DIRE DAWA UNIVERSITY

SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

Externship Report

March–June 30, 2024

At

Wonji/Shoa Sugar Factory.

Extern: Yared Workineh Shewalul

October, 2024
Table of Contents
CHAPTER ONE ......................................................................................................................................... 1
1. COMPANY PROFILE ......................................................................................................................... 1
1.1. INTRODUCTION .................................................................................................................. 1
1.1.1. Vision ............................................................................................................................... 3
1.1.2. Mission ............................................................................................................................ 3
1.2. MAIN INPUTS, PRODUCTS AND END USERS OF THE COMPANY ............................ 3
1.3. PRODUCTION CAPACITY OF THE COMPANY .............................................................. 4
1.4. FACILITIES OF THE COMPANY ....................................................................................... 4
1.5. ORGANIZATIONAL STRUCTURE OF THE COMPANY ................................................. 6
1.6. OVERALL WORK FLOW OF THE COMPANY ................................................................. 7
1.7. PRODUCTION DEPARTMENTS ......................................................................................... 7
CHAPTER TWO ...................................................................................................................................... 10
2. EXTERNSHIP EXPERIENCE .............................................................................................................. 10
2.1. OVERALL EXTERNSHIP EXPERIENCE ......................................................................... 10
2.2. DEVELOPING AND IMPROVING PRACTICAL SKILLS .............................................. 11
2.3. IMPROVING THEORETICAL KNOWLEDGE ................................................................. 12
2.4. IMPROVING TEAM PLAYING SKILLS ........................................................................... 12
2.5. IMPROVEMENT IN LEADERSHIP SKILLS .................................................................... 13
2.6. UNDERSTANDING OF WORK ETHICS RELATED ISSUES ......................................... 13
2.7. GAINING ENTREPRENEURSHIP SKILLS ...................................................................... 13
CHAPTER THREE .................................................................................................................................... 14
3. THE CHALLENGES AND MEASURES TAKEN TO OVERCOME THE CHALLENGES ............................ 14
3.1. MAJOR CHALLENGES DURING WORK TASKS........................................................... 14
3.2. MEASURES TAKEN TO OVERCOME CHALLENGES .................................................. 14
3.3. DESIGN AND CONSTRUCTION IN TERMS OF SAFETY AND ECONOMY .............. 15
CHAPTER 4 ............................................................................................................................................ 16
4. EXTERNSHIP PROJECT ................................................................................................................... 16
4.1. INTRODUCTION ................................................................................................................ 16
4.2. PROBLEM IDENTIFICATION ........................................................................................... 16
4.3. SHORT SUMMARY OF THE PROJECT: .......................................................................... 16
4.4. PROBLEM STATEMENT AND JUSTIFICATION ........................................................... 16
4.5. OBJECTIVE OF THE PROJECT......................................................................................... 17

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4.6. LITERATURE REVIEW ..................................................................................................... 17
4.7. METHODOLOGY: .............................................................................................................. 18
4.8. RESULT AND DISCUSSION ............................................................................................. 20
4.9. RECOMMENDATIONS FOR THE COMPANY: .............................................................. 20

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 CHAPTER ONE

1. COMPANY PROFILE

1.1. INTRODUCTION
Wonji Shoa Sugar Factory is found in Oromia Regional State near Adama city 110 km away
from the capital city, Addis Ababa. In the past, Wonji Sugar Factory and Shoa Sugar Factory
were the oldest and pioneer sugar factories in Ethiopia. They started production in 1954 and
1962 respectively. Both factories were established as a share company between the Ethiopian
government and Handles-Vereening Amsterdam (HVA), a Dutch company. HVA also carried
out the construction for both factories.

After serving more than half a century, both factories have stopped production due to
obsolescence. In an effort to replace the factories with a new and modern one, an expansion
project was carried out by the government in 2006. The new plant expansion project came
into its completion in July 2013, and has been renamed Wonji Shoa Sugar Factory. The
Factory has a climate with a maximum temperature of 26.9°C and minimum of 15°C on
average annually. Based on monthly rainfall recorded, the annual average rainfall is 800 mm.
Wonji Shoa Sugar Factory has been allocated a total land area of 16,000 hectares for its
sugarcane plantation.

The plantation has a productivity potential to produce 160 tons of sugarcane per hectare, and
the harvesting age of the sugarcane is 18 months on average. The Factory uses diversion
water from Awash River for irrigation. The sugarcane plantation applied sprinkler and pump
irrigation method.

