REPORTS OF RAYA BREWERY S.

WOLDIA UNIVERSITY

INSTITUTE OF TECHNOLOGY

SCHOOL OF MECHANICAL AND CHEMICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

TITLE: - INTERNSHIP REPORT

HOSTING COMPANY: RAYA BREWERY SHARE COMPANY

Student name

1. AWET KAHSU
2. BRHAN G/KIROS
3. GIRMAY TADESSE
4. SENAIT HAFTU
ADVISOR NAME: Mr. NIGUS TEAME

Submission date 26/07/2021

MAYCHEW, TIGRAY, ETHIOPIA

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Declaration

Based on Ethiopia institute of technology Woldia university program with the cooperation of
university industrial linkage and companies, we have been working our internship experience in
Raya Brewery Share Company for the specified three months. With this regard we have certified
that this paper is our original work and all materials used in this internship report have been duly
acknowledged. Thus, we have completed our internship program successfully with the advice of
our university advisor and company supervisor.

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Acknowledgment

First and for most, we would like to thanks to God who helps us and being with throughout our
endeavor and also we would like to give our great thanks to our advisor Mr Nigus Teame for his
relevant advice about how to properly work in the company and has to make this report and for
his relevant information about how we working the activities which are carried out in the factory
and how to save ourselves and the machines from any danger. We would like to express our
deepest gratitude to all of operators and team leaders for great assistance throughout the
company. Lastly we heartily thank our family for their support and encouragement.

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Executive summery

This report tries to present the company background, the main product of the company, the
overall work flow, overall benefit from internship program we gain and work flow of the section
we work. The overall work flow of the company focus on the main structure of the company. 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
and upgrading theoretical knowledge skills are shown clearly.

Each section has machines, like de-stoning, drum sieve, hammer milling, pre-mashing, mash
kettle, mash filter, wort pan, whirlpool, boiler, bottle washer, filler, crater and other machine.

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Table of Contents

Declaration........................................................................................................................................i

Acknowledgment.............................................................................................................................ii

Executive summery........................................................................................................................iii

CHAPTER ONE..............................................................................................................................1

BACKGROUND OF HOSTING COMPANY...............................................................................1

1.1 INTRODUCTION.................................................................................................................1

1.2 Objective of the company......................................................................................................2

1.3 Vision of the company...........................................................................................................2

1.4 Values.....................................................................................................................................2

1.5 Main product and service of Raya brewery S.C....................................................................3

1.6 Main customers (end users of) Raya brewery S.C.................................................................3

1.7 Work flow of the company....................................................................................................4

1.8 Raya brewery management structure.....................................................................................5

CHAPTER TWO.............................................................................................................................6

OVERALL INTERNSHIP EXPERIENCE.....................................................................................6

2.1 How you get into the company..............................................................................................6

2.2 In which section of company you have been working?.........................................................6

2.3 How does the work flow in section look like?.......................................................................6

2.3.1 Brew house......................................................................................................................7

2.3.2 Fermentation and Filtration.............................................................................................9

2.3.3 Utility.............................................................................................................................10

2.3.4 Packaging Room............................................................................................................14

2.4 Which work piece or work task you have been executing?............................................26

2.5 Procedures and methods while performing task..................................................................27

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 REPORTS OF RAYA BREWERY S.C

2.6 How good you have been in performing your work task?...................................................27

2.7 What challenge you have been facing while performing your tasks?..................................27

2.8 What measures you have taken in order to overcome these challenges?.............................28

CHAPTER-THREE.......................................................................................................................29

OVERALL BENEFIT GAINED FROM THE INTERNSHIP.....................................................29

3.1 In terms of improving practical skills..................................................................................29

3.2 In terms of upgrading Theoretical Knowledge....................................................................30

3.3 In term of improving Interpersonal communication skills...................................................30

3.4 In terms of improving team playing skills...........................................................................30

