INTERNSHIP REPORT done by Didier Iradukunda (Electrical and Computer Engineer) at Bralirwa in 2019

August-October 2019
INTERNSHIP REPORT
Done by Didier Iradukunda
ABSTRACT
Through critical and deep study, this
report explains clearly how beers are
produced in Bralirwa Plc Gisenyi
Brewery and how beers are packed
using knowledgeable and very
intelligent robots performing
automatically complex tasks in few
minutes that could be being
performed by more than 100 people.
didier.iradukunda01@gmail.com
My email

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October 2019 INTERNSHIP REPORT done by Didier Iradukunda
DECLARATION
I, Didier Iradukunda a student from Electrical and Electronics Engineering department at
University of Rwanda – College of Science and Technology, hereby declare that this report
written in partial fulfillment of the requirements of award of bachelor’s degree with honors in
Electronics and Telecommunication Engineering is my very own work reporting internship I
conducted at BRALIRWA Plc Gisenyi Brewery during a period of 2 months from August to
October 2019.
I also declare this report is my original and individual work and the content of this document has
never been presented or submitted to any other institution. However, the citations, quotations, and
references to other people’s work or sources of information used have been given.
………………………………….
Didier Iradukunda

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DEDICATION
To the almighty God for the gift of life, love and protection,
To my beloved mum and the whole family,
To all my friends,
Most importantly to my beloved Bralirwa Plc Gisenyi Brewery Staff,
To University of Rwanda especially CST staff
I dedicate this report.

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ACKNOWLEDGEMENTS
As this is a report of the internship I did in Bralirwa Plc Gisenyi Brewery during a two months’
period from August to October 2019, first and foremost, I would like to acknowledge and deeply
thank Bralirwa staff especially the recruitment team for choosing and giving me an internship in
their company. However, the success of this report and all work I did during the internship period
would hardly be achieved without the help and guidance from different people to whom I express
my gratitude.
It is not however easy for me to mention each and every one’s name for their valuable contribution
to the success completion of this work. But special heartfelt appreciation goes to my supervisor
UKUNDWANIMANA Fabien for his kind assistance, Engineering manager MBUGUJE
Dieudonne, MANIRIHO Theogène for his valuable contribution of teaching us and time he gave
us, Bizoza Innocent for his cooperation, MBERABAHIZI Félicien, AMANI Claude,
MUNYEMANZI Evaliste, NYAMURANGWA Joackim, NDAYISENGA Theogène,
IRYAMUKURU Pierre, DUFATANYE Prosper, SHABANTU Jackmay, NSHIMIYIMANA
Gerard, SIBOMANA Emmanuel and so on.
I feel highly indebted and full of gratitude to all Bralirwa Gisenyi Brewery staff and workers in
general for their kindness, love, and assistance because I noticed that each one would like to help
every intern to gain all knowledge for example about the working principle of the machines and
they not only helped me that but also they gave me important advice that may help me to be
successful in my career and to reach my dreams.
Last but not least, my deep gratitude goes to UNIVERSITY OF RWANDA CST Staff for their
kind assistance and motivation especially KANYESHURI Alexandre, KANAZAYIRE Carine
Secretary of Department of Electrical and Electronics Engineering, Head of Department Dr. Louis
SIBOMANA, Assistant Dean of School of Engineering Dr. Philbert NSENGIYUMVA, and our
beloved Principal of UR-CST Dr. Ignace GATARE.
I would not forget, as well to thank my fellow interns with whom I spent long hours, working
together, and for sure we made a winning TEAM and Together Everyone Achieved More.
May God bless you all.

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ABSTRACT
This document is a report of Internship I did at Bralirwa Plc Gisenyi Brewery from 5th
August to
5th
October 2019 and this period has been a very important moment of my life especially in my
career of Electrical and Electronics Engineering, to get working experience, good practical hands
on skills as well as other valuable skills I learnt needed for someone who is working for a given
institution.
I was given this internship in Technical department where we have been working in Process,
Utilities and in Packaging room (both lines 2&3) which I can call sub departments. In addition, we
also had chance to visit every part of the industry and got explanation about how everything is
done to produce beer as Bralirwa is a beverage company. We got to understand how the beer like
Heineken is produced from high quality malt and then packed using genius robots working on a
high and latest technology. After packaging, the final product is ready to be delivered to the final
consumers with high quality.
This report includes the introduction about Bralirwa Plc as a company, its electrical network and
electrical equipments, energy utilization, modern control of different machines as well as about
the process and all its mains activities, packaging of beers and water treatment of all water used in
the Brewery.
Finally, I concluded that my internship has been one of my success work despite some of things
which I recommend to be improved. Everything is included in this report and surely, it is full of
knowledge and practical skills that I recommend everyone to read it.

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CONTENTS
...............................................................................................................................................
DECLARATION............................................................................................................................. i
DEDICATION................................................................................................................................ ii
ACKNOWLEDGEMENTS...........................................................................................................iii
ABSTRACT................................................................................................................................... iv
CONTENTS.................................................................................................................................... v
LIST OF FIGURES .....................................................................................................................viii
LIST OF ACRONYMS/ABBREVIATIONS................................................................................ ix
LIST OF TABLES.......................................................................................................................... x
CHAPTER I. GENERAL INTRODUCTION ................................................................................ 1
I.1. INTRODUCTION................................................................................................................ 1
I.2 ABOUT BRALIRWA........................................................................................................... 1
I.2.1 HISTORICAL BACKGROUND OF BRALIRWA....................................................... 2
I.2.2 MISSION OF BRALIRWA ........................................................................................... 3
I.2.3 CORE VALUES OF BRALIRWA ................................................................................ 3
I.2.4 OWNERSHIP OF BRALIRWA .................................................................................... 3
I.2.5 MANAGEMENT OF BRALIRWA............................................................................... 3
I.2.6 ORGANIZATION CHART OF TECHNICAL DEPARTMENT.................................. 4
I.3 ABOUT MY INTERNSHIP.................................................................................................. 4
I.3.1 OBJECTIVES OF MY INTERNSHIP........................................................................... 5
I.3.1.1 MAIN OBJECTIVE ................................................................................................ 5
I.3.2.2 SPECIFIC OBJECTIVE.......................................................................................... 5
I.3.2 SITE LOCATION .......................................................................................................... 5
CHAPTER II. UTILITIES, BEER PRODUCTION AND PROCESS........................................... 6
II.1 UTILITIES (MACHINES ROOM) ..................................................................................... 6
II.1.1 ELECTRICAL POWER RECEPTION AND DISTRIBUTION.................................. 6
II.1.2 TREATMENT OF STEAM.......................................................................................... 7
II.1.2.1 STEAM BOILER................................................................................................... 7
II.1.2.2 WORKING PRINCIPLE OF A BOILER.............................................................. 8
II.1.3 TREATMENT OF COMPRESSED AIR ..................................................................... 9

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II.1.4 COLD TREATMENT................................................................................................. 10
II.1.5 CO2 RECOVERY ....................................................................................................... 12
II.2 BEER PRODUCTION AND PROCESS........................................................................... 14
II.2.1 BREWING .................................................................................................................. 15
II.2.2 FERMENTATION...................................................................................................... 15
II.2.3 BEER CONDITIOING ............................................................................................... 16
II.2.4 FILTERING AND DILUTION OF BEER ................................................................. 16
CHAPTER III. PACKAGING AND MAINTENANCE OF MACHINES.................................. 17
III.1 PACKAGING OF BEERS ............................................................................................... 17
III.1.1 CONVEYOR SYSTEMS .......................................................................................... 18
III.1.1.1 DESCRIPTION OF CONVEYORS................................................................... 19
III.1.1.2 SPEED CONTROL OF CONVEYORS............................................................. 20
III.1.1.3 SPEED REDUCERS OF CONVEYORS........................................................... 20
III.1.1.4 REDUCTION GEARS OF CONVEYORS........................................................ 21
III.1.2 UNPACKER/ DECTRATOR MACHINE ................................................................ 22
III.1.3 BOTTLE WASHER MACHINE............................................................................... 23
III.1.3.1 BOTTLE WASHING REQUIREMENTS ......................................................... 24
III.1.3.2 WORKING PRINCIPLE OF BOTTLE WASHER............................................ 24
III.1.4 EMPTY BOTTLE INSPECTOR............................................................................... 26
III.1.5 FILLING AND CAPPING MACHINE..................................................................... 28
III.1.5.1 FILLING PART.................................................................................................. 30
III.1.5.2 CAPPING PART ................................................................................................ 31
III.1.6 FULL BOTLLE INSPECTOR .................................................................................. 31
III.1.6.1 WORKING PRINCIPLE OF FBI....................................................................... 31
III.1.6.2 FBI OF BRALIRWA GISENYI BREWERY .................................................... 34
III.1.7 PASTEURIZER......................................................................................................... 35
III.1.8 LABELING MACHINE............................................................................................ 37
III.1.8.1 WORKING PRINCIPLE OF LABELER........................................................... 38
III.1.8.2 CHANGEOVER OF LABELER........................................................................ 38
III.1.9 VIDEOJET................................................................................................................. 39
III.1.10 CRATE WASHER MACHINE............................................................................... 39