The Factory has a design capacity of crushing 6,250 tons of sugarcane per day, and produces
174,946 tons of plantation white sugar annually; with further expansion, the production could
reach up to 12,500 TCD maximizing production to 220,700 tons of sugar a year.

Wonji Shoa Sugar factory has also a production capacity of 72,200 tons of molasses annually.
The Factory has already engaged in joint venture agreement with a private company to
develop the ethanol plant in the factory. An ethanol plant will initially have an expected

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production capacity of 10,000 meter cubes of ethanol yearly; with further expansion it has the
potential to reach 12,800 meter cubes annually.

Wonji Shoa Sugar Factory has the capacity to produce 31megawatt electric power. After
satisfying its consumption with 11 megawatt from the total production. The factory has the
potential to contribute the rest (20 megawatt electric power) to the national power grid as
additional source of revenue after Full Maintenance of Turbine plant on 2018 E.F.Y. Its
agricultural expansion project was carried out around the areas known as Wakie Tiyo,
Welenchiti and Dodota areas. The Factory, with the help of this agricultural expansion
project including cultivation fields of out-grower farmers association, was expected to have
16,000 hectares of sugarcane plantation field in total.

In 2014, from the total allocated plantation area, 12,800 hectares of land have been developed
to grow sugarcane. Out this developed land 7000 hectares have been covered by 31 sugarcane
outgrowing associations.

But during 2017/18 due to Occurrence of instability in Oromia region Sugar cane farms most
of outgrowing associations was burnt Especially Waketiyo and Welenchity as a result
existing and newly developed sugar cane producer farmer associations were withdraw from
producing sugar Cane and reaches from 7000 hectares of outgrowing cane area now a days
only 2400 hectares of land under sugar cane production so that the factory is lacking sugar
cane Supply and unable to produce on its crushing capacity.

The Factory has created favorable conditions in giving irrigated land for the out growers,
delivering special seed and giving vocational and technical support so as to benefit them from
growing sugarcane and selling it to the Factory. With regard to social responsibility, over
13.48 Million birr spent to the construction of various social institutions such as schools,
health stations, potable water centers, etc. Furthermore, over 6,491 members the surrounding
community have benefitted from the job opportunities created by the Factory as a permanent,
contract, seasonal employees.

Wonji Shoa Sugar Factory is one among the five sugar factories which have become
autonomous by the Council of Ministers on March 2022 Regulation Number 496/2022 .

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The authorized capital of Wonji/Shoa Sugar factory is Birr 15, 886,955,307,.28 (Fifteen
billion eight hundred eighty six million nine hundred fifty five thousand three hundred seven
birrand twenty eight cents) of which birr 3,971,738,826.82 (Three billion nine hundred
seventy One million seven hundred thirty eight thousand eight hundred twenty six birr and
eighty Two cents) is paid up in cash and in kind.

1.1.1. Vision
Building competitive, profitable and Center of excellence sugar industry in 2028

1.1.2. Mission
Exploiting well established production Capability and Opportunities to increase
Organizational efficiency produce sugar, sugar bi-products and co-products thereby support
and contribute at large to the nation’s Economic development.

1.2. MAIN INPUTS, PRODUCTS AND END USERS OF THE COMPANY

1.2.1. Raw materials Input

The main inputs for sugar production typically include:

❖ Sugarcane: The primary source of sugar.
❖ Water: For irrigation, processing, and cooling during production.
❖ Fertilizers
❖ Pesticides and Herbicides: For pests and weeds.
❖ Labor: Skilled and unskilled workers for planting, harvesting, and processing.
❖ Machinery and Equipment: For planting, harvesting, crushing, and refining sugar.
❖ Energy: Fuel or electricity for machinery and processing facilities
❖ Transport: For raw materials and finished products.
❖ Processing Chemicals: Lime and sulfur dioxide for the refining process.
These inputs work together to cultivate the crop, process it into sugar, and distribute the final
product.
1.2.2. Main Product of the Company
Major Products:
✓ White Sugar: The primary product produced by the company, essential for various
industries and consumer needs.
By-Products:
✓ Molasses: A thick syrup produced during sugar extraction, used in food products and
as animal feed.
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 ✓ Bagasse: The fibrous residue remaining after sugarcane is crushed, utilized for energy
production as a raw material.
Co-Products:
✓ Electricity: Generated from bagasse after the implementation of energy-efficient
practices in 2018 EFY (Ethiopian Fiscal Year).
✓ Ethanol: Currently under construction, this facility will produce ethanol, expanding
the company's product line and sustainability efforts.
Other Products:
✓ Wheat: Cultivated as an additional agricultural product.
✓ Fruits and Vegetables: Grown to diversify the company's agricultural output.
✓ Animal Fattening and Poultry: Engaged in livestock activities to enhance food
production and support local markets.
1.2.3. End Users of the Company
Local Market and Society:
✓ The primary consumers of white sugar, molasses, and other agricultural products,
supporting community needs and local economies.
Alcohol and Beverage Factories:
✓ Significant users of molasses and ethanol, contributing to the production of alcoholic
beverages and other related products.

