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Executive Summary
This project addresses the gap in the market for a more automated restaurant environment. The
product features drinks ordered and dispensed by the customer from their seat. With fewer waiting
staff needed, the wage burden on the restaurant is significantly reduced. With drinks more quickly
and easily accessible, more will be sold, and as a high margin product, the profit to restaurants will
increase. Therefore, this makes the product attractive to restaurants.
The solution proposed in this report is the Auto Ceiling Tap dispensing system. The solution consists
of a piping system that pumps drinks from the cellar, through a network of pipes situated along the
ceiling and down to each table. At the centre of each table there will be a single dispenser housing the
pipework and valves to control the fluid flow. The customer will control the drinks dispensed using
hand held tablets. These tablets will also be used to order food, further reducing waiter workload.
There will be a choice of up to ten drinks, up to the discretion of the restaurant, but predicted to be a
variant on two wines, two lagers, four soft drinks, sparkling and tap water.
The design of the dispensers will be sleek and smooth, with a cladding that can be customised to each
restaurant aesthetic. A more futuristic restaurant might want all the working parts on show, for
example, a clear cladding might be chosen, while others might want a selection of colours, textures
and patterns. The manufacturers of the product will accommodate these desires.
This product is marketed at high capacity restaurant chains, such as Wagamama, a chain of 110 UK
restaurants that all seat over 100 customers. Wagamama serves lower end drinks. This means that
customers will not be put off their drinks because they are dispensed rather than poured.
Assuming a 21-table restaurant, each will be charged 50,000 upfront for the installation of these
dispensers. There is also consideration in this report for smaller restaurants, though they are not the
target market. The restaurant will then be charged 20% of the projected profit every month for the
ten-year lifespan of the product. In exchange, maintenance of the dispensers will be carried out,
replacing the parts that have a five-year warranty. The projected profit for a 21-table restaurant is
7,389 per month. Restaurants will be charged 1,477 of that, leaving them with a profit of 5,911per
month. The upfront cost, as well as the lack of turnover through closure for installation, is repaid
within eleven months. The construction and installation costs for the company are repaid within ten
months. This means that after one year of installation, both the restaurant and the company are
making a profit that will continue for a further nine years.
The company cash flow is dependent on the monthly instalments, since the dispensers cost 79,282
per large restaurant. This means that for the first five years, the company will be in debt while it
recoups the cost of the installations. However, once a critical number of restaurants have had
dispensers installed, the total monthly repayments will exceed the cost of installing more. This means
that after ten years, the difference between operational costs and income will be 491,911 per month
and rising. This large profit margin makes Auto Ceiling Tap worth investing in, and a sure bet for the
future. The market is very wide, with restaurant chains existing in a large number of countries
throughout the world. The potential earnings are great, and rapid expansion is likely.
Contents
Executive Summary.................................................................................................................................. i
Nomenclature and Abbreviations .......................................................................................................... vi
1
Introduction .................................................................................................................................... 1
3.1.2
3.1.3
Method............................................................................................................................ 4
3.1.4
3.1.5
Analysis ........................................................................................................................... 7
Trunking ................................................................................................................................ 14
4.2.1
4.2
4.3
Costings ................................................................................................................................. 16
Displacement ................................................................................................................ 18
6.2.2
Torsion .......................................................................................................................... 19
6.2.3
6.2.4
Vibration........................................................................................................................ 20
6.2.5
Modelling ...................................................................................................................... 20
6.2.6
Assembly ....................................................................................................................... 24
6.3.2
Aesthetics ...................................................................................................................... 25
ii
7.1.2
7.1.3
7.1.4
7.2.2
7.2.3
7.2.4
Control operation.......................................................................................................... 47
8.2.2
Communication ............................................................................................................. 47
8.2.3
Tablet ............................................................................................................................ 48
