BAHIR DAR UNIVERSITY

Bahir Dar Institute of Technology

Faculty of Mechanical and Industrial
Engineering
Mechanical Engineering Program
Internship Report

Project Title: Design of cork belt elevator conveyor

Hosting Company: MOHA Soft Drinks Industry S.C

Name ID
1. Israel Eyob 1011979

Mentors: Mr. Amare

October 2022
 Declaration
I would like to declare that we have successfully completed 4 months of internship program at
Addis ababa Teklayhaymanot MOHA soft drinks factory. During that time we have improved
our theoretical and practical knowledge. We have done project during the internship program and
included as part of this report. I want to assure that this report and project exactly belongs to us.
Here by state that this final internship report has been submitted to Bahir Dar Institute of
technology, Faculty of Mechanical and industrial Engineering in partial fulfillment of the
requirements of an internship report.
Name of Student Signature
1. Israel Eyob .................................
Certified that the above statement made by the students is correct to the best of our knowledge
and belief. This is to confirm that we have read this Internship Report and that the information
enclosed is correct, satisfactory, and acceptable. Therefore, we approve this report is good in
scope and quality, as internship report.
Name of academic advisor Signature
1. Mr. Amare ............................
Name of Company supervisor Signature
1. Mr. Solomon. G ................................

I
INTERNSHIP REPORT

Acknowledgment
First of all thanks to God for keeping all things to be happened in a good manner. We would like
to thank Bahir Dar University for giving us this opportunity to get practical skills and to have
some important and essential knowledge about soft-drink processing from raw materials to
finished product from this company. Indeed we would like to express our gratitude to Mr.
Solomon supervisor of production for his incredible level of advice, many suggestions and
constant support at every step of this internship program. Also we would like to gratefully
acknowledge our mentor Mr.Amare who is Mechanical engineering department instructors for
their provision of necessary idea. Finally, we would like to thank all those whom we did not
mentioned their name and who helped us directly or indirectly in the internship period and this
report.

II
INTERNSHIP REPORT

Executive Summery
MOHA soft drink industry S.C is one of the leading competitive companies in Ethiopia which is
found in most Ethiopian region. MOHA soft drink industry teklayhaymanot plant found in Addis
ababa region. This company uses old technology, different machines, materials, human skills and
methods to manufacture its products qualitatively and quantitatively. The international Pepsi
Cola plant has more than hundred types of food and beverage products. But there are only few
products are producing in our country and these products became well known brands of Pepsi in
Ethiopia. These products are Pepsi, Mirinda, 7UP, Mirinda Tonic and Mirinda Apple in their
discovering order and later cool water (mineral water) is added. Specifically when we come to
moha plant Pepsi, Mirinda and sometimes 7UP are produced. This Internship program introduces
us to the real world and test our performance on solving the different types of problems that we
have faced during MOHA soft drink industry. This report is detailed covered all the activities in
the internship program from the beginning until the end. Those are describing the company
history, overall benefits we gained from the internship and describing the project work for the
selected main problem. As well as solutions used to overcome challenges and suggestions. In
addition, project work is included in the report. , there are five chapters in all. Cork belt elevator
conveyor were the main topics covered in this internship project. Our project is used to transport
cork from storage the crowner feeder.

III
INTERNSHIP REPORT

Table of contents
CHAPTER ONE...........................................................................................................................................................1

1. COMPANY BACKGROUND.................................................................................................................................1
1.1 Brief history of the company................................................................................................................................1
1.2 objectives of the company....................................................................................................................................1
1.3 Vision of the company..........................................................................................................................................1
1.4 Mission of the company.......................................................................................................................................1
1.5 Core values of the company.................................................................................................................................2
1.6 main products of the company.............................................................................................................................2
1.7 Main Customers of the Company.........................................................................................................................2
1.8 Organizational structure of the company.............................................................................................................3
1.9 Work flow structure of Gondar pepsi cola plant.................................................................................................4

CHAPTER TWO..........................................................................................................................................................5

2.OVERALL INTERNSHIP EXPERIENCE.............................................................................................................5

2.1 Reason for selecting the company........................................................................................................................5
2.2 The Sections We Have Been Working.................................................................................................................5
2.2.1 water treatment room....................................................................................................................................6
2.2.3 Soft water treatment....................................................................................................................................11
2.2.4 Boiler room.................................................................................................................................................12
2.2.5 Syrup preparation room...............................................................................................................................13
2.2.6 Bottle Washer machine...............................................................................................................................16
2.2.7 Mechanisms of bottle washer machine.......................................................................................................16
2.2.8 Filler room...................................................................................................................................................18
2.3 Work tasks we have been executing...................................................................................................................24
2.4 Engineering methods, tools and techniques used...............................................................................................24
2.5 Challenges we have Been facing while performing Our work tasks..................................................................24
2.6 Measures we have been taking in order to overcome the challenge..................................................................24

CHAPTER THREE....................................................................................................................................................25

3.BENEFITS GAINED FROM INTERNSHIP........................................................................................................25

3.1 Improving practical skills...................................................................................................................................25
3.2 Improving theoretical knowledge.......................................................................................................................25
3.3 Improving team playing skills............................................................................................................................25
3.4 Improving leadership skills................................................................................................................................25

IV
INTERNSHIP REPORT

3.5 Improving work ethics and related skill.............................................................................................................25

3.6 Entrepreneurship skill.........................................................................................................................................26
3.7 Improving inter personal communication skill...................................................................................................26

CHAPTER FOUR.......................................................................................................................................................27

4. PROJECT WORK..................................................................................................................................................27
Design of belt elevator conveyor..............................................................................................................................27
4.1 INTRODUCTION..............................................................................................................................................27
Components of belt conveyor.............................................................................................................................27
4.1.1 Short summary of the project......................................................................................................................29
4.2 Statement of the problem....................................................................................................................................29
4.3 Objective of the project......................................................................................................................................30
4.4 Literature review................................................................................................................................................30
4.5 Methodology.......................................................................................................................................................31
4.6 Design of belt conveyor......................................................................................................................................31
4.6.1 Determination of belt characteristics..........................................................................................................31
4.6.2 Belt construction.........................................................................................................................................32
4.6.3 Angle of inclination.....................................................................................................................................33
4.6.4 Belt width....................................................................................................................................................34
4.6.5 Belt speed....................................................................................................................................................34
4.6.6 Belt length...................................................................................................................................................34
4.7 Conveying length................................................................................................................................................35
4.8 Conveying capacity............................................................................................................................................35
4.9 Power requirements............................................................................................................................................35
4.10 Idler dimensions...............................................................................................................................................38
4.11 Belt breaking strength.......................................................................................................................................40
4.12 Determination of forces....................................................................................................................................41
4.13 Belt tension.......................................................................................................................................................43
4.14 Pulley diameters...............................................................................................................................................46
4.15 Result................................................................................................................................................................47
4.16 Cost Estimation................................................................................................................................................48
4.17 DISCUSSION...................................................................................................................................................50
4.18 CONCLUSION................................................................................................................................................50
4.19 RECOMMENDATION....................................................................................................................................50

CHAPTER FIVE........................................................................................................................................................51

5.GENERAL CONCLUSION AND RECOMMENDATION................................................................................51

V
INTERNSHIP REPORT

5.1 General conclusion.............................................................................................................................................51

5.2 General recommendation....................................................................................................................................51
References................................................................................................................................................................52
APPENDICE A........................................................................................................................................................53
APPENDICE B.........................................................................................................................................................55
3D Models & Drawings............................................................................................................................................56

