Report on Mai Ayni Right Highland Company

ADIGRAT UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF ELECTRICAL AND COMPUTER

ENGINEERING

INDIVIDUAL FINAL INTERNISHIP REPORT

PREPARED BY: ABADI GODIFAY.……………………………….ID NO: RET 0002/06

HOSTING COMPANY : MAIAYNI / RIGHT BOTTELD BUSINESS COMPANY

DURATION OF TIME: 01/02/2010-03/06/2010 E.C

ADVISOR: I/R Yirga.A

SUBMITED TO ELECTRICAL AND COMPUTER ENGINEERING DEPARTMENT

SUBMISSION DATE: 03/05/2010 E.C

Report on Mai Ayni Right Highland Company

Declaration

I, Abadi Godifay student of Electrical and Computer Engineering Department (Power Engineering
Stream) at Adigrat university, hereby declare this Internship report of Mai Ayni Right bottle Water
Company is original work, has not been presented for a degree in this or any other universities.

Student Name Id No Signature

Abadi Godifay RET 0002/06 ______________

This report has been submitted for examination and Seminar presentation of the Report was
made on 30th February 2018 with my approval as a university advisor.

Project Advisor Signature

Mr.Yirga.A ______________

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ACKNOWLEDGMENT

First and for most, I would like to GOD for granting me a strength to accomplish this task
successfully. Second, I would like to thank department of Electrical and computer Engineering
in collaboration with Adigrat University Industrial Linkage and department to provide as, the
internship program.

Next I would like to express my deepest gratitude to my advisor, instructor Yirga Amaha for
his outstanding professional guidance and encouragement throughout this work.

Special thanks goes to all Mai Ayni staff members starting from the manager to all workers for
their remarkable support and motivation. The work culture in maiayni really motivated me.
Everyone is friendly and cheerful companion there.

I owe my greatest gratitude to Mr.Solomon for his unlimited support and extreme guidance in
which it has contributed me tremendously to the completion of my Internship at the company
successfully.

Further I would like to extend my sincere thanks to Mai Ayni staff members; which are all
engineers, workers, service providers and etc that I didn’t mention their name for their
remarkable support and contribution through out my Internship period.

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Report on Mai Ayni Right Highland Company

EXECUTIVE SUMMARY

Internship programme are designed to expand the depth and breadth of academic learning in a
particular areas of study. It is an opportunity to receive experience in applying theories learned
in the classroom to specific experiences in the community and work world. An internship can
also heighten your awareness of community issues, motivate you to create opportunities,
embrace new ideas, and give direction to positive change. A successful internship can give a
valuable information in making decisions about the direction of future studies or employment.
An internship is an opportunity to not only use and develop industryrelated knowledge and
skills, but also to enhance some of the skills that are transferable to any professional work
setting. That’s why according to Ethiopian curriculum it has been added this internship
program to all undergraduate students in all universities.

During my four months’ internship in Mayayni Right Bottle Water Company, I gained a lots
of benefits in terms of improving practical skills, upgrading theoretical knowledge, improving
interpersonal communication skill, improving team playing skill, improving leader ship skill,
understanding about work ethics, and entrepreneurship skill. Additionally, I gained practical
experiences about injection machine, water chiller (water cooling machine), and blowing
machine in the production section of the company. I gathered practical experiences about
injection machine equipment like colour mixer equipment, the base, the hopper, the barrel, and
the clamping unit, feed water tank and water treatment. I also get practical experiences about
three in one machine which involving Pet Bottle Rinsing, Filling, Capping. Coming with label
shrink tunnels, these are suitable for water filled bottles packaging as the desired (required)
number of bottle. Another I get the knowledge about the Activated carbon (AC) filtration is
effective in reducing certain organic chemicals and chlorine in water. Additionally,
microorganism or contaminant is attracted to and held (absorbed) on the surface of the carbon
particles.

It has been a wonderful experience in Mai Ayni right bottle company and I recommend the
right highland company organises more of such programmes on the company to widen its
sphere of operation. It will be of much benefit to the company if it continues to create similar
platforms for students across all Ethiopian universities.

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Report on Mai Ayni Right Highland Company

ABBREVIATION

EEPCO Ethiopian Electric Power corporation

APF Addis Pharmaceutical Factory

P.L.C Private limited company

PET Polyethylene terephthalate

PLC Programmable logic control

ML Milliliter

List Of Figures

Figure 1. 1: General structure of the factory work flow .........................................................................

7 Figure 2. 1: General electrical work flow of the company ....................................................................
11 Figure 2. 2 : panel board .......................................................................................................................

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12 Figure 2. 3 : Three in one machine .......................................................................................................

