result in low efficiency of the machine.
• The machine in some case can take extra hours to perform the same function.
• It degrades performance of the machine.
• It may lead the device to draw large currents, that may further cause over-heating.
Figure 2. 11 Overview of utility room

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2.4.6 Power distribution and motor starting method Section
In this section I have done the induction motor starting control systems.
Figure 2. 12 Practically working of motor starting method in control room
Among those I have done:

A. Direct On-Line Starter (DOL)
The Direct On-Line (DOL) starter [9] is the simplest and the most inexpensive of all starting
methods and is usually used for squirrel cage induction motors. It directly connects the contacts
of the motor to the full supply voltage. The starting current is very large, normally 6 to 8 times
the rated current. The starting torque is likely to be 0.75 to 2 times the full load torque. In order
to avoid excessive voltage drops in the supply line due to high starting currents, the DOL starter
is used only for motors with a rating of less than 5KW. There are safety mechanisms inside the
DOL starter which provides protection to the motor as well as the operator of the motor.

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The DOL starter consists of a coil operated contactor K1M controlled by start and stop push
buttons. On pressing the start push button S1, the contactor coil K1M is energized from line
L1.
The three mains’ contacts (1-2), (3-4), and (5-6) in figure (2.13) are closed. The motor is thus
connected to the supply. When the stop pushbutton S2 is pressed, the supply through the
contactor K1M is disconnected. Since the K1M is de-energized, the main contacts (1-2), (3-4),
and (5-6) are opened. The supply to motor is disconnected and the motor stops.
The power and control circuits of induction motor with DOL starter are shown in figure below.
* K1M Main contactor
A) Power circuit of DOL B) Control circuit of DOL
Figure 2. 13 Power and Control circuit of DOL
B. Star delta starter

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The star delta starting [9] is a very common type of starter and extensively used, compared to
the other types of the starters. This method used reduced supply voltage in starting. Figure
below shows the connection of power and control circuit of star-delta starter.
The method achieved low starting current by first connecting the stator winding in star
configuration, and then after the motor reaches a certain speed, throw switch changes the
winding arrangements from star to delta configuration.
By connecting the stator windings, first in star and then in delta, the line current drawn by the
motor at starting is reduced to one-third as compared to starting current with the windings
connected in delta. At the time of starting when the stator windings are start connected, each
stator phase gets voltage VL/ where VL is the line voltage. Since the torque developed by
an induction motor is proportional to the square of the applied voltage, star- delta starting
reduced the starting torque to one – third that obtainable by direct delta starting.
➢ K2M Main Contactor

➢ K3M Delta Contactor
➢ K1M Star Contactor
➢ F1 Thermal Overload Relay
A) Power circuit of star-delta starter B) Control circuit of star-delta starter

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Figure 2. 14 Power and Control circuit of star-delta starter
When star auxiliary contact (1) (which is placed on Main Contactor coil circuit) become NO
to NC it’s complete The Circuit of Main Contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactor’s Main and Auxiliary Contactor Change its Position from NO
to NC. This sequence happens in a friction of time. After pushing the ON push button switch,
the auxiliary contact of the main contactor coil (2) which is connected in parallel across the
ON push button will become NO to NC, thereby providing a latch to hold the main contactor
coil activated which eventually maintains the control circuit active even after releasing the ON
push button switch. When Star Main Contactor (KM1) close it connect Motor connects on
STAR and it’s connected in STAR until Time Delay Auxiliary contact KT (3) become NC to
NO. Once the time delay is reached its specified Time, the timer’s auxiliary contacts (KT) (3)
in Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit (4) change its Position from NO to NC so Delta coil
energized, and Delta Main Contactor becomes NO to NC. Now the motor terminal connection
change from star to delta connection.
A normally close auxiliary contact from both star and delta contactors (5&6) are also placed
opposite of both star and delta contactor coils, these interlock contacts serve as safety switches
to prevent simultaneous activation of both star and delta contactor coils, so that one cannot be
activated without the other deactivated first. Thus, the delta contactor coil cannot be active
when the star contactor coil is active, and similarly, the star contactor coil cannot also be active
while the delta contactor coil is active. The control circuit above also provides two interrupting
contacts to shut down the motor. The OFF-push button switch breaks the control circuit and
the motor when necessary. The thermal overload contact is a protective device which
automatically opens the STOP Control circuit in case when motor overload current is detected
by the thermal Overload relay, this is to prevent burning of the motor in case of excessive load
beyond the rated capacity of the motor is detected by the thermal overload relay.
2.4.7 Water treatment room

Asku plc uses its own ground water from 300 m deep well [10]. The submersible pump
inserted in the well which deliver water to 5 tankers that have a capacity of 200,000 liters.
The water is then passes through sand filter, carbon filter, micro filter, titanium filter and
ozone. The main reason for treating water includes removing harmful contaminants and
stabilizing its physical properties.

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In water treatment, there is hard water and soft water treatment process.
Hard water treatment
During this process a number of reactions takes place concurrently which includes Alkalinity
reduction, Color removal, Odor removal, Organic removal (Bacteria, germ), Water sterilization,
and Residual chlorine removal.
Soft water treatment
Soft water taken to use then it goes into titanium filter tanker to kill microorganism less than
0.01. After all this process, the water treated is ready to the production process like, filler,
chiller and etc.
The reason why soft water is required is due to serious effects of hard water on different
machine parts. Some effects of hard water are It not suitable for drink, it causes corrosion of
metals, it creates scaling on metal surface, and even it may close small pipes due to ion
accumulation.
Machine used in water treatment room:
Pump: -They are used for supply water from reservoir tank to treatment room.
Pipe: -are chained with reservoir tank and pneumatic valve.
Pneumatic Valve: -Used to adjust water flow rate. To reduce the explosion of valves.
Cyclone: -Used to identify water and settled unwanted grit/sand comes from reservoir tanker.
Raw water pump: -Used to supply water from raw water to sand filter tanker.
CIP pump: -Used when RO was washed.
Terminal Pump: -Used to supply water from ozone tanker to titanium filter.
Booster Pump: -Used to supply water from pure tank to Ozone.
High Pressure Pump: -Used to supply water from RO to pure tanker.
Delivery Pump: -Used to pump water for cooling blowing area and scattered on conveyer area.
Mixer Pump: -Used to mix Water and Ozone.
2.4.8 Production room
I. Blow molding machine: -Used to manufacture hollow plastic parts. The blow molding
process begins with melting down the plastic and forming it into a prison or preform .

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Figure 2. 15 Blow Molding Machine
Workflow and control system of Blower Machine:
Figure 2. 16 Workflow and control system of Blower Machine
II. Rinsing, filling, and capping machine: - Receive empty bottles from blowing machine
and fill water. After filling it caps the bottles as needed. Capping is also a part of filling
machine.
III. Labeling machine is used to label the product with full information of the company
product. Indicate name of the product, company name, chemical analysis information
and logo of the company.