8.2.4
Design detail.......................................................................................................................... 51
9
10
8.3.1
8.3.2
8.3.3
Wiring ............................................................................................................................ 53
Demand ................................................................................................................................. 60
Cash Flow .............................................................................................................................. 63
The Partners .......................................................................................................................... 65
Further Work......................................................................................................................... 65
11
Discussion.................................................................................................................................. 66
12
Conclusion ................................................................................................................................. 67
13
References ................................................................................................................................ 68
iii
14
Appendices ................................................................................................................................ 71
Project Plan ........................................................................................................................... 71
Engineering Drawings ........................................................................................................... 72
Piping System ........................................................................................................................ 73
14.3.1
14.3.2
14.3.3
14.3.4
14.3.5
14.3.6
14.4.2
14.4.3
14.4.4
14.4.5
14.4.6
14.4.7
14.9.2
14.12.1
Tablet ........................................................................................................................ 95
14.12.2
14.12.3
14.12.4
iv
I (m4)
D (m)
B (m)
d (m)
B (m)
W (N)
L (m)
E (Pa)
(rad/s)
T (Nm)
Ip (m4)
G (Pa)
Krot (Nm/rad)
(N)
Mb (Nm)
Sb (Pa)
(N)
Mt (Nm)
(N)
Fn (Nm)
A (m2)
(N)
Meq (Kg)
d (rad/s)
n (rad/s)
(-)
T (s)
Q (m3/s)
P (Pa)
v (m/s)
Z (m)
(Kg/m3)
g (m2/s)
hloss (N/m2)
D (m)
(-)
(-)
(-)
(m2/s)
K (m)
Vdrop (V)
I (A)
Rwire (Ohm)
QHT (W)
Cp (-)
(k)
Q (W)
Tf (oC)
Ta (oC)
vi
Ds (m)
(W/(m2.oC))
k (W/m.k)
MOPD (Pa)
Kv (m3/hr)
F (m3/hr)
SG (kg/m3)
N (-)
p (-)
t (-)
nt (-)
c ()
I ()
()
w ()
o ()
s ()
m ()
tr ()
ma ()
s (m)
v (m/s)
u (m/s)
t (s)
a (m/s2)
Bag-in Box
Polyvinyl chloride
Video Electronics Standards Association
Metal Oxide Semiconducting Field Effect
Transistor
electromotive force
Failure Modes and Effects Analysis
Light Dependant Resistor
Point of Sale
General Purpose Input/Output
Mini Circuit Breaker
User Requirement Specification
Light Goods Vehicle
Heavy Goods Vehicle
Limited Laibility Partner
Metal Inert Gas
Maximum operating pressure differential
vii
1 Introduction
The self-service sector is a rapidly expanding market branching into all areas of life, revolutionising the
way humans go about their daily tasks. Self-service machines can be found anywhere ranging from
the supermarket giants right through to airport security. In all of these a machine helps the user
assume a role typically performed by someone else.
Restaurants have been slow to react to this developing technology, hence presenting a gap in the
current market for the Auto Ceiling Tap. The product consists of a self-service drinks dispenser that
allows the customer to independently order, dispense and collect their drink without having to leave
their seat. The product aimed to fulfil the following criteria:
Be profitable for the restaurant
Be installed at each table within the restaurant
Give the customer the ability to access and use the dispenser at their table
Have the ability to dispense lager, wine, water and soft drinks
Include a food ordering system
Not decrease the capacity of the restaurant
The product would be aimed at lower to mid-range restaurant chains looking to modernise their
method of delivery, such as Wagamamas. The product s closest competitor on the English market is
Table Tap LLC. This consists of a normal beer tap situated on each table. The customer has to pour
their pint like a bartender and is limited to only dispensing beer. Furthermore this product is only
available within public houses.
This report explores the fully designed product and the design process behind it, followed by the
commercial considerations and a business plan to turn this idea into a profitable company.
A project plan was drawn up detailing each part of the design. This can be seen in appendix 1. The
project milestones are highlighted in red. Each aspect of the design was given a time period in which
it should be completed. The project plan also describes which members of the team completed which
tasks.
Flow rate
To ensure a fast and repeatable delivery the drinks have to be dispensed with a constant flow
rate. A flow rate Q corresponds to one pint in ten seconds, as outlined in out user requirement
specification (Q1=0.05683 ltr/s=0.5683E-4 m/s), because it ensures a fast delivery and is
common within existing tap systems.
The beer, syrup and the carbonated water are pumped with the help of pressurized CO2 tanks. The
wine is pumped with a CO2/N2 mixture because it has to have a low CO2 concentration as to not affect
the i e staste. The gas is reduced to the desired operating pressure by the primary and secondary
pressure regulators. It is then used to press the drink out of the keg, through cooling equipment and
to the tap. The syrups, so- alled ag-in- o BIB ,a epu pedsepa atel f o a o ated ate a d
are mixed at the nozzle.
