RAYA UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY,

DEPARTMENT OF MANUFACTURING ENGINEERING

Hoisting Company Raya Brewery S.C

Internship Report

DURATION TIME; 72 DAYS

PREPARED BY ID/NO

1. HAGOS TUEMAY------------------------------------------------------- 00232/10

2. HAGOS BARAKI---------------------------------------------------------00233/10

3. SELEMON HILUF------------------------------------------------------00335/10

4. SEYFU FKRE-------------------------------------------------------------00342/10

Submission Date; 03/01/2016 E.C

Submitted To; Manufacturing Department

Adviser Name; Mr.Elias G/Kros

Maichew Tigray Ethiopia

 Declaration
We are fifth year manufacturing engineering students in Raya University. We have undertaken our
internship experience in Raya brewery Share Company, for 72 days under the guidance of Academic
advisor and company advisors. We certify that our work is original and compiled according to the
internship report writing guideline given by the Institute-Industry Linkage office of the Institute.
 Acknowledgements
First of all, We would like to thank God who gave us strength to finish this internship program and we
would like to give a great respect and appreciation to Raya brewery S.C for providing this precious
opportunity that enable us to familiar with practical skill and it is great pleasure to thank for those
people who individually helped us during the internship program also we would like to give our great
thanks to university advisor Mr.Elias G/Kiros for his relevant advice about how to properly work in the
company. We would also thanks to the company advisor Mr.Naod for his relevant information about
how we working the activities which are carried out in the factory. We would like to express our deepest
gratitude to all of operators and team leaders for great assistance throughout the company. Lastly we
would like to thank for our friends that they apply in the same company because they share ideas of
them and we offer our regards and blessing to individuals that are supporting during the completion of
the internship program.
 Excutivesummery
This report tries to presents the company back ground, the main product of the company, the overall
work flow, overall benefit from internship program we gain and work flow of each section we work. The
overall work flow of the company focus on the main structure of the company from pure water
treatment to waste water treatment. It consists pure water treatment, raw material, malt handling,
wort production processing, the processing of filtration and fermentation, packaging and waste water
treatment. In term of getting benefit, improving leadership skills, understanding about work and ethics,
practical skill , upgrading theoretical knowledge skills, are improving interpersonal communication skill,
entrepreneurship skill and team playing skill all these are shown clearly. Each section has machines, like
de-stoning, drum sieve, magnets, hammer milling, pre-mashing, mash kettle, mash filter, wort pan,
whirlpool, boiler, CO2 recovery, cooling, bottle washer, DE palletizer, unpacked, crate washer, bottle
washer, EBI, filler, pasteurizer, labeler, packer, palletizer, and other machine.
 Table of Contents
Declaration.......................................................................................................................................i
Acknowledgements.........................................................................................................................ii
Excutivesummery...........................................................................................................................iii
Table of Contents...........................................................................................................................iv
List of Figures.................................................................................................................................vi
List of tables..................................................................................................................................vii
Acronyms.......................................................................................................................................ix
Chapter One.....................................................................................................................................1
Introduction.....................................................................................................................................1
1.1 Background of the hosting company.....................................................................................1
1.2 Objective of the Company.....................................................................................................2
1.3 Visions of Raya Brewery Are:...............................................................................................2
1.4 Mission of Raya Brewery......................................................................................................3
1.5 Main Products or Service of the Company............................................................................3
1.6 Main Customer and End Users of the Company Products....................................................3
1.7 Overall Organization Structure..............................................................................................4
1.8 Work Flow.............................................................................................................................5
Chapter Two....................................................................................................................................6
Overall Internship Experience.........................................................................................................6
2.1 Company Entrance.................................................................................................................6
2.2 We Select This Company for Better Information;.................................................................6
2.3 Section of Company we Had Been Working;........................................................................6
2.3.1 Work Flow In Section Look Like as;..................................................................................6
2.3.1.1 Malt handling area …......................................................................................................6
2.3.1.2 Malt cleaning proc.………………………………………………………..……………7
2.3.2 Brew house ……………………………………………………………………………....8
2.3.3 Fermentation ……………………..……………………………………………………
2.3.3.1 Yeast propagation…………….………………………………………………..
2.3.3.2 Steps of fermentation …………………………………………………….
 2.3.4 Filtration ………………………………………………………………………….
2.3.5 Utility plants …………………………………………………………………………
2.3.5.1 Co2 recovery plant ……………………………………………………………………
2.3.5.2 Cooling plant ……………………………………………………………………………
2.3.5.3 Boiler plant ………………………………………………………………………………
2.3.5.4 Water treatment plant ……………………………………………………….
2.3.5.5 Waste water treatment ………………………………………………………………
2.4 Packaging ……………………………………………………………………………………
2.4.1 Bottling line ……………………………………………………………………….
2.4.3 Kegging line …………………………………………………….……………………
2.5 The work piece or work task we had been executing ...........................................................34
2.6 Procedure and Methods We Have Been Using To Perform Our Task...................................34
2.7 Major Challenges We Have Been Facing While Performing Our Work Tasks Are;.............35
2.8 Measure We Have Been Taking In Order To Overcome the Challenge................................35
2.9 Some Problems of the Company and Possible Solutions.......................................................35
Chapter Three................................................................................................................................36
Over All Benefit Gained From Internship.....................................................................................36
3.1. Improving Practical Skills...................................................................................................36
3.2. Improving Theoretical Knowledge.....................................................................................36
3.3. Improving Interpersonal Communication...........................................................................37
3.4. Improving Team Playing Skills..........................................................................................37
3.5 .Improving Leadership Skills...............................................................................................37
3.6. Understanding about Work Ethics......................................................................................38
3.7. Improving Entrepreneurship Skill.....................................................................................38
CHAPTER FOUR.........................................................................................................................39
CONCLUSION AND RECOMMENDATION...................................................................................39
4.1Conclusion............................................................................................................................39
4.2 Recommendations................................................................................................................39
Reference.......................................................................................................................................41
 List of Figures
Figure1. 1Back Ground Of Hosting Company................................................................................2
Figure1. 2Main Product And Service Of Raya Berewery...............................................................3
Figure1. 3 Organizational structure.................................................................................................4
Figure 1.4 Work flow of organization.............................................................................................5
Figure 2.1 pre-masher......................................................................................................................9
Figure 2.2mash kettle....................................................................................................................10
Figure 2.3mash filter......................................................................................................................10
Figure 2.4wort collector................................................................................................................11
Figure 2.5wort pan (wort boiling).................................................................................................12
Figure 2.6whirl pool......................................................................................................................12
Figure 2.7plat heat exchanger........................................................................................................13
Figure 2.8Fermentation tanks (CCT).............................................................................................14
Figure 2.9 Filtration room.............................................................................................................15
Figure 2.10working flow of Packaging.........................................................................................18
Figure 2.11over view of De-palletizer machine............................................................................20
Figure 2.12 over view of Unpacker...............................................................................................20
Figure 2.13over view of Crate washer...........................................................................................21
Figure 2.14 over view of Bottle washer........................................................................................23
Figure 2.15 over view of EBI........................................................................................................24
Figure 2.16Over View of Filler.....................................................................................................25
Figure 2.17over view of full bottle inspection..............................................................................25
Figure 2.18over view of pasteurizer..............................................................................................26
Figure 2.19Bottle decorations (labeling........................................................................................27
Figure 2.20over view of video jet..................................................................................................27
Figure 2.21Packer..........................................................................................................................28
Figure 2.22Palletizer......................................................................................................................28
Figure 2.23 Empty turning machine..............................................................................................29
Figure 2.24over view of external washer machine........................................................................29
Figure 2.25 over view of internal washer and filler......................................................................30
Figure 2.26 Rating system.............................................................................................................31
Figure 2.27over view of labeling...................................................................................................31
Figure 2.28video jet.......................................................................................................................32
Figure 2.29Full turning machine...................................................................................................32