13 Figure 2. 4 : Flow diagram of water treatment plant ...........................................................................
14 Figure 2. 5 : Injection machine
.............................................................................................................. 15 Figure 2. 6 : Flow diagram of
PET bottle production ............................................................................ 15 Figure 2. 7 : Flow diagram of
polypropylene (PP) bottle caps production ........................................... 16 Figure 2. 8 : Ozone producing
machine ................................................................................................ 16 Figure 2. 9 : Film blow plastic
machine ................................................................................................. 17 Figure 2. 10 : : Plc model
....................................................................................................................... 18 Figure 2. 11 : Injection
machine with plc .............................................................................................. 18 Figure 2. 12 : Circuit
breaker ................................................................................................................. 19 Figure 2. 13 : PET
................................................................................................................................... 20 Figure 2. 14 :
PET-perform cavity .......................................................................................................... 21 Figure 2. 15
: PET-bottle blowing process ............................................................................................. 21

List Of Tables

Table 1. 1: National standard chemical analysis of the company ...........................................................

3

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Table of Contents
Declaration .............................................................................................................................................. I
ACKNOWLEDGMENT ............................................................................................................................ II
EXECUTIVE SUMMARY ........................................................................................................................ III
ABBREVIATION ....................................................................................................................................... IV

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List Of Figures......................................................................................................................................... IV
List Of Tables ........................................................................................................................................... V
CHAPTER ONE ......................................................................................................................................... 1
BACKGRUND OF INTERNSHIP HOSTING COMPANY ................................................................................ 1
1.1 BRIEF HISTORY OF THE COMPANY................................................................................................ 1
1.1.1. Objective of the company ..................................................................................................... 1
1.1.2 Mission and Vision of the company ....................................................................................... 2
1.1.3 Raw materials and inputs to the company ............................................................................ 2
1.2 Main products or services ............................................................................................................ 4
1.3 Main customers or the end user of service .................................................................................. 4
1.4 Overall organization and work flow.............................................................................................. 5
1.4.1 Roles and Responsibilities’ of Company Workers .................................................................. 5
CHAPTER TWO ........................................................................................................................................ 8
OVERALL INTERNSHIP EXPERINCE........................................................................................................... 8
2.1 HOW I GET IN TO THE COMPANY ................................................................................................. 8
2.2 WORK SECTION I HAVE BEEN WORKING IN THE COMPANY ........................................................ 8
2.3 How does the work flow in the section look like? ........................................................................ 9
2.3.1 Work flow of the machineries.............................................................................................. 10
2.4. Which work piece or work task you have been executing? ...................................................... 21
2.4.1 Maintenance section ........................................................................................................... 21
2.4.2 Work shop practices ............................................................................................................ 21
2.5. What procedure you have been using while performing your workTask ................................. 22
2.6. How good you have been in performing your work task .......................................................... 22
2.7. Main challenges that faced you during Internship time............................................................ 22
2.8. The measures you have taken to solve the challenges ............................................................. 22
CHAPTER THREE .................................................................................................................................... 23
BENEFITS I GAINED FROM THE INTERNSHIP ......................................................................................... 23
3.1. In terms of Improving Practical Skills......................................................................................... 23
3.2. In terms of Upgrading Theoretical Knowledge .......................................................................... 24
3.3. In terms of Improving Interpersonal Communication Skill........................................................ 24
3.4. In Terms of Improving Team Playing Skill .................................................................................. 24

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3.5. In terms of Improving Leadership Skill ...................................................................................... 25

3.6. In terms of Understanding about Work Ethics .......................................................................... 25
3.7. In terms of entrepreneurship skill ............................................................................................. 25
CHAPTER FOUR ..................................................................................................................................... 26
Conclusion and recommendation ......................................................................................................... 26
4.1 Conclusion................................................................................................................................... 26
4.2. RECOMMENDATION .................................................................................................................. 27
REFERENCE ............................................................................................................................................ 27

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Report on Mai Ayni Right Highland Company

CHAPTER ONE

BACKGRUND OF INTERNSHIP HOSTING COMPANY

1.1 BRIEF HISTORY OF THE COMPANY

MaiAyni/ right bottled water company is one of the Ethiopian highland purified mineral
water producing companies, which is found in Eastern zone of Tigray region at Adigrat
town. The company is 900Km far away from Addis Ababa and 126km from Mekelle
capital city of Tigray region. This company is private limited company which produces
purified mineralized water from natural spring water at the highland of golaa. Its
foundation was begun in 2000E.C having a total construction area of 3500 care meter
and it was completed in 2002E.C. After the construction was completed; it starts its
production since January 2003E.C. And the factory was designed to produce 3600
bottled water per hour and the company gives job opportunity for 120 people. The
amount of Birr needed for the total construction of the company was about 21,000,000
birr.
MaiAyni purified mineral water factory is a private limited company (P.L.C) owned by
Dori Kebede and now it has a total area of 7000 Carrie meter. The main source of the
spring water needed to MaiAyni purified mineral water factory is from enda yowuhans
holy water. In this factory, the purified mineral water is packaged in plastic bottles that
are manufactured by the factory itself. Purified mineral water can be classified as
carbonated or non-carbonated water; but mai ayni Business Company produces
carbonated bottled water. This company is organized to work eight hours per a day.

1.1.1. Objective of the company

General Objective; -

 The objective of the company is to build sustainable business that ensures financial
sustainability while making the company as a good corporate citizen.

