Faf Report

WACHEMO UNIVERSITY
COLLEGE OF ENGINNERING AND

TECHNOLOGY
DEPARTMENT OF MECHANICAL
ENGINNERING
HOSTING COMPANY WONJI SHOA SUGAR FACTORY
DURATION JUNE 1, 2023 TO OCTOBER 1,2023
PREPARED BY : Fasika Tekabe
ID NO : 1201575
COMPANY SUPERVISOR : Abebe Defaru

UNIVERSITY ADVISOR : Yared Z
SUBMISSION DATE : SEPTAMBER 12, 2023
HOSSANA SNNP ETHIOPIA

WACHEMO UNIVERSITY DEPARTMENT OF MECHANICAL ENGINEERING 2016
Declaration
I here by declare that the report work entitled "final internship report" submitted to Wachemo
University Engineering and technology department of mechanical engineering is a record of
original work done by me under the supervisor and guidance of our esteemed mentor Ato Abebe
Defaru and Ato Yared Z. And this report/project work is submitted in the partial fulfillment of
the requirements for internship session of 2015/2016 held for 4th year students of Wachemo
University engineering ang technology department of mechanical engineering. The results
embodied in this report have not been submitted to any other University or Institution for the
award of any type of work.
Student name : Fasika Tekabe Signature: _________________
Mentor name : Yared Z . Signature: _________________
Supervisor name : Abebe Defaru Signature: _________________
FINAL INTERNSHIP REPORT Page

WACHEMO UNIVERSITY DEPARTEMENT OF MECHANICAL ENGINNERING 2016
Acknowledgment
I wish to acknowledge and thank all our supporters in our internship program. In particular, I would like
to express our deepest gratitude and appreciation to Ato Abebe Defaru and Yared Z. , and internship
program coordinator for his limitless support and giving advice during our inter period in Wonji shoa
sugar factor.
I was very grateful to Dereje Adise for his supervision, giving necessary materials and support in Wonji
shoa sugar factory during our internship program.
I extend our gratitude to all Wonji shoa sugar factory workers who were willing to share their knowledge
and skills.
In closing, I deeply grateful to Wonji shoa people for their hospitality and kindness during our stay at
Wonji shoa .
FAINAL INTERNSHIP REPORT Page ii

ABSTRACT
Sugar processing technology is an advanced technology and faster growing in our country Ethiopia. Now
a day Ethiopian government planned to install ten new sugar factories. Therefore, it is very important to
deal with this technology to give important direction. Sugar is a broad term applied to a large number of
carbohydrates present in many plants and characterized by more or less sweet taste. The primary sugar,
glucose is a product of photo synthesis and occurs in all green plants, the sugar occur as a mixture that
can’t readily be separated in to the components. The main purpose of this technology lies in the extraction
of juice from sugar cane and changing it in to crystal.
From the byproduct of sugar processing (bagasse and molasses) energy of the factory produced. Again
utilizing the byproduct of Ethanol large benefit is gained. But, in Wonji shoa factory huge amount of
money thrown away every year therefore, this research may enlighten factory manager’s eyes to give
attention and to invest on these byproducts for the benefit of our country and initiate researchers to study
more.
FAINAL INTERNSHIP REPORT Page iii

Executive Summary
This section of the report is written with the aim of providing general information about the internship
program which helped us to gain practical know how on our field of study.
The hosting company of our internship program is called Wonji shoa sugar factory which is located 110
km east of Addis Ababa it was established in 1951.The main purpose and mission of the organization is
to produce sugar of standard quality with a least possible cost and satisfy the needs of its customers. In
addition to the production it utilizes all resources at disposal without creating any kind of pollution to the
environment.
Main activities of the factory are
 Grow sugar cane and process it to produce sugar.

 Distribute and sell sugar.
 Produce ethanol by processing the molasses coming out as a byproduct from sugar production to
mix it with petroleum for cars.
 And the rest byproduct is used for bio compost (fertilizer) production.
During our internship we were able to work on the whole process of sugar production starting from the
cane handling up to the last sugar packing. In addition to this we were able to see the production of
ethanol from the sugar byproduct /molasses/. We started our work from the cane handling and
preparation section where the harvested cane is weighed and prepared for extraction process by reducing
its size. Then we proceeded to the next station which is the juice extraction section. Here we worked on
the mechanisms that the juice inside the cane is extracted. Next to this we worked on the milk of lime
preparation station, in this station milk of lime is prepared from raw calcium oxide to be used in different
processes. Then after lime station we proceeded to so gas generating station where so is produced to be
used in other processes. Next what we worked on was the juice clarification station. Here the extracted
juice coming from the mills will be clarified. After clarification the proceeding plant was the evaporation
plant where the clarified juice from the clarifier is evaporated to brix it up. Then we passed to
crystallizing plant where crystals of sugars are formed. After the crystals are formed the next station we
passed on was the centrifugal and drying process where the formed sugar crystals are separated from the
massecuite by a centrifugal machine. Then the last unit operation we observed was the drying and
packing station. Finally in addition to the sugar producing plant we had the chance to work on the ethanol
production plant.
FAINAL INTERNSHIP REPORT Page iv

Abbreviation and Acronym

B: bagasse
Br: degree brix
C: cane
CJ: clear juice
E1: water evaporated at evaporation unit
E2: water evaporated at vacuum plant unit
ELPA: Ethiopian electric power authority
FC: filter cake
HVA: Hangler Vonder Amsterdam
ICUMSA:international commission for uniform method of sugar analysis
Imb: imbibition
Imp: impurities
MIS: management information system
MJ: mixed juice
Mo: molasses
MSF: metehara sugar factory
Pol: polarization
RS: reducing sugar
S: sugar
W: water
FAINAL INTERNSHIP REPORT Page v

List of table
Table 1 some difference between two tandems in wonji shoa sugar factory________________________________26
Table 2: parameters controlled in extraction unit_____________________________________________________27
Table 3 : Hydraulic pressure (bar)_________________________________________________________________28
Table 4 Pre-charging nitrogen pressure (bar)________________________________________________________28
Table 5 : Mill rotor’s speed (rpm)_________________________________________________________________28
Table 6 : Mill turbine’s rotational speed (rpm)_______________________________________________________29
Table 7The overall cost that we design for conveying purpose is as follow_________________________________56
Table 81 material selection______________________________________________________________________64
Table 9 factor of safety (n) for roller and silent chains_________________________________________________64
Table 10 : bearing selection______________________________________________________________________65
Table 11 ultimate tensile strength and yield strength__________________________________________________66
Table 12 The recommended value of the kb and kt___________________________________________________66
List of figure
Figure 1 : overall organizational work flow__________________________________________________________10

Figure 2 company profile vew____________________________________________________________________11
Figure 3 processes take place in sugar factory_______________________________________________________12
Figure 4 mill roll_______________________________________________________________________________13
Figure 5 sprocket and the chain__________________________________________________________________14
Figure 6 juice returning, screening and imbibitions process Bagasse conveying_____________________________15
Figure 7 : juice pumping_________________________________________________________________________16
Figure 8 Oliver campbell________________________________________________________________________18
Figure 9 centrifugal separation___________________________________________________________________23
Figure 10 sugar conveying belt___________________________________________________________________24
Figure 11supporting bar________________________________________________________________________38
Figure 12 : slat________________________________________________________________________________38
Figure 13 : bolt and nut_________________________________________________________________________38
Figure 14: sprocket For_________________________________________________________________________41
Figure 15Schematic diagram of drive shaft__________________________________________________________43
Figure 16Schematic diagram of the driven shaft______________________________________________________49
Figure 17roller conveying chain___________________________________________________________________58
Table of Contents
Declaration_____________________________________________________i
Acknowledgment_________________________________________________ii
Abbreviation and Acronym_________________________________________v
FAINAL INTERNSHIP REPORT Page vi

CHAPTER 1____________________________________________________10
INTODUCTION_______________________________________________10
1.1, Location and Foundation of WSSF______________________________10
1.2, Purpose of establishing sugar factory____________________________11
1.3, Relation of WSSF factory with other sugar factory_________________11
1.4, New wonji/shoa sugar factory__________________________________11
1.5, Main products or service of WSSF______________________________13
1.6, Main customers or end user from WSSF_________________________13
1.7, Overall organization and work flow_____________________________15
CHAPTER 2____________________________________________________16
2.1, How we get in to WSSF_________________________________16
2.2, Section/plants we allowed to learn in WSSF______________________16
2.2.1, Juice extraction (milling) plant_______________________________17
2.2.2, Clarification and evaporation plant____________________________21
2.2.3, Steam and power generation plant__________________________XXIV
2.2.4, Pan and centrifugal plants___________________________________27
2.3, The piece of work we have been executing_______________________30
2.3.1, The Overall Sugar Production Process______________30
2.4, Procedures we have been using during performing our work tasks_____34
2.5, How we was good in performing our work tasks___________________34
2.6, Challenge I faced while performing our work_____________________35
2.7, measures we take in order to solve the challenge___________________35
CHAPTER 3____________________________________________________36
OVERALL BENEFIT OF THE INTERNSSHIP______________________36
3.1Improving practical skills______________________________________36
3.2, Upgrading theoretical knowledge_______________________________36
FAINAL INTERNSHIP REPORT Page vii