List of tables
Table 1 Deference Between Beer And Draft.................................................................................33
 Acronyms
BBT---------------------------------------------------------Bright Beer Tank
BTLS--------------------------------------------------------Bottles
CCT---------------------------------------------------------Conical Cylinder Tank
CIP-----------------------------------------------------------Clean Internal Place
EBI-----------------------------------------------------------Empty Bottle Inspection
E.C-----------------------------------------------------------Ethiopian Calendar
FBI-----------------------------------------------------------Full Bottle Inspection
G.C----------------------------------------------------------Gregorian calendar
HPI----------------------------------------------------------High Pressure Inspection
KEG---------------------------------------------------------Draught
S.C-----------------------------------------------------------Share Company
WWT--------------------------------------------------------Waste Water Treatment
WW----------------------------------------------------------Waste Water
DIO------------------------------------------------------------Days Inventory Outstanding
KMK----------------------------------------------------------Kilometer
KMS-----------------------------------------------------------Kilometers
HL--------------------------------------------------------------Hectoliter
ETC------------------------------------------------------------Excetra
MR-------------------------------------------------------------Mister
ATP------------------------------------------------------------Energy
CEO------------------------------------------------------------Chief Executive Organization
HR---------------------------------------------------------------Human Resource
BGI--------------------------------------------------------------Brasseries Et Glarciers International
 Chapter One
Introduction
Internship report is a document that summarizes and evaluates the expriance,tasks and achievement of
an individual or group work in company during their internship program.typicaly it includes details about
the organization where the organization the internship was conducted ,the project or assignment under
taken ,the skill gained ,challenge faced, conclusion and recommendations for Improvement etc.

1.1 Background of the hosting company

Raya Brewery S.C is established in 2013 G.C and (Commercial production in Feb. 2015 G.C) being the
pre-eminent Brewery in the region producing standard strong beer. The Brewery is equipped with the
state art technology imported from Germany: Kroners, Czech Republic: DIO, Belgium: Maura,
Netherland: Hoffman, America: Cole palmer. Company has more than 500 employees, many with
decades of experience in food and beverage industry. The Brewery is located in the historical town
Maichew 660 Km from Addis Ababa to the North. Raya Brewery has an initial annual total capacity of
600,000 hectoliters (180million, 33cl bottles of beer per year. enough to supply the population of Ethiopia
with 2 bottles each) current production output stand at 300,000 hectoliters (90 million bottles).Despite its
young age. the bottle line fill 36.000*33cl bottles every hour (or more than quarter million bottles in an
8hr shift .the kegging line will also fill 120*30 litter kegs per hour (or more than 25.000 litters in a single
shift. The plant has been allocated 18.5 hectares of land. The site is located along Maichew - Korem
asphalt road, on the western side at about 10 meters off the asphalt road and 1.9km from Maichew town.
It is easily accessible with vehicle both in wet and dry seasons. The project site is generally a gently
sloping terrain found just at the foot slope of Bokhra Mountain. The site was selected mainly due to the
availability of soft spring water which has been tested and found to exceed the minimum brewing water
requirements in all respects. Besides, the yield of the spring being 55.0175 liters per second is sufficient
enough to meet the requirement of four breweries of this size. Water source of Raya Brewery S.C is
natural spring water called “Mai-muk” found at about 7KMs distance from the factory site. It is also
believed that its establishment at Maichew is strategically advantageous, since there is no other brewery
in Tigray region. The site of the plant is accessible through all-weather roads. A plot of land measuring or
an area 150,000 m2 has been given by the regional administration free of charge. The basic infrastructural
support required for a brewery namely water, land and electric power are reported to be available
sufficiently. The company was officially launched on May 08, 2010 E.C at Maichew town. Presently it
has more than 400 shareholders and its head office is setup in Bole Sub City, Kebele 03/05, Robel Plaza-
building. The capacity of the Raya brewery to be established shall be based on the following production
program.

 Total output = 300,000hl sales beer per annum.  Out of this: 85% is produced as bottled beer.15% is
produced as draft beer. Total production loss is taken to be 10%.
 Figure 1.1Back Ground Of Hosting Company
1.2 Objective of the Company
To produce beer and draft with quality and quantity within country.

To reduce poverty strategy of the country by creating job for citizens..

To create sustainable market by supplying competitive products that fulfills customer’s requirements.

To create job opportunities.

1.3 Visions of Raya Brewery Are:

To be leader in countries beer industries with respect to quality.

Be a great place to work where people are inspired to be the best they can be.
Nurture a winning network of customers and suppliers, together we create mutual, enduring value.
Be a responsible citizen that makes a difference by helping build and support sustainable communities.
Maximize long-term return to share owners while being mindful of our overall responsibilities.