This product adds to the existing bar equipment of the restaurant. That means the equipment
mentioned in section 3.1.2 is not supplied together with the product. However, any missing parts
adapters or additional equipment to guarantee a full working system can be supplied.
3.1.3 Method
The system is modelled as a steady, incompressible flow inside a tube. Therefore the fluid properties
can be calculated with the Bernoulli equation (3.1) with pressure drop across a streamline:
+
(3.1)
Where , are the pressures in N/m, , are the flow velocities in m/s, , are the absolute
heights in m, is the density of the fluid in kg/m and g is the gravitational acceleration in m/s. The
subscripts specify the location along the streamline. The flow velocities are calculated using equation
(3.2) by dividing the flow rate Q in m/s by the cross section area in m2 of the pipes:
=
(3.2)
The term , represents the pressure drop or pressure loss in N/m in the pipes between the
locations 1 and 2, calculated with the Darcy-Weisbach equation:
(3.3)
Where the first term represents the major losses due to the pipe length and the second term the
minor losses due to the components in the system, with being the pipe length in m of that section,
the pipe diameter in m, , the flow velocities in m/s, the Darcy-Weisbach friction coefficient
and
the minor loss coefficient. The subscripts specify the different sections with different
properties.
The Reynolds-number for the flow inside a pipe is defined as:
=
(3.5)
Where is the kinematic viscosity of the fluid in m/s. The Reynolds Number determents if the flow
inside the pipe is laminar or turbulent, a distinction which is necessary to select the method to
calculate the Darcy-Weisbach friction coefficient . Because all the flows have a Reynolds number that
is higher than the critical Reynolds number for flows inside a pipe (
=
) the Darcy Weisbach
coefficient can be determined by iterative solving the Colebrook equation (see appendix 3.2):
= log
(3.4)
Where k is the absolute roughness of the pipe material in m, in this case for PVC pipes k=0.7E-5 and
is the Reynolds-number at the calculated section. (The Engineering Toolbox, 2015)
The minor loss coefficient is an empiric non-dimensional measure for the pressure loss due to the
different components in the system. This table shows the minor loss coefficients for the different
components in the system. (The Engineering Toolbox, 2015)
Part
T-Connectors
Solenoid Valve
Check Valve
The highest pressure losses occur when the flow rate and therefore the velocity is the highest. For
that it is assumed that all dispensers are dispensing the same drink at the same time. Because of that,
the flow rate in the pipe upstream of two other pipes is always the sum of them as seen in figure 3.2.
The following labelling is introduced in figure 3.3 and shows the flow rates in the pipe stages as a
multiple, written in blue, of the desired tap flow rate Q1=0.5683E-4 m/s.
The pressure loss in the large system is too high, compared to the maximum pressure of 10 bar a CO2
pump can supply. Additionally, applying the method demonstrated in figure 3.2 on the large system
means that the highest possible flow rate is 21 times the tap flow rate. To increase the efficiency of
the system and guarantee that standard CO2 pumps can be used, the pressure losses have to be
reduced. This can be done by increasing the diameter of some of the pipes in which the highest flow
rate is passing through. However, using higher diameter pipes conflicts with the objective to use
standard pipes. The solution is to split the large system into two smaller ones, one with 10 and one
with 11 dispensers.
The resulting highest pressure losses for the two systems are shown below (see appendix 3.4). This
method, splitting a large system into smaller ones, can be used if larger systems with more dispensers
are required.
Part
Large, line 1
Large, line 2
Fluid
Lager
Wine
Syrup
Water
Small
3.38
3.27
3.38
3.38
Large
4.00
3.91
4.00
4.00
The CO2 and CO2/N2 pumps used in bars can supply up to 10 bar. They are therefore sufficient for the
operational demands of the product.
