Abrham, Agmas, BiraraN2ST Flour Factory
Abrham, Agmas, BiraraN2ST Flour Factory
INTERNSHIPE REPORT
Chapter one
INTRODUCTION
……..
Background of the company
The N2ST flour factory was established 2004 and it started at October 28 in 2009 EC and was
inaugurated in Amhara regional state south Gonder zone Debre Tabor town with Initial capital
was 40million Birr under Effort with total production area of nearly 7000 s q m with building
area of 2000Sqm and it is far apart 2.5km from the center of Debre Tabor town.m . N2ST are
represents the first letter of the name of the members in which N represents Nauru, 2S represents
two members of Said and the last letter T indicates Toffik.
The factory which initially started trial production of 420 quintal per day, First rank flour 280
quintal and the remaining is second and third rank flours. There were 12 workers employed
.currently the total worker force in N2ST flour factory are 39 workers which are 32 man and 7
women employees.
This flour industry consumes 104kw electrical power to run the machines. The raw material of
the factory is wheat, 20%from country wheat and 80% from foreign wheat the foreign wheat
comes from like Canada, USA, and so on. The ownership of the factory is privet organized
peoples; those peoples have three flour factories Bahirdar, Gonder addition to Debre tabor.
MISSION AND VISION OF THE COMPANY
Vision _To becomes the most competitive wheat flour producer in south Gondar
To construct and operate a regional, short flow flour mill in South Gondar.
Goals- Taking in to consideration the SWOT (Strengths, Weaknesses, Opportunities, and
Threats) analysis the following strategic goals are set.
1) To strengthen the capital of the company consistently via increasing sales volume and market
expansion through supplying high quality products to global and local markets. (Ensure
sustainable profitability and wealth growth of the company)
Three types of flour products such that first flour, second flour and third flour but first and
second flour is the some quality used to bread only .the third flour is less quality than the first is
not quality bread but used food like enjera and others.
Furishica is the other quality so all over the biggest bread flour and furishikilo and used animal
food.
Furishikilo is less than the furishica used animal food. Differ from one another its quality.
Individual
Group
Private Company
General director
Control comimittee
DIRCTOR BOARD
Secretary
Finance service and plan project Human resource Selling and buying service
desk and stor service information
Work section
since we are mechanical student we are working in maintenance and production activities, we are
always there wherever maintenance of production equipment’s and machineries is being done. There
are the sections we have been working below.
1. Pre cleaning
2. Cleaning
3. Transfer
4. Milling
5. Packaging section
ELEVATOR
Is lift work of the solid part, used by indicate cables and moves with its own set of guide rails
along hoist way walls estimate pre luminary load by using space by space method.
Capacity =1-3t/h Speed =172rpm Power =0.56kw
Figure Elevator
BLOWER
Is rotating by process of electric motor and impeller or blade to rotate and produce air pressure to
be forced. On the center of the impeller passé through the impeller and diffuser and finally inter
the volute causing and goes out with high pressure. This condition more air push into cylinder
combustion chamber the impeller run at very high speed Capacity =4-7.2t/h
Speed =450-460rpm
Power =0.55kw
Figure Blower
AIR LOCK
The air lock comprises of the front entrance area to amber Hodge and consists of the external
entrance door controlled by magnetic device and asset of internal doors controlled magnetically.
Each set of doors operates separately and independently from the other set and cannot be opened
to gather. the internal door cannot be opened until the external doors have been closed and vice
versa.
Power =1kw
Speed =1400rpm
Frequency =50 Hz
Figure Air lock
ROTARY SEPARATOR
As an aspiration and sieve cleaning facility that sieving is predominant with the aide air
classification, the rotary sieve classifier is design to classify the stocks automatically when the
stock move down along the sieve cover and go through the meshes spirally by their own gravity
and under the action of gyroscopic force given by the sieve box.; in the meantime, the light
impurity will be removed due to different suspension velocity when the stocks go by the vertical
aspiration channel.