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III.1.11 PACKER/CRATER MACHINE ............................................................................. 40
III.2 MAINTENANCE OF MACHINES ................................................................................. 40
III.2.1 PLANNED MAINTENANCE (PM) OF MACHINES ............................................. 41
III.2.1.1 GOAL OF PLANNED MAINTENANCE ......................................................... 41
III.2.1.2 PLANNED MAINTENANCE ACTIVITIES..................................................... 41
III.2.1.3 PLANT EQUIPMENT IMPROVEMENT TEAM............................................. 41
III.2.2 TOTAL PRODUCTIVE MAINTENANCE (TPM).................................................. 42
CHAPTER IV. MEASUREMENT, AUTOMATION AND WASTE WATER TREATMENT. 43
IV.1 MEASUREMENT AND AUTOMATION ...................................................................... 43
IV.1.1 BASIC MEASUREMENT THEORIES.................................................................... 43
IV.1.2 LEVEL MEASUREMENT ....................................................................................... 46
IV.1.3 LEVEL TRANSMITTER.......................................................................................... 46
IV.1.4 CONTROL VALVES................................................................................................ 47
IV.1.5 SENSORS AND REGULATORS............................................................................. 49
IV.1.5.1 TEMPERATURE SENSORS............................................................................. 49
IV.1.5.2 PRESSURE REGULATORS ............................................................................. 50
IV.1.6 ELECTRIC MOTORS .............................................................................................. 51
IV.1.7 AUTOMATION USING PLCs ................................................................................. 52
IV.1.7.1 LADER LOGIC OF STEP 7 PROGRAMMING............................................... 53
IV.1.7.2 FUNCTION BLOCK DIAGRAM ..................................................................... 54
IV.1.7.3 BASIC TASKS................................................................................................... 54
IV.2 WASTE WATER TREATMENT.................................................................................... 56
CHAPTER V. CONCLUSION AND RECOMMENDATION ................................................... 57
V.1 CONCLUSION.................................................................................................................. 57
V.2 RECOMMENDATION ..................................................................................................... 57
REFERENCES ............................................................................................................................. 58
BOOKS..................................................................................................................................... 58
WEBSITES............................................................................................................................... 58

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LIST OF FIGURES
Figure 1. Organization chart of Gisenyi brewery ........................................................................... 4
Figure 2. Google map showing Bralirwa sites................................................................................ 5
Figure 3. A steam boiler used in the machine’s room (SDM)....................................................... 8
Figure 4. compressed air room (field photo) ................................................................................ 10
Figure 5. Schematic diagram of refrigeration cycle of ammonia ................................................. 11
Figure 6. Packaging house Line 3................................................................................................. 18
Figure 7. Conveyors of crates and bottles..................................................................................... 19
Figure 8. Unpacking machine; field photo from line 3................................................................. 22
Figure 9. Bottle washer machine .................................................................................................. 24
Figure 10. Diagrammatic View of a typical five-compartment bottle washer ............................. 25
Figure 11. Empty Bottle Inspector (EBI) Machine....................................................................... 26
Figure 12. Functional parts of EBI ............................................................................................... 27
Figure 13. Base inspection unit Figure 14. Foreign container detection unit........................ 28
Figure 15. Filling and capping machine ....................................................................................... 30
Figure 16. Diagram of FBI............................................................................................................ 32
Figure 17. Field photo of FBI ....................................................................................................... 32
Figure 18. Inspection unit 1 of FBI............................................................................................... 33
Figure 19. Inspection unit 2 of FBI............................................................................................... 34
Figure 20. Field photo of pasteurizer............................................................................................ 36
Figure 21. field photo of Labeling machine.................................................................................. 38
Figure 22. Field photo of Videojet and prints on bottle................................................................ 39
Figure 23. Field photo of crate washer machine........................................................................... 40
Figure 24. Block diagram showing process (measuring cycle) .................................................... 44
Figure 25. Control valves photos.................................................................................................. 48
Figure 26. Resistor Temperature Detector (RTD) ........................................................................ 50
Figure 27. Single-stage pressure regulator.................................................................................... 51
Figure 28. Photo of PLC in control cabinet (downloaded from internet)..................................... 53
Figure 29. Overview of SIMATIC STEP 7 .................................................................................. 55
Figure 30. Field photo of waste water treatment plant. ................................................................ 56
Figure 31. Treated water sent in lake Kivu................................................................................... 56

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LIST OF ACRONYMS/ABBREVIATIONS
BRALIRWA: Brasserie et Limonaderies du Rwanda
UR: University of Rwanda
CST: College of Science and Technology
AC: Alternative Current
ANR: Automatic Network Replenishment
A.S: Air Supply
ASC: Analytical Indicating Controller
DC: Direct Current
DP: Distributed Periphery
EBI: Empty Bottle Inspector
FBI: Full Bottle Inspector
FCV: Flow Control Valve
FT: Flow Transmitter
IPA: Industrial Programmable Automat
LIC: Level Indicating Controller
LRV & URV: Lower-And Upper-Range-Value
LT: Level Transmitter
LV: Level Valve
PAC: Panel Access Control
PSI: Pounds per Square Inch
PLC: Programmable Logic Controller
LTD: Limited
SP: Set Point
TCV: Temperature Control Valve
TIC: Temperature Indicating Control
TT: Temperature Transmitter
VLT: Variable Speed Transitions
SDM: Salle Des Machin

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LIST OF TABLES
Table 1. Pressure of signals and valve position………………………………………………….49

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CHAPTER I. GENERAL INTRODUCTION
I.1. INTRODUCTION
As one part of the program for the fulfillment of the requirements in pursuing a bachelor’s degree
in University of Rwanda, Internship is mandatory especially for students who finishes third year
and are going to be in the final year of their program. On my way pursuing a bachelor’s degree in
Electronics and Telecommunication Engineering from Department of Electrical and Electronics
Engineering in University of Rwanda College of Science and Technology, I fortunately got
internship in Bralirwa Plc Gisenyi Brewery in Department of Technical from 05th
August to 05th
October 2019.
Internship is a good period and occasion to students to learn practical knowledge in their career
and create a link between theories learnt in class and their real world applications. Internship also
help students to recognize that they have ability to use what they have learnt in school to solve real
world problems and challenges faced by people around the world. Me personally, I got to
understand many things included in my career and even those ones which are not included in my
career which is also important to me to know. I also got other valuable skills from my workmate
during internship period like Leadership skills, Communication skills, interpersonal skills and so
on.
I.2 ABOUT BRALIRWA
Bralirwa Plc is a public company limited by shares since 9th June 2010 incorporated in the
Republic of Rwanda under the law no7/2009 of 27th April 2009 relating to companies and
registered by the Registrar General Office under no 100004348. Bralirwa Plc was the first
company listed on the Rwanda Stock Exchange (RSE) as from 31st January, 2011.Bralirwa Plc is
a proudly Rwandan company with roots in the country that date back over 56 years to 1959 when
the Company’s flagship Rwandan beer brand, Primus, was first produced in Gisenyi.
Bralirwa Plc is now one of the largest companies and the highest taxpayer in Rwanda that produces
and distributes beers and soft drinks. It has two branches that are: Limonaderies of Kigali that
produces soft drinks and the Brewery of Gisenyi that produces beers. Bralirwa Kigali produces

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non-alcoholic drinks for example like Coca-Cola, Fanta Orange, Fanta Citron, Krest Tonic, Sprite,
Fiesta and so on
Bralirwa Gisenyi Brewery which is my concern here because it is where I did my internship
produces alcoholic drinks(beers) for example Primus, Miitzig, Amstel, Turbo King, Legend, and
Heineken.
I.2.1 HISTORICAL BACKGROUND OF BRALIRWA
The history of Bralirwa goes back to 1957. The management of the breweries of
the Congo and Burundi, then under the management of Brasseries de Leopoldville (Brewery of
Kinshasa), decided to build another brewery in the Eastern region. The city of Gisenyi, on the
northern shores of Lake Kivu, was selected to house the new brewery. Gisenyi was selected for
two reasons: (a) It was easily accessible, by water, land and air and (b) Lake Kivu has a large
quantity of proven reserves of methane gas, a source of alternative energy. The brewery became
operational in 1959 and began producing Primus beer, the only brand produced until 1987. In
1987, a new premium local beer brand, Mützig was introduced. In 1989, Bralirwa began
making Guinness under license.
In 1971, the Heineken Group, a Dutch brewing conglomerate, acquired a 70 percent majority
shareholding in Bralirwa. With the acquisition, Bralirwa greatly improved its brewing process. In
1974, Bralirwa diversified into the production of soft drinks. A soft beverages plant was opened
in Kigali, Rwanda's capital and largest city. The brewer partnered with the Coca-Cola Company,
which allowed Bralirwa to widen the range of products manufactured
In 1991, BRALIRWA started to import Heineken beer from the Netherlands. In 2001, the
Company started importation of Amstel beer brand from BRARUDI in the Republic of Burundi,
before it started local production of the beer in 2006. The year 2007 marked the launch of Primus
Ntoya in the 33cl bottle. In 2008, the technical capacity at the brewery (Gisenyi) was increased
with the installation of 5 additional fermentation tanks and an upgrade of the bottling line to meet
the demand.
In 2010, following its investments in production capacity, improved sales execution and intensified
marketing activities, the Company will record the highest sales volume ever in its history with an
expected volume of at least 1.3 million hectoliters of beer and sparkling beverages.