3.1.5 Analysis
The above calculated operating pressures are for the maximum required pressures for the longest and
most complex line in the system. This means that only that line has the desired tap pressure at the
end. All other lines have a higher tap pressure, because they have lower pressure losses. Furthermore,
the assumption made for this calculation was that all dispensers are operating simultaneously,
meaning that a drink is delivered to all of the dispensers at once. With less dispensers working at the
same time the tap pressure rises, because the flow rates are not as high due to the decreased demand
for the same drink. A higher tap pressure results in a foamy drink and a resulting flow rate and drink
velocity that does not fit the requirements. Therefore, the tap pressure has to be regulated down to
the desired value, regardless of how many dispensers are operated. This is done with a single stage
pressure regulator, which is a valve that restricts the pressure to a certain pre-adjusted pressure value.
These regulators are at the top of the dispenser and regulate the flow of every drink to the desired
tap pressure. They have to be able to handle the highest inlet pressure, which is the operating pressure
and lower it to the tap pressure.
Detailed Design
Using the calculations and the analysis above, the parts used to embody the system can be chosen.
The pipes are a trunking of 14 pipes, each with a diameter of 10mm as seen in figure 3.5. This is for
the ten different drinks and the four coolant lines (see section 4). The required length can be found in
table 3.5.
Small
Medium
Large
Figure 3.4: Pipe Trunking
The T-connectors seen in figure 3.6 are used as the manifolds. These T-connectors have speed fit
connections to ensure fast installation. Table 3.6 below shows how many T-connectors are needed,
which is determined by the number of dispensers.
Small
Medium
Large
Number of T-Connectors
90
140
210
Table 3.6: Number of T-Connectors
The pressure regulators that fit the requirements, shown in section 3.1.5, are depicted below. They
are needed for every drink line at every dispenser. The required number of regulators can be found in
table 3.7 below.
Small
Medium
Large
Number of Regulators
100
150
210
A detailed drawing of the resulting pipework in the cellar and the dispenser can be found in appendix
3.6.
Installation
The pipe trunking will be cut and adjusted during installation. As a result of the insulation, the pipe
trunking is not very flexible. Therefore, to ensure that the pipework can be bent to the correct position
and to connect the pipes to the T-connectors, the insulation may be interrupted.
The piping system is installed in the following steps:
4 Cooling (Shaun)
Beverage Cooling
The dispenser system increases the capacity of the restaurant to dispense many more drinks
simultaneously compared to their previous system where drinks are stored in the cellar and served at
the a , k o as a ella to a s ste . This ea t that o erns were raised regarding their
e isti g e uip e t s ooli g apa it . O a e age, due to staffi g est ai ts a d the u e of
existing beverage dispensing points, it would be reasonable to suggest that only 4 to 6 drinks would
be dispensed simultaneously in the restaurants existing setup. This would be in comparison to the 15+
drinks that could be dispensed simultaneously using the dispenser.
Knowing that the worst case scenario would be when each dispenser operates simultaneously, the
maximum cooling capacity was calculated. In the URS, it was decided that the beverage dispense rate
would be 1 pint in 10 seconds (0.0568 ltr/s). This means that the maximum possible flow rate would
be 0.0568 ltr/s multiplied by the number of dispensers in the restaurant. Therefore the maximum
cooling capacity for the standard small, medium and large restaurant installations were calculated
(shown in table 4.1) using this worst case scenario and the equation (4.1).
Where:
(4.1)
Small
3.5
Medium
5.3
Large
7.6
These heat exchange rates were found to exceed hat ouldt pi all efou di e isti g ella to
a s ste s.The efo e,se e al o epts e e aisedtoo e o etheissue.These e edesig ed
against the following criteria:
Firstly, electronically limiting the number of beverages that could be dispensed at any one time or
over a specified length of time was considered. This would be done within the dispensing software on
the server provided with the system. It would essentially place any drinks ordered that exceed a predetermined limit, based on the restaurants cooling equipment specifications in a queue. It would then
allow a pre-defi edti etopass,allo i gthe ooli ge uip e tti eto e o e , efo e eleasi g
the drinks orders to the dispensers. Although this was a cost effective solution it conflicted with the
U s e ui e e tfo d i ksto ese ed o de a d a dit asfeltthatthis ouldu de i ethe
nature of the product.
10
Secondly, the use of keg chillers was considered. These are essentially cold plates on top of which the
kegs would be placed and would pre-cool its entire contents. They would need to be activated several
hours before the restaurant started operating due to the considerable quantity of fluid that would
require cooling. Although this would be a simple solution for the beverages contained in kegs it could
not e used o the BIB p odu ts li es. This ethod as the efo e eje ted e ause it as t a
universal solution for all types of drink, which would aid in reducing the cost and complexity of the
system.