 We are committed to our customers to provide what they expect to have a healthy life.
 To address social and environmental issues, and finding innovative ways to optimize
use of power, energy, and water.

 Overcoming a continuous search for social welfare of the organization to create a

pleasant community life.
Specific objective; -

 To create job opportunities

 To use modern technologies and machineries  To increase the work efficiency.

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1.1.2 Mission and Vision of the company

Mission

 By introducing latest technologies of water treatment mechanisms, producing market

demanded purified mineral water in the company;
Vision

 By producing more purified mineral water creating a healthy world at a future;

 Producing purified mineral water creating an increased future consumers Of treated
water;
 By increasing the consumers of purified mineral water, Maximizing future profit of
the factory;

1.1.3 Raw materials and inputs to the company

The main raw material used in Mai Ayni purified mineral water business factory was
spring water. As we had observed, the source of this water was from enda yewuhans
holy water. There were many types of raw materials and inputs in mai ayni bottled Water
Company; these are:

 PET (Polyethylene terephthalate) was used for making of plastic bottles.

 Chlorine: was used for disinfecting of water contaminated microorganisms.
 HDPE and LDPE (High and low density polyethylene) were used for making plastic
and capes.

 Ground water (spring water) was the main source of water needed for treatment.
 Master bunch was used for making of plastic bottles and capes by mixing with PET,
HDPE and LDPE to have the bottles and capes blue color.

 Hydrogen peroxide chemical was used for washing of filter types of the company.
 Citric acid was used to wash the filter media of hallow filter.
Amount of mineral constituents present in the purified water of the company are listed in
the following:

Table 1. 1: National standard chemical analysis of the company

Chemical analysis Amount (mg/l)

Sodium (Na) 3.4
Calcium (Ca) 11.0

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Magnesium (Mg) 2.9

Potassium (K) 1.1

Chloride 9.5
Sulphates 6.6

PH. 7

Fluoride 0.06

1.1.4 Machinery of the company

The company had been many types of machineries which were used during production process.
The main machineries of the company are listed as follows.

 Injection machine: this machine was used to make injected plastic bottles and caps.
 T-shirt bag maker plastic machine: this machine was used to make for small plastics.
 Three in one machine: this machine have three functions; filling, washing and capping
 Blowing machine: was used to blow the injected bottle to make original shape of Plastic
bottles.

 Steam generating machine: this machine was used to produce steam and this steam was
used to adhere the plastic that holds national written mineral contents on the external
surface of the bottles.

 Sharing machine: this machine used to package the purified bottled water by flat
plastics.
 Domino (printing) machine: this machine used to write expired date and manufacturing
date.

 Ozone generating machine: this machine was used to change atmospheric oxygen
molecule (O2) to ozone molecule (O3).
 Water droplet drier: was used for drying of water droplets present on the external
surface of the plastic bottle.
 Mixer machine: was a machine which is used to mix the raw materials like PET and
HDPE with master bunch.

 Stainless Steel Conveyor: Made of S.S, used for conveying of empty washed bottles to
the filling machine.

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 Air compressor: was a device that converts power in to potential energy stored in
pressurized air. By one of several methods, an air compressor forces more air in to a
storage tank, increasing the pressure.

 Chiller: was a device which used to cold mold.

 Condenser: was used to cool down the injection machine and molding machine.
 Film blow machine: was used to make plastics needed for packaging of bottled water.

1.2 Main products or services

MaiAyni business Company mainly produces a purified packed mineral water. In
addition to this the factory produces other products like plastic bottles and plastics;
which were not sealed to the distributors and other consumers; rather they were directly
used by the company for packaging. [10]

The Factory manufactures different sizes of packed water and all of its accessories by itself:

 600 ML packed water:

 1L packed water

 2L packed water

 20L packed water

 Bottle:
 0.6 liter
 one liter
 Two liter
 Cap
 Plastic bag

1.3 Main customers or the end user of service

The purified mineral water produced in this company had been some essential mineral
contents to the human body. Hence these minerals were found in nature; but based on
the national standard of the country they could be minimized or maximized if they were
found above or below to the standardized one; and the company produces a high quality
purified mineral water. Due to high quality product of the company; the company leads
to have many customers in all societies of Tigray region. Generally, the customer of the
company includes:
 All Governmental and Non-governmental organizations of Tigray region
 All urban and semi urban towns of Tigray region

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But the main customers of the company were western region of Tigray; this is because
of the environmental weather condition of the region. Since the weather condition of the
region is very hot; then it needs more mineralized water which leads the water to be
strong to drink by the peoples. And it easily stays for a long time after drinking.

1.4 Overall organization and work flow

Mai Ayni packed Water Company has two main categories of management structure to
pave the overall activities inside the factory. These general manager and technical
manager. General Manager supervises the whole work of the factory and the technical
manager works with technical aspects of the company. [9]

And the company has been four Production departments. These production departments were:

 Chemistry
 Mechanical
 Electrical
 Biology
 Grade 5-12 students

1.4.1 Roles and Responsibilities’ of Company Workers

Manager: Responsibilities to manage the business, enter into agreement, sign contract, strike
deal, supervise and manage overall business operations.