VI
INTERNSHIP REPORT

List of figures
Figure 1. 1 Main product of MOHA soft drinks..............................................................................2
Figure 1. 2 Organizational structure of MOHA soft drinks.............................................................3
Figure 1. 3 Processes Flow Diagram...............................................................................................4
Figure 2. 1 Pepsi cola plant water treatment flow diagram.............................................................6
Figure 2. 2 Coagulation Tank..........................................................................................................7
Figure 2. 3 Sand filter tank..............................................................................................................8
Figure 2. 4 Carbon filter tank..........................................................................................................9
Figure 2. 5 Cartridge filter tank.....................................................................................................10
Figure 2. 6 Ultra Violet (UV) Unit................................................................................................10
Figure 2. 7 softener tank................................................................................................................11
Figure 2. 8 Boiler machine............................................................................................................12
Figure 2. 9 Sugar dissolving tank..................................................................................................13
Figure 2. 10 Candle filter tank.......................................................................................................14
Figure 2. 11 Heat exchanger for simple syrup...............................................................................14
Figure 2. 12 Simple syrup cooling tower.......................................................................................15
Figure 2. 13 Bottle washing machine............................................................................................16
Figure 2. 14 Slider crank mechanism............................................................................................16
Figure 2. 15 Four-bar linkage........................................................................................................17
Figure 2. 16 Bottle washer machine washing steps.......................................................................18
Figure 2. 17 Empty bottle inspection (EBI)...................................................................................18
Figure 2. 18 Water and syrup reservoirs........................................................................................19
Figure 2. 19 cooling tower for ammonia compressor....................................................................19
Figure 2. 20 Filler machine............................................................................................................20
Figure 2. 21 Capping machine.......................................................................................................21
Figure 2. 22 Full bottle inspection.................................................................................................22
Figure 2. 23 Date coder machine...................................................................................................22
Figure 2. 24 Mechanical bottle counter.........................................................................................23
Figure 2. 25 Air compressor room.................................................................................................23
Figure 4. 1 Components of belt conveyor.....................................................................................28
Figure 4. 2 Capping machine.........................................................................................................29
Figure 4. 3 Methodology flow chart..............................................................................................31
Figure 4. 4 Inclination angle of a belt conveyor............................................................................33
Figure 4. 5 Types of troughing idler..............................................................................................38
Figure 4. 6 single pulley head drive stress points..........................................................................44
Figure 4. 7 angle of wrap...............................................................................................................45

VII
INTERNSHIP REPORT

List of tables
Table 2. 1 Manufacturing techniques............................................................................................24
Table 2. 2 Maintenance technique.................................................................................................24
Table 4. 1 Cover thickness gauges.................................................................................................32
Table 4. 2 Gradient values of cover surface..................................................................................32
Table 4. 3 standard dimension of cleats.........................................................................................33
Table 4. 4 Standard Belt Widths....................................................................................................34
Table 4. 5 Recommended belt speed based on duty type..............................................................34
Table 4. 6 Standard Values of belt speed.......................................................................................34
Table 4. 7 Width factor..................................................................................................................36
Table 4. 8 Length Factor................................................................................................................36
Table 4. 9 working condition factor Kf..........................................................................................37
Table 4. 10 Degree of efficiency value..........................................................................................37
Table 4. 11 Standard electric motor power....................................................................................38
Table 4. 12 standard diameter of idlers..........................................................................................38
Table 4. 13 standard idler length...................................................................................................39
Table 4. 14 mass of set of idlers....................................................................................................39
Table 4. 15 Friction value factor....................................................................................................40
Table 4. 16 Breaking Strength Loss at Joint Factor Cv.................................................................41
Table 4. 17 Standard property of belt types...................................................................................41
Table 4. 18 Length factor C...........................................................................................................42
Table 4. 19 Artificial friction factor...............................................................................................42
Table 4. 20 drive factor value........................................................................................................45
Table 4. 21 standard pulley diameter and weight..........................................................................46
Table 4. 22 Group and application of pulley.................................................................................46

VII
I
INTERNSHIP REPORT

CHAPTER ONE

1. COMPANY BACKGROUND

1.1 Brief history of the company

MOHA soft drink industry Teklaymanot branch is one of the soft drink company in Addis ababa
region of Ethiopia. It was established by Emperor Haile Selassie May 4, 1954 (GC). In that time
the company employed 62 employers and produced 5000 bottle/day and the products were Pepsi
Cola and Mirinda. The employer’s salary had been below 50 birr. Teklayhaymanot Moha soft
drink industry (MOHA) is a member of Mohammad International Development Research
Organization Companies (MIDROC). It is Ethiopian technology group companies which are
engaged in manufacturing and selling of different types of soft drink in Ethiopia. The overall
activates of the company are managed and administrated by Sheik Mohammed Hussein Ali Al-
Amoudi also he is the chairperson and the owner. MOHA soft drink S.C. holds 52% of the
market share in soft drink industry in the country with an expansion and replacement of absolute
machinery production capacity of the plant has increase substantially.

1.2 objectives of the company

Areas to both protect company are committed to the production and Supply of high quality and
safe products that satisfy the need of customers. And creating values by making their products
the first choice of the customers[2].

1.3 Vision of the company

MOHA’s vision is to make each of Pepsi products to be a drink of first choice among consumer
and obtainable throughout the Ethiopian market and also creating superior value for
shareholders, customers and employees.

1.4 Mission of the company

The mission of the company is to be the best soft drink industry in the country .They believes
they will continuously improve their customers need, employees, partners and the communities
in which they serve. These will accomplished through the development of their employees, an
emphasis on cost, efficiency, market expansion and profitability. The company will expand their
marketing and improve their positions by placing emphasis on innovation and technological to
the competition.

1
INTERNSHIP REPORT

1.5 Core values of the company

 Customer satisfaction
 Enhancement of positive corporate identity and image
 Ensure employees empowerment
 Be committed to social responsibilities, sustainability of quality and
 Excellence in work and build a winning team

1.6 main products of the company

In Gondar plant, MOHA Soft Drinks Industry S.C. produces Pepsi, Mirinda and 7-UP as shown
in the figure below. The rest of the products are not available due to the old technology of the
machines. These all products are 300ml (0.3L). To produce the above-mentioned products,
MOHA Soft Drinks Industry S.C got an authorized license from international Pepsi Cola
Company. This company controls the quality and safety of the products in the market.

Figure 1.1: Main product of MOHA soft drinks

1.7 Main Customers of the Company

Different factories The products always uses in local market from main distributor up to the
whole seller. The main customers/end users are:-
 Individual peoples
 Different factories
 Cafes, Restaurants and Hotels and others

2
INTERNSHIP REPORT

1.8 Organizational structure of the company

The plant has their own organization structure to perform their task. The following diagram
shows the overall organizational structure of MOHA soft drink industry[2].

Figure 1.2 : Organizational structure of MOHA soft drinks

3
INTERNSHIP REPORT

1.9 Work flow structure of pepsi cola plant

Figure 1.3 : Processes Flow Diagram

4
 INTERNSHIP REPORT

CHAPTER TWO

2. OVERALL INTERNSHIP EXPERIENCE

2.1 Reason for selecting the company

We chose this company because MOHA soft drink S.C. holds 52% of the market share in soft
drink industry in the country. MOHA Won four awards in 2010 from Pepsi Cola international, as
per the accomplishment of standard required by AIBI – an internationally recognized third party
audit firm. Besides it has different wide plant sites across the country. MOHA plant sites include
Teklehaimanot plant, Summit partners plant, Dessie plant, Bure-Baguna plant, Hawassa
Millennium plant and Mekelle plant.

2.2 The Sections We Have Been Working

In Gondar MOHA soft drink plant we have been working on the filler section. there are also
different sections. These sections were very essential for the manufacturing of soft drink and
they have their own procedure and safety majors to be ready for the final production. Those
sections are:-
 Water treatment room
 Boiler room
 Syrup room
 Air compressor room
 Bottle Washer
 Filler room
 Packaging and store rooms

5
INTERNSHIP REPORT

2.2.1 water treatment room

Whether the water comes from a borehole or from the town mains, it must comply with current
national legislation as well as meet the company water standard. Water treatment is the process
of removing undesirable chemicals, biological contaminant, suspended solids and gases from
raw water and that makes the water more clean and acceptable for specific end use. The source
of the water for teklahymanot MOHA soft drink is usually ground water. There are two types of
water treatment process Hard water treatment and soft water treatment . There are two types of
water treatment process these are:-
 Hard water treatment
 Soft water treatment

Figure 2.1: MOHA Pepsi cola plant water treatment flow diagram

2.2.2 Hard water treatment

Hard water usually the ground water and the final treated hard water is used for the syrup
preparation and filling section. It is treated through the following treatment tanks.

6
INTERNSHIP REPORT

I. Coagulation tank
Coagulation (Reaction) tank is the first tank in the water treatment room. The desired chemical
reaction takes place and water is sanitized. It is a chemical water treatment process by changing
smaller particles in to heavier so that they can quickly settle out. The coagulant, usually
Aluminum sulfate with the assistance of the chlorine and lime, forms heavy flock which entraps
particles of debris, dirty organic matter and other undesirable material in the water, and settles
slowly toward the bottom of the tank. The flock because of its own weight is left behind
continuously trapping particles of debris as it settles.

