P.O.

BOX: 1162 Kigali-Rwanda

Tel: +250 788593519
Website: www.Amekicolor.com
E-mail: info@amekicolor.com

REPORT FOR INDUSTRIAL ATTACHMENT DONE IN

AMEKI COLOR CO.LTD FROM 28 THDECEMBER 2020 TO
26TH FEBRUARY 2021

Submitted by: KARASIRA Fred Bruno

Registration number: 19RP00311
Department: Electrical and electronics Engineering
Option: Electrical Technology
E-mail: brunokfred04@gmail.com
Tel: +250 780 347 389
Academic year: 2021-2022

Supervised by HAKUZIYAREMYE Philbert

Tel: +250 788405280

November, 2022
 DECLARATION
I declare that this industrial report is a result of the work carried out during my industrial
attachment at AMEKI COLOR LTD during 8weeks from 19th September 2022 to 11th
November 2022. I declare to the best of my knowledge that this work is original and has
never been presented or submitted to any other University or higher Learning Institution. Any
work quoted in is indicated and acknowledged by means of a list of references.

KARASIRA Fred Bruno

Signature…………. Date……/…../….

i
 CERTIFICATION

This is to certify that KARASIRA Fred Bruno has completed an industrial Training in
AMEKI COLOR LTD from 19th September 2022 to 11th November 2022. We also confirm
that his report was revised and corrected to be relevant to manufacturing process as applied in
AMEKI COLOR Co.LTD.

IPRC KIGALI ILO OFFICER SITE SUPERVISOR

Name and Signature:

Name: HAKUZIYAREMYE Philbert

…………………………

Date…../…../2021 Signature: .......................................

ii
 DEDICATION

I, KARASIRA Fred Bruno dedicate this work to Almighty God who strengthen me to reach
to this level. I also dedicate this work to all staff of my college and AMEKI COLOR LTD
especially those of Electrical Engineering(Plastics) who guide me with their tough ideas to
achieve all I had gotten. I dedicate this work to my parents, my class mates and my family
who raised me till now. I also dedicate this work to all colleagues, friends, and AMEKI
COLOR LTD workers especially those of Plastics Department who made a big effort with
their great ideas to achieve to the knowledge that I had gotten during my industrial
attachment.

iii
 ACKNOWLEDGEMENTS

I wish to express my gratitude and appreciation to the Almighty God for life, constant
mercies, love, favour, care, good health and inspirations He endowed on me throughout the
period of this internship. I also use this opportunity to thank my colleagues and friends and a
host of others too numerous to be mentioned here for their contributions, encouragement and
concern.

I’m also very indebted to my supervisor, Philbelt HAKUZIYAREMYE for his insight
professional supervision, encouragement and guidance importing the knowledge and skills
whenever required and for giving a wide view of any concepts during my industrial
attachment. I would like to acknowledge the commitment, sacrifice and support of all
workers of AMEKI COLOR LTD.

iv
 ABSTRACT

The industrial training is the special period of time particularly for young engineers where the
theoretical knowledge gained in the class have to be adapted with practical works
thereby developing the mind and hand on skills of the student about what was already done
on working field. I firstly conducted the training in AMEKI COLOR LTD.

This report involves all activities and explanations that I have made during 8 weeks. In this
phase, I have participated in different activities, especially in Electrical activities in Plastics
department where many of many plastics are fabricated and all Electrical maintenance
activities are conducted, where I have been able to learn working principles of different
machines, Hydraulics, Pneumatics and Electrical Equipment. Thus practical knowledge
obtained at AMEKI COLOR LTD effectively backed up the theoretical knowledge that has
been obtained at IPRC KIGALI in Electrical and Electronics Engineering.

v
 TABLE OF CONTENTS

ABSTRACT ........................................................................................................................... v
LIST OF FIGURES.............................................................................................................. viii
LIST OF SYMBOLS ........................................................................................................... viii
CHAP I: INTRODUCTION................................................................................................... 1
1.1. Background information about amekicolor..................................................................... 1
1.1.2. Site localization AMEKI COLOR ............................................................................... 1
1.1.3. Products/Services ......................................................................................................... 1
1.1.4. Background and necessity of the training .................................................................... 2
1.1.5. Training benefits and motivation ................................................................................. 2
1.2. TRAINING OBJECTIVES ............................................................................................. 2
1.2.1. General objective.......................................................................................................... 2
1.2.2. Specific objective ......................................................................................................... 3
1.3. METHODOLOGY.......................................................................................................... 3
1.3.1. Observation ............................................................................................................... 3
1.3.2. Interview ................................................................................................................... 3
1.3.3. Documentary approach ............................................................................................. 4
1.3.4 Participatory approach ............................................................................................... 4
1.3.5. Discussion and evaluation ........................................................................................ 4
CHAP II: LITTERATURE REVIEW.................................................................................... 5
2.1. PLASTIC MAKING ....................................................................................................... 5
2.1.1. Plastic Injection Moulding Machines........................................................................... 5
2.1.2. The Cycles of the Injection Moulding Process ............................................................ 6
2.1.3. MASTER BATCH ....................................................................................................... 7
2.1.4. HEATERS .................................................................................................................... 8
2.1.5. COOLING SYSTEM ................................................................................................... 8
2.2. PROTECTIVE EQUIPMENT ...................................................................................... 10
2.3. MILLING AND GRINDING MACHINES.................................................................. 11
2.4. Hand Grease Pump ........................................................................................................ 11
2.5. AIR COMPRESSOR..................................................................................................... 13
2.5.1. Pneumatic Control...................................................................................................... 13
2.5.2. Use of compressed air: ............................................................................................... 14
2.5.3. Properties of air .......................................................................................................... 15
2.6. FORKLIFT.................................................................................................................... 16