Production Manager: He/she will be involved in the planning, coordination and control
of manufacturing processes and should ensure that goods are produced efficiently and
that the correct amount is produced at the right cost and level of quality.

Purchase Officer: He/she was responsible for buying the best quality equipment, raw materials
for a company or organization at the most competitive prices.

Accountant: He/she could keep the daily records of the business.

Supervisor: He/she coach, mentor and advocate employees and company.

Machine Operator: They were operating the machines.

Marketing and Sales person: He/she was responsible for the marketing plan,
campaigns and developing new innovative ways to market the products and selling of
products within agreed time scales.

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Guard cum Store keeper: He/she was responsible for looking after the production unit and
keeping the inventories and raw materials properly and safely.

Part-time Labor and Others: was responsible Loading, unloading, transporting, maintenance,
etc.

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The overall organizational work flow of the factory can be shown as follows:
General Manager

Technical Manager
Executive
Secretary
Mechanical Electrical
Supervisor supervisor

HRM Sales Manager Finance Manager Store Manager

Sales Production Market Unit

Supervisor

Figure 1. 1: General structure of the factory work flow

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CHAPTER TWO

OVERALL INTERNSHIP EXPERINCE

The main aim of higher education institutions, especially technology institutions, is producing
knowledgeable, well skilled, country builder and receiver, productive and talented students.
Those students, after graduation, will be work in different companies, organizations and other
working sectors all over the country. Almost all practical engineering applications are done
based on the theories and principles of different engineering fields that have been developed
progressively.

2.1 HOW I GET IN TO THE COMPANY

When I was fourth year student the curriculum allows for all university student involve an
Internship program to improve our theoretical skill and develop practical experience by
involving in the real world or actual place. For this reason, I take acceptance paper from Adigrat
University and joined a hosting company. Initially I have two options given by the university
industry linkage office (UIL office) of Adigrat University to get willing companies. The first
option was to search and find by myself. The other option was the UIL office’s available
candidate companies. So per the second option the university industry linkage office (UIL
office) of Adigrat University send me to Mai Ayni Business Company. In October 02, 2010 E.c
I start my Internship program in the company and for the last four month's I was able to
experiences in the company and upgrade my knowledge and skill.

2.2 WORK SECTION I HAVE BEEN WORKING IN THE COMPANY

In my stay in the company, I have been working in the technical maintenance and product
section especially in the electrical department. This section has many elements like electrical,
mechanical, chemists, biologists and many machine operators and daily workers.
In the section, there are much electronic and mechanical machines and equipment that I have
been taught theoretically and what I have not seen before. Some of the machines are: plastic
injection machine, film blow plastic machine, t-shirt bag maker machine, chiller/cooler
machine, mixer, Generators, Transformers, motors, capacitors, different types of cables,
extreme number of sensors and additionally, different lumps, the PLC ( programmable logic
control) ,the brain of the company.
To verify some of them where and when they are available:

 Film blow plastic machine: is used to make flat plastics. Plastic injection machine:
Plastic injection molding machine, in structure of horizontal toggle clamping structure
with various pumps, are used for injection molding of various thermoplastic plastics,
which can be molded by one shot to be plastic products with complicated contour,
accurate dimension and plug-in parts.

 Chiller/cooler machine: is one type of machine which is used to cool the hot water and
reject the cool water to another machines such as plastic injection machine to cool it
and received a hot water from the machines to cool. Generally, the cooling system of
the machine is continuous and cycling.

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 Mixer: Is a machine used to mix an ingredient of the Ambo product like gas and water.

 The control cabinet: are touch screen to control machines provided for each machines

 control panel; a panel with electrical elements like circuit board, switch, contactors,
relays, circuit breakers, soft starters, PLC, different BUS used to The control and install
the overall operation of the machineries.

 The generator: Used at the time there exists problem with EEPCO, to generate

 Motor: An electric motor is an electrical machine that converts electrical energy into
mechanical energy and pressure related tasks in the production process.

 Soft starters: electrical equipment that controls the starting speed of any running
machineries of the company, allow machineries to start at very low speed.

 PLC: an electrical material used to manage the overall machineries within the company

 Conveyor: this machine has only one conveyer which is used to move plastic filled by
product and long about 50 meters.

 Transformers: an electrical material used to transform the power coming from EEPCO
as well as from the generators as per requirement.

 Control transformers: this control transformer is used for adjusting the amount of
voltage and the phase. As an example we can mention phase shifter transformer. This
component shifts the three phase voltage supplied to the machine in to two phases.

 Indicator lamp: This tells the operator when the power is applied and indicates the status
of operation of the machine.

 Relay: an electromagnetic device composed frame or core with an electromagnetic coil

and contacts.