3.3, Improving interpersonal communication skills_____________________37

3.4, Improving team playing skills__________________________________38
3.5, Improving leadership skills____________________________________38
3.6, Understanding about work related issues_________________________38
3.7, Entrepreneurship skill acquired_________________________________39
CHAPTER 4____________________________________________________40
4.1, PROBLEM IDENTIFICATION AND THEIR PROPOSED SOLUTION
_________________________________________________________40
4.2, PROBLEM SELECTED (ROLLER CONVEYING CHAIN)_______41
4.2.1, Design analysis____________________________________________41
4.2.3 Material selection__________________________________________42
4.3, DESIGN AND CALCULATION_______________________________44
4.3.2Design of sprockets_________________________________________46
4.3.3 Design of shaft__________________________________47
i. Design for drive/head shaft_________________________48
4.3.4, Design of the key__________________________________________58
4.3.4, Bearing selection___________________________________________60
A bearing is machine elements which support another moving machine
element. It permits a relative motion between the contact surfaces of the
members, while carrying load. A little consideration will show that due to
relative motion between the contact surfaces, a certain amount of the wasted
in overcoming frictional resistance and if the rubbing surfaces are in direct
contact, there will be rapid wear. In order to reduce frictional resistance,
wear and in some cases to carry away the heat generation._____________60
4.4Cost analysis_________________________________________________61
Conclusions____________________________________________________64
Recommendation________________________________________________65
Appendix_____________________________________________________66
FAINAL INTERNSHIP REPORT Page viii

Appendix A: Basic Terminologies_______________________66

Appendix B: Material balance__________________________69
Appendixes__________________________________________69
References_____________________________________________________72
FAINAL INTERNSHIP REPORT Page ix

CHAPTER 1
INTODUCTION
1.1, Location and Foundation of WSSF
Wonji/shoa sugar factory is located at southeast of the country and far from Addis Ababa
110km at Adama-Asalla road. This company is founded by kaizen in 2011. But wonji/shoa
sugar factory produce sugar at the wonji town that is the upper reach of Awash Ethiopia 112km
southeast of Addis Ababa after taking the land of nomads in 1951, Ethiopia government granted
a concession of 5,000 hectares. For increasing demand of sugar in Ethiopia, the wonji estate
expanded to include an addition of 1,600 hectares of land from shoa, about seven km from
wonji town. The wonji/shoa sugar factory started sugar production in 1962.
The late king Haile-selassie described this large-scale commercial investment in Ethiopia that
could very well make Ethiopia self sufficient in sugar production and exports to its
neighbouring countries. Emperor Haile-silassie further claimed that with the crushing capacity
of 1600 tonnes of canes per day. Wonji/Shoa sugar factory started as joint venture between the
Dutch, Handlers-Vereeniging Amsterdam (HVA) firm and the Ethiopian government. The HVA
owned about 90 percent of sugar plantation and while sugar factory owned only 10 percent.
Also in its operation of sugar factory, HVA remitted 10 percent of the invested capital and 15
percent of the annual profits to its headquarters.
With the change of government in 1974, under pro-clamination No 31 of 1975, all the sugar
factory in Ethiopia became nationalized and administered under the centralized bureaucratic
administration of the new military government. Though; the Wonji Company was very
productive until the 1980’s, It eventually stagnated because of the atrocities and red terror
committed by the military government causing competent and effective workers to leave the
factory and run for their lives.
Finally, in 1991 as the ensuing civil war completely devastated the authoritarian apparatus of the
military administration in Ethiopia, the sugar corporation was dissolved by law and all existing
factory were re-established as public enterprise to be run by the Ethiopia sugar development
agency starting in 1992. To revive the sugar industry, the Ethiopia sugar development agency
was formed as a share company of the development bank of Ethiopia,
FAINAL INTERNSHIP REPORT Page 10

Ethiopian insurance company and then the existing of three sugar factories (i.e. Wonji, shoa and
metehara) in 1998. FurthermorPage 5 of 56e, under the Council of Regulation Minister’s (No.
192/2010), in 2010. The current Ethiopian sugar corporation was then formed replacing the
sugar development agency.
1.2, Purpose of establishing sugar factory
The most conspicuous reasons for the establishing of sugar Corporation were to:
 Grow sugarcane and other yielding crop
 To fulfil social need of sugar in the country
 Process and produce sugar, sugar products and sugar by products
 Sell the products and by-products in domestic and export market
 Encourage and supports the sugarcane grower who supply their cane
 Cooperate with educational institutions to produce the required type, number and
quality of trained man power for the sugar industry (sugar corporations and Ethiopian
sugar industry profile March 12, 2013).
1.3, Relation of WSSF factory with other sugar factory
The Wonji/shoa sugar factory Corporation is currently carrying out expansion projects within
the existing sugar factory at Metehara, Finchaa, Tendaho and other additional sugar factories
like Beles in the centre of Amhara region, Wolkait in northern Tigray area, Kesem in the north-
eastern of Afar regional state, and six more factories in the south omo zone of the southeast
Nation nationalities and peoples’ region.
1.4, New wonji/shoa sugar factory

This factory to become self-sufficient in sugar production by the end of 2013 and diversify the
products of sugar cane into ethanol, electrical power, fertilizers, and build tissue culture laboratories,
the corporation is visualizing creating the sugar industries to be competitive enough to maintain a
sustainable growth pattern at the international level. In order to develop trained and disciplined
employees the Ethiopian sugar corporation is instructing its employees in the use of Japanese
philosophy of continuous improvement by applying kaizen’s processes and technology to improve
the company’s production culture and leadership. Kaizen corporate culture is a continuum off
resolving cycles of continual,

dynamic and self-motivated practice in the quest of recreation of self-disciplined and self
innovation organizations. It also is conductive to realization of human potential of all members
of the organization (Minister of Industry, 2011).
To implement kaizen, about 7,537 members of leadership at various levels and staffs of the
corporation and sugar factory have been trained on kaizen, quality control circle (QCC), the
seven types of waste , their causes and their preventive measures and their application methods.
The country plan to increase the sugar production of sugar from 314,000 tons in 2009 to 2.25
million tons in 2015 and 1.25 million tons of sugar and sugar related factory are to be exported
(Minster of Industry , June 2011)
1.5, Main products or service of WSSF
Wonji/shoa sugar factory is mainly depends on agricultural of sugar cane as raw materials and
produces output likes;
White sugar,
Final bagasse,
Electric power and
Final molasses.
This the main supply from the factory, but there are many by-products which is use for different
uses. Example from bagasse, it produces steam in boiler, writing paper, fiber board, newsprint
produced in other factories
1.6, Main customers or end user from WSSF
Wonji/shoa sugar factory have different plants whose have own purpose; like milling house
plant (input of sugarcane, output of final bagasse and raw juice), clarification and evaporation
house plant (input of raw juice and steam, output of syrups), steam generation house plant (input
of treated water and final bagasse, output of steam,) power generation house plant (input of dry
steam, output of electric current) and pan house plant (input of steam and syrups, output of
sugar and molasses). Those output from different plants have their own costumers like;

Customers of white sugar (from pan house product)
East Africa (coca cola company)
Moha soft drink factory (Pepsi company)
FAO (food and agricultural organization) the united nation
MEWIT (JINAD) which distribute white sugar to the whole market of

the country.
Customers of molasses (from pan house product)
Belazaf alcohol and liquors factory

Desta alcohol factory
National liquor and alcohol factory
Customers of final bagasse (from mill house)
Tendaho sugar factory for boiler
Customers of electric current (from power generation)
Ethiopian Electric power associated (EELP)

1.7, Overall organization and work flow
Management
board
General Manager
Internal audit
Executive assistant
to general manager Secretary
Public relation estate

and environmental
Management and improvement

Project implementation service productivity
and productivity
improvement
Legal service Commercial
department
Factory and
Agricultural
logistics
operation
division
manager
manager Finance and
Human
Wonji technical Resource
Plantation
Manager
Dept
Wonji process
LPCD Dept’ Finance Dept’
Shoa technical
Harvesting
Shoa process dept Human
Field Resource
Logistics department
equipment
Medical
Civil eng.Dept
Confectionery works department
Figure 1 : overall organizational work flow

CHAPTER 2
OVERALL INTERNSHIP EXEPRIENCE
2.1, How we get in to WSSF
Figure 2 company profile vew
During the end of 3rd year, we collect the internship paper from the department and taking to
wonji/shoa sugar factory at a summary vacation. Wonji/shoa sugar factory confirming our
internship letters request and appreciation to learn during staying in company by dividing
students into different plants, day to day follow up, activities of industries like operation,
maintenance and repair. This helps as by increasing our knowledge and identifying the problem
with appropriate solution.
2.2, Section/plants we allowed to learn in WSSF
In our staying in the WSSF for internship duration, we work on the whole company that are
related to our field and supporting to our project design. But the factory supervisor is restricted
to four plants for four months. Those are:
Juice extraction (milling) plant
Clarification and evaporation plant
Steam generation and power generation plant and

Pan and centrifugal plant

Figure 3 processes take place in sugar factory
2.2.1, Juice extraction (milling) plant
The main purpose of juice extraction plant is well extraction of raw juice by mill and separate
from final bagasse. This final bagasse has no content of sugar.
Also in this plant there are many machines that are use for different purpose from preparation of
cane to raw juice and final bagasse produce. Those are like;
Cane trucks: this is by lifting the whole vehicle on a tipping platform with the rear gate of the
truck swinging open to allow the cane to discharge into a feeder carrier
Spiller tables: cane is often discharge from large vehicles into elevated feed conveyors which
are wide as the length of the truck or trailers.
Kicker or tumbler: is usually fitted at the top of the feeder table before the cane discharge to
cane conveyor. This consists of a slowly rotating shaft that the cane fails smoothly off the
discharge end avoiding a heavy fall of a large mass of cane.
Cane conveyors: there are many types of cane carries like apron, belt, chain and slot carriers.
They are used to conveyor the cane from the feeder tables to mill.
Magnets: it used almost impossible to prevent the entry of tramp iron into the system. Removal
of tramp iron in this way pays for itself very quickly, since the damage caused to

cane preparation equipment and mill roll can be severe leading to increased downtime and
reduce recovery.
Cane knives: it is driven by electric motor that is used to reduce the height or size of the piece of
cane to the size suitable for handling in the extraction process.
Mill conventional: refers to mill feed and discharge rolls at a common level and vertically floating
top cells. Although some variations was proved successful.
Head stocks: is to maintain the working element particularly the roll in their desired orientation.
Mill roll: are usually constructed of a shaft of steel, on to which is shrunk a cast iron shell.
Figure 4 mill roll
Mill bearings: the majority of mill bearing are of hollow (ported) construction, either cast
entirely of bronze or comprising a steel housing with a bronze using.
Lubrication: the maximum permissible bearing pressure for bronze bearing is usually 9 to
11mpa, depending on the design and lubrication.Roller bearings: alternatively to bronze bearing
is spherical roller bearings;
 low friction
 no cooling water needed
 no wear of roller journals
 reduced roll length between centre (lower bending stress)  Tolerant of small
misalignments.
Mill drives: power absorbed by a mill depend on many factory
 The crushing rate (power and fibber throughout)