Lastly, the use of additional flash cooler units was considered. This would involve the placement of
additional flash coolers in parallel with the existing units, as shown in figure 4.1, already present. This
would better utilise the existing equipment already owned by the restaurant and would increase the
overall heat exchange rate of the system allowing multiple beverage lines of each type to pass through
each cooler. Although, these additional flash cooler units would increase the cost of a typical
installation, due to the nature of the product and its need to e a le to fulfil the usto e s o
de a d e ui e e t,it asde idedthatit asthe ostsuita leoptio .I di ati ediag a sof hat
would already be present at the restaurant and how the additional flash coolers would be installed
are shown in figure 4.2. The number of each piece of equipment in the figures below are for simplicity
and is not accurate to what would actually be present/installed more accurate pipework and cellar
equipment schematics can be found in appendix 3.6.
Using the required heat exchange rates noted in table 4.1 above the Tayfun T160F, see appendix 4.5,
was sourced as a suitable flash cooler. An additional 3, 5 and 7 of these units would be required for
11
the standard small, medium and large installations, assuming that at least 1 flash cooler is already
present. Each additional flash cooler would require 800W to operate. Based on 12 hours of operation
per day for 6 days a week, an additional 255KWhrs will be used per additional flash cooler per month.
At 0.13GBP per KWhr this will equate to an additional monthly electricity cost of 99.48GBP, 165.80GBP
and 232.12GBP for the small, medium and large installations respectively. These costs are less than
0.3% of the anticipated savings and increased profits of the restaurant and have therefore been
deemed to be negligible.
It was noted that the additional flash cooling equipment could result in a rate of heat rejected to the
ella spa ethat a e eedthe ella sheat o t ols ste .lthoughthe ella sheat o t ols ste
is not deemed to be within our standard supply, we would assess its capacity during our initial site
visits and if it is not suitable would offer the supply and installation of a larger capacity unit.
Where:
(4.2)
Small
215
Medium
315
Large
383
Using the rate of heat transfer per meter of 8.43W from the same calculations above and equation
4.3.
Where:
(4.3)
is the time taken in minutes for the temperature of the beverage to raise by 1 oC
is the rate of heat transfer with the environment (W/m)
12
The time taken for the beverages to reach an unacceptable temperature of 4oC was calculated to be
5.7 minutes for each installation size. The workings for this can be found in the appendix 4.2. Several
concepts were raised to overcome this issue. These were designed against the following criteria:
Must have the ability to control the dispensed beverage temperature
Must be simple and cost effective
Ideally use industry standards equipment
Fi stl ,theideaof o e - ooli g the e e ages as o side ed.This ouldesse tiall e ui e ooli g
the beverages below the required dispensing temperature by a set amount which would account for
the time in and the heat exchange rate of the piping system. However, due to the limiting factor of
the beverages freezing at temperatures below 0oC (degrees Celsius) and since the period of time spent
in the pipes cannot be predicted, the final temperature cannot be modelled. This would lead to an
undesirable passive system where the exact control of the required beverage temperature could not
be maintained.
Secondly, heat exchangers local to the final beverage dispensing point were considered. This would
have the benefit that the fluid in the beverage lines would spend little time warming after being
cooled. This would require the beverages being re-cooled back down to the desired dispensing
temperature negating the warming incurred whilst the fluid was in the piping system. However, due
to aesthetic restraints imposed on the size of the dispenser and cost restraints a relatively small heat
exchanger would be required. This raised an issue regarding the rate of cooling that would be required.
After initial calculations a heat exchange rate of approximately 7KW would be required and was
deemed to be unattainable whilst the previous two restraints were maintained.
Lastly, since the coolant for the local heat exchangers would have to travel to the dispensers, that
coolant could instead be used to cool the pipes along the ceiling. Using the pipe work itself as the heat
exchanger was considered. This would negate the issues of cooling the fluid over a short period,
dramatically reducing heat exchange rates. After researching this method of cooling, it became
apparent that this type of system was already used within the drinks industry as a standard method
of ooli g supe ool lage s. The use of spe ifi gl ol hillers located with the rest of the cellar
equipment and trunk beverage lines are used to achieve this as shown in figure 4.3.
