DIRE DAWA UNIVERSITY INSTITUTE OF TECHNOLOGY

SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

DEPARTEMENT OF INDUSTRIAL ENGINEERING

INTERNSHIP REPORT
HOSTING COMPANY: DIRE DAWA FOOD COMPLEX SHARE COMPANY (DDFSC)

DURATION OF INTERNSHIP: FROM JUNE- 15 TO AUGUST-8

PROJECT TITLE: PRODUCTIVITY IMPROVEMENT THROUGH ERGONOMIC ASSESSMENT

PREPRED BY: ID NO

1. SOLAN EDOSA……………………………………………………R/0825/09

2. ERMIAS YOHANNES……………………………………………R/1113/09

3. HAMZA IBRAHIM………………………………………………R/0192/08

Advisor: Ins. Tsinukal. B.

Sub-Date: August 18, 2021.

 DECLARATION

This internship report and project work is our clear work that has been made in the period of from June
15 , to August 8, 2021 G.C.in DireDawa food complex company,certainly assure on our signature.

Students Name Signature

Solan Edosa ________________

Ermias Yohanis ________________

Hamza Ibrahim ________________

Approvals

Mentor Name:_________________________ Signature:________________

Company Supervisor

Name:___________________________ Signature:_______________

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 ACKNOWLEDGMENT
First of all, we have to readily acknowledge and thank to God, the omnipotent and
omniscient who created everything and in giving Us the ability to start and complete this
project.

We thank to DDFCSC staff members who support and encourage us during our internship from their
devotion and generosity.

Special thanks also go to our supervisors, Ermias ,Samuel, Abdi and all members of flour production,
biscuit production and bread production section staff.

And we wish to express our sincere gratitude to our adviser ins. Tsinukal B. who was abundantly helpful
and offered valuable assistance, support and guidance well.

We would like to thank our beloved families for their constant love and encouragement which help us in
completion of this project.

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 EXECUTIVE SUMMARY
Internship is such a nice program which helps the students to perform their theoretical knowledge
practically.
This internship report is a written document that describes the way we spend in the period of 2 months in
relation to apply our theoretical knowledge and upgrade our practical skill.

This internship report also shows in detail all about the information’s and tasks of the DDFC Share
Company departments depending up on the existing system of the company.

During our internship program we have observed that there is an ergonomic problem in which the job
doesn’t fit the employers which in turn leads the employers a discomfort and dissatisfaction and
depending on this problem, we have done a project that can be a solution for the problem, and also the
project shows in detail that if the company should work up on the employers comfort, satisfaction
(ergonomics), the productivity will be improved.

We have got lots of practical experiences from the internship such as practical skills like how to operate
machines, inspection, entrepreneur skill, communication skills, team working skills,

There are different types of operations that are carried out relative to industrial engineering course in Dire
Dawa Food complex company.

The main raw product in the company is wheat of two type’s soft and Hard wheat’s.t and the main
operations in the company are; wheat cleaning, dumping, milling, packing, mixing of ingredients, dough
forming, backing, defect inspection, packing, and transporting.

Dire Dawa food complex produce different kinds of foods, flour, pasta, macaroni, biscuit and bread
production, Animal feeds.

More than a plain account of tasks, the objective of this text is to reflect upon the experiences collected
during the internship from the perspective of an industrial engineering student in ergonomics, Material
handling and facility lay out, production planning management I&II,TQM, SQC.

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 TABLE OF CONTENTS
DECLARATION ............................................................................................................................................................i
ACKNOWLEDGMENT .............................................................................................................................................. ii
EXECUTIVE SUMMARY ....................................................................................................................................... iii
1. 1 BACKGROUND OF DIRE DAWA FOOD COMPLEX . ................................................................................ 1
1.2 Vision ...................................................................................................................................................................... 2
1.3 Mission ....................................................................................................................................................................2
1.4 Values......................................................................................................................................................................2
1.5 Land ........................................................................................................................................................................ 2
1.6 The objective of company .....................................................................................................................................2
1.6.2 Specific objectives of the company ....................................................................................................................3
1.7 Main Customers ................................................................................................................................................... 3
1.8 Service of Company ...............................................................................................................................................3
1.9 Main products of Company ..................................................................................................................................3
1.10 The raw material for the company ..................................................................................................................... 4
1.11 Resource ...............................................................................................................................................................4
1.13. OVERALL INTERNISHIP EXPERIENCE ....................................................................................................7
1.13.2. The Section of the Company We Have Been Working. ................................................................................7
1.13.3. Work flow in our working section .................................................................................................................. 7
1.13.4 The work piece or work task we have been executing. ................................................................................ 15
1.13.5 How good are we in performing our task in the company? ....................................................................... 15
1.13.6 The kind of challenges we have faced in company of our wok tasks .......................................................... 16
1.13.7 The Measure We Took To Over Come Those Challenges .......................................................................... 17
1.13.8 The design and construction in terms of safety and economy..................................................................... 17
1.14. OVERALL BENEFITS OF THE INTERNSHIP PROGRAM .................................................................... 18
1.14.1 Improving Practical Skill. .............................................................................................................................. 18
1.14.2 Benefits gained in terms of improving theoretical knowledge .................................................................... 18
1.14.2.1 The wheat flour flow process ...................................................................................................................... 19
1.14.2.2 Types of Machine and their uses. ............................................................................................................... 19
1.14.3 Benefits in terms of interpersonal communication skills............................................................................. 22
1.14.4 Benefits Gained in terms of Improving Team Playing Skills ........................................................................... 22
1.15 Benefits Gained in terms of Improving Leadership skills ...................................................................................23
1.16 Benefits Gained in terms of Understanding about Work Ethics and Related Issues ..........................................23
1.17 Benefits gained in terms of entrepreneurship skills ............................................................................................ 24
1.18.THE PRODUCTION SECTION OF THE COMPANY WE ARE WORKING IN ................................... 25

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1.18.1 Introduction .................................................................................................................................................... 25
1.18.2 The company generally produces four main product products .................................................................. 25
1.18.2.1 Flour production .......................................................................................................................................... 26
A. Pre-cleaning section of wheat: ............................................................................................................................. 27
B. Cleaning section of Wheat .................................................................................................................................... 28
A. Separation by size ................................................................................................................................................. 29
B. Separation by density ........................................................................................................................................... 29
C. Separation by shape .............................................................................................................................................. 29
D. Separation by the magnetic force ........................................................................................................................ 29
C. Milling of Wheat ................................................................................................................................................... 32
D. Flour Packing ........................................................................................................................................................ 33
1.18.2.2Biscuit Production ........................................................................................................................................ 34
A. Mixer stage ............................................................................................................................................................ 35
B. Dough Forming (Roller) stage............................................................................................................................ 35
C. Baking(oven stage) ............................................................................................................................................... 36
D. cooling ................................................................................................................................................................... 37
E. Packing .................................................................................................................................................................. 38
1.18.2.3 Bread Production ......................................................................................................................................... 39
A. Mixer stage .................................................................................................................................................. 39
B. Rolling or rounding stage ........................................................................................................................... 43
C. Staying in proofing champers house .......................................................................................................... 43
D. Oven stage:- ................................................................................................................................................. 43
1.19 CONCLUSION AND RECOMMENDATION ............................................................................................... 45
1.19.1 Conclusion ....................................................................................................................................................... 45
1.19.2 Recommendation ............................................................................................................................................ 45
CHAPTER TWO ....................................................................................................................................................... 46
2. PROJECT: Productivity Improvement through Ergonomics Assessment ...................................................... 46
2.1 Executive Summary ........................................................................................................................ 46
2.2 Problem Statement and Justification ............................................................................................ 46
2.3 Objective Of The Project................................................................................................................ 47
2.3.1 General Objective .................................................................................................................... 47
2.3.2 Specific objectives ................................................................................................................... 47
2.4 Significance Of The Study .............................................................................................................. 47
2.5 Scope Of The Study ........................................................................................................................ 48
2.6 Literature Review ........................................................................................................................... 48

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 2.6.1 Ergonomics ............................................................................................................................... 48
2.6.2 Productivity .............................................................................................................................. 49
2.6.3 Ergonomics Seating Standards ............................................................................................... 50
2.6.4 Seating comfort ........................................................................................................................ 51
2.6.5 Definitions of comfort and discomfort ................................................................................... 51
2.7 Methodology .................................................................................................................................... 51
2.7.1 Data collection .......................................................................................................................... 51
2.7.1.1 Primary data collection method.................................................................................................. 52
2.7.1.2 Secondary data collection method ............................................................................................... 52
2.8 Data Analysis ................................................................................................................................... 52
2.8.1 Data Analysis on Existing Productivity.................................................................................. 53
2.8.2Analysis on an existing workers chair ................................................................................... 54
2.9 Proposed Solution ........................................................................................................................... 55
2.9.1 Chair Design ............................................................................................................................. 55
2.9.1.1 Back Rest and Seat........................................................................................................................ 55
2.9.1.2 Chair Legs...................................................................................................................................... 55
2.9.2 Strength Analysis ..................................................................................................................... 57
2.9.2.1 Seat Pad.......................................................................................................................................... 57
2.9.2.2 Backrest ......................................................................................................................................... 60
2.10 Result and Discussion ................................................................................................................... 61
2.10.1 Cost Analysis .......................................................................................................................... 61
2.10.1.1 Cost of Production Loss.............................................................................................................. 61
2.10.1.2 Medical cost ................................................................................................................................ 62
2.10.1.3 Absenteeism cost ......................................................................................................................... 62
2.10.1.3 Cost of designed chair ................................................................................................................. 63
2.11 Conclusion and recommendation .................................................................................................... 64
2.11.1 Conclusion ...................................................................................................................................... 64
2.11.2 Recommendation............................................................................................................................ 65
References .................................................................................................................................................................. 66