Capacity =3.5t/h
Speed =145r/min
Power =0.55kw
Function
When TQLM series of rotary sieve classifier is in operation , stocks are fed onto the spreading
plate [2] through the feed port [1] where the stocks center the upper sieve cover [3] uniformly
under the action of gyroscopic force of sieve box for screening . The though enter the lower sieve
cover [4] while the tailing [large –size impurity] enter the large impurity discharge chute [5] and
go our though the large impurity out let. The small impurities [6] and discharge through the large
impurities out let. [7] as the main stream ,the tailing on the lower sieve cover flow into a separate
aspiration channel through the discharge port [8] where the light impurity are removed .
Figure 7 Rotary separator
Magnetic separator
Magnetic separator is used to catches up metals and other magnetic materials. If these metals
pass to the next section, they can ability to damage the machine in addition to decreases the
quality of flour, so magnetic separator is very important in machine wheat flour factory. This
machine is found in pre cleaning, cleaning and milling section of the factory mostly above the
wheat scourer machine
Cleaning Section
For the next cleaning section the wheat transfer by the elevator that is motor twenty Eight (M28)
and it transfer to the separator .During this process the wheat is cleaned once Again to remove
any remaining small impurities like seed sand broken wheat. It is then brushed again to remove
the outer layer and then put through the de-stoner to remove any remaining stones. It is then
disposed in to a hydrating machine where water is Added to bring the wheat to the humidity
levels required for processing .The wheat is Then stored in the tempering silos for a specific
amount of time so that it can absorb The required humidity(wheat tempering). And the wheat
transfer to the drier cylinder. In this section there are two drier cylinders the first drier cylinder.
That separates the wheat from large size wheat like component and then transfer to the sectors
that crash the wheat without water and transfer to the Secondary drier cylinder that separate then
wash the wheat by water
Wheat washer
Wheat washing machine adopts wet method to clean wheat. It is applicable to remove stones
and sands in the wheat cleaning process. In the process, the wheat washing machine can remove
the dust on the surface and in the ventral groove of the wheat, as well as pesticide, microbes and
pollutes. The wheat washing machine can increase the moisture of the wheat and change the
physical property and grinding procedure in conjunction with wheat tempering. This is the end
stage for cleaning section. The wheat will be ready for the milling proses. The machine needs
7.5kw power. And it has a speed of 460rpm.wheat washing machine have also the mass of
2150kg Wheat Seeds were feed into hopper auger. Due to the rotation of the auger, the wheat to
be washed and suspended in water, then sent to dryer box. Stones and other impurities drop into
the auger for their bigger gravity. By the opposite rotation of the auger, the sand fall in sand
bucket under the water tank.
Figure cleaning machines
Screw Conveyor
In this industry screw conveyors are used to move the wheat horizontally from one process to the
other. It is found on the silo, washing room etc.it have the rotating shaft inside it then when the
screw is rotated the wheat will move from one place to other place for next operation It could
remove light stones whose sizes are similar to grain size. It is employed for the continuous stone
removing process, and it also fits for the classification of heavy and light grains.
There is a big difference in the suspending speed between grain and high-density materials such
as stones, metals and glasses, while the suspending speed for heavy and light grains also varies.
Based on these, the mixed heavy impurities will be separated from the grains, and effective
gradation between heavy and light grains is achieved.
Transferring section
After washing the wheat it transfer to the third section that transferring section Store and
conveyer for this section the wheat need eight hours for during .After eight Hours motor32 stand
and the conveyer rotate and push the wheat to the elevator and The elevator transfer the wheat to
the next section that is grinding section before Grinding there is small store and the sensor that
sense the amount of wheat .When This sore is full motor32 stop running and transfer the wheat
then motor38 is start to Run transfer the wheat to the grinder and vice versa.
Milling Section
It is part of changing the wheat in to the flour by crashing it in different size in a long process.
Four different milling methods were used with the goal of obtaining a coarse, medium, fine, and
extra-fine granulation out of each wheat sample.
Coarse grind It was obtained by running the hammer mill at 4,000rpm’s, with a3.0 mm screen
size.