Figure 2.2 : Coagulation Tank

7
INTERNSHIP REPORT

II. Sand filter tank

The purpose of sand filter tank is to remove physical matters and unwanted materials from the
raw water like floating dirt’s present in the ground water except chlorine from water. The sand
tanks (filter) has three layers, at the bottom there are sands (gravel) and relatively large in size
followed by medium size sand filter that covers a few height above the gravel . Fine sand filters
are filled above the medium sized sand filter followed by anthracite top up which enhances
effective filtration of foreign matter or suspended particles coming with raw water that may
occur during storage at the concrete tank (reservoir).

Figure 2.3 : Sand filter tank

8
INTERNSHIP REPORT

III. Carbon filter tank

The water that comes from the sand filter tank is entered in to the carbon purifier. This is used to
remove chlorine by using activated carbon that present in the water. If the color is changed then
the water has chlorine, therefore the water can be corrected by removing chlorine before it enters
in to the polisher because the presence of chlorine can change the color and test of the final
product. Regeneration of activated carbon takes place by the incoming steam from boiler room
once in a week.

Figure 2.4 : Carbon filter tank

9
INTERNSHIP REPORT

IV. Cartridge Filter (Polisher, 1micro Sized)

This is used to remove suspended activated carbon that comes from the carbon purifier and other
unwanted particle that may be passed through the carbon purifier before transferred to
Ultraviolet (UV) Radiation. The filter bag used for filtration is called polisher. Cartridge filter
contains five polishers inside and can be used for one month. A new white polisher replaced by
the old one that is used for one month.

Figure 2.5 : Cartridge filter tank

V. Ultra Violet (UV) Radiation

It is the final treatment for the product water. It is used for destroying any microorganisms
present in water. It’s known as the critical control point for the quality of the water. After passing
through UV, now the water can be used for production purpose, such as syrup preparation and
filling room.

Figure 2.6 : Ultra Violet (UV) Unit

10
INTERNSHIP REPORT

2.2.3 Soft water treatment

There are two softener tanks which are similar size and application but at a time only one of
them will work while the other one will be regenerated using brine tank that holds sodium
chloride. Generally, its application is to change the hard water into soft water that is used in the
washer machine and boiler room. Its mechanism is to remove calcium and magnesium in their
carbonate form which could increase the hardness of the water.

Figure 2.7 : softener tank

11
INTERNSHIP REPORT

2.2.4 Boiler room

A boiler or steam generator is a device which is used to create steam by applying heat energy to
water. The boiler is made up of stainless steel, because it is less corrosive. This generated steam
has different functions in different sections of the company. Such as:-
 Washing bottles in washing section
 Dissolving sugar in syrup room
 cleaning and sterilizing internal parts of machines

Figure 2.8: Boiler machine

12
INTERNSHIP REPORT

2.2.5 Syrup preparation room

The syrup preparation is the initial step in the making of soft drinks and provides the final
product with its distinct flavor and color, the process of syrup preparation is starting from sugar
treatment. For the treatment process Hyflo or diatomite and activated carbon is used. The process
begins by adding of sugar in the sugar dissolving in tank. the tank have 700L of water with 60 0c
of temperature, then 1,128 kg of sugar is added in to the tank, in addition 4kg of activated carbon
and 2 kg of sylatom is added then agitate in order to mix and wait until the temperature rise to
800c.

Figure 2.9 : Sugar dissolving tank

13
INTERNSHIP REPORT

The activated carbon is important for the odor and removing un-wanted thing in the sugar.
Sylatom or diatomaceous earth is useful to catch up the activated carbon. In the other tank Hyflo
will mix with water in order to catch up or separate the activated carbon from sugar in the candle
filter tank.

Figure 2.10 : Candle filter tank

Through circulation the mixture of dissolved sugar and Hyflo will be contact in the candle filter
tank then the activated carbon will be absorbed by Hyflo, then the pure sugar will be passing
through the heat exchanger in order to lose its temperature and entering to the syrup mixing tank.

Figure 2.11: Heat exchanger for simple syrup

14
INTERNSHIP REPORT

The heat exchanger is connected to cooling tower of syrup outside the syrup preparation room.
The simple syrup (heated sugar) will be transferred to this cooling tank. Its purpose is to cool
down the temperature of simple syrup below 25 0c before getting to syrup mixing tank.
Decreasing the temperature is important because if the simple syrup gets into syrup mixing tank
with high temperature it may damage the flavor in syrup mixing tank besides high temperature
may be suitable for microorganisms.

Figure 2.12 : Simple syrup cooling tower

After all this process the final syrup will be produced by mixing this simple syrup with the
standard ingredients of Pepsi or mirinda in the syrup mixing tank. There are four huge tankers
and they are used to store and convert the simple syrup in to the final syrup. The simple syrup
which has less than 250c transferred in to these tankers from heat exchanger .Then flavors and
dry component will be mixed with simple syrup in order to give final syrup. Standard ingredients
of Pepsi: Carbonated Water , Sugar , Color (Caramel E150d) , Acid (Phosphoric Acid) and
Flavorings (including Caffeine) Standard ingredients of Mirinda: Carbonated water , potassium
benzoate (preserves freshness) , Sodium chloride ( better taste and long shelf life ) and sodium
citrate.

15
INTERNSHIP REPORT

2.2.6 Bottle Washer machine

Bottle washing is one of the main important steps in the production of soft drinks. The shelf life
of soft drinks depends very greatly on the state of the cleaned bottle. Empty bottle are returned
from different customers must be cleaned to a hygienically perfect condition.

Figure 2. 13 : Bottle washing machine

2.2.7 Mechanisms of bottle washer machine

I. Slider-crank mechanism
A slider-crank mechanism is basically a four-bar mechanism with three revolute joints, or
turning pairs and a prismatic joint or a sliding pair.

Figure 2.14 : Slider crank mechanism

16
INTERNSHIP REPORT

II. Four-bar linkage

The conventional numbering system is to label the ground frame as link I, and then to number
links clockwise around the mechanism "loop" as shown.

Figure 2.15 : Four-bar linkage

Cleaned bottles are transferred to the conveyor, and then to the filler machine. The bottles are
transported in rows through the bottle washer. During passage through the machine the bottles
pass different washing steps.
A. Pre and intermediate spraying
This is the first stage for bottle washing and presoaked in one or more baths at increasing
temperature the bottle is washed internally and externally with soft water by using spray jet.
B. Caustic I
In this step the bottles sink in a chemical called caustic soda and boiled with temperature of 72 0c-
850c. This is controlled by diaphragm valve which senses the temperature from the boiler in the
form of steam. Thus, the diaphragm monitors the temperature range to be in between 72 0c- 850c
where if it goes out of the range it opens and closes the valve by a pressure that comes from the
compressor.
C. Caustic II
The difference from the former step is there is no caustic soda to be added here or t he strength of
caustic II is less than caustic I and also the temperature is decreased by some amount 25 0c- 280c
from caustic I but it is assumed to be not free from this chemical due to carry over in it and the
most important thing in this step is more water is used to clean the bottles.
D. Warm water
The bottles are washed by hot water (the water heated by steam). This is temperate water which
is not very hot but moderate one which is heated by conduction system via steam comes from
boiler.
E. Cold water
The bottles are cleaned by cold water. In this part the bottles get more cold water to be washed
before it gets to the next step.
F. Fresh water
This is the final stage for bottle washing process the bottles washed by fresh and treated water
that comes from water treatment section in order to protect the bottle from microorganism and
other unwanted materials and the water is comes from. Finally, they are ready to go to the filling
room.

17
INTERNSHIP REPORT

Figure 2.16 : Bottle washer machine washing steps

2.2.8 Filler room

It is one of the production sections whose purpose is to verify that containers are consistently
filled to the correct level as established by correct volume or weight for the brand and package
type. There are a series of processes under filling section these are Empty Bottle inspection
(EBI), Mixer Machine, Filler Machine, Capping machine, Full Bottle Inspection (FBI) Date
coder and mechanical bottle counter.
I. Empty Bottle Inspection (EBI)
The purpose of inspection is to insure the safety of the work in the processes. Inspect empty
bottle that comes from the bottle washer manually by peoples and electrically through light
screening.

Figure 2.17: Empty bottle inspection (EBI)

18
INTERNSHIP REPORT

II. Mixer Machine

The basic purpose of this machine is to mix the three main contents of the product, which are
water, finished syrup and carbon dioxide. This process is called Carbonation. The water comes
from water treatment room and it is well treated water and the finished syrup comes from syrup
room whereas the carbon dioxide comes from CO2 tank.