3.5 In terms of improving leadership skills................................................................................31

3.6 In terms of understanding about work ethics.......................................................................31

3.7 In terms of entrepreneurship skills.......................................................................................32

CHAPTER FOUR.........................................................................................................................33

CONCLUSION AND RECOMMENDATION............................................................................33

4.1 Conclusion...........................................................................................................................33

4.2 Recommendations................................................................................................................34

Reference.......................................................................................................................................35

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List of figures

Figure 2. 1 over view of De-palletizer machine............................................................................15

Figure 2. 2 over view of Unpacker................................................................................................17

Figure 2. 3 over view of Crate washer...........................................................................................17

figure 2. 4 over view of Bottle washer..........................................................................................20

Figure 2. 5 over view of EBI.........................................................................................................21

figure 2. 6 over view of filler.........................................................................................................22

figure 2. 7 Bottle decorations (labeling)........................................................................................23

figure 2. 8 Packer...........................................................................................................................24

figure 2. 9 Palletizer......................................................................................................................24

figure 2. 10 Empty turning machine..............................................................................................25

figure 2. 11 Rating system.............................................................................................................26

figure 2. 12 Full turning machines.................................................................................................27

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CHAPTER ONE

BACKGROUND OF HOSTING COMPANY

1.1 INTRODUCTION

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. The 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 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 Bokhara 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.

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The company was officially launched on May 08, 2010 at Maichew town. Presently it has more
than 400 shareholders and its head office is setup in Bole Sub City, Keble 03/05, Robel Plaza-
building. The capacity of the Raya brewery to be established shall be based on the following
production program. Total output is 300,000hl sales beer per annum. Out of this: 85% is
produced as bottled beer, 15% is produced as draft beer and total production loss is taken to be
10%.

1.2 Objective of the company

The main objectives of Raya brewery S.C are

 To refresh the nation through producing quality beer.

 To increase the annual beer production of Ethiopia

 To create value and job opportunity of people

1.3 Vision of the company

 To support socio economic development of Tigray region in particular and to the

overall development of the country in general.

 To give value for eco environment in friendly manner.

 By generated profit to improve the socio-economic wellbeing of the Tigray region.

 To produce and seek quality beer at reasonable profit.

1.4 Values

 Integrity, accountability and transparency.

 Full Customer satisfaction and strive to exceed their expectations.

 Always add value, handle properties with care and ensure efficient utilization of
resources.
 Work hard to be best in class and lead the way for quality.
 Work hard to be best in class and lead the way for quality.
 Organizational and individual development.

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 Ensure safe working conditions to all employees.

 Build sustainable, closer and long-lasting relationship with customers and
partners.
 Provide necessary support to our employees as much as possible.

1.5 Main product and service of Raya brewery S.C

The main products of Raya brewery are: -

 Raya beer
 St. George beer
 Castel beer
 Drought beer

1.6 Main customers (end users of) Raya brewery S.C3

The company 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. The
regions are:

Region 1: covers Desie, Addis Ababa and Mekelle.

Region 2: this covers the whole Tigray region.
Region 3: east and south parts of Ethiopia

1.7 Work flow of the company

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Malt dust metals, stone and impurities husk

Pure malt
Silo Drum sieve Di stoners
Dry Pre mash
milling

Mash
Trub
Sd
hd Wort Sweet work
Mash filter Mash
hh
Whirl Wort
collector kettle
d
pool

Keg
line

Filler &
Fermentation BB FBI
crown
&filtration T
machine

De-
palleti Unpa Bottl
zer cker e
Visual
wash
inspection
er

From customer

Crete
washer

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Palletize Packer
Labeler Pasteurizer
r

To customer

1.8 Raya brewery management structure

Board of director

CEO

Production Procure
Project Commerci Finance and
and technical ment
5 manager al director administrate
and
sourcing
director
 REPORTS OF RAYA BREWERY S.C

PRODUC

Technic
Product Sales
al Finance
ion

Logistic Plannin
g Marketi
s HR and
ng
adminis
Procure tration
ment

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CHAPTER TWO

OVERALL INTERNSHIP EXPERIENCE

2.1 How you get into the company

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 then we start the work.
We were select this company by its condition, besides of the distance and its new company we
get information that is good and moderate machines.