vi
CHAPTER III :CLASS THEORIES RELATED TO THE TRAINING ............................. 17
3.1. ELECTRICAL MOTORS............................................................................................. 17
3.2. TRANSFORMER ......................................................................................................... 19
3.3. ELECTRICAL GENERATOR ..................................................................................... 20
3.4. HYDRAULIC SYSTEM............................................................................................... 21
3.5. PUMP ............................................................................................................................ 22
3.5.1. Pumpingtheory: .......................................................................................................... 22
35.2. Pump classification: .................................................................................................... 22
3.5.3.pump installation ......................................................................................................... 25
3.6. RESERVOIRS .............................................................................................................. 25
3.6.1. Sizing of reservoirs..................................................................................................... 26
3.7. HYDRAULIC DISTRIBUTOR (DIRECTION CONTROL VALVE: D.C.V) ............ 27
3.7.1. Main causes of hydraulic distributor to fail ............................................................... 28
3.8. EMULSFIER PAINT MIXER ...................................................................................... 29
3.8.1.General Safety Measures............................................................................................. 30
3.9. PLIERS, SIDE CUTTERS, KNIFE AND AN ASSORTMENT OF ............................ 32
SCREWDRIVERS: .............................................................................................................. 32
3.10. WELDING MACHINE............................................................................................... 32
4.1.CONCLUSION .............................................................................................................. 35
4.2. RECOMMENDATION ................................................................................................ 36
4.2.1. Recommendations to AMEKI COLOR. ................................................................. 36
4.2.2. Recommendations to RP/ IPRC KIGALI ............................................................... 36
4.2.3. Recommendation to the Students in IPRS .............................................................. 37
APPENDIX .......................................................................................................................... 38
References ............................................................................................................................ 38

vii
 LIST OF FIGURES

Figure 9: Plunger type Injection Moulding................................................................................ 5

Figure 10: Injection Moulding Machine .................................................................................... 6
Figure 11:.Master batch ............................................................................................................. 7
Figure 2:Air compressor .......................................................................................................... 13
Figure 3:Pneumatic system ...................................................................................................... 14
Figure 7: Forklift machine. ...................................................................................................... 16
Figure 12.hydraulic system ...................................................................................................... 21
Figure 13.Reservoir.................................................................................................................. 26
Figure 15:Hydraulicdistributor (D.C.V) .................................................................................. 28
Figure 16:Emulsifier paint mixing machine ............................................................................ 29
Figure 17:Screw drivers ,knife, and pliers .............................................................................. 32
Figure 19:Welding machine..................................................................................................... 33

viii
 LIST OF SYMBOLS

IPRC: Integrated Polytechnic Region Center

WDA: Workforce Development Agency

RP: Rwanda Polytechnic

DCV: Directional Control Valve

CO: COMPANY

LTD: LIMITED

ILO: Industrial Liaison Office

IAP: Industrial Attachment Program

VCR: Vapour compression refrigeration

VAR: vapour absorption refrigeration

EAC: East Africa Community

ix
 CHAP I: INTRODUCTION

1.1. Background information about AMEKI COLOR

AmekiColor is part of the Ameki Group, which was founded in 1982 and also comprises
AmekiMeubles (furniture), Ameki Polyester & Plastic, and Ameki Real Estate. It was
founded in 1982 by Jacques Rusirare, a Rwandan entrepreneur, as Atelier de Meubles de
Kigali (Ameki) started small as a furniture workshop. But as demand for furniture continued
to grow, the quality of raw materials, such as varnish to polish the furniture, were becoming
increasingly expensive to access in the local market. The situation was very unfavourable to
the furniture makers but Rusirare spotted an opportunity he never regrets to have grabbed and
exploited it to the maximum. Entrepreneurial as he was, Rusirare decided to set up a small
paint-making plant primarily to make raw materials such as vanish for his furniture products.
But still demand for paint was also growing, and with time Rusirare increased the capacity of
the paint factory until it grew to surpass the furniture section. Since 1989, when AmekiColor
was added to the initial furniture section, the paint plant has grown to become Rwanda’s
leading paint maker, serving over 50% of the local market and exporting to the neighbouring
countries high-quality and long-lasting varieties of water and oil-based paints for different
purposes. Today, the Ameki brand, which has headquarters in the GIKONDO Industrial Park,
in Kigali, has four operational sections, which include AmekiColor, AmekiMeubles
(furniture), Ameki Polyester & Plastic, and Ameki Real Estate.

1.1.2. Site localization AMEKI COLOR

AMEKI COLOR LTD is located in Kigali Special Economic Zone , Kigali city, GASABO
District, Masoro

1.1.3. Products/Services
AmekiColor is the largest manufacturing section of the Ameki Group, generating the biggest
share of the company’s turnover. Through AmekiColor, the company manufactures a wide
range of water and oil-based paints and it also has a section that assembles aluminium tins
that carry the finished paints ready for the market. The plant currently produces various
paints, including matt emulsion paint, pure acrylic emulsion paints (weather guard), wall
master paints for exterior use, silk vinyl emulsion paints for interior use; high resistant floor
paints (epoxy), non-priming roofing paints, high-traffic road marking paints, office and wood
glue, and window putty.

1
1.1.4. Background and necessity of the training

As Academic year of IPRC KIGALI are planned, it is compulsory and necessary for every
undergraduate student in different department to perform the industrial attachment, As
Mechanical Engineering expect an industrial attachment for every undergraduate student
enrolled in Production department to acquire practical skills and application of the theoretical
knowledge learnt in subjects at the faculty. For this reason, I was performed my industrial
attachment in AMEKI COLOR from 19th September 2022 to 11th November 2022. As
results of training, Student should present the knowledge and skills acquired during the
period of industrial attachment in a form of Report to academic staffs at the institute at the
end of industrial attachment

1.1.5. Training benefits and motivation

I liked this industrial attachment for couple of reasons that some are even hard to express due
to better cooperation, attitude and motivation people I worked with in this period. I had meet
zealous people who could leave their work to explain everything I was eager to know.
Besides that, I learnt some machine operations and maintenance in the industry and at the end
I was capable to explain working systems and principal of some machine. Most of time in our
daily classes we spend time on theoretical knowledge which was the backbone during my
internship to put it into practice. We would reach the extent that skills acquired from the class
would work in addition to observation on the field. All above insight built in me to like my
career than before and everything I have learnt in class have its own way of practice and I
have opportunities to explore.