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 LIST OF TABLES
TABLE1 1 ,COMPANY MANPOWER ...................................................................................................... 5
TABLE1 2 ,SAFETY LIMIT OF WHEAT ................................................................................................ 26
TABLE1 3 CHEMICAL COMPOTES OF THE WHEAT ........................................................................ 26
TABLE1 4,COMPOSITION RATIO OF INGRIDENT OF BREAD ........................................................ 42
TABLE1 5,INGRIDENT OF BREAD ....................................................................................................... 42
TABLE1 6 ,OVEN ZONE .......................................................................................................................... 43
TABLE2 1, EMPLOYEE IN SELECTED PRODUCTION SECTION….………………………………49

TABLE2 2,PRODUCTION LOSS DUE TO MSDS FOR DDFC ............................................................. 61

TABLE2 3,MEDICAL COST FOR DDFC ................................................................................................ 62
TABLE2 4 ,ABSENTEEISM COST FOR DDFC...................................................................................... 62
TABLE2 5,ANALYZED COST OF DESIGNED CHAIR ........................................................................ 63

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 LIST OF FIGURES
FIGURE1.1, PRODUCTS ............................................................................................................................ 4
FIGURE1. 2, ORGANIZATIONAL STRUCTURE. ................................................................................... 6
FIGURE1.3, PARTS OF WHEAT. .............................................................................................................. 8
FIGURE1 .4, WHEAT FLOUR MILLING MACHINE ............................................................................ 10
FIGURE1.5, BUCKET ELEVATOR ......................................................................................................... 11
FIGURE1.6 PNEUMATIC CONVEYOR (BLOWER) ............................................................................. 12
FIGURE1.7 CHAIN CONVEYER ............................................................................................................. 13
FIGURE1.8 SCREW CONVEYOR ........................................................................................................... 13
FIGURE1.9, FLOUR SECTION FLOW PROCESS .................................................................................. 14
FIGURE1.10,WHEAT FLOUR FLOW PROCESS ................................................................................... 19
FIGURE1.11, SEPARATOR MACHINE .................................................................................................. 20
FIGURE1.12, DAMPING .......................................................................................................................... 20
FIGURE1.13, DE STONER MACHINE .................................................................................................... 21
FIGURE1.14, SCORER MACHINE AND SCORER ENTIRE PART...................................................... 21
FIGURE1.15, ROUNDING MACHINE .................................................................................................... 22
FIGURE1.16, WHEAT ............................................................................................................................... 26
FIGURE1.17, FRESH WHEAT STORE IN SILO..................................................................................... 27
FIGURE1.18 , FIRST AND SECOND CONDITION (DAMPENING) .................................................... 31
FIGURE1.19, SEMOLINA ........................................................................................................................ 32
FIGURE1.20, ROLLER MACHINE .......................................................................................................... 33
FIGURE1 21, PACKING MACHINE ABOVE 50KG AND ABOVE 10KG ........................................... 34
FIGURE1.22,MIXER ................................................................................................................................. 35
FIGURE1.23 THE SECOND STAGE OF DOUGH REDUCTION .......................................................... 36
FIGURE1.24, OVEN .................................................................................................................................. 37
FIGURE1.25COOLING BELT .................................................................................................................. 37
FIGURE1.26, PACKING MACHINE ........................................................................................................ 38
FIGURE1. 27, MIXING MACHINE .......................................................................................................... 40
FIGURE1. 28,SYMBOLS OF OPERATING MIXING MACHINE ......................................................... 40
FIGURE1.29, BREAD BAKING FLOW PROCESS................................................................................. 44

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 CHAPTER ONE

1. 1 BACKGROUND OF DIRE DAWA FOOD COMPLEX SHARECOMPANY

Dire Dawa Food Complex S.C is located in Dire Dawa town in the eastern Ethiopia which is around
515kms from Addis Ababa. The company starts operation in 1995 GC and it is one of the modern Food
processing plants in East Africa. Dire Dawa food complex share company is known for the Production of
its famous Vera pasta product in the country. The company also produces flour, pastini, macaroni , biscuit
products, and Animal feeds.

The Company uses two types of wheat those are hard wheat and soft wheat. Hard wheat used for pasta,
macaroni and pastin and soft wheat used for bread, and biscuit. The flour milling plants has been
upgraded recently from 120 ton/day capacity to 200 ton/day capacity and the product wheat flour is used
for the industrial consumption as in put and supply of producing companies.

The pasta plant has two lines for making of long pasta and short cut pasta. The two lines have a capacity
to produce about 50 tons of pasta products per day. The two biscuit plants produces soft-sweet and hard
biscuits and has a capacity of 10 tons per day each. The rest of wheat flour about 50-60 tons is supplied to
bread producing plants.

The company has 459 permanent employees among these, 57 employees in flour section,45 employees in
bread section and 15 employees in biscuit section .The factory has 5 silos that can store 10,000 tons of
raw materials or wheat. The silos have pre-cleaning facilities, sieving and aeration. In addition the four
mixing bins and twelve metallic conditioning bin. Chemicals and hard wheat are imported via Djibouti
and transported to Dire Dawa by truck and train. The main processes in the flour production plant include
pre-cleaning, mixing, intensive cleaning, conditioning, milling, impurity removal, blowing, by product
packaging, transporting of flour to storage silos and flour packaging. The main processing steps in flour
production are dosing, mixing, extrusion, shaping and cutting, pre-drying, cooling, intermediate storage,
weighing and bagging, packaging and final storage. The main steps in biscuit productions are ;
(Ingredients and flour )Mixing, dough forming, shaping, baking, cooling ,packing, inventory storage.
Dire Dawa food complex is the leading plant in Ethiopia in terms of its new technology and complex
operations.

1
1.2 Vision
The vision of the company is to be a famous pasta producer with the known brand VERA in east Africa
and COMESA member countries, fulfilling the internationally accepted standards.

1.3 Mission

The organizational mission of the company is to produce quality flour and flour based products for the
best satisfaction of the customer based on the food safety principles HACCP ISO 9001: 2005 quality
system and ISo14001.2005 Environment management system requirements.

1.4 Values
The major values of the company are the dedication and the commitment of the workers for their
company and produce quality product to satisfy customer requirement, the good reputation of the
company products obtained through time. All effort shall be exerted in order to keep and improve these
values.

1.5 Land
The company has been planted on 28,484 square meters land area and also another site located where
(GENDE BOYE) AROUND PAPA on 10,800 square meters land area with four stores used for raw
materials and mass products storage.

1.6 The objective of company

1.6.1 General objective of the company

The company produces flour, pasta, macaroni, pastin, biscuit, and bread products. It is to produce and sell
flour related products profitably. The company has been already playing the role of substituting the
import and this will be kept in the planning year. The company strives to produce quality products and
keep its reputation by maintaining the implemented management system. The company strives to stabilize
the food price escalation by distributing products to the government institutes, market corporatizes and to
the public at large with reasonable price.

2
1.6.2 Specific objectives of the company

Reduce the defects by 2% for pasta product by improving the efficiently of maintenance and production
capability man power competence and Applying modern technology. Maintain and improve the
implemented management system and re certified HACCP, ISO 9001: 2000 and ISO 14001: 2004 system.

1.7 Main Customers

The main customers of Dire Dawa Food complex S.C are:-
 ETHIOPIAN UNIVERSITIES: Dire Dawa University, Haramaya University, Gondar
University, Mizan Tepi University and so on.
 Supermarket
 Non-governmental Aid Organization
 Shops and the public at large.

1.8 Service of Company

For employer to facilitate work, laundries for washing clothes of employer, free transportation for their
customers Cover 75% of payment for those who learn extension education to improve their knowledge.
Gives continues training for workers and customers about product. The employers have insurance if the
machine cuts their bodies, free health service for employers and free transportation during wedding.

1.9 Main products of Company

The main products of Dire Dawa Food complex S.C are
 Wheat Flour
 Vera pasta (spaghetti)
 Vera macaroni (various shape)
 Vera pastini
 High energy zebib biscuit
 Fruit biscuit
 Bread
 Animal feed

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 FIGURE1.1, products

1.10 The raw material for the company

The only raw materials for the the company DDFCSC is wheat from different locations.
Local material: from Jigjiga, Adama, Bale state farm, colleen enterprise, chelalo, state farm and Arsi
state farm.

Foreign material: Durum wheat and soft wheat is imported from Australia.

1.11 Resource
Man power: The man power resource as compared to the total requirements of the company is
insufficient. But the company is in a relatively better position as compared to the major competitors
especially for technical staff. The quality and dedication of the manpower is one of the strong features
of the company.

Even though the salary scale is relatively competitive and attractive, the high cost of living, the
distance location of Dire Dawa from the capital and the weather condition does not motivate skilled
manpower to serve so long.

4
 Factory has totally 459 employees.

NO employee sex total remark

M F

1 Permanent 174 75 249

2 Temporary(picrate 45 84 129
worker)

3 Contract 17 11 28

4 Load and unload 53 0 53 Only male

workers

total 289 170 459

table1 1 company manpower

Facilities and others

The company has the following facilities for its working activities:-

 About three trucks for raw materials and packing materials transportation.

 Automobile and service buses to facilitate the day to day activities.