1.3. PRODUCTION CAPACITY OF THE COMPANY

The annual rated capacity of the plant will be 985pcsper days; 8 hours of single shift per day.
The plant will operate at 65% of its rated capacity in the first year, 75% in the second year‟
90% in the third and at full capacity starting from the fourth year and then after
Time Eff = 65.1%
Attendance = 90% = P%
Utilization = 85% = U%
Floaters Performance standard = 60%

1.4. FACILITIES OF THE COMPANY

The company infrastructure supports all of its efforts to produce different kind of products at
each department/section. The company has required Infrastructure for each production
department and management office for people/employees, technology, systems, procedures,
policies, processes and more. Out of all of these elements the basic infrastructures like

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machines, technology use, machines operation principle or system and objective of the
machine.

1.4.1 Economic and social Infrastructures

The WSSF has the following infrastructures such as electricity, telecommunication, postal
and banking services and hospitals, clinics, schools, residential houses, clubs, cinema houses,
sport field facilities, etc

Health Facilities The estate gives free medical service to all employees of the organization
along with their families. WSSf has 1 (One) primary hospital, 3 poly clinics and 9 Satellite
clinics

1.4.2 Educational facility

The estate is well served with educational facilities, 8 Kindergarten and Elementary, 5 Junior
and High school and 2 Preparatory school and TVET

1.4.3 Other Amenities

4 Sport fields,2 Swimming pool ,3 Club/Canteen, around 5000 Residential houses and 2
Cinema.

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 1.5. ORGANIZATIONAL STRUCTURE OF THE COMPANY

Managment Board

General Manager

Office of General
Internal Audit service
Manager
Planning and Managment Info. Service
Legal and and Insurance
Service Quality management Service

Recearech and extension Service

Agricultural Division Factory Division Finance department HRM and Supply Division

Production
Agricultural Department HRDM Department
Department

Field Equipment Maintenance Supply and Facility

Technique management
Department
department Department

Civil and Irrigation Engineering

Department

Figue 1. Organizational Structure of the Company

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 1.6. OVERALL WORK FLOW OF THE COMPANY
Work is flows through different departments from Cultivating/harvesting to shipment. The
overall work flow of the factory can be shown in the following diagram.

Cultivating Harvesting Cane weighing Cane Loading

Packing Refining Evaporating Milling and

Juicing

Figure 2. Overall Work flow of the Company

1.7. PRODUCTION DEPARTMENTS

The company has three main integrated section/ department, namely: -

1. Milling
2. Evaporation
3. Pan House

1.7.1. Milling Department

This department is responsible for the first phase of the Sugar production process: The
milling department in sugar production plays a crucial role in the initial processing of raw
materials, primarily sugarcane. Its duties include reception and weighing of sugarcane,
preparation of the feedstock, which includes cleaning and chopping the raw materials to
facilitate efficient juice extraction. Utilizing specialized machinery, the department extracts
the juice from the prepared feedstock, subsequently subjecting it to clarification processes to
eliminate impurities. This ensures that the juice is of high quality before it undergoes further
processing.

In addition to extraction and clarification, Quality control measures are implemented

throughout these processes to guarantee compliance with industry standards and to maintain
product integrity. Furthermore, the department engages in routine maintenance of milling
equipment to ensure operational efficiency, manages by-products such as bagasse, and

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collaborates with other departments to streamline production workflows. Accurate record-
keeping of processes and yields is also essential for operational transparency and efficiency,
alongside adherence to safety protocols to safeguard personnel and equipment during
production activities. The operations performed in milling section include:

✓ Feeding Sugarcane
✓ Chopping
✓ Extraction

Figure 3. Milling section

1.7.2. Evaporation Department

The evaporation department in sugar production is primarily responsible for concentrating the
clarified juice extracted from the milling process into a syrup. This is achieved through the
application of heat in evaporators, where water is removed from the juice, thereby increasing
the sugar content. The department regulates temperature and pressure conditions to optimize
evaporation rates while preventing the degradation of sugar quality. Continuous monitoring

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of these parameters ensures that the syrup achieves the desired consistency and concentration,
which is crucial for subsequent crystallization. In addition, the department is tasked with
maintaining equipment integrity through regular inspections and maintenance, ensuring
operational reliability. Effective coordination with boiling departments, is essential to
streamline production processes and uphold product quality standards throughout the sugar
manufacturing chain.