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It is also a machine which is used to label the label magazine on the bottle. Main parts of labeler
with their importance:
In feed worm – spaces the bottle to the machine pitch.
In feed star wheel – picks up the bottles from the in-feed worm and transfers it to a plate which
are driven by servo motor.
Glue pump – is used to transfer glue from its container on the roller.
Roller – is used to transfer glue to a pallet machine when it is rotating.
Pallet – is a rotating machine driven by gearing system. The glue on the pallet is transferred to
label magazine.
Gripper – is used to take the label from the pallet and pastes (sticks) it on the bottle.
Brushes – are used to brush the label to the bottle when the bottle passes (reciprocate).
Servomotor – is used to control position. Used to reciprocate (rotate at given angles)
bottles on the plate.
IV. Light inspection points after filling line and the other after labeling.
The boiler or steam generator creates steam by applying heat energy to the raw water which
comes from the raw water tank and the steam will be supplied into the steam channel.
V. Date coder machine: -is used to print manufacturing date and expire date of the
product.
VI. Glue and Spray chemical: -is used to attach the labeling.
VII. Conveyer system: -the factory belt conveyer used to transport the bottled water starting
from filling machine up to packaging machine.
VIII. Palletizer: -used to arrange the packed bottles.

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Figure 2. 17 Palletizer
2.4.9 Control room

In Asku plc to control over all industrial automation many devices were used.
Variable Frequency Driver

(VFD)
Contactor
Relay
Timer
Circuit Breaker
Thermal
Overload
Fuse
Figure 2. 18 Control Devices of Asku Plc

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Those are: -
I. Programmable logic controller (PLC)
Programmable Logic Controller (PLC) is used to control the operations of electro-mechanical

devices especially in tough and hazardous industrial environments [9].
PLCs are generally used for incorporating automation in open loop systems where processes
are to be performed in a sequential manner. PLCs are used for automation of assembly lines in
industries. They are generally designed for multiple input multiple output (MIMO) systems. In
PLCs, instructions are saved in nonvolatile memory. Some of the advantages of PLCs are:
✓ Cost effective
✓ To adjust temperature parameter
✓ Flexibility and ability to use similar system for other processes
✓ Programming interface is easier in comparison to other processers
✓ Resistant to impact and vibration
✓ Resistant towards electrical and mechanical noise
✓ Ability to work at high temperatures
Figure 2. 19 Programmable logic controller structure and functioning

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Figure above shows the basic elements of a PLC. It is basically a microprocessor-based control
system. Microprocessor communicates with the operators with input/output devices via a
circuitry.
This circuitry protects the microprocessor and other elements of PLC from the high voltages
and currents coming to the PLC.
Microprocessor does its basic functions of taking decisions according to the instructions written
in the programs which are stored in the memory. PLC scans a set of sensor inputs rapidly and
repeatedly. Then it evaluates their logic relationships to defined outputs according to a logic
program. At last it sets the outputs according to the programmed logic.
II. Human Machine Interface
I operate the machine by Human Machine Interface (HMI), The HMI has 12 F function key
that starts from F1 up to F12 and 15 K control key.
Definition of overall situation control key: - K1: Navigation, K10: Auto, K2: Run/Stop
K11: Oven, K3: Oven, K12: Angle Set, K4: Blow Bottle, K13: Trim, K5: Feeding, K14:
Pipeline, K6: Fans, K15: Option, K7: Statistics, K16 Logout, K8: Alarm
Figure 2. 20 Practically control training on Human Machine Interface
So using HMI I communicate with the machine. There are forty sensors that make the machine
operate as it required.

40
III. Gearbox
A gearbox otherwise known as a gear reducer or speed reducer is a set of gears that can be
added to a motor to drastically decrease speed and/or increase torque. Each gearbox type works
in unison with a motor to achieve the desired speed-torque output. For motor-only applications,
the slower the motor speed, the larger the motor needs to be. Large motors can be expensive
and may not fit within the allowable envelope space of an application. Using a gearbox with a
smaller motor enables the unit to operate at lower speeds. In order to understand the importance
of using a gearbox to decrease motor speed, consider this scenario. You have a pastry conveyor
that adds cherry filling as the pastries go by. Because this is a fairly light load, you would not
want the conveyor running at 1500 rpm. If it was, there would be pastries and cherry filling
everywhere. Torque is directly proportional to the volume of a motor (diameter squared times
length). This means that a very large motor and a relatively small gearbox could provide the
same amount of output torque. Let’s look at our example conveyor application again. Say your
customer overloads torque on the conveyor motor. If you have a stand-alone motor, it may not
have enough torque to move 50 heavy bottles. You will need to have the additional torque
provided by a gearbox.
IV. Contactors:
A contactor is an electrical device which is used for switching an electrical circuit on or off. It
is considered to be a special type of relay. However, the basic difference between the relay and
contactor is that the contactor is used in applications with higher current carrying capacity,
whereas the relay is used for lower current applications. Contactors can be field mounted easily
and are compact in size. Generally, these electrical devices feature multiple contacts. These
contacts are in most cases normally open and provide operating power to the load when the
contactor coil is energized. Contactors are most commonly used for controlling electric motors.
There are various types of contactors, and each type has its own set of features, capabilities,
and applications. Contactors can break current over a wide range of currents, from a few
amperes to thousands of amperes, and voltages from 24 VDC to thousands of volts. In addition,
these electrical devices come in varying sizes, from hand-held dimensions to sizes measuring
a meter or yard on one side (approximately). The most common application area of the
contactor is high-current load. Contactors are known for their capability to handle currents of
over 5000 amperes and high power over 100 kW. Heavy motor currents produce arcs when

41
being interrupted. These arcs can be reduced and controlled using a contactor. The following
three are crucial components of the contactor:
i) Coil or Electromagnet: This is the most crucial component of a contactor. The driving force
that is required to close the contacts is provided by the coil or electromagnet of the contactor.
The coil or electromagnet and contacts are protected by an enclosure.
ii) Enclosure: Just like the enclosures used in any other application, contactors also feature an
enclosure, which provides insulation and protection from personnel touching the contacts. The
protective enclosure is made from different materials, such as polycarbonate, polyester, Nylon
6, Bakelite, thermosetting plastics, and others. Generally, the open-frame contactor features an
additional enclosure, which protects the device from bad weather, hazards of explosion, dust,
and oil.
iii) Contacts: This is yet another important component of this electrical device. The current
carrying task of the contactor is done by the contacts. There are different types of contacts in a
contactor namely, contact springs, auxiliary contacts, and power contacts. Each type of contact
has an individual role to play.
Operating Principle of a Contactor:
The current passing through the contactor excites the electromagnet. The excited electromagnet
produces a magnetic field, causing the contactor core to move the armature. A normally closed
(NC) contact completes the circuit between the fixed contacts and the moving contacts. This
permits the current to pass through these contacts to the load. When current is removed, the
coil is de-energized and opens the circuit. The contacts of the contactors are known for their
rapid open and close action.
V. Relays
Relays are switches that open and close circuits electromechanically or electronically. Relays
control one electrical circuit by opening and closing contacts in another circuit. As relay
diagrams show, when a relay contact is normally open (NO), there is an open contact when the
relay is not energized. When a relay contact is Normally Closed (NC), there is a closed contact
when the relay is not energized. In either case, applying electrical current to the contacts will
change their state. Relays are generally used to switch smaller currents in a control circuit and
do not usually control power consuming devices except for small motors and Solenoids that
draw low amps. Nonetheless, relays can "control" larger voltages and amperes by having an