 Five metal silos, 12 of metal silo and two large ware houses for storing raw
materials.

 Relatively well equipped quality control laboratory.

 Laundry service for clothes of workers.

 Houses for the production and technique professionals.

 Car Parking area.

 Workers cafeteria.

5
 1.12 Over all organizational structure and work flow cart
Director board

Auditing
inspection
General
Manager
Auditing

Administrat Plan & Statics Quality control &

improvement

Persona Health General

training center Service

Finance Trade Production & AA brunch

technic office

General Flour
Price, budget & finance

Branch auditing

Selling & market

auditing

Nazreth wheat

coordinator
Pasta
calculation
Price

finance
Badge &

Cashier Accommodat &

Buying

study
store
e test money Biscuit
Maintenanc
e main
division
Mechanical
maintenance
Priority Market Buying & selling
Electrical
administration study
maintenance

Market & Market promotion Biller united

information division maintenance
Buying Selling
coordinator coordinator

FIGURE1. 2 organizational structure.

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1.13. Overall Internship Experience

1.13.1 The Process Enter To the Company

Dire Dawa University Institute of Technology School of Mechanical and industrial Engineering
Department planed an internship for 5th year Industrial engineering student to apply an internship
experience at different company located in Ethiopia to experience it with theoretical knowledge. The
Department found the company that were comfortable or suitable for the student and the student
themselves. There were a short (one day) trip while we learn the course of PPC that we visited the Dire
Dawa food complex company and On June 15 /2013e.c we decided to apply our internship program in
this company. After that we submitted our internship letter to the company and, the company received the
letter then we started our internship program.

1.13.2. The Section of the Company We Were Working in.

The company’s secretary of the human resource manager (HRM) of the company invite us and take us to
the boiler department and technician manager of maintenance division. After that we asked and told him
our department of study is industrial engineering so that he can understand the working principle of field
and classify us to concerned department. At that time he tried to review for us the overall working
principles. The HR manager has assigned a supervisor for us to follow up our accomplishments in the
company. So, in shortly our working section are generally wheat flour production room, pasta production
room, bread production room, biscuit production room pastini and macaroni production room and but our
detail more attended wheat flour production, bread production and biscuit production.

1.13.3. Work flow in our working section.

Wheat is the most important useful cereal product and also the main raw material in the in Dire dawa food
complex company. There are five huge stores of silos in which Each can capture about 10,000 quintal
or(1,000,000kg) of fresh wheat. It’s imported from Australia and some local area such as Bishoftu, Jigiga,
Bale and Arsi etc. Wheat is one kind of cereal grain, which is a raw material to the production of bread,
biscuit, Pasta, macaroni and other food. The following image is the three parts of the wheat.

7
 FIGURE1.3, parts of wheat.

Bran...about 14% of the kernel weight. Bran is in clouded in whole wheat flour and can also be bought
separately.
Germ ...about 2.5% of the kernel weight. The germ is the embryo or sprouting section of the seed. It is
often separated from flour because the fat content (10%) which Limits shelf life. Wheat germ is a part of
whole wheat flour and can be purchased separately.
Endosperm
Endosperm....about 83% of the kernel weight and the source of white flour.
The endosperm contains the greatest share of protein, carbohydrates, and iron.

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Flour Mill plant generally consists of four main processing sections these are:
I. Pre cleaning III. Milling
II. Cleaning IV. Transferring

I. Pre- cleaning section.

In this part, the raw grain of wheat is delivered to the building using truck, ship or train. Truck delivery is
the most common since the other two deliveries require special conditions. The grain that is brought
enters the intake room unusually placed beneath the ground level. Then the material is transported using
conveyers and elevators up to the top. This dirt material has entered the grain during harvesting and
transfer. We must first get rid of these unwanted impurities in the pre-cleaning. By that we ensure that the
product will go through process safely and improve its quality and storing. Here we use machines
detecting dirt stones, insect, soil and other unwanted particles. When the wheat is pre-cleaned it must be
stored and prepared to get in the process. There must be always enough raw material available and
prepared to go in process. That is why we must store the grain in the income silos. The material waits in
the bins store in the environmental friendly conditions. That is why the intake and pre-cleaning is a bit
separated from the rest. The shortage of material could cause unnecessary lowering the capacity or in the
worst case stopping the mill completely which is costly not only for the price of stopping and starting up
but also the mill does not produce the outcome.

II, Cleaning and Conditioning.

It is important to prepare the material for the most important part of the process which is milling that
comes afterwards so in this section the cleaning has the same purpose as pre-cleaning, but this time the
material gets cleaned more properly and more carefully. This ensures us that there will be no impurities
that could cause a damage to a sensitive milling machine. The most common impurities in the cleaning
waste are straw, wood, foreign seeds or stones. Those will be detected and removed according to the
differences in shape, weight, color or magnetism. After the cleaning, the first tempering will take place.
The water is added to the process and let the material rest to sink it in. This will take from 10 to 20 hours
to achieve the required amount of moisture. This moisture is important for the process of removing the
kernel’s cover. This process is called the second cleaning.

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III, Milling

Milling is often considered as the heart of the whole flour making. The wheat is grinded in the series of
mills. There the endosperm is separated from the hull and germ. Then the material is transported to sifters
where the product is sorted according to the reached quality of grinding. For sorting we use sieves with
various size of the grid. If the product is not grinded enough it will be returned to the process of grinding.
If the quality is sufficient the material proceeds to another stage of the mill. The flour has many level of
qualities and types.

FIGURE1 4 Wheat Flour Milling Machine

IV, Transporting

In order to put product through the whole process of milling it is necessary to transport product on large
distances. The total length of the product transport can reach up to a several kilometers in one mill. The
material is traveling in all kinds of transport devices. It might be;

A. Gravity Piping (Spouting)

B. Bucket Elevators
C. Conveyers: Pneumatic Conveyers, Screw Conveyers and Chain Conveyer
D. Belt Conveyer and Many Others.

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A, Gravity piping – spouting
Spouting is used mainly in the milling section where the flour is sorted to units. Each unit needs to get its
own piping and individual approach how to be handled. The spouting is a vertical piping going from the
top point downwards. On its way, the product is pushed only by the gravitational force.

B, Bucket Elevator
Elevator is strictly vertical mean of transport. It consists of a line of shovels. Shovels scoop up the flour
and take it up on the top where shovel rolls over and the substance is poured. When designing the
elevators, we must keep in mind that when the shovel takes up the load it bends under the weight a bit. It
is very common problem in the vertical conveying.

FIGURE1.5, Bucket Elevator

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C, CONVAYORS
Pneumatic conveyor (blower)
Pneumatic conveying systems are widely used in manufacturing plants and process industries. They
provide a practical method of bulk-solid material transport. A surprisingly wide variety of powders and
granular material can be effectively moved
from one location to another within the plant.

FIGURE1 6 Pneumatic conveyor (blower)

Chain conveyer

Chain conveyer is pushing the material using pedals mounted to the chain. As the chain moves, pedals
push and mix the material. This way of transport is less efficient that the screw conveyer and used less.

12
 FIGURE1 7Chain conveyer

Screw conveyor
Screw conveyer is a machine transporting powdery material. It is using the principal of screw in the
enclosed pipe. The shaft has a thread along the way and as the shaft is rotating, the thread is pushing the
powder forward to the spill point. The faster the revolving is, the faster is the transport itself.

FIGURE1 8Screw conveyor

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General Work flow in Flour section

Pre-clean section

In put wheat breaker worm convey T1 elevator E1

Silos

Separator Elevator E2 Cain convey T2 Mixing beam

Clean section

Screw convey C2, C4, C5 Magnetic separation Air resistance Separation

Distorting long and round separation Elevator E2 1 st scouring

aspiration Elevator E1 pumping Screw convey WC2

1st condition mixing unit 2nd condition Screw convey metallic silo

FIGURE1. 9, Flour section Flow process

14
1.13.4 The work piece or work task we have been executing.

 Packing biscuits and inventory storage.

 Increasing work of motivation and moral of the workers

 Decreasing the lost time at work.

 As a media b/n the office supervisor and technician.

 Inspecting the defects of (bread and biscuit).

 In the company we have been also working in wheat flour production, Biscuit production and
bread production room.

 Assisting the company flour production station and biscuit production room.

 Informing the office which task has been accomplished with in every weekend as a weekly
report2.5 The procedures we have been using while performing our work tasks

 Starting from our first day we were punctual to our practical class every day and while in
practicing we always ask our working section operators the names of machines, the working
principles, their advantages, usage time, and process flow and control the system.

 We write down some points while the operators brief with the new terms.

 We ask questions to gain knowledge about the work, workers, and machines and procedures on the
working section of our company.

 Then we began to search if any a process generating any form of problem in our working section
of our company and we discuss about on that point.

 After that we recommended our generating idea to our company adviser on our report.

 Following up the execution of the tasks along with the technicians.

1.13.5 How good are we in performing our task in the company?

 On our first day everything seems complex and hard to perform because we only have theoretical
knowledge and new to perform the works.

 We act politely while we do our jobs and while we ask question to every workers.

15
  Even if we think it is not fair to judge and put forward some convincing points, now we are able
to win the challenges and the overlook of any concerned body to our general achievement.

 But at this time we realize and even begin to think and wonder about the things we have come
across in beating our wishful mind.

 Now we are very happy to understand our working environments which have made us very
curious about our prospects.

1.13.6 The kind of challenges we faced in company of our wok tasks.

There are so many kinds of challenges in our company. We have learned a good lesson which could help
us in our working environment in the future.