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In 2013, Bralirwa launched Primus 50cl (knowless) and Recently in the starting of 2019, Bralirwa
started producing Heineken at Bralirwa Gisenyi Brewery. As of 2018, Bralirwa is a regionally and
internationally recognized brewer and soft beverage manufacturer with an expanding portfolio of
alcoholic and non-alcoholic beverages
I.2.2 MISSION OF BRALIRWA
The Company’s mission is “To become a world class sustainable beverage producing company in
Rwanda with high quality brands that satisfy needs and give enjoyment to our consumers, while
respecting our people, society and environment in which we live.”
I.2.3 CORE VALUES OF BRALIRWA
BRALIRWA’s three core values are derived from its parent Company’s (Heineken N.V) values,
being Respect, Enjoyment and Passion for quality. The values are based on the company’s passion
for quality beverages. Second one is Enjoyment for life as the company participates in making life
more enjoyable by producing high quality beers and sparkling beverages and marketing them
responsibly through innovative sponsorships, advertising and countrywide promotions. The last
but not least value of Bralirwa is Respect for People, Society and the Environment we live in.
I.2.4 OWNERSHIP OF BRALIRWA
The Company is a subsidiary of Heineken N.V. based in the Netherlands, which owns 75% of the
total shareholding while the remaining 25% is owned by the public. The Company has a capital of
Rwf 5,142,850,000 divided into 1,028,570,000 ordinary shares with a nominal value of Rwf 5.00.
I.2.5 MANAGEMENT OF BRALIRWA
Bralirwa Plc management includes the Board of Directors and management team. The Board of
Directors is responsible for the overall governance of the company and is accountable to the
shareholders for ensuring that the company complies with the law and the highest standards of best
practices in corporate governance and business ethics. Board of Directors includes Chairman, Vice
Chairman and 3 Non-executive Directors.
The Management Team comprises the Managing Director/Vice –Chairman and other Senior
Managers occupying a strategic role in the company. It is responsible for agreeing priorities,
allocating resources, setting overall corporate target, agreeing and monitoring functional strategies

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and plans and has responsibilities for superintending the affairs of the business on a day-to-day
basis. Senior managers comprise Managing Director, Financial Director, Company Secretary,
Marketing Director, Sales Director, Supply Chain Director, Human Resource Director, Corporate
Affairs & Communication Manager, and Process and Control Improvement Manager
I.2.6 ORGANIZATION CHART OF TECHNICAL DEPARTMENT
Figure 1. Organization chart of Gisenyi brewery
I.3 ABOUT MY INTERNSHIP
Specifically, I did my internship in Department of Technical in Bralirwa Plc Gisenyi Brewery. In
this department, we were responsible for technical operations done in Process, Utilities (SDM),
Packaging and in Waste water treatment plant.
‘Process’ is where beers are brewed and fermented` Utilities (Salle des machines) is where the
steam and gases used are treated. Packaging is where the beers are packed in crates after being
packed in bottles and this part was very crucial for me because it comprises a lot of practical
knowledge I have been learning in theories. The last but not least is Waste water treatment plant
which take the water used and process it and filter it to be used again in daily activity.

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I.3.1 OBJECTIVES OF MY INTERNSHIP
I.3.1.1 MAIN OBJECTIVE
The main objective of my internship was to learn how the theories I leant in class can be put into
practice to solve a real world problem as well as to get tangible working experience.
I.3.2.2 SPECIFIC OBJECTIVE
 To re-inforce my practical capacity by linking theoretical skills to the practice.
 To build expertise-learn more about the subject matter, studies and develop expertise at
different levels than I do in class.
 To develop professionalism, communication, interpersonal and organizational skills.
 To learn and understand how Bralirwa produces any type of beers or soft drinks from
cereals and other chemical additive.
I.3.2 SITE LOCATION
Bralirwa Plc Gisenyi Brewery is located in Western Province, Rubavu District, Nyamyumba
Sector, in 5 Km from Rubavu town. The head office is in Kigali city, Kicukiro district.
Figure 2. Google map showing Bralirwa sites

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CHAPTER II. UTILITIES, BEER PRODUCTION AND PROCESS
II.1 UTILITIES (MACHINES ROOM)
Utilities mean some of important things which need to be supplied to the Brewery like Electricity,
water, gas and so on.
Everything related to utilities is taken care in the Machine Room also known in French as Salle de
machines (SDM). SDM deal with the electricity reception, production and distribution in different
sections of the Brewery. The consumed power is controlled by utilities and energies engineer
working in the machine room (SDM). This room is responsible for Electricity distribution control,
Steam treatment, Compressed Air Treatment, CO2 generation and recovery, Cold treatment and so
on.
II.1.1 ELECTRICAL POWER RECEPTION AND DISTRIBUTION
Electric power used at Bralirwa Gisenyi Brewery is provided by EUCL at high voltage (30 kV).
At the arrival the 30 kV pass throughout a main switch (Sectionnaire Principale) and it is divided
into two main branches before it is received by two parallel transformers which have reactive
power f 1000Kva each one. These Transformers have a transformer ratio of 30kV//400V it means
that they are stepping down the voltage from 30kV to 400V. This last is used in the installation for
supplying three-phase machines. Single phase of 220V is also provided to supply loads such as
lighting, welding, connecting computers and charging apparatus.
In the case of EUCL power failure two Electric Generators which are GR. POLYMA and GR.
CATERPILLAR are provided to help the brewery in the continuous operating of the machines and
other required tasks. GR. POLYMA generator has three branches having reactive power of 530
KVA, 380 KVA and 380 KVA each. At the other hand GR. CATERPILLAR has a reactive power
of 1250 KVA. The synchronization is done manually whenever there is a black-out or cut-off of
EUCL source. The use and electrical demand of a single industrial unit are often unknown and the
electrical supply equipment will need to be flexible in order to meet a changing demand due to
expansion or change of use. And before each blanch and channel is circuit-breaker to cut-off the
line in time of maintenance.

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II.1.2 TREATMENT OF STEAM
The steam is a result of heating water over 100 degrees Celsius. Steam is used in many different
areas such as brewing house, water heating, cleaning process, and washing and in fermentation
room. In Gisenyi Brewer, stream is produced by using Electric Boilers.
II.1.2.1 STEAM BOILER
Steam boilers are fuel-burning appliances that produce either hot water or steam. But steam is
preferred over hot water in some applications, such as absorption cooling, kitchens, laundries,
sterilizers, and steam driven equipment. The produced steam gets circulated through piping for
heating or process uses.

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Figure 3. A steam boiler used in the machine’s room (SDM)
II.1.2.2 WORKING PRINCIPLE OF A BOILER
Gisenyi Brewery uses three steam boilers in order to produce sufficient steam. Figure shows one
of this steam boiler. These boilers are oil fired boilers. They use controlled combustion of the fuel
to heat water. The components of a boiler include the burner, combustion chamber, heat exchanger,
exhaust stack, fan, pumps and controls.
A burner is provided with high voltage (15 kV) electromagnetic igniters. There is a pair of two
parallel electrodes in reverse that create a spark by friction when an AC current is plugged. This
spark starts the combustion of fuel squirted in the burner and presence of oxygen, the combustion
goes on. This combustion takes place in the combustion chamber, the combustion chamber is most
of time made of cast iron or steel, and the temperature inside it can reach several hundred degrees
very quickly, fan brings oxygen in combustion chamber because when no oxygen no combustion
and the heat exchanger makes hot fuel going to be burned, heat exchangers may be made from cast
iron, steel tube bundles, or, in the case of some smaller boilers, copper or copper-clad steel and the
exhaust stack or flue conveys the hot combustion gasses away from the boiler to the outside.
The Steam produced by steam boilers flows through pipes from areas of high pressure to areas of
low pressure, unaided by an external energy source such as a pump. Steam utilized for heating can
be directly utilized by steam using equipment or can provide heat through a heat exchanger that
supplies hot water to the equipment.
The boilers require controls to regulate the ignition, burner firing rate, fuel supply, air supply,
exhaust draft, water temperature, steam pressure, and boiler pressure. Boiler controls help in the
production of hot water or steam in a regulated, efficient, and safe manner. All required controls
(Combustion and operating) regulate the rate of fuel use in order to meet the demand. The main
operating control monitors hot water temperature or steam pressure and sends a signal and the
firing rate, the rate at which fuel and air enters the burner is controlled. Common burner firing
sequences include on/off, high/low/off and modulating. High pressure and temperature, high and
low gas/oil pressure, and high and low water level and flame safeguard controls are key points in
Boiler safety controls.

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The steam pressure controls maintain the steam pressure of the electric boiler within the desired
boiler operating pressure. By energizing the heating elements, the steam pressure will build up
until the upper-limit operational pressure is reached, and then electric power supply to the heating
elements will be cut out. When the steam pressure drops below the lower limit, the heating
elements will be re-energized to ensure the pressure works within the pre-determined limits. The
pressure switch is a vital device to control the generation of the steam.
In order to allow constant visual observation of the water level in the boiler; every electric steam
boiler must be fitted with at least one water level gauge of transparent material to detect if there is
fewer or more water in boiler. And in addition to that; not only a suitable stop valve connecting
the boiler to the system have to be fitted to an electric steam boiler but also an air fan should be
fitted at the highest point of the boiler to release air trapped inside the boiler during flash up or to
prevent creation of vacuum during shut down.
II.1.3 TREATMENT OF COMPRESSED AIR
Compressed air systems are important areas to improve energy efficiency in Bralirwa Gisenyi
Brewery.
A properly compressed air is needed in pneumatic systems (automatic valves, racking, packing
robotic systems …) and its system management can save energy, reduce maintenance, Decrease
downtime, increase production throughout, and improve product quality.
At Bralirwa Gisenyi Brewery air is obtained by use of two types of Air compressors: two
alternating compressors and one rotating screw compressor (ATLAS – COPCO). In alternating
compressors, air is compressed by alternative motion of pistons in cylinders whereas in rotating
compressors, air is compressed by a rotating Archimedes screw compressed all these compressors
are driven by asynchronous motors. They breathe in air from the room and push it back in a drier
toward a buffer tank from which it is done the distribution to different users of compressed air.