1.2. TRAINING OBJECTIVES

1.2.1. General objective

The general objective of this internship was to provide the student with the opportunity to
integrate relative practical experience with class theory. The student intends to get an
opportunity to relate academic programs and career goals to professional work experience.
For us as students our main objective is to improve our skills especially in practices, to get
technical skills and to apply knowledge based on applications, and maintenance of different
machines and gaining knowledge of production technology, and to know the difference
machines and their working principle for skills development.

2
1.2.2. Specific objective
In order to achieve the general objective of the internship, the following specific objectives
have been carried out:

 To understand very well the various functions of interesting machines.

 To get various information and explanations about how the machines works.
 To listen and follow the instructions of technicians on each concerning works.
 To work together with technicians in checking of the problems they are facing
and knowing how to give solutions to those problems.
 To observe the functions of each machine and see how its processes are done
until the final products.

1.3. METHODOLOGY

Methodology is the systematic,theoretical analysis of the methods applied to gather all

necessary data and information to accomplish this industrial attachment report.The following
are the basic ones.

1.3.1. Observation

Through the 8 weeks that I spent in the AMEKI COLOR , I have used to follow, observe and
undestand all activities happening in maintenance and technical service department like
hardware maintenance and repairing some machines such us injection molding machines
,pumps ,cooling systems,performing some operation plastics made machine and other
different activity like electrical installation.

1.3.2. Interview
I have used to ask some AMEKI COLOR techinicians questions about the working principle
of many electrical equipments how to install, repair and maintain and other curiosity
questions concerned with hands on skills all with the purpose of acquiring the knowledge
about them.

3
1.3.3. Documentary approach

I have utulized books,internet(website) and different service manuals of medical equipment

to collect all datas and information that help me to take over all mentioned in this internship
such as using internet for getting some knowledge concerning with information technology
and precaution before starting to use a machine.

1.3.4 Participatory approach

Since I reach there,I didn’t try to be like a manager for watching and following what was
taking a place.But observing,asking what was not clear for me and following instruction,I
have tried my best to participate in a daily activities happening in maintence department .

1.3.5. Discussion and evaluation

On every friday in this period of internship, we have had discussion gathering student and all
technicians talking about many issues like mistakes was committed and the manner of
correction,what wasn’t understandable and other application of the technology we have seen
rather than it was desinged before.

4
 CHAP II: LITTERATURE REVIEW

In this chapter Iam going to discuss some machines, I saw in AMEKI COLOR

2.1. PLASTIC MAKING

2.1.1. Plastic Injection Moulding Machines

Injection moulding process is generally used to achieve high speed moulding of thermo
plastic. It works on the principle that the molten thermo plastic is injected into a mould and a
high pressure is applied the desired shape is obtained. Plunger system is used for achieving
high pressure.

 Operation

The material that is to be used for moulding is loaded into hopper from where it is transferred
to the heating section. It is transferred using a feeding device where the temperature is about
150°C – 370°C.The material is melted and it is forced by an injection ram or by a plunger
through a nozzle in a closed mould.

 Maintenance of moulds

In my internship we have completely maintained different plastic moulds, by replacing the

oldest parts to another new manufactured one.

Figure 1: Plunger type Injection Moulding

This type of injection moulding system has two units. They are the injection unit and
clamping unit. In some cases these units may be split in order to eject the finished

5
component. First the selected thermosetting plastic is filled in a hopper. Then it goes to the
heating section where the thermo setting plastic is melted and the pressure is increased. With
the help of ram the heated material is injected under pressure. This makes the material to get
filled in the mould cavity through the nozzle to get the required shape of the plastic. In this
type of moulding system water is generally is used for cooling purpose.

Figure 2: Injection Moulding Machine

2.1.2. The Cycles of the Injection Moulding Process

Injection moulding involves a high pressure injection of a polymer into a mould where it is
shaped. The individual parts of this process are very short. The whole injection moulding
process usual lasts from 2 seconds to 2 minutes. There are four stages in the cycle. These
stages are the clamping, injection, cooling and ejection stages.
Clamping
Before the mould is injected with material, both halves of the mould have to be closed. They
are closed by a clamping unit. Both halves are then attached to injection moulding machine
and one half can slide. Material is then injected as the clamping unit pushes the halves
together and both halves are held tightly while material is injected. Larger machines
(machines with more clamping power) take longer to close and clamp the mould.
Injection
Plastic pellets are fed by means of a hopper into the injection moulding machine. These
pellets move towards the mould by the injection unit. The heat surrounding the barrel and the
pressure serve to melt the pellets. The volume of material injected is called the ‘shot’. This
injection time finished when 95%-99% or the mould is filled. It is hard to calculate exactly
the injection time because the flow of the plastic is always changing and dynamic. Injection
time can be estimated by other factors such as injection pressure,power and shot volume.

6
The injection pressure can range from 35-140 MPa. The rate of injection and the pressure
which can be reached are determined and controlled by the hydraulic system in the machine.
Cooling
The cooling process involves the plastic inside the mould beginning to cool after it makes
contact with the interior mould. As the plastic cools when it hardens it will take the desired
shape. The part may shrink slightly during cooling. Only when the cooling period has
elapsed can the mould be opened.
It is from the wall thickness of the part and the thermodynamic properties of the plastic that
the cooling time can be estimated.
Ejection
The last stage is ejection from the machine. This is done with an ejection system. When the
mould opens the part is pushed out, Force must be used because the part shrinks and sticks to
the mould. The mould can be shut again after ejection and another shot can be injected for the
process to begin again.

2.1.3. MASTER BATCH

Is a solid product (normally of plastic, rubber, or elastomer) in which pigments or additives
are optimally dispersed at high concentration in a carrier material. The carrier material is
compatible with the main plastic in which it will be blended during moulding, whereby the
final plastic product obtains the color or properties from the master batch.

Figure 3:.Master batch

7
2.1.4. HEATERS

Induction Ceramic Band Heater For Injection Molding Machine is on in many types of
heaters used in plastic melting, Ceramic band heaters are widely used for the barrels of plastic
injection molding machines, extruders, tanks and in a broad range of other industrial

applications.