Figure 2. 18 : Water and syrup reservoirs

As the beverage is chilled, it absorbs carbonation. Most beverage operation use cooling to 20°C
for cold filling. The finished beverage is cooled by ammonia gas the cooling tower for ammonia
compressor is available in the company.

Figure 2. 19 : cooling tower for ammonia compressor

19
INTERNSHIP REPORT

III. Filler Machine

Filler machine is used to fill the bottles with the drink that has been prepared in the mixing
machine. It is also connected with the capping machine.

Figure 2. 20 : Filler machine

The machine works by lubrication system automatically. There are also 16 filling valves called
vents and expanding tubes where these tubes have small holes that are used to transport the gas
as well as the drinks respectively.

20
INTERNSHIP REPORT

IV. Crown capping Machine

Capping machine is device used to pack or seal the bottle with crown corks. It has cork feeder on
top part and is added manually. The cork drop by the action of gravity to seal the incoming full
bottle Inverted corks will not be dropped down because a simple horizontal bar prevents them.

Figure 2. 21: Capping machine

21
INTERNSHIP REPORT

V. Full Bottle Inspection (FBI)

Like EBI, this inspection area also inspects the status of a full bottle. There are parameters used
to check the full bottle. This inspection method is also done manually by people.

Figure 2. 22 : Full bottle inspection

VI. Date Coder Machine

It is a machine used to label the best before date and the factory’s abbreviation name with the
time of production. It has no contact area with the bottle it only prints the date by spraying the
ink through the print head. A product without a label of best before date will not be available for
market.

Figure 2. 23 : Date coder machine

22
INTERNSHIP REPORT

VII. Mechanical bottle counter

Counts the number of filled bottles so that the total number of final products is known.Atmospheric air is
sucked and filtered by dust filter to avoid undesired particles. Then the filtered gas is then transferred to
vacuum suction to form pressure difference which enables to transfer the sucked air to the desired
location. Then this air is transferred to the compressor in order to develop pressure in parallel with
temperature and then cooled in two stages in both cases. After air is stored in storage tank, it is used for
different applications. Such as:
 To clean the bottle
 To operate the piston of the bottle on filler machine
 To dry the moisture on the bottle
 To cool the soft drink
 To operate pneumatic valve

Figure 2. 25 : Air compressor room

23
INTERNSHIP REPORT

2.3 Work tasks we have been executing

 Observe every section of the company when the machines are functioning.
 Save bottles from breakage
 Pick up under fill bottles from conveyer belt and put in to cases
 Arranging some cases & bottles when come improper position on the conveyer belt
 Helping the operators and workers if they need
 Quality checking at FBI and EBI

2.4 Engineering methods, tools and techniques used

I. Manufacturing techniques
Manufacturing techniques are described in the following table
Table 2. 1: Manufacturing techniques
Engineering methods and techniques Tools /machines used
 welding technique  grinder machine
 grinding  bench vise
 loosening and tightening nuts  spanner
 electrodes
 welding machine
Activated in different maintenance activities during this time we follow engineering methods and
techniques that are presented in the following table
Table 2. 2: Maintenance technique
Engineering methods and techniques Tools /machines used
 inspection  monkey wrench
 lubrication  Allen key
 cleaning  ball hammer
 spare part replacement  lubrication can
 predictive and corrective maintenance  clean, dry clothes
 Pipe wrench

2.5 Challenges we have Been facing while performing Our work tasks
 Most of manuals on the company are written by foreign language.
 Since MOHA Gondar plant is an old plant: There is no enough data of the company.
 Almost all operators don’t have sufficient idea about machines.
 Noises of production machineries

2.6 Measures we have been taking in order to overcome the challenge

Here are some of the measures we have been taking
 Revise our previous knowledge that would support the our internship time
 Use the available manuals and time effectively
 By using internet access to support our internship program

24
 INTERNSHIP REPORT

CHAPTER THREE

3. BENEFITS GAINED FROM INTERNSHIP

3.1 Improving practical skills

We have gained multidimensional practical skills such as
 How to operate boiler and bottle washer machines.
 Fulfilling safety requirements(wearing glass, leather shoes and gloves).
 How to identify the problem of filler machine.
 Solving the problem of filler machine by tightening the bolts around the piston. We have
improved theoretical knowledge such as understanding the process of soft drink
preparation from raw materials.

3.2 Improving theoretical knowledge

We have improved theoretical knowledge such as understanding the process of soft drink
preparation from raw materials.

3.3 Improving team playing skills

We have learned a lot on how to improve interactions with our team members. When activities
are done in group the acceptability, reasonability and accuracy were found to be always better
than those done by individually.

3.4 Improving leadership skills

We gain the following skills in terms of leadership
 Ability to encourage and motivate workers to do their best.
 The ability to accept problems and focus on its solution.
 Commitment and dedication
 Learned how to find solutions for any problems developed.

3.5 Improving work ethics and related skill

We gain different skills related to work ethics and related skills such as:
 Accept and follow rules and regulations of the company
 Being punctual
 Being tolerant and patient
 Change the style of dressing and wear over coat and helmets
 Smooth relation with colleagues
 Have a positive work attitude

25
INTERNSHIP REPORT

3.6 Entrepreneurship skill

We gained the following abilities or skills:
 Risk management
 Self-confidence
 Creativity skill

3.7 Improving inter personal communication skill

We have improved the following interpersonal communication skills.
 How to ask a question to our co-workers in a polite way
 How can we develop a friendly relationship with our co-workers
 How can we communicate with my managers and supervisors

26
INTERNSHIP REPORT

CHAPTER FOUR

4. PROJECT WORK

Design of belt elevator conveyor

4.1 INTRODUCTION
Conveyor systems are mechanical devices or assemblies that transport material with minimal
effort. While there are many different kinds of conveyor systems, they usually consist of a frame
that supports either rollers, wheels, or a belt, upon which materials transport from one place to
another. They may be powered by a motor, by gravity, or manually. These material handling
systems come in many different varieties to suit the different products or materials that need to
be transported.

Belt Conveyors are material handling systems that use continuous belts to convey products or
material. The belt is extended in an endless both ends have a roll underneath. The conveyor
belting is supported by either a metal slider pan for light loads where no friction would be
applied to the belt to cause drag or on rollers. Power is provided by motors that, use either
variable or constant speed reduction gears. The belt themselves can be made from numerous
materials, which should correspond to the conditions under which the belt will be operating.
Common conveyor belting materials include rubber, plastic, leather, fabric and metal. Belt
conveyors are typically powered and can be at various speeds depending on the throughput
required. Belt conveyors have different types of components like idler rollers, drum pulley, cleat,
belt, motor, etc[3].

Components of belt conveyor

Idlers are used to provide to support and protection of a belt conveyor, reduce motion resistance
as well as support for transported materials.

Drum pulleys are power transmission components used in conveyor and bulk handling
application.

Cleat are used to hold the material and help maintain forward momentum

Belt a conveyor belts are used to move objects from one place another with minimal effort. The
conveyor belt pace, direction, curvature and size varies based on the needs of the user. In some
industries a conveyor belt brings products through a manufacturing or packaging line and back
again.

Motor Ac induction motors are ideal for conveyor systems that operate continuously in one
direction.

27
INTERNSHIP REPORT

Frame the belt conveyor frame is a metal structure usually normal and stainless steel conveyor
frame used to support idlers. pulley and belt tension. There will be other types of components
due to the type of conveyors.

Figure 4. 1: Components of belt conveyor

28
INTERNSHIP REPORT

4.1.1 Short summary of the project

The focus of this project is on the design of light-duty belt conveyor system for transporting
corks to the capping machine. There are stated problems, general and specialized objectives, and
a list of work tasks under this term. The other part of this project is methodology which is the
system of methods used in this particular study and literature review. The next step is to design
each component of the conveyor system using established procedures. Finally, the findings are
examined, and suggestions are made.

4.2 Statement of the problem

The most successful manufacturing industries nowadays concentrate on the most efficient and
effective techniques to reduce labor effort. As a result, a belt conveyor system is a method of
reducing worker effort. The problem we saw with MOHA soft drink was that the personnel
working on the filler and capping equipment were under too much stress. So, we’re going to
make a belt elevating conveyor to let the operators add cork from the cork storage to the top of
the capping machine, which will address this problem and lessen the operators work.

Figure 4. 2 : Capping machine

29
INTERNSHIP REPORT

4.3 Objective of the project

I. General objective
The overall goal of this project is to design inclined belt conveying system to transport cork from
storage to the capping machine’s top by the use bucket cleats in which they are attached with the
belt.
II. Specific objective
 To perform parts design analysis.
 Selection of standard components
 To draw its parts and assembly drawing in CAD software.

