Company Name: Document No.

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 1 of 19

Bottling Overhaul Maintenance Plan
I. FILLER MACHINE

From: Oct.16/23 to Oct.21/23

No. Description Date/Time Assigned person Remark

A Cleaning
1  Removing and cleaning of broken 16-10-23 4hr Be Caution : sensors

bottles sludge from the filler and

Assigned Operators
capping head machine.
 Clean the machine area thoroughly.
B Disassembly work Be Caution : sensors
1  Disassemble of all 50 filling valve 1 hrs
from the machine. 30 min Assigned Operators
 Dismantle all the filling valve into 3hrs Assigned Mechanics
parts 1 hr Assigned Electricians
 Dismount all infeed and out feed star, worm 20min
screw both filler capping m/c. 40 min

 High performance synthetic oil for gears and bearings

 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
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NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

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Bottling Overhaul Maintenance Plan
 Disassemble the capping head and
reveal the revolving shaft cover
 Dismantle pneumatic filter
 Disassemble cap sorter and clean
C Maintenance
Cleaning
 the machine body thoroughly
1 including the cap sorter and its Assigned Operators Be caution sensors
pneumatic system
 vacuum pump and piping system
 clean all the filling valve parts
2 Maintain Assigned Operators
 Check wear, damages on all the Assigned Mechanics
filling valve parts and lubricate Assigned Electricians Check food grade
lubricate
o check and maintain the spring, Remove the protective

 High performance synthetic oil for gears and bearings

 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
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Revision: 0 Document Title: Page 3 of 19

Bottling Overhaul Maintenance Plan
centering guide and seal status sleeve on the worm

 lubricate lifting cylinders screw cardan

 cardan worm screw and lubricate

 Capping Heads Lubricate gears and
cam of the capper heads.
 Grease and central lubrication for all Assigned Operators  Check that food
the necessary parts Assigned Mechanics grade oil and
 Check the level of oil on the side of the Assigned Electricians grease
lubricant pan:  synthetic oil for
 Centralized lubrication: gears and bearings
o Oil level, Connections, piping
 check and maintain vacuum pump
Toothed wheel under machine table
 Check the status of the joints for
wear and lubrication any damage. If
necessary lubricate or replace.
 High performance synthetic oil for gears and bearings
 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 4 of 19

Bottling Overhaul Maintenance Plan
 After completing the lubrication
process, check that all points are
sufficiently lubricated.
 Check clean, lubricate and maintain
the lifting cylinder
 Check the level of the gear motor oil
and if needed top off.
 Product regulation valve (modulating
valve)
 Check machine safety system
 Check all electrical system
 Check and clean all sensors and
Electrical board

Pneumatic Parts: Assigned Operators

3  Air treatment units: Check for Assigned Mechanics
condensate and drain if needed Assigned Electricians Bleed off

 High performance synthetic oil for gears and bearings

 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 5 of 19

Bottling Overhaul Maintenance Plan
 Connections, piping, valves, pressure/media before

cylinders, filters, pressure gauges performing works

 Check seal, fastening and general

status. If necessary, replace the parts
involved

 High performance synthetic oil for gears and bearings

 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

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Revision: 0 Document Title: Page 6 of 19

Bottling Overhaul Maintenance Plan
5 Check and Tighten Assigned Operators
 if any loosen bolt for central Assigned Mechanics
distribution star and others Assigned Electricians
 loosen union both product supply
and vacuum pipelines (Valve actuator/
pipe connection taps)
 Check operation and for any product
leakage. If necessary repair or
replace.
 Transmission belts and chains
(Check for correct tension, surface
wear, or any damages.)
C. Assemble
Assemble all part and subpart Assigned Operators
 Make sure infeed screw is in phase Assigned Mechanics
with feed and discharge star Assigned Electricians

 High performance synthetic oil for gears and bearings

 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

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Bottling Overhaul Maintenance Plan

D. Testing
Check and test run Assigned Operators
Assigned Mechanics
Assigned Electricians

II. WASHING MACHINE

From: Oct.16/23 to Oct.21/23
Switch off main power and push emergency button

No Description Date Time Assigned Person Remark

A Cleaning Production
1 Machine and around the machine Production Be caution of
2 Clean all the part thoroughly Production sensors
 clean both interior (detergent bath )and
external part
 High performance synthetic oil for gears and bearings
 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