13
4.1 Trunking
Trunking was chosen to cool the beverage lines as they travel from the cellar equipment to their
dispensing point. As this method is well used in the restaurant industry, the trunking is readily
available, easy to source and relatively inexpensive.
The trunking is made of several individual components consisting of the glycol coolant pipes, beverage
lines, reflective thermal wrap, foam insulation and vapour barrier as can be seen in the diagram in
figure SF4. The glycol and beverage lines are made of braided PVC hose and are specified as such to
ensure that there is no bleeding or contamination between the lines and that they can withstand the
required operating pressures. The reflective and traditional foam insulation is present to ensure that
a low K value (an industry standard unit describing thermal conductivity) is attained with regards to
the t u ki g s the al p ope ties. The
Figure 4.4: Beverage and Coolant Trunking Complete With Cross Section View
14
In a standard trunked pipe, the cold fluid runs to the destination through the centre of the bundle, but
the hot fluid running from the destination runs parallel to this, again through the centre of the bundle,
as shown in figure 4.4 by the blue (cold) and red (hot) pipes. It was decided for our system to instead
run the cold pipe outside the bundle, separately insulated. This would stop heat exchange between
the hot and cold coolant flows and increase the efficiency of the system. Although this would require
additional pipework it could be achieved since running the pipe work system through the ceiling space
allowed additional work space in compariso tosta da d ella to a s ste s.
Concerns were raised again due to the requirement of long lengths of piping system pipework. Several
calculations were therefore performed based on our standard small, medium and large systems to
ensure that the trunking would be suitable.
4.2.1 Glycol Coolant Flow Rate
The coolant flow rate required to negate the system losses was calculated by treating the trunking
system as a reverse flow heat exchanger. The heat exchange rate between the beverages and the
ambient temperature of the ceiling space was calculated using the previous static cylinder assumption
as the beverage temperatures should not change across the length of the piping system. Using the
previously calculated heat transfer rates in table 4.2 the required coolant flow rates for each
installation size were calculated using equations (4.4) and (4.5) and are shown in the table 4.3 below.
S4.1 to:
(4.4)
as the beverage inlet and outlet temperatures are the same. This reduces equation
Where:
(4.5)
Small
0.012 ltrs/s
Medium
0.018 ltrs/s
Large
0.021 ltrs/s
15
Using the required coolant inlet temperature, system heat transfer rates, coolant flow rates and noted
in tables 4.1 and 4.2 above and the system pipework lengths noted in section 3 the UBC-EG3/4P (see
appendix 4.6) was sourced as a suitable glycol chiller.
Where:
(4.6)
4.3 Costings
Costs for all of the above mentioned equipment in addition to connection accessories and vales can
be found in the bill of materials appendix 11
16
5 Cleaning (Shaun)
The cleaning of beverage lines is a necessary practice in restaurants and pubs to keep the beverage
lines clean of bacteria and yeast. If this is not done it can lead to unwanted, distasteful flavouring of
thedispe sed e e agei additio to a te iale elsthata epote tiall haza doustothe usto e s
health. Lines are therefore cleaned regularly to avoid this. It was also documented that although the
cleaning of beverage lines was essential to keep customer satisfaction high, it was often neglected by
landlords and restaurant managers due to the amount of time required. Therefore, a requirement of
the product was to keep the cleaning process as short and simple as possible.
Ea h e e agehasitso lea i gi te alasspe ified thed i k s a ufa tu e .Thiste dsto e
once a week for lager and beer lines, once a quarter for red and white wines and never for syrup and
water lines. To ensure that cleani g is a ied out at suita le ti e i te als the e t al se e s
software will send email messages highlighting that cleaning needs to be performed on a specific
beverage line type to a manager or other suitable email address. A confirmation email will be sent to
the same address once the cleaning procedure has been carried out.
Li e lea i g illal a s epe fo edoutside estau a t sope i ghou s.Tope fo lea i gofa
certain beverage line type a member of staff will select the required cleaning optio f o astaff s
fu tio e u ithi the dispe se s ta let e u. This ill e pass o d p ote ted as to a oid
usto e spe fo i ga a tio s ithi thisstaff sfu tio e u.The cleaning procedure can be
found in appendix 5 of this report.