We have written down some of the main points below:-

 No pocket money (no enough payment) and transportation service for the internship program
which was a great challenge.

 There is lack of well-trained human resource. So most of the work is accomplished through the
medium of experience which intern does not give comfort.

 There is a lack of refresh area for the workers of the company.

 In most of the departments there is no right worker for the right job strategy.

 There is lack of well registered machines manuals.

 There is no any good documentation in the company.

 Measurement errors in the implementation of tasks.

 There is lack of leadership experience between employees and labourer workers.

 There is no Wi-Fi connection in anywhere in the company.

 Lack of practical materials.

 Languages (same of the manual written with Italy).

 Most of the machine are controlled with PLC (programmable logic control).

16
1.13.7 The Measure We Took To Over Come Those Challenges
 Since there is a lack of right person for the right job most of the workers with experience so, We
suggest the company to start knowledge share between workers and managers in order to avoid
knowledge gaps about industrial engineering.

 Guided the industrial and chemical engineer department staffs to solve.

 Focusing and working on improvement of customer satisfaction.

 Inspecting the quality of products.

 Reduce of Defects and wastages.

 Cost minimizing and cost saving.

 Increasing productivity and profit.

 Working on the employees comfort, safety and healthy.

 Guided the mechanical staffs to have repair (maintenance) rule including.

 Minimize the measurement errors.

 Reduce failure of related parts.

 Reducing the major failure.

1.13.8 The design and construction in terms of safety and economy.

Dire dawa food complex company is a new plant the Production of pasta products in the country and
Food processing plants in East Africa. Within a one day wheat flour mill with 120 tons per day grinding
capacity and capacity to produce about 50 tons of pasta products per day. This means 1ton=10(quintal)
=1000kg. So that 120x1000kg= 120,000kg flour product per day.
And in one day around 1200 to 1300 pack of biscuit is produced each of which contain 48 single pack of
biscuit, means 1300x48=62400 single pack of biscuit per day.

17
1.14. OVERALL BENEFITS OF THE INTERNSHIP PROGRAM

1.14.1 Improving Practical Skill.

The objective of internship program is to develop practical skills of students additionally to
academically theory knowledge. For the past four years we were more concentrated in theoretical parts
and developing a deeper understand of concept through seeing it in context of a greater whole and
understanding the why behind it, but after the internship we have been highly developed a deeper
understanding of a concept through the act of doing and personal experience.

And also some of the tasks we have been experiencing are as below:

 Inspection and process follow up of logistics from raw material to final product.
 Working principle of machines.
 Improving team work spirit.
 Improving communication skill with the workers and higher managers.

1.14.2 Benefits gained in terms of improving theoretical knowledge.

Upgrading of theoretical knowledge is a base in order to improve our skills, to getpractical knowledge
remembering of the theory that we have learnt in a classroom is anessential.
Some of theoretical knowledge’s are:
 How to read the manual of machines which inturn help us to learn the working principles of
machines.
 How to keep the safety in each machine.
 And also we have upgraded Theoretical knowledge of what we have learned on different courses like,
Ergonomics, operation management I and II, PPC I and II, industrial engineering Design,
maintenance, logistics etc.

18
1.14.2.1 The wheat flour flow process

Pre- Clean section

In put wheat breaker chain convey T1 bucket elevator E1

Weighting storage Silos

Separator Bucket Elevator E2 Cain convey T2 Mixing beam

Clean section

Screw convey C2, C4, C5 Magnetic separation Air resistance Separation

Distorting long and round separation Elevator E2 1 st scouring

aspiration Elevator E1 damping Screw convey WC2

1st condition mixing unit 2ndcondition Screw convey metallic silo

FIGURE1.10, wheat flour flow process

1.14.2.2 Types of Machine and their uses.

 Milling machine
 Separator machine
 Packing machine
 Magnetic Separator
 Roller machine
 DE-stoner machine
 Rounding machine
 Scorer
 Mixing machine and any others
 Damping machine
 Weighting machine
 Trier cylinder

19
Separator machine: - Separators have two sieves:
The first sieve impurities that are bigger than the wheat size retain on their it and the size impurities
dump. It is Vibrating screens remove bits of wood and straw and almost anything bigger or smaller than
wheat

FIGURE1.11, separator machine

Magnetic Separator: - The wheat first passes thru magnet that removes iron and metal particles

Damping machine: - It is a machine which used to mixing wheat with water.

FIGURE1.12, damping

20
DE-Stoner:- Using gravity, the machine separates the heavy material from the light to remove stones that
may be the same size as wheat kernels.

FIGURE1 13, DE stoner machine

The scorer: - The scourer removes outer husks, crease dirt and polish the outer surface with an intense
scouring action. Currents of air pull all the loosened material away.

FIGURE1.14, Scorer machine and scorer entire part

Roller machine: - Rolling machine is a machine which used to make roll broad. The machine can be used
divided the dough in to rectangle shape. The divided dough of the same weight it consists many simple
machine this are three parts

A. Rolling gauge: - Consists of in belt it is asset of cylinder for rolling the dough or taking the dough.

B. Cutter: - It consist a set of cutting that arranged consecutively with alternating on rotating shaft.

C. Letter out feed belt: - for the piece of cut dough for linking to rolling machine

21
 FIGURE1 15, rounding machine

Rounding machine: - Rounding machine is used to produce round shape bread. The machine can be used
divided the dough in to the circle shape. The same parts of rolling machine.

1.14.3 Benefits in terms of interpersonal communication skills

At the beginning there was a communication gap between us and factory workers. But gradually

considering importance of communication, we gained acceptance in most workers of all

section. We met different persons that have worked on their work place/position. These

include ; administration, plant manager, shift leaders, head of each department

and operators.

We learnt from them how to approach with employees, the way of asking
questions that have not under stood during observation, understanding their technical

words with relative to scientific words.

Communication also helped us to understand the governing of economic market.

1.14.4 Benefits Gained in terms of Improving Team Playing Skills

Team playing skill is concerned with taking responsibilities in group and role of individual
as group member. The role of team playing is the basic thing for the production
process of the company in order to produce the expected product.
 Having good team working in thecompany can lead to increase productivity
of the company as well as it improve good quality of production.

22
 This skill helps to solve problems occurred in the factory easily.
 Great team work relies on genuine interpersonal relationships.

1.15 Benefits Gained in terms of Improving Leadership skills

During internship period we have got the following benefits in terms of leadership skill.
 How workers initiation towards work can be increased.
 Organizing group member.
 Way of ordering peoples and the value of giving responsibility for
others and taking responsibility.
 Way of assembling workers and allocating for different tasks.
 Solving the problems faced and handling the employees.
 To make sure the working environment is safe for the workers

1.16 Benefits Gained in terms of Understanding about Work Ethics and

Related Issues

The Internship program also shows me necessity of work ethics in working environment
and worker with good ethical skill gets reward in many ways.
 Punctuality & Hard worker

 Loyalty for work& How to see all workers equal

 How to respect other labour Moral thinking

 Giving emphases for work

 The operators must wear a suitable working clothes

 The other importance is acceptance with other workers.

23
 1.17 Benefits gained in terms of entrepreneurship skills

Knowing condition of factory and types of technologies used in factories helps to identify
required product in the market. Also during the internship ways of processing and
mechanisms used in the factory are observed.
 Problem solving to decrease the idle time and increase productivity.
 Job creativeness.
 Knowing about our career, challenges and way of business establishment in this
Profession
 How to coordinate good working condition always being ready to create better world for
yourself and your country as a whole.
 How to solve challenges in terms of global market, management and risks
 Ability to manage time and people
 Ability to take responsibility and make decisions in terms of industrial psychology.

24
 1.18 THE PRODUCTION SECTIONS OF THE COMPANY WE WERE
WORKING IN

1.18.1 Introduction
Dire dawa food complex share company and others food industry has used raw material for the product
only wheat. Wheat is one kind of cereal grain, which is a raw material to the production of bread, biscuit,
Pasta, macaroni and other food. Therefore, wheat the main raw material of Dire Dawa food complex S.C
or other food industry. Wheat is the most important useful cereal product in the world. It import Australia
and some local area such as DebreZet, Jigiga, Bale and Arusi. There are two types of wheat these hard
wheat and soft wheat.

1.18.2 The company generally produces four main products.

1 Flour production 3.Pasta, Pastini and Macaroni

2. Biscuit production and 4.Bread production room

The Moister
Moister means the wetness of the wheat. It is one of the important parameters to determine wheat. Wheat
coming from different area of the county and out of the country likes IRS and durum wheat. After it
reached the company the sampler were taken the sample and to give the laboratory technician. The lab
technician was put the sample to the stand smooth plate and well mixed the wheat. Turn /switch/ on the
rapid moister tester. “It says fill the wheat” then the wheat inserted to the rapid moister tester until it level
to the edge of the tester. Finally press and read the percentage wetness of the wheat then recorded.
Determining moisture content is an essential first step in analysing wheat or flour quality. Flour millers
adjust the moisture in wheat to a standard level before milling. Moisture content of14% is commonly used
as a conversion factor for other tests in which the results are affected by moisture content. Moisture is
also an indicator of grain stability. Wheat or flour with high moisture content (over 14.5%) attracts
mould, bacteria, and insects, all of which cause deterioration during storage.