1.7.3. Pan House Department

The Pan House department in WSSF is primarily responsible for the crystallization of sugar
from the concentrated syrup produced in the evaporation phase. This process involves
carefully controlling temperature, pressure, and time to facilitate the formation of sugar
crystals. The department utilizes vacuum pans to achieve a controlled environment, allowing
for the efficient extraction of sugar while minimizing the risk of caramelization. Additionally,
the Pan House is tasked with monitoring the syrup's supersaturation levels, as this is critical
for optimal crystal growth and yield.

Moreover, this department plays a crucial role in ensuring product quality through various
quality control measures. This includes assessing the purity of sugar crystals and managing
the separation of molasses from the crystallized sugar. The department also engages in
continuous process optimization, employing techniques such as seed crystallization to
enhance crystal size and quality. By maintaining precise operational parameters and
implementing best practices, the Pan House contributes significantly to the overall efficiency
and effectiveness of sugar production, ensuring that the final product meets industry
standards and consumer expectations.

Figure 4. Pan house department

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 CHAPTER TWO

2. EXTERNSHIP EXPERIENCE
2.1. OVERALL EXTERNSHIP EXPERIENCE

The externship program covers practical work-based activities that facilitate appropriate
skills. Over the past four months at Wonji/Shoa Sugar Factory, I have gained a
comprehensive understanding of the company's operational processes, while actively
engaging in their practical applications.

This externship experience has significantly broadened my knowledge of the sugar industry.
Primarily, I have gained various benefits, such as the ability to align theoretical principles of
manufacturing with their industrial applications. I have developed a clearer understanding of
the duties and responsibilities inherent in each manufacturing department.

Furthermore, this externship has provided me with tangible experience in effective

communication with diverse groups of individuals and workers. Additionally, the externship
program has contributed to the enhancement of both my theoretical and practical skills
related to engineering. I have been able to identify the strengths and weaknesses of the sugar
factory from a critical perspective. Consequently, I now recognize the responsibilities that
future generations must undertake within this sector to ensure that our country remains
competitive on a global scale.
I. How I Got into the Company
I secured my externship at Wonji Shoa Sugar Factory through a combination of academic
connections and personal initiative. After learning about the factory's reputation for
excellence in sugar production, I reached out to the company workers. They provided me
with valuable contacts within the company. Following an offer from our Industry Linkage
and the company, I was joined that aligned with my interests.
II. Activities I Have Been Working In
During my externship, I primarily worked in the milling department, where I engaged in
various activities related to the processing of sugarcane. My tasks included assisting in the
milling process, ensuring the efficient operation of machinery, and assisting in the
maintenance of equipment. This hands-on experience allowed me to gain insights into the
critical role of milling in sugar production.

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III. Workflow in the Section
The workflow in the milling department is organized and systematic. It begins with the
weighting of sugarcane, which is then fed into the milling machines. The extracted juice is
separated from the fibrous material, and this process is monitored closely to ensure optimal
efficiency. Regular checks are conducted on machinery to prevent breakdowns, and
communication among team members for smooth operations.
IV. Work Tasks I Have Been Executing
Throughout my externship, I performed several key tasks related to the maintenance of rollers
and trash plates. I assisted in inspecting the rollers and trash plate for wear and tear,
performed routine cleaning, and helped adjust settings to optimize performance. Additionally,
engaged in lubrication of bearings.

V. Procedures Used While Performing Work Tasks

While performing my work tasks, I followed to established procedures and safety guidelines.
This included following standard operating procedures (SOPs) for machine maintenance and
operation. I also ensured that all safety protocols were observed, such as wearing appropriate
protective and reporting any issues to my supervisor promptly and documentation of
maintenance activities for tracking performance.

VI. My Performance in Executing Work Tasks

Overall, I believe I performed well in executing my work tasks during my externship. I
consistently met deadlines and demonstrated a strong understanding of the milling processes.
My supervisors provided positive feedback on my attention to detail and willingness to learn.
I was proactive in seeking guidance when needed, which helped me improve my skills and
contribute effectively to the team.