1.4 Mission of Raya Brewery

Of Raya brewery Share Company is to produce unique quality beers.
To operate in ethical and environmentally friendly standards while hand crafting our product.
To produce a unique quality beer that is second to none.

1.5 Main Products or Service of the Company

The main products of the company are:
Pasteurized Drought beer
Castle beer
St George beer

Figure1. 2 Main Products and Service of Raya Berewery

1.6 Main Customer and End Users of the Company Products

The company OVERALL manufactures and distributes high quality beer in order to meet maximum
customer satisfaction and there is no any limit or boundary in order to be a customer for Raya Brewery
Share Company. The products are distributed across the country in three regions and three warehouses.

The regions are:

Region 1: covers Dessie, Addis Ababa and Mekelle.
Region 2: this covers the whole Tigray region.
Region 3: east and south parts of Ethiopia. There are three warehouses: thus are Maichew,
Mohony and Alamata.
1.7 Overall Organization Structure

Figure 1.3 Organizational structure

1.8 Work Flow

Figure 1.4 Work flow of organization

 Chapter Two
Overall Internship Experience
2.1 Company Entrance
We get in to Raya brewery S.C by entering a letter that comes from our campus then in the company we
get an acceptance. By getting the acceptance we were happy more. The reason why we were select this
company is by its condition, besides of the distance and its new company and also it can going parallel
with our field due to that we get information that is good and moderate machines then we start the
work.

2.2 we Select This Company for Better Information;

We select Raya brewery Share Company because of the following reasons:

To know the name and application of the materials that have been in raya brewery

It uses many electrical, mechanical machines instruments and controlled materials on its application.

To know the overall production processes of the company brewery

To observe the mechanical parts and their mechanisms clearly

To know the working conditions of the robot machines with their degree of movements

2.3 Section of Company we Had Been Working;

During our 72 days internship program we have been experiencing all over the work flow of the
company. Particularly we were working at packaging section by integrating with the main operators who
are certified by their professions.

2.3.1 Work Flow in Section Look Like as;

Beer is an industrial product. A beer is one of the oldest and most complex in the preparation of
alcoholic drink. To create the final product brewers use the latest technology and very expensive
equipment. But, as before, the integral components of beer are four ingredients. These are Malt, Water,
Yeast, Hop and other additives.

Malt: is the main raw material for beer, Beer cannot be made without malt; consequently
malt production from barley is the first step in beer production. Its uses depend on the fact that barley
has high starch content. Malt provides sugar for fermentation process, color of beer and flavor and foam
of beer.

Water: Is the fundamental ingredient of brewing beer and about 90% of beer is water but the quality of
water has great significance on beer quality.
 Hop: Is an ingredient of beer that provides aroma, bitterness due to having alpha-acid and even
facilitate foam head formation. Raya Brewery S.C uses two kind of hops which are IKE (isomerize ketone
extract) & co2 extract hop. These two kind of hops are different on their amount of alpha acid (having
20-30% & 40% alpha acid) respectively.

Yeasts: Are micro-organisms that are playing a role of fermentation process on sugar to produce alcohol
and carbon dioxide.

The overall fabrication of brewery passes through four stations from beginning brew house up to end
packaging those are stated below individually.

Brew House
Almost 70% of the production process is achieved in brew house. The preparation of beer is called
brewing. The most important process in beer production is the fermentation of the sugars containing in
the wort to form alcohol and carbon dioxide. To provide the necessary conditions for this, the initially
insoluble components in the malt must be converted into soluble products, and in particular soluble
fermentable sugars must be produced. The formation and dissolving of these compounds is the purpose
of the wort production Processes like malt handling, milling, mashing, wort separation, wort collecting,
wort clarification and wort cooling, wort aeration.

Capacity of brew house: 8 brews per day.

The most important processes in beer production carried out in brew house operation are Malt
reception and handling, milling section, Pre-mashing, mashing, mash filter, wort collector and whirl pool.

1. Malt reception and handling

Malts from malt store are put in to the malt reception by the labor workers or chain conveyer, and
transported to the silos through screw conveyers and bucket elevators. Raya brewery S.C. has six silos.
Four of which, are with ability of storing 300 tons. The remaining two silos can store 30 tons each. After
storing the malt in the silos, the malt needs to be cleaned before it enters the next step which is milling.
The malt should be free from stones, oversized particles and metals.

Objective of malt cleaning;

To prevent equipment damaging;

To prevent loss efficiency of milling;

To prevent explosion;
To prevent increasing of sparks;

Equipment used for cleaning of malt is:

Aspiration: used to suck off dusty air and provides cooling to malt.

Drum sieve: remove materials which are over size such as grass, malt and others based on sieve size.
This separates 5 tones per hour’s malts.

De-stoner: removes high density materials and stones.

Magnets: separates materials which have magnetic behavioral.

2. Milling section
This section is used to crush malt in to smaller size (to extractable section) using hammer mill. It has a
capacity to crush 8 tons of malt per hours.

Objective of milling;

To get proper mashing,

To the total conversion of starch,

To get efficient extraction,

To have fast mixing,

To get rapid &complete separation of wort.

3. Pre-mashing
Used to mix the milled grist(5950kg) with a brewing water(136hl) at T° of 52-55°C with contact time 20
minutes& water to grist ratio is 2.286L/kg.

Type: Vertical

Material;

* All parts in contact with the product are made of AISI 304 stainless steel.

Objective of pre-masher:

To prevent protein coagulation.

To activate protease enzyme for protein degradation (initiates enzyme activity).

To mix grist with water uniformly.

 Figure2.1 pre-masher

4. Mashing in (mash kettle)

Is the mashing process that used to starch hydrolysis and protein degrade to simple sugars and amino
acids by the help of increasing T° using steam and adding additives with time intervals.

objective of mash kettle:

Starch degradation.

Hydrolysis of proteins and poly peptides.

PH adjustment and activate enzymes based on temperature zone.

Starch conversion (carried out by optimizing the temperature of the kettle from (64-78)°C
using steam).
 Figure 2.2 mash kettle
5. Mash filter
Mash filter is the separation of wort from spent grain. This mash filter separates wort through sparging
and compression. Sparging is washing the extraction of wort with hot water while compression is
separating worth by pressing the mash under pressurized air.