2.2 In which section of company you have been working?

During our three-month 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.

2.3 How does the work flow in section look like?

Beer is an industrial product. A beer is one of the oldest and most complex in the preparation of
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 production .The raw material for malt is
barley. Its uses depends on the fact that barley has high starch content and the
husk still adheres to the gain, even after threshing and processing to malt.

 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.

 Yeasts: Are micro-organisms that are playing a role of fermentation process on

sugar to produce alcohol and carbon dioxide.
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Raya beer has four main sections those are:-

 Brew house

 Fermentation and filtration

 Utility section and

 Packaging.

2.3.1 Brew house

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.

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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.

Equipment used for cleaning of malt is:

 Aspiration: used to suck off dusty air.

 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 by settling whereas malt pick up
on space and passed to sieves.

 Magnets: separates materials which have magnetic behavioral starting next to aspiration
up to de-stoner last.

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2. Milling section

This section is used to crush malt in to smaller size (to extractable section) using hammer mill.
Its capacity to crush 8 tons of malt per hours. Purpose of milling to get efficient extraction, fast
mixing & mashing, total conversion of starch, rapid &complete separation of wort.

3. Pre-mashing

It is used to mix the grist with hot water & cold water. The objective of pre-masher are pre

Figure -mush-in tank

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Venting protein coagulation and to activate protease enzyme for protein degradation.

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.

5. Mash filter

Mash filter is the separation of wort from spent grain. This mash filter separates wort through
sparking and compression. Sparking is washing the extraction of wort with hot water while
compression is separating wort by pressing the mash under pressurized air. Finally using positive
displacement pump discharge the spent grain to its temporary storage called silo.

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.

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 0C.
Boiling of wort is carried out in wort pan via steam for different purpose. Mainly the aim of wort
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boiling is to stabilize the wort compassions, Removal of undesirable volatile compounds, to

remove water in the form of vapor and extract the desirable material from hops which gives to
beer its characteristics aroma and flavor. 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
 Concentration of wort
 Sterilization of the wort to prevent wort spoilage
 Stopping enigmatic action
 Evaporation of some water
 Isomerization of bitter substances
 Precipitation of protein polyphenol complexes

8. Whirl pool

Whirl pool is used to separate trub from the hopped wort and then the hopped wort is transferred
in to fermentation tank but trub is stored in trub tank.

2.3.2 Fermentation and Filtration

1. Fermentation

Fermentation can be preceded by respiration is performed by wort sedimentation in kettles,

flotation, centrifugation or filtration. Aeration is used to ensure that the yeast is supplied with an
adequate amount of oxygen in order to support cell multiplication. Later on, the metabolism of
the yeast changes from respiration to alcoholic fermentation; then processes the carbohydrate
molecules contained in the wort to produce ethanol and carbon dioxide. Other ingredients of the
wort are also converted. The resulting fermentation products significantly influence the character
of the beer produced. The duration and course of the fermentation are determined by the yeast
strain and by controlling the process of parameters are pressure and temperature. Fermentation
takes place in cylindro-conical tanks (CCTs). CCTs are installed outdoors. The CO2 produced
during the fermentation process can be collected by a CO2 recovery system. Fermentation is the

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process of converting sugar into ethanol and carbon dioxide using microorganism which is
known as yeast.

2. Filtration

This is the final process to be considered in beer treatment prior to packaging and the process
involves removal of any remaining yeast cells and the removal of precipitated protein and
polyphenol haze materials. 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 process involves the removal of any
remaining yeast cell and Removal of precipitated protein and polyphone haze material. 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. Before filtered beer is stored in bright beer tank carbonation (CO2) will
dose on line for the purpose of beer stabilization & extend the shelf life of the beer.