 The mill speed (power and fibber x torque)
 Mill configuration (no, size and arrangement of roll)
 Power lost in bearing
 Mill feed method
 Mill setting and the hydraulic load on the top of roll
Rotary juice screen: wedge bar type rotary screen for screening unstrained containing 50%
suspended solid/fine cush cush particles. Rotary drum juice collect trough and other parts in
contact with juice shall be SS304. Rotary juice screen shall have auto cleaning system with
water and steam periodically.
Sprockets and supports: if the inter carrier is also to serve as a mill feed roller, the slats will
generally required additional support around the head pulley.
Figure 5 sprocket and the chain

Chevrons: are notches cut into top of mill to assist feeding the bagasse through the mill.
Donnelly chutes: Donnelly observed that the angle of the bagasse feed plate into a mill has a
marked effect on the pressure and hence on the friction grip of the bagasse on the feed roll.
Pusher feeders: are mechanical device designed to forced bagasse into a mill. They are drive by
an electric and have a reciprocating action.
Imbibitions: in order to extract as much as possible of the sugar which it retains, it is therefore
necessary to restore to an artifice, since this moisture contents cannot be made to replace by
water the juice comprising it.

Figure 6 juice returning, screening and imbibitions process Bagasse conveying
a) Bagasse belt conveyors: the most convenient and cost effective means to convey
bagasse is by conventional troughed belt conveyors. This belt is used to elevate bagasse
at inclinations of up to 23 o from the horizontal, provided that the feed arrangements are
suitable.
b) Bagasse chain conveyors: for bagasse conveyance, chain and slat conveyors are more
costly initially and in maintenance than are belt conveyors of equivalent capacity. Their
use is usually confined to applications where belts are not suitable. Example are:
Where elevations steeper than 23o are required.
Where multiple off takes are required.
Where bagasse is transported in both direction.
For feeding bagasse in to boiler chutes.
Bagasse feeding to boiling: for satisfactory boiler performance, bagasse must be fed reliable at
high rate into narrow enclosed chutes, keeping them full without chocking or generation
excessive dust.
Juice recycling: apart from the first mill, the juice from the first extraction stage of a mill (e.g.
from the pressure feeder of a pressure fed mill or the first roll of a four roll mill) is generally
of lower brix than the average for the mill. Recycling can be usually be taken to saturation of
the feed materials, which is a wetness level of 500% to 600% on fiber, beyond which there is no
benefit to be gained.

2.2.2, Clarification and evaporation plant
The aims of clarification are;
 To form floes to trap all suspended matter which can be at satisfactory rate
 To produce clarified juice of high quality with a minimum turbidity, colour, and a low
calcium contents.
The aim of evaporation also;
 To remove water from juice up to desired brix and to thick juice or syrup without any
change in sugar and reducing sugar.
 To maintain clarified juice PH around(7±1)
Some machines used in these plants are:
Juice mass flow measurement: it is commonly practice to employ batch scales to measure the
mass of raw juice produced. Because of most other metering device do not approach the same
accuracy.
Batch scales: a batch scale system consists of supply tank above a weight hopper, which accept
batch of juice and records the mass before discharging. The weight hopper is tarred before
accepting a new batch. This weight hopper is supported on three or four load cells to record the
mass.
Juice pumping: raw juice contains some sand and fibrous bagasse particles and is abrasive and
corrosion. To specify the pump duty, it is necessary to know the average and maximum flow
rate to be pumped including filtrate return, as well as the head on the pump under both
conditions.
Figure 7 : juice pumping

Pump selection: the total pump head required is made up of the following.
 The difference between liquid levels on suction and discharging sides.
 Any difference between vacuum and/or pressire on the inlet and outlet side liquid free
surface
 friction i.e. the head required to overcome resistance to follow through pipe and fitting
 pressure drop across the control valve
 head loss through equipment such as heaters in the system  The velocity head at
final discharge.
Plate heater: the plate heater is a pack of thin plates arranged in a frame so that the space
between each alternative plate is open to the same fluid.
Flashing: the purpose of flashing is to force outlet the air presents in the juice, to cause the
bagacious particles to burst and then sink with the flock and to insure constant flashed juice
temperature. A practical check on flashing is to observe the vapour coming out of the flashing
tank vent, if there is no vapour than flashing is not taking place.
Filtration: the clarification process separates the juice in to two layers;
 The clear juice, which rise to the surface.
 The mud which collects at the bottom.
The clear juice goes to manufacture that is direct to evaporation. But the mud has first to be
filtered, in order to separate from the juice the suspended matter which it contains, with the
absolute salts formed and the fine bagasse entrained with them.
Flocculated mud settles in the clarification process in the lower layer and the under flow is
removed at a steady rate. The mud has then to be filtered to recover the juice from the soil and
mud solids, mostly with the addition of fine bagasse particles, known as bagacillo, as a filtration
aid. Filtrate is returned to the juice heating system.
The operation of the mud withdrawal from the clarified compartment is regulated by the
operator to keep the mud upper level in the clarifier close to a desired target. Various aids to the
operators have been used. These involve variable speed mud pumps, and draining off the mud
for timed periods, combined with maintaining a constant level in a mud-receiving tank.
The advantage of filtering is only mud derived from weak juices: hence also the advantage of
substituting water for the juice in the cake, by washing, and by carrying the washing as far as
possible.

The disadvantage of this type of filter is overload the clarification station. When the latter is
working near the limit of its capacity, it is undesirable to increase the volume of the jiuces, and
consequently their speedof circulation in the clarifier, by a fraction which represents
approxmately.
Figure 8 Oliver campbell
Evaporation:
The clarification process has given a clear juice. This consists of sugar dissolved in water,
together with certain impurities. Now that we have removed the impurities as far as possible it
remains to remove water.
Pre-evaporators: refers to an evaporator that is dedicated to vapour bleeding. Juice from

the pre-evaporation feed the first effects that use exhaust steam for evaporation.
Optimum operating condition: the best performance from an evaporator set is obtained
when it is run as steadily as possible. This is generally achieved through the use of
automatic controls.
Effect of superheat: if the superheat is excessive, it is possible for the heat transfer rate
to be affected adversely. In this case a significant proportion of the heat transfer has to
take place from the vapour phase to the tube surface, rather than by the far more rapid
form of heat transfer in condensation.
Flash pots: if vapour flashing is to be practiced, the condensate is usually collected in a

receiver or flash pot, which has to be sized to permit the flashing to occur without re-

entraining too much liquid.

Syrup pumping: because syrup is extracted from the last effect at its boiling point, the
NPSH (net positive suction head) available on the pumps may be low. In addition is
common to install a strainer on the pump station, which, if it blocks; introduces a suction
line pressure drop that makes the situation worse.
2.2.3, Steam and power generation plant
The aim of steam generation is;
 To produce steam from boiler by burning of dry bagasse in furnace and heating treated
water in boiler.
The aim of power generation is;
 To produce electric power by steam that is produced in steam generation plant in case
rotating turbine for the factory and for other customers like ELPA.
Steam generation plant
The amount of steam generated from bagasse depends on the efficiency of the boiler. The
pressure at which the is generated and the calorific value (determine by moisture and ash
contents) of the bagasse.
The amount of bagasse lost in the raw juice and the filters depends on whether milling or
diffusion is being practiced.
Some machines used in this plant are;
Bagasse distributors: because of its low density and high drag coefficient bagasse is best
distributed pneumatically rather than mechanically in to furnace.
Fans: a boiler to operate successfully it must have enough grates to allow the fuel to be burned
efficiently and enough fan capacity to provide the air required to complete combustion and
exhaust the products of combustion from the unit. Four types of fans: o Primary air fan: supply
hot air to the underside of the grate o Over fire air (OFA) fan: supplies the additional air
required to combustion.
o Induced draft (ID) fan: exhausts the products of combustion from the boiler to atmosphere
o Distribution air fan: used to convey the bagasse in to the furnace
Furnace: has to be equipped with a fuel feeding system, an air distribution system and an ash
removal system.
FAINAL INTERNSHIP REPORT Page XXIV