As mentioned in the cleaning procedure a drainage funnel has been housed in the lower table support
hidden under the drip tray. This funnel is connected to a tap at the bottom of the table support to
allow either a container to be placed underneath or a hose connected to it. This allows easy collection
of cleaning fluids and waste beverages when line cleaning needs to be performed. These components
can be seen in figure 5.1 below.
17
It is clear that restaurants can only make money when they are open. Therefore the
installation of the dispensers should be kept to the quickest possible time. As a result a
simple design is needed to speed up this insulation process.
No two restaurants are the same, and therefore a degree of flexibility should be
incorporated into the design. This would make it possible to install the dispensers into any
restaurant.
There must be a cavity within the structure. This is to accommodate the working parts of the
dispensers, such as the values and nozzles. Furthermore there has to be room to allow the
pipes flowing in and out of the unit along with any electrical wiring.
Maintenance must be able to be carried out on the dispenser without having to take the
entire structure down. As a result it must be easy to gain access to the working parts.
The design that was chosen was shown within figure 6.1. It is built up out of two sections, the first is
a fix length square section that would accommodate the dispensing system. The second part consist
of four circular rods that fasten the table to the top section. Different lengths of rods can be used to
compensate for restaurant having different ceiling heights. A breakdown of these two sections are
shown within figure 6.2.
Design Development
6.2.1 Displacement
To find out if this design would work when implemented, a modelling process was needed. However
again as no two restaurants are the same a degree of flexibility was needed to be incorporated into
modelling process. It was decided that writing a program within MatLab would offer this degree of
flexibility. This meant during implementing of the structure into a different restaurant, the whole
process would not have to be repeated. The different restaurant parameters, such as the ceiling
height, would be the only thing that would have to be changed.
The MatLab program needed to be able to tell the user important information about the structure.
Firstly the displacement of the table due to an impulse force needed to be calculated. This was
18
conducted by modelling a person walking into or banging the table as they walked past (a not so rare
occurrence within a busy restaurant). In order to do this, the second moment of area for both the
different sections of the structure was calculated. The formulas used to calculate the second moment
of area for a hollow square and that of a circular rod are shown in equations (6.1) and (6.2).
=
(6.1)
(6.2)
Where and are the outer dimensions of the structure in m and and are inner dimensions in
m. Furthermore after substituting equation (6.3) into equation (6.4) it was possible to obtain the
stiffness of each individual section of the structure.
(6.3)
(6.4)
Here and
refer to the length in m and force applied in N respectively, whereas is the You g s
modulus of the material in Pa. Once these were obtained the setup can be modelled as springs in
series and parallel to generate the overall stiffness of the structure. After all of this information has
been collected the force, applied by the nock, needed to be implemented into equation (6.5) to output
the displacement felt by the table.
=
(6.5)
6.2.2 Torsion
After the deflection of the structure had been incorporated into the MatLab programme, torsion had
to also be included. This again is an important parameter for the code to output as the table must not
be able to twist past a certain angle. Clearly when the table is fully loaded the customer does not want
their food to be spilt by a small force, which would cause the table to twist out of control. To gather
this information the following process was applied to both the top section and bottom section of the
structure.
Firstly, the twist angle, measured in radians, was generated. This is shown in equation (6.6).
=
(6.6)
and are the torque in Nm and length in m respectively while and are the polar second moment
of area in m4 and the shear modulus of the section in Pa. As a result, it was possible to generate the
rotational stiffness,
measured in Nm/rad of the material using equation (6.7) below.
=
(6.7)
Finally, after using the same process, as with the deflection, it was possible to obtain the equivalent
stiffness of the system which then could be used to find the angular displacement.
19
Bending stress: =
, where
, where
the
Torsional stress: =
Normal stress: =
where
An equivalent tensile stress, , measurd in N/m2 can be calculated with the help of the von Mises
yield criterion equation (6.8):
= + +
(6.8)
Once this was obtain it is possible to compare it against the yield stress of the material that is being
used. This makes it possible to generate the factor of safety.
6.2.4 Vibration
The final way that the structure was modelled was to calculate how long the system would vibrate for
once an impulse force was applied. The response of the system to a lateral impulse force was analysed
again within the MatLab program. The response to a generic impulse was modelled using equation
(6.9).