Figure 2.3mash filter

6. Wort collector
Wort collector is used to store the wort and its total capacity to store 31 m 3.Wort collectors is temporary
storage of wort and no chemicals are added. The presence of wort collector saves time by allowing the
next process to take place until the wort is fully collected. Here the collected wort is heat up by using
plate heat exchanger from the energy water tank from 78℃ to 88℃.
 Figure 2.4 wort collector

7. Wort pan (wort Boiler)

Wort pan is conical cylindrical tank used to mix the wort with hop to change color of the wort and to
increase its alcoholic content by the rotating agitator at a temperature about 96°C . Boiling of wort is
carried out in wort pan via steam for different purpose. The wort entered with a temperature of 78°C is
increased to 91°C by steam addition and pressurizing.

Objective of wort boiling are:-

Removal of undesirable volatile compounds

Isomerization of bitter substances

To stabilize the wort compositions

To remove water in the form of vapor

To extract the desirable material from hops this gives to beer its characteristics aroma and flavor

To inactivate enzymes or terminating enzyme action

Hot and cold break formation

Formation of coloring substances

 Figure 2.5 wort pan (wort boiling)
8. Whirl pool
In this unit operation, wort is entered tangentially to draw out hot trub from wort via centripetal force
by settling non-dissolving substances to bottom center of the whirl pool and takes rest for 20 minutes.

Sequence of whirl pool:

Fill for 20minute tangentially.

Wort transfer for 60minute.

Trub removal for 10minute.

Figure 2.6 whirl pool

9. Wort cooling
The hot wort must be cool down to the starting temperature of yeast to grow. After boiling the
temperature of the wort must back down to (9-12)0C to pitch yeast using plate heat exchanger by ice
water at 2 0C from cooling plant. After the wort is cooling it must be aerated. Because oxygen is
absolutely essential for yeast growth.

Figure2.7 plat heat exchanger

Fermentation and Filtration

Fermentation
Fermentation is the process of converting sugar into ethanol and carbon dioxide using microorganism
which is known as yeast. It is an exothermic process. It is energy yielding process in which organic
compounds are metabolized under anaerobic or micro aerobic conditions.
Objective of fermentation
To convert sugar in order to produce ethanol and CO2.

To produce lager beer or maturated beer.

To give flavor to the beer. Etc.

Fermentation depends on;

The mineral contents of water.

Temperature of fermentation.

Pitch rate of yeast.

Amount of aeration.

Factors that affect fermentation;

Temperature

Pressure
Yeast population

Yeast viability

Wort composition

Fermentation process takes place in two different ways:

1. Using yeast which comes from propagation tank
2. Using harvesting yeast which comes from the harvesting yeast storage tank
The breakdown of sugar is seen below taken during fermentation process.
2C6H12O6 yeast2CH3CH2OH+2CO2+2ATP

Figure 2.8 Fermentation tanks (CCT)

Filtration
This is the final process to be considered in beer treatment prior to packaging. This is the clarification of
beer to a standard that is acceptable for sale. It should be done after the Beer has been laagered. The
beer must be rendered stable So that visible changes don’t occur on its commercial or shelf life. The
filtered beer is pumped into the bright beer tank and stored for 2 – 3 days. Bright beer tank are buffer
vessel between the filter and they are mostly constructed as vertical stainless steel tanks without
internal fitting.

The main Objectives of filtration is;

To clarify the beer

To avoid spent yeasts
To avoid polyphenols which cause haze to the beer
To remove other unnecessary substances from beer

Figure 2.9 Filtration room

Utility

In Raya brewery s.c utility is the widest section. It is mainly concerned with supplying the demands to its
customers. The customers of utility are brew house, fermentation, filtration, water treatment, waste
water treatment, packaging etc. Utility section provides steam, treated water, ice water, cold degassed
water and pure CO2 for its customers. There are five subsections under utility. These are water
treatment, cooling plant, steam generation, waste water treatment, and carbon dioxide recovery.

Cooling plant

Cooling plant is one of the subsections of utility which provides ice water to cool the wort where came
from brew house, cold degassed water used for dilution of beer and glycol used for cooling CCTS, wort
used for propagation etc.
Carbon dioxide Recovery

During fermentation carbon dioxide is recovered by separating from foam by foam separator. The
carbon dioxide from the separator is purified to 99.99% to send in to the gas balloon which is stored in
the form of gas. The gas balloon is used as a temporary storage of carbon dioxide gas. When the gas
balloon reaches its capacity above 65% of carbon dioxide by volume, it is passed to gas washer by the
help of booster. The booster is used to suck carbon dioxide and increase pressure of carbon dioxide. The
gas washer used to remove dead yeasts, foam and other impurities using water. Next carbon dioxide is
transferred from gas washer to centrifugal compressors by the help of pumps. The compressors work
based on the amount of CO2 but their function is increasing temperature and pressure of CO 2 to 35°C and
17.5bar respectively is cool down by glycol and this passed to drier. The drier is used to remove moisture
content and other unpleasant odors.

The purified CO2 is sent to reboiler to heat up then after this sent to condenser containing ammonia to
change the CO2 from gas to liquid form but non condensable materials are remove at this stage then
after returns to reboiler in order to trap the non-condensable materials that are not condense in the
condenser. CO2 stored in storage tank in the form of liquid but changed to gas by sending to evaporator
that contains expansion valve that helps to change the liquid CO 2 to gas CO2.CO2 used to increase shelf
life of beer, during bottle wash used to remove oxygen and used for pH adjustment etc.

Boiler

In this plant the evaporation of water in to steam is carried out due to the requirement of steam for
different purpose. For example steam used for sterilization of yeast in yeast propagation step, for
preparing degassed water in filtration, in water treatment for killing of micro-organisms, pasteurization
for beer. In boiler there are steps to boil water.

Softener unit: water coming from water treatment is 60% softened. It is using two softener units which
have volume of (380-400) m³ and work one after the other to soften the water to 100%.

Condenser: this tank has many functions but mainly used as storage of condensed steam returned.

Economizer tank: because of the steam returned boil water that is at normal temperature to above
85°C, it saves energy consumed by heating water.
Deration tank: the condenser tank can be used as degassed water tank due to avoiding of oxygen from
water.