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Revision: 0 Document Title: Page 8 of 19

Bottling Overhaul Maintenance Plan
 clean all filtering system
B Maintenance work
1 Check and Maintain all Electrical systems
 Check and clean electrical cable and board
 PLC System Be cautions
 Dismantling all sensors, clean and checking
sensors
the functionality
Assigned Operators
 All pressure sensors and soda bath level
sensor and others Assigned Electricians
 Check and maintain all safety and interlock
system
 Replace damaged bottle loading and
unloading window switches from operator
control side.
2 Detergent bath
Assigned Operators
- level Maintain/replace soda level sensor if
Assigned Electricians
necessary
3 1st soda bath Pump Assigned Operators

 High performance synthetic oil for gears and bearings

 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 9 of 19

Bottling Overhaul Maintenance Plan
- dismantle, clean discharge pressure sensor Assigned Mechanics
maintain/replace
4 1st rinse bath Pump
- dismantle, clean discharge pressure sensor
maintain/replace
5 2nd rinse bath Pump Assigned Operators
- dismantle, clean discharge pressure sensor Assigned Mechanics
maintain/replace Assigned Electricians
- Bottle loading mechanism dismantle, sensor
6 cleaning/maintenance/replace if needed
- Disassemble, clean and maintain both
circulation pumps.
- Disassemble bottle carrier sets and case
7 maintaining for cleaning/maintaining the
internal chains, sprocket, lubricate, and
replace damaged gaskets if they exist

 High performance synthetic oil for gears and bearings

 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

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Bottling Overhaul Maintenance Plan
8 - Descaling internal components of the soda
bath, first and second soda bath, rinsing bath
and nozzles
9 Steam line
 Steam pressure sensor and valve
check/maintain or replace if needed
10 Rinsing system: Assigned Operators
- Final rinsing system cleaning/ Assigned Mechanics
maintenance/replace Assigned Electricians
- Fix sprocket and chain adjustments
12 Air treatment unit maintenance
14 Dismantle label remover mechanism, maintain/
replace damaged components, clean
Bottle Spray nozzle - disassemble and descale
with chemical.
15 All drainage lines disassemble, clean, maintain

 High performance synthetic oil for gears and bearings

 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 11 of 19

Bottling Overhaul Maintenance Plan
16 Check and replace all damaged bottle basket
17 Replace loading and unloading cam UC Bearing
Replace all gearbox oils
C Assembling
1 Assemble back all components, reconditioning Assigned Operators
worn-out parts/ components Assigned Mechanics
Assigned Electricians
D Lubricating
1 Lubrication All components of the machine Assigned Operators Food grade
E Cleaning
Clean machine and around the machine Assigned Operators

F Testing
Check and test run Assigned Operators Check the spray
nozzle in in line
Assigned Mechanics
with the bottle
 High performance synthetic oil for gears and bearings
 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 12 of 19

Bottling Overhaul Maintenance Plan
Assigned Electricians

III. LABELLING MACHINE

From: Oct.16/23 to Oct.21/23
Before start up please turn of the power and depressurize the unit before carrying out any work on the pneumatic
system.
No Description Date Time Assigned Technician Remarks
A Cleaning 2 hr.

 High performance synthetic oil for gears and bearings

 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 13 of 19

Bottling Overhaul Maintenance Plan
0 Machine and around the machine Assigned Operators

B Disassembly work 16 hrs.