Medium grind it was obtained by running the hammer mill at 6,000 rpm’s with a3.0mm screen
size. After the two grinding that is course grind and medium grind there is the sifter that the
broken particles of wheat are elevated through pneumatic tubes and then dropped in to huge,
vibrating, box-like sifters where they are shaken through a series of bolting Cloths or screens to
separate the larger from the smaller particles. Inside the sifter, there may be as many as 27
frames, each covered with it her any on or stain less steel screen, with square openings that get
smaller and smaller the farther Down they go. Up to six different sizes of particles may come
from a single sifter. Larger particles are shaken off from to, or “scalped,” leaving the finer flour
to sift to the bottom. The “scalped” fractions of endosperm called middling's are reduced in a
smooth roller system to the particle size of flour. In hard wheat mill, the product is then
subjected to a purifying process. A controlled flow of air lifts bran particle while at the same
time a bolting cloth separate sand grades coarser fractions by size and quality
Maintenance Section
In this section we were doing the preventive maintenance approach because this maintenance is
the care and servicing by personal for the purpose of maintaining equipment in satisfactory
operating condition by providing for systematic inspection, detection, and correction of incipient
failures either before they occur or before they develop into major defects. The work was
carried out on equipment in order to avoid its breakdown or malfunction. It is a regular and
routine action taken on equipment in order to prevent its breakdown. This maintenance includes
tests, measurements, adjustments, parts replacement, and cleaning. In the factory I observed
that every one day per week there is a deep cleaning day. In this day mostly at the morning time
every workers of the factory are participated actively in cleaning program. Brushing, assembling
and dis-assembling of machines parts, lubricating, cleaning by using simple machines like
compressor changing a broking spare parts, grazing and others are done in the cleaning program
WORKING TOOLS
Wrenches: - it is
used to tightening or losing the bolt and nut, there is different type for different applications.
Ruler: - to measure the instrument
Cutting tool: - are hand tools that are used to move and corrected the material
CHAPTER TWO
.
Respect for the job, regularity, seriousness To maintain professional demonstrated at all time
CHAPTER THREE
PR
OBLEM IDENTIFICATION
In N2ST flour factory the transportation of wheat, is used manual but not use material handling .The
manual material handling system has so many feed backs, such as need high efforts, costly, large number
of labors, time consumption, reduced Flour quality, case of conflict, and damage of materials and injury
of workers.
During weighing system balanced by manual balancing Machine, in this case there is spending and
contaminate of flour
There are many dust particles that get from wheat and flour dust. Due to this, there is very high
diffusion of dust and the number of eye infections and else were, were at an increased risk of
developing pulmonary symptoms, as strong association exists between exposure flour dust and
wheat dust and prevalence of respiratory problems, and functional impairments of the lungs
among the workers.
There is no generator. Which is very important for the company since power is not common
based on our country’s context
In our working place we have got a lot of problem because our internship company cannot give
us the machine working manual for reading and understanding the working procedure and
electrical installation for the motor.
N2ST Flour Factory is a modernized company there should be an internet access but there is no
internet access.
CHAPTER FOUR
CONCULUSION
In the last four months of our internship time we saw and learn a lot of things about wheat Flour
production industry. How to produce wheat flour is along and interesting work, what quality
means and in what procedures and methods can we keep the quality. We learned wheat flour
production process from pre-cleaning to Packaging of the flour. In addition, when we stay in the
industry, we understand the main function of maintenance in practical way. Without maintenance
we cannot be successful and profitable in every factory. because, every parts of the machine
need`s maintenance. We got a lot of skills. Before we start our intern, we don’t have that much
skills and confidence. Not only that we were so afraid how we will join and work in the factory.
But after we inter and we start our intern it was so interested. Most things are more than we
expected. We get a chance to meet with different people. We get more knowledge from
operators, mechanics, electricians, publics etc... Internship has a great application for
mechanical engineering students. In different ways Intern is very important for students and it
has no other choice if we use it properly. We can know everything from intern that was discussed
in the class theoretically and we get them in practical way. So, using it and changing our back
ground is must be our responsibilities. Generally focusing on internship is more than the class
courses.