 Heater/Boiler: used for drying of water droplets on the packed water and also for
melting a plastic.
 Float Switch: is a device used to detect the level of liquid within a tank. The switch
may be used to control a pump, as an indicator, an alarm, or to control other devices.

2.3 How does the work flow in the section look like?
As I have tried to mention, MayAyni bottled Business Company is one of the most
effective company all over the country that aimed at producing purified water drinks. In
the section one I have been assigned to work is in the maintenance and controlling of
the electrical machines, in general the machinery used by the company was classified in
to five classes. These were:
A) Water treatment machineries
B) Filling, Capping, and Packing Unit machineries
C) PET stretch Blow Molding Unit machineries
D) Ozone production machine

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E) Film blow plastic machine

 All the above listed machineries are work automatically by the control of PLC
and Sensors. Generally, the machineries of the company are latest and
modified machines.

2.3.1 Work flow of the machineries

The total amount of power required to run the full section the company is 180kw but the
transformer of the company has 120kw capacity and this deficiency of power causes the
company sections to run shift by shift. There are two sections in the company. [7]

These are:

 Treatment section
 Production section
Both sections cannot run simultaneously because of the insufficient electrical power in
the company, means the transformer that the company use is small rating. Therefor the
two sections are run shift by shift, when treatment section runs the production section
must stop and when the production section runs the treatment section stops.

Generally the electrical work flow of the company is shown below:

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EEPCO

Transformer

Panel board

Treatment Section

Three in Inspectio Convey

One n or
Machin Machine
e

Production Section

Film Stretch Ozone Bottle Cup

Blow Blow Productio Injectio Injection
plastic Machine n Machine n Machine
Machine Machin

Figure 2. 1: General electrical work flow of the company

Transformer:

The transformer is probably one of the most useful electrical devices ever invented. It can raise
or lower the voltage or current in an ac circuit, it can isolate circuits from each other, and it can
increase or decrease the apparent value of a capacitor, an inductor, or a resistor. Furthermore,

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the transformer enables us to transmit electrical energy over great distances and to distribute it
safely in factories and homes.

The transformer used by the company is a step down transformer with a rated capacity of 120kw,
but the company needs 180kw to perform its full operation. However, to overcome this problem
they use the machines in the production and treatment section shift by shift.

Panel board:

Panel board is a panel with electrical elements like circuit board, switch, contactors, relays,
circuit breakers, and soft starters, PLC, different BUS used to control and distribute the electrical
installation of the overall operation of the machineries.

Figure 2. 2 : panel board [1]

Treatment section:

In the water treatment section, the machineries are having latest technologies and simple for
workers to use. The machineries are work for 10 hours per day.

In this section the power coming from the transformer directly enters to the electrical
panel board in the section. Then the panel board distributes the electric flow depending
on the rating of the machineries.

The machineries in the treatment section are:

 Water treatment machineries

 Filling, Capping, and Packing Unit machineries

Three in one machine:

This machine has Filling, Capping, and Packing units. This machine has washing, filling and
capping functions.

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The following are parts of the machine

 Rinser, Filler, and capper (with accessories)

 Light checking box
 Caps sterilizing cabinet
 Shrink labeling machine
 Printer machine
 Conveyor with motor and extension  Air compressor

Figure 2. 3 : Three in one machine [2]

Inspection machine:

Conveyor: This machine is used to convey or to move the products to their final destination
and it longs about 50 meters.

Generally the process flow diagram of water treatment in the treatment section is:

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Figure 2. 4 : Flow diagram of water treatment plant Production

section:

The electrical work flow is the same with the treatment section. However, the amount of power
consumed by this section is much more than that of treatment section.

In the production section the following electrical machines are found:

 PET stretch Blow Molding Unit machineries

 Film blow plastic machine

PET stretch Blow Molding Unit

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This unit has the following parts:

• Stretch blow moldings with two high pressure air compressor air receiving tank
• Mold, ½ lit PET bottle
• Mold, 1 lit PET bottle
• Caps Production line
• Injection Machine
• Mold for caps
• Condenser

:
Figure 2. 5 : Injection machine[3]

Figure 2. 6 : Flow diagram of PET bottle production

Flow diagram of polypropylene (PP) bottle caps:

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Figure 2. 7 : Flow diagram of polypropylene (PP) bottle caps production

Ozone production machine:

Ozone is unstable, colorless gas, a powerful oxidizer and a potent germicide. It has a
much higher disinfection potential than other disinfectants such as chlorine. Ozone is
used in the bottled water industry because it controls the growth of bacteria in water. It
is desirable

Figure 2. 8 : Ozone producing machine[4]

Because it can do this without leaving a residual taste, such as you would find with
chlorine. The lower the total dissolved solids level, the higher the solubility of the ozone.

Film blow plastic machine:

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This machine was used to make plastics needed for packaging of bottled water. This machine
has latest technologies and easy to control.