42
amplifying effect because a small voltage applied to a relays coil can result in a large voltage
being switched by the contacts.
Protective relays can prevent equipment damage by detecting electrical abnormalities,

including overcurrent, undercurrent, overloads, and reverse currents. In addition, relays are also
widely used to switch starting coils, heating elements, pilot lights and audible alarms. Basic
parts and functions of electromechanical relays include:
Frame: Heavy-duty frame that contains and supports the parts of the relay.
Coil: Wire is wound around a metal core. The coil of wire causes an electromagnetic field.
Armature: A relays moving part. The armature opens and closes the contacts. An attached
spring returns the armature to its original position.
Contacts: The conducting part of the switch that makes (closes) or breaks (opens) a circuit.
Reset Level: The value of current or voltage below which a relay opens its contacts and comes
in original position.
Operating Time of Relay: Just after exceeding pickup level of actuating quantity the moving
mechanism (for example rotating disc) of relay starts moving and it ultimately closes the relay
contacts at the end of its journey. The time which elapses between the instant when actuating
quantity exceeds the pickup value to the instant when the relay contacts close.
Reset Time of Relay: The time which elapses between the instant when the actuating quantity
becomes less than the reset value to the instant when the relay contacts return to its normal
position.
Reach of Relay: A distance relay operates whenever the distance seen by the relay is less than
the pre-specified impedance. The actuating impedance in the relay is the function of distance
in a distance protection relay. This impedance or corresponding distance is called the reach of
relay. A relay is used in control circuit while a contactor is used in power circuit.
VI. Circuit Breaker
An electrical circuit breaker is a switching device which can be operated manually and
automatically for controlling and protecting an electrical power system. As the modern power
system deals with huge currents, special attention should be given during designing of a circuit
breaker to ensure it is able to safely interrupt the arc produced during the closing of a circuit
breaker. The circuit breaker mainly consists of fixed contacts and moving contacts. In normal

43
“ON” condition of the circuit breaker, these two contacts are physically connected to each other
due to applied mechanical pressure on the moving contacts. There is an arrangement stored
potential energy in the operating mechanism of circuit breaker which is released if the
switching signal is given to the breaker. The potential energy can be stored in the circuit breaker
by different ways like by deforming metal spring, by compressed air, or by hydraulic pressure.
But whatever the source of potential energy, it must be released during operation. The release
of potential energy makes the sliding of the moving contact in a speedy manner. The circuit
breaker has to carry large rated or fault power. Due to this large power, there is always
dangerously high arcing between moving contacts and fixed contact during operation of the
circuit breaker. Again, as we discussed earlier the arc in circuit breaker can be quenching safely
if the dielectric strength between the current carrying contacts of circuit breaker increases
rapidly during every current zero crossing of the alternating current.
VII. Variable Frequency Drive:
VFD is a power electronics-based device which converts a basic fixed frequency, fixed voltage
sine wave power (line power) to a variable frequency, variable output voltage used to control
speed of induction motor(s). It regulates the speed of a three-phase induction motor by
controlling the frequency and voltage of the power supplied to the motor. Frequency (or hertz)
is directly related to the motor’s speed (RPMs). In other words, the faster the frequency, the
faster the RPMs go. If an application does not require an electric motor to run at full speed, the
VFD can be used to ramp down the frequency and voltage to meet the requirements of the
electric motor’s load. As the application’s motor speed requirements change, the VFD can
simply turn up or down the motor speed to meet the speed requirement. Any Variable
Frequency Drive or VFD incorporates following three stages for controlling a three-phase
induction motor.
A) Rectifier Stage
A full-wave power diode based solid-state rectifier converts three-phase 50 Hz power from a
standard 220, 440 or higher utility supply to either fixed or adjustable DC voltage. The system
may include transformers for high voltage system.
B) Inverter Stage
Power electronic switches such as IGBT, GTO or SCR switch the DC power from rectifier on
and off to produce a current or voltage waveform at the required new frequency. Presently most

44
of the voltage source inverters (VSI) use pulse width modulation (PWM) because the current
and voltage waveform at output in this scheme is approximately a sine wave. Power Electronic
switches such as IGBT; GTO etc. switch DC voltage at high speed, producing a series of short-
width pulses of constant amplitude. Output voltage is varied by varying the gain of the inverter.
Output frequency is adjusted by changing the number of pulses per half cycle or by varying the
period for each time cycle. The resulting current in an induction motor simulates a sine wave
of the desired output frequency. The high-speed switching action of a PWM inverter results in
less waveform distortion and hence decreases harmonic losses.
C) Control System
Its function is to control output voltage i.e., voltage vector of inverter being fed to motor and
maintain a constant ratio of voltage to frequency (V/Hz). It consists of an electronic circuit
which receives feedback information from the driven motor and adjusts the output voltage or
frequency to the desired values. Control system may be based on SPWM (Sine Wave PWM),
SVPWM (Space Vector modulated PWM) or some soft computing-based algorithm. In an
induction motor induced in stator, E is proportional to the product of the slip frequency and the
air gap flux. The terminal voltage can be considered proportional to the product of the slip
frequency and flux if stator drop is neglected. Any reduction in the supply frequency without
a change in the terminal voltage causes an increase in the air gap flux which will cause magnetic
saturation of motor. Also, the torque capability of motor is decreased. Hence while controlling
a motor with the help of VFD or Variable Frequency Drive we always keep the V/f ratio
constant. Depending on the model a VFD's operating parameters can be programmed via
dedicated programming software, internal keypad, external keypad, or SD card. VFDs will
often block out most programming changes while running. Typical parameters that need to be
set include: motor nameplate information, speed reference source, on/off control source and
braking control. It is also common for VFDs to provide debugging information such as fault
codes and the states of the input signals.
Merits of using Variable Frequency Drives
➢ Energy Saving
➢ Increased Reliability
➢ Speed Variations
➢ Soft Starting
➢ Extended Machine Life and Less Maintenance

45
➢ High Power Factor
Applications of Variable Frequency Drive
❖ They are mostly used in industries for large induction motor (dealing with variable
load) whose power rating ranges from few KW to few MW.
❖ Variable Frequency Drive is used in traction system.
❖ They are also used in modern lifts, escalators, and pumping systems.
❖ Nowadays they are being also used in energy efficient refrigerators, AC’s, and
Outside-air Economizers.
2.5 Workflow in the section of the company
The chemists check the quality of pre-form, cap, and body label in the physicochemical
laboratory by measuring the mass of the pre-form and cap. In addition, they also check whether
the body labels are properly printed and contain all the information needed. The chemists take
sample from the pure water tank and perform physicochemical analysis every 30 minute. The
operators of the treatment section control the purification process starting from the sand filter
up to UV light and perform CIP (cleaning internal part) according to cleaning and sanitation
schedule and procedure. After they perform CIP, the chemists take sample and check the PH.
The pre-forms are stored in the storage room and only pre-forms required for immediate use
are kept in the bottle blowing area. Pre-forms arrive at the blowing machine with cartons inside
covered with poly bag and opened immediately before putting it to the pre-form conveyor to
avoid contamination. Touching pre-forms with bare hand is not allowed, so if it is necessary to
touch pre-forms on the conveyor the operators always did this with glove. The operators
remove deformed and improperly blown bottles before going to the filling machine. The
blowing machine operators were always alerted to check the quality of the blown bottle. The
blowing machine was cleaned and polished regularly. Operators of the filling machine always
cover their mouth and nose because direct breathing, sneezing, and coughing towards the filling
machine is avoided. The cap conveyor was closed and cleaned regularly. The light inspection
personnel’s check the purity of the water, over fill/under fill, accurate capping and proper
blowing of bottles, proper labeling, and date coding of bottles. Operators of the labeling
machine check whether the labels are putted on each and every bottle. The products are stored
according to their production date.