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  Safety limit of wheat in silo
No Parameters Allowable value max%
1 Wheat moisture 14
2 Silo temperature 27
3 Relative moisture 75
table1 2 Safety limit of wheat
As the company specification of wheat moisture is 12% max and periodical recycling of wheat maintains
the wheat temperature on the allowable range and prevents the wheat form biological hazard. In pre-
cleaning section the following points is given due attention for preventing food safety hazards.

 Chemical Compotes of the wheat (%)

Component Min % Max %
Protein 7.0 18.0
Ashes 1.5 2.0
Fat 1.5 2.0
Water 8.0 18.0
Starch 60.0 68.0
Pentose’s 6.2 8.0
Sucrose 0.2 0.6
Maltose 0.6 4.3
Cellulose 1.9 5.0

table1 3 Chemical Compotes of the wheat

1.18.2.1 Flour production

FIGURE1.16, wheat

26
Wheat Flour production is the four main processing included.

A. Pre cleaning C. Milling

B. Cleaning D. flour packing

A. Pre-cleaning section of wheat:

In this section, the raw grain is delivered to the building using truck, ship or train. Truck delivery is the
most common since the other two deliveries require special conditions. Than the material is transported
using conveyers and elevators up to the top. This dirt material has entered the grain during harvesting and
transfer. We must first get rid of these unwanted impurities in the pre-cleaning. Here we use machines
detecting dirt stones, insect, soil and other unwanted particles. That is why we must store the grain in the
income silos. That is why the intake and pre-cleaning is a bit separated from the rest.

FIGURE1 17 , fresh wheat store in silo

Pre-cleaning Flow process.

Wheat get in chain convey T1 Bulk Elevator E1 Wheat weighting

Wheat store Magnetic separator Separator

Flowchart-4, pre-cleaning flow process

27
B. Cleaning section of Wheat
Objective: to remove any admixtures other than sound wheat Impurities which are included with the
incoming wheat are:

 Stones and sand.

 Glass and plastics.

 Ferrous material.

 Long and round seeds.

 Poisonous seeds.

We clean wheat for the following basic reasons:

 Impurities negatively affect quality of the produced flour (colour, odour, and baking
properties of the flour)

 Impurities are unfit for human consumption

 Impurities likes’ sand stones damage machineries and sprouting

 Dust explosion

 Negatively influence effective fumigation

Basic principles for impurities separation are:

 Size

 Density

 Shape

 Friction

 Magnetic force

 Air resistance

 Gravity and centrifugal force.

28
A. Separation by size
It is the first cleaning section is the separator, a sieving machine which separates based on the difference
in size of impurities as compared with the wheat. Its basic function is to remove impurities bigger than
wheat kernels size.

B. Separation by density
It is unable to separate the stones with the same sizes as wheat. The second machine in the first
cleaning is the dry stoner which separates stones from wheat.

C. Separation by shape
Both the separators and De stoner are unable to remove long and round seeds which have the same size
and density with the wheat. The third machine called truer battery separates these impurities based on
shape difference.

D. Separation by the magnetic force

For removing impurities like rust flakes and other ferrous parts (washers, screws, nails, etc.) negatively
influence the safety of food, damage machineries and are causes for dust explosion.

E. Separation by air resistance

Light impurities as chaffs and dusts can be removed by air using aspirators installed at scourer and
separator.
F. Separation by gravity and centrifugal force
For the recovery of the good broken grains, rejected by the indented cylinders together with the vetch,
spiral separator is used which employs gravity and centrifugal force to divide the vetches and other seeds
from the broken grains.

29
Working principle of cleaning section machineries
 Separator

Objective: to separate impurities bigger and smaller in size than the wheat.

Rotating movement of the separator causes whirl formation of strings, chaffs etc…, which tails over the
sieve due to reciprocating movement and gravity.

 De-stoner

Objective: to remove stones from wheat

By means of counter flow of air, the stones are completely separated from the wheat and discharged
through the stone outlets. Is an operation in which stones are separated from grain mass wet and dry
destining systems both of which work on the principle of specific gravity difference.

 Try-cylinder

Objectives: to remove long and round seeds from wheat based on shape difference.

Used for cleaning process and the most important of cleaning operation. As the name indicate tire means
three and three parts with packets to separate the impurities from the grain depending on the shape such as
long seed, round seed and husk.

 Aspirator

Objective: to separate light impurities based on their difference for air resistance.

This operation is aimed to removing light impurities with the help of air resistance. The machine is
mounted usually together with separator and scorer.

 Volumetric Measurer

Volumetric measurer measures and blends the wheat in the required percentages according to its bulks
density.

30
  Intensive dampener

Dumpling machine: - It is a machine which used to mixing wheat with water.

Objective: for addition of water to the wheat and for mixing the wheat with water. Water addition and
mixing with calculated amount of water is being done by the action of beaters which are mounted at an
angle of 70 on a rotating durum.

Wheat conditioning

Objective of conditioning

 Uniformity in the milling process

 For quality flour production

 For easy separation of germ and bran as it swells

 Increasing wheat moisture

 Minimizing the difference of milling in different wheat varieties

 Minimizing power consumption

FIGURE1.18 , first and second condition (dampening)

31
C. Milling of Wheat
Objective: to separate the bran and germ from the endosperm part of the wheat kernel and produce flour
or semolina.

Semolina
FIGURE 1.19, semolina

We remove the bran for the following basic reason.

 Bran contamination in a flour increases the ash content of the flour and affect the color of flour

 Bran contamination in a flour affects the baking quality of the flour as it disrupts and weakens the
protein film in the viscoelastic mass (dough system)

We remove germ for the following basic reasons

 Germ shortens the shelf life of flour as it creates rancidity in the flour

 Germ gives ceramic colour to the flour

 Breaks: Produce maximum semolina, some middling, some flour and some bran

 Reduction: Produce maximum amount of flour

 Purification and sifting: Produce branny stock, Produce scratch stock and Produce purified
stock

32
 FIGURE 1.20, Roller machine

Working principle of milling section machineries

 Roller bodies; the basic principle is separation based on compression and shearing force

 Plan sifter; the basic principle is separation based on the size.

 Purification process; The main objective of purification is to segregate stocks based on their
quality or density so as to produce flour of low ash content and semolina for packing or mixing

 Filter: is used as to separate the dust flour laden air into clean air and flour dust

D. Flour Packing
This is the final section where the produced flour from storage silos is either packed for local bread
markets and biscuit or transferred in bulk to pasta factory. There are four silo in the store of wheat flour
and each of them more than 1200ton of wheat flour. There is a wide range of bags you can put the flour in
from light paper bags to rough wicked bags. The weight of the bag highly depends on the chosen bag
material but it can vary from 10 – 50 kilograms.

33
 FIGURE1 21, Packing machine above 50kg and above 10kg.

1.18.2.2 Biscuit Production

Biscuit production is one of the major production department in Dire Dawa food complex company.

It has a five major stages

a. Mixer stage.
b. Dough forming(ROLLER) stage.
c. Baking (OVEN) stage.
d. Cooling (long belt) stage.
e. Packing stage.

34
A. Mixing stage

mixing This is a process where all ingredients are put together in right proportion for dough formation.
ingredient are then fed into Mixers where mixing is done and dough is prepared for molding .

Major ingredients are flour , salt, sugar ammonium bi carbonate, margarine and others as per the
product one would like to have.

FIGURE 1.22,Mixer

B. Dough Forming (Roller) stage

In forming sections the dough is passed through several rolls to form sheets , these sheets are then
converted into One uniform sheet of desired thickness.

Reduction in sheet is achieved through numerous gauge roll stand . there are four stand gauge rolls and
Reduction are achieved in stages as not to create too much stress on the sheet , webs are provided in
between for relaxation even an additional web is provided prior to cutter to release stress from dough
sheet. Best results are achieved at the last fourth stand gauge rolls.

35
 FIGURE1 1. 23 The second stage of dough reduction
Dough sheet conditioning : Dough sheet conditioning is done as per the ambient conditions in the plant .

Blower : to dry the dough surface. Flour dusting : to dry the wet surface of the dough .

C. Baking(oven stage)

Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panel web.
Heat is transferred to biscuit on band through all the three ways of heat transfer i.e. conduction,
convection , radiation.

Following are the chemical and physical changes which occurs in oven, When dough piece is passed on to
oven .

Physical changes of dough.

1. Formation of crust 2. Melting of fat 3.gas expansion in dough piece due to co2 expansion at higher
temperatures . 4. Water converted into steam .

Escape of gases and steam would result in collapse of biscuit structure , Hence these are passed on to
different zones with gradual increase or decrease of temperature .

zones are classified as

1. Heating zone 2. Baking zones 3.Coloring zones

36
Chemical changes

1. Gas formation 2.starch gelatization 3. Protein changes 4. caramelisaion of sugar 5. Dexterisation

FIGURE1.24, Oven

D. Cooling

Cooling process is as important than any other process , When biscuit comes out with oven the
temperatures of biscuit are around 70-95deg c, These biscuit can be cooled by letting it travel for distance
of 1.5 times of baking time .

so if you have a oven of 200 ft then cooling conveyor length would be approx 300 - 350 . In some places
forced cooling is also done due to space constrain or for special features .

Cooling brings temperatures to room temperature for handling of biscuit for packing .

FIGURE 1.25Cooling belt

37
E. Packing

Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which
converts free flowing biscuits into uniform achieved through stacker which converts free flowing biscuits
into uniform stacks .These are done through guidelines which could be adjusted as per type of biscuits .