4.4 Literature review

Belt conveyor technique, This paper is mainly based on the combination of Belt & Bucket
Conveyers to perform complex task within a short time and successfully in a cost effective way.
Belt conveyor & Bucket elevator are the media of transportation of material from one location to
another in a commercial space. Belt conveyor has huge load carrying capacity, large covering
area simplified design, easy maintenance and high reliability of operation. Belt Conveyor system
is also used in material transport in foundry shop like supply and distribution of molding sand,
molds and removal of waste. On the other hand Bucket elevator can be of great use during bulk
material handling. On account of this, a machine and its physical description is covered here with
some basic calculation[4].

A JAGTAP (2015) , This paper discusses the design calculations and considerations of belt
conveyor system for plastic packaging using 3 rolls idlers, in terms of size, length, capacity and
speed, roller diameter, power and tension, idler spacing, type of drive unit, diameter, location and
arrangement of pulley, angle and axis of rotation, control mode, intended application, product to
be handled as well as its maximum loading capacity in order ensure fast, continuous and efficient
movement of crushed biomass wood while avoiding fatalities during loading and unloading. The
successful completion of this research work has generated design data for industrial uses in the
development of an automated belt conveyor system which is fast, safe and efficient[5].
A.W. ROBERTS and A. HARRISON, This paper outlines recent research in the area of belt
conveying a review of design trends associated with long overland conveyors is presented
indicating the influence of economic and technical considerations in the design methodology.
Aspects of conveyor dynamics are discussed and research and development work concerned with
specific subjects including belt drum friction, rolling resistance and bulk solid and conveyor belt
interaction. A test rig for examining stability between bulk solids and conveyor belts during
transportation is described[6].

Konakalla Naga Ananth, Belt conveyor is the transportation of material from one location to
another. Belt conveyor has high load carrying capacity, large length of conveying path, simple
design, easy maintenance and high reliability of operation. Belt Conveyor system is also used in
material transport in foundry shop like supply and distribution of molding sand, molds and

30
INTERNSHIP REPORT

removal of waste. This paper provides to design the conveyor system used for which includes
belt speed, belt width, motor selection, belt specification, shaft diameter, pulley, with the help of
standard model calculation[7].

4.5 Methodology
Planing Method
observing problems
contact company
superviser to discus
company shortcomings
and issues

3D Modeling And Drawings Data Collection

primary and secondary data collection method
solidworks

Material Selection
Strength Durability
Cost and availability of material
Result And Conclusion

Geometrical Analysis

Figure 4.3 : Methodology flow chart

4.6 Design of belt conveyor

4.6.1 Determination of belt characteristics

The selection of the belt specification depends on the application. The application is a light duty
type so we chose the belt material to be PVC (polyvinyl chloride) because it has the following
advantages: Strong and lightweight, Easy to install, Durable ,Cost-effective, Safe material
(nontoxic) and Fire resistant. The following items mentioned below should be considered
carefully to select the proper belt characteristics.

31
INTERNSHIP REPORT

4.6.2 Belt construction

Covers
The belt is protected against outside influences by the covers which are normally made out of
either rubber or PVC. It is available in different qualities of rubber or PVC.
I. Cover thickness
Carrying side Cover thickness The thickness of the carrying side cover depends upon the nature
of the load and loading conditions (type of load, gradient, height of fall etc.)

Table4. 1 Cover thickness gauges [4].

Light package conveying can be selected for our application then for the material to be
transported, cork, the carrying and pulley side cover thickness is 2mm. Return side Cover
thickness. The carrying side cover should not be more than 3 times thicker than the running side
cover. Carrying side : Return side 3 : 1.
I. Cover surface type
The carrying side surface depends on the load, the inclination of the installation or depending on
the use of the belt, smooth, profiled, cleated and with corrugated edges.
Table4. 2 Gradient values of cover surface[4].

Cover Surface Belt type Max gradient Application

Smooth Normal 18° - 20° Unit and
bulk loads

T-cleats Belts with Up to90o Piece and bulk

with or without Corrugated side walls load
corrugated edges with or without T-
Cleats

Profiled Fishbone Ruff top up to 35° Piece and bulk

load

The cover surfaces of the belt have cleats and the application is conveying pieces of corks.

32
INTERNSHIP REPORT

4.6.3 Angle of inclination

The maximum angle of inclination of a belt conveyor depends on the friction value between
material and belt and the form of material. For steeper inclinations up to 90°, profiled belts, belts
with cleats or elevator belts are used. Knowing angle of inclination is important to convey the
materials efficiently[4].

Figure4. 4 Inclination angle of a belt conveyor

The space in the working area of the filling and capping machines is narrow so we don’t want
to take a smaller angle because the smaller the inclination angle the wider its space on the ground
therefore from table 4.2 the inclination angle is chosen δ=75o
For better material handling we chose the High incline or Bucket cleat. The dimensions of the
cleat can be determined from the table below.

Table4. 3 standard dimension of cleats[4].

Form Type Measurements Weight

Designation (mm) (Kg/m)
H B D
Straight T 15/20 15 20 0.18
T-Cleat T 20/40 20 40 0.27
T 40/70 40 70 0.70
T 60/80 60 80 1.04
Sloping TS 50/65 50 65 7 0.88
T-Cleat TS 70/80 70 80 60 0.82
Bucket Cleat B 80 80 80 1.90
B 110 110 80 2.90

 Since the dimension of the bucket cleat selected as Height (H) =80mm, Width( B)=80mm
and weight of cleat (mʹc ) = 1.90 kg/m

33
INTERNSHIP REPORT

4.6.4 Belt width

The type of the materials determines the minimum belt width. Wherever possible a standard belt
width should be selected.

Table4. 4 Standard belt widths[4].

The cork storage which is at the top of the bottle capping machine have a diameter of 450 mm
and this bottle capping machine works at a lower speed if the feeding rate due to larger belt
width is increased, the storage will be filled and corks will dropped down. Therefore in order to
avoid filling of the storage we have to take the minimum belt width available that is less than
450mm from the standard belt width table. The chosen belt width is B=300mm.

4.6.5 Belt speed

The belt or Conveying Speed ʋ (m/s) must be appropriate for the material composition and
operation conditions. The recommended belt speed can be selected from the table below.

Table4. 5 Recommended belt speed based on duty type[4].

Duty v (m/s)

Unit Loads, Assembly Lines ≤ 1.68

Mobile Conveyors 0.52 - 1.68
Very dusty loads such as Flour, Cement ≤ 1.31
Ash and Refuse ≤ 1.68

 Our duty is unit load so the belt speed can be less than or equal to 1.68 m/s selecting the
standard belt speed which is less than 1.68 from the table below.
Table4. 6 Standard values of belt speed [4].

Speeds V (m/s)
0.42 - 0.52 - 0.66 - 0.84 - 1.05 - 1.31 - 1.68
2.09 - 2.62 - 3.35 - 4.19 - 5.20 - 6.60 - 8.40

 The capping machine works at a lower speed so we have to select the minimum speed
possible. Therefore the value of belt speed ʋ=0.42m/s.

4.6.6 Belt length

The purpose is to design belt conveyor which have elevation distance of 2.6m from this we can
calculate the belt length.

34
INTERNSHIP REPORT

(m) (1)
where H~ Elevation distance=2.6m
δ ~ Angle of inclination (o)

L=5.4m

4.7 Conveying length

Conveying length
(m)---------------------------(2)
L=2.7m

4.8 Conveying capacity

For the calculation of the conveying capacity for unit loads the following formula applies [4].

Quantity conveyed
(p/h)---------------------------(3)
Where ʋ = Belt Speed (m/s)
lst = Piece Length in direction of travel (m) = piece length of a single cork =32mm
ɑst = Spacing of pieces (m) 2mm
p/h =(piece per hour)

=24,000 p/h

Load stream (capacity)

(t/h)---------------------------(4)
Where mst = Piece Weight(kg) = piece weight of single cork =3g

Qm=0.133t/h

Weight of load
(kg/m)---------------------------(5)

=0.088kg/m

4.9 Power requirements

With the aid of the following formula, power requirements can be roughly assessed. The
accuracy is sufficient for normal installations with simple straight-forward running conditions.
Power at Drive Pulley PT=P1+P2+P3 (kw)----------------------------(6)
35
INTERNSHIP REPORT

Power for empty Conveyor and Load

(w)----------------------------(7)

Where CB= width factor

CL = Length factor
Kf = service factor

Table 4. 7 Width factor[4].