46
2.6 Work tasks that I have been executing
Work tasks that I have been executing are asking operators about machines and understanding
how those machines work, operating different machines, executing different works with
operators like maintenance (welding, replacing crushed bolts), cleaning machine parts,
lubricating rolling machine part and adjusting machine when it is in abnormal position. Also,
I have been working on some part of machine-like horizontal Lathe Machine, chopper, milling
machine, construct control panel and winding, by advising of Lab assistant when I was
participating in the work.
2.7 Work pieces
A piece of raw materials that are used in the process of manufacturing in the Electrical
workshop and mechanical workshop are : Steel rule 300mm, Combination Plier 200mm,
Electricians Knife, Screw driver 200mm, 10mm, Ball peen hammer 220gm, Gimlet 25mm,
Neon tester 0-500V, Wire stripper, Firmer chisel 5/8”, Iron sheet metal (t=1.5mm & t=2.5mm),
Shafts , Aluminum sheet metal, Pulley , Bolts and nuts , Bearings , Belts, Electric motors ,
Shaft couplings , Gears & etc.
A piece of machines that are used in the process of manufacturing in the Electrical workshop
and mechanical workshop are: Lathe Machine, Milling Machine, Shaper Machine, Power
Hacksaw Machine, Drilling Machine, Surface Grinder, Tool Grinder,
2.8 Electromechanical Engineering Methods, Tools and Techniques I Have Been

Using While Performing my Work Tasks
2.8.1 Electromechanical devices and components
There are many electromechanical devices that are found in bottling section, filling section,
capper section, video jet, utility section, labelling sections packing section and palletizer
section of the company. Those are: PLC, HMI, Backup switch, Photocell, Encoder, Sensor,
and Transducers.
1. Programmable logic controller (PLC): - They are used extensively in industrial

manufacturing. There are three different functional types: opposed (through beam),
retro-reflective, and proximity-sensing (diffused). Conceptual through-beam system
to detect unauthorized access to a secure door, If the beam is broken, the detector
triggers some remote alerting device.

47
MEMORY
PROCESSOR
INPUT / OUTPUT
DEVICES
Figure 2. 21 Programmable logic controller (PLC) software controlling system
Component of programmable logic controller
A typical programmable machine has three major categories as shown in Figure above
1. Processor, which processes the information collected from measurement system and takes
logical decisions based on the information. Then it sends this information to actuators or
output devices.
2. Memory, it stores

48
a) the input data collected from sensors
b) the programs to process the information and to take necessary decisions or actions.
Program is a set of instructions written for the processor to perform a task. A group of
programs is called software.
3. Input/output devices: these are used to communicate with the operator.
Typically, a PLC system has five basic functional components in which are used by Asku plc.
Those are: Power, CPU, Input and Output device, Communication Module (Signals), and
Interface module.
Basic Principle of operation of PLC: PLC functions using relay, ladder logic programming.
Ladder logic allows PLCs to perform any command within the loop at any time without
executing previous commands. There are three states of operations: -
I. Detect incoming signals

II. Process it
III. Generate outputs to control various devices.
Programming a PLC
PLCs are programmed through concept of ladder logic. In general, there exists a graphical
user interface (GUI) to program a PLC that makes it different from other processers. Ladder
logic comprises of two columns. Left column shows input devices like switches, sensors
while in output column is at right side which shows actuators like cylinders, motors.
Microprocessor
It is a multi-purpose, programmable device that reads binary instructions from a storage

device called memory, processes the data according to the instructions, and then provides
results as output. It also known as CPU (central processing unit).
2. Human Machine Interface (HMI)
The function key depends on the operation personnel operate the common I use are listed
below:-
F1: Press F1 on HMI, enter “login” dialog box, then type username and passwords; Press F1
again, enter automatic controlling page. (Remark :)
F2: pressF2 to realize switching between chines and English operation interface

49
F3: press F3, enter user management
F4: press F4 exit the current user page
F8: press F8 if u want to login in other account
F10: press F10 switch to original page
3. Backups: -Is an inductive sensor which is used to detect an overload. It is mainly

found at the side of bottle conveyor. It works by using comparator, solenoid, and
copper conductor.
4. Photocell: - It is a device used to detect the presence and absence of bottles or crates.
Some photocells have two different operational types, light operate, and dark operate.
Light operates photo eyes become operational when the receiver "receives" the
transmitter signal. Dark operates photo eyes become operational when the receiver
"does not receive" the transmitter signal. It has sender (LED) and receiver
(photodiode) parts. The LED emits light, and the photo diode receives this light and
change to current signal to input the PLC.
5. Encoder: -It is an electrical input device used for synchronization and position
control purpose. It operates by pulse counting that an object moves. Encoder can be
used in applications where length, positions, speed, or an angular position are
measured. They transform mechanical moments into electrical signals and can be
divided in to incremental and absolute measuring system.
6. Transducer: -It is electro-mechanical devices which convert physical quantities, such
as pressure, to a proportional electrical value, such as voltage or current. A transducer
is a device that converts one form of energy or physical quantity into another, in
accordance with some defined relationship. A transducer is the sensing element that
responds directly to the physical quantity to be measured and forms part of an
instrumentation or control system. Then the transducer is often referred to as a sensor.
It is a device that converts a primary form of energy into a corresponding signal with
a different energy form. The primary energy forms are mechanical, thermal,
electromagnetic, optical, chemical, etc. It is the form of a sensor or actuator.
7. Sensors: -Are an electrical input device used to sense different status of a system.
There are many sensors in production system. It is a device that receives a stimulus
and responds with an electrical signal. Consider a prototype of industrial assembly
line with 3 stations

50
At first station ST1, the sensor identifies an object (finished product) on the conveyer belt and
sends a signal to the controller. Controller processes this information and actuates the electric
motor to run the conveyer belt.
Second Station ST2: It is allotted for the inspection of the finished product or object. At ST2,
conveyer belt stops. In case any fault diagnosed by the inspection system, the product will be
taken away by the pneumatic actuators placed at Station 3, ST3.
The most common used sensors in production system are: -
i. Level sensor: 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. They
have vertical floats that move with the liquid level, and this movement is used to
operate switch contacts. It operates by sensing the change in capacitance and
frequency value. In filling house to control level of tank and in filler machine to detect
whether the bottle is full or not.
ii. Temperature sensor: -It is a device used to detect the temperature of liquid, gas, etc.
It commonly used in motor control applications, those are thermostats and
thermocouples.
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. They work by the combination of R= Ro (1+∝ (∆𝑇))
when R↑, 𝑇 ↑ and when R↓, 𝑇 ↓.
iii. Capacitive sensors: -It is a proximity sensor that can be used to detect nonmetal
objects, such as liquids and plastics an inductive sensor is a proximity sensor which
detects metallic objects without touching them.
iv. 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
v. Conductivity sensors: -It is widely used in manufacturing applications. It senses
when the conductivity of water (ionization) increases above the setting value.
vi. 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