Major function of packaging are

1. Protect from mechanical damage in transit and loading and unloading

2. Protect from loss of moisture and any foreign odour contaminations

3. Protect from Foreign body infestation.

4. Legal compliance for values and ingredients for consumers

5. Advertisement Biscuit are wrapped with packing machines and wrappers are sealed as long and ends.
These are sealed with helps of heaters .

FIGURE1.26, packing machine

38
1.18.2.3 Bread Production
In dire dawa Food Complex S.C bread production is one of the big plant.

Bread making process consists of four major stages these are

a. Mixing and kneading,
b. Cutting and moulding proofing baking
c. Champers house
d. Packing

Four Bread production of making machine

1. Mixing stage
2. Roller and Round stage
3. Staying in proofing champers house
4. Oven stage.

A. Mixer stage
There are two mixers in this plant. Their operation is the same before starting the work cycle. We have to
check that:
 The machine is in stable level position on a flat smooth and solid surface.
 The machine has been fastened to the flour.
 The machine has been connected to the power supply.
 The machine parts are clean.

This machine commands required to carry out a work cycle are located on the front panel

39
 FIGURE1 27, Mixing machine

Start open Emergence switch

FIGURE1 28Symbols of operating mixing machine

Raw materials of bread production

I. Flour
II. Salt
III. Improver
IV. Water
V. Yeast

Bread making process consists of four major stages. First at the mixing stage on the ingredients (in the
case of our company flour salt, improve, yeast, and water) are put all together in a mixer and subjected to
a mechanical work to transform the mix into fully matured dough of desired viscous elastic property
suitable to the specific type of bread in extended to produce. Then the prepared dough is manually fed to
one of the machines we have to be cut in to pieces of desired weight according to specific
market/customer demand. This is the stage where the bread acquires its peculiar porous texture property.
After the dough pieces are puffed up to appealing volume it will be backed at around 286 degree Celsius

40
temperature for about 15minutes. Passing through the oven the bread is puffed as it loses part of its
moisture in phenomenon known as oven spring. The moisture lose at this stage is about 15% of the initial
dough weight. Then the bread with acceptable quality is connected to the outlet and is allowed to cool and
get in to carets which make it ready for delivery .In this department, there are about 16 piece rate workers
of which one is to be unique identified as a mixer operator, 5 counter piece rate workers who handle the
packing of the bread, a chive operator who controls the overall activities, and a co-operator assistant to
the chive operator in a single shift. There are three shifts in a total to complete the 24 hrs circle activity.
Currently the plant produces the type of bread: 100gm and 120gm in weight which are intended for the
local market and for the universal supply.

Yeast

Yeast is the leading we use for the for mention process of bread making. It is made up of many tiny
single celled mostly available in dried and compressed from. The yeast contains an enzyme, enzymes that
produce co2 and alcohol from degrading sugar available in the medium.

Improver

Improvers are used specifically to improve production methods and the quality of bakery products.

Improvers are mixtures of food including additives intended to facilitate or simplify the production of
beaked goods to components are for changes in processing properties due to fluctuations in raw materials
and to influence the quality of baked goods.

Water

When we add water in the mixture the protein molecules in the flour take up moisture and swell
transforming in to joint forms. And as we work on the dough the gluten matrix begin to develop and form
a continuous, complex elastic network around the starch granules. This matrix is the most important form
of the protein. We grain from the dough development. In addition to water helps to uniformly distribute
all dissolved ingredients throughout the dough mass and provide a favourable environment for the yeast
activity as well. And dispending on the quality of water minerals present in the water enhances the gluten
matrix cross-link formation.

41
Salt: Salt is virtually all bakery foods contain salt (sodium chloride), except for a small number of
products made for individuals on low sodium diets salt is quite functional in yeast – leavened bakery
products.

Performance standards of the company’s Bread production

Component of Standard
Ingredient Market bread 100g Unversity bread Units gram
120g
Flour 0.75 0.75 g

Improve 0.42 0.41 <<

Yeast 0.42 0.41 <<

Water 2 46 <<

Salt 0.85 0.85 <<

table1 4Composition ratio of ingrident of bread

From which we can calculate our way to a specific amount of each inputs we should use per a given
amount of product taking the possible lose along production in to consideration. Therefore we will start
with the recipe and work out simple material balance that our finally get to the specific product.

Ingredient Recipe of dough mix Unit

Flour 100 Kg
Water 40 Lt
Salt 0.5 Kg
Yeast 0.5 Kg
Improver 1 Kg
Total in a bach 102+40 Kg/lt
table1 5Ingrident of bread

42
 B. Rolling or rounding stage
In this bread production house,there are two rolling machines which consumes 5kw power and it has three
motors. This motors are activated by 380v supply here connector, breaker, contactor respectively used.
The process stated as follows:

The dough inters to rolling machines,in this machine there are two cutters which cuttes the intered dough
at required by size. The required size of the dough is 143-144 grams. After this process the dough get’s
out of the roller. Then the dough goes to proofing champers house by using man power.

C. Staying in proofing champers house

Thi house has vital importance in the production of bread. It is filled with afull of steam. This steam is
produced by steam heater and steam generator.

Steam heater has two advantages over steam generator:

 It controls humudity in addition to temperature

 It spends less time to release steam,in the case of steam heater the dough spends 1:40 hours but in
the case of steam generator it spends 2:15 hours.

The dough starts to expand,when it spends some time. After it spends 1:40 hours in proofing chamber
house,it expands more and becomes fat. Then the dough get’s out from the house and it entered to the
oven.

D. Oven stage:-
It is abelt which is called wire mesh. The oven is used to cook the dough. This oven is afull of highly
resistive metals and also contains thermosensors which senses the temperature of the oven. The oven is
divided in to upper and lower zones. Upper and lower zones are also divided into three depending up on
the temperature. The oven zones are:
Zone 1st 2dn 3rd
Uper 150 250 285
Down 220 250 290
table1 6 oven zone

43
Bread baking flow process

inputs:
water, salt, Shaping
improover, process: Oven:
yeast and rolling or cooking
flour rounding process

MIXER: proofing output:

mixing chamber: bread
process to expansion
get dougn process

FIGURE 1. 29, Bread baking flow process

44
1.19 CONCLUSION AND RECOMMENDATION

1.19.1 Conclusion

Our experience of working in Dire Dawa Food Complex Share Company was interesting. The entire two-
month industrial internship was a big experience. The internship gave us a chance to develop practical
knowledge and apply what we learn theoretically in class practically. The industrial internship gives us
not only this but also to understand the difficulties in the working environments, this initiate us to search
for solutions since engineers are problem solvers. This experience also helped us to know more about our
field of study in the future.

1.19.2 Recommendation

The company should have to use schedule maintenance to minimized high downtime, since there is no
oriented schedules for maintenance.
Safety materials for all the working section for the workers such as hand gloves, ergonomically chair,
close, ventilator and others are not enough.
The rigidity of the company is not limited but extended to not to provide resource and facilities such as
library, internet access and other reference materials for the staff reference and for the intern students to
progress for any type of intended project for further insight should be fulfilled.
On the other hand, neither the company gives no pocket money nor the pocket money given by the
university to the internship students is enough. It may be difficult to survive for students from poor
background. The serious of sense of punctuality and team working in the company should be admired and
promoted for further success.
Lastly, I believe that this internship has to be continued since it has lot of virtues.

45
 CHAPTER TWO

2. PROJECT: Productivity Improvement through Ergonomics Assessment

2.1 Executive Summary
Ergonomics is concerned with making the workplace as efficient, safe and comfortable as possible.
Effective application of ergonomics in work system design can achieve a balance between worker
characteristics and task demands. This can enhance operator productivity, provide worker safety and
physical and mental well-being and job satisfaction. The main aim of this project is to demonstrate the use
of ergonomics in productivity improvement in terms of labor productivity and also using ergonomically
scale like assessment of human strain in response to workplace stresses is an integral part of any
ergonomically risk evaluation process. Strain assessment has relied on two types of outcome measures,
namely, objective and subjective rating scale.in this paper the problem statement, cost analysis,
methodology and proposed solution are indicated here. The primary and secondary data collection was
undertaken; the primary data was collected through interview and observation. Secondary data was
collected from handout, books and internet. From the data’s we observed that the productivity of the firm
is decreasing due to of work station design that does not give comfort for the employees based on that
quality and production of the product is declining. From this using ergonomics tool like subjective and
objective rating scale can measure the comfort and discomfort of employee with their sitting condition ,
six local body part and overall whole body part and try to propose a new designed ergonomically sitting
chair that makes employees comfortable for their working conditions and prepare check list to assess the
effectiveness of the new designed chair and show the new improved productivity and reduce total used
medical cost allowance of the company. Finally, possible recommendation is given to the concerned body
to solve the problem concerned with physical ergonomics. Applying this project will save loss of
10982,467.98 birr per year.

2.2 Problem Statement and Justification.

The application of ergonomics and safety skill are poor in DFCSC .Especially in wheat flour, biscuit and
bread production section. Productivity of this section is low due to many factors. One of which is the
absence of ergonomic design of chairs for the employees, who perform their activities in a sitting position
and standing position. The design of the current chair is based on “design for average” in which one size
or dimension fits all. This design approach resulted in a scenario in which only a few people find comfort
in the chair where as a very large number of the user is not been fitted.

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This problem resulted in MSDs like back pain, abrasion, muscle strain, neck pain, arm and leg pain and
numbness among non-fitted workers; totally 27 employees are affected by MSDs with in six month
period from February one to July 30 which in turn results in frequent absenteeism, low productivity and
low morale among workers,

The company has wheat flour, pasta, macaroni, biscuit and bread production section. The productivity of
these sections is decreasing due to many factors. One of which is the absence of an ergonomics chair
design of employees as mentioned above which contributes total of 13.23% for reduction of productivity
of employees as [1,2]

2.3 Objective Of The Project

2.3.1 General Objective
The main aim of this project is to improve the productivity of the DDFCSC through Ergonomics
Assessments.