The grate: in step grates, combustion takes place on the steps. The dead plate which precedes
them serves to remove the excess moisture from the bagasse before it comes to the grate. The
ash grate which follows the steps grate serves to complete the combustion and utilise the heat
transmitted by radiation from the incandescent bagasse the ashes are dropped in to the ash pit.
Heating surface: the heating surface comprises that of the boilers tube and the tube of water
walls, when these are provided. The total heating system/surface has no great signification in
modern boilers, an account of the difference in rate of heat transfer existing between the
difference components of the boiler units.
Boiler bank: the steam drum and boiler drum are connected by a set of tube are called bank
tubes. The boiler bank is almost a convection heat transfer section.
Air pre-heater: air heater can be successfully employed to recover heat from flue gas at lower
temperature level than is possible with economizer. The heater rejected chimney can be reduced
to higher extent thus increase the efficient of the boiler.
Deaerator: the solubility of oxygen, air and carbon dioxide in water is a function of the water
temperature. Deaerators use steam for clear water for boiler.
Feed water treatment: dosing should take place as far upstream as possible to protect the pre-
heater system as well.
Steam usage: process steam usage of the cane mill depends on such factors as cane crush rate,
number of evaporator effects target sucrose extraction and hence imbibitions % fiber and use
downstream evaporator vapour for pan and juice heating.
Power generation plant
To optimize mill electricity generation, the following parameters must be considered:
process steam demand
 bagasse availability for fuel
 factory electrical demand
 irrigation power requirements
 electricity sale price
 cost of supplementary fuel
 emergency power sources
steam turbines : steam turbine take in steam at relatively high pressure and temperature and

exhaust the steam either to process or in some cause to a condenser operating under sup_
atmosphere pressure for a constant steam flow through the turbine (i.e no steam bleeding )the
difference in total heat per unit mass ( specific enthalpy ,KJ/kg) at te steam inlet and the outlet
of the turbine . represent the energy extracted from the steam in the form of mechanical work
used either to drive a mechanical load or the drive a rotating alternating current generator
Impulse or impulse-reaction turbines: steam turbines are either “impulse” or
“impulsereaction”. There are no pure reaction turbines.
In an impulse turbine, the steam pressure is caused to drop across stationary nozzles,
generating high steam velocity with increased kinetic energy. This high steam velocity
steam impinges on moving blades which extract the energy by reducing the velocity.
There is no pressure drop across the blade moving. This turbine is simpler and cheaper
because there no pressure sealing across the moving blades. The efficiency of this
turbine is around 84%.
In an impulse-reaction turbine, which is always multi-stage, there is a steam pressure drop

across both the fixed and moving blades. This turbine is more efficient because there are
more stages of steam pressure drop, each of which has fewer losses. The efficiency of
this turbine is around 78%.
Transformers: transformers transform electrical power from one supply voltage to another, with
high efficiencies, typically 98 to 99%. Transformer must be operating within their design limits as
regards current, voltage and operating temperatures. Maintenance of transformers also include
elimination of oil leaks, maintenance of breather desiccant, ensuring adequate cooling and most
important, regulate oil quality checks followed by oil drying and filtering.

Use for bagasse: excess bagasse may find very profitable use as,
 Raw material for the manufacture of fire proofed insulating boards used for building
purpose
 Raw material for the fabrication of paper pulp
 Raw material for the manufacture of various solvents utilised in industry.
2.2.4, Pan and centrifugal plants
The objective of centrifugal is also to separate massecuite from the surround molasses or matter
liquids.
The objective of pan house is also to obtain maximum amount of sugar syrup through
crystallization by concentration under vacuum in vessels. The crystallization stage in a sugar
house involves crystallizing as much as possible from evaporator syrup.
Crystallization in a vacuum pan continues until the point is reached where further crystallization
would result in a massecuite that stops circulating or that cannot be discharged from pan.
Massecuite leaving a vacuum pan is supersaturated and hot, in the range 63 or 75oc.
Feed tanks: syrup A and B molasses are usually stored in tanks on the ground floor, with small
feed tanks provides on the pan floor, from which the feed passes to the pans.
Vacuum seed receivers: are often provided on the pan floor provide flexibility in pan floor
operation. These vessels are normally cylindrical in shape, insulated, and with a horizontal
stirrer rotating at about 1min that scrapes close to the internal surfaces.
Strike receivers: these U-shaped horizontal troughs fitted with horizontal rotating stirrers. The
receive massecuite from batch pans on strike, and provide a buffer between the bath pans and
continuous crystallizers or centrifugals.
Centrifugal separation: after crystallization, the sugar crystals are separated from the
massecuite by centrifuging. Because of the nature of the mother liquor, particularly the high
dissolved solids content and high consistency, centrifugal forces need to be high, requiring high
speed machines.

Figure 9 centrifugal separation

Centrifugal drives: is machines were driven by fixed speed motors or pole-changing motors to
accommodate the different speeds required for spinning, feeding and discharging.
Feed mixers: a horizontal feed mixer is usually installed close to the centrifugals, which are fed
from the mixer through one or more valves.
Washing: this is achieved by addition of water and steam. Because of the short time the
machine crystal dissolution is low. The extent to which the water and steam mix with the
mother liquor to reduce its viscosity and the extent to which the water and steam actually wash
the molasses film off the crystal is know.
Seed growing pan: the basic material used in the pan boiling is syrup of 50 to 65 % brix and 80-
85% purity. The PH is also between 5-5.4. The brix of the sugar is assumed as 100%. As a result
the concentration of syrup to massecuite is from 60-100% brix. This is achieved by two ways as
below
 Concentration of 60 to 100% brix
 Formation of sugar crystal
Rotary cascade drier: is which has comprises a cylindrical drum, rotating at a slight slope to
the horizontal, running on steel rollers or cradles. The holdup of a rotary drier varies with the
feed rate, the number of flights, the shell diameter and the air rate.
Rotary louver driers: unlike the cascade variant, little design information has been published
on rotary louver driers, perhaps because they are designed by relatively few suppliers, and the
information is regarded as proprietary.

Screw conveyors: these devises comprise a central shaft running along the axis of a Ushaped
trough, with a screw or helical ribbon attached to the shaft. The greatest disadvantage of this
type conveyor is that the sugar crystals may be ground between the screw and the shell.
Vibrator conveyors: this operates on the same principle bit using high frequency vibration.
These can be enclosed (dust-free) but consume more power and certainly classify the sugar.
Twin conveyors: overcome the vibration problem of a grasshopper by oscillating two identical
units 180o out of phase.
Slip-stick conveyors; are a recent innovation, operating by means of a slow forward stroke
followed by a rapid return stroke. They rely on the sugar slipping on the return stroke to
advance the sugar along the conveyor.
Belt conveyors: are continuous belts consisting of several plies of fabric impregnated, bonded
and coated with rubber. These run on idler, spaced at intervals of about 1 to 1.5m for the top,
load-carrying strand and much larger spacing’s for the lower, empty strand. Belt conveyors may
inclined, does not recommend more than 22.5 o for dry sugar. Prefers a limit of 20 o and
recommends 16o. Belt speeds of 1.2 to 1.6 m/s are common, except for shiploading conveyors
which can run at around 2.9 m/s.
Figure 10 sugar conveying belt
Bagging and packaging: sugar packaged into sack, bags and packages ranging in size from a
few grams to 1000kg. Bags for commercial customers are usually 25kg, 50kg and 100kg.

2.3, The piece of work we have been executing
During the internship period, we were working in the preparatory section and loom shed. In this
group, we were working maintenance of different parts of the machines. The term maintaining
can be defined as something to repair or to bring functional which were non- functional due to
many problems. In this time, we were able to know different machine parts, which we learned in
the last seven semesters of our educations. In addition, we know how to maintain machine parts
and we can see the integration of mechanical and electrical machine parts.
2.3.1, The Overall Sugar Production Process

In our four month internship period we experienced whit the sugar production process by the help of
different persons like Forman, operators, team leaders, coordinators and etc. Here there are different tasks
that we worked on. This task includes:
2.3.1.1, Cane Handling and Preparation

Cane handling and preparation is the first unit operation in sugar producing process in which cane is
prepared for extraction process. The task that take place here is includes, cane weighing, cane unloading
and leveling, size reduction, transportation, ferric material separation. Wonji shoa sugar sugar factory has
two tandems that has different capacity and working conditions. The main objective/ purpose of this unit
operation is to prepare cane for extraction plant by reducing the size and exposing cells to be extract. The
whole process derived by steam and electrical motor. We have worked here for about a week with all
types of personnel in both tandem. The two tandems has some difference that make them different in
production capacity.This difference is shown in the following table clearly.

Table 1 some difference between two tandems in wonji shoa sugar factory
Specification/parameters Tandem A (old) Tandem B (new)
Capacity 15-20 cart cane/hr. 25-30 cart can/hr.
One cane table capacity 2tonn 2tonn
First cutter power 285KW 290KW
First cutter speed 585rpm 591rpm
Second cutter power 30KW 30KW
Second cutter speed 460rpm 585rpm
Fiberizer speed 600rpm
2.3.1.2, Cane Juice Extraction Process

Cane juice extraction is the process of separating juice from bagasse. We have worked here for about two
weeks in both tandems with all types of personnel. In metehara sugar factory there are two tandems that
use different methods to extract juice. The first use five mill that arranged in series. And the second uses
three mill and one bagasse diffuser, diffuser extract juice by diffusion and leaching. But mills extract
juice by using hydraulic pressure. In first tandem juice from the first two mill screened and sent to
process. The remaining mill’s juice is used as imbibition. In the second tandem juice from first mill and
diffuser sent to process and the remaining mill’s juice used as press water. The bagasse that sent to last
mill takes hot/cold water as imbibition. And the final bagasse sent to boiler plant as fuel. Here there are
some parameters and specifications that controlled in extraction unit. These are listed in the following
tables. The table also contain the reason of the parameters are controlled in the range specified.
Table 2: parameters controlled in extraction unit
Parameters/specifications Amount/result Reasons