2.1.5. COOLING SYSTEM

A pair of molds is a heat exchanger, heat by melting plastic into the mold, and then by the
mold into the constant circulation of cooling media-ice water, only a small part of the air and
injection molding machine pressure template. It is well known that the plastic molding cycle,
a considerable part of the cooling, sometimes can account for more than 80% of the plastic
molding cycle, so it is absolutely necessary to control the cooling time to the minimum. For
example, a mold forming cycle of the general play for 20 seconds, such as the original
cooling water tower to switch to the ice water chiller produced by cooling, it can be shortened
to 16 seconds. Although the initial selection of a chiller with a higher cost, it can increase
production by 20%, in the long-term production, can make great profits. So, how to choose
ice water energy?

From above we can know that it is related to the specific heat capacity of the molding
material, the temperature of the melt, the weight and the temperature when the product is
demoulding. We all know that the application of a wide range of chillers, of which there is an
application is the cooling of the mold, basically most of the mold production plant are

8
essential to this equipment, so today I specifically here to you in detail in the production of
molds how to choose the appropriate chiller. In addition, because the injection molding
machine is often used in conjunction with the chiller, so it is unavoidable to introduce.

The relationship between flow rate and pipe diameter:

Pipe diameter: 3/8″, 1/2″, 3/4″, 1 ", 1 '/4″, 1 '/2″, 2″, 3″

Flow: 12, 20, 35, 60, 90, 130, 230, 560

The formula for the energy of ice water required for a pair of moulds is: Q=W×C×T×S

In the formula: Q for the required ice water energy kcal/h;

W is the plastic raw material weight kg/h;

C for plastic raw material specific heat kcal/kg℃;

T is the temperature difference ℃ when the melt glue temperature and product remolding;

q=50x0.48x200x1.35=6480 (kcal/h), 6480kcal/h cooling capacity per hour, can choose ls203s
Chiller. In the actual selection of chillers, it is difficult to obtain more complete data.

9
2.2. PROTECTIVE EQUIPMENT

OPERATOR GUARDS DOOR

This explains the choice of the studied safety function, which is called “stop and prevent the
clamping movement of the movable platen by opening the operator’s guard.” It protects
against one of the machine’s main hazard when the operator’s guard is open,

The safety function is identified as follows:

 Safety action: stop the clamping movement of the machine’s movable platen;
 Dangerous element: movable platen;
 Safety action trigger: opening the operator’s guard;
 The function’s validity condition: valid during the entire operating mode.
SAFETY LIGHT CURTAINS(oribiter)\
Safety light curtains protect personnel from injury and machines from damage by creating a
sensing screen that guards machine access points and perimeters. Banner offers intuitive,
easy-to-use safety light curtains for a wide variety of safety applications.

10
2.3. MILLING AND GRINDING MACHINES

MILLING OPERATIONS

Milling is the process of machining flat, curved, or irregular surfaces by feeding the
workpiece against a rotating cutter containing a number of cutting edges. The milling
machine consists basically of a motor driven spindle, which mounts and revolves the milling
cutter, and a reciprocating adjustable worktable, which mounts and feeds the work piece.
Milling machines are basically classified as vertical or horizontal. These machines are also
classified as knee-type, ram-type, manufacturing or bed type, and planer-type. Most milling
machines have self-contained electric drive motors, coolant systems, variable spindle speeds,
and power-operated table feeds.

2.4. Hand Grease Pump

A grease gun is a common workshop and garage tool used for lubrication. The purpose of the
grease gun is to apply lubricant through an aperture to a specific point, usually from a grease
cartridge to a grease fitting or 'nipple'. The channels behind the grease nipple lead to where
the lubrication is needed. The aperture may be of a type that fits closely with a receiving
aperture on any number of mechanical devices. The close fitting of the apertures ensures that

11
lubricant is applied only where needed.

There are four types of grease gun:

 Hand-powered, where the grease is forced from the aperture by back-pressure built up
by hand-cranking the trigger mechanism of the gun, which applies pressure to a spring
mechanism behind the lubricant, thus forcing grease through the aperture.
 Hand-powered, where there is no trigger mechanism, and the grease is forced through
the aperture by the back-pressure built up by pushing on the butt of the grease gun,
which slides a piston through the body of the tool, pumping grease out of the aperture.
 Air-powered (pneumatic), where compressed air is directed to the gun by hoses, the
air pressure serving to force the grease through the aperture. Russell Gray, inventor of
the air-powered grease gun, founded Graco based on this invention.[citation needed]

 Electric, where an electric motor drives a high pressure grease pump. These are often
battery-powered for portability.

The grease gun is charged or loaded with any of the various types of lubricants, but usually a
Keep your face away from the discharge port to avoid spraying. Some undesirable things
such as machine dust and chemicals may spew out if you stay close to the tool.

12
Caution when using grease gun

 Read the instructions carefully and perform maintenance regularly

 Always wear protective equipment (protective gear, shoes,...) when installing and
disassembling
 Do a daily check
 Use strictly according to specification
 Stop using when you feel it is dangerous or unusual
 Prevent water and dust from entering the machine as these impurities may affect the
grease quality
 Oil in the machine may be spilled, so please operate with care

2.5. AIR COMPRESSOR

The air compressor provides the necessary air to be used in the pressing process in terms of
Pressure. From AMEKI Color, this pressure is needed to remove the plastic shape that has
been finished on different machine like buckets mould making machine, Jerry can mould
making machine, handles mould, bucket- cover mould and others.

Figure 4:Air compressor

2.5.1. Pneumatic Control

Pneumatic systems use pressurized gases to transmit and control power.

Pneumatic systems typically use air (rather than some other gases) as the fluid medium,
because air is a safe, low cost and readily available fluid. It is particularly safe in
environments where an electrical spark could ignite leaks from systems components.
However pneumatic pressures are quite low due to explosion dangers involved if components
such as air tanks should rupture (less than 250psi), hydraulic pressure can be as high as
12000psi.