2.3.2 Specific objectives

 To identify basic effects that lead to decreasing of productivity.

 To assess the existing workers chair design problems.

 To identify problems associated with the existing ergonomically issues found in production
sections.

 To Design ergonomically designed chair which will satisfy maximum percentile of the user
population.

2.4 Significance Of The Study

The results of this study have the following significances.

 It will increase the productivity of DFCS Company.

 It will increase the workers satisfaction.

 It will minimize MSDs for operators.

 It will enhance the employee morale.

 It could be a reference for future studies.

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2.5 Scope Of The Study
This project is done in production department of the company specifically in wheat flour, biscuit and
bread production sections to improve the company’s productivity through applying ergonomically
designed chair for the employers so that they can be satisfied and experience their job effectively.

2.6 Literature Review

2.6.1 Ergonomics
The word „ergonomics‟ has its origin in two ‘’Greece words ergo’’ meaning laws and nomics meaning
work (i.e. Rule of the work). So it is the study of the man in relation to his work. Its engineering sciences
to achieve optimum mutual adjustment of men and his work. Ilo defines human engineering as, “the
application of human biological sciences along with being measured in terms of human efficiency and
well-being.” The human factors or human engineering is concerned with man-machine system. controls
for human operations and complex man-machine systems.” Human engineering focuses on human beings
and their interaction with products, equipment facilities and environments used in the work.

Human engineering seeks to change the things people use and the environment in which they use the
things to match in a better way the capabilities, limitations and needs of people. Ergonomics is a very
wide concept that comprises all the factors that affect humans. In the workplace, the ergonomics are about
to designing for people, to make the workplace comfortable and efficient. It includes everything from
physical loads, environmental condition (temperature of the room, lighting and noise) and to the social
relationship with the colleagues. On the other hand, such all comprehensive term is not very practical to
work with. Hence, the ergonomics have been separated into specific areas such as physical and cognitive
ergonomics. The physical ergonomics concerns with human body’s response to physical and
physiological work demands whereas cognitive ergonomics concerns mental processes, such as
perception, stress and psychological perspective. It is hard to separate between physical and cognitive
ergonomics, because in some respects they are closely related [4].

Ergonomics in perspective of industry is defined as the design of the workplace, equipment, machine,
tool, product, environment and system considering human’s capabilities and optimizing effectiveness and
productivity of work systems while assuring safety, health, and wellbeing of workers [5].

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2.6.2 Productivity
Productivity is generally defined as a ratio between the output volume and the volume of inputs. In other
words, it measures how efficiently production inputs are being used to produce a given level of output.

Productivity from a manufacturing perspective is the ratio of output to input in production and is a
measure of efficiency which means the quality and effectiveness of the work being done.

Numerous productivity measures can be founded food factory, but in our project work we usually use
three traditional types of index productivity measures which are distinguished below:

 Partial productivity measures - ratios of output to one source of input, such as labor, capital,
material or energy.

 Total-factor productivity measures - ratios of net output (total output minus intermediate goods
and services purchased) to the sum of associated labor and capital input. This type of productivity
is sometimes referred to as value added productivity or multi-factor productivity [2].

 Total productivity measures - ratios of total output to the sum of all input factors.[2] Based on the
above productivity measurement method we tried to use a partial productivity method in order to
show the impact of employees on the productivity of the company.

Total man power requirements of DDFC Share Company in the flour production, bread
production and biscuit production section are listed in the table blow.

Position Number of employees

Production manager 3
Supervisors 5
Flour production 57
Bread production 45
Biscuit production 15
Total 125

Table 2.1employee in selected production section

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2.6.3 Ergonomics Seating Standards
The challenge of designing for the human body is that it comes in so many different sizes and shapes. As
a result, a design that may be comfortable for one person can be inappropriate for others. Obviously
clothes and shoes come in different sizes to accommodate these differences. Proper fit becomes much
more important when it relates to a product that a person will be physically interacting with for hours at a
time, for example, an office chair. To improve chair designers‟ abilities to meet the needs of users several
organizations have compiled standards. Those in use in America include the following:

 Human Factors and Ergonomics Society: ANSI/HFES 100-2007

 Business and Institutional Furniture Manufacturers Association: BIFMA G1-2002

 Canadian General Standards Board: CGSB-44.232-2002

 Canadian Standards Association: CSA-Z412-2000

 International Standards Institute: ISO 9241- Part 5

The chair standards are intended as a reference and a starting point for design. They are updated
periodically to reflect accepted research and best practices. The standards provide design guidance to
meet minimum requirements in addition to adjustability ranges to increase the percentage of the
population accommodated. The standards propose dimensional specifications based on body dimensions
of the 5th percentile (small) female to the 95th percentile (large) male. This range covers only 90%of the
population and is intended to meet the minimum requirements of users.

Ergonomics seating products are based on state-of-the art research and are designed to exceed standards,
meeting the needs of a broad range of users.

The standards are compiled by experts in the fields of human factors and ergonomics in partnership with
the leading manufacturers of chairs and office systems. These standards represent the combined
cumulative knowledge of these experts for the purpose of improving the accommodation of people, and
reducing the risks of injury in the working environment in order to improve productivity.[4]

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2.6.4 Seating comfort
The true objective of an ergonomics chair is to provide worker only the proper function but to ensure the
subtler yet all important aspects of user comfort. People who are more comfortable in their chairs are
more likely to be able to sit and be productive for longer durations. Chairs that do not provide effective
support and adjustability can significantly increase the spinal stresses resulting in discomfort and
increased injury risk and musculoskeletal disorders.

2.6.5 Definitions of comfort and discomfort

Comfort:- is, as a subjectively-defined multifaceted construct, a positive feeling in the form of relief,
encouragement, enjoyment, well-being, satisfaction, and/or pleasantness that results from interactions
with the environment ( merriam-webster online dictionary 2007 edition)

Discomfort:- has been widely used and generally accepted as a proxy or risk factor for musculoskeletal
disorders, and discomfort measures have been commonly used to evaluate ergonomics interventions. It is
also known that discomfort relates to poor biomechanics and circulation, restlessness, and fatigue.

2.7 Methodology

2.7.1 Data collection

Data collection is the systematic approach to gather and measure information from a variety sources to get
a complete and accurate picture of an interest area. We used quantitative data collection method since we
use all the information’s about the ergonomic of employees is quantized.

The data of this study is collected from both primary and secondary source of data.

The data collected from primary source are both structured and unstructured interviews and field
observation related to the study in the Host Company and interviews.

The secondary data collected from different books, the company documents, and internet.

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2.7.1.1 Primary data collection method

Interviews:- we asked employees of the company Like operators, quality mangers, shift leader, and
safety, health and environmental manager and also other employees about the company backgrounds ,the
working environment and also whether they are satisfied with their job and or not, since their contribution
on the productivity of the company is high.

Observation:-is the act of noticing something or perceiving information.. the point of the observation is
to find if any problem that we can be able to solve that is related to our field of study. we used
ergonomics assessment tools to collect data in our each day to day practice Ergonomics assessment tools
like subjective and objective factor scale method are used at the time of observation and we observed that
there is the absence of an appropriate design of chair in the company.

Meeting:- we tried to discuss with quality team leader and safety, health and environmental manager in
order to get all information about the employees , we asked how much the company works up on the
employees comfort and if their job is fitted to them ergonomically.

2.7.1.2 Secondary data collection method

Reading some of industrial safety and ergonomics books written such as; ergonomic analysis for
manufacturing industry 2001, company document and other materials in the organization like reports,
plans, manuals, Internet access etc.

We have used the following data representation methods;

 Flow charts and Table representation.

2.8 Data Analysis

We used quantitative data analysis method one of which is Descriptive Statistics.

Typically descriptive statistics (also known as descriptive analysis) is the first level of analysis.

It helps us to provide absolute numbers and also to summarize the data and find patterns.

By using descriptive data analysis we have analyzed different costs analysis such as; cost of production
loss, cost of absenteeism, medical cost and also cost of Designed chair.

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2.8.1 Data Analysis on Existing Productivity
Numerous productivity measures can be found in the literature, but usually three traditional types of index
productivity measures are distinguished which practicable on food processing factory :

Partial productivity measures - ratios of output to one source of input, such as labor, capital, material or
energy.

Total-factor productivity measures - ratios of net output (total output minus intermediate goods and
services purchased) to the sum of associated labor and capital input. This type of productivity is
sometimes referred to as value added productivity or multi-factor productivity.

Total productivity measures - ratios of total output to the sum of all input factors.

Based on the above productivity measurement method we tried to use a partial productivity method

in order to show the impact of labor on the productivity of the firm.

Figure.2.1a existing workers chair in biscuit production section

53
 Figure. 2.1b Absence of ergonomically designed chair in bread production section

2.8.2Analysis on an existing workers chair

As analyzed from the above figures;

 No adjustable seat height and angle

 No back rest ,No arm support and No contoured front edge of seat
 Made from wood and metal parts
 No adjustable footrest
 No safety cloth such as hand glob, shoes
 No swivel and No wheels or casters

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2.9 Proposed Solution
2.9.1 Chair Design
Before developing the final chair concept, the design of different parts on the chair has been investigated.
This is to ensure the best solutions for each component before combining them to a holistic product. The
chair is divided in to four parts; arm rest, chair legs, back rest and seat as shown in fig 2.2 bellow.