51
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.
vii. 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 sensing surface. The presence of
a metallic object (actuator) in the operating area causes a dampening of the 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.
8. Blower Machine
The machine is highly automatic and intelligent, performance is stable and reliable, high
production rate while low cost, products are not contaminated by intermediary production
process.
It is a high-speed rotary bottle-blowing mechanism molding bottles by the way injecting the
high-pressure air into the heated PET preforms adopting the world-class bottle making
technique.
Electromechanical control method section of blower machine
The electricity control section is composed of Programmable logic Controller (PLC), human-
machine interface (HMI), transducer, power adjuster, communicable current monitor, and
infrared heating system etc. It completes the running and control of the whole machine. The
adopted communication, control net includes Device Net (1769), ControlNet (1756), Ethernet
(1734), PROFIBUS(S300) Complete parameter gathering and measurement of heating
temperature, the preform temperature and out feeding bottle temperature by analog module;
Adopt HMI to realize the local control and monitor.

52
A) Panel of Programmable logic Controller (PLC) B) Human-machine interface (HMI)
Figure 2. 22 Practically control training on Programmable logic Controller

Parameters and adjustment of Blowing Machine
Auto run system of Blower machine
Table 2.1 Auto run system of Blower machine data [10]

NO Description Value Unit NO Description Value Unit
1 Out put 18000 BPH 7 Pump cycle 100 R
2 Main motor 33.3 Hz 8 Preform send 20 Hz
3 Fan Hz 25 Hz 9 Preform feed 15 Hz

53
4 Pump fun 25 Hz 10 Preform trim Hz 35 Hz
5 Mouth 15.4 C° 11 Preform 14.3 C°
6 Current angle 0.0 Deg 12 Mouth cool 35 %
Air Pressure Alarm Setting
Table 2.2 Details of Air Pressure Alarm Setting [10]

NO Description Value Unit NO Description Value Unit
1 High Pressure High 10 Bar 7 High Pressure High 20 Bar

Alarm Alarm
2 Low Pressure High 12 Bar 8 High Pressure High 5.0 Bar

Alarm Back Alarm
3 Low Pressure High 10.0 Bar 9 High Pressure High 5.0 Bar
Alarm Alarm
4 Pre blow High Alarm 15.0 Bar 10 Pre-Blow Low Alarm 2.0 Bar
5 Pilot High Alarm 9.0 Bar 11 Pilot Low Alarm 6.0 Bar
6 Stretch High Alarm 8.0 Bar 12 Stretch Low Alarm 6.5 Bar
Oven
Table 2.3 Oven data [10]

No Description Value Unit
1 Ejectors preform counter 0.0 B
2 Pre-Temp SP 88.0 ◦C
3 Pre-Temp PV 14.4 ◦C
4 Present voltage 386.6 V
5 Pre-Temp Adjust Scale 100 %
6 Fan HZ 100 Hz
7 Pump Fun 20 Hz

54
Heater
Table 2.4 Heater data [10]

No Description Front Back
1 1st 38.0 38.0
2 2nd 32.0 32.0
3 3rd 20.0 20.0
4 4th 45.0 45.0
5 5th 50.0 50.0
6 6th 24.0 24.0
7 7th 15.0 15.0
8 8th 0.0 0.0
9 Oven Temp SP 17.9 18.2
10 Power out Scale 100.0 100.0
11 Oven stand sp 60.0 60.0
Angle setting
Table 2.5 Details of Angle setting [10]

No Description Low limit High limit Take time
Value Unit Value Unit Value Unit
1 Seal 45.0 Deg 220.0 Deg 1313.0 Ms
2 Stretch 25.0 Deg 180.0 Deg 1163.0 Ms
3 Preblow 53.0 Deg 79.0 Deg 195.0 Ms
4 Main blow 80.0 Deg 160.0 Deg 600.0 Ms
5 Exhaust 30.0 Deg 1125.0 Deg 180.0 Ms
Options
Table 2.6 Options data [10]

No Description Value Unit
1 Shield Mould Angle Min 85.0 Deg

55
2 Shield Mould Angle Max 280.0 Deg
3 Base Mold Protection Angle Min 265.0 Deg
4 Base Mold Protection Angle Max 295.0 Deg
5 Base Mold Orbit Act Max Deg 340.0 Deg
6 Fan work time after oven stop heating 600.0 S
7 Start fans after oven starts 3 S
8 Start feeding when high pressure recovers 1 S
9 Current angle 0.0 Deg
9. Filler machine
The filler machine of new plant is DSL-40*12 filling-capping Monobloc. This machine has 40
filling valves and 12 capping heads. This machine adopts many latest technologies, processing
flow, and structure, which makes is rank top on packaging machinery industries. It mainly
features neck handling, that is to say, the bottles are transferred with neck held by holding
plates and upper shaped plates which are driven by star-wheel. Thus, the whole process of
filling and capping finishes. This method is outstanding at the low friction to bottle format,
stable transmission, and precise processing flow, and so on.
Electromechanical control method section of filler machine

56
Figure 2. 23 Practically control training on HMI of Filler Machine
The filling machine has the following technical data:
Table 2.7 Filling machine technical data [10]

Items Technical Data
Type of Filling Gravity Filling
Max. Speed(500ml) 18000BPH
Number of Filling Heads 40
Number of Capping Heads 12
Voltage of Power Supply AC380V/50Hz-G+E
Auxiliary Voltage 24V
Main Motor Power 4Kw
Other Power 12Kw
Dimension (LxWxH) 4800x3500x3300
Filler Machine System
As filling machine composed of filling valves, filling tank/bowl, capping machine with its
capping heads, and cap hoper with its cap elevator. These all components of the filler machine
work together to fill and cap the bottle. To perform their tasks, these components need some
system. There are systems like electrical system, mechanical system, and pneumatic systems.
The electrical system is used to energize the machines drive, sensors, and solenoid valves. And
mechanical systems are like gear system, star-wheels arrangement, bottle guide and all rotating
parts. And pneumatic systems are used to push the caps from the cap elevator along the cap rail
to the cap distributor.
Three position probes fitted in the filling tank automatically regulates the machine speed based
upon product inflow, using a panel mounted PLC. “NO BOTTLE NO FILLING” system
arrangement is standard features of the machine.
The bottle feed moving on transfer rotor, this transfer rotor/star wheel feeds the bottle from the
filler rotor to the capper rotor. The Capper Rotor bringing the bottle below the sealing head in
the subsequent indexing part, meanwhile the rotating head pick up a cap from the cap star
wheel/cap distributor which is receiving from delivery chute of cap transferring rail, where the
body and the neck of the bottle are positioned below the rotating head, where the sealing head