2.2. DEVELOPING AND IMPROVING PRACTICAL SKILLS

Over the past four months, I have participated in an externship program at Wonji Sugar
Factory, focusing on the development and enhancement of practical skills relevant to my role
as a mechanical engineer. This experience has provided me with a comprehensive
understanding of the sugar production process, particularly within the milling department.

During the externship, I engaged in several critical tasks that contributed to my professional
growth and technical tasks. I was involved in the operation and maintenance of milling

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equipment, where I assisted in the calibration of machinery to ensure optimal performance.
This included assisting in the settings for cane feeding rates and adjusting parameters to
maximize juice extraction efficiency.

Additionally, I participated in routine inspections and preventive maintenance activities. I

learned to identify wear and tear in mechanical components, which allowed me to contribute
to the development of a maintenance schedule aimed at minimizing downtime. My
involvement in troubleshooting mechanical issues further enhanced my problem-solving
skills, as I collaborated with senior engineers to diagnose and rectify operational challenges.

In summary, my externship at Wonji Shoa Sugar Factory has equipped me with essential
practical skills and insights into the milling process of sugar production. The experiences I
have gathered will undoubtedly serve as a solid foundation for my future endeavors as a
mechanical engineer in industrial sector.

2.3. IMPROVING THEORETICAL KNOWLEDGE

During my four-month externship at Wonji Shoa Sugar Factory, I significantly enhanced my

theoretical knowledge in mechanical engineering, particularly in the context of industrial
processes. Engaging with experienced professionals and participating in hands-on activities
allowed me to bridge the gap between theory and practice. I explored into the principles of
fluid dynamics and thermodynamics as they relate to the milling process, gaining insights
into the mechanical properties of materials used in sugar production machinery. Additionally,
I explored advanced concepts in equipment design and maintenance strategies, which are
essential for optimizing operational efficiency and ensuring reliability in production systems.
This comprehensive exposure not only solidified my understanding of core engineering
principles but also enriched my ability to apply theoretical frameworks to real-world
challenges in the sugar manufacturing industry.

2.4. IMPROVING TEAM PLAYING SKILLS

During my externship, I have an opportunity to develop my teamwork skills. I have trained to

take responsibility, expose my opinion, support and listen to other team members. The
relationships I make is important to build my network and get future recommendations.

Another value which I get in team players is trust, which is built from honest attitude and
transparency especially in hard situations, I establish good teamwork whether in the daily

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basis activities. Respect others’ opinions and differences, and be happy sharing knowledge
and helping colleagues.

2.5. IMPROVEMENT IN LEADERSHIP SKILLS

During my externship at Wonji Shoa Sugar Factory, I had the opportunity to enhance my
leadership skills. By taking the initiative in the milling department, I learned how to
effectively coordinate tasks among team members. I organized maintenance schedules for
rollers and trash plates, which improved teamwork and communication. Additionally, I
practiced decision-making by addressing equipment issues and proposing solutions, which
helped me build confidence in leading small groups.

2.6. UNDERSTANDING OF WORK ETHICS RELATED ISSUES

My externship also deepened my understanding of work ethics. I observed the importance of

punctuality, responsibility, and integrity in a professional setting. Working alongside
experienced professionals, I recognized how ethical behavior fosters a positive work
environment. I learned the value of accountability by taking ownership of my tasks, ensuring
that maintenance work was completed efficiently and safely. This experience emphasized that
strong work ethics are essential for personal and organizational success.

2.7. GAINING ENTREPRENEURSHIP SKILLS

In terms of entrepreneurship skills, my time at the sugar factory provided insights into
operational efficiency and problem-solving. I learned to identify areas for improvement
within the milling processes and maintenance practices. By analyzing workflow and
suggesting enhancements, I developed critical thinking skills that are vital for
entrepreneurship. Additionally, observing how the factory operates as a business helped me
understand the significance of cost management and resource allocation, which are crucial for
any entrepreneurial venture.

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 CHAPTER THREE

3. THE CHALLENGES AND MEASURES TAKEN TO

OVERCOME THE CHALLENGES

3.1. MAJOR CHALLENGES DURING WORK TASKS

As I did my Externship program in Wonji/Shoa Sugar Factory & I worked in Milling

Department, the following statements are challenges during tasks:

✓ Improper Ladder Placement: The ladders used for maintenance tasks were not placed
securely, posing safety risks during operations.
✓ Sulfur Dioxide Exposure: The presence of sulfur dioxide in the environment was
degrading building materials and posed health risks to workers.
✓ Electricity Shortages: Frequent power outages disrupted operations in the milling
department, affecting productivity and maintenance schedules.
✓ Transportation Issues: There was a shortage of transportation resources, making it
difficult to move laborer, equipment and materials to and from the worksite
efficiently.
✓ Maintenance Delays: Limited access to spare parts led to delays in maintaining rollers
and trash plates.