Boiler: there are two boiler units which exchanged weekly to perform their function. These boilers are
standardized to load up to 240°C and 15bar pressure. But currently they work at temperature of 140°C-
150°C and 10.5bar maximum pressure.

Air compression plant

Air compressor is a device that converts power (usually from an electric motor, a diesel engine or a
gasoline engine) into kinetic energy by compressing and pressurizing of air. The main objective of this
plant is to change low pressure atmospheric air into high pressurized air by the process of compression.
In case of this company the type of compressor used is the screw type compressor. The quality
parameters that we check for air compression plant is the moisture content of the atmospheric air.
Therefore, this plant uses air dryer to remove moisture from the atmospheric air. Main areas that need
compressed air include Wort aeration, transporting spent grain in mash filter, conveying of grist to the
mash tun, for pneumatic valves.

Water Treatment Plant (WTP)

Water is the major raw material for beer processing. It must be free from impurities and
microorganisms. Water in Raya brewery is taken from a place called May Muk which natural ground
water and treated to the desired quality. The main aim of WTP is to treat untreated water to get clear
water. In order to be suitable for use in brewing, water must be microbiologically pure, Clear and
colorless (turbidity and color can be caused by suspended solids), Tasteless and odorless (chlorinated
water can affect beer flavor), pH neutral (pH 7, or slightly acidic), Free from heavy metal ions. The
water treatment plant at Raya brewery is designed for treatment of water. The main substances or
chemicals that used for WTP are: Ferric chloride, Anti scale, Sodium hydro oxide, Sand, biocide,
Chlorine and Active carbon filter.

Waste Water Treatment Plant(WWT)

Waste water is the dirty (contaminated) water collected from all the processing units and from the
production environment. The source of waste water is from Brew house, Production, Bottling, Utility and
working environment.

Packaging (Bottling and Kegging)

Packaging is the main process room in the brewery company and Beer must be packaged before
it is sold.

Once the beer has been produced and stored in the bright beer tank it is then ready for
packaging. There are two types of packaging here in Raya beer, which is bottle and keg.

The difference between beer and keg is that during keg the beer is first pasteurized (flash type
pasteurization) then cooled in a plate heat exchanger up to 3°C then packed. But in the case of
bottles the beer is first filled and pasteurized (Bottles use tunnel type pasteurization).

This diagram is the working flow of Packaging

Figure 2.10 working flow of Packaging

Packaging is the final process in beer production factory.

There are two main lines in packaging process:

1. Bottling line

2. Kegging line
 1 Bottling line

This section is mainly concerned about packing bottles containing beer and delivering this
product to customers. Averegically it packed about 36000 bottles per hour. Before that it receives
crates of dirty bottles on pallets separating the crates from the pallets and the bottles from the
crates and then washing the empty bottles. Bottling into nonreturnable bottles involves receiving
new glass bottles, which only require rinsing not the thorough cleaning associated with washing
dirty bottles. It ensures the product that can be supply to customers being free from micro-
organisms. Bottling line is described as follows step: -

De-palletizer
It receives customer bottles from the forklift. Each pallet has a capacity of holding 48 crates. The transfer
carriage picks the first layer (8 crates) with the help of gripper at a time and put it to the discharge table
by moving horizontally for further transfer moment can be performed. The first row of crate of the layer
is conveyed to the stop plate. The stop plate moves down and the separating fingers move the row of
the crates on the pack discharge. Then the discharge conveyer starts and takes the crates to the un-
packer.

Full pallets in feed as: - fork lift put pallet on in feed roller the roller starts role and pushes the pallet in
to proper position for De-palletizer.
Empty pallet discharge ፦ when the in feed pallets completely discharge by the de palletizer the roller
discharge the empty pallet to palletizer.

This is the process of separating pallet from crate containing unclean bottles. De palletizer is a robotic
system which is used to separate pallet and empty bottles with their crates. It has some components
such as base, belt conveyor, controller sensor, actuator and effecters (gripper).

Base: - the base of de palletizer is fixed to ground for the purpose of every activities stand with
balanced.

Belt: - is a mechanical part of de palletizer which is used degree of freedom for the purpose of moment
with in the direction of up and down and also sliding mechanism motion.

Controller: - it is a device with hard and soft ware support for giving commands to the drive.

Sensor: - it is used to give feedback information for subsequent action of arm (mechanical gripper) as
well us to interact with the environment which the de palletizer is working.

Actuator: - it is a device which is used to causing the manipulated arm to move.

Gripper: - is a part of de palletizer which is used to holding .This mechanism is done by the pneumatic
presser system.

Figure2.11 over view of De-palletizer machine

Unpacker
The crates those are discharged from de palletizer are conveyed to the unpacker. Unpacker machine is
fully automatic machine. And it helps to discharge the empty bottles from the crate by pneumatic (air)
system. After that the empty bottles convey to the bottle washer and the empty crate convey to the
crate washer. It has two motion mechanisms. One is oscillating mechanism and the other is up and
down motion. They up and down motion takes place by the belt driver associated with in host motor but
the oscillating mechanism is oriented by gear box to hinged pillar push rod, crank, cross transport drive
and function tube to perform their functions.

Figure2.12 over view of Unpacker

Crate washer

Crate washer machine is a machine which is used to wash the crate that are dirty which comes
from the customer. The crate wash with cold water and caustic, and high pressure spray from
different direction, then the washed crate moved to packer machine to put down finished
bottled beer.
 Figure2.13 over view of Crate washer

Bottle washer
Bottle washer machine is the most important machine which is used to disinfect and wash dirty bottles.
Bottle washer machine can wash 40,000 bottles per hour and this machine has washing cycle and
consists of the following distinct phases.

Pre-wash

The pre-soaking stage takes place in one or two stages; after leaving the presoaking area, the bottles are
overturned and emptied; the dripping water fall onto a collection pan and is filtered before returning
into the presoaking area itself. The presoaking area is maintained at a constant temperature and
continuously renewed by hot water coming partly from the first rinsing area and partly from the
detergent sprayer’s tank, without any additional energy consumption. An internal sprayer and an
external shower perform a double step heat recovery process to increase bottles and carriers
temperature before immersion in the main detergent tank.