57
is performing perfect operation of sealing. The Capping adopts a unique “PICK & PLACE”
mechanism for capping in conjunction with an efficient bottle anti-rotating device. The bottle
is held at the neck firmly during capping to produce absolutely leak-proof results
Electrical System
The motor drives the biggest gear that runs the filler and other pinions are interlocked to run
the star-wheels. The star-wheels are driven by the spur gears of themselves attached to each
other. The main drive receives the power directly from the motor and all the rest pinion gears
are run by this gear. The main machine drive motor has variable speed A.C. Drive, by which
the machine speed can be varied depending upon the bottle size to be run.
Mechanical System
The mechanical system of fillings machine is like spur gears system, bottle guide, star-wheels,
and filling valves.
Spur Gear System
The spur gears are interlocked to run the filling machine, the capper, and all the star-wheels.
The gears are connected to each other by the help of their teeth. The main drive gear receives
the speed from the main motor drive. Then it directly transfers the rotation to empty bottle-
feeding star-wheel and filled bottle to the capper. Other star-wheels are connected to each
other receiving the rotation from the empty bottle feed to the filling valve.
Figure 2. 24 Coupled star-wheels

58
The star-wheels are arranged in according to transfer the blown bottle from blowing machine
to the filling machine. They all rotate inversely to each other giving and taking the bottle by
hanging the bottle at the bottle neck. There is a mechanism called bottle guide that helps the
bottle to transfer from one star-wheel to another.
1st star-wheel receives bottle from blower
2nd star-wheel
3rd star-wheel
4th star-wheel to transfer to bottle delivery star-

wheel.
Figure 2. 25 Transfer star wheel

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The Filling Valve
The Mono bloc rotary gravity filling machine in 40 filling valves which are functioning
independently. No Bottle No Fill for individual head, hence no spillages. The filling system is
a gravity filling. Since the product is spring
water there is no need of any pressure to fill the bottle. The mechanical filling valves, mounted
radically on the rotary filling tank, are actuated automatically by the bottles when lifted up to
commence filling. Here again the bottles are held at the neck by neck holding grippers which
ensures precise valve centering. Consequently, there is no bottle damage or water wastage
during filling.
Pneumatic System
Pneumatic system of filling machine is used to provide the cap from the cap hoper to capping
head of capper.
Caps are fed into the machine by an automatic cap elevator having ground level hopper. This
hopper also has an automatic agitator, which gets activated as soon as the caps stop moving
inside the cap hopper. Thus, the elevator is never starved of caps since it is to be filled
periodically. The elevator orientates and feeds caps at the desired rate through the cap rail to
the capper distributor rotor. Shortly before cap pick up the caps are exposed to UV light for
sterilization. After capping, the bottles are discharged on to the out-feed/ delivery conveyor.
Pushes the cap towards the rail

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Air is blown to push along

the rail to chute
Figure 2. 26 Pneumatic system of filling machine
Capper Machine
The capper is found in the Mono Block Three in One filler machine. It is chuck type and has
12 heads. The use of capper is to tighten and seal bottles by applying consistent torque by the
rubber inserted in the chuck to reliably seal each bottle.
Capper chute machine
It is a component that holds cap in place and ready for the next bottle that passes under the
chuck. The chute itself uses several components to ensure that the capping machine will be
able to tighten bottles continuously and consistently.
Figure 2. 27 Capper chute machine

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2.9 The challenge I have faced during my Internship Program

2.9.1 Challenges
During my internship program I have been faced many challenges. The challenges are:
➢ Most of the time supervisors of each department busy, due to this it is difficult to get more
information when I want any time.
➢ Ignorance from workers
➢ Shortage of time
➢ Limitation of internet access
➢ Shortage of materials and machineries
➢ Shortage of safety materials
➢ Transportation problem.
2.9.2 Solutions
➢ Using of personnel available with the most possible way regarding technical part since
they are better in respect to practical view and reading what I have learnt before and
being timely in working area to solve manpower problem.
➢ My transportation problem was solving by using any alternative tax service.
➢ Regarding material and machinery shortage efficient utilization of materials, making
useless things useful and using machineries in free time were some of solutions
➢ Creating peaceful working environment using interpersonal communication to solve
problems and talking to workers wisely to solve ignorance from worker.
➢ I kept safety by bought safety shoes in order to involve my hand in the job.

62
CHAPTER THREE
THE OVERALL BENEFITS I GAINED FROM THE INTERNSHIP
Internship is one method of making opportunity for university students potentially valuable
and explores general career avenues as well as specific companies such arrangements can
provide me with valuable work experience (both practical and for resume enhancement) and
an opportunity to line up a job before graduation, in addition to securing good work experience.
Internship programs are also potentially valuable to company. Unfortunately, some companies
continue to regard interns as little more than a free source of labor to catch up on filing and
other tedious office tasks. While I participate in this internship, I expect that only practical and
theoretical knowledge will be gained in the internship but after completing of the internship I
was able to realize that I got so many benefits, some of them are describe below from intern
perspective view and company perspective view. The major benefits that I get form the
internship are classified and stated as below briefly.
3.1 Knowledge and Acquaintances Acquired

3.1.1 Technical Skill I Gained
I gained practical experience of applying engineering judgment and working successfully with
others.
Creativity and an innovative approach to solving problems.

The ability to analyze and interpret diverse.
Critical thinking and the ability to solve problem.
Effective assessment and management of resources and time.
Interpersonal sensitivity, persuasiveness, and the ability to work as part of a team.
3.1.2 Management skill I gained
Management is a process of leading the careers of the company. Problems in the company
come in all size, shape, and color in different period of time. Thus, a person who is in the
position of awareness of ethical issues and the wider impact of work leadership seeks optimal
solution to problems and should be smart enough to manage those individuals whom he/she is
leading.

63
What I gain from the internship regarding improving leadership is that to inspire workers into
higher levels of teamwork, there are certain things must be known to do that.
Those are: -
Know their selves and seek self-improvement.

Be technically profession.
Make sound and timely decisions.
Keep workers informed.
Develop a sense of responsibility in workers.
Ensure that tasks are understood, supervised, and accomplished.
3.1.3 Acquaintances I Acquired
In the company, I have gained an experience from our internship program. Individuals often
learn different things from colleagues through communication. For any individual,
communication is an important way of learning, which can be defined formally as the act,
process, or experience of gaining knowledge or skills.
Good communication in life is crucial part of life. And it takes many forms, such as speaking,
writing, and listening, it has the following advantages.
To handle information
To persuade people
To improve relationships with others.
During this time, I have gained confidence on how;
➢ To ask different questions.

➢ To make discussions.
3.2 In terms of Improving Practical Skill
From the beginning internship program is prepared for the purpose of making students skillful
practically. So, this internship program is used for me in order to upgrade practical skills.
Although the time for the internship program is not much enough to be perfect skilled, I tried
to improve my practical skills. Generally, I got the following practical skills from my internship
program.