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Figure 4. compressed air room (field photo)
II.1.4 COLD TREATMENT
This is the process that leads to the removing of heat from spaces, objects, or materials and
maintaining them at a temperature below that of the surrounding atmosphere.
Low temperature is needed in beer process (fermentation, bottle washing machine) for cooling.
Cold is transported by a mixture of water and ethanol in proportion to 23 to 25% of alcohol cooled
down by ammonia (NH3) refrigeration system. The objective of mixing water with ethanol is that
water freeze and become ice at a temperature of 0o
C while ethanol can attain a temperature of -
114o
C without freezing due to the principle of temperature equilibrium the mixture can reach a
range of negative temperatures around -6o
C to -4o
C.

11
The refrigeration system is a closed circuit has four main components: compressor, condenser,
throttling device (expansion valve) and evaporator as fig. indicates. NH3 refrigerant used to cool
alcoholic water is prepared. The gaseous NH3 refrigerant is compressed by compressor. After being
compressed pressure and temperature of NH3 refrigerant increase, and a hot compressed gas is
discharged out to condenser to reduce its heat. Discharged NH3 contains some oil that comes from
the lubrication of compressors cylinders. An oil separator, with slippery inner walls, working on
the principles of densities and viscosity is provided. To reduce the heat of NH3, it is condensed at
a constant pressure using cold water and fans and it is digested in an accumulator tank. At this
point, its pressure and temperature are still high even though it is condensed.
To reduce both temperature and pressure at low values, the refrigerant NH3 flows through
expansion valve, after passing through it the coldness is found at low temperature around -6o
C to
-4o
C. A cold refrigerant passes through evaporators that act like heat exchangers by exchanging
heat between hot alcoholic water from users and cold ammonia so that alcoholic water goes to
users is cold. After refrigerant comes from the evaporator, it is discharged out to compressors to
be compressed and the cycle restarts.
Figure 5. Schematic diagram of refrigeration cycle of ammonia

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The alcoholic water cycle is just a simple thermal conduction cycle. Alcoholic water is cooled
down using a NH3 refrigeration system. Internal heat energy of alcoholic water is absorbed by NH3
in heat exchangers. Alcoholic water becomes then colder and is sent to users. In beer process,
substances to be cooled down meet the coolant in heat exchangers. That coolant absorbs heat
contained in the substance by cooling it down until a thermal equilibrium is set. The temperature
of the coolant increases and the coolant is transported back towards initial heat exchangers to be
cooled down by NH3.
Figure 6. Schematic diagram of production of cold
II.1.5 CO2 RECOVERY
Carbone dioxide (CO2) is a gas resulting from the combination of Carbone and Oxygen. In
Bralirwa Gisenyi Brewery, this gas is used in brewing, in conditioning process and in packaging.
CO2 recovery process involves chemical as well as physical concepts. In terms of financial projects
and savings breweries can now recover CO2 gas from fermentation earlier and still provide food-
grade CO2 to meet the demand for beer production, with a surplus of food grade CO2 that can be
used to produce carbonated soft drinks. The main advantage is that fermentation CO2 produced
from beer or other fermentation processes itself guarantees that the recovered CO2 has
fundamentally no food-alien substances and is food-grade.

13
During fermentation, Glucose (C6H12O6) is decomposed into alcohol (C2H5OH) and Carbone
dioxide (CO2) giving off some amount of heat (Equation below).
Before its use, recovered CO2 has to be purified and conserved. Firstly, an automatic Foam
Separator is used to separate raw CO2 from its foam gathered from fermentation vats. This is done
whenever the mixture made of CO2 and the foam come into contact with an electrode which in
turn send an electric signal in the control box and excite the relay. This relay makes the magnetic
valve ascent and open and the foam is sprayed. After the foam is evacuated the CO2 is recovered,
it moves forward the Gas balloon and there is an electrode installed so to give a signal as well as
foam is detected in the balloon and the balloon in turn compensate for CO2 arrival in the
fermentation room in order to avoid continuing stop- start of the compressor. At this step,
thermodynamics and mechanics are involved in compressing CO2; from atmospheric pressure up
to a pressure of about 19 bars. This compression, according to the ideal gas equation;
; raises its temperature up to 120o
C (the allowed maximum value). Where is pressure; is the
volume; is the number of moles; is the ideal gas constant and is the temperature.
After being protected from Over pressure; CO2 is washed so that elements that are soluble in water
are removed and then sent in the compressor. Compressed CO2 pass through an activated carbon
filter at constant pressure and then dried through silica gel to remove water vapors. In Bralirwa
Gisenyi Brewery two filters (deodorizers) and two dryers are provided such that when one is in
service another is set in regeneration. After the drying step, CO2 must be at least 99.97% pure with
a dew point of 74 – 78o
C. Daily tests of CO2 purity using a CO2 Purity Tester and dew point using
acetone and solid CO2 are done. Dried CO2 goes to condenser.

14
Figure 7. Process of CO2 recovery
Since gases occupy more volume than liquids, thermodynamics process is involved to condense
gaseous CO2 by letting it go through heat exchangers where it is discharged of its heat by
refrigerant products (Freon R22). Refrigeration process to condense CO2 is done by using Freon
R22 (CHClF2) refrigerant. R22 is compressed, and condensed at constant pressure and expanded
through a throttling device. At this stage, it is a mixture of liquid and gas. Next, it is allowed to go
through evaporators where it takes heat off from gaseous CO2. R22 becomes a gas and comes back
into compressors and the cycle restarts. Liquid CO2 is then stored in a tank. CO2 stored in the tank
serves to two tasks: a part of it is packed in gas cylinders and taken to Kigali where it serves in the
manufacturing of soft drinks. Another part is evaporated using cool air and water through heat
exchangers and becomes a gas, which can be used directly in the industry.
II.2 BEER PRODUCTION AND PROCESS
Beer is produced in a process of Brewing. Gisenyi Brewery uses techniques are required for
brewing beer. Many components and products such as malt, maize, sugar, water, co2, compressed
air, and other different material are used to in brewing the brewing process. Work in brewery
several steps such as: Milling, Mashing, Lautering, Boiling, Cooling, Fermenting, Conditioning,

15
Filtering, and Filling. Brewers make choices at every step of the process, from ingredient selection
to determining mash and fermentation temperatures, that all have significant effects on the quality
of the end product.
II.2.1 BREWING
The brewing process is very important stage in production of beer. It consists a large number of
process, starting with mashing and lautering, then boiling and cooling the wort; and finally
fermentation and filtration are the following one. In all of these processes you relay on precise
monitoring Temperature, pressure, the pH value or conductivity.
The process of malts to get the brew house from the main store. Pneumatically, the malts are
pushed into big conduit up the garrets in the brew house from which are moved steadily and
continuously out to be polished in polisher (polishing machine) and grinded into powder in mill
machine. The powder is kept into the malt’s powder hopper and then is poured out to the mixing
tank (CM) where it is mixed with brewing water to give wort while on the other side, wort from
maize are prepared in the same way as malt wort.
Both wort are combined together in the filtration tank (CF), and then the mixture of wort is boiled
and kept into the Whirlpool from where it goes to cool down, waiting for Fermenting and
filtration.
II.2.2 FERMENTATION
Fermentation starts as soon as yeast is added to the cooled wort. This is also the point at which the
product is first called beer. It is during this stage that the yeast reproduces and sugars won from
the malt are metabolized into carbon dioxide C02, alcohol, and a host of other flavorful and
aromatic compounds that add complexity to the beer. Fermentation tanks are typically made of
stainless steel. If they are simple cylindrical tanks with beveled ends, they are arranged vertically,
as opposed to conditioning tanks which are usually laid out horizontally.
After high kraeusen a bung device is often put on the tanks to allow the CO2 produced by the yeast
to naturally carbonate the beer. This bung device can be set to a given pressure to match the type
of beer being produced. The more pressure the bung holds back, the more carbonated the beer
becomes. Once the available sugars have been consumed the yeast cells clump together or floc and
fall to the bottom of the fermenting tank.

16
II.2.3 BEER CONDITIOING
When fermentation is complete, I mean when the sugars in the fermented beer have been almost
completely digested, the beer is removed from the yeast by cooling it to around freezing; proteins
are coagulated and settled out with the yeast. Unpleasant flavors such as phenolic compounds
become insoluble in the cold beer, and the beer's flavor becomes smoother. During this time
pressure is maintained on the tanks to prevent the beer from going flat. If the fermentation tanks
have cooling jackets on them, as opposed to the whole fermentation cellar being cooled,
conditioning can take place in the same tank as fermentation. Otherwise separate tanks (in a
separate cellar) must be employed. Once the beer is clear it is ready to filter and package.
II.2.4 FILTERING AND DILUTION OF BEER
Filtering the beer stabilizes the flavor, and gives beer its polished shine and brilliance. Not all beer
is filtered. There are many types of filters. Many use pre-made filtration media such as sheets or
candles, while others use a fine powder made of, for example, kieselguhr, which is introduced into
the beer and recirculated past screens to form a filtration bed. Filters range from rough filters that
remove much of the yeast and any solids (e.g. hops, grain particles) left in the beer, to filters tight
enough to strain color and body from the beer. Normally used filtration ratings are divided into
rough, fine and sterile. Rough filtration leaves some cloudiness in the beer, but it is noticeably
clearer than unfiltered beer. Fine filtration gives a glass of beer that you could read a newspaper
through, with no noticeable cloudiness.
Since beer is much more alcoholic concentrated, the dilution process is necessary to reduce the
proportion of alcohol. This is done by Calboblender. Depending on which kind of beer is being
brewed, the Calboblender machine automatically dilute the beer using well treated water at a given
proportion and also control the levels of CO2 and Oxygen contained in beer. Beer is deposited in
a tank from which it is taken to be packed for being put to the market.