2.3.3 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.

1. 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. Under this cooling plant, there are two main cooling
processes.

First, ammonia in liquid form at a temperature of 40°C under 10bar pressure is stored in a
permanent closed tank. But this must be transported in to storage tank 02 and storage tank 01.

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Glycol is brought from its source at -2°C but glycol for cooling must be -4°C. Liquid ammonia
converts to temperature and pressure to -7°C and to 2bar respectively by expansion valves. Then
glycol is cooled by transported to storage 02 is used to cool glycol but before it enters to that
tank, it is better to reduce the tem ammonia in plate heat exchanger to -4°C temperature and
returns to its storage whereas ammonia is passed to compressors as it is. Then after reaches its
temperature to 120°C. This also passed to condenser in order to cool down to temperature of
40°C by fan and cold water.

Secondly: cooling of water by glycol: water used for cooling purpose and the degassed water
used for dilution of beer is cooled by glycol after being cooled by ammonia. Ammonia that was
storing at T° of 40°C and under pressure of 10bar is transferred to storage 01 to reduce its
temperature of 3°C and pressure of 3bar by expansion valve. Brew water and degassed water are
brought at a temperature of 27°C. Then cooled by ammonia in plate heat exchanger to 5°C
temperature but ammonia changed from liquid to gas return to storage 01 and after sent to
compressors that reached to temperature of 120°C then passed to condenser to cool down to
temperature of 40°C whereas brew water and degassed water are cooled by glycol at a
temperature of -4°C to 1.5°C and 2°C respectively in plate heat exchanger.

2. Carbon dioxide Recovery

Co2 is very important in beer making companies in order to prevent direct contact between air
and beer as well as draft by creating pressure. But raw co2 has odor test and impurities so co2
recovery plant is necessary.
 CO2Rawgas contains a lot of odors, tastes and in purities.
 The gas needs to be cleaned and purified by a CO2 system according the latest technology
 Afterwards it can be used in the rest of the brewery or soft drink industry
Steps in the process
 Cleaning of possible foam remains
 Washing to take out solid parts and alcohols
 Compression in 2 stages
 Taste and odors removal
 Drying
 Cooling down to liquefaction of the CO2
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 Storage in liquid form

 Evaporation
 Reduction of pressure and temperature for factory usage
Why this special treatment
 Cleaning of the gas (foam separator / gas washer)
o Dissolving foam, alcohol and other dissolvable components
 Deodorizing (ACF)
o Absorbs the smell containing compounds
 Liquefying (Condenser)
o Turn gas into liquid (most economic point at 17,5 Bar @ -24 °C) and removing
non-condensable gasses
o Drying (Driers)
o To remove the moisture from the gas before it is liquefied (else the pipes in the
condenser get blocked
Why Liquefaction of the CO2
 The total volume of CO2 storage decreases
o In case CO2 is stored in gas phase the storage volume would be 500 x bigger!
 The purity of the CO2 will improve
o Only CO2 is turned into liquid at 17,5 Bar @ -24°C
o Air and other non-condensable gases are still present
o These gases can easily be blown off from the CO2 condenser
o With stripping technology the separation is even better
Parts of CO2 recovery process
 Foam Separator
 CO2 gas balloon
 Booster (option)
 CO2 gas washer (High Pressure)
 CO2 Compressor
 ACF / Driers
 CO2Reboiler

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 CO2 condenser + Cooling system

 CO2 Pump
 CO2 Tank
 CO2 Evaporator
 CO2 Reducing station
A. foam trap
Main Function
 To avoid that foam that can come along with CO2 from the CCT’s enters the CO2
recovery plant
B. Boosters
Main Function
 To compress the CO2 gas from a lower pressure to a higher pressure
 Provides positive pressure necessary to overcome distances line losses and Gas washer
resistance.
 Increases the suction pressure on the 1ste stage of the CO2 compressor which increases the
capacity.