Caustic spraying

The washing stage takes place in the main detergent bath where also three label extraction (caustic1,
caustic2, caustic3) stations are located those caustic chemicals have basic property. The time of
immersion (water jet), caustic (chemical NaOH) and the temperature can be set according to the specific
characteristics of the bottles being cleaned. After the soaking in the hot caustic solution the bottles are
turned upside down until they’re completely emptied. A final washing stage is then performed by a set
of sprayers directing a jet of detergent solution inside the bottle.

Rinsing (post jet)

This process is performed after the complete process of caustic. At rinsing stage the bottle is washed
internally and externally to clean the caustic (since the chemical is base). Therefore at this stage acidic
properties chemical are used since basic properties are deactivate by acidic property chemical.

Hot water

In this stage the bottle is washed by the hot water to clean and deactivate completely the chemical
properties in the exterior and interior part of bottle in the earlier processes.
Cold water

After the hot water washing process is performed since the bottle is very hot so to decrease the
temperature we use fresh water that is came from water treatment room. And although before
discharging we use fan to dry the water and caustic foam.

Types of pumps installed in the bottle washer with their function are: -

Recirculation pump: - is used to control the viscosity of caustic.

Jetting pump: - is used for the cleaning interior and exterior parts of the bottles.

Dosing pump: - is used to control the entrances

Extraction of hydrogen (H2): -container (bottle) with in thin Aluminum foil feeds in to the machine in
the form of label stick to the bottle and the aluminum foil decomposes in the caustic solution as result
hydrogen is released in to the space of bottle washer. Therefore hydrogen reacts with oxygen to form an
oxy hydrogen explosive mixture which can be easily ignited. Because of the ignition it can destroy the
containers and other parts of machines. Then to protect this explosive we must extract before hydrogen
react with oxygen from the bottle washer by using extractor pump (from production area).
The main mechanical components of bottle washer are: -
In feed :- is the process of trans partition of bottle in to the bottle washer and the main components of
in feed bottle are ,bump ,s. shapes ,agitator, plastic profile, bottle pusher shaft with bearing, arm (push
rod), piston and gears (bevel and spur) with their Mechanisms. The in feed activity is performed by the
mechanism of gear, shaft, piston, pusher rod, bearings system. The main purpose of in feed is to reduce
the over loads and the power transmission is controlled by bevel gear system.
Agitator:-is a component of in feed system and it works only with back pressure and easily replaced.
Agitator itself moved by eccentric shaft

Bottle slide:-is used for smooth transmission bottles on the discharge easily to access and it has a plastic
profile with exchangeable.

Chain conveyor: -it is very important for the purpose of transmission of bottles at the whole bottling
process.

Spray nozzles: -are used to spraying water and caustic for the purpose of cleaning internal and external

Gears: - it used for power transmission and for easily moment mechanism. The main preferable gears in
the bottle washer are warm and bevel gears.

Bevel gear:-is used for power transmission in the place of in feed and discharge position only. Worm
gear:-is founds at every gear boxes for the purpose of the rotational motion change in to linear motion
from each gear box placed position.

Rip pan:-is a very important for removable droplets and mixture from the bottle.
Discharge:-used for good treatment of the empty bottles. It works by synchronous drive Smooth and
silent setting down of the bottles a good transfer on to the discharge conveyor. In bottle washer used to
only one motor for all activities by synchronies operation system within the universal joint arrangement
force and torque transmission as required process. After the bottles remove, the crates will travel to the
crate washer which washes the crates through the conveyor with water by consecutive levels.

Figure 2.14 over view of Bottle washer

Visual bottle inspection

It is done manually with human eye using light. If the bottles are broken, unclean, labeler contain, they
are rejected.

Empty bottle inspection (EBI)

In Raya brewery s.c there are three different sensors used for empty bottle inspection. The first sensor
removes bottles other than St. George, Raya, and castle bottles, the second sensor remove bottles that
are too high and the last sensor bottles too low in height. Using camera checked in order not to present
like suspended caustic, oil, residual liquid etc. All are rejects presents in bottles.
 Figure 2.15 over view of EBI
Filler
From the BBT, the beer is transferred to the filling machines by a pump or by the CO 2 pressure in the
tank.

Filler has the following steps:-

First evacuation: used to remove O2 from bottles.

Carbon dioxide flashing: rinsing carbon dioxide in bottles.

Second evacuation: allows the displacement of CO2.

Pressurization: helps to add CO2 in bottles.

Filling: beer displaces CO2 from bottles.

Snifting: used to control pressure releasing.

 Figure 2.16 over View of Filler
Closing the bottles with crown
After filling the bottles are closed faster in order to prevent the beer from contaminants and entering
gases. To prevent the oxygen intake during the time of closing the bottle with a cork a continuous fine
stream of water is sprayed in to the still open bottles so that some of the content immediately foam out
and prevent entry of oxygen. The bottles are closed with a crown cork which has Thickness - 0.235mm
thick stainless steel plate, Number of teethes – 21 and Outer diameter -32mm.

High pressure inspection (HPI)

It is used to control air before bottle is entered to capper.

Full bottle inspection1

After filling the bottles are inspected to make sure they are correctly filled to the filling bright and
properly closed and the unsatisfactory closed bottles and under fill bottles are separated out gripper
heads and placed on a large conveyor from where they are transported to the sorting machine.

Figure 2.17 over view of full bottle inspection

Pasteurization
Pasteurization is ensuring to increase its shelf life by means of destroying or reduce the number of harm
full microorganisms in a product in order to increase its biological stability. The objective is the effective
kill of harmful organisms with the minimum use of energy that can grow and cause beer spoilage in the
bottle. The tunnel pasteurizer in Raya Brewery has pasteurization capacity of 36,000btls/h and one
bottle at least 45 minutes to be pasteurized. In the pasteurizer there are 10 Induction motors. The
pasteurizer operates as put in a three series zones.

The first three zones (1, 2&3) are called heating zones and temperature set point is 25°C-45°C.

The next four zones (4, 5&6, 7) are called pasteurized zones at maximum temperature of 65°C.

The last three zone (8, 9&10) are called cooling zones at temperature range of (45°C-25°C).