Imbibition water flow 35-40m3/hr. Deviation from this range is uneconomical

rate
Final bagasse moisture 50% • Taking the moisture content below this is
content impossible
• If it is above it affect energy production

process
Juice loss with final 2.5% • Making less than this take more cost
bagasse < • Making above is loss of sugar
1st mill extraction 60-70% Deviation in both direction

is uneconomical
capacity
10 juice purity and brix >84% and It mostly depend the mill capacity and cane
sucrose content
>190Br
20 juice purity and brix 82-83% and It mostly depend the mill capacity and cane
10-110Br sucrose content
MJ brix, sucrose content and 16- The result of 10 and 20juice. When their quality
purity 170Br,13140Z fluctuate the MJ also fluctuate
and >84%
Diffuser temperature 70-750C • Below 70 lead to inefficient juice

extraction.
• Above 75 lead to additional steam cost
Retention time of 45min To extract more juice the bagasse need more
bagasse in diffuser time but the very longer time is undesired since no
more juice extracted in the added
time duration.
Table 3 : Hydraulic pressure (bar)
1st 2nd 3rd 4th 5th

Mill
Turbine 190-200 150-160 150-160

side TA
Opposite side 190-200 150-160 150-160

TA
Turbine 120-140 120-140 140-160 150-170 160-180

side TB
Opposite side 120-150 130-150 150-170 160-180 170-190

TB
Reason of pressure decrement is extraction inefficient as the bagasse goes from the first to the last
mill since the liquid content is decreased.
Table 4 Pre-charging nitrogen pressure (bar)
Mill 1st 2nd 3rd 4th 5th
Pressure TA 16o 135 135
Pressure TB 115 115 135 145 150
Table 5 : Mill rotor’s speed (rpm)
Speed TA 4-6 4-6 4-6
Speed TB 4-6 4-6 4-6 4-6 4-6
Table 6 : Mill turbine’s rotational speed (rpm)
Speed TA 5000-6000 5000-6000 5000-6500
Speed TB 5000-7500 5000-6500 5000-6500 5000-6500 5000-6000

2.4, Procedures we have been using during performing our work tasks
The procedures we were following during our internship practice are-
 First, we understand how the machines operate.
 Then we ask the operators and maintenance workers how the work is to be
executed
 And after that we try to do the jobs ourselves and if we get problems which
need further
 explanation and something we don’t know we write down them and

discuss at our break
 time and discussion time with our supervisor and try to know more
 There were many textile activities, which are not concerned under
mechanical, and these terms were difficult to understand for us.
2.5, How we was good in performing our work tasks
As our supervisor told us and comparing, what we do with what we learn and with what the
other workers do, we were very nice. We were also punctual and well enter acted with the
workers. And the other thing that makes us to say we were very nice is we were not only asking
for our supervisor to know more but also we were referring different books and web sites
related to the department we have been working.

2.6, Challenge I faced while performing our work
During the training in the company, we faced many challenges that influence our work. This
includes:
Number of student increase at one place

Sound of some machine can be disturbed
Load capacity on the supervisor
No internet coverage in the company
Environmental is also very hot
Some other student limitation of language
2.7, measures we take in order to solve the challenge
In order to solve those challenges we take some measure
Following day to day

Active participating
Gather information by interview and observation about machine in whole plant
Asking experienced technical documentary room
Referring manual document from different room

CHAPTER 3
OVERALL BENEFIT OF THE INTERNSSHIP
After completing the training we gained many benefit from this internship program like the
following:
Improving practical skill
Upgrading theiortical knowledge
Improving interpersonal communication skills
Improving team playing skill
Improving leadership skills
Understanding about work related issues
3.1Improving practical skills
Wonji/shoa sugar factory is a huge company in our country that produce sugar for the
costumers. So it goes in different process and plants. Due to this complex process there is some
linkage, broken of machine, corrosion, bending and disassembling are occurred. Therefore, to
solving this problem there are many ways taking like welding, assembling, engaging and
disengaging of the gear, valve, pump, pipe and tanks. Also how hydraulic and pneumatic system
is worked.
So, we really understanding by seeing, sharing aid with the operators of that place and also
working with them practically. This encourages as increasing our confidence to operate the
machine by itself.
3.2, Upgrading theoretical knowledge
Theoretical knowledge is prerequisite for practical provision of recommendation for

maintenance activities. For examples,
Pump selection: the total pump head required is made up of the following;
o The difference between liquid levels on suction and discharge sides

o Any difference between vacuum and/or pressure on the inlet and outlet
side liquid free surfaces
o Friction, i.e. the head required to overcome resistance to flow through

pipes and fittings
o Pressure drop across the control valve o Head loss through equipment
such as heaters in the system o The velocity head at final discharge
Bearing selection: the following consideration takes place for selection of bearing
o Low friction o Minimum lubrication use and no contamination of juice
o No cooling water needed and no wear of roller journals o Tolerant of

small misalignments
o Reduced roll length between centres (lower bending stress)
Valve selection: to select the exact valve for replace or change must to know
o Valve weight o Valve stroke
o Valve opening orifice area (A0) o Valve cross section area (Av) o
Friction loss at delivery and waste valve
If pump is stop working it should be replacing by other pump. During replacing some
consideration should also take place like, pressure of suction side and discharging side, types of
pump we selects, speed of rotation and number of impellers and size of the pumps. Therefore
upgrading theoretical knowledge we applied our skill at real world practices without any
confusion.
3.3, Improving interpersonal communication skills
Wonji/shoa sugar factory has different plants from cane transporting to sugar story house. This
is done by its group of workers in different plants. During their team works they are
communicating to each others, putting idea if some problem was occurred and supporting their
idea for solving the problem.
Communicating to each other’s is facilitating their jobs and increasing the productive of the
sugar supplying for their customers. Therefore we can also gained many wisdom from company

worker by asking and changing idea to each other.

3.4, Improving team playing skills
Working with group is the one which facilitate the productivity of the factory. So we improve
the team working skills by discussion with our supervisor and his colleagues in different action
and solving problems. This team playing skill is that necessary in all anyway, because one
support others to increase their productivity in all case. So we can improve the team playing
skills by decision making in group where some problem are exists.
3.5, Improving leadership skills
In WSSF there are many work flow in different plant from company manager to the last labour
that decrease the load on someone and this increase the company profited. From this we ensure
the following improvement:
 Ability to solve problem quickly
 Understand behaviour of the worker and manage them properly
 Facilitate the new idea from this colleagues and making decision
3.6, Understanding about work related issues
To fulfill of the goal one product, ethics has its own advantage. Because, in any company if
there is environmental health, work division, enough material and no corruption the
productivity and supply of the company is increase. We also gain this work ethics during us
staying in WSSF. Therefore we also some work ethics like
 Punctuality
 Keeping rule and regulation of the factory
 Safety first
 Honesty
 Accountability and transparency
 Responsibility
 Polite communication with manager and colleagues

3.7, Entrepreneurship skill acquired

Entrepreneurship is the process of creating something new with value by devoting the necessary time
and effort, assuming the accompanying financial, psychics and social risk and receiving the
result reward of Monetary and personal satisfaction of independency. This is gained by the
following characteristics.
 Low fear of failure
 Self-confidence
 Use of feed back
 Use of resource
 Clear goal setting
 Internal locus of control
 Long term plan
Therefore from the above characteristics we acquired the concept of the entrepreneurship for
putting idea of new creation or modifying the existing material for increasing the capital of the
individual and members.


CHAPTER 4
PROJECT WORK
4.1, PROBLEM IDENTIFICATION AND THEIR PROPOSED

SOLUTION
In WSSF, the corporation between the worker is solve more problem occurred in the company.
But some problem occurs at different place/plants. We are also identified at least four problems
that is available in this factory:
Steam pipe: This problem is occurred in steam generation plant. The pipe use in this
plant is not well give function. Because of pressure drop across the pipe, steam was
leaved pipe. The longer distance has flow, the lower velocity we shall choose for the
steam, so as to avoid excessive pressure drop.
Bulk pile storage of bagasse: In wonji/shoa sugar factory, this problem is occurred at
final bagasse storage area which discharged from mill plant, Because of the large area
involved this usually means storage in open air. Pile management of the company
becomes important in maintaining sloping piles and ensuring that no dams from which
can catch and hold water.
Conveying problem: In the company material/product are conveyed by the belt at many
areas. This belt is repeatedly failed and material is stored for long time without giving
function. So we have an idea to change this conveying by chain that has long life
without any fail.
Ash conveying belt: This problem is occurred in steam generation plant that after
bagasse is burned in furnace and the waste of bagasse ash and smoke gas are to be
discharged. Smoke gas is taking to chimney to release the gas to outside or environment.
But ash is taking to discharge by means of belt. This belt is usually out of function
because of the burned bagasse has maximum temperature. So the concerned company
manager take to solve this problem by take the minimum reduction with belt to fall and
increase the belt quality to resist heat of ash.
So from the above problem those occurred in the WSSF, we select “design of roller conveying
chain” to solve the problem of material conveying from one place to other place.

4.2, PROBLEM SELECTED (ROLLER CONVEYING CHAIN)

Introduction
Roller conveying chain is mostly preferred in sugar factory to transport goods like sugar by sack. This
roller conveying chain is to solve the problem occurred in the factory that the sugar sack is conveying to
the sugar storage area..
Belt conveying has the following problem:
 It has more linkage
 Has maximum slip due to smooth surface
 Fails under high temperature
 Low carrying capacity i.e. convey only 50kg per meter length
Therefore roller conveying chain I design has the following advantage over belt conveying:
 Carry heavy load i.e. 100kg per meter length
 Discharging rate is maximum
 Required low human power and low cost
 Operate at high temperature
 Reduce the labour and time of convey/transport
 Low maintain
 Long life
 Has no linkage, slip and failure like a belt
4.2.1, Design analysis
Drive end: Apply driving power to the discharge end of a conveyor so that only the
carrying run is under maximum tension. Apply power to the head sprocket through
another chain and sprocket.
Pre-tension and take-ups: Provide take-ups in all conveyor installations to ensure slack
for installation and maintenance and to compensate for elongation due to wear. Install
the catenary take-ups at the head end of the conveyor; install all other take-ups at the
foot or loading end of the conveyor.