Figure 2. 9 : Film blow plastic machine

Machine Control and Protection

Machine control:

Machine controls range from electromagnetic relays and timers to computer driven solid state
devices. Computers not only control the process sequences, but also perform quality control
functions, real-time reject recognition, fault analysis, record keeping, and instant set up
procedures. Additionally, computer systems aid in the design and construction of the molds.
The company uses the latest machine control technologies such as plc, sensors, timers etc.[7]
PLC:

Programmable Logic Controller (PLC) is a digital computer used for the automation of various
electro-mechanical processes in industries. These controllers are specially designed to survive
in harsh situations and shielded from heat, cold, dust, and moisture etc. PLC consists of a
microprocessor which is programmed using the computer language.

Figure 2. 10 : Plc model [5]

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Figure 2. 11 : Injection machine with plc

Timer:
Timer is an electrical device which is used to control machineries or events by setting of time.
The company utilizes two kinds of timers the delay on and delay off timer.
Delay ON Timer:
A delay on timer is a timer which is used to turn-on a machine or an event by delaying of a sated
time. The company uses this timer on the air compressor machine, when the air compressor
receives low pressure signal then the air compressor runs after few second delay.
Delay OFF Timer:
This kind of delay is used to turnoff an event such as a machine by delaying of a sated time by
the user. The company uses this type of timer on the mixer machine, once the mixer machine is
turned-on and doing its function until the sated time finishes, then when the sated time is
finished it is turned off by itself.
Machine Protection:
Protection of electrical machine from electrical shocks is a fundamental task that an industrial
company should consider. MaiAyni Business Company uses circuit breaker, relays and fuse for
the protection of the machines.

Relays:
Relays are devices that detect abnormal conditions in the electrical circuits by constantly
measuring the electrical quantities which are different under normal and abnormal conditions.

Circuit breaker:
A circuit breaker is an automatically operated electrical switch designed to protect an
electrical circuit from damage caused by over-current, typically resulting from an
overload or short circuit. Its basic function is to interrupt current flow after a fault is
detected. Unlike a fuse, which operates once and then must be replaced, a circuit breaker
can be reset (either manually or automatically) to resume normal operation.

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Figure 2. 12 : Circuit breaker [6]

Fuse:
Fuse is an over-current protective device for opening a circuit by means of a conductor designed
to melt and break when an excessive current flows along it for a sufficient time. The fuse
comprises all the parts that form the complete device.

Production of PET-bottles

PET is the abbreviation for polyethylene terephthalate. It is a polyester (chain of individual

“ester”) which is formed by poly-condensation of two types of monomers called ethylene glycol
and purified terephthalic acid. PET is produced from either crude oil or natural gas

Figure 2. 13 : PET

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The manufacturing of bottles from PET primary granules is done by injection molding of
performs using standard types of injection molding machines. Injection molding is perhaps the
most common and important of all plastic processing processes. The process is extremely
versatile, and can produce very complex shaped parts, with the use of multi-sided molds. Even
parts with metal inserts can be produced. While injection molding dies are expensive to produce,
each die can be used to make tens of thousands of components at very rapid rate, so that per-
part cost is very low. Its work flow be:
 Performs are loaded into the hopper, which holds up to 3000 performs at a time.
 An elevator moves performs up to a gravity-based sorter, which aligns performs on a
conveyor.
 Performs are then aligned and loaded onto a chute, where they are gravity-fed into the
perform holders. Four performs simultaneously move through two parallel heat tunnels,
each with eight heat zones and two quartz heating elements.
 The performs move through the heat tunnels, where they are heated to the optimal
blowing temperature prior to entering the molds. A sensor at the end of the tunnels
monitors the perform temperature. If temperature has not reached the minimum preset
temperature of approximately 194º F (90º C), the performs move through the molds and
are not blown.
 From the heaters, performs are loaded into the custom-designed molds where four bottles
are blown at a time. A pressurized liquid chiller keeps the mold temperature in a
controlled range to ensure that consistently high quality bottles are blown.
The simplest form of injection molding is shown in the schematic below.

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Figure 2. 14 : PET-perform cavity

PET-bottle blowing process

Preform is preheated Open the mold and insert

The preform

Allow the bottle to cool for Blowing of air into

Solidification as desired preform
shape

Open the mold and eject the

Component

Figure 2. 15 : PET-bottle blowing process

2.4. Which work piece or work task you have been executing?
 Maintenance
 Work shop practices
2.4.1 Maintenance section
During my internship period in the company I observe and do some maintenance of the
electrical equipment.

For instance

 Maintenance on panel board

 Maintenance on PET preform cavity

2.4.2 Work shop practices

We made some work shop practices with my internship partners.

For instance:

 We made some practice on float switch

 About forward reverse connection of induction motor
 About delay on off timer

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 About contactor

2.5. What procedure you have been using while performing your workTask
While I work in the company the first thing I do is to be arrive on time then after that I wear my
safety and protection wearing’s. After that I meet my supervisor and observer the whole
machine if there is abnormality but since most of the machineries are latest and modified fault
occurrence on the machines are rare. Then we discuss about the next thing we are going to see
but most of the time we are busy on the working principle of the machines.