Bottle decoration (labeling)

Labeler is used to label the brand name and kind of beer on the body and neck of bottles using glue
which use to stamp the papers with the bottle, also there are brushes used to clean the bottles. The
essential components of labeling machine are the label holder and the label transferring device. The
label holder receives the labels and ensures a continuous feeding of the labels. In the unending struggle
for market share, the appearance of the bottle is very important. The number and size of labels, their
color and design, their arrangement and the overall effect should be showing for the customer that is
producer’s beer but not only the best it also the most attractive. In Raya brewery S.C every bottle labels
with Body label, Neck label and Labeling is also describe expire date of the beer, chemical content,
gradient and place of product.

Figure2.19 Bottle decorations (labeling)

Full bottle inspection-2
This is used to check whether the bottles are packed and weather the bottles are fill or not fill to their
standard settlements and label properly.

Video jet
The main function of this machine is to print the production date, the name of the Production Company
and expired date of the beer. In this we don’t have any sensor that detects the incoming of bottles but it
uses encoder of the servo drive to print these bottles by using gamma ray.

Packer
Packer is used to put bottles with in
crates. It is the same as unpacker but the difference is packer is bottle loading or inserting in the crate so
the Imamate picks 4 crates of bottle (96 bottles) at once & un packer is removing the bottle from the
crate, so that same structure, working principle, but different in work.

Figure 2.21 Packer

Palletizer
Palletizer is used to put crate containing full bottles to pallet. It is similar to de palletizer in their
construction, but different in their function and degree of freedom. In palletizer number of sensors are
much amount than de palletizer even crate pusher machine is present in palletizer but not in de
palletizer. The moment of palletizer is up and down sliding and also rotational motion is presence but
not in de palletizer. Other components are the same to the one.

Figure 2.22 Palletizer

Keg line
Draught beer is filled on keg. A keg is a standardized cylindrical metal barrel made of chrome nickel
steel. Advantages of kegs are: all conveying and storing process can be automated, cleaning, sterilizing
and filling can be automated, and they are closed vessels with automatic leakage detection and require
fewer manipulations. Steps in the draught beer are;

Flash pasteurization

In this case before filling the beer should be pasteurize by flashing method. Flash pasteurization occurs
before the beer put to its final container but the pasteurization is carried out on line using heat
exchanger at temperature of 74°C for 30 seconds. The difference between bottled beer and draught
beer are pasteurization way, pasteurization temperature and time, shelf life. The shelf life of draught
beer stays for one month.

Empty turning machine

Also it is called inverter machine. Used to invert the kegs where came from the input and this passed to
external washer machine.
 Figure 2.23 Empty turning machines
External Washer Machine

External washer is a machine used to wash external part of the keg at temperature of 40°C-50°C for 7
seconds.

Figure2.24 over view of external washer machine

Internal washer and filler

In Raya brewery S.C there are two internal washers and fillers each. The process of internal keg cleaning
filling has three stages at temperature of 80°C-82°C for 40 seconds using 90% concentration of caustic
and acid concentration is 16 % for cleaning case.

Stage-1: first pressurizing the keg to remove the residual materials from the keg and rinsing by water.

Stage-2: blowing out of water, rinse by caustic, blowing out of caustic and rinsing by hot water.

Stage-3: blowing out of hot water with steam at temperature of 85°C, steaming, venting and CO 2
pressurizing and filling of draught beer.
 Figure2.25 over view of internal washer and filler
Rating system

This is called weight sensor used to check weight of full keg. If the full keg is under fill or over fill, it is
pushed using pusher. Then the weight of full keg 39kg. But 9kg is the weight of the keg whereas 30kg is
equal to volume of kegging i.e. 30 liters of draught beer.

Figure2.26 rating system

Labeling
The labels carry important and effective imprints used to decorate the kegs glues are used to stamp the
papers with the kegs.
 Figure 2.27 over view of labeling
Videojet
It used to write the shelf life of the draught beer on the keg. The labels carry important and effective
imprints used to decorate the kegs glues are used to stamp the papers with the kegs.
 Figure 2.28 video jet
Full turning machine

It is called full inverter machine used to invert the full kegs sent to the output.

Figure 2.29 Full turning machines

 Main Difference between Bottled Beer and Draft Beer

Table 1 Deference between Beer and Draft

2.4 The Work Piece or Work Task We Had Been Executing Is;
In Raya brewery S.C. the overall process is done automatically even if there is done manually they do by
the operators only. This is told when we enter the company as rule of the company by our company
adviser. The only we have the task we work are to see properly and listing and to do simple tasks which
are done manually by operates are those:-

Put the unclean bottles and labeler contains in to the crate and put the barked bottle to the storage tank
which is rejected by visual bottle inspection.

Adjust the dilapidated bottles and open the closed bottles by using stick at the intern of bottle washer.

Adjust the crate when miss the line of motion.

Closing the keg.

Put the keg to the roller chain before entering the empty turning machine.

2.5 Procedure and Methods We Have Been Using To Perform Our Task
The main procedures and methods are:

Understanding the function and characteristics of each devices and machines.

By observing and attending in the whole steps that we have seen from the operators and from our
supervisor.

By using sequential step of observation to know each and every processes of the plant and by identifying
their problems.

By reading Manuals of every machine and devices.

From group discussion among students and supervisors, by formal and informal interviews with workers
and technicians.
2.6 .Major Challenges We Have Been Facing While Performing Our Work
Tasks Are;
Most of manuals on the company are written by Germany language since the installation is done by
Germen company.

We don’t have enough safety equipment to perform our tasks safely.

There are some restricted areas that we cannot enter without safety equipment.

Our advisor on the company is a production supervisor of the company, So he have no free time to help
us.

2.7. Measure We Have Been Taking In Order To Overcome the Challenge

In parallel to these challenge we have been facing, we were also expected to take measures to
overcome the challenges. Here are some of the measures we have been taken:-

Use the available manuals and time effectively.

By following the company rules and regulations.

Asking the operators politely to corporate with us at their free time.

Make close relationship with each of workers and operator of the company.

Revise our previous knowledge that would support the specific task we are doing.