Points to consideration
1. Ensure that chains always engaged with at least three sprocket teeth
2. For long conveyors use take-up devices to eliminate chain slack. Take-up
stroke = (c*0.02) =S
Where: c = center distance between sprockes
S = catenary sag allowance
But this equation is for conveyors longer than 50ft.
Long shaft center distances: For unusually long shaft centers, either use two conveyors
with a transfer point or use bearing roller chain.
Return chain supports: On chain conveyors more than fifteen feet long, support the
return strand on a track or guide to minimize pulsation and whip and to prevent the
sagging chain striking obstacles
Operating temperatures: Standard conveyor chain can be operated normally in
ambient temperature between 150F and 1400F. Select the appropriate chain for condition
out of this range, including operation in freezing chambers or heat-treatment ovens.
4.2.3 Material selection
The material selection for our design has the following consideration:
Availability of material
Low cost
Suitability of the materia
l Easy replaced/maintain
I take material selection from appendixes table 1.
The frame:
The frame is the basic component on which all the other component is tight on it. It used for
supporting the overall weight of the machine. This frame is 10m in length and 1m in width. This
frame is carry the weigth of the sugar conveyed up to 10 quintal of sack and the weigth of the
chain, sprocket, slat and motor up to It is made up of rectangular steel bar that structure is
shown as below.

Figure 11supporting bar

Slats:
The slats are where the product is carried on it. This slat is made up of light metal which is
resist the friction, rust and corrosion. This is shown below
Figure 12 : slat
Nut and bolt:
Bolt and nut are used to tight the component of the machine together for have same rotation and
reduce sliding. Bolt and nut are shown as fig below
Figure 13 : bolt and nut


4.3, DESIGN AND CALCULATION
4.3.1, Design of chains
In the design of chain, some consideration takes place
No slip takes place during chain drive
It gives high transmission efficiency (up to 98%) It

transmits more power
It transmit horizontal convey
To simplify the design process, the following assumptions are made depending on the desired
geometry and shape of the machine.
Module, m =4mm
Diameter of sprocket 1 = sprocket 2 = sprocket 3 = sprocket 4 =650mm

Velocity ratio of the chain drive and sprocket is 1
Appropriate center distance for pitch diameter of 250mm, x = 10000mm
Rotational speed of the motor, N = 900 rpm
Rotational speed of the shaft sprocket N =60rpm Power
transmitted by the driven pulley is 12KW
Roller type chain
From these values, we calculate
Number of teeth for each sprockets, T1 =T2 =T3 = T4
T = ∏*D/p
T = ∏*650/250 = 8.16
T =8
To calculate the length of chain and number of chain
The length of one side chain, L = B*P, where B = number of chain of one side To
calculate the total length of the chain

L = 2*length of travelled + 2 (½ ∏*diameter of the sprocket)

Diameter of the sprocket is Ds = P*cosec(180/T)
Where T = number of the teeth

P= pitch
Ds = diameter of the sprocket
Ds = 250mm*cosec (180/8)
Ds = 650mm
Therefore L = 2* 10000mm + ∏*(650) L

= 22041mm
We also calculate the number of chain
B = L/P
B = 22041mm/250mm
B = 88
From the appendix table 2; For roller type chain with the speed of the sprocket 60rpm, the factory
of safety for chain can be taken as, n = 7
Pitch line velocity of sprocket; V=∏*Ds*Ns/60=∏*0.65m*60rpm/60=2.04m/s

Load on chain W = rated power/pitch line velocity = P/V
W = 12KW/2.04m/s
W = 5.88kN
The total load of the chain, W = ,
n = safety factory = 7
Therefore the breaking load on the chain is calculated as
Wb = W*n = 5.88KN*7

Wb= 41.16KN
4.3.2Design of sprockets
In the conveyor two chains and four sprockets are employed it is nprmal practice to keyway the
driving sprocket to the shaft as a pair. The teeth should be in line to ensure equal load sharing.
When a pair of sprockets is mounted on a shaft the long bosses of the sprockets should be
assembled so as to face each other, i.e. towards the shaft midpoint. This allows the sprockets to
lie close to the shaft bearing, giving maximum support to the load, while at the same time
required only the minimum width of conveyor structure.
Figure 14: sprocket For
the pitch diameter of 250mm and number of teeth is 8 The

diameter of the sprocket is D = PT/∏
D = 250mm*8/∏
D = 636.9mm
Therefore from standard table we take diameter of each four sprocket is D =650mm
The torque applied on the tooth of sprocket is
Torque = chain pull x radius of the sprocket
Torque = W*r = 5.88kN*0.325m
Torque = 1.911kNm

4.3.3 Design of shaft

Shaft is a rotating member, usually of circular cross-section, used to transmit power or motion
from one point to the other. It provides the axis of rotation or oscillation of elements such as
gear, pulley, flywheel, cranks, sprockets and the like. An axle is a non-rotating member which
carries no torque and is used to support rotating wheels, pulley, and the likes.
Types of shaft
Shafts are classified as follows according to their industrial application.
Line spindle: It is a shaft which transmits power to several machine elements.
Spindle: A spindle is a short revolving shaft. Example: head stock spindle, drill press spindle
etc
Stub shaft: a shaft that is integral with an engine, motor or prime mover.
Counter shaft: A short shaft that connects a prime mover to a line shaft of a machine
According to the application, shafts may be divided in to two types
Transmission shafts: these shafts transmit between the source and the machines adsorbing
power. Counter shaft and line shafts, over head shafts and all factory shaft are transmission
shafts. Since these shafts carry machine parts such as pulleys, gears etc. Therefore they are
subjected to bending in addition to twisting.
Machine shaft: these shafts form an integral part of the machine itself. Example: crank shaft,
stub shaft.
Shaft material: When greater strength is required, as in high-speed machinery, such as

nickel, or chrome vanadium steels are used. When resistance to corrosion is desired, some
copper alloys are used. The material used for shafts should be have the following properties
 It should have high strength
 It should have good machinability
 It should have low notch sensitivity factory

 It should have good heat treatment properties
 It should have high wear resistant properties
For calculation of design of shaft we select the plain carbon steel C-30 for all shafts from
appendixes table 1.
Having selected the size of conveyor chain required for a system, another important is the
diameter of the sprocket shafts. The head shaft takes the greatest stress and attention for
design.
We select two shaft one for drive and other for driver
i. Design for drive/head shaft

This shaft is subjected to two supporting bearing, force applied on the sprocket and also force
applied by transmission drive motor pulley.
Figure 15Schematic diagram of drive shaft
For roller conveying chain the weight applied by sprocket is the summation of:
 Weight of the total conveying sugar sack for 10m are 10 quintals per unit length i.e.
Wp = 10x100kgx10m/s2 = 10000N. But this weight is equal disturbed on four
sprockets equally, for each spocket weight = 10000N/4 = 2500N
 The pulley shaft drive force by is 500N
Calculation of maximum bending moment
The maximum bending moment induced in the conveyor head shaft. From the diagram the
arrangement of two conveyor sprockets are located equidistant from the respective nearby

shaft bearing (40mm), whilst the transmission chain sprockets on the overhanging shaft, that
distant from the one end of the bearing (50mm).
FP=500N 140mm FSC = 2500N FSD =2500N
A B C D E
FRB 100mm 900mm 100mm FRE
To calculate the maximum bending moment on the shaft, first calculate the reaction force.
Therefore to calculate the reaction force at point E we take the summation of moment at point
B is zero.
∑MB= 0
-500Nx140mm + (2500Nx100mm) + (2500Nx1000mm) - FRE*1100mm = 0
FRE = 2436N
To calculate the reaction force at point B, the summation of force along y-axis is zero ∑F Y
=0
-500 + FRB -2500 – 2500 + 2436 = 0
FRB = 3064N
Therefore to calculate the maximum bending moment, for each section
Section AB
140mm ∑MB = 0
A B FV MB = 500Nx140mm
MB = 70000Nmm
The shearing force at point b is
∑FY = 0,

-500N + FV = 0,
FV = 500N
Section AC
500N 140mm FV
A B C
3064N 100mm
∑MC =0
-500Nx240mm + 3064Nx100mm - MC =0
MC = 186400Nmm
The shearing force at point C is also
∑FY = 0
-500N + 3064N – FV =0
FV = 2564N
Section DE
∑MD = 0
MD -2436Nx100mm = 0
MD = 243600Nmm

FV D E The shearing stress along y-axis is zero
100mm ∑FY =0, -FV + 2436N = 0
2436N FV = 2436N
At point A and E the bending moment of the shaft is equal to zero and the maximum bending
moment is at point D that is 243600Nmm. So from the above data we draw bending moment
diagram
500N 2500N 2500 N
A
B C
3064N 2436N
D E
Shaft length in mm
243.6Nm
186.4kNm
Mb
70Nm
Bending moment for driven shaft
Therefore the above diagram the maximum bending is Mmax = 243.6KN
Calculation of twisting moment (TORQUE)
Torque on the shaft is calculated as
T = 60P/2∏N = 60*12kW/2∏*60
T = 1910Nm
From equivalent bending moment
Meq = √(kbMb)2+(ktT)2 where kb and kt is 1 for stationary load applied
Meq = √(243.6KNm)2 +(1.91KNm)2
Meq = 243.6KNm
From appendix table 7; Ultimate tensile strength for material we selected plain carbon steels
of C-30 is 550N/mm2 and yield strength is 300N/mm2
For the safety factory of 7
We know that the allowable tensile stress
= / = 550mpa/7
= 78.57mpa
Therefore = 32Meq/∏d3

d3 = (32Meq/ ∏ d3 =
(32x243.6Nm/∏*78.57*106N/mm2) d=
0.0318m d = 31.8mm
From the standard of the shaft diameter it take, d = 38mm
From equivalent twisting moment
The maximum torsion stress occurred is
= x Te where = shearing stress, Te = equivalent torque
d = diameter of the shaft
The torque transmitted by the shaft
T = Px60/2∏N = 12X60X103/2∏*60, T =1910Nm
The allowable shearing stress is equal to
= /2
= 300 /2
= 150Mpa
From this the diameter of the shaft is calculated as

d3 = 16Te/∏ d3 = 16*1910Nm/∏*150*106N/m2
d = 0.0401m d = 40.1mm
From the standard shaft diameter we select, d =44mm
Therefore from the two equivalent moments the maximum shaft diameter is allowed. So the
shaft diameter for drive is d =44mm ii. Design for driven shaft
This shaft is subjected to bearing supporting at both side and two sprocket that is equal
distance from bearing.

