TRIBHUVAN UNIVERSITY

INSTITUTE OF ENGINEERING

PASCHIMANCHAL CAMPUS

POKHARA

A REPORT ON

INDUSTRIAL ATTACHEMENT AT

LUMBINI SUGAR INDUSTRIES PVT. LTD.

Sunwal, Nawalparasi

Submitted by:

UTTAM DHAKAL (PAS076BME047)

Submitted to:

DEPARTMENT OF MECHANICAL AND AUTOMOBILE ENGINEERING

PASCHIMANCHAL CAMPUS

LAMACHAUR, POKHARA-16

DECEMBER 2023
 TRIBHUVAN UNIVERSITY

INSTITUTE OF ENGINEERING

PASCHIMANCHAL CAMPUS

DEPARTMENT OF MECHANICAL &AUTOMOBILE

ENGINEERING

It is hereby certified that this report, entitled

“A Report on Industrial attachment

at Lumbini Sugar Industries Pvt. Ltd.”

prepared by Uttam Dhakal

is an outcome of the internship undergone at

“Lumbini Sugar Industries Pvt. Ltd.”

The content of this report is based on perspective of knowledge and understanding

throughout the internship, where the work was reviewed and praised by the Mechanical
Engineer of Lumbini Sugar Industries Pvt. Ltd. This report will partially fulfill the
requirement for degree of Bachelor in Mechanical Engineering.

Head of Mechanical and Automobile Department

Dr. Durga Bastakoti

i
 ACKNOWLEDGEMENT

I would like to express my heartfelt thanks to Lumbini Sugar Industries Pvt. Ltd. for
giving me a platform that was encouraging and helpful during my internship at their
company.

I want to start by expressing my gratitude to the Department of Mechanical and

Automobile Engineering at the Paschimanchal Campus in Pokhara for the internship
opportunity. According to Tribhuvan University regulations, during their final year,
students are required to work for at least two weeks in an industry that focuses on
manufacturing, fabrication, repair, service, and maintenance. For the industrial
attachment, I connected with Lumbini Sugar Industries Pvt. Ltd.

I would like to thank Er. Dambar Bahadur Thapa, the Chief Engineer, Er. Ratan Shanker
Jha, the General Manager of Technology and Er. Padam Singh Thapa, the Mechanical
Engineer, for their assistance, guidance, and welcoming atmosphere throughout my
internship.

Lastly, I would want to express my gratitude to all of the engineers, operators,

technicians, and employees who helped me acquire responses to all of the questions I
needed to know the answers to.

ii
 ABSTRACT
Under the direction of the company and the Department of Mechanical and Automobile
Engineering, IOE Paschimanchal Campus, this report details the activities completed as
part of the final year internship program and presents the experiences, skills, and profess
ional practices during the period taken at Lumbini Sugar Industries Pvt. Ltd., Sunwal-
1, Nawalparasi.

The primary focus of the report is on how the students applied their theoretical
understanding of management and technical components in real world situations while
pursuing a Bachelor's degree in Mechanical and Automobile engineering. The purpose of
this study is to learn about the company's present state of operations, management style,
organizational structure, and technology and work environment utilization.

The principal concern in the report is about the hands-on engagement with various aspects
of mechanical systems within a sugar manufacturing facility, offering exposure to real-
world challenges and opportunities for professional development.

iii
 TABLE OF CONTENTS

ACKNOWLEDGEMENT ................................................................................................. ii

ABSTRACT ........................................................................................................................ iii

TABLE OF CONTENTS................................................................................................... iv

LIST OF TABLES .............................................................................................................. vi

LIST OF FIGURES .......................................................................................................... vii

LIST OF SYMBOLS AND ABBREVIATIONS ............................................................ ix

CHAPTER-ONE: INTRODUCTION.............................................................................. 1

1.1 Historical Background ....................................................................................... 1

1.2 Vision and Mission.............................................................................................. 1

1.3 Organization Structure ............................................................................................ 2

CHAPTER-TWO: PERSONNEL MANAGEMENT .................................................... 3

2.1 Personnel policy ........................................................................................................ 3

2.2 Manpower planning.................................................................................................. 3

2.3 Recruitment and selection of manpower ............................................................... 3

2.4 Training and development of manpower .............................................................. 3

2.5 Wages and incentives ................................................................................................ 4

2.6 Job analysis, evaluation and merit rating ............................................................. 4

2.7 Employment ............................................................................................................... 4

CHAPTER-THREE: PRODUCTION, PLANNING AND CONTROL PROCESS. 5

3.1 Product Quality ......................................................................................................... 6

3.2 Input Materials For 1 Quintal Sugar..................................................................... 7

3.3 Distillery ..................................................................................................................... 7

3.4 Effluent Treatment.................................................................................................... 8

3. 5 Water.......................................................................................................................... 9

iv
 3.6 Flow Pattern ............................................................................................................ 10

3.7 Inventory Control ....................................................................................................11

CHAPTER FOUR: MACHINERY AND EQUIPMENTS ......................................... 12

CHAPTER FIVE: SAFETY PRACTICES AND PREVENTIVE MEASURES .... 22

CHAPTER SIX: WORK PERFORMED AND LESSON LEARNED DURING

INTERNSHIP .................................................................................................................... 24

6.1 Operation of Lathe Machine, Planar Machine, Shaper Machine and Milling
Machine .......................................................................................................................... 24

6.2 Installation of New Machine ................................................................................. 24

6.3 Division of Work ..................................................................................................... 25

6.4 Motivation to Workers ........................................................................................... 25

6.5 Design and Development ....................................................................................... 26

6.6 Supervision Skills .................................................................................................... 26

CHAPTER SEVEN: MAINTENANCE AND QUALITY CONTROL .................... 27

7.1 Maintenance............................................................................................................. 27

7.2 Quality Control ....................................................................................................... 29

CHAPTER EIGHT: CONCLUSION ............................................................................. 30

v
 LIST OF TABLES

Table 1: Quality Indices of A-sugar ..................................................................................... 6

Table 2: Input Materials For 1 Quintal Sugar ..................................................................... 7

Table 3:Raw Materials Required for One Kilo Litre of Rectified Spirit ........................... 8

Table 4: Quality Indices of Rectified Spirit......................................................................... 8

Table 5:Main Machinery and Equipment’s ....................................................................... 12

vi
 LIST OF FIGURES

Figure 1: Lumbini Sugar Industries Pvt. Ltd Premises ....................................................... 1

Figure 2: Organizational Structure of Industries ................................................................. 2

Figure 3: Process Flow Chart of Lumbini Sugar Industries Pvt. Ltd ................................. 5

Figure 4: Lagooning System for Effluent Treatment .......................................................... 9

Figure 5: Water Tank and Cooling Tower ............................................................................ 9

Figure 6: Flow Pattern ........................................................................................................ 10

Figure 7: Inventory .............................................................................................................. 11

Figure 8: Hook Type Crane ................................................................................................ 13

Figure 9: Overhead Crane ................................................................................................... 13

Figure 10: Feeder Table ...................................................................................................... 14

Figure 11: Kicker................................................................................................................. 14

Figure 12: Fibrizer............................................................................................................... 14

Figure 13: Roller Milling Tandem ..................................................................................... 15

Figure 14: Clarifier .............................................................................................................. 15

Figure 15:Vacuum Filter ..................................................................................................... 16

Figure 16: Evaporator ......................................................................................................... 16

Figure 17:Vacuum Pan ........................................................................................................ 17

Figure 18:Batch Type Centrifugal ...................................................................................... 17

Figure 19:Continuous Centrifugal...................................................................................... 18

Figure 20:Continuous Fermenter ....................................................................................... 18

vii
Figure 21:Boiler .................................................................................................................. 19

Figure 22:Steam Turbine .................................................................................................... 19

Figure 23: Water passage motor and pipe of cooling tower ............................................. 20

Figure 24:Shaper Machine .................................................................................................. 20

Figure 25:Milling Machine ................................................................................................. 21

Figure 26: Planar Machine.................................................................................................. 21

Figure 27: Lathe Machine ................................................................................................... 21

Figure 28:Ongoing project at workshop ............................................................................ 24

Figure 29:Foundation for Installation of Machine ............................................................ 25

Figure 30:Installation of Machine and Motor ................................................................... 25

Figure 31: Design and Development ................................................................................. 26

Figure 32: Maintenance of Cooling Tower ........................................................................ 28

Figure 33:Repairing of New parts for Scrubber ................................................................ 28

Figure 34:Reconstructing of Boiler Heaters ...................................................................... 28

viii
 LIST OF SYMBOLS AND ABBREVIATIONS

Hp = horsepower

Kg = kilogram

Ltrs =Litre

Pvt. =Private

Ltd. =Limited

TRS =Total Reducing Sugar

(CH3)2CHCH2OH = Isobutanol

(CH3)2CHCH2 CH2OH= Isoamyl alcohol

T =Tonne

H.S. =Heating Surface

F.A. =Filtering Area

m = meter

mm =millimeter

hr =hour

kw =Kilowatt

ix
 CHAPTER-ONE: INTRODUCTION

1.1 Historical Background

Nepal has 14 sugar mills. One of the most well-known companies among them is Lumbini
Sugar Industries Pvt Ltd.
The People's Republic of China and the Government of Nepal worked together to
establish the 1,000 metric ton Lumbini Sugar Factory in Nawalparasi in 2045 BS, with
an approximate 400 million rupees investment. Also, this factory was founded in the
public sector. It covers the land of 86 Bigha.
It ended up being sold to the Agrawal Group for 110 million rupees and annual land rent
of 4 million rupees for 25 years by the Government of Nepal at 2062/63 BS because of
the mismanagement and political instability. Afterwards, it becomes private limited.

Figure 1: Lumbini Sugar Industries Pvt. Ltd Premises

1.2 Vision and Mission

The vision and mission of Lumbini Sugar Industries Pvt. Ltd is:
i. To help Nepal to be self-sufficient in A-sugar.
ii. To help Nepal to be self-sufficient in industrial alcohol.

1 1
1.3 Organization Structure
Lumbini Sugar Industries Pvt. Ltd. follows the functional organizational structure and has
the private form of ownership (Private Limited Company).

Chairperson

Managing Director

Chief Cane Manager Chief Engineer (Mechanical) Chief Executive Officer

Cane Manager General Manager of Technology

(GMT)

Engineers

Technicians and Operators

Administrative Manager Sales Manager Human Resources Manager

Administrative officers Sales Officer Workers

Figure 2: Organizational Structure of Industries

2
 CHAPTER-TWO: PERSONNEL MANAGEMENT
Personnel management includes selecting the proper people, assisting them in developing
through training, and ensuring that everyone is working well to achieve the organization's
goals while maintaining a positive and encouraging workplace environment.

2.1 Personnel policy

Company’s personnel policy serves as a guide to the subordinates in taking quick
decisions. This company formulates policy to achieve personnel and organizational
objectives.
The chief objectives of Company’s personnel policies are:

i. Maximum development of workers, maximum use of their abilities, skills and

talents.
ii. Good labor relations.
iii. Safeguard the interest of labor and customers etc.
iv. A good personnel policy must include sources of recruitment, good selection
process, training and welfare program, good wages and incentives promotion
policy and retirement plan.

2.2 Manpower planning

Manpower planning is the company’s important aspects of personnel policy. Human
resource manager (HR) of Lumbini Sugar Industries Pvt. Ltd. deals with the process of
properly maintaining the available human resources inside company to achieve maximum
outcome. Lumbini Sugar Industries Pvt. Ltd. has regular and seasonal employees. Regular
employees work for whole year whereas seasonal employees work for the season of
operation of industries i.e., Poush to Jestha.

2.3 Recruitment and selection of manpower

Lumbini Sugar Industries Pvt. Ltd. accepts both internal and external sources of
recruitment but their selection is done by taking the interview of each individual and also
checking the background of every individual. Interview is taken by a Human resources
manager.

2.4 Training and development of manpower

Training and development are much necessary to attain organizational goals. Company
provides training and development programs more often in 7 days to make clarity in work.

3
2.5 Wages and incentives
Wages and incentives are the most important motivation to work for the organization.
Lumbini Sugar Industries Pvt. Ltd. also provides good wages and good incentives to their
employees.

2.6 Job analysis, evaluation and merit rating

Managers and Engineers observe all the individuals working under them while they are
doing their jobs and evaluate them accordingly. At the end of every month all the workers
are given a self-evaluation form where they have to evaluate themself and each form is
again checked by the managers and engineers. If any individual has bad performance and
rating for several months and doesn't perform efficiently then he/she has to justify their
reason for their low performance and based on their answers action is taken whether to
fire them or give them more chance to improve.

2.7 Employment
1. Direct Employee
More than 500 employee works during seasonal and more than 80 employee work
during off season.
2. Indirect Employee
Sugar cane farmer: 5000 approximately.

4
 CHAPTER-THREE: PRODUCTION, PLANNING AND CONTROL
PROCESS

The conventional Double Sulphitation process is used to produce white sugar. Lumbini
Sugar Industries Pvt. Ltd. Produces only one quantity of sugar, A-sugar. However other
two intermediate products, B and C sugars are also produced and are reprocessed to yield
A-sugar. The cane is feed to the industries by using feeder table and the product of A
quality of sugar gets from the centrifugal machine to pan machine.

Figure 3: Process Flow Chart of Lumbini Sugar Industries Pvt. Ltd

5
3.1 Product Quality

The quality indices of A-sugar produced by Lumbini Sugar Industries Pvt. Ltd. is follows:

Table 1: Quality Indices of A-sugar

Indices Amount Remarks

i. Polarization 99.6% Minimum
ii. Invert 0.1% Maximum
Sugar
iii. Ash content 0.1% Maximum
iv. SO₂ content 30-50 ppm
v. Moisture 0.06% Maximum
content
vi. Colour 150-120 ICUMSA

i. Polarization:
It is the amount of sucrose present in the sugar solution and is expressed in
degree.
ii. Invert sugar:
It is a mixture of glucose and fructose formed by the hydrolysis of sucrose. It is
used as a sweetener and to prevent crystallization in sugar products.
iii. Ash content:
It is the residue that remains after the sugar is burned. It is a measure of the mineral
content of the sugar and is expressed as a percentage of the sugar weight.
iv. SO₂ content:
It is the amount of sulfur dioxide present in the sugar. It is used as a preservative
and to bleach the sugar.
v. Moisture content:
It is the amount of water present in the sugar. It is expressed as a percentage of
the sugar weight and is an important factor in determining the shelf life of the
sugar.
vi. Colour:
It is an important quality parameter for sugar. The colour of the sugar is
determined by the presence of impurities such as molasses and is expressed in

6
 ICUMSA units (International Commission for Uniform Methods of Sugar
Analysis).
3.2 Input Materials For 1 Quintal Sugar
The average input of main and auxiliary raw materials required to produce one quintal of
sugar in Lumbini Sugar Industries Pvt. Ltd. is as follows:
Table 2: Input Materials For 1 Quintal Sugar

Raw Materials Quantity

i. Sugar Cane 1100 Kg
ii. Quick lime 2 Kg
iii. Sulphur 0.7 Kg
iv. Phosphoric Acid 0.3 Kg
v. Filter Cloth 0.005 Kg
vi. Flocculant 0.004 Kg
vii. Diesel 2.5 Ltrs
viii. Alum 0.15g

i. Sugar cane is the primary raw material used in the sugar industry
ii. Quick lime (calcium oxide) is used in the carbonation process to remove
impurities from the sugar juice.
iii. Sulphur is used in the sulphitation process to bleach the sugar and to prevent the
formation of color and flavor compounds.
iv. Phosphoric acid is added to the sugar juice to precipitate some of the colloids and
coloring matter it contains.
v. Filter cloth is used in the filtering process to remove impurities from the sugar
juice. Flocculant is used to improve the settling rate of suspended solids in the
sugar juice, resulting in clearer juice and less mud volume.
vi. Diesel is used as a fuel for the boilers that generate steam for the sugar production
process.
vii. Alum is used in the clarification process to remove impurities from the sugar juice.

3.3 Distillery
The Alcohol Production Process is based on Chinese cascade fermentation technology
with nine contineous fermenters and three column distillation.

7
The quantity of various materials required to produce one kilo litre of Rectified Spirit
(Industrial Alcohol) in distillery of Lumbini Sugar Industries Pvt. Ltd is given below.

Table 3:Raw Materials Required for One Kilo Litre of Rectified Spirit

Raw Materials Quantity Remarks

Final Molasses 4166 Kg 50% TRS

Steam 5000 Kg

Ammonium Sulphate 12.5 Kg Nitrogen 20.8%

Sulphuric Acid 20.8 Kg 98%, Specific gravity 1.84

The quality indices of finished product of finished product Rectified Spirit of distillery
are as follows:
Table 4: Quality Indices of Rectified Spirit

Indices
i. Appearance Transparent
ii. Strength(V/V) % ≥95 at 20℃
iii. Specific Gravity 0.81144 at 95℃ & 20℃
iv. Fuel oil as
(CH3)2CHCH2OH ≤0.04%
(CH3)2CHCH2 CH2OH
v. Methyl Alcohol ≤0.25%
vi. Acidity ≤0.002%
vii. Residue on Evaporation ≤0.0025%
viii. Permagnate Reaction Time 15 minutes

3.4 Effluent Treatment

Distillery effluent is the major sources of pollution. Previously the effluent was
neutralized with lime and discharged in the Somnath stream after adequate dilution to

8
minimize pollution. But now lagooning system is built for effluent treatment and capacity
of two lagoon are 4325 m³ each. Each lagoon is good for 40-60 days for effluent
settlement.

Figure 4: Lagooning System for Effluent Treatment

3. 5 Water
During crushing season, 10,000 m³ per day from deep tube wells under the surface and
the Turia River are utilized. For the purpose of cooling circulation water, there are four
cooling towers, each with a capacity of 300 m³/hr. For the distillery, there is a single
cooling tower with a cooling capacity of 105 m³/hr.

Figure 5: Water Tank and Cooling Tower

9
3.6 Flow Pattern
Flow Pattern means the system to be adopted, for the movement of raw materials, from
the beginning and up to the end of manufacturing. The overall objective of the Flow
Pattern is to plan for the economical movement of the raw materials throughout the plant.

Figure 6: Flow Pattern

The flow patterns can be classified into the following:
1. Horizontal Flow
There are five types of horizontal flow lines:
 I-Flow or Line Flow
 L-Flow
 U-Flow
 S-Flow

10
 2. Vertical Flow
 Processing downward or upward
 Centralized on decentralized elevation
 Unidirectional or Retractional flow
 Vertical or Inclined flow
 Single or Multi-flow

The horizontal flow is adopted on cane crushing while vertical flow is adopted on sugar
product formation.

3.7 Inventory Control

Inventory control is the process of maintaining a business’s stock level to meet customer
demand and minimize costs. This involves inventory tracking and maintenance of goods.
It also includes making decisions to get the most profit from stock and planning
purchases. The most needed materials are maintained at optimum level in order to prevent
idle machine time. Inventory control is a crucial aspect of managing operations in the
sugar industry. Efficient inventory management ensures that there is a balance between
the demand for sugar products and the supply of raw materials, finished goods, and other
resources.

Figure 7: Inventory

11
 CHAPTER FOUR: MACHINERY AND EQUIPMENTS
The main machines and equipment’s used on Lumbini Sugar Industries Pvt. Ltd. is as
follows:
Table 5:Main Machinery and Equipment’s
Machine/Equipment Working Capacity Number of Quantity
i. Hook Type Crane 10T 10

ii. Overhead Crane 600 T 8

iii. Feeder - 2

iv. Kicker - 1

v. Fibrizer - 1

vi. Roller Milling Tandem 710×1370mm 15

vii. Clarifier 100m³ 1

viii. Vacuum Filter F.A 35m² 2

ix. Evaporator H.S. 450/350m² 5

x. Vacuum Pan 30T 4

xi. Batch Type Centrifugal 500kg/charge 6

xii. Continuous Centrifugal 3 T/hr 3

xiii. Continuous Fermenter 37/32m³ 9

xiv. Boiler 15T/hr 3

xv. Steam Turbine 1500 kw 2

xvi. Cooling Tower 300/150 m³/hr 5

xvii. Lathe Machine - 4

xviii. Planar Machine - 1

xix. Milling Machine - 1

xx. Shaper Machine - 1

12
 i. Hook type Crane:
A cane weighing bridge is a machine used in the sugarcane industry to measure
the weight of harvested sugarcane.

Figure 8: Hook Type Crane

ii. Overhead Crane:

A crane equipped with a hook for lifting and transporting heavy loads. In the
context of sugar mills, it might be used for handling equipment or materials.

Figure 9: Overhead Crane

iii. Feeder Table:

The sugarcane canes get entered into milling house through feeder table by the
process of loader and unloader and send them to the Kicker.

13
 Figure 10: Feeder Table

iv. Kicker:
This is a machine designed to cut or shred sugarcane into smaller pieces for further
processing and send them to the Fibrizer.

Figure 11: Kicker

v. Fibrizer:
The equipment used for the preparation of sugarcane prior to juice extraction and
send them to the Roller Milling Tandem.

Figure 12: Fibrizer

14
vi. Roller Milling Tandem:
A set of multiple roller mills arranged in tandem, used to extract juice from
sugarcane by crushing it between the rollers and filter the juice and send juice to
the Juice heater and Bagasse to the boiler.

Figure 13: Roller Milling Tandem

vii. Clarifier:
It removes impurities and solids from sugarcane juice, ensuring a clearer liquid
for subsequent processing.

Figure 14: Clarifier

15
viii. Vacuum Filter:
It filters the juice to remove remaining impurities and solid particles under
vacuum conditions.

Figure 15:Vacuum Filter

ix. Evaporator:
It concentrates the sugarcane juice by removing water, leaving a more
concentrated solution.

Figure 16: Evaporator

16
x. Vacuum Pan:
It is used to further evaporate and crystallize the sugar solution under vacuum.

Figure 17:Vacuum Pan

xi. Batch Type Centrifugal:

The Batch Centrifugal machines separate sugar crystals from the molasses by
spinning the mixture at high speeds.

Figure 18:Batch Type Centrifugal

17
xii. Continuous Centrifugal:
Similar to the batch type, but this machine operates continuously for a more
efficient sugar separation process.

Figure 19:Continuous Centrifugal

xiii. Continuous Fermenter:

It is often used in ethanol production, this equipment facilitates the fermentation
process. This machine is used in Distillery plant of industries.

Figure 20:Continuous Fermenter

18
xiv. Boiler:
It generates steam used in various processes, including driving turbines for power
generation and heating in the sugar production process.

Figure 21:Boiler

xv. Steam Turbine:

It converts the energy from steam into mechanical energy, often used to drive
generators.

Figure 22:Steam Turbine

xvi. Cooling Tower:

It cools down water or other fluids used in industrial processes during operation.

19
 Figure 23: Water passage motor and pipe of cooling tower

xvii. Lathe Machine, Planar Machine, Milling Machine, Shaper Machine:

These are various types of machine tools used for shaping, cutting, and machining
metal or other materials for the repair of parts of the machine.

Figure 24:Shaper Machine

20
Figure 25:Milling Machine

Figure 26: Planar Machine

Figure 27: Lathe Machine

21
 CHAPTER FIVE: SAFETY PRACTICES AND PREVENTIVE
MEASURES

In order to protect worker health and safety, avoid accidents, and preserve a safe working
environment, safety procedures and knowledge are essential in the industry. The
following are some essential elements of safety knowledge and procedures followed by
the Lumbini Sugar Industries Pvt. Ltd:

a) Training Program
 Implement thorough safety training programs for all personnel, including topics
like machine operation, chemical handling, emergency response, and general
safety protocols.
 Provide continuing training to staff to keep them up to date on new safety
measures and technology.
b) Machine Safety

 Regularly inspect and maintain machinery to ensure it is in good working

condition.
 Implement machine guarding to protect workers from moving parts and
potential hazards.
 Train workers on proper machine operation and safety protocols.
c) Chemical Safety:
 Clearly label and store chemicals in accordance with safety regulations.
 Provide training on the safe handling, storage, and disposal of chemicals.
 Encourage the use of less hazardous substances whenever possible.
d) Fall Protection:

 Implement fall protection measures for employees working at heights, such as

on platforms or elevated surfaces.
 Provide proper training and equipment for working in elevated areas.
e) Emergency Preparedness:
 Develop and regularly update emergency response plans.
 Conduct drills to ensure that all employees are familiar with evacuation
procedures, first aid, and emergency contacts.

22
f) Noise control
 Identify areas with high noise levels and implement measures to reduce
exposure.
 Provide hearing protection for workers in noisy environments.
g) Regular Safety Inspections:

 Conduct regular safety inspections to identify and address potential hazards.

 Encourage employees to report safety concerns and incidents promptly.
h) Fire Protection

 Install fire detection and suppression systems in key areas.

 Conduct regular fire drills and ensure that employees are trained in the use of
firefighting equipment.

23
 CHAPTER SIX: WORK PERFORMED AND LESSON LEARNED
DURING INTERNSHIP

Due to the industry's seasonality, I have gained knowledge of many maintenance

tasks, installation of new machine but not the industry's operations. I have performed
following work and lesson learned during my 15-day period of Internship:

6.1 Operation of Lathe Machine, Planar Machine, Shaper Machine and Milling
Machine
Knowledge of the operation of different machines in a workshop is required for a
mechanical engineer. At first, I learned the operation of a four-jaw lathe machine and
practiced some of the materials. Krishna Poudel, sir, shared his knowledge and skill for
its operation. And then I gained knowledge of using a planar machine, a shaper machine,
and a milling machine at the workshop. Workshop is required for repairing parts and
manufacturing it.

Figure 28:Ongoing project at workshop

Being skilled in the workshop is essential to succeed as a mechanical engineer.

6.2 Installation of New Machine

The factories required two more centrifugal machines for the large production of sugar.
I’ve been lucky to experience the installation of machines from the beginning. It took lots
of days to install the two centrifugal machines, which are B-type and C-type machines.
Different operations, such as gas welding, grinding, cutting, lifting, etc., are performed
for the foundation of the machine. Also, drawings are required for the foundation and
installation of machines. Centrifugal machine is used to separate molasses and sugar.

24
 Figure 29:Foundation for Installation of Machine

Figure 30:Installation of Machine and Motor

6.3 Division of Work

The important things to work in industries is by dividing the works among the workers
with their respective skills. This helps to complete the project with quality and time
management.

6.4 Motivation to Workers

As the supervisors of the project, if he/she works in a field and helps them to figured out
the problem in polite behaviors’ helps in motivation to workers.

25
6.5 Design and Development
The main application of Surface development of drawing is at the designing at the flow
of pipe at the industries and at the different field of flow and analysis process.

Figure 31: Design and Development

6.6 Supervision Skills
By working with the experienced engineers at the industries for 15 days I have learned
some of the skills which may be applicable for the coming days.

26
 CHAPTER SEVEN: MAINTENANCE AND QUALITY CONTROL

7.1 Maintenance

Maintenance is mainly done to sustain the prevailing condition of mechanical parts,

equipment, and machineries. However, it is also done to upgrade their existing conditions.
It is very important aspect of any industry or, company. It ensures the smooth operation
of the company by eliminating or, solving any encountered problems. It also ensures the
good working condition for the workers in the company.

 Preventive maintenance
This type of maintenance tries to minimize the problems of breakdown maintenance.
It helps to locate weak spots (such as Bearing surface, parts under excessive vibration
etc.). in all the machine and provides regular inspection and minors repairs thereby
reducing breakdown. Examples:
1. Material Handling Equipment’s such as cranes, trucks etc.
2. Safety equipment’s such as safety alarms, fire extinguishers etc.
3. Process machine such as juice heater, centrifugal machine, turbine, generators.
4. Water, steam pipe, air compressors.
 Scheduled Maintenance
They are those type of maintenances, which are being carried out in certain interval
of time. The time interval at which these maintenances are carried out is
predetermined. They ensure the smooth and effective running of the machine. They
are performed after starting of off seasonal and completed before every year before
the running of seasonal of operation of industries. This process involves the greasing,
parts repairing, inspection report of all machines etc.
It includes:
1. Maintenance of boiler chimney, Pan chimney, Distillery chimney
2. Maintenance of Centrifugal machine, Boiler, Heater, Pan
3. Maintenance of Steam Turbine, Compressors, Generators
4. Maintenance of Cooling Tower
5. All the process involving machine for industry.

27
 Figure 32: Maintenance of Cooling Tower

Figure 33:Repairing of New parts for Scrubber

Figure 34:Reconstructing of Boiler Heaters

28
 Breakdown maintenance
This is such type of maintenance, which is carried out when there is actual failure in
the equipment or, machineries. It is very costlier, time consuming and effort
consuming. They are un-certain in nature and thus might significantly stop the entire
operation of the industry. Hence, this type of maintenances is avoided as far as
possible through preventive and scheduled maintenances.

7.2 Quality Control

Quality control is a process through which a business seeks to ensure that product quality
is maintained or improved. Quality control requires the company to create an environment
in which both management and employees strive for perfection. This is done by training
personnel, creating benchmarks for product quality, and testing product to check for
statistically significant variations.

A significant aspect of quality control is the establishment of well-defined controls. These

controls help standardize both production and reactions to quality issues.

I have already shown the Quality Indices of A-Sugar and Rectified Spirit. Please refer to
the Table 1 and Table 4 for any query.

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 CHAPTER EIGHT: CONCLUSION

In conclusion, the internship at Lumbini Sugar Industries Pvt. Ltd has been a rewarding
experience for me. I got to work with the experienced Engineers and professional at the
industries. During the time of internship, I spent most of time on Machine Installation,
Development drawing, Supervision on maintenance and reviewed the project for my
knowledge. This helps me to gain the skill related to the industrial field. I feel lucky to be
part of internship at the off seasonal time of industries, as it helps me to figure out the
problem and solution for different obstacles on the operation of industries.

Overall, Lumbini Sugar Industries Pvt. Ltd was a great place to practically learn what I
had been learning in the books, therefore this internship become a connecting bridge
between my academics and industry.

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