64
Able to connect the wiring of starting methods of induction motors.
❖ Star-delta starting
❖ Direct online starting method
It enables me to be rewinding of motor.
It enables me to improve my practical skill in the maintenance and repair of different machine
and electrical instrument.
Improve my practical skill in the operation of different machineries.
In improving my practical skill this internship has played a vital role because I have seen and
worked on different material, control parts and other equipment’s. I have tried my best to
correlate my classroom studies to the actual world and I have referred books again to remember
the theoretical part. I have observed problems and I have worked on the solution in practice
with co-workers of the company.
3.3 In terms of upgrading my theoretical knowledge
Internship program gives me the opportunity to apply my theoretical knowledge in real world
environments, in addition to the practical skill. Almost all the courses I took were focused on
theoretical part, thanks to this internship program; I am now able to upgrade my theoretical
knowledge by practice. Generally speaking, my theoretical knowledge got strengthen more by
those practical techniques invested on site. It assists me in moving toward my career goals by
combining what I had learned from course, practical and supervised work experience; it thus
explained the necessity of every student to undergo this process.
3.4 In terms of improving my team playing skills
Even if tasks are done in together by the respective person at different section of the company,
there are times at which different individuals come together to work for common goals of the
company for increasing productivity. The most important point in team playing skill is just
reaching an agreement from different points on the work to be done. Furthermore, to have a
common understanding on the task that is to be accomplished, I always try to listen carefully
those individuals with whom I am working. Generally speaking, a person whose have a good
team playing skill have the following qualities
✓ Demonstrates reliability
✓ Communicates constructively

65
✓ Listens actively
✓ Functions as an active participant
✓ Shares openly and willingly
✓ Cooperates and helps others
Some advantages of teamwork skill are the following.
✓ Provide a valuable opportunity to achieve high quality outcomes.

✓ Foster collaboration, as well as competition.
✓ Develop workers confidence and active participation.
✓ Develop a supportive working environment.
✓ Bring together people with differing expertise and different perspectives.
✓ Lead to creative and innovative solutions to complex problems.
✓ Give workers a chance to perform a number of different roles.
✓ Develop other skills such as project management, time management, problem solving,
communication, conflict resolution and negotiation skills.
3.5 In terms of improving my leadership skills
Leadership is a process of leading the careers of the company. Problems in the company come
in all size, shape, and color in different period time. Thus, a person who is in the position of
leadership seeks optimal solution to problems and should be smart enough to manage those
individuals whom he/she is leading. What I gain from the internship regarding improving
leadership is that to inspire workers into higher levels of teamwork, there are certain things
must be known to do that, these are:
✓ Know our selves and seek self-improvement

✓ Be technically proficient
✓ Must be confidential
✓ Must be punctual
✓ Must be active and self- reliant
✓ Try to understand problems and able to give solution
✓ Seek responsibility and take responsibility for actions
✓ Make sound and timely decisions
✓ Know peoples and look out for their well-being
✓ Keep workers informed

66
✓ Develop a sense of responsibility in workers

✓ As a leader to have clear and defined goals, missions, and visions
✓ Ensure that tasks are understood, supervised, and accomplished finally what I grasp is,
and becoming a leader is not easy because it takes a conscious commitment and
consistent effort to develop one’s leadership skills.
3.6 In terms of understanding about work ethic, industrial psychology, and

related issues
In today’s complex world, Ethical conduct of workers is very important for developing healthy
working environment and increasing productivity. Ethical work conduct enables us in order to
posses’ appropriate behaviors in the work and so I develop proper relationships with coworkers,
and it helps us to create good working environment. There are two common types of ethics.
These are: -
I. Personal ethics and

II. Professional ethics
3.6.1 Personal Ethics
These principles of personal ethics are values which are expected to be possessed by all
individuals in their life and contribute a lot for a smooth interaction among individuals and
peaceful coexistence of a society. What I gained in the company principles of personal ethics
include:
• Honesty
• Fairness
• Compliant to the law
• Benevolence (doing good)
• Refusing to take un-fair advantage
3.6.2 Professional Ethics
Professional ethics refers to the standards or a set of moral principles for regulating behaviors
of a certain defined profession. In order to consider that an activity to be a profession, it should
be carried out by one who has advanced education, knowledge, and skills. Thus, for developing
healthy working environment and increase productivity, ethical work conducts are important

67
medium. The following are some of the common professional ethical principles what I gained
in the internship period.
Punctuality- means keeping the companies work beginning and ending time and to complete
a given task within the given period.
Office disciplines- in work place you do not have to disturb the working atmosphere. For
example, abstain from opening loud voice, loud music, songs, and things which disturb other
workers’ working mood.
Reliability- The worker should be qualified for the part he is supposed to be performing.
He/she must have appropriate skill and knowledge for the task assigned.
Honesty- Regarding this value each worker regardless of its status should abstain from bad
behaviors such as cheating, bias, corruption etc.
Cooperation- Each worker should interact and cooperate with each other while working. That
is because it is through such system problems could be easily solved.
3.7 In terms of entrepreneurship skills
Entrepreneurship is the development of a business from the ground up – coming up with an

idea and turning it in to a profitable business. Therefore, entrepreneurial skills are skills needed
to have to succeed in business. Entrepreneurial skill can be defined as the ability to create
something new with value by devoting the necessary time and effort. I have understood a good
entrepreneur have the following skills.
➢ Technical knowledge and expertise

➢ The wisdom to seek out and listen to the advice of those who know what he/she does
not know.
➢ Ability to learn from his mistakes.
➢ Self-discipline.
➢ Ability to make quality decision: the talents to analyze complex situation and draw
conclusions that will make the business succeed.
➢ Hard work: being capable of doing the work and enjoying it.
➢ Concentration: sticking it out through distraction to get the work done.

68
➢ Communication skills: the ability to express yourself and to understand others so that
ideas can be shared.
➢ Motivation: the mental and physical drive to succeed, to accomplish chosen tasks on
your own terms.
➢ Organizational skills
➢ Decision making skills
➢ Supervision/management skills
Participating in an internship allows me to gain a better perspective of post-graduation

employment by applying the principles and theories I have developed in the classroom. This
practical application creates an easier transition for me from the classroom to the working
world.
While participating in this internship I realize that creativity and problem solving is one of the
starting points of entrepreneurs. And motivates me not to be employee because it enables me
to know more about my career, the real challenges and way of business establishment in this
profession.
3.8 In terms of improving my interpersonal communication
Communication skill is a means of sharing an idea between different peoples through verbal
language, activity, participation, and teamwork. Communication skill is important in
relationship, education, and work. As we know most of work in the industry is teamwork and
for teamwork good interpersonal communication skill is compulsory.
In the company, I was working with all the staff members and any individual peacefully, by
the experience I have gained from my internship program. For any individual, communication
is an important way of learning, which can be defined formally as the act, process, or
experience of gaining knowledge or skills.
• To handle information
• To persuade people
• To improve relationships with others
I learnt that one full system should work efficiently with union of so many professional by
collaborating with each other in order to make good and fantastic work.

69
CHAPTER FOUR
OVERALL CONCLUSION AND RECOMMENDATIONS FOR THE
COMPANY
4.1 Conclusion of internship program
The program that developed between the University and the company helps me to introduce
my selves to a new environment & upgrades my theoretical knowledge and incorporated with
the practical skills. "Learning theory without practice is lame and practice without theory is
blind" (Albert Einstein). The internships Asku plc makes the new curriculum so good to give
real practical skills and make the students familiar with equipment’s and to the outside world.
Even though there was a gap between the things which I know in the class with the outside
environment, I got practical work experiences and benefits at the company of Asku plc.
The period was so good, and things what I gained are beyond my expectation. The operation
and maintenance team are a huge and well organized, and for such huge company facilities and
resource requirements must be seen seriously so that the benefits would so be helpful in country.
I have seen in the workshop that safety is the primary condition.
In generally I concluded some of internship benefits as follow: -
• Allow me to make and develop professional contacts, for my future job search.
• Assist me in developing greater understanding of my own strength and weakness,
• Know about how engineering assumptions are made to minimize errors.
• Observe the machine structures and their respective usage.
• Creates chance to put my theoretical knowledge in to practice in the real world.
• The knowledge of company’s workflow
• Develop industrial problem-solving capability
• Knowing working standards
• Internship has helped me to interrelate the theory & practical aspects.
• I learned work ethics
I can generalize that the overall apprenticeship program was very fruitful in terms of helping
me gain experience in the real-world working environment.