2.8. Some Problems of the Company and Possible Solutions

Problems that we observe in the company are; specifically in packaging section there is no bottle brake
machine and no mechanism use to enter and release the keg all these are done by human labor.
Therefore, this task affects the overall production. The possible solutions are

Need a machine used to brake the bottle

Need a machine used to put the keg to the conveyer at the start and at the end of the packaging section

Need a machine used for packing the bottles released from the conveyor chain since they are detected
as not clear during empty bottle inspection because the bottles are packed by human labor

In bottling under fill beer is drained as waste but it is possible to recycle it by designing appropriate
method of recycling
 Chapter Three
Over All Benefit Gained From Internship
From experiences of internship we have seen practically what we learned theoretically. Therefore
internship enables students comparing theoretical knowledge with practical work. Generally benefits
gained from internship can be classified in terms of:

3.1. Improving our practical skills

3.2. Improving our theoretical knowledge

3.3. Improving our interpersonal communication skills

3.4. Improving our team playing skills

3.5. Improving our leadership skills

3.6. Understanding about work ethic related issues

3.7. Entrepreneurship skills

3.1. Improving Practical Skills

During lecture class that we gain the theoretical knowledge changes to practical access through the
internship period that we apply in 72 days. Theoretically we know some mechanical and electrical
equipment’s which work mutually for one work to have clear working result properly. From this learning
we develop our practical experience how can to operate some machines in somehow. We can offer:
creativity and an innovative approach to solve problems .we get so many practical skills from
experienced mechanics. For example:

Bottle inspection.

How to insert labeling papers.

3.2. Improving Theoretical Knowledge

Internship program gave us the opportunity to apply our theoretical knowledge in real world
environments, in addition to the practical skill. We can also improve our theoretical knowledge by
observing all over the processes of the machine how it work by this activity already develop our
theoretical knowledge. For example

Material handling and movement system

All the mechanism movement of parts

 3.3. Improving Interpersonal Communication
Skills In the company, we were working with all the technicians and operators peacefully and we are
wisely communicated easily with them in order to facilitate the work. When you are skillful with
communication it helps for the following advantages.

To gather information.

To read easily the work condition.

To improve relationships with others and within.

3.4. Improving Team Playing Skills

The most important point in team playing skill is just reaching an agreement from different points on
the work to be done. Therefore it’s very important to work together in order to achieve higher
productivity and save time. Furthermore, to have a common understanding on the task that is to be
accomplished, we always try to listen carefully those individuals with whom we are working. After
listening others idea, we provide an idea which we think is very constructive for the task being done.

3.5 .Improving Leadership Skills

it`s leading the careers of the company. Problems in the company come in all size, shape and color in
different period time. Thus, a person who is in the position of leadership seeks optimal solution to the
problems and should be smart enough to manage those individuals whom he/she is leading.

In terms of improving leadership skills, we offered the following:

To plan, prepare and schedule all necessary materials

To become more reasons because in action

To know ourselves and to make self-important

To become precise and more skill on our judgment

To give technical support

To increase our work status

Be technically proficient

Seek responsibility and take responsibility for actions

Make decisions.
3.6. Understanding about Work Ethics
Related issues in today’s complex world, Ethical conduct of workers is very important for developing
healthy working environment and increasing productivity. Ethical work conduct enables us in order to
possess appropriate behaviors in the work and so, we develop proper relationships with coworkers and
it helps us to create good working environment. . It also involves such characteristics as honesty and
accountability. In our period of internship, we understand what work ethics, one of ethics is punctuality.
To be punctual is duties of every worker that they could achieve their task with the time given. Some of
work ethics are listed as follows:

Reliability

Punctuality

Office disciplines

Honesty

Avoiding potential or apparent conflicts of interest

Co-operation

3.7. Improving Entrepreneurship Skill

Most skills are included in entrepreneurship skill like management skill, communication skill, the ability
to work, the ability to decide& taking responsibility. I have improved entrepreneurship skill by
performing task effectively and working cooperatively with the staff workers. From the internship
program I gained different ideas like;

Good time management: Good time management is how to use your time to perform task perfectly. The
company workers have good time management and they perform their task on time including their
punctuality. My supervisor on the company advices and help me to perform my task efficiently and to be
punctual. This enables to improve good time management ability.

Accountability: Accountability is being responsible for the problem seen on the task you perform I have
been improved the habit of accountability during internship period.
 CHAPTER FOUR
CONCLUSION AND RECOMMENDATION
4.1Conclusion
Generally it is concluded that this internship program is very useful to know the practical work in
relation with the theoretically knowledge. It also helps us to understand and get ready for the work that
expects us after graduation. We were taking our internship program in Raya Brewery S.C and it was very
successful and gave us so many advantages. Some of them are:

Allow us to both make and develop professional contacts, for our future job search

Assist us in developing greater understanding of our own strength and weakness

To understand the company’s Work flow

Upgrade our theoretical knowledge at school

Industrial automation system

Leadership skill

Knowing the industrial always used terms

Knowing working standards

Work ethics

Team playing skills

4.2 Recommendations
During the 72 days of internship experience period some positive and negative things have seen in the
hosting company. In this part some points are suggested to hosting company.

Safety shoe should be given for trainee students because they are members of the workers so they need
safety for the duration of their internship.

Give freedom to the intern students after learn to practice.

We recommend using material handling equipment’s to save human tired or from safety purpose.

Helmet should be given for all workers for the sec of their safety.

Spur parts for all machines should be available as much as possible in spur part store for maintenance
and changing of damaged parts.
Row material such as malt is not produce in Ethiopia its highest quantity; as a result the company enters
to high cost because of transportation. So the company must motivate to the farmers to produce the
malt in Ethiopia to mutually benefit.

Therefore, it is recommended that, the company should host more intern students in the future for the
common good of the student and its company.
 Reference
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Woodhead Publishing Limited and CRC Press, 2004.

2. Den Skandinaviske Bryggerhøjskole Packaging Packaging Technology Abstracts Module.

3. Operating Manual Filler – Modular Design, Base-Handling System by krones 2013.

4. Operating Manual Double-End Bottle Washer by krones 2013.

5. Technology Brewing and Malting, Wolfgang Kunze, International Edition, 1999.

6. Louis F Hertman &A.L. Oppencheim (December 1950). ‘On Beer and Brewing Techniques in Ancient
Mesopotamia.

7. Badnmus, M. A. (2011). Fore casting area and production of sorghum in Nigeria using autoregressive
integrated moving average model.

8. Asante, S. A. (1995). Sorghum quality and utilization African Crop Science Journal. A.

9. Dadzie, S. K. (2012). Adoption of modern agricultural production technologies .