3.2. MEASURES TAKEN TO OVERCOME CHALLENGES

✓ Maintained Cleanliness: Ensured that maintenance areas were cleaned properly to
promote safety and efficiency.
✓ Utilized Alternative Transportation: used optional transportation methods to reduce
delays.
✓ Effective Communication: Regularly reported difficulties and challenges to
supervisors for timely resolution.
✓ Collaborated with Professionals: Pursued assistance from professional mechanics
when faced with complex issues beyond my expertise.
✓ Proposed Cleaning Initiatives: Suggested the implementation of a sugarcane cleaning
process to supervisors to improve overall operational efficiency.
✓ Participated in Training: Engaged in training sessions to enhance my skills and
knowledge regarding machinery maintenance and safety protocols.

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 ✓ Documented Issues: Kept detailed records of challenges encountered and measures
taken for future reference and continuous improvement.
✓ Promoted Team Collaboration: Fostered a collaborative environment by encouraging
team discussions on problem-solving strategies.

3.3. DESIGN AND CONSTRUCTION IN TERMS OF SAFETY AND

ECONOMY
✓ Ladder Placement Issues: The ladders in the pan house were not placed optimally
during construction, posing a safety risk for workers.
✓ Sulfur Dioxide Concerns: The presence of sulfur dioxide is degrading building
materials, necessitating the use of more resilient materials to enhance safety and
longevity.
✓ Fire Hazard Management: Current fire hazard measures are inadequate and do not
meet intended safety standards, requiring immediate reassessment and improvement.
✓ Road Conditions: The poor condition of access roads hinders operational efficiency
and does not reflect the standards expected of a leading and profitable company in
Ethiopia.
✓ Overhead Crane Challenges: The overhead crane in the pan house department
complicates processes, potentially leading to safety risks and inefficiencies in
operations.
✓ Economic Implications of Safety Measures: Investing in proper safety measures and
infrastructure upgrades will reduce long-term costs associated with accidents and
material degradation.
✓ Need for Comprehensive Safety Protocols: Implementing comprehensive safety
protocols is essential to protect workers and ensure compliance with industry
standards.
✓ Focus on Sustainable Materials: Utilizing materials that withstand sulfur dioxide
exposure can lead to significant cost savings and improved safety over time.
✓ Continuous Improvement Initiatives: Regular assessments of design and construction
practices are necessary to enhance both safety and economic performance in
operations.

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 CHAPTER 4

4. EXTERNSHIP PROJECT
4.1. INTRODUCTION

The sugar industry plays a vital role in the global economy, with roller mills being critical
components in the extraction and processing of sugar from cane. These mills are subjected to
significant mechanical stresses, abrasive wear, and corrosive environments, leading to
premature failure and increased maintenance costs. As a extern, the focus of this project is to
investigate methods for enhancing the mechanical properties of roller mill shafts.

4.2. PROBLEM IDENTIFICATION

The milling process in sugarcane production is critical for extracting juice efficiently. At
Wonji/Shoa Sugar Factory, the rollers play a vital role in this process by crushing the
sugarcane to facilitate juice extraction. However, these rollers frequently encounter issues
related to material degradation and breakage, particularly due to the presence of hard rock
feed mixed with the sugarcane.

4.3. SHORT SUMMARY OF THE PROJECT:

This externship project focuses on enhancing the material properties of rollers used in the
milling process at Wonji/Shoa Sugar Factory. The current rollers often suffer from breakage
and wear due to the abrasive nature of rock feed mixed with sugarcane, leading in higher
maintenance costs, and reduced efficiency in juice extraction.

The project aims to investigate the existing materials and their performance. By exploring
alternative materials or surface treatments, the goal is to develop a roller that offers improved
durability and resistance to wear. The anticipated outcome is a significant reduction in
maintenance frequency and costs, along with enhanced milling efficiency, ultimately
contributing to higher juice yield and quality.

4.4. PROBLEM STATEMENT AND JUSTIFICATION

The current roller materials used in the milling operation are prone to breakage and wear
when subjected to the abrasive nature of rock feed. This leads to increased downtime for
repairs, higher maintenance costs, and reduced overall efficiency in the milling process. The

16
frequent failure of rollers not only disrupts production but also affects the quality and
quantity of juice extracted from the sugarcane.