C. Gas balloon
Main Function
 Equalize the difference between the CO2 supply from fermentation and the capacity of
the CO2 compressor.
 To create a gas buffer to avoid excessive starts and stopping of the CO2 compressor.
 Balloon size always depending on plant / fermentation capacity.

D. Gas washer

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 Remove water dissolvable impurities from the incoming CO2 gas

E. CO2 Compressor
 A Compressor is a mechanical device that increases the pressure of a gas and can
transport the gas through a pipe by reducing its volume. Co2 compressor is a specific
type of gas compressor. Pump pressurizes and transport liquid. Reciprocating piston
compressor is appositive displacement type of compressor. It uses piston driven by
crankshaft.
Main Function
 To compress the fermentation gas (P approx. 1 bar abs) from the gas washer to approx.
17, 5 Bar before it enters the ACF/Driers.
 The compression is done in 2 stages
 After each compression stage the warm CO2 needs to be cooled down by coolers (Inter-
After cooler) Different cooling media can be used.
 Additional cooling of the cylinder head is required.
F. ACF/Drier
Main Function
 Remove the impurities from the CO2 gas that are not already been removed in the gas
washer by means of Active Carbon

G. CO2 Storage
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Main function
 To store the produced liquid CO2 of the recovery system
H. CO2Evaporater
Main Function
 To evaporate liquid CO2 form the Tank into gas to be used in the brewery (brewery
consumption
I. CO2 reducing valve
Main function Back Pressure station
 To hold minimum pressure in the CO2 storage tank

3. 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.

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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.

. It has different components of material to boil the water:-

 Water softener tank
 Economizer tank
 Boiler tank
 Drainage tank
 Oil tank
 Valves; -boll valve
 -needle valve
 -safety valve

 Centrifugal pup
 Gear pump
 Servo meter
 Pressure gage

4. 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

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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.

5. 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.

In Raya brewery water comes from May Muk through the help of centrifugal pumps in to
water treatment plant using four wall. Then its turbidity is checked online by amplifier, and if
turbidity less than normal Turbidity Unit it enters in to well water tank otherwise drain.

6. Waste Water Treatment Plant

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.

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2.3.4 Packaging Room

In packaging section the work flow looks like as follows

BBT Keg

Filer & Visual Bottle

crown inspection washer
machine EBI

Unpacked
FBI Crate washer

Pasteuriz
ation

Labeler Packer Palletizer De-palletizer

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Empty bottle
Packed beer for from customer
customer customer

Packaging is the final process in beer production factory.

There are two main lines in packaging process:

1. Bottling line

2. Kegging line

Bottling line

This section is mainly concerned about packing bottles containing beer and delivering this
product to customers. Averagically it packed about 36000 bottles per hour. It ensures the product
that can be supply to customers being free from micro-organisms. Bottling line is described as
follows step: -

1. 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 dischar.ge
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.

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Empty pallet discharge ፦ when the in feed pallets completely discharge by the de palletizer the
roller discharge the empty pallet to palletizer.

Figure 2. 1 over view of De-palletizer machine

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.

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 Gripper: - is a part of de palletizer which is used to holding .This mechanism is done by

the pneumatic presser system.

2. 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.

Figure 2. 2 over view of Unpacker

3. Crate washer

Crate washer machine is a machine which is used to wash the crate that are dirty which comes
from the customer. First the dirty create enter in to pre wash stage after completing this stage it
washes with steam and water and rinse with water and convey to the packer machine.

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Figure 2. 3 over view of Crate washer

4. 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 four 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 are 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)
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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,

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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

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Figure 2. 4 over view of Bottle washer

5. Visual bottle inspection

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

6. 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. in bottles to reject.