17
CHAPTER III. PACKAGING AND MAINTENANCE OF MACHINES
III.1 PACKAGING OF BEERS
Packaging of beer is another important part of the Brewery where by the beers are taken from
Brew house and are packed in bottles as well as in crates to be packed in cars for being delivered
on the market. Beer packaging is ensured by operators who work on it on a daily basis in shift and
with the help of PM technician who are responsible of machine maintenance. All this is under the
Technical Department; the quality Control and the TPM service for high working and safety
quality. Before being distributed to clients, well packed beers go to the store controlled by the
Logistics management.
Packaging is done by high technology machines which do interact or communicate while their
individual tasks; this means that they are very well synchronized with each other. Packaging has
two production Lines; mow the Brewery is using Production Line 2 and Production 3 since the
Production Line 1 has been removed and is no longer being used nowadays. Both Line 2 and Line
3 work in the same way despite that the Production line 3 is using the latest and modern technology
as compared to Line 2 and is new to Line 2.
First the process starts by bringing the crates containing empty bottles in Line 2 or 3 depending on
what they have decided to use. Then, Unpacker machine is there to unpack these bottles from the
crates, and then the crates continues their way to crate washer as also the bottles continue to the
bottles washer. The bottle washer washes the bottles and send them to EBI which inspect them and
send them in the Filler machine which fills in bottles the beer and seal bottles with bottle cap. After
the beers are sent in the Pasteurizer which give them guaranty to them and then they undergo
through different full bottle inspection. After the beers are sent in Labeler machine which put on
labels on the bottles. After beers are sent to the packer which takes beers and put them in the
cleaned crates and from here the beers are moved through conveyor systems on their way to be
packed in truck for market.
Below is the working principle of different machines used in packaging of beers, some of which
is are called robots.

18
Figure 6. Packaging house Line 3
III.1.1 CONVEYOR SYSTEMS
Bralirwa Gisenyi Brewery uses a conveyor system to move crates and Bottles from one location
to another. When the bottles arrive, they are put on the receiver belt conveyor that drives them to
de-carter, then bottles are conducted by conveyor during the process. The part of the conveyor
which moves the Bottles is made of chains while as the other part that moves crates is made of
Rollers and Belts. An electrical motor connected with the gear head or speed reducer is the source
of motion of the conveyor system.
There are two types of conveyor here in Packaging house: crate conveyors and bottle conveyers.

19
Figure 7. Conveyors of crates and bottles
III.1.1.1 DESCRIPTION OF CONVEYORS
A conveyor system is a common piece of mechanical handling equipment that moves materials
from one location to another. Conveyors are especially useful in applications involving the
transportation of heavy or bulky materials. Conveyor systems allow quick and efficient
transportation for a wide variety of materials, which make them very popular in the material
handling and packing industries. Many kinds of conveying systems are available, and are used
according to the various needs of different industries. Conveyor systems are used widespread
across a range of industries due to the numerous benefits they provide.
 Conveyors are able to safely transport materials from one level to another, which when
done by human labor would be strenuous and expensive.
 They can be installed almost anywhere, and are much safer than using a forklift or other
machine to move materials.

20
 They can move loads of all shapes, sizes and weights. In addition, many have advanced
safety features that help prevent accidents.
 There is a variety of options available for running conveying systems, including the
hydraulics, mechanical and fully automated systems, which are equipped to fit individual
needs.
III.1.1.2 SPEED CONTROL OF CONVEYORS
There are speeds reducers that are designed to change the rotational speed from an input shaft into
a lower output speed. Speed reducers of these applications are composed by conveyors automation
equipment, and are widely used in construction machinery and other industrial machines. Reducers
are advantageous in many situations for a large number of processes and equipment. The benefits
of using automated speed controller include technology objectives such as:
 Power savings through a load-dependent control of the belt speed
 Efficiency increase
 Minimization of system perturbations
 Reduction of gear and belt wear
 Improvement and increased equipment longevity
III.1.1.3 SPEED REDUCERS OF CONVEYORS
Speed reducers are designed to change the rotational speed from an input shaft into a lower output
speed. During equipment operation, the motor transmits power to the input shaft of the reducer.
The speed reducer then converts this power into lower output speed, which the reducer transmits
to the connected load through the output shaft. Speed reducers are known by many names and are
available with a variety of modifications to suit the right purpose. Each one is designed with
specific load and torque capacities. Speed reducers contain a set of gears, and input and output
shafts. Speed reducers are used in a variety of applications, including automation equipment,
conveyors, compressors, printing presses, pumps, compressors, generator and robotics

21
applications and are widely used in metallurgy machinery, mine machinery, robotics, construction
machinery and other industrial machines. Reducers are advantageous in many situations for a large
number of processes and equipment. The benefits of using speed reducers include speed
optimization, performance improvement and increased equipment longevity. In addition, a wide
array of gear configurations is available for use in different applications.
III.1.1.4 REDUCTION GEARS OF CONVEYORS
Reduction gears are mechanisms that lower the speed or torque of a rotating input shaft through
use of gears with varying circumferences. Speed reducers such as gear boxes rely on reduction
gears to perform their function of decreasing the number of rotations per minute. They are made
of strong durable metal like steel and are available in a wide range of sizes and reduction ratios,
the ratios of the input speed to the output speed. When several reduction gears are used in
succession, the multistage speed reducer is able to achieve ratios of up to 1,000:1. Average ratios
are measured in integers such as 5:1 or 250:1. Reduction gears are the central component in
gearboxes, gear heads, gear drives and other speed reducers; these devices would not function
without them. Other devices that slow the speed of an input shaft using different techniques such
as cyclo reducers and planetary gearboxes.
Reduction gears find wide usage in industrial and manufacturing processes and are used in
conveyor belts, robotic assemblies, material handling, packaging applications and more. Perhaps
the most well-known example is the transmission found in motor vehicles. Reduction gears use at
least two gears of differing sizes that work together to slow the input speed. In single stage
reductions, there are two gears, one with a circumference larger than the other. Because the large
gear requires has a longer distance to turn to complete one full rotation, the small gear will turn at
least twice as the large gear turns. This is the basic principle behind reduction gears. The number
of rotations required for the input gear to equal the output gear provides the reduction ratio, which
allows the operator to calculate the best gearbox for the job.

22
III.1.2 UNPACKER/ DECTRATOR MACHINE
Unpacker is an electro-pneumatic machine used to remove empty bottles from the crates so that
the bottles went to the bottle washer to be washed and the crates move to the crate washer. The
main part of Unpacker/Packer are: The Crates Conveyor, The Grippers, Bottles Conveyor, Drive
mechanism (this consists of the main motor-reducer, the device shaft control it means arm
swinging and lifting, control mechanism and the binding chassis) and The Electric control.
Figure 8. Unpacking machine; field photo from line 3
The crates containing bottles are sent to the Unpacker continuously when the crates passing by the
transit roller between quick case input device and case in feed are checked and counted by sensor
when four crates are counted the case blocking device installed on the end of case quick in feed
device will lift and stop the next crate entering. The crates will stop at a right position under the

23
action of case blocking and bottle guiding then with the movement of arm swinging and lifting
device the grippers (By a pneumatic control) will descend to a suitable height after each gripper
tightly grasps a bottle, the grippers will ascend to a certain height then horizontally moves a certain
distance to bottle collecting platform, the grippers will descend to a suitable height and release the
bottles.
The grippers will return and grasp the bottles again according to the same way with arm swinging
and lifting, then grasping and releasing bottles move in cycles. Bottles unloaded on the bottle
collecting platform will be sent out of the Unpacker. After bottles unloaded, the bottle guiding
device will be back, the crates will be sent out of the machine, meanwhile, case blocking device
in end of quick case in feed be back and another group of cases input.
III.1.3 BOTTLE WASHER MACHINE
Bottle washer is a machine that used to wash bottles, to remove old labels,

24
Figure 9. Bottle washer machine
III.1.3.1 BOTTLE WASHING REQUIREMENTS
Bottle washing consists of soaking or flushing the bottles with caustic soda solution, sometimes
combined with other cleansing agents such as soda ash, sodium aluminate, or Nitrium phosphate.
The bottles are then scrubbed both inside and out before they are rinsed with potable water. In order
to have an efficient washing process, several factors must be controlled in the bottle washing
operation.
 Adequate concentration of sterilizing and detergent agents;
 Proper composition of the agents;
 Adequate temperature of the washing solution;
 Sufficient exposure time of the bottles to the washing and sterilizing agents;
 Proper rinsing water; and
 Proper maintenance of the bottle washing equipment.
The bottle-washing equipment may be classified into three types, namely: immersion or soaker
washers; immersion with brushing washers; and Hydro washers using powerful jets. The bottles
enter the washer through an automatic loader which handles the bottles separately from each
other.
Then, they get a pre-rinse before they enter a series of soaking compartments containing caustic
solutions at a specific temperature. After the bottles go through final rinsing, they are discharged
from the washer in a gentle motion and placed in an upright position for further visual inspection.
The washing solutions will gradually lose its caustic strength as the washing process progresses.
Reaction with impurities depletes the NaOH in solution therefore; there is a need to check the
causticity periodically so that the caustic concentration may be adjusted as required.
III.1.3.2 WORKING PRINCIPLE OF BOTTLE WASHER
Dirty bottles returned to the plant are first uncased and conveyed to the bottle washing machine.
Within the bottle washing equipment, the bottle washing process takes places in a series of stages.
First, the bottles are pre-rinsed by jetting with warm reclaimed water. Then, the dirty bottles go
through a series of soaking in compartments filled with caustic solution. The number of caustic

25
compartments of Bralirwa Gisenyi Brewery bottle washing machine is four. After the last caustic
compartment, the bottles are soaked in a hot water compartment, which removes most of the
caustic solution from bottles. Finally, the bottles are rinsed in a two-stage mode, that is, in
compartment Five (V) and in the final rinsing compartment. The bottles that come out of the bottle
washers are further inspected before they can be filled by the product.
It must be emphasized that these specifications for the soaking and rinsing processes, proper
temperature, caustic solution concentration and contact time must be carefully observed in order
to efficiently clean the bottles.
An electric motor, on to which a chain that rotates the axle is connected, is the source of motion.
The axle rotates on a high speed that may cause the chain carrying the bottles through the
compartments to go first whereby it may result into improper washing of the bottles. Therefore, a
speed reducer connected to the axle reduces its speed making the chain carrying the bottles to
move slowly, thus helping in effective washing of bottles. The ejectors move on the same speed
to that of the bottles, following them while flushing in the inside of the bottle.
Figure 10. Diagrammatic View of a typical five-compartment bottle washer

26
III.1.4 EMPTY BOTTLE INSPECTOR
Empty Bottle Inspector (EBI) checks the foreign substances, for the inspection of various defects
using the various detectors.
Figure 11. Empty Bottle Inspector (EBI) Machine
This inspector checks also the bottles damaged and of the bottle containing of the residual liquids,
but also those having visible defects, like signs of wear machine. This installs rests on a system
which combines successfully simplicity, the hygienic design, and of the maximum insurance of
inspection of bottles. It offers functions of inspection complete empty bottle, including the
inspection stops bottle, apart from the bottle, the inspection of the external walls, inside the
inspection of the interior walls of the bottle, inspection of the base of the bottle, and the residues
liquid inside the bottle

27
Figure 12. Functional parts of EBI
Foreign bottle detection unit with rejection at the infeed (color, height, diameter, contour) are A,
B and C.
All the other parts numbered on the diagram aboveare explained in details down here:
1. Variostation 1 with sealing surface inspection by camera
2. Base inspection 1 by camera
3. Variostation 2 with base inspection unit 2, full thread or inner side wall inspection by
camera
4. Variostation 3 with inner side wall, thread or lateral neck finish inspection by camera
5. Variostation 4 with sealing surface or lateral neck finish inspection by camera
6. High-frequency residual caustic Detection
7. Infrared residual liquid detection
8. Side wall inspection by camera
9. Optimized scuffing detection
EBI (Empty Bottle Inspector) contains some detection units like Base detection unit, foreign
container detection unit, and so on.

28
Figure 13. Base inspection unit Figure 14. Foreign container detection unit
Inspection unit above has sensor for detecting the color of glass containers and a CCD camera for
detecting the contour, diameter and height of glass and returnable containers.
For Base inspection unit, a camera captures an image of the container base while an LED lamp
provides uniform illumination of it. The high grey-scale resolution guarantees a consistently high
image quality even in containers with different levels of permeability to light.
III.1.5 FILLING AND CAPPING MACHINE
Filling and capping machine commonly known as Filler is a machine which fills beverages bottles
out coming from EBI and put capes on these bottles. I can say that Filler is one of the most
intelligent machine by seeing all the work it accomplishes of filling beer in bottles and capping
them. The beers are put in bottles together with CO2 and this task is done by Filler and it
automatically do this and cape the bottle directly so that there will be no entry of oxygen in the
bottle of beer. It also works on a high speed filling and capping many bottles in less time.
This is the machine which is used in industrial packaging with different names like filling
equipment, filler, filling system, filling machinery, filling line and so on. Filler machine is used to
fill different kind of beer and wine products with predetermined volume and weight into containers
such as bottle and other containers as plastic, metal, glass boxes.

29
Different types of filler are used for different types of industrial applications. Filler machine are
mainly used in the industries such as dairy, cosmetic, biomedical, pharmaceutical, chemical,
beverages, food, oil and paints. Different technologies are used in different types of filling
machines. Those technologies must be most reliable, economical and precise in order to make the
best and high quality filling machinery. Namely technologies used are manual filling, semi –
automatic filling, automatic filling as per feature and application of the product. They can be semi
or full automatic and built so that the performance can be enhanced to meet production demand
with maximum accuracy with minimum product wastage.
Some of the most widely used filling equipment are Liquid Filling Machine, Gravity Filling
Machine, Powder Filling Machine, Overflow Filling Machine, Piston Filler, Pump Filling 33
Machine, Rotary Filling Machine,
Tube Filling Machine, Hazardous Filling Machine, Pressure Filling Machine and Corrosive Filling
Machine. In manual filling, product is filled in the container by Hand operate. There is no power
supply required. It is very simple to use and maintain but takes more time to complete filling
operation. It is suitable for filling of liquids, gels and creams for small range of applications. In
semi-automatic filling machine, half of the filling operation is done by filling machine and the
operator will carry out rest of the operation manually. In semi-automatic filling machines
containers are placed by hand and then filling products by operating machine. It is suitable for
liquid filling including viscous liquids containing particles such as foods. It takes more time
compared to automatic filling machines. Fully automatic filling machine are used for high speed
and wide range of applications. It is essential for bulk production and on time production is
required. Automatic filling machines are speedy, gives accurate results, and durable. It is costlier
compare to manual filling and semi-automatic filling machine.

30
Figure 15. Filling and capping machine
Filling and Capping machine has two parts, one for filling beer in bottle and another part for
capping.
III.1.5.1 FILLING PART
The filler machine of Bralirwa Gisenyi Brewery is classified as a fully automatic filling machine
and as a pressure-filling machine. Its type is cobravac 100/20, which indicates that it has filling
valves and 20 head capper. The cobravac filling machine is a counter-pressure, fully automatic
machine whereby the direction of the liquid (soft drink) enters in counter or opposite direction to
that of the compressed air. This gives the filing pressure recorded by the Dome gauge =3.9 bar, it
is also considered as the pressure in the filling valves. The bottle supporting cylinders: these bottle
supporting cylinders they hold the bottles up to the filling valves and the elevation (up moving of
the cylinders) is due to the compressed air of about 3 atm. The cylinder pressure which was seen

31
to be recorded on the cylinder gauge is 3.5bar therefore it is realized that the pressure of the filling
valves is approximately equal to that of the cylinders and it is this counter pressure that holds the
bottle when being filled with the drink.
III.1.5.2 CAPPING PART
The cap-sealing machine is used to put covers on the bottles after being filled with the drink. The
capacity of the cap-sealing machine is used depending on the capacity of filler machine in use. For
example, at Gisenyi Brewery, the cap-sealing machine in use has 20 head cappers whereas the
racking machine has 100 filling valves. The capper has an electrical motor that rotates the wheel
positioned in the hopper hence initiating the movement of the covers down the passage to the head
cappers.
III.1.6 FULL BOTLLE INSPECTOR
As the name of this inspector, bottles filled and closed occur in this machine for the inspection
from various defects using the detectors. For example, stowaways inside bottles (escapes), this
inspector checks also bottles filled and badly filled, the organic particles glare and bad labeled
bottles. It can also equip with level of filling and the units of inspection of the CAP.
The FBI checks the filling with a tolerance zero defect finally to reject bottles which do not fulfill
the given requirement of quality.
The Full Bottle Inspection (FBI) ensures quality bottled products every time. FBI is a complete,
ultra-high speed system, reliably detecting defects and rejecting bottles off the line before they
reach retailers and consumers.
This complete vision system always meets manufacturer's requirements by inspecting a wide
variety of bottles to provide accurate fill level, cap skew and tamper band seal verification. It
inspects also some escapes from closed bottles. Says no to foreign particles in the bottle.
III.1.6.1 WORKING PRINCIPLE OF FBI
The unit consists of two modules– one module is located at the machine’s inlet and one at its
discharge. Each module contains a camera with VGA resolution as well as an LED lamp shining
through the entire height of the bottle.

32
Each camera generates three different, overlapping images of the bottle. For gap-free, all-around
inspection, the bottles are rotated by 90° between the first and the second module.
Figure 16. Diagram of FBI
These parts from 1 to 4, it is Detection of foreign
objects lying on the container base.
Figure 17. Field photo of FBI
5. Detection of floating foreign objects
6. Fill level and slanted cap inspection
7. Detection of cap design
8. Base inspection (light field)
9. Base inspection (dark field)
10. Height detection by P.E. sensor
DETECTION OF FOREIGN OBJECTS ON THE BASE:
Three different mutually complementary modules are available for inspection of the container
base.

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INSPECTION UNIT 1
Base inspection
(dark field)
Figure 18. Inspection unit 1 of FBI
INCLINED-ANGLE BASE INSPECTION.
In order to reliably detect foreign objects, the bottles pass through two consecutive inspection
modules. In each module there are two opposite CCD cameras pointed at the bottle. By way of a
special optic, they capture images of the bottle base at an inclined angle and map it segment by
segment. LED flash lamps provide the necessary brightness, illuminating the bottles uniformly as
they pass by. To inspect the bottles from all sides, they are rotated through about 90° between the
two modules.
INSPECTION UNITS 2
Detection of cap
Detection of foreign
object on the base
Base inspection
light field
Fill level and design floating
foreign objects
Detection of slanted cap
inspection

34
Figure 19. Inspection unit 2 of FBI
DETECTION OF FLOATING FOREIGN OBJECTS
Using a special optic, a CCD camera captures three images of the bottle body illuminated all
around by an LED panel light.kr
FILL LEVEL AND CAP INSPECTION
A CCD camera captures two images of the neck and cap area of the bottle using a special optic.
The telocentric optic provides an ideal angle of view of the cap closure and the fill level. The
camera checks that the bottle is correctly filled and also detects slanted or severely deformed
crowns.
DETECTION OF CAP DESIGN
In order to detect wrong, damaged or incorrectly printed caps, a CCD camera inspects the
containers from above. The intelligent system can also differentiate between cap logos as
necessary.
III.1.6.2 FBI OF BRALIRWA GISENYI BREWERY
There two FBIs for each production line. The first FBI machine checks bottles after filling and
sealing. It does the inspection of filled bottles and tightly closed. it uses also different detectors
of the inspections of various defects. When the bottles enter this machine, it checks the presence
of badly filled bottles which means bottles bellow or above the needed level of the product, also
the presence of organic particles glares and other strange objects in the filled bottles. This
machine checks the filling with no tolerance of any defect, finally to reject bottles which do not
fulfill the given requirement of quality.
The second FBI machine comes after labeling machine. It uses highly sensitive cameras and clever
detection software, it detects even the smallest foreign bodies, particles, and contaminations. This
way, you provide your customers and your product with the maximum safety. And you can be sure
that only faultless products reach the point of sale.

35
III.1.7 PASTEURIZER
Pasteurizer is a machine which give guaranty to the beer after being filled in bottles and after being
inspected by the full bottle inspector.
It is a process in which the packaged beer are treated with mild heat, usually to less than 100 °C
(212 °F), to eliminate pathogens and extend shelf life. The process is intended to destroy or
deactivate organisms and enzymes that contribute to spoilage or risk of disease, including
vegetative bacteria, but not bacterial spores. Since pasteurization is not sterilization, and does not
kill spores, a second "double" pasteurization will extend the quality by killing spores that have
germinated.
The process was named after the French scientist Louis Pasteur, whose research in the 1880s
demonstrated that thermal processing would inactivate unwanted microorganisms
in wine. Spoilage enzymes are also inactivated during pasteurization. Today, pasteurization is used
widely in the dairy industry and other food processing industries to achieve food
preservation and food safety.

36
Figure 20. Field photo of pasteurizer
Pasteurization is the process of preventing fresh packaged beer from bacterial contamination by
gentle heating and rapid cooling it.
The filled and closed packages of beer are conveyed through different sections of a “tunnel”
pasteurizer and sprayed with temperate water increasing, holding, and then decreasing the
temperature. The beer is finally re-cools rapidly within minutes. All these tasks are accomplished
within the Pasteurizer which is a PLC (Programmable Logic Controller) machine fitted with level
sensors. Inductive proximity sensors were used to detect the presence of liquid inside the
Pasteurizer.
To receive the total pasteurization heat units required; every package must be sprayed with water
for the necessary time and of the correct temperatures. Too little may result in poor flavor stability
of the beer because of the remaining live microorganisms. Too much may have a cooking effect,

37
causing accelerated staling of the beer. The balanced, tightly controlled and gentle treatment results
in stable and fresh tasting beer. Pasteurization is depending on kind of micro-organism and the
possibility of micro-organism to grow/survive environmental conditions.
III.1.8 LABELING MACHINE
Labeling machine also known as Labeler is a machine which put labels on the bottles of beer
announcing the kind of the product on bottles.

38
Figure 21. field photo of Labeling machine
III.1.8.1 WORKING PRINCIPLE OF LABELER
The principle of the labeling machine is that the item is fed to the labeling machine at a constant
speed on the conveyor. The mechanical fixture separates the items a fixed distance and pushes the
item in the direction of the conveyor.
It has a drive wheel, a labeling wheel and a reel. The drive wheel intermittently drags the label
strip movement such that the label strip is pulled out of the spool while the label strip is pressed
against the article by the labeler wheel. An open-loop displacement control is used on the reel to
maintain the tension of the label strips because the label strips are connected to each other. The
label belt is continuously stopped and stopped so that the label tape is attached to the article with
the labeling wheel moving at the same speed as the article. When the conveyor reaches a certain
position, the label drive wheel accelerates to the speed at which the belt matches. And after the
label is attached, it decelerates to a stop.
Since the label may slip slightly, it has a mark on it to ensure that each label is placed correctly,
which is read by a sensor. During the deceleration phase of the label, the drive wheel will re-adjust
the position to correct any errors on the label.
III.1.8.2 CHANGEOVER OF LABELER
Changeover is done when we want to label another product. When changing the format, the new
type is first of all selected on the touch-screen. If new containers or labels are to be processed for
the first time, all of the label parameters can be set and then saved from the menu by following the
instructions on HMI (Human Machine Interface). Each labelling station is adjustable along a
horizontal cross slide, and the glue pallets can be replaced together with the associated shafts.

39
III.1.9 VIDEOJET
Videojet is a printer that prints by jetting ink on the product without contact between the printer
and the product. This machine is designed to print messages with small block capitals. Bralirwa
uses this machine for coding the product with the following specification:
The printer Videojet has Four (4) main parts which are the Electronic compartment, the Pneumatic
compartment, the Hydraulic compartment and the Printing header.
Figure 22. Field photo of Videojet and prints on bottle
III.1.10 CRATE WASHER MACHINE
Crate washer is a machine which washes crates. After removing empty bottles from crates, the
crates are sent in the crate washer to washed so that they continue their way to be packed again
with filled beer bottles. This operation is done by crate washer as also the bottles on the other hand
are being washed by bottle washer.

40
Figure 23. Field photo of crate washer machine
III.1.11 PACKER/CRATER MACHINE
As I mentioned above on the Unpacker machine, Packer also work in the same way as Unpacker
except that it does the reverse operation.
Packer or Crater machine is responsible for packing the filled bottles into the crates to be taken
out. Even the outlook of them are similar.
III.2 MAINTENANCE OF MACHINES
Bralirwa uses Planned maintenance and Total production management tools in order to achieve
zero equipment breakdowns, preserve equipments and Plant in excellent shape so that the
productivity is not affected negatively instead this is done in order to maximize the production
benefits.

41
These tools are of great help to a Plant like Bralirwa which has many equipments that should be
catered for. Bralirwa has been successful with these tools, this is indicated by the fact that it is till
now using some of machines and equipments of many years ago in 1982.
III.2.1 PLANNED MAINTENANCE (PM) OF MACHINES
III.2.1.1 GOAL OF PLANNED MAINTENANCE
The goal of Planned Maintenance (PM) is to achieve ‘ZERO EQUIPMENT BREAKDOWNS’ by
implementing systems of ‘PARTS REPLACEMENT BEFORE FAILURE’ Time Based
Maintenance (TBM) and Condition Based Maintenance (CBM). Also by following Equipments
total maintenance standards, Production autonomous maintenance system, and PM standards
which are General inspection standards and Annual maintenance plans.
III.2.1.2 PLANNED MAINTENANCE ACTIVITIES
Support autonomous maintenance activities by Technical support, breakdown analysis,
demarcation between production and PM systems, analysis for chronic breakdowns, conditions
based maintenance items, spares parts and Maintenance day practice.
III.2.1.3 PLANT EQUIPMENT IMPROVEMENT TEAM
Achieve systematic breakthroughs in equipment’s six big losses and establish standards for basic
machine conditions. The basic machine conditions are: Cleaning standards, Lubrication standards,
and Bolt-tightening standards.
Six Big Losses for equipments are:
1. Breakdown losses
2. Speed losses
3. Set up losses
4. Defect losses
5. Start-up losses
6. Minor stoppage losses

42
III.2.2 TOTAL PRODUCTIVE MAINTENANCE (TPM)
Total Productive Maintenance (TPM) is a system of maintaining and improving the integrity of
production, safety and quality systems through the machines, equipment, processes, and
employees that add business value to an organization.
TPM focuses on keeping all equipment in top working condition to avoid breakdowns and delays
in manufacturing processes.
The goal of TPM is the continuous improvement of equipment effectiveness through engaging
those that impact on it in small group improvement activities. Total Quality Management (TQM)
and total productive maintenance (TPM) are considered as the key operational activities of the
quality management system. In order for TPM to be effective, the full support of the total
workforce is required. This should result in accomplishing the goal of TPM: "Enhance the volume
of the production, employee morale and job satisfaction. Motivated people works better all the
time.

43
CHAPTER IV. MEASUREMENT, AUTOMATION AND WASTE WATER
TREATMENT
IV.1 MEASUREMENT AND AUTOMATION
According to Wikipedia, Measurement is the assignment of a number to a characteristic of an
object or event, which can be compared with other objects or events. The scope and application of
measurement are dependent on the context and discipline. In the natural sciences and engineering,
measurements do not apply to nominal properties of objects or events, which is consistent with the
guidelines of the International vocabulary of metrology published by the International Bureau of
Weights and Measures.
Automation is the technology by which a process or procedure is performed with minimal human
assistance. Automation or automatic control is the use of various control systems for operating
equipment such as machinery, processes in factories, boilers and heat treating ovens, switching on
telephone networks, steering and stabilization of ships, aircraft and other applications and vehicles
with minimal or reduced human intervention.
Automation covers applications ranging from a household thermostat controlling a boiler, to a
large industrial control system with tens of thousands of input measurements and output control
signals. In control complexity, it can range from simple on-off control to multi-variable high-level
algorithms.
IV.1.1 BASIC MEASUREMENT THEORIES
By measuring the quantity, we are interested in, we usually transmit a signal representing this
quantity to an indicating or computing device where either human or automated action then takes
place. If the controlling action is automated, the computer sends a signal to a final controlling
device which then influences the quantity being measured. This final control device usually takes
one of the following forms:
 Control valve for throttling the flow rate of a fluid
 Electric motor
 Electric heater

44
Both the measurement device and the final control device connect to some physical system which
we call Process. To show this as a general block diagram:
Figure 24. Block diagram showing process (measuring cycle)
Industrial measurement and control system have their own unique terms and standards, which is
the primary focus.
These are some common measurement and instrumentation terms and their definitions used:
 Process: The physical system we are attempting to control or measurement. Examples:
water filtration system, steam boiler, power generation unit, and so on.
 Process variable (PV): The specific quantity we are measuring in process. Example:
pressure level, temperature, flow, electrical conductivity, position, speed, and so on.
 Set point (SP): The value at which we desire the process variable to be maintained at. In
other words, the ‘’target’’ value of the process variable.
 Primary sensing element (PSE): A device that directly senses the process variable and
translates that sensed quantity into an analog representation (electrical voltage, current,

45
resistance; mechanical force, motion, etc.). Examples; thermocouple, bourdon tube,
potentiometer, electrochemical cell, and so on.
 Transducer: A device that converts one standardized instrumentation signal into another
standardized instrumentation signal, and / or performs some sort of processing on that
signal. Often referred to as a converter and sometimes as a ‘’relay’’. Examples: I/P converter
(converts 4 – 20mA electric signal into 3 – 15PSI pneumatic signal), square-root extractor
(calculates the square-root of the input signal).
 Transmitter: A device that translates the signal produced by primary sensing element
(PSE) into a standardized instrumentation signal such as 0.2 – 1.0 bar air pressure, 4 – 20mA
DC electric current. Field bus digital signal process, etc., which may then be conveyed to
an indicating device, a controlling device, or both.
 Lower-and Upper-range valves (LRV & URV): The values of process measurement
deemed to the 0% and 100% of a transmitter’s calibrating rang. For example, if the
temperature transmitter is calibrated to measure a range of temperature starting at 0 0
c and
ending at 100 o
c, 0 o
c would be the LRV and 100 o
c the URV.
 Controller: a device that receives a process variable (PV) signal from a primary sensing
element (PSE) or transmitter, compares that signal to the desired value for that process
variable (called the set point), and calculates an appropriate output signal value to be sent
to a final control element (FCE) such as an electric motor or control valve.
 Final control element (FCE): A device that receives the signal from a controller to directly
influence the process. Examples: variable-speed electric motor, control valve, electric heat.

46
 Automatic mode: When the controller generates as output signal based on the relationship
of process variable (PV) to the set point (SP).
 Manual mode: When the controller’s decision-marking ability is bypassed to let a human
operator directly determine the output signal sent to the final control element.
IV.1.2 LEVEL MEASUREMENT
Accurate continuous measurement of volume of fluid in containers has always been a challenge to
industry. There are very simple systems employ external sight glasses or tubes to view the height
and hence the volume of the fluid. Others utilize floats connected to variable potentiometers or
rheostats that will change the resistance according to the amount of motion of the float.
This signal is then inputted to transmitters that send a signal to an instrument calibrated to read out
the height or volume. Differential Pressure (DP) capsules are the most commonly used devices to
measure the pressure at the base of a tank. When a DP transmitter is used for the purpose of
measuring a level, it will be called a level transmitter.
IV.1.3 LEVEL TRANSMITTER
It is a device that translates the signal produced by a primary sensing element (PSE) into a
standardized instrumentation signal such as 0.2-1 bar air pressure, 4-20 mA DC electric current,
Field bus digital signal packet, etc., which may then be conveyed to an indicating device, a
controlling device, or both. The purpose of this device is to sense the liquid level in the tank and
report that measurement to the controller in the form of an instrument signal.
The type of signal is pneumatic: a variable air pressure sent through metal or plastic tubes. The
greater the water level in the drum, the more air pressure output by the level transmitter. Since the
transmitter is pneumatic, it must be supplied with a source of clean, compressed air on which to
run. This is the meaning of Air Supply entering the top of the transmitter.
This pneumatic signal is sent to the next instrument in the control system which is Level indicating
controller.

47
The purpose of this instrument is to compare the level transmitter’s signal with a set point value
entered by a human operator. The controller then generates an output signal telling the control
valve to either introduce more or less liquid into the tank to maintain the liquid level at set point.
As with the transmitter, the controller in this system is pneumatic, operating entirely on
compressed air. This means the output of the controller is also a variable air pressure signal, just
like the signal output by the level transmitter. Naturally, the controller requires a constant supply
of clean, compressed air on which to run, which explains the Air Supply tube connecting to it.
IV.1.4 CONTROL VALVES
A control valve is a valve used to control fluid flow by varying the size of the flow passage as
directed by a signal from a controller. This enables the direct control of flow rate and the
consequential control of process quantities such as pressure, temperature, and liquid level.
In automatic control terminology, a control valve is termed a "final control element".
The opening or closing of automatic control valves is usually done
by electrical, hydraulic or pneumatic actuators. Normally with a modulating valve, which can be
set to any position between fully open and fully closed, valve positioners are used to ensure the
valve attains the desired degree of opening.
Air-actuated valves are commonly used because of their simplicity, as they only require a
compressed air supply, whereas electrically-operated valves require additional cabling and switch
gear, and hydraulically-actuated valves required high pressure supply and return lines for the
hydraulic fluid.
The pneumatic control signals are traditionally based on a pressure range of 3-15psi (0.2-1.0 bar),
or more commonly now, an electrical signal of 4-20mA for industry, or 0-10V for HVAC systems.
Electrical control now often includes a "Smart" communication signal superimposed on the 4-
20mA control current, such that the health and verification of the valve position can be signalled
back to the controller. The HART, Fieldbus Foundation, and Profibus are the most common
protocols.

48
1. Air-actuated control valves each with a 4-20 mA 2. Globe control valve with pneumatic diaphragm actuator
Figure 25. Control valves photos
An automatic control valve consists of three main parts in which each part exists in several types
and designs:
 Valve actuator - which moves the valve's modulating element, such as ball or butterfly.
 Valve positioner - Which ensures the valve has reached the desired degree of opening. This
overcomes the problems of friction and wear.
 Valve body - in which the modulating element, a plug, globe, ball or butterfly, is contained.
Table below shows signal pressure and valve position

49
Controller input signal pressure Control valve position
0.2 bar 0% open(fully closed)
0.4 bar 25% open
0.6 bar 50% open
0.8 bar 75% open
1.0 bar 100% open
Table 1. Pressure of signals and valve position
IV.1.5 SENSORS AND REGULATORS
In short, a sensor is a device, module, machine, or subsystem whose purpose is to detect events or
changes in its environment and send the information to other electronics, frequently a computer
processor.
In automatic control, a regulator is a device which has the function of maintaining a designated
characteristic. It performs the activity of managing or maintaining a range of values in a machine.
Bralirwa Gisenyi Brewery uses a variety of sensors and regulators which are very useful in every
work of the brewery. Below, I am going to talk about some of them.
IV.1.5.1 TEMPERATURE SENSORS
The most commonly measured physical parameter is temperature whether in process industry
applications or in laboratory settings. A temperature sensor is a device, usually an RTD (resistance
temperature detector) or a thermocouple, that collects the data about temperature from a particular
source and converts the data into understandable form for a device or an observer. Temperature
sensors are used in many applications like HV and AC system environmental controls, food
processing units, medical devices, chemical handling and automotive under the hood monitoring
and controlling systems, etc.
There are different types of temperature sensors used in the market today including resistance
temperature detectors (RTDs), thermocouples, thermistors, infrared sensor, and semiconductor

50
sensors. Each of them has a particular operating parameters. These sensors come in different
varieties, but have one common thing: they all measure temperature by sensing a change in the
physical characteristic.
RTD sensor is one of the most accurate sensors. In a resistor temperature detector, the resistance
is proportional to the temperature. This sensor is made from platinum, nickel, and copper metals.
It has a wide range of temperature measurement capabilities as it can be used to measure
temperature in the range between -270oC to +850oC. RTD requires an external current source to
function properly.
Figure 26. Resistor Temperature Detector (RTD)
IV.1.5.2 PRESSURE REGULATORS
A pressure regulator is a control valve that reduces the input pressure of a fluid or gases to a
desired value at its output. Regulators are used for gases and liquids, and can be an integral device
with an output pressure setting, a restrictor and a sensor all in the one body, or consist of a separate
pressure sensor, controller and flow valve. A pressure regulator's primary function is to match the
flow of gas through the regulator to the demand for gas placed upon it, whilst maintaining a
constant output pressure.
If the load flow decreases, then the regulator flow must decrease as well. If the load flow increases,
then the regulator flow must increase in order to keep the controlled pressure from decreasing due
to a shortage of gas in the pressure system.
A pressure regulator includes a restricting element, a loading element, and a measuring element:

51
 The restricting element is a valve that can provide a variable restriction to the flow, such as
a globe valve, butterfly valve, poppet valve, etc.
 The loading element is a part that can apply the needed force to the restricting element. This
loading can be provided by a weight, a spring, a piston actuator, or the diaphragm actuator in
combination with a spring.
 The measuring element functions to determine when the inlet flow is equal to the outlet flow.
The diaphragm itself is often used as a measuring element; it can serve as a combined element.
Figure 27. Single-stage pressure regulator
In the pictured single-stage regulator above, a force balance is used on the diaphragm to control a
poppet valve in order to regulate pressure. With no inlet pressure, the spring above the diaphragm
pushes it down on the poppet valve, holding it open. Once inlet pressure is introduced, the open
poppet allows flow to the diaphragm and pressure in the upper chamber increases, until the
diaphragm is pushed upward against the spring, causing the poppet to reduce flow, finally stopping
further increase of pressure.
IV.1.6 ELECTRIC MOTORS
An electric motor is an electrical machine that converts electrical energy into mechanical energy.
Most electric motors operate through the interaction between the motor's magnetic
field and electric current in a wire winding to generate force in the form of rotation of a shaft.

INTERNSHIP REPORT done by Didier Iradukunda (Electrical and Computer Engineer) at Bralirwa in 2019

INTERNSHIP REPORT done by Didier Iradukunda (Electrical and Computer Engineer) at Bralirwa in 2019

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