=
(6.9)
The structure was chosen to be fabricated out of mild steel. This was chosen for several reasons,
pa ti ula l due to the fa t that it s e p edi ta le ate ial p ope ties allo ed us to odel the
material easily and accurately, as well as its good fatigue strength that would maximise the lifetime of
20
our product. On top of this, mild steel is a widely use material in construction, which means obtaining
the sizes needed for the structure very easy.
After running the code, the first major concern was a result of the impulse force. When an impulse
force of 400 N was applied to the structure at table level, the table would displace up to 17.5 cm. The
table would then carry on to vibrate notably for the next two and a half seconds. The results of this
are shown in a displacement time graph in figure 6.3. This would clearly not be acceptable for
restaurant table loaded with drinks and food.
In light of this new information, a way to reduce this initial amount of displacement was needed.
Figure 6.4 shows an additional weight, also known as a tuned vibration absorber, which was added to
the bottom of the table to try and absorb some of this unwanted vibration.
However this approach soon proved to be unrealistic. This was because the tolerance of the additional
weight and its connecting rods would have to be very small in order for this method to work. As this
method only works when the weight of the additional component are correct. Manufacturing these
component to have high accuracy would increase the fabrication cost well past what it was intended
to be.
21
The other option that could have possibly reduced the vibrations was to increase the second moment
of area. From the derivation of the code it becomes clear that this and the length of the structure is
directly related to the stiffness, equation (6.3), which in turn is related to the displacement, equation
(6.4). Therefore as the height between the table and that of the ceiling is fixed for each restaurant,
the second moment of area would have to be increased to also increase the total stiffness. It is
important to note here that the second moment of area is essentially the geometry of the structure.
Therefore it can be proven that the second moment of area for that of a square rod is greater than its
equivalent circular rod. As a result the first amendment consisted of making the four circular rods that
fastened the table to the structure, square. This did see a positive result in the reduction of the
displacement.
Now that the bottom section of the structure had been improved, the top half was next considered.
By reducing the size of the cavity running through the centre of the square section, i.e. reducing b and
d in Equation 1, the second moment of area would increase. After performing iterative calculation
with adjustments of D, B, d and b the total displacement was reduce to 4 mm when D=B=230mm and
d=b=150mm. This result is shown in Figure 6.5.
However by increasing the thickness of the top structure, the actual mass of the structure increased
significantly to 546 kg. Due to the large mass of the system, the assumption that the ceilings would be
able to support our dispensers was now floored. In order to solve this concern, different options were
explored.
The first was to look at installing a network of I-beams running through the restaurant that would
support these dispensers. However after going back and looking at the original criteria for the design,
this soon proved to be unfeasible. This was due to the fact that restaurants can only make money
when they are open. To close a restaurant for a duration of time to undergo extensive structural work
would therefore not be appealing to the restaurant owners. After careful consideration it was decided
to abandon the hanging table approach, and instead add additional supported from the floor.
6.2.6 Modular Design
Now that the structure was to be re-designed it was important to first go back to what needed to be
achieved in the final design. After looking again at the criteria, the solution was to make the structure
from a modular design. This meant that the table would be supported by a central column running
through the centre of the table, which would be made up on average by three of these modules. In
22
turn this meant that the overall fabrication costs, which include the cutting and joining of the
materials, could be kept as small as possible. Furthermore as the fabricators were only manufacturing
one type of module, they could adopt the use of jigs. This would speed up this process and further
reduce costs. On top of this the modules gave the structure the degree of flexibility needed to cope
with a wide range of different restaurants. This is due to that fact that they can be stacked one on top
of the other from the floor to reach the required height of the ceiling. Ultimately this means that the
dispensers do not have be to be custom built for each restaurant, saving the company both time and
money.
To make the installation process as quick as possible the number of modules used should be kept to
the lowest possible amount. As a result, the modules need to be as tall as possible. The tallest each
module can be is equal to the height of the table, as the table sits on top of the first module. After
looking into the ergonomics associated with tables, it was found that the 95th percentile of people
require a table height of 750 mm (Caglar, 2015). This is therefore the maximum height the module
can be. In terms of the other dimension, the modules had to be able to accommodate the valve and
nozzle plate which both were 