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Figure 2. 5 over view of EBI

7. Filler

After EBI bottles are sent to filler and the air inside bottles was sucked out by vacuum chamber,
then CO2 is charged to bottles to remove O2 from bottles after slightly difference beer is filled
by taking from BBT. Filling beer is operated at high pressure even sterile with hot water
continuously the bottles in order to remove air from head space with foam and crowned with
carbon dioxide. 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.

Sniffing: used to control pressure releasing.

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Figure 2. 6 over view of filler

8. 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.

9. High pressure inspection (HPI)

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

10. Full bottle inspection 1

Filled bottles were checked for under fill and proper crowning by full bottle inspection machine
then bottles are transported to pasteurization.

11. 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.

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 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).

12 .Bottle decoration (labeling)

Labeler is used to label the brand name and kind of beer on the body and neck of bottles using
glue. 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.

Figure 2. 7 Bottle decorations (labeling)

13. Full bottle inspection-2

This is used to check whether the bottles are packed and label properly.

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14. 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 & unpacker is removing the bottle in the crate, so that
same structure, working principle, but different in work.

Figure 2. 8 Packer

15. 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
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. 9 Palletizer

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2 Keg line

Draught beer is filled by keg. A keg is a standardized cylindrical metal barrel chrome nickel
steel. Steps in the draught beer

1. 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 15 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.

2. 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. 10 Empty turning machine

3. External washer

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

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4. 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 CO2
pressurizing and filling of draught beer.

5. 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.

Figure 2. 11 Rating system

6. Videojet
It used to write the shelf life of the draught beer on the keg.
7. Full turning machine

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

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Figure 2. 12 Full turning machines

2.4 Which work piece or work task you have been executing?

In Raya brewery Sc. 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 the operators those are:-

 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 Procedures and methods while performing task

 By see when the operators are work

 Integrating with the operators

 To help the operators as they are work by labor

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2.6 How good you have been in performing your work task?

In the first month we were that much good in performing the works .After the first month we
work by ourselves means student to student as there is happening of coved 19 operators are not
work as the first month beside this we have the chains to learn by student to student. Then
through practice we became good persons in understanding different type works in the company
process sections. Experience will be obtained from involvement therefore; we have involved in
different work of the company and have gain a good experience. We have learned from our
mistakes and developed our strong sides. So we believe that we have performed our work in
accordance with the scope of the intern ship.

2.7 What challenge you have been facing while performing your tasks?

 In the first month we were confused with everything because we are new for the
environment and also for work.

 In the first month as coved 19 enters to Ethiopia there is misgiving to work properly.
Every operator are care there selves as they have not more information about the
coved 19.
 After coved 19 there also happen regional problem which give the chance to enter
more students to this company, besides this we miss so much chances as the company
is over load students are accepted.
 Have not internet access to follow up the work task, the manuals are not clear to
understanding and there was also shortage of translated manual in English language.
 We have not freedom to work properly.
 Failures of some devices in process and misgiving between the theoretical and
operational of the machines.
 Lack of library access to read manual and some reference are the main.

2.8 What measures you have taken in order to overcome these challenges?

 After the time we were familiar with everything especially with work.

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 To know the whole information and the operation of the machines we ask the
operators.
 By using one student to other student as the internet accesses means that by sheering
idea with other intern students and the operators
 Asking supervisor for help to integrate theoretical knowledge to tactual knowledge.
Taking some actual considerations between theoretical and actual variations
 Recommending the workshop workers to maintain failed device.
 We shift the time to inter the company to decrease the over load.
 Obeying carefully the rule and regulations of the company

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CHAPTER-THREE

OVERALL BENEFIT GAINED FROM THE INTERNSHIP

Internship allowed us the opportunity to apply our knowledge and skills in a professional setting
while still in school. Internship offer carefully planned and monitored work experience with the
goal being to gain additional knowledge from one the job exposure. Internship is also part of an
educational program in which can earn academic credit from our university. Internship is
arranged independently from the curriculum in which we would gain work experience only.