Figure 16Schematic diagram of the driven shaft
This shaft is applied force by two sprocket (each of weight of 10kg * acceleration due to
gravity 10m/s2), F1 = F2 = 2500N
 Also it is supported by two bearing that located by pins located from sprockets by
140mm distance apart.
Calculation for maximum bending moment
FSB=2500n 900mm FSC=2500N
A B C D
140mm 140 mm
FRA FRD
The force applied at point B is 2500N by sprocket, so to calculate the reaction at D we taking
a moment at point A is equal to zero.
∑MA = 0
(2500N*140mm) + (2500N*1040mm) - (FRD*1180mm) = 0
FRD*1180mm = 53000Nmm
FRD = 2500Nmm
To get the bearing reaction at point A, we calculate the summation of all force along y-axis is
zero
∑FY = 0
FRA – 2500N -2500N + FRD = 0
FRA – 2500N -2500N + 2500N = 0
FRA = 2500N
To calculate the maximum bending moment for each point, it is calculate for each section.
For section AB
140mm FV ∑MB =0
A B MB -2500N*140mm = 0
FRA = 2500N MB = 35,0000Nmm
To calculate the shearing force, summation of force along y-axis is zero,
FV –FRA =0
FV = 2500N
For section CD
FV ∑MC = 0, MC – 2500N*140mm = 0
1 40mm MC = 350,000Nmm
C D FD = 2500N
To calculate the shearing force along y-axis the summation of force is zero.
FV – 2500N = 0
FV = 2500N

Therefore the maximum bending moment is obtained at point B and C is 350000Nmm and
the minimum bending is at point A and D will be zero. From the above data we draw the
maximum bending moment diagram.
A B C D
b M
350000Nmm
Length of the shaft in mm

0
Therefore the maximum bending moment is obtain at point B and C are Mmax =350Nm
The torque due to sprocket on the shaft is,
T = F sprocket * radius of the sprocket
T = 5000* 325mm
T = 1625000Nmm

From the maximum bending moment and torque produced, we calculate the equivalent
moment,
M eq = ( t ) +( )
From the appendixes table 5; we select kt for torsion and kb for moment that is applied load at
stationary. Therefore, kt = kb = 1
Meq = ( t ) +( )
Meq = √(1625000)2 +(350000)2
Meq = 1662265Nmm
Calculation for twisting moment (TORQUE)
For the driven shaft rotate at similar to drive shaft by 60rpm and the power of 12KW, the
torque applied on the shaft is calculated as
T = 60P/2∏N
T = 60*12X103/2∏*60
T =1.91KNm
From equivalent bending moment
Meq = ( t ) +( )
Meq = √(1625000)2 +(1910)2
Meq = 1662265Nmm
For the shaft material of plain carbon steel C-30, the ultimate tensile strength is 550N/mm 2
and yield strength is 300N/mm2, The safety factor of 7
The allowable tensile stress is calculate as

= / = 550mpa/7
= 78.57mpa
Therefore to calculate the diameter of shaft
= 32Mmax/∏d3
d3 = 32 /∏
d3 = 32x1662.265Nm/∏*78.57x106N/m2 d
= 0.05995m d = 59.9mm
From the standard shaft table we take d= 65mm
4.3.4, Design of the key
Key is piece of mild steel inserted between the shaft and sprocket to connect these together in
order to prevent relative motion between them. Key is used as temporary fastening are subjected
to considerable crushing and shearing stresses.
Types of key
 Sunk keys
 Saddle key
 Tangent keys
 Round key
 Spline key
From the above key, key that we select is rectangular sunk key. The usual proportions of this
key are
For driver shaft,
For the d =44mm

T = 1910Nm
τall = 150Mpa
Width of the key, w = d/4 = 45mm/4 = 11.25mm
Thickness of the key, t = 2w/3 = d/6 =45mm/6 = 7.5mm

Length of the key,
T = F*d/2 = *w*l*d/2
L = 2T/ *w*d = 2*1910Nm/150*106N/m2*0.01125m*0.044m L
=0.0514m
L = 51.4mm
For driven shaft
For the d =65mm
T = 1910Nm
τall = 150Mpa
Width of the key, w =d/4 = 65mm/4 = 16.25mm Thickness
of the key, t = 2w/3 = d/6 = 65mm/6 = 5.4mm Length of
the key
T = F*d/2 = *w*l*d/2
L = 2T/ *w*d = 2*1910Nm/150*106*0.01626m*0.065m L
= 0.0237m
L = 23.7mm
4.3.4, Bearing selection

A bearing is machine elements which support another moving machine element. It permits a
relative motion between the contact surfaces of the members, while carrying load. A little
consideration will show that due to relative motion between the contact surfaces, a certain amount
of the wasted in overcoming frictional resistance and if the rubbing surfaces are in direct contact,
there will be rapid wear. In order to reduce frictional resistance, wear and in some cases to carry
away the heat generation.

Roller conveying chain has used bearing at shaft supporting end. This bearing we selected has
the following consider
 Low starting and running friction
 Ability to withstand momentary shock
 Accuracy of shaft alignment
 Low cost of maintenance
 Small overall dimensions
 Reliability of service
 Easy to mount and erect
 Cleanliness
Lubrication of bear
Bearing are lubricated for the following purposes:
 To reduce friction and wear between the sliding parts of the bearing,
 To prevent rusting or corrosion of the bearing surfaces
 To protect the bearing from water, dirt, etc., and  To dissipate the heat.
For driver shaft of the diameter of 45mm we select the bearing number 209 are selected and also
for the driven shaft of the diameter of 65mm bearing number 313 is selected from appendix
table 3.
4.4Cost analysis
Table 7The overall cost that we design for conveying purpose is as follow
Component Dimension Material Quantity Price (in

birr)
Chain 22.04m Mild steel 2 2200
Sprocket Dia 650mm Mild steel 4 500
Shaft Dia 45x 1240mm Mild steel 5 650
Dia 65x 1100mm

Bearing 209- Carbon 10 1750

chromium
313-
steel
Key 11.25mmx7.5mmx51.4mm Mild steel 6 300
16.25mmx5.4mmx23.7mm
Slats 250mmx1100mm Light metal 88 8800
Frame body 0.02x0.02x32m Cast iron 1 1300
steel
Nut and bolt M24 Mild steel 372 1116
Total cost 16616

Figure 17roller conveying chain

Conclusions
After we joined in to wonji//shoa sugar factory for four months, we have gained many benefit
that concerning to our field what we have been learn in the class theoretically by seeing, asking
and operating some machine and part of increase our skill in many ways. So this university-
industrial linkage was prepared or conducting by department for engineering student after taking
some course will be bring student self relief and confidence to know what they learn by theory
and also opportunity to know what industry look like. When student join in to factory and
finding some problem occurred in the factory and give their proposed solution for that problem
was increase high quality productivity and give student to bring the new idea and appreciate to
discover the new machine. Therefore this course or internship is important for student in term of
student increase to link their theoretically knowledge with practically.

Recommendation
Wonji/shoa sugar factory was the first sugar factory in Ethiopia that produce raw sugar, sugar
product and sugar by product for internal market and for export. This factory produces sugar in
high quality and also produces electric power from steam by itself. But we recommend that, the
WSSF factory is to
 Produce steam by two pair of boiler rather than single boiler to increase power
generation
 Decrease by air pollution by reducing the amount smoke released from the boiler
 Increase the productivity per day as much as possible
 Increase the efficiency of the turbine that produce electricity to 32MW
 Give pocket money for student during internship
 Additional plant like ethanol, work shop, i.e. and
 Decrease the wastage of the steam by increase the efficiency of pipe flow.
 Decrease the extravagance of lime during uptake from the land during for mixing.
 Avoid improper ash drop in steam generation plant by increasing size of ash conveying
belt and making its coverage through which the ash is dropped.
 Minimize bursting of steam pipe by using a pipe which can stand with high pressure
and temperature.