70
4.2 Recommendation
During my four months of internship experience period, I have seen some positive and negative
sides about the internship hosting company. In this part of my report, I will try to suggest some
ideas for internship hosting company and university.
4.2.1 Recommendation for the university
Having an internship offers a list of advantages to the students, for instance it helps us to grow
not only practical experience and knowledge related to our academic and career goals.
Should design and prepare a web site to communicate with different company for easy
Integration of student with company.
Should pay the intern payment of student at the right time.
The student must have a health insurance in the internship program
During internship program time, I have faced financial problem as the ongoing inflation
outpaced the allocated budget. Therefore, I recommend the budget allocation
inconsideration with the broad economic instability.
The university should arrange some practical visit in some courses. Because it helps
the students to easy understand what they are learnt in laboratory and lecture class. In
this internship I saw how it is easy to understand on practical work.
I recommend the university to improve the following points: -
✓ There is lack of coordination between university industrial linkage and host companies
✓ The university should assign the students (the one who does not get hosting company)
in good companies on time but it does not
4.2.2 Recommendation for my internship hosting company

Aqua Addis bottled water company- Asku plc is highly profitable company through good
leadership, good team work and through hard working. Even if the company is highly profitable,
it has some problem. Based on the internship experience I have some recommendation for the
company. Asku plc must improve the following problem in order to be more competitive:
✓ Forming of relation between university and company is less so, the company should
be linked for developing theoretical knowledge into practical and for future job
search.
✓ The company should provide full safety to the employees.

71
✓ The company does not have well organized workshop and does not enough workshop
Materials; the company should be full filling those materials for effective work and
desired products.
✓ The internship program holds benefits to the field supervisor and hosting company by
providing motivated workers at are relatively small cost to an organization and
furnishing the opportunity to train possible future employees for the organization.
Participating in internship program allows the field supervisor and organization to
maintain a working relationship with the university in which I am enrolled. Therefore, I
suggest that
✓ The company should host more intern students in the future for the common good of the
student and its company.
Also the company should be creating safe working area to attract the workers daily and to
increase their activity. Additionally, it should be full fill good service for ley workers and for
intern students in case of giving dignity for all human being is the interesting thing.
I recommend that the meters should be changed from analog to digital meters for reporting
accurate measured values of power, voltage and current. Then I suggest to our supervisor its
good when the analog systems change to digital.
Because of: -
➢ To measure the value of parameters correctly

➢ To identify the type of fault
➢ To get multifunction
➢ To reduce the cost and other
When I ask them to do in practical, they say there is no equipment, software, and internet access.
In this case I could not done in practical.
So, I recommend them in ideal. Generally, the Asku plc can solve the facing problems by
improving the old model machineries of their design systems; by changing the manually control
systems by automatic control systems and the best solution. After this all improvements the
company will be more efficient company in the country.
Generally, my comment to overcome the abovementioned challenges and problems can be: -

72
✓ The company should finish any type of an agreement on design of the electrical
installation and mechanical project work, and it must sure that the site ready to the
apparent student before hosting in order to help them in gaining the practical
knowledge from the site of Asku plc.
✓ The analog part must be substitute with digital.

73
REFERENCES
[1] Aqua Addis Bottled water company- Asku plc., "Information source of the company," Plant
Manager, Addis Ababa, 7 March 2022.
[2] Aqua Addis Bottled water company- Asku plc, "www.askuplc.com.et".
[3] ABIG ( Asku and Berhane Investment Group), "www.ab-ig.com".
[4] Aqua Addis Bottled water company- Asku plc., "Oranogram," Quality system Head, Addis
Ababa, 20 August 2021.
[5] Daily activity , My Self (Milkesa) Note Book Of Internship Program, Addis Ababa, July
01,2022-October 30,2022.
[6] Data orally I collected from the Mechanical & Electrical supervisor, Addis Ababa: Milkesa,
July 01,2022-October 30,2022.
[7] B. K. Bose, Modern Power Electronics and AC Drives, Prentice-Hall, N.J., 2002..
[8] Enternet, Google / Wikipedia.
[9] C. W. d. Silva, "Mechatronics," in Mechatronics An Integrated Approach, CRC Press, Nov 29,
2004, p. 1348 pages.
[10] Oral data I recorded from Machine operators, Addis Ababa: Milkesa, July 01, 2022- October 30,
2022.

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APPENDIX: Certification of Completion

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ARBA MINCH UNIVERSITY

COLLEGE OF ENGINEERING AND AGRO-INDUSTRIAL

DEPARTMENT OF ELECTROMECHANICAL ENGINEERING

INDUSTRIAL INTERNSHIP REPORT

HOSTING COMPANY: AQUA ADDIS BOTTLED WATER

FROM JULY 01, 2022 - OCTOBER 30, 2022 (FOUR MONTHS)

BY: MILKESA TEREFE BANGO

ACADEMIC MENTOR: Mr. UMAR RESHID

COMPANY SUPERVISOR: Mr. GUDETA BARI

Milkesa Terefe Bango RAMIT/1314/11

Approval of the Academic Mentor:

Mr. Umar Reshid ______________ ______________

Members of the Examining Board:

1. Rajkuamr Jonnakuti ________ ___________

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

2.4.6 Power distribution and motor starting method Section ........................................................ 31

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

ABIG Asku and Berhane Investment Groups

AC room Air Compressor room

CIP Cleaning Internal part

CSD Carbonated soft drink

DOL Direct On-Line Starter

EEPCO Ethiopian electric power corporation

HACCP Hazard analytical critical control point

ISO International Standards Organization

PET Poly Ethyl Terephthalate

Plc Private limited company

PLC Programmable logic control

TDS Total Dissolved solid

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

1.1.1 Background of the organization

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

Figure 1. 1 Asku Plc Actually and Map view

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

1.1.4 Vision of the Company

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

I. Amenti Food Processing plc

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

VII. Asku plc

1.2.2 Main products of the organization

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

1.3 Main customers

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

Figure 1. 4 Process of customer supply line of the company

The main customers end users are:

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

1.5 Over all Organization Workflow

Purchase Raw material receiving Raw material storekeeper

Test Report Raw Material

Sales Order Production

Chlorinated Treated from

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

No Regulat QA analyst &

Water Free Treated from Treatment

Treated Free from fine Treatment

Free from Free from fine

Standard Ozone Tower Ozonized Treatment

FINAL INTERNSHIP REPORT BY MILKESA TEREFEE BANGO 2022 G.C

Mr. Umar Reshid

1. Rajkuamr Jonnakuti ___