Duty Belt Width B (mm)

300 400 500 650 800 1000 1200 1400 1600 1800 2000 2200
Light 31 54 67 81 108 233 194 227 29

Medium 36 59 76 92 126 187 277 320 468 54 691 745

Heavy 65 86 103 144 241 360 414 644 727 957 1033

From the above table a value of 31 for CB is obtained.

Table 4. 8 Length factor[4].

L (m) 3 4 5 6 8 10 12.5 16 20

CL 667 625 555 526 454 417 370 323 286

L (m) 25 32 40 50 63 80 90 100 150

CL 250 222 192 167 145 119 109 103 77

The conveying length is 2.7≈3m, By using interpolation we can find length factor CL
× (x-x1) (kw)---------------------------(8)

Where x1=3, x2=4, x=2.7≈3

y1=667, y2=625, y=659.02
Therefor the value of length factor CL for a conveying length of 2.7 is 654.5

36
INTERNSHIP REPORT

Table 4. 9 working condition factor Kf [4].

Working Conditions Kf

Favorable, good alignment, slow speed 1.17

Normal (Standard Conditions) 1

The working condition will be favorable, good alignment and slow speed so the value of the
working condition factor Kf is 1.17
Therefore, the Power for empty Conveyor and Load (P1 )
=1.7kw----------------------------(9)

The Power for lift (or fall)

(kw)---------------------------(10)
Where H = conveying height =3m
P3 Is the sum of additional power for trippers, skirt board friction, ploughs
So P3= 0

Total power at the drive PT=P1+P2+P3

PT=1.8kw
Required motor power (w)---------------------------(11)

Where η=degree of efficiency

The degree of efficiency is obtained from the above table with respect to type of drive unit.
Table 4. 10 Degree of efficiency value[4].
Types of Drive η

V-Rope drive 0.95

Pulley motor 0.96

Normal coupled drive 0.94

Hydraulic motor 0.86

Type of drive Pulley motor can be selected and the respective efficiency value is 0.96
The required motor power calculated as
Pm=1.875kW
Installed Motor or Nominal motor power PN is selected from standard list.

37
INTERNSHIP REPORT

Table 4. 11 Standard electric motor power[4].

1.5 2.2 3.0 4.0 5.5 7.5 11 15 18.5 22 30 37
45 55 75 90 110 132 160 200 250 315 400 500
630

1.5kw can be selected because it is the least motor power and it can cover the power
consumption since the application is small and running at low speed.

4.10 Idler dimensions

A flat type troughing of idler is selected for the carrying and return because the belt width of the
conveyor is small and less space[4].

Figure 4. 5 : Types of troughing idler

I. Idler diameter
The minimum idler diameter can be calculated as

Di = (mm)---------------------------(12)
Where Di = idler diameter
nR = idler revolution (rpm )
But, the idler rotation should not be greater than approximately 650 rpm
So calculating the minimum idler diameter
Di=12.35mm
Idler diameter that is higher than 12.35mm is selected from the table below
Table 4. 12 standard diameter of idlers[4].

Carrying Idlers 51 63.5 88.9 108 133 159 193.7 209

Impact Idlers _ _ _ 156 180 215 250 290

Support Discs 120 138 150 156 180 215 250 290

So idler diameter Di=51mm is selected for the carrying and return idler roller.

38
INTERNSHIP REPORT

II.Idler length
The standard idler length is obtained by the belt width from the table below
Table 4. 13 standard idler length[4].

For flat troughing type we have select a minimum belt width 300mm of the idler length
Li=380mm because of spacing of the room.
III.Mass of idlers
The mass of idlers is also obtained from a standard table

Table 4. 14 mass of set of idlers[4].

Belt width B Idler Rollers Idler Roller Diameter (mm)

(mm)
51 63.5 88.9 108 133 159 193.7 219.1
Flat 1.6 2.2 3.2 _ _ _ _ _

2 part 2.3 3.4 4.1 _ _ _ _

Flat 2 2.7 2.9 5.6 _ _ _ _

2 part 2.6 3.7 4.7 6.6 _ _ _ _

3 part 2.9 4.4 5.4 7.3 _ _ _ _

For flat type idler with diameter of 51 mm the mass of carrying and return idler is obtained as
Mass of one set of carrying idler roller ( mRO)=1.6 kg
Mass of one set of return idler roller (mRU )=1.6 kg
The return side is also flat so the mass of the carrying and return idlers are equal.

39
INTERNSHIP REPORT

IV.Idler spacing
Values for Pitch of carrying idlers
lO=0.5-1(m) For Small installation or high impact
lO =App. 1.2m For Normal installation
lO =1.4-4(m)For High tension installation

Selecting lO=0.5m to prevent belt sag conditions

Pitch of return idlers can be calculated as
lu=2× lO=2×0.5m=1m----------------------------(13)
Number of carrying idlers No= 5 idlers--------------------------(14)

Number of retun idlers Nu= 2 idlers--------------------------(14)

Number of revolution nR= ----------------------------(15)

4.11 Belt breaking strength

From the power calculations, the belt type can be closely determined. The actual nominal belt
weight can be used in the more precise calculation of the belt . This formula is to enable
calculation of belt breaking strength and applies to installations with a single pulley head
drive[8].
Breaking strength
( )----------------------------(16)
Where CR=Friction value factor
Cv=Breaking strength loss at joint factor

Table 4. 15 Friction value factor[4].

Drive Pulley Surface Friction Belt Width B (mm)
Value
300 400 500 650 800 1000 1200 1400 1600 1800 2000
2200

bare,wet,rubber 0.15 98 74 59 45 37 30 25 21 18 16 15 14

rubber 0.25 69 52 41 32 26 21 17 15 13 12 10 9

lagged,wet,dirty 0.30 62 46 37 28 23 18 15 13 12 10 9 8

bare,dry,lagged,wet 0.35 57 43 34 26 21 17 14 12 11 9 8 8

It will be assumed that the conveyor will operate in a bare dry situation so the value of CR is then
57 also the value of friction value (μ) is 0.35.

40
INTERNSHIP REPORT

Table 4. 16 Breaking Strength Loss at Joint Factor Cv[4].

DUNLOP Belt Type Splice Type Ply Rating Factor Cv

DUNLOFLEX 2 ply overlap 100% 1.00

1 ply overlap 50% 0.50

FERROFLEX Zig-Zag Splice Joint 0.90

DUNLOPLAST Finger Splice Joint 0.90

The belt material is DUNLOPLAST so the factor value Cv is 0.9

Now calculating the breaking strength
=2.7N/mm
The nominal Breaking KN Strength is obtained by rounding up the calculated breaking strength
value (k) to the next highest belt type
Table 4. 17 Standard property of belt types[4].
Belt type Cover thickness(mm) Cover thickness(mm) Weight(kg/m2 )
DLP 250 PVC BLS 2+1 4 3.0
DLP 315 PVC BLS 3+1.5 6 7.5
DLP 400 PVC BLS 4+2 8 10.0
DLP 630 PVC BLS 5+3 11 13.75
From this table the rounded up value of K N will be 250 , the first on the table. So the specific belt
type of the application is DLP 250 PVC BLS. the value of the belt weight is also on the table
mG=3kg/m2

4.12 Determination of forces

I. Peripheral force (FU)
It is the steady state running peripheral force. For installations with one loading point, as a rule
the following summation applies.
---------------------(17)
Where C=Length factor
f=Artificial friction factor
l=Conveying length =2.7m
g=acceleration due to gravity = 9.81m/s2
m'R=Mass of rotating carrying and return idlers(kg/m)
m'G=Mass of the belt(kg/m)
m'L=Mass of load (kg/m) = 0.078 kg/m
δ=angle of inclination=750
H= conveying height-2.6m
The influence of Factor C will decrease as the conveyor length increases.

41
INTERNSHIP REPORT

Table 4. 18 Length factor C(DUNLOP ENERKA)[4].

The value of C obtained from the graph for a conveying length 2.7 of It is approximately about 9
Artificial friction factor(f)
The friction factor f is used for the calculations of the resistances to motion. It provides an
estimate of the resistance to rotation of the idlers, the belt resistance (flexing and idler
impressions) and material impression resistance. Values for the factor f are dependent upon the
working conditions and construction characteristics of the installation.
Table 4. 19 Artificial friction factor[4].