13
Figure 5:Pneumatic system

Pneumatic systems have the following components:

1. An air tank to store a given volume of compressed air.

2. A compressor to compress the air that comes directly from the atmosphere.

3. An electric motor or other prime mover to drive the compressor.

4. Valves to control air direction, pressure and flow rate (discharge).

5. Actuators to perform the useful work, which are similar in operation to hydraulic actuators.

6. Piping to carry the pressurized air from one location to another.

2.5.2. Use of compressed air:

In pneumatic systems, compressors are used to compress and supply the necessary quantities
of air. Compressors are typically of the piston, vane or screw type. Basically a compressor
increases the pressure of a gas by reducing its volume as described by the perfect gas laws

14
The compressed air is piped to each circuit through an air filter to remove contaminants
which might harm the closely fitting parts of pneumatic components such as valves and
cylinders.

The air then flows through a pressure regulator, which reduces the pressure to the desired
level for the particular application.

Because air is not a good lubricant, pneumatic systems require a lubricator to inject a very
fine mist of oil into the air discharging from the pressure regulator, this prevents wear of the
closely fitting moving parts of pneumatic components

2.5.3. Properties of air

Air is actually a mixture of gases containing about 21% Oxygen, 78% Nitrogen and 1% other
gases such as Argon and Carbon dioxide. Air also contains up to 4% water vapour depending
on the humidity. Earth is surrounded by a blanket of air called the atmosphere. Because air
has weight, the atmosphere exerts a pressure at any point due to the column of air above that
point. Air is compressible, thus its volume will vary to fill the vessel containing it.

15
2.6. FORKLIFT

A forklift (also called a lift truck, a fork truck, or a forklift truck) is a powered industrial truck
used to lift and move materials short distances. In Amekicolor is used to move the empty
pallet to the packaging and also the pallet with full bottle from packaging to the store. Again
it is used to lift the sugar from its store to the sirup hall and move other heavy materials.

Figure 6: Forklift machine.

16
CHAPTER III: CLASS THEORIES RELATED TO THE TRAINING

Below theories have been studied in 3 years and much of these theories were obtained in
practice during Internship

3.1. ELECTRICAL MOTORS

INTRODUCTION

An electric motor is a device which converts electrical energy into kinetic energy (i.e.
motion). Most motors described in this guide spin on an axis, but there are also specialty
motors that move linearly. All motors are either alternating current (AC) or direct current
(DC), but a few can operate on both.

Motor Classification

10 Alternating Current (AC) MotorsAC motors include 3-phase and single phase types. 3-
phase AC induction motors are the most widely used motors in industrial and commercial
applications. They are divided into two sub-categories:

 Squirrel cage motors

 Wound rotor motors

3-phase Synchronous motors are most commonly used in very large industrial applications or
where exact speed is required. Single phase induction motors are used where three phase
power is not available; typically in residential, commercial and agricultural applications.
They are also used in applications with power requirements below 1 horsepower (HP).

17
The main sub-categories include:

 Split phase
 Capacitor run
 Capacitor start
 Capacitor start – capacitor run
 Shaded pole
 Universal motors

Universal motors are mostly operated on AC power, but they can operate on either AC or
DC. Tools and appliances are among the most frequent applications.

OPERATING PRINCIPLES

Major Parts All motors have two basic parts:

•The STATOR (stationary part)

•The ROTOR (rotating part)
The design and fabrication of these two components determines the classification and
characteristics of the motor. Additional components (e.g. brushes, slip rings, bearings, fans,
capacitors, centrifugal switches, etc.) may also be unique to a particular type of motor.

Operation

The motors described in this guide all operate on the principle of electromagnetism. Other
motors do exist that operate on electrostatic and Piezoelectric principles, but they are less
common. In electric motors, the magnitude of the force varies directly with the strength of the
magnetic field and the amount of current flowing in the conductor.

18
Operating principles

F = ILB , where
F – Force (newtons)
I – Current (Amperes)
L – Length (metres)
B – Magnetic Flux (webers/m2)
In general, the rotor of an electric motor lies within a magnetic field created by the stator. The
magnetic field induces a current within the rotor, and the resultant force caused by the
magnetic fields in the stator and rotor (and thus torque) causes it to turn.

3.2. TRANSFORMER

Working principle of transformer

A Transformer is a static electrical device that transfers electrical energy between two or
more circuits through electromagnetic induction. A varying current in one coil of the
Transformer produces a varying magnetic field, which in turn induces a varying
Electromotive force (e.m.f) or “voltage” in a second coil. Power can be transferred
Between the two coils through the magnetic field, without a metallic connection between
the two circuits. Faraday’s law of induction discovered in 1831 described this effect.
Transformers are used to increase or decrease the alternating voltages in electric power
applications.

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E.M.F Equation of Transformer

3.3. ELECTRICAL GENERATOR

Introduction
Industrial generators are versatile and robust equipment, recommended for different
industries, but also for other demanding applications such as the health, the communication /
information and the agriculture sectors, among others.
A power failure in any of these sectors can lead to dramatic situations, as it can mean critical
damage, such as production losses, loss of data and information, or even serious accidents.
For this reason, they are designed and produced according to strict legal norms and
production parameters, so that, when operating as a continuous or emergency power source,
they can guarantee the operation of various devices and heavy machinery and ensure an
effective response, in the absence of mains power.
Main advantages of industrial generators:
 They can operate either as a continuous power supplier, being the main source of
energy, or as a standby power supplier, safeguarding the correct functioning of the
electrical appliances, in the event of a mains failure
 They provide energy over long distances, without sacrificing efficiency – which is
essential for events, major construction works, logistics centers, hospital services,
among others

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  As in any range, there are several solutions for industrial generators that are adapted
to the diverse needs of the various areas of industrial work. But all products in this
range are characterized by being capable of an efficient and vigorous energy
supply.

3.4. HYDRAULIC SYSTEM

Figure 7.hydraulic system

There are six (6) basic components required in hydraulic system:

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1. A tank (reservoir) to hold the hydraulic oil.

2. A pump to force the oil through the system.

3. An electric motor or other power source to drive the pump.

4. Valves to control oil direction, pressure and flow rate.

5. An actuator to convert the pressure of the oil into mechanical force or torque or motors
(hydraulic) to provide rotary motion.