2.6. How good you have been in performing your work task
Since this is my first time industrial experience there are things hard to do and to know in the
first few weeks for example, knowing of all the materials takes its own time, how to use the
equipment also its own difficulty, but generally through time I am familiar with everything in
the company, so when I am working my task it is not hard but if there is something I did not
know I ask questions to my supervisor and he answers my question properly. But generally my
adviser, my supervisor and the company workers are the answer.

2.7. Main challenges that faced you during Internship time

Challenge is something that everybody faces during his or her work time. MaiAyni
Business Company was one of an internship place we had been. So, in our internship
Company we had been faced so many challenges. These challenges were:

 The company did not have well-trained operators; as a result, they did not give as
enough information related to the production process of the company.
 Having no an electrical engineer in the company; we had a lack of some
information’s related to our department.
 There had not been written data related to the overall activities of the company;
then this leads as not to do our report and project effectively.
 The company has no enough electric power to perform all the unit operations at a
time. This means there are unit operations that operate once per a month. Then we
did not have a full of concept related to these unit operations.

2.8. The measures you have taken to solve the challenges

The measures we had taken to solve the challenges we faced during our internship are;

 By inviting other internship companies like APF, and Walia liquor factories, we had
already known the operating principle of similar unit operations. These companies
had chemical engineer professionals; then by asking to these engineers we got so
many information related to the production process of our internship company.
 By searching a Google and preparing questionaries’ we collect a full of data related
to the company.
 Asking the company chemist, we got some concepts related to the machineries that
work per a month.
 By inviting our internship company effectively, we tried to understand the overall
Production process of the company.

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CHAPTER THREE

BENEFITS I GAINED FROM THE INTERNSHIP

In the Internship program I have gained benefits which helped me to explore my skills, qualities
and abilities. Since it is my first practical experience everything done is new and interesting to
me. For something that takes inputs there is something in return, a benefit. In our Internship too,
there were some benefits those are gained accordingly. The benefits are:
 Practical skills
 Theoretical knowledge
 Interpersonal communication skills
 Team playing skills
 Leadership skills
 Work ethics related issues
 Entrepreneurship skills

3.1. In terms of Improving Practical Skills

From the Internship program I had gained a lot of advantages in applying my Theoretical
knowledge into practical skill. Hence, I had developed an experience to do anything in
my field of study. When we say Internship the main objective was to improve practical
skills; before we had theoretical knowledge about: -

 PLC

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 Circuit Breaker
 Transformers
 Sensors
 Motors and Generators
 Many types of switch s
 Generally, most of electrical materials.

I had gained practical skills about all of the above, since I had been participated in all sections
of the company.

3.2. In terms of Upgrading Theoretical Knowledge

The knowledge about the electrical engineering I got in class goes deeper and deeper
when I do it practically saw. Now my knowledge is combined with practical
experiences. As a student I might forgot the theories I study for an examination; but now
it is printed in my mind that I could not forget it. This Internship program help to be a
perfect professional that could change myself, my carrier and the enterprise I could be
employed.

3.3. In terms of Improving Interpersonal Communication Skill

In the company I was working with the professional staffs as well as non-professional
employees. During this time, I had a good communication both my superiors and juniors. I learn
how a superiors give an order to their subordinates. And the subordinates respect the order of
their superior. When I have doubts about the work I used to task explanation from the
experienced workers and senior professionals. So I learn Interpersonal communication is vital
to any work particularly construction works. The most important interpersonal communication
skills I learned therefore are:-  Good personal behavior;
 Respect others;
 Respect the orders of the superior;
 Persuade others;
 Improve personal relationships with other workers

3.4. In Terms of Improving Team Playing Skill

The most important point in team playing skill was just reached an agreement from
different points on the work to be done. Furthermore, to have a common understanding
on the task was about to be accomplished. Always we focus on the team work carefully
and improve our team work skill. Team work, especially for engineers, is a key point
for solving specific problems on a given task. When chemists share their idea to solve
the problem created in the laboratory analysis and shift Engineers, supervisors and
operators exchange their idea when suddenly problem was happened. During this a
group works to solve a specific problem, we improve our team playing skill.

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3.5. In terms of Improving Leadership Skill

Leadership is never easy, but every one of us had been the potential to be a leader every
day. In the Factory, we got a good understanding of leadership by observing every bit
of the leaders, starting from the senior operators to the general manager. So we gained
plenty of experience from them on how to handle workers, how to order, how to control
and manage works done in each section, and etc.

3.6. In terms of Understanding about Work Ethics

Work ethics is a generally accepted guideline for right and wrong behavior in work place
and it involves several principles related to effective work habit and personal qualities.
The work ethics that a company requires from its workers were ;

 Honesty;
 Hard working;
 Reasonableness;
 Transparency;
 Truthfulness and punctuality;
 Being responsible and accountable for everything you do.

3.7. In terms of entrepreneurship skill

Participating in an Internship helps me to improve my entrepreneurship skill.