2.9.1.1 Back Rest and Seat

Backrest is one of the part of the chair that used to support the back body of the people. When sitting in a
chair for a long period of time, it is important that the body get sufficient support. If not there is a high
risk of developing back, neck, shoulder or head pains. The most important concern regarding this is the
lower back and upper back. It is vital to support the luminary spine so that it will keep its natural and
correct curve. If a person sits “slumped” forwards for a long time, there is a risk of overstretching the
spinal ligaments and strain the spinal discs causing back pain. A sitting person for the chair backrest it is
therefore important that the shape supports the back and lets the spine rest in a natural curvature.

2.9.1.2 Chair Legs

There are many kinds of design and structures of chair legs. In order to makes it easier for the user to
move around on the floor in the company at workplace near the machine, the chair has wheel. The chair
moves by the wheel horizontally from left to right and from right to left. The operators have need to move
on leg and need to stand for a long time at the workstation. Without standing up from the chair, the
operators move near the machine by rotating the chair’s wheel through the shaft which connect the chain
with the wheel of the chair. Another common feature of the chair is 360 degree rotation in the horizontal
direction. The following figure shows the 2d drawing of the designed chair:

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Figure2.2 engineering drawing of the proposed chair

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We have selected plastic material and 304 stainless steel for the designed chair, because of its:

 Low price

 Durability

 Light and easy to move

2.9.2 Strength Analysis

2.9.2.1 Seat Pad

Material selected for the chair is a polypropylene plastic with the following mechanical properties

density 905 kg/m 3

Tensile strength 33mpa

Module of elasticity 1.4gpa

Assuming that the average weight of personnel is 80 kg, the applied force on seat pad can be calculated as
follows:

F = mg where m = mass of personnel

g = gravity

Therefore, F = 80kg×9.81m/s2 = 784.8N

The force applied is actually a distributed force over the surface of the seat pad and it will be distributed
to the whole distance.

Fx = FS = 784.8×814.5 mm

Fx = 639,219.6Nmm

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 Figure.2.3 distributed force resolution

There are two reaction forces from the legs of the chair

Figure.2.4 Force analyses

ʃ FY = 0

Fr2 - F2x + Fr3 = 0

A concentrated applied force on the seat pad surface is the average weight of the person sits on the chair.

Fr2 + Fr3 = F2x Fr2 + Fr3 = 639,219.6Nmm

Taking moment at rx3

-F2x (407.25) + Fr2*814.5 = 0 ,

639,219.6*407.25 + Fr2*814.5 = 0

Fr2 = 639,219.6*407.25 = 319,609.8N

Substituting this on the equation, the reaction forces will be

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 Fr2 = Fr3 = 319,609.8N

The area of the plate is

a = w*l where w = width = 814.5mm

l = length = 814.5mm

a = 814.5*814.5 = 663,410.25mm2

The allowable tensile stress will be

σ = f/a = 639,219.6n = 0.96mpa

663,410.25mm2

σ = 0.96Mpa. which is much less than the ultimate tensile strength the selected material so the design is
safe.

Shear force and bending moment diagram

Shear force diagram Bending moment diagram

Figure.2.5 Shear force and bending moment diagram

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2.9.2.2 Backrest
Since a horizontal load is applied to the back rest with a bottom support, assume the components as a
cantilever beam. The cross section of the vertical back o the beam is rectangular

B = 10mm, h =15mm total length of the beam is l = 283.8mm

Moment of inertia will be

i = bh3 = 5*153 = 1406.25

The force applied on the beam is one third of the total weight that is 261.6N.

Moment at the beam will be

M = Fl = 216.6n*283.8mm = 74243.08Nmm

Distance from the neutral axis to the extreme fiber (y) is

y =h/2 = 15/2 = 7.5mm

σ/y = m/i therefore, σ = my/i

σ = 74243.08nmm*7.5mm = 395.95N/mm2

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2.10 Result and Discussion
2.10.1 Cost Analysis

2.10.1.1 Cost of Production Loss

Production Monthly Target monthly Production
month production production (ton) loss(ton)
(ton)
January 184 190 6

February 177 190 13

March 167 190 23

April 158 190 32

May 175 190 15

June 165 190 25

Total 1026 1140 114

table2 1production loss due to MSDs for DDFC

Production loss due to MSDs = 114 tones

 For one item of bread (200g) volume of bread production loss due to MSDs
0.00002 ton of bread = 2ETB

1300 ton of bread = ?(X) where,1300 is the production of bread per six month.

= 130,000,000ETB

 For Zebib biscuit volume of production loss due to MSDs

0.000015 ton = 7ETB

520 ton = ?(X) where, 520 is the production of biscuit per six month.
= 24266667ETB

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 2.10.1.2 Medical cost
Production month No of affected Medical cost DDFC in ETB
employee
January 5 9675 3500
February 3 4265.6 3500
March 4 8677.3 3500
April 7 12785.1 3500
May 3 5275 3500
June 5 8451 3500
Total 27 49129 125*3500 =2625000

table2 2medical cost for DDFC

Total medical cost for DDFC in six month is = 49129ETB

2.10.1.3 Absenteeism cost

Production month No of absent per month Monthly salary Payment per day
January 16 3500 134.62
February 14 3500 134.62
March 17 3500 134.62
April 18 3500 134.62
May 19 3500 134.62
June 18 3500 134.62
Total 102 42×134.62 = 5654.2

table2 3 absenteeism cost for DDFC

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There are 26 working days in a month total 26*6 =156 working days in six month and the monthly fee of
employees is 3500ETB per month
Payment per month = 3500ETB
Payments per day = x , from these payments per day =134.62ETB
Loss due to absenteeism = 102 absents day × 134.62ETB = 13731.24ETB per semi annual.
Total cost = loss due to medical cost + loss due to absenteeism + production cost

=49129+13731.24+24,266,667 =24,286052.24ETB per semi annual.

2.10.1.3 Cost of designed chair

Materials used for chair Unit price (birr)

Aisi 304 stainless steel 432.02 birr

Polypropylene plastic 66.13 birr

table2 4analyzed cost of designed chair

3 kg of aisi 304 stainless steel is required

1 kg = 432.02 birr

3 kg = x

=3 kg×432.02 birr/ 1 kg

=1296.06 birr

5 kg of polypropylene plastic is required

1 kg = 66.13 birr

5 kg = x

=5 kg×66.13 birr/ 1 kg

= 330.65 birr

Total cost of designed chair = 1,626.71 birr

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 In wheat flour, bread and biscuit production sections a total number of 125chairs are required

1 chair = 1626.71 birr

125 chairs = x

Total cost of chairs = 125*1626.71 birr

= 203338.75ETB

2.10.2 Result

If the company implements the ergonomically designed chair, it will save the productivity loss of

Loss = total cost – cost of designed chair

Loss =24286052.24 - 203338.75 =24,082713.49ETB per semi- annuals

2.11 Conclusion and recommendation

2.11.1 Conclusion

A company should be maximize a profit in order to survive in a market. One of the factors that affect
company’s productivity is an ergonomic design of employee chair, so the company should have a new
designed ergonomically sitting chair for the employees which satisfy maximum percentile of the user
population. In DDFC share company we are observed that the company have no an ergonomically
designed chair for the workers. The design of the workers chair existing before is based on “design for
average” in which one size or dimension fits all beyond gender consideration. Usually this type of design
approach is used when designers have no knowledge about the variability of the population and it is not
recommended.

This problem resulted in musculoskeletal disorders among non-fitted workers; it results in frequent
absenteeism, decreasing in productivity and derogation morale among workers. And also the company
can get the following benefits by applying a new designed ergonomically sitting chair for the employees:

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  Decrease musculoskeletal disorders (MSD)

 Decrease repetitive motion, stress and awkward postures

 Increase safety and health of the workers

 Decrease absenteeism

 Decrease lost time at work

 Increase work quality

 Eliminate compensation cost due to MSD

 Improve job satisfaction

 Increase productivity

2.11.2 Recommendation

In order to increase the company’s productivity the dire dawa food complex company should work up on
employee’s satisfaction and comfort since the employers satisfaction and productivity are directly related.
And also the company should change its current workers chair design to a new designed ergonomically.
Specially in the company’s section; wheat flour, biscuit and bread production the employees have jobs
where they sit or stand for a long periods working in one position which can lead to muscle pain and
strain. In order to reduce this problem and to improve productivity the company should:-

 Apply ergonomics approaches in the production section to reduce or avoid MSDs of the workers.

 It is better to have an ergonomics experts in this section due to there are different ergonomics
problems exists.

 Change the existing productivity system by improving the existing one or changing by
ergonomically designed chair in order to increase the productivity of the company & minimize
the workers’ health problem..

 The workers should be aware and have to regular exercises during rest time.

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 References

1. DDFC share company document

2. Bailey, D. and Hubert, T. (1980), Productivity Measurement, London: Gower Press.

3. http://www.ijisrt.com/

4. Ergonomics.vol32, No.4, 359-371.

5. ergonomics analysis for the manufacturing industry 2001.

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 APPENDEXIS

EMS…………………....Environmental management system

ISO……………………..International standard organization

HACCP………………...hazard analysis critical control point.

CMOESA………………common market of Easter and southern African

LCP… ………………….Long Cut Pasta (pasta)

SCP……..………………Short Cut Pasta (Macaroni)

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