Favorable working conditions, easily rotating idlers, material with low 0.017
internal friction and good tracking, good maintenance
Normal installation, normal material 0.020

Unfavorable conditions, low temperature, material with high internal 0.012 - 0.016
friction, subject to overload, poor maintenance

Assuming the application with normal installation and normal material so the respective value of
(f) is 0.020

42
INTERNSHIP REPORT

Mass of rotating carrying and idler rollers

The mass of rotating parts m'R (kg/m) is calculated from the weight of the rotating idler rollers on
the carrying and return runs.
m'R= (kg/m)-----------------------------(18)
Where mRo=Mass of one set of carrying idler rollers=1.6kg
mRu =Mass of one set of return idler rollers=1.6kg
lo =Pitch of carrying idlers=0.5m
lu =Pitch of return idlers=1m

Hence m'R=4.8kg/m
Mass of the belt
Total mass of the belt = mass of belt + mass of cleats
m'G=(mG×B)+m'c (kg/m)----------------------------(19)
Where mG=belt weight ( = from table for DUNLOPLAST belt =5kg/m2)
B=Belt width=0.3m
m'c=mass of cleats(from table for bucket cleat type =1.9kg/m)
Hence m'G=(5×0.3)+1.9
m'G=3.4kg/m
Now substituting all the parameters to find the force
FU=C×f×l×g×[m'R+(2× m'G+ m'L) × cosδ]+H×g× m'L
=9×0.02×2.7×9.81[4.8(2×3.4+0.078)×cos(75)]+2.6×9.81×0.078
FU=42.72N
II. Peripheral force FA at start-up
At the breakaway and start-up of a loaded installation, the inertial resistances to motion of the
masses to be moved, have to be overcome. The belt stresses during acceleration kept to a
minimum. The initial pulley peripheral force at start-up must not exceed a certain value.
Recommendations The maximum peripheral force F A should not be greater than approx. (1.3
to1.5 )×Fu, the steady state running peripheral force.

So peripheral force at start up FA=(1.5)×Fu..........................................................(20)

FA=64.09N
Acceleration
ɑ= (m/s2)...........................................................(21)
Where
mˈRed=4.32 m/s2
Hence ɑ=0.678m/s2

4.13 Belt tension

First the individual resistances are calculated as follows:
Main resistance (FH)
…………………………………….(22)

Secondary resistance(FN).............................................................................................(23)

43
INTERNSHIP REPORT

Friction resistance
carrying side (Fo)
……………………………………(24)

Return side (Fu)

…………………………………….(25)

Slope resistance
carrying side (Fsto)
…………………………………….(26)

Return side (Fstu)

…………………………………….(27)

Inertial resistance
carrying side (Fɑo
…………………………………….(28)

Return side (Fɑu)

…………………………………….(29)

Determination of the point tensions of single pulley head drive (T1to T4 and TA1 to TA4 with the
help of individual resistances (for peripheral force FU ≥ 0, positive).

Figure4. 6 single pulley head drive stress points

I. Belt Tension at steady state

…………………………………….(30)

44
INTERNSHIP REPORT

where C2 =drive factor ( )..........................................................(31)

μ =Friction coefficient=0.35 ɑ=angle of wrap

The angle of wrap of the conveyer is 1800 because no snub pulley is used in the application

Figure4. 7 angle of wrap

Hence substituting the angle of wrap value in the drive factor equation C2=0.5
The value of drive factor can also be obtained from the table
Table 4. 20 drive factor value[4].
Angle of wrap ɑ Friction coefficient μ
160 3.10 1.92 1.34 0.99 0.76 0.60 0.49 0.40
170 2.90 1.78 1.24 0.91 0.70 0.55 0.44 0.36
180 2.71 1.66 1.14 0.84 0.64 0.50 0.40 0.32
0
With an angle 180 of wrap and friction coefficient 0.35 the value of drive factor C2 is 0.5
Now we can calculate the tension on different points
T2
T2=21.36N
T3................................................................................................(32)
T3=22.62N(compression)
T4............................................................................. (33)
T4=22.62N(compression)
T1.......................................................................................................(34)
T1=120N
II. Belt Tension at non steady state (working)

Where C2A=drive factor slack side at start up

C..........................................................................(35)
2
=μ×0.05=0.4
C2A=0.312
TA2
…………………………………….(36)
TA2=20N
TA3............................................................................................................(37)
TA3=49.95N(compression)
TA4............................................................................... (38)
TA4=49.95N(compression)

45
INTERNSHIP REPORT

TA1..........................................................................................................(39)
TA1=113N

Min belt tension

…………………………………….(40)
Tmin=213.3N
Startup time = …………………………………….(41)
tA=0.62s
Startup distance S = …………………………………….(43)
A

SA=0.13m

4.14 Pulley diameters

Drum Style Pulleys - the selected pulley is drum style pulley for allowing for continuous full
contact with the conveyor belt. The contact surface is constructed from a cylindrical shell, tube
or pipe.(Selection of drum pulley according to DUNLOP ENERKA ). The Pulley minimum
drive diameter can be calculated as[4].
where FU, idler force, k, length factor force=98N
bo, belt width=300mm
, angle of contact=1800
dA=130.7mm

Table 4. 21 standard pulley diameter and weight(DUNLOP ENERKA)[4].

Belt type Cover Cover Weight( ) Pulley minimum
thickness(mm) diameter(mm)
thickness(mm)
A B C
DLP 250 PVC BLS 2+1 4 5.0 160 125 100
DLP 315 PVC BLS 3+1.5 6 7.5 250 200 160
DLP 400 PVC BLS 4+2 8 10.0 315 250 200
DLP 630 PVC BLS 5+3 11 13.75 500 400 315

Table 4. 22 Group and application of pulley[4].

Group Application
A Pulleys in the areas of high belt stress Drive Pulleys
B Pulleys in areas of low belt stress Tail Pulleys
C Pulleys with an angle of wrap ≤ 90°, Snub Pulleys
The selected material was DLP 250 PVC BLS so the corresponding pulley diameter is
Diameter of drive pulley (DP,D)=160mm
Diameter of tail pulley (DP,T)=125mm
The angle of wrap is 1800 so we don’t need a snub or deflection pulley.

Number of revolution (drive pulley) nR= ----------------------------(44)

46
INTERNSHIP REPORT

nR=50.15rpm

Number of revolution (drive pulley) nR= ----------------------------(45)

nR=64.2rpm

4.15 Result
Part Value

Installation Conveying height 2.6m

Conveying length 2.7m
Angle of inclination 75
Type of drive Single head pulley drive
Type of motor AC induction 5HP
Belt characteristics Belt material PVC
Belt type DLP 250 PVC BLS
Carrying side cover thickness 2mm
Pulley side cover thickness 2mm
Return side cover thickness 2mm
Belt width 300 mm
Belt speed 0.42m/s
Belt weight 3kg
Cleat Cleat type Bucket cleat
Cleat width 80mm
Cleat height 80mm
Cleat weight 1.90 kg/m
Conveying capacity Quantity conveyed 24,000P/h
Load stream (Capacity) 0.133t/h
Weight of load 0.088kg/m
Power Power for empty conveyor and 1.704kw
load over the horizontal
distance
Power for lift (or fall) 0.96kw
Additional power 0kw
Total power at the drive 1.8kw
Required motor power 18.75w
Installed motor power 1.5kw
Idler Diameter 51mm
Length 380mm
Mass of One set of carrying 1.6k/g
idler
Mass of One set of return idler 1.6k/g
Pitch of carrying idler 0.5m
Number of carrying idler 5

47
INTERNSHIP REPORT

Number of return idler 2

Number of revolution 157rpm
Force Steady state running 42.72N
Peripheral force
Peripheral force at start up 64.09N
Individual resistances Main resistance 6.2N
Secondary resistance 49.5N
Friction Carrying side 4.5N
resistance Return side 2.65N
Slope Carrying side 88.7N
resistance Return side 86.7N
Inertial Carrying side 20.7N
resistance
Return side 14.1N
Belt tension At steady T1 21.36N
state start up T2 -22.62N
T3 -22.62N
T4 120N
At non TA1 20N
steady state TA2 -49.95N
Working TA3 -4.95N
TA4 113N
Pulley Head pulley diameter 160mm
Tail pulley diameter 125 mm
Number of Head pulley 50.15rpm
revolution Tail pulley 64.2rpm