Some benefits includes:

 How a business is running and managing;

 How a Industrial company is organized;
 How organize and control resources to ensure the profit for my business;
 The challenges and success of an Industrial company;
 What types of machines and professional that Industrial company had;  To gain a better
perspective of employment after my graduation.

 The creativity and problem solving is one of the starting points of entrepreneurs.
This Internship motivates me to work hard because it enables me to know more about my
career, the real challenges, and the business establishments in this profession.

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CHAPTER FOUR

Conclusion and recommendation

4.1 Conclusion
Generally, this is great opportunity for me so far to have experience and to work with technicians
and operators of the company and other who works in the company.

The internship program has been helpful experience in exposing myself into the real engineering
work. It helped me to solve the real challenges by the theoretical knowledge I have already
gained.

As undergraduate student, I grasp the basic principles and theories of electrical and computer
engineering in my last four years of studying in Adigrat University in the electrical engineering
department. But this theoretical knowledge is not enough to being a qualified electrical engineer
at the time of graduation. Knowing the practical work and the real situation beside the
theoretical knowledge in time of studying makes someone experienced in practical and
theoretical knowledge at the time of graduation. This is why the university needs its students to
have an Internship program before graduation.
MaiAyni Business Company is a private limited company which produces a purified mineral
water located in the eastern Tigray Adigrat town. The company uses a modern machineries and
technologies for the water treatment and producing of raw materials. Such machineries are the
ozone production machine, injection machine .and many types of sensors, compressors. There
are many types of raw materials and inputs in MaiAyni bottled Water Company; these are: PET
(Polyethylene terephthalate, Chlorine, HDPE and LDPE (High and low density polyethylene),
Ground water (spring water) which is the main source of water needed for treatment, Master
bunch, Hydrogen peroxide chemical, and Citric acid. MaiAyni business Company mainly
produces a purified packed mineral water. In addition to that, the company produces plastics for
packaging purposes. The general filtration process of the company includes: reservoir tank, 1st
Quartz sand filter, 2nd sand filter, precision filter, security filter, ultra-filter, UV- ray, pure water
tank, ozone mixing tower, and titanium filter. After filtration is done, purified water is fed to
three in one machine where the bottles are washed, filled, and capped. The customer of the
company includes All Governmental, Non-governmental organizations of Tigray and other
regions. Technology of MaiAyni Business Company includes process production of the
company and source of the technology used by the company. Challenge is something that
everybody faces during his or her work time. MaiAyni packed Water Company has two main
categories of management structure to pave the overall activities inside the factory. Material
and energy balance in the company is done based on the amount of substance and energy enters
and leaves from each production process equipment’s. The overall plant efficiency of MaiAyni

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purified mineral water factory is about 75 percent. During internship we gained so many benefits
in terms of improving practical skills, upgrading theoretical knowledge improving interpersonal
communication skill, improving team playing skill, improving leader ship skill, understanding
about work ethics, and entrepreneurship skill. In water factories the treatment process is most
of the time free from different contaminants that are released to the environment from each
filter.

4.2. RECOMMENDATION
MayAyni business Company is one of the famous companies in Ethiopia which targets for
quality of works and to the satisfaction of its clients. During the four months of internship; I
have some appreciations in all respect. So I recommend that it has to continue with its strong
points.
There are some points that to my Knowledge should be corrected. These are: -
 The company has not an engineer professional. So it must have an engineer to
increase the efficiency of the production process of the company.
 The company have not any backup generator in case power is lost, so there must
be a backup generator to work without disruption and waste of time.
 The company quality department is not open to tell us with the problems related to
the company; which means that, the department hid as with quality related
production process.
 The road to the company is not comfortable so, the company should consider it.
 Main customers of the company are western region of Tigray. Because the
company purified water is hard to drink to other zones of Tigray. So, to increase
its customers it must install reverse osmosis filter to reduce the mineral
constituents of purified water.

REFERENCE
[1] K.Electricals,“indiamart,”2016.[Online].Available:

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https://www.indiamart.com/proddetail/digital-motor-starter-control-panel-
board6943741497.html.

[2] “DIYtrade,”[Online].Available:
https://www.diytrade.com/china/pd/7409804/Automatic_water_washing_filling_capping_
machine_3_in_1_machine.html.

[3] “payal,”[Online].Available:http://www.payal-india.com/plc-plastic-injection-
mouldingmachine.htm.

[4] “Norland,” [Online]. Available: https://www.norlandintl.com/product/water-treatment/.

[5] j.wales,“WikimediaCommons,”2016.[Online].Available:
https://commons.wikimedia.org/wiki/File:MITSIBISHI_PLC_Panel.jpg.

[6] J. Ma, “alibaba.com,” 2016. [Online]. Available: https://www.alibaba.com/productdetail/IMO-

6kA-Miniature-Circuit-Breakers_114530639.html.

[7] J. GUPTA, Machine Design.

[8] [Online]. Available: www.google.com.

[9] C. W. A. Manager, Interviewee, [Interview].

[10] C. F. B. Michaud, Water Technology, Multi-Media Cartridges, 1994.

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