4.5. OBJECTIVE OF THE PROJECT

4.5.1. General Objective

✓ The main objective of this project is to enhance mechanical properties of roller mill
shafts.
4.5.2. Specific Objectives
Objectives regarding this project are as follows:
✓ To investigate the current material properties of rollers used in the milling process.
✓ To explore alternative materials or treatments that could enhance durability and
resistance to wear.
✓ To propose a solution that minimizes downtime and maintenance costs while
improving milling efficiency.

4.6. LITERATURE REVIEW

The milling process in sugar production is critical for extracting juice from sugarcane, and
the durability of rollers used in this process significantly impacts operational efficiency.
Rollers are subjected to high mechanical stress and abrasive wear, particularly when
processing rock feed, which can lead to premature failure. This literature review explores
recent advancements in materials science aimed at enhancing the performance of rollers in
sugar milling operations.

Traditional materials used for rollers, carbon steels, are often subjected to wear and
deformation under harsh milling conditions. The introduction of high-carbon alloys has
shown promise in improving wear resistance due to their enhanced hardness and toughness
According to Kwon et al. (2020). However, these materials can be brittle, leading to
catastrophic failures if not properly engineered.

The alloying elements such as chromium and molybdenum can improve the overall toughness
of steel, making it more resilient against impact loads from rock feed, it emphasizes the need
for a balance between hardness and ductility in roller materials Zhao et al. (2021).
Furthermore, surface treatments like hardening and coating have been identified as effective
methods to enhance wear resistance without compromising the material's inherent properties
(Smith & Jones, 2022).

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The exploration of advanced composite materials has gained traction in recent years.
Composite rollers, which combine metals with polymers or ceramics, have been reported to
exhibit superior wear resistance and reduced weight (Nguyen et al., 2023). These materials
can potentially reduce energy consumption during milling, thereby increasing overall
efficiency.

In addition to composites, ceramic coatings have emerged as a viable option for enhancing
the surface properties of steel rollers. The ceramic coatings can significantly improve
hardness and thermal stability, allowing rollers to withstand higher temperatures and abrasive
conditions encountered during milling Patel et al. (2022).

The literature indicates a clear trend toward the development of advanced materials and
innovative engineering solutions to enhance the durability and efficiency of rollers used in
sugar milling. By integrating findings from materials science and surface engineering, it is
possible to design rollers that can withstand the rigors of processing rock feed with
sugarcane. Future research should focus on long-term performance evaluations and further
optimization of material properties to ensure sustainable operations at facilities like Wonji
Shoa Sugar Factory.

4.7. METHODOLOGY:

4.7.1. Research Design

The study was conducted as a qualitative research project aimed at enhancing the mechanical
properties of roller mill shafts at Wonji Shoa Sugar Factory. The methodology employed a
combination of interviews, direct observations, and literature reviews to gather
comprehensive insights into the existing conditions and potential improvements.

4.7.2. Data Collection Methods

[Link] Interviews

Interviews were conducted with mechanical engineers, maintenance staff, and operators
involved in the milling process. The interviews aimed to gather expert opinions on the current
performance of roller mill shafts, common failure modes, and suggestions for improvement.

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A set of open-ended questions was developed to facilitate discussion and allow interviewees
to express their insights freely.

[Link] Observations

Direct observations were carried out in the milling department to assess the operational
conditions of the roller mills. This involved observing the roller mill shafts during regular
operations, in addition during maintenance. Noting the signs of wear or failure. Observational
data helped identify specific areas where mechanical properties could be enhanced.

[Link] Literature Review

A comprehensive literature review was conducted to explore existing research on the

mechanical properties of roller mill shafts and related components. Academic journals,
industry reports, and technical papers were reviewed to understand the current state of
knowledge and identify best practices in material selection. The literature review provided a
theoretical framework for analyzing the findings from interviews and observations.

4.7.3. Data Analysis

The data collected from interviews and observations were analyzed qualitatively. Thematic
analysis was employed to identify recurring themes and patterns related to the mechanical
properties of roller mill shafts. Key insights were categorized into themes such as material
selection, and maintenance practices. The findings from the literature review were integrated
with the qualitative data to support conclusions and recommendations.

4.7.4. Limitations

It is important to note that this study did not include surface treatment experiments, Finite
Element Analysis (FEA), or physical material testing. Therefore, the conclusions drawn are
based on qualitative insights rather than quantitative data. Future research may consider
incorporating these methods for a more comprehensive analysis.