4.16 Cost Estimation

1.Estimated cost for Belt
Belt material=PVC
Density=14001400kg/m3
Cost per kg=1.5$(APPENDICE A)
W=0.3m t=0.004m l=5.4m
Volume V=l×w×t
V=0.0065m3
Mass m=v×ρ
M=9.1kg
Cost C=m×Cost per kg
C=9.1×1.5=13.65$
2. Estimated cost for Cleats
Cleat material=PVC
Density=14001400kg/m3
Cost per kg=1.5$(APPENDICE A)
A=1225.4mm2=0.0012254 w=0.08m
Volume V=A×w
V= 0.000098m3

48
INTERNSHIP REPORT

Mass m=v×ρ
M=0.1372kg
Cost C=m×Cost per kg
C=0.1372×1.5=0.2$
3. Estimated cost for Frame
material=high strength 4330.
Density=7800 kg/m3 (APPENDICE A)
Cost per kg=1.34$
Total area of the frame=3.43m2 t=0.002m
V=A×t
V=0.00686m3
M= v×ρ
M=53.5kg
C=71.7$
4.Estimated cost for hopper
material=high strength 4330.
Density=7800 kg/m3 (APPENDICE A)
Cost per kg=1.34$
A=0.72m2 t=0.002m
V=0.00144 m3
M=11.2kg
C=15$
5.Estimated cost for idlers
Material cast iron
Density=7800 kg/m3[APPENDICE B]
Cost per kg=1.63$
Volume V=π/4(D2−d2)×L=0.00022342m3
M= v×ρ=1.75kg
C=2.85$
6.Estimated cost for Pulley
The pulley is made from cast iron
Density=7800kg/m3
Cost per kg=1.63$
I. Head pulley
Volume V=π/4(D2−d2)×L=0.000822523m3
M=6.4kg
C=10.5$
II. Tail pulley
Volume V=π/4(D2−d2)×L=0.000636792m3
M=4.96kg
C=8$
7. Estimated cost for Stand (Legs)
The stand is made up from steel, high strength 4330.
Density=7800kg/m3(Appendix A)
Cost per kg=1.34kg
V=0.002923m3

49
INTERNSHIP REPORT

M=22.8kg
C=30.5$
COST RESULT
Part Name Material type Quantity Estimated cost Total cost
Belt PVC 1 13.65$ 13.65$
Cleat PVC 16 0.2$ 3.2$
Frame Steel, high 1 71.7$ 71.7$
Strength
4330
Hooper Steel high 1 15$ 15$
strength
4330
Idler Carrying Cast iron 6 2.85$ 17.1$
return 3 2.85$ 8.55$
pulley Head Cast iron 1 10.5$ 10.5$
Tail 1 8$ 8$
Stand Steel high 1 30.5$ 30.5$
strength
4330
Motor 5 hp 1 50$-500$ 300$
Total Estimated cost 478.2$

4.17 DISCUSSION
The results we finally found almost have shown us some progresses and successes in our design
project. Because, as we can see from the overall design analysis, there are components of belt
conveyor system which are designed in appropriate way of dimensional analysis and load. All of
the components of belt conveyor system are designed by using appropriate formulas for each and
suitable material to avoid failures. At the end of the result we have obtained following this
analytical approach but also the personal ideas.

4.18 CONCLUSION
 The parts are selected according to an international standard of DUNLOP ENERKA.
 The overall tension, power and force results are safe for the working condition.
 Belt speed belt width and conveying length are obtained depending on the
working condition of the company.

4.19 RECOMMENDATION
 Allowance must be taken during manufacturing in order to fulfill the desired task
 The company should follow installation of the belt conveyor with the right way
 The company should follow preventive maintenance schedule with the right way and
right persons to decrease a frequent break down of equipment and loss of production.

50
INTERNSHIP REPORT

CHAPTER FIVE

5.GENERAL CONCLUSION AND RECOMMENDATION

5.1 General conclusion

Generally we concluded that the internship program helps to improve and develop our
Leadership skill, Team working skill, Work ethics related issues, Industrial problem-solving
capability and Practical and theoretical knowledge. Specifically we have gained practical skills
such as how to operate filler and capping machine.

5.2 General recommendation

 Take care for used working equipment, since the company is profitable they do not
care about little thing that can cost them high amount of money.
 The company must assigns the operator with their qualification level.
 Bahir Dar university must assign MOHA soft drink Company to help internship students
properly.
 Enough operator instructions and manuals should be present in the worker /operators for
each section to perform appropriate activities.
 The university industry linkage should be focus on technical work for the students
during the internship rather than visualization, Therefore the university should have
a good linkage with the industry.

51
INTERNSHIP REPORT

References
[1] https://mohasoftdrinksindustry.com.
[2] Manual of MOHA Soft drinks.
[3] McGuire, P. M. (2021, 12 11). Belt Conveyor. Retrieved 12 11, 2021, from
Wikipedia: https://en.wikipedia.org/wiki/Conveyor_belt
[4] Belt conveyor design Dunlop textbook(2009, DUNLOP ENERKA).
[5] Aniket. A. Jagtap Et Al. ―Design Of Material Handling Equipment: Belt Conveyor System
For Crushed Biomass Wood Using V Merge Conveying System‖ Ijmerr Vol. 4, No. 2, April 2015
[6] A. W. Roberts And A. Harrison ―Recent Research Developments In Belt Conveyor
Technology‖ Sunderesh S. Heragu And Banuekren ―Materials Handling System Design‖
[7] Konakalla Naga Sri Ananth Et Al [8] ―Design And Selecting The Proper Conveyor-Belt‖
Ijaet Vol. Iv Issue Ii April-June, 2013
[8] Khurmi, R. S., & Gupta, J. K. (2005). A Textbook of machine design. Eurasia publishing
house Ltd

52
INTERNSHIP REPORT

APPENDICE A

53
INTERNSHIP REPORT

54
INTERNSHIP REPORT

APPENDICE B

55
 3D Models and Drawings (mm)

2700

300

DR BY ISRAEL EYOB BAHIR DAR UNIVERSITY

BAHIRDAR INSTITUTE OF TECHNOLOGY
CHKD BY FACULITY OF MECHANICAL AND
INDUSTRIAL ENGINEERING
DATE
ID 1103545
TITLE:-Belt
SECTION

56
 51

380

400

DR BY EZEDIN & HUD BAHIR DAR UNIVERSITY

CHKD BY BAHIRDAR INSTITUTE OF TECHNOLOGY
FACULITY OF MECHANICAL AND
DATE INDUSTRIAL ENGINEERING

ID 1011979&1011823
TITLE:-Idler
SECTION

57
 460

420

380

3000

DR BY ISRAEL EYOB BAHIR DAR UNIVERSITY

CHKD BY BAHIRDAR INSTITUTE OF TECHNOLOGY
FACULITY OF MECHANICAL AND
DATE INDUSTRIAL ENGINEERING

ID 1103545
TITLE:-Frame
SECTION A

58
 510

300

40

500

DR BY ISRAEL EYOB BAHIR DAR UNIVERSITY

CHKD BY BAHIRDAR INSTITUTE OF TECHNOLOGY
FACULITY OF MECHANICAL AND
DATE INDUSTRIAL ENGINEERING

ID 1103545
TITLE:- Hooper
SECTION A

59
 300

DR BY ISRAEL EYOB BAHIR DAR UNIVERSITY

CHKD BY BAHIRDAR INSTITUTE OF TECHNOLOGY
FACULITY OF MECHANICAL AND
DATE INDUSTRIAL ENGINEERING

ID 1103545
TITLE:- Cleat
SECTION A

60
 330

160

DR BY ISRAEL EYOB BAHIR DAR UNIVERSITY

CHKD BY BAHIRDAR INSTITUTE OF TECHNOLOGY
FACULITY OF MECHANICAL AND
DATE INDUSTRIAL ENGINEERING

ID 11O3545
TITLE:- Drum pulley
SECTION A

61
 2800 3200

460

DR BY ISRAEL EYOB BAHIR DAR UNIVERSITY

CHKD BY BAHIRDAR INSTITUTE OF TECHNOLOGY
FACULITY OF MECHANICAL AND
DATE INDUSTRIAL ENGINEERING

ID 1103545
TITLE:- Assembly
SECTION A

62
 DR BY ISRAEL EYOB BAHIR DAR UNIVERSITY
CHKD BY BAHIRDAR INSTITUTE OF TECHNOLOGY
FACULITY OF MECHANICAL AND
DATE INDUSTRIAL ENGINEERING

ID 1103545
TITLE:- 3D Assembly
SECTION

63