3.1 In terms of improving practical skills

From this internship program we have got a good chance to improve our practical skill highly.
We can see practically that we learned theoretical concept by visualizing different images. Some
lecturers took the initiative and tried to illustrate the practical part of this field by displaying
different graphic images in their lecture or suggested materials that were more or less illustrative
or ever took us to the site to show what the actual engineering looked like. But these trials were
fruitless and failed to give us the clear picture when compared from this practical skill. So this is
the best way to understand pictures simply. This internship program was exactly what we needed
to reduce the lack of practical skills we had. We improve our practical skills in many aspects. For
example malt storage, raw material handling, brew house, beer processing, bottling, keg plant,
utility and final product storage room which enables the best process flow, integrity among
different sections. We also improve the ability of maintaining all machine parts that is active
preventive maintenance that prolong the service life of machines and minimizing the productive,
maintenance time and cost as a result of reluctance to take active preventive maintenance. If the
corrective maintenance is found to be the only solution to sustain the normal working conditions
In general we have been improving our practical skills like: Creativity and innovative approach
to solving problems, The ability to analyze and interpret diverse, complexity, Critical thinking
and the ability to evaluate designs, plans and projects.

3.2 In terms of upgrading Theoretical Knowledge

In the previous 3 years that we were lingering in chemical engineering, we have taken many
Courses which improve our theoretical knowledge. Even if we know the science how something

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works and operates with in a paper, we could not imagine the working principle machines, the
operational methods. This internship program enables us to consolidate what we have taken
before and easily understand the invisible concepts that had been missed. We can gain detail and
clear way of application of equipment, machines, chemicals and instruments for the production
of beer. We can also identify the types of chemical process that they used and types of chemicals
added in each types of process. We can gate further theoretical knowledge by looking working
Principles of machines.

3.3 In term of improving Interpersonal communication skills

At the beginning of this program we were totally new for everything in the site. This was
difficult to ask any questions and motivated to know these questions. However after a few days
we were communicating with the operators simply. In our day to day activities we were contact
each person and develop our communication skill by asking a question that don’t understand for
us. In general we learn that we have to create a smooth relationship among different workers in
order to get social life and improving theoretical and practical knowledge.

3.4 In terms of improving team playing skills

Even though we are campus students and develop our team playing skill in the campus, we have
gate further skill by;

1. Develop listening skill.

2. Make a close relationship with guests at any time

3. Solving problem and identify it

When activities are done in group the acceptability, reasonability, accuracy and precision found
to be always better than those done individually. Here being respecting each other while we
discuss about some idea and ability to listen carefully are the mandatory tasks. Most of the tasks
we completed were assigned as group duty. However we had to work independently but at the
same time. While we were doing this different tasks, ideas where rose and there were arguments
between us. But at the end we agree on acceptable terms which believe helped us share what we
have in our mind. This thing helps us to develop our team playing skills to some extent.

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3.5 In terms of improving leadership skills

In this internship program we have understood the ways of wise leadership; firstly thinking
globally not personally then respect listen and work with all concerned bodies of the company. In
Raya brewery there are managers who have good leadership ability that they follow the rules and
regulation of the company including the constitution of the country. These managers lead
honestly as per rules and regulations of the company. We have seen how each worker is
controlled and organized to perform its day to day activities. Among all other managements we
have seen that human resource management is the most important one. We have actually
observed the method of controlling the working time and types of work done by each worker so
that the work proceeds according to the work plan. In generally Leadership is a skill to guide,
control and monitor peoples and for effective leaders a person should have an excellent
communication skill, confidence, share experience and devotion are very important role.

3.6 In terms of understanding about work ethics

In our understanding work ethics is a set of values on hard work and diligence, it also believes in
normal benefit of work and its ability to enhance. Actually any person should have ethics not
only in the work place but also in his/her social life. We have been guided and obeyed by the rule
and regulation of the company. Some of the work ethics include:

Punctuality: keeping the companies work beginning and ending time and to complete a given
task within the given period.