1 Detaching accessories label magazine, Assigned Operators -
glue pump etc.
2 Disassembling covers and safety guards -
3 Dismounting gripper drum, brushes, Assigned Operators -
glue roller, infeed worm Assigned Mechanics
4 Disassembling bottle distribution Assigned Electricians -
system, inlet and outlet star, infeed
screw, central distributer or counter
star
5 Dismantling upper chariot labeling & -
sensor group
6 Disassembling label hooks drum shaft -
& scroll unit

 High performance synthetic oil for gears and bearings

 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 14 of 19

Bottling Overhaul Maintenance Plan
7 Dias assembling plates
- Disassembling plate rest assembly
8 Disassembling central head
- Dismantling head jack
- Dismantling head cam plate
9 Disassembling lower crank case
10 Disassembling cardian system
11 Dismantling all driving gears
C Maintaining 10 – 16
hrs.
12 Cleaning work, Maintenance, Assigned Operators
reconditioning Assigned Mechanics
The set pressure is normally at 6 bar Assigned Electricians
Replace the brushes when the bristles
are bent or have become too short,
damaged

 High performance synthetic oil for gears and bearings

 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

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Revision: 0 Document Title: Page 15 of 19

Bottling Overhaul Maintenance Plan
Check and replace centering bells
Replace damaged bottle plate
Fix all the problem regarding with glue
roller
 Check and fix any wear part
 Retighten screw joints of the
machine components.
Clean and maintain all pneumatic
system
 Check air hoses and replace if
damaged
 Clean filter regulator; if required,
change filter
Check and maintain all electrical Assigned Electricians
system, safety systems
 De dust (clean) sensors and
electrical boards (Clean switch
cabinet housing interior and
components with vacuum cleaner
 High performance synthetic oil for gears and bearings
 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

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Revision: 0 Document Title: Page 16 of 19

Bottling Overhaul Maintenance Plan
(never blow with blast air!))
 Check all sensors and fix on
position if any loosen
 Check safety and interlock system
functioning
 Check insulation and earthling
D Assembly work 16 hrs.
13 Assembling parts and sub components Assigned Operators &
Mechanics

E Lubrication 1 hrs.
Check the central lubrication system Assigned Operators &
(oil level and pump) Mechanics
14 Greasing and filling oil sumps
- Replace gear oil
Lubricate all necessary points with
central lubrication

 High performance synthetic oil for gears and bearings

 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

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Revision: 0 Document Title: Page 17 of 19

Bottling Overhaul Maintenance Plan
 Red – lubricate daily
 Yellow – apply weekly
Lubricate manually (cannot be reached
through the central lubrication unit)

 Top part with vertical adjustment

(cover)
 Bottle table with bearing
 Worm bearing
Slip ring maintenance – every 1500hr
F Testing 2 hrs.
15 Test run with and without bottles Assigned Operators,
Mechanics &
Electricians

 High performance synthetic oil for gears and bearings

 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
 Company Name: Document No.:

NATIONAL ALCOHOL & LIQUOR FACTORY OF/NALF/016

Revision: 0 Document Title: Page 18 of 19

Bottling Overhaul Maintenance Plan

IV. CONVEOR
From: Oct.16/23 to Oct.21/23
No Description Date/Time Assigned person Remark
A Cleaning
1 Clean all the conveyor and cable tray 27/06/22 and Production
28/06/22
2 Clean electrical board 28/06/22 Assigned Electricians

B Lubrication
 Nozzles (conveyor lubrication, spray, Assigned Operators &
wash)
Mechanics
 Check nozzles visually for impurities if
necessary: Clean or replace. The
 High performance synthetic oil for gears and bearings
 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.
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Bottling Overhaul Maintenance Plan
nozzles must not be clogged or
damaged.
1 Lubricate the conveyor 29/06/22 Assigned Mechanic
C Maintain
1 Check all conveyor motors and invertor Assigned Electricians
2 Check the positions of conveyor line
sensors
3 Check and replace conveyor idler and
sprocket gear
Check and replace electrical switches
lights
D Testing
1 Test run with and without bottles Assigned Mechanics &
Electricians

Note: tasks are not limited to the list in the above table. Some more works might be included

 High performance synthetic oil for gears and bearings

 For filler and labelling machine clean only with cloth, brush and vacuum cleaner. Never clean the machine with water
hose or high-pressure cleaner (vapour spray). Units, electric motors and switch cabinets are only designed for and secured
against spray water.
 Assigned Mechanics: - Kasaye G., Alemayehu K. & BA’alem T.
 Assigned Electricians:- Ayalew and Mulugeta

Coordinators: Mesfin, Nebyu, Nega and production team

Supervisor: Tesfaye and Tadele A.