Appendix
Appendix A: Basic Terminologies
Ash: Solid residue determined gravimetrically after incineration in the presence of oxygen. In analysis of
sugar products, sulfuric acid is added to the sample, and this residue as sulfated ash heated to 525 °C is
taken to be a measure of the inorganic constituents. Sometimes it determined indirectly by measurement
of electrical conductivity of the product in solution.
Bagasse: Cane residue leaving mills after extraction of juice.
Brix: Measure of dissolved solids in sugar, juice, liquor or syrup using a refractometer, otherwise
referred to as refractometric dry solids. For solutions containing only sugar and water, Brix = % sugar by
mass.
Casandra: Tubular or plate heating element in a vacuum pan or evaporator vessel.
Centrifugal: Centrifuge used to separate sugar from mother liquor.
Clarifier: Apparatus for the separation by sedimentation of suspended solids from a turbid sugar
solution.
Clarified Juice: Juice from clarifier also referred to as clear juice.
Color: Attenuation index, determined by absorption of light under defined conditions. Generally
Cooling Crystallization: Crystallization by cooling of the massecuite.
Crystal Content: Proportion by mass of crystals in massecuite, often expressed as a percentage, and
referred to total massecuite mass or to massecuite dry substance (Brix).
Crystallization: Nucleation and growth of crystals.
Dissolved Solids: are all solute material which is in solution, including sucrose, monosaccharaides, ash
and other organic impurities.
Dry Substance: A measure of total solids obtained from evaporating a solution or massecuite under
vacuum to dryness. Also it referred to as total solids by drying or dry solids.
Evaporator Effect: One of a system of evaporators operating in series as a multiple effect system (e.g.
First effect, second effect). Condensates and vapors are labeled correspondingly (e.g., first condensate
and vapor one: condensate and vapor from the first effect respectively).
FAINAL INTERN SHIP REPORT Page 69

Extraction: Proportion of sugar extracted from cane in the extraction plant; equals mass of sugar in raw
juice as a percentage of mass of sugar in cane.
False Grain: Undesirable small crystals, formed spontaneously by secondary nucleation when the super-
saturation during crystallization is too high.
Fiber: The dry fibrous insoluble structure of the cane plant. Generally taken to mean all insoluble
material in the cane delivered to a mill, and therefore includes soil or other extraneous insoluble matter in
cane.
Filter Cake: Material retained on the filter screens and discharged from the filters after filtering clarifier
muds.
Filtrate: Liquid passed through the screens of the filters.
Flocculants: Polyelectrolyte in solution added to juice to assist clarification.
Imbibition: The process of adding imbibition water to the extraction plant to increase extraction. Water
added is called imbibition water.
Liming: Process step in juice purification in which lime is introduced into the sugar juice in the form of
milk of lime or lime saccharide solution.
Liquor: sugar syrup, a term generally used in sugar refining.
Massecuite: The mixture of crystals and mother liquor resulting from the crystallization process.
Massecuites are classified according to purity as A, C, or D massecuites.
Molasses: The mother liquor separated from the crystals by centrifuging. A, C or D molasses is derived
from the corresponding massecuites. C molasses is also referred to as final molasses.
Mother Liquor: Liquid phase in the massecuite during crystallization; refers to syrup or liquor in which
the crystals are growing.
Non-sucrose: Dissolved solids contained in any process stream other than sucrose.
Non-sugar: Common overall term for dissolved solids other than sugar contained in any process stream.
Polarization: (or the apparent sucrose content expressed as a mass percent measured by the optical
rotation of polarized light passing through a sugar solution. This is accurate only for pure sucrose
solutions.
Press Water: Juice expressed from dewatering mills after a diffuser.

Purity: The true purity is the sucrose content as a percent of the dry substance or dissolved solids
content. The solids consist of sugar plus non-sucrose components such as invert, ash, and colorants.
Apparent purity is expressed as polarization divided by refractometer Brix multiplied by 100.
Reducing Sugars: Generally referred to and/or interpreted as invert sugar, determined by measuring
reducing substance content by laboratory analysis.
Saturation: A sugar solution at saturation will not dissolve any more crystals at the temperature of the
solution.
Seed: Suspension of fine crystals in saturated solution of alcohol, or the initial grain resulting from
seeding in a vacuum pan.
Strike: Massecuite as a completed boiling, all of which is discharged from the pan.
Sugar: Term for the saccharide sucrose and products of the sugar industry, essentially composed of
sucrose.
Sulphitation: Introduction of sulfur dioxide into juice or liquor.
Super-saturation: The degree to which the sucrose content in solution is greater than the sucrose content
in a saturated solution.
Suspended Solids: Insoluble solids in juice or other liquid, removable by mechanical means.
Syrup: The concentrated juice from the evaporators.
Trash: Cane tops, leaves, dead stalks of cane and any other vegetable matter delivered with the cane.

Appendix B: Material balance
Appendixes
Table 81 material selection
Component Material
Chain Mild steel
Sprockets Mild steel
Shaft Mild steel ( C-30)
Bearing Tin-based alloy
Supporting bar Mild steel
Nut and bolt Mild steel
Slat Light metal
Table 9 factor of safety (n) for roller and silent chains
Type Pitch Speed of sprocket

of of 50 200 400 600 800 1000 1200 1600 2000
chain
chain
in
mm
Bush 2012- 7 7.8 8.55 9.35 10.2 11 11.7 13.2 14.5
roller 15-25
chain
30-35 7 8.2 9.35 10.3 11.7 12.9 14 16.3 -

30-35 7 8.5 10.2 13.2 14.8 16.5 19.5 - -
Silent 12,7- 20 22.2 24.4 29 29 31.0 33.4 37.8 42.0
chain 15.87
19.5- 20 23.4 26.7 30 33.4 36.8 40.0 46.5 53.5
25.4

Table 10 : bearing selection
Bearing No. Bore (mm) Outside diameter (mm) Width

(mm)
206 62 16
306 30 72 19
406 90 23
207 35 72 17
307 80 21
407 110 25
208 40 80 18
308 90 23
408 110 27
209 45 85 19
309 100 25
409 120 29
210 50 90 20
310 110 27
410 130 31
211 55 100 21
311 120 29
411 140 33
212 60 110 21
312 130 29
412 150 33
213 65 120 22
313 140 31
413 160 35

Table 11 ultimate tensile strength and yield strength

Material Ultimate tensile Yield strength,
Strength, N/mm2 N/mm2
Plain carbon steels
C 07 320 - 400 200
C 10 340 - 420 210
C15 370 - 490 240
C20 440 - 520 260
C25 460 - 550 280
C30 500 - 600 300
C40 580 - 680 330
C45 600 - 750 380
C50 660 - 780 380
40 Ni 3 750 - 1050 600
30 Ni4 Crl 1000 - 1150 600
40 Cr 3 Mol V20 1350 1120
40 Crl 700 – 850 540
Table 12 The recommended value of the kb and kt
Nature of loading Kb Kt
Stationary shaft
Stationary applied load 1 1
Suddenly applied load 1.5-2.0 1.5-2.0
Revolving shaft
Suddenly applied load 1.5 1
Minor shock load 1.5-2.0 1-1.5
Heavy shock load 2.0-3.0 1.5-3.0

References
1) Hand book of cane sugar engineering. 3rd completely revised, edition
2) Cane sugar engineering, Peter Rein
3) Machine design –R_S_khurmi,kGupta text book
4) Strength of materials 4th. By Ferdinand l. Singer_Andrew Pytel
5) Shingley_s mechanical engineering design 8th edition
6) Fundamental of material science and engineering
7) Www. Roller conveying chain
8) Wonji/shoa sugar factory manual
9) Hugot. (1986),hand book of cane sugar engineering, third, completely revised, edition.
Elevier-Amsterdam-Oxford-New york-tokyo
10) D.P Kulkarni. (1995), Cane sugar manufacture in India. The sugar technologist association
of India, New Delhi, India
11) Peter Rein. (2007), cane sugar engineering. Verlas Dr. Albert Bartens KG-Berlin

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WACHEMO UNIVERSITY

COLLEGE OF ENGINNERING AND

COMPANY SUPERVISOR : Abebe Defaru

SUBMISSION DATE : SEPTAMBER 12, 2023

HOSSANA SNNP ETHIOPIA

Student name : Fasika Tekabe Signature: _________________

Mentor name : Yared Z . Signature: _________________

Supervisor name : Abebe Defaru Signature: _________________

FINAL INTERNSHIP REPORT Page

FAINAL INTERNSHIP REPORT Page ii

FAINAL INTERNSHIP REPORT Page iii

Main activities of the factory are

 Grow sugar cane and process it to produce sugar.

FAINAL INTERNSHIP REPORT Page iv

Abbreviation and Acronym

Br: degree brix

CJ: clear juice

E1: water evaporated at evaporation unit

E2: water evaporated at vacuum plant unit

ELPA: Ethiopian electric power authority

FC: filter cake

HVA: Hangler Vonder Amsterdam

ICUMSA:international commission for uniform method of sugar analysis

MIS: management information system

MJ: mixed juice

MSF: metehara sugar factory

RS: reducing sugar

FAINAL INTERNSHIP REPORT Page v

Figure 1 : overall organizational work flow__________________________________________________________10

FAINAL INTERNSHIP REPORT Page vi

FAINAL INTERNSHIP REPORT Page vii

3.3, Improving interpersonal communication skills_____________________37

FAINAL INTERNSHIP REPORT Page viii

Appendix A: Basic Terminologies_______________________66

FAINAL INTERNSHIP REPORT Page ix

1.1, Location and Foundation of WSSF

FAINAL INTERNSHIP REPORT Page 10

1.2, Purpose of establishing sugar factory

 Grow sugarcane and other yielding crop

 To fulfil social need of sugar in the country

 Process and produce sugar, sugar products and sugar by products

 Sell the products and by-products in domestic and export market

1.3, Relation of WSSF factory with other sugar factory

1.4, New wonji/shoa sugar factory

FAINAL INTERNSHIP REPORT Page 11

1.5, Main products or service of WSSF

Electric power and

1.6, Main customers or end user from WSSF

FAINAL INTERNSHIP REPORT Page 12

Customers of white sugar (from pan house product)

East Africa (coca cola company)

Moha soft drink factory (Pepsi company)

FAO (food and agricultural organization) the united nation

MEWIT (JINAD) which distribute white sugar to the whole market of

Belazaf alcohol and liquors factory

FAINAL INTERNSHIP REPORT Page 13

1.7, Overall organization and work flow

to general manager Secretary

Public relation estate

Management and improvement

Legal service Commercial

Figure 1 : overall organizational work flow

FAINAL INTERNSHIP REPORT Page 14