Office disciplines: in work place you don’t have to disturb the working area. For example
abstain from opening loud voice and things which disturb other workers working mood.

Reliability: the worker should be qualified for the part he/she is supposed to be performing.
He/she must have appropriate skill and knowledge for the task assigned.

Honesty: regarding this value each worker regardless of its status should abstain from bad
behaviors such as cheating bias corruption etc.

Cooperation: each worker should interact and cooperate with each other while working that is
because it is through such system problems could be easily solved. From this perspective, we
have gained a valuable lesson that transparency and carefulness are two very important work

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ethics one needs to abide and live by. These statements of intended conduct are expected of
every member (permanent members, associate members, contract members and student
members) of the Raya brewery.

General moral imperatives: As a Raya member we will contribute to society and human
wellbeing, avoid harm to others be honest and trustworthy, be fair and take action not to
discriminate, respect property rights and respect the privacy of others. Additional

Professional obligations: As a Raya brewery entrant we will strive to achieve the highest
quality in the processes and products of our work and Acquire and maintain professional
competence.

3.7 In terms of entrepreneurship skills

Emphasizing the growth of entrepreneurship would not only lead to new robust industry of its
own but also is a basis for improving the social and economic capability of the country. In this
internship program we learned small business enterprises startup skills where we should be
empowered with knowledge and skills to become effective entrepreneur. The state of being an
entrepreneurship can be realized when one engages in profitable risks and creates something of
value. These set of skills are what make a certain individual able to create a brand new set of
ideas that may help in the production process not only in the construction stream but also in any
form of activity that has a certain end product to it. During the program, we were not able to
come up with a whole new set of ideas that were implemented into action.

In general we have a wide range of entrepreneur skills from above skills including personal traits
and management skills. These are the ability to manage time and people successfully, the ability
to work both as part of a team and independently, able to plan, coordinate and organized
effectively.

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CHAPTER FOUR

CONCLUSION AND RECOMMENDATION

4.1 Conclusion

Generally it is concluded that this internship program is very useful to know the practical work
in relation with the theoretically knowledge of four years in the university. 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

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4.2 Recommendations

During the three months 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 to save human tired or from
safety purpose.
 Helmet should be given for all workers for the protection 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.
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.

Finally, raya brewery Share Company palletize 40 kg filled keg manually by operators. This
company uses above 5 operators per shift. Actually the maximum operating capacity of these
operators is 100 number of keg per hour (0.6 minute per keg). But the production capacity of the
company is 120 number of keg per hour (0.5 minute per keg). Thus there is loss of time.
Indirectly there is also lost of operator’s energy. As a result the labor cost of the company will be
high and the production speed of the company will be decrease.
When we calculate the loose

 There is 20 number of keg per hour, implies that 160 number of keg per one operating
shift which gives that 480 number of keg loose per day.
 There is 0.1 minute loose when they lift one keg due to they spent 0.6 min to lift one keg
which implies that 96 minute loose per one operating shift this gives 288 minute (4.8
hour) loose per day.

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During all these times we also was thinking to submit a project for the company to increase the
production capacity of packaging department but we could not done any project in case of
internet access, instability and in the cause of time. Finally we recommended that, to solve
those problems the company should be given as a project to the next intern students.

Reference
1. A manual Raya Brewery Sh.Co Brew House Wort Production Compiled By: Ermias Teshome,
November 2015.
2. Brewing science and practice, Dennis E. Briggs, Chris A. Bolton, Peter A. Brookes and Roger
Stevens, Woodhead Publishing Limited and CRC Press, 2004.
3. Den Skandinaviske Bryggerhøjskole Packaging Packaging Technology Abstracts Module

3, 2006.

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

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

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

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