6. Piping which carries the oil from one location to another.

3.5. PUMP
The pumps are the heart of hydraulic system, pump transform the mechanical energy they
receive from the prime mover (electric motor) into fluid energy.

3.5.1. Pumpingtheory:

All pumps operate on the principle that a partial vacuum is created at the inlet of the pump
due to internal operation of the pump. This allows atmospheric pressure to push the fluid out
of the reservoir and into the pump intake. The pump then mechanically pushes the fluid out
into the discharge line.

35.2. Pump classification:

There are two broad classifications of pumps;

 Hydrodynamic or non-positive displacement pumps.

 Hydrostatic or positive displacement pump.

a) Hydrodynamic or non-positive displacement pumps.

These are low pressure, high volume flow pumps. They are used only for fluid transport and
are most used in fluid power industry. In these pumps, there is large clearance between
rotating and stationary elements and hence the discharge rate is low. Their flow rate depends
not only on rotational speed but also on external resistance. Their discharge decreases with
increase in external resistance. It is also possible to completely stop the pump discharge at
maximum pressure (resistance) during pump operation. This maximum pressure is termed as
“shut-off head”. These pumps are longer in size, they have relatively small volumetric

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efficiency compared to positive pumps and low pressure discharge output. Examples of these
pumps are:

 Centrifugal pumps (Impeller pumps).

 Axial pumps (Propeller pumps).

b) Hydrostatic or positive displacement pumps.

The hydrostatic or positive displacement pumps eject a fixed volume of flow into the
hydraulic system per revolution of pump shaft rotation. These pumps overcome external
pressure (from mechanical loads and resistance to flow due to friction) and are small and
compact in size. They have large volumetric efficiency and high pressure discharge output
based on the nature of the sliding motion between the relative parts and based on
construction.

These pumps are broadly classified as:

 Rotary pumps.
 Reciprocating pumps.
 Rotary pumps.

In rotary pumps (Gear pump, Vane pump, Screw pump, lobe pump, Gerotor pump); the
drivers are coupled with the prime mover and rotate inside a housing. The driven element
(gear, screw, and lobe) rotates in the opposing direction. At the inlet, they move away from
each other creating high pressure to push the liquid into the discharge line. In vane pumps,
the vanes moves out of their radial slots near the inlet and move in near the discharge port.

 Reciprocating pumps.

In reciprocating pumps (Piston and cylinder arrangement), the piston moves away at the inlet
valve resulting in partial vacuum. This pushes the fluid into the cylinder from the reservoir,
as the atmospheric pressure is large, when the piston is reversed the valve that opened during
suction is closed and this increase in pressure opens the discharge valve and pushes the fluid
into the discharge valve. Example: Piston pump (Radial, Inline, Axial types). In the piston
pump, the piston sucks- in and pushes out a fixed volume for every revolution of the shaft.
This is called the “NOMINAL DISPLACEMENT”

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 It follows that:

In reality, the mating components are not a perfect fit and so small leaks may occur past the
valves and pistons. The crank area would have to be drained in order to stop it filling and
pressurizing. The leakage increases with pressure.

The volumetric efficiency is defined as:

The leakage is the difference between the ideal and actual flow rate.

SHAFT POWER (SP)

The shaft power of a pump is the mechanical power transmitted to it by:

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SP = WT Where W is the angular speed of the shaft in radians and T is the torque transmitted
in Nm. Since the spee3d is more usually measured in rev/min, the alternative formula is: SP =
2πNT / 60 N is the speed in rev /min.

FLUID POWER (FP)

Fluid power is the energy per second carried in the fluid in the form of pressure and quantity.
Fluid power is defined as: FP = Q*ΔP

Q is the flow rate in m3/s and ΔP is the change in pressure with the pump.

OVERAL EFFICIENCY (n)

The overall efficiency is the ratio of output power (Fluid power) to the input power (shaft
power). Because of friction and internal leakage, the power input to a pump is larger than the
fluid power (added to the fluid). The overall efficiency of the pump is hence: n = 𝑭𝑷𝑺𝑷

3.5.3.pump installation

We have installed 2 pumps; one for supplying water to the offices toilets and other for the
recuperated water after the treatment of waste water.

3.6. RESERVOIRS

Reservoir serves not only as a storage space for the hydraulic fluid used by the system but
also as the principle location where the fluid is conditioned. The reservoir is where sludge,
water and metal chips settle and where entrained air picked up by the oil is allowed to escape.
The reservoir is constructed by welded steel plates. Every reservoir contains a baffle plate
which extends lengthwise across the centre of the tank. Its height is about 70% of the height
of the oil level. The purpose of the baffle plate is to separate the pump inlet line from the
return line to prevent the same fluid from recirculating continuously within the tank. In this
way all the fluid is uniformly used by the system.

Essentially the baffle plate serves the following functions:

1. Permits foreign substances to settle to the bottom.

2. Allow s entrained air to escape from oil.

3. Prevents localized turbulence in reservoir.

4. Promotes heat dissipation through reservoir walls.

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Figure 8.Reservoir
In my internship we install many reservoirs alongside pumps that must have to supply
emulsifier paint mixing machine.

3.6.1. Sizing of reservoirs

The sizing of reservoir is based on the following criteria:

1. It must make allowance for dirt and chips to settle and for air to escape.

2. It must maintain the oil level high enough to prevent a whirlpool effect at the pump inlet
line opening otherwise; air will be drawn into the pump.

3. It should have a surface area large enough to dissipate most of the heat generated by the
system.

4. It must be able to hold the oil that might drain into the reservoir from the system.

5. It should have adequate air space to allow for thermal expansion of the oil.

A reservoir having a capacity of three times the volume flow rate of the pump has been found
to be adequate for most hydraulic system where average demand are expected.

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3.7. HYDRAULIC DISTRIBUTOR (DIRECTION CONTROL VALVE: D.C.V)

One of the most important considerations in any fluid power system is a control. If
control components are not properly selected, the entire system does not function as
required .In fluid power controlling elements are called ways.

A valve is device that receive an external signal such as mechanical signal, fluid plot
signal, electrical or electronic signal to release, stop or redirect the fluid that flow through
it.

The function of hydraulic distributor does this by changing the position of the internal
movable parts and also is to control the direction of fluid in any hydraulic system.

To be more specific, a DCV is mainly required for the following purpose:

 To start, stop, accelerate, and decelerate and change the direction of motion of the
hydraulic actuator.
 To permit the free flow from the pump to the reservoir at low pressure when the
pump’s delivery is not needed into the system.
 To vent the relief valve by either electrical or mechanical control.
 To isolate certain branch of a circuit.

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Figure 9:Hydraulicdistributor (D.C.V)

3.7.1. Main causes of hydraulic distributor to fail

1. Hydraulic fluid contamination

It is very important to ensure that both components and fluids are clean prior to use. Fluid
contamination forces hydraulic valve and whole system to wear prematurely resulting in
hydraulic system failures and damaged system components.

2. Overpressure system

Faulty or incorrectly adjusted pressure control devices such as pressure relieving and
reducing valves and variable-pump pressure compensators cause over pressurization.

Uncontrolled decompression, thermal expansion (in load-holding circuits) or back through of

flow in check valves or logic elements can result in pressure transients (spikes)

In systems experiencing rapid changing in loads, the reaction time of the pressure control
devices may not be fast enough to prevent pressure transient that exceeds design lined
directly to the reservoir through dedicated penetration.

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Preventing over pressurization

In most system, examination the operation and adjustment of pressure of pressure control
devices at regular interval will prevent over pressurization.

3.8. EMULSFIER PAINT MIXER

This is very important machine in painting industrial making because it is the one which you
will put different kind of paint ingredient together.

It play a big role in making one homogeneous color by agitating. Those different raw
materials into one thing of one color.

Figure 10:Emulsifier paint mixing machine

This machine has 4main parts.

Base

This is a very durable flat casted which hold up and steady this equipment.

Column

This is a tall cylindrical section, where the head is moving to up and down as you wish.
29
Head

Which is the main part that contain the driving movement from the main drive motor and
directly to the mixer or agitator part.

Hydraulic system

Which the important part to this equipment, where it play a big role to move up or down the
head on the column.

Also it has the electrical control system, where it play a big role too, to rotate the agitator
part. Most parts are necessary to clean and lubricate them frequently like the column where
this head will need to move on, and every part that must to be move. Bearings also need to be
lubricated.

Care should be taken on the circulating part (agitator) which rotate on high speed and also it
is sharp so that it can easily agitate and penetrate or mix very rapidly the paint. Particles
easily and very fast. So make sure that you are so far away while it is yet about to start
performance.

3.8.1.General Safety Measures

Degree of Hazard. Each supervisor is responsible for ensuring that special precautions are ta
ken,designating the equipment required, and advising the crew of the specific hazards of each
job. Ignoringthese hazards will increase the odds that accidents will occur.

A good safety program that has adequate safety procedures willprovide protection against the
three major types of hazards: accidents, fire, and toxicity. All personnelshall observe all esta
blished precautionary measures and safety rules, and shall be thoroughly familiarwith all safe
ty measuresGeneral Health. Only personnel not sensitive to heights shall work on ladders, sca
ffolding, or rigging.Painting crews shall be composed of personnel who have a proper attitud
e toward safety and who are ingood physical condition. The medical examiner shall determin
e that employees are physically able to perform work and use respirators.

30
Protective Clothing. Personnel shall wear adequate clean clothing and gloves to prevent skin
contactwith painting and cleaning materials. Clothing with cuffs, loose pockets or rips, and lo
ose ties and jewellery shall not be worn since they are potential causes of hang-ups.

The following precautions shall be adheredto with regard to protective clothing:

(1) Gloves, proper eye protection, and safety helmets shall be worn during abrasive blasting.

(2) Hard-hats and steel-

toed safety shoes shall be worn wherever there is possible danger from

Falling objects.

(3)Non-skid, rubber-
soled shoes shall be worn for work in enclosed spaces or where flammable

Vapours may be present (spark prevention).

(4) Acid-proof clothing shall be worn when handling acid or caustic cleaners.

(5)Acid-proof, air-
supplied suits shall be worn when using acid or caustic cleaning materials in

Enclosed areas.

c. Buddy System. Personnel shall never work alone in hazardous areas.

At least two crewmembersshall be assigned to such jobs with at least one additional person a
vailable for rescue work, should theperson in the tank be overcome. (Personnel performing su
ch duties shall be properly trained to performtank rescue work. Additional personnel with suc
h training should be available.) These individuals shallmaintain communication with each oth
er at all times during operations in hazardous areas. If an accident occurs in
a tank or other confined space, the crewmember stationed on the outside must never enter the

tank to give assistance alone, but shall seek the help of the additional person available for res
cue work.

Multiple deaths have occurred from failure to follow this basic precaution. Personnel entering
tanks shallbe equipped with suitable approved respiratory protective equipment, lifebelts or h
arnesses and lifelines.

31
If the accident happens outside a confined space, the other crewmember can seek help or com
e to theaid of the injured one.

Inspection Safety Precautions. Safety precautions that shall be taken to ensure safety during

Inspection of tanks, voids, and other hazardous areas to be painted.

Entry Requirements. Do not enter any enclosed or poorly ventilated space until a Marine

Chemist or Competent person has certified that the space is free of noxious fumes and flamm
able gasesand sufficient oxygen is present. After the area is certified, the marine chemist or c
ompetent person maymonitor the area to make sure the area stays within the limits

3.9. PLIERS, SIDE CUTTERS, KNIFE AND AN ASSORTMENT OF

SCREWDRIVERS:
Those are very important tools in mechanical field as well as in electrical, because the used to
dismount the mate parts which were already joined with screw and to grab wires.

Figure 11:Screw drivers ,knife, and pliers

3.10. WELDING MACHINE

Welding machine is a machine in which is connected to the cable in order to help anyone to
do the welding

What is welding?

Welding is the metal joining together of two or more pieces of metal by heating them to a
temperature high enough to cause softening or melting, with or without the application of

32
pressure, and with or without the use of filler metal. Any filler metal used either has a melting
point approximately the same as the metals being joined.

In short, welding is defined as a process of permanently joining two or more metal parts, by
melting both materials. The molten materials quickly cool, and the two metals are
permanently bonded.

Figure 12:Welding machine

3.10.1. Safety precautions

Introduction to safety precautions :

Welding and cutting of metals involve the application of intense heat to the objects being
welded or cut. This intense heat is obtained from the use of inflammable gases, (e.g.,
acetylene, hydrogen, etc.) or electricity. The intense welding heat and the sources employed
to produce it can be potentially hazardous.

Therefore, to protect persons from injury and to protect building and equipment against fire,
etc., a set of recommendations concerning safety and health measures for the welders and
those concerned with the safety of the equipment, etc., have been published. By keeping in
mind these recommendations or precautions, the risks associated with welding can be largely
reduced. Therefore, it is suggested that the beginner in the field of welding must go through
and become familiar with these recommendations which also have been discussed .

Personal Protective Equipment (PPE) :

1. Do not weld in confined spaces without adequate ventilation or individual respiratory

equipment. 2. Do not pick up hot jobs or objects.

33
3. Use goggles with non-flammable lenses and frames.

4. Never do any chipping or grinding without suitable goggles.

5. Do not weld painted or galvanized surfaces in a badly ventilated space.

6. Do not use matches for lighting torches. This may result in hand burns.

7. Before welding starts, make sure that the protective clothes such as overcoat, long sleeves,
cap, leather gloves, safety shoes, welding goggles are worn as illustrated below.

Safety of the Working place

1. Fire extinguishers or sand should be available at the working place.

2. Before starting gas welding or cutting remove from the neighbourhood any combustible
material or anything that might be damaged by heat or sparks which are often thrown a long
distance.

3. Make sure that there are no flammable materials nearby.

4. Working place should be clean.

5. Working place should have adequate ventilation otherwise it should be equipped with
respiratory equipment.

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CHAPTER IV: CONCLUSION AND RECOMMENDATION

4.1.CONCLUSION

After complete my industrial training, I had been exposed to Electrical Technicians and
Engineers working life. Throughout my internship, I could understand more about the usage
of many different electrical machines and equipment and tools. Analysis, correction of many
different faults that can occurs in machinery performance and also prepare myself to become
a responsible and innovative technician in future. Along my training period,

I realize that observation is a main element to find out the root cause of a problem. Not only
for my project but daily activities too. During my project, I cooperate with my colleagues and
operators to determine the problems. Moreover, the project indirectly helps me to learn
independently, discipline myself, be considerate/patient, self-trust, and take initiative and the
ability to solve problems. Besides, my communication skills are strengthening as well when
communicating with others. During my training period,

I have received criticism and advice from engineers and technician when mistakes were
made. However, those advices are useful guidance for me to change myself and avoid myself
making the same mistakes again. Apart from that, I had also developed my theoretical skills
through various activities that I had done. This also helps sharpen my skills in electrical
engineering, since most of the activities were done with the aid of different equipment. In
sum, the activities that I had learned during industrial training really are useful for me in
future to face challenges in a working environment.

Throughout the industrial training, I found that several things are important:

 Critical and Analytical Thinking

To organize our tasks and assignment, we need to analyse our problems and assignment, and
to formulate a good solution to the problem. We would have to set contingency plan for the
solution, so that we are well prepared for the unforeseeable situations.

 Time Management

As overall Technician and Engineers are always racing against tight timeline and packed
schedule, a proper time management will minimize facing overdue deadlines.

35
An effective time management allows us to do our assignment efficiently and meet our

Schedules. Scheduling avoids time wastage and allows us to plan ahead and gaining more as
a result.

 Goal Management

Opposing to a Herculean goal seemed to be reachable at first sight, it is better to sub-divide

the goals to a few achievable tasks, so that we will be gaining more confidence by
accomplishing those tasks.

 Colleague Interactions

In working environment, teamwork is vital in contributing to a strong organization.

Teamwork is also essential in reaching the goals of the organization as an entity. Thus,
communicating and sharing is much needed in the working environment. Therefore, we
should be respecting each other in work, and working together as a team, instead of working
alone. This is because working together as a team is easier in reaching our targets, rather than
operating individually. I would like to once again appreciate everyone who has made my
industrial training a superb experience.

4.2. RECOMMENDATION

4.2.1. Recommendations to AMEKI COLOR.

Ameki Color Company is a big company and helps interns improve and develops their skills.
I would recommend them to keep hiring interns with different educational background, to
help build and improve the company with the knowledge they gained from their studies.

4.2.2. Recommendations to RP/ IPRC KIGALI

We suggest that RP/IPRC KIGALI administration would make a special cooperation with
many industries so that RP/IPRC KIGALI students could be allocated there for their
industrial attachment period.

Thus, practical knowledge obtained at AMEKI COLOR LTD effectively backed up the
theoretical knowledge that has been obtained at RP/IPRC KAIGALI in Electrical and
Electronics Engineering and it can be recommended that RP/IPRC KIGALI should establish

36
partnerships with industries and universities both locally and internationally. Special target
should be those institutions in EAC, and Commonwealth regions and RP/IPRC KIGALI
students should be allocated to those institutions for internships and visits. This would help
the students to update themselves and thus become more innovative and competitive at the
market place.

Additionally, RWANDA POLYTECHINC (RP)/IPRC KIGALI,particularly the Mechanical

engineering and mineral resources department ought to strength its relationship with
metalwork Companybecause it has a lot that benefits the students in terms of practical work.
However more, it is better the internship is done before the final year in order to help students
to find many helpful ideas from different sites during their final year projects researches.

4.2.3. Recommendation to the Students in IPRS

Especially, Electrical technology students are encouraged to do their industrial training

internship at AMEKI COLOR LTD in order to experience and improve the application of
courses theoretically done in class

37
 APPENDIX

This include photos taken while I was in Plastic Workshop

38
 References

1. R.S Khurmi (2005), Theory of machines, 14th Ed, New Delhi

2. www.wikipedia.com
3. Weekly logbook
4. Lecturer’s notes
5. Metal work solution book

39