4.7.5. Conclusion

This methodology provided a structured approach to understanding and enhancing the

mechanical properties of roller mill shafts through qualitative means. The integration of
interviews, observations, and literature review enabled a holistic view of the challenges and
opportunities within the milling process at Wonji Shoa Sugar Factory.

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4.8. RESULT AND DISCUSSION

The externship program at Wonji Shoa Sugar Factory provided a unique opportunity to
explore the mechanical properties of roller shafts used in sugar milling processes. The
findings from the literature review, combined with practical observations during the
externship, underscore the importance of selecting and engineering materials that can
withstand the demanding conditions of sugarcane processing.

To begin with, the traditional use of carbon steels in roller shafts has been shown to be
inadequate due to their susceptibility to wear and deformation under high-stress conditions.
The literature indicates that high-carbon alloys, as highlighted by Kwon et al. (2020), can
enhance wear resistance; however, they also present challenges related to brittleness

In addition, the survey of advanced composite materials, as discussed by Nguyen et al.

(2023), revealed promising results in terms of both wear resistance and weight reduction. So,
Implementing composite rollers at Wonji Shoa Sugar Factory will not only enhance
operational efficiency but also reduce energy consumption during milling. So, suggesting
these materials could be a viable alternative to traditional steel rollers.

Furthermore, Chromium coatings are known for their hardness and wear resistance. They
provide a tough surface that can withstand high contact stresses, making them ideal for
applications in harsh environments like sugar processing (Zhang et al., 2022). Ceramic
coatings, as proposed by Patel et al. (2022), were also reviewed during the externship. The
ceramic coatings on existing steel rollers can also improve surface hardness and thermal
stability.

It can be concluded that, to enhance mechanical properties of a sugar mill shaft of Wonji
Shoa Sugar Factory based on operation conditions, expected load on the shaft, and cost, the
combination of heat treatment, quenching for mechanical strength and surface hardness, and
surface coatings of chromium for protection against wear and corrosion would be well suited.

4.9. RECOMMENDATIONS FOR THE COMPANY:

During my four-month externship at Wonji Shoa Sugar Factory, I worked in the milling
department, focusing on the maintenance of rollers and trash plates. Based on my
observations, I have developed several recommendations to enhance the factory's operations
and safety.

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✓ It is important to implement a more effective cleaning process for sugarcane before it
enters the milling stage. This will help remove dirt, leaves, and other impurities,
leading to higher quality sugar production and reduced wear on milling equipment.
✓ A thorough assessment of fire hazards in the factory is necessary. Areas where sugar
dust accumulates should be identified and managed to reduce fire risks. Additionally,
fire extinguishers should be strategically placed throughout the facility, ensuring they
are easily accessible. Regular training for employees on fire extinguisher use is also
recommended.
✓ The Panhouse department handles heavy materials, making it essential to introduce an
overhead crane system. This system will improve material handling efficiency, reduce
manual lifting, and minimize the risk of injuries. These recommendations will
enhance efficiency and safety at Wonji Shoa Sugar Factory, supporting high-quality
sugar production in a safe environment.
✓ Future research should focus on the long-term performance of composite materials in
real-world milling conditions. This includes fatigue testing and impact resistance
evaluations to ensure that selected materials can withstand operational stresses over
time.
✓ The implementation of chromium coatings should be further explored through
controlled trials to assess their effectiveness across different roller designs and
operating conditions.

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 REFERENCE

1. Chen, Y., & Wang, L. (2023). "Optimizing Roller Design Using Finite Element Analysis."
*Journal of Manufacturing Processes*, 45(2), 123-135.
2. Kwon, J., Lee, H., & Park, S. (2020). "Wear Resistance of High-Carbon Alloy Steels in
Sugar Milling." *Materials Science and Engineering*, 789(1), 112-120.
3. Lee, J., Kim, T., & Choi, Y. (2021). "Stress Distribution in Roller Systems: A Finite
Element Approach." *International Journal of Mechanical Engineering*, 15(4), 456-467.
4. Nguyen, A., Tran, B., & Vo, C. (2023). "Composite Materials for Enhanced Roller
Performance." *Composites Science and Technology*, 220(3), 310-320.
5. Patel, R., Desai, K., & Shah, P. (2022). "Ceramic Coatings for Increased Roller
Durability." *Surface Engineering*, 38(5), 789-795.
6. Ramos, M., Silva, J., & Costa, R. (2023). "Comparative Study of Roller Materials in Sugar
Milling." *Sugar Industry Journal*, 145(7), 456-467.
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*Journal of Materials Engineering*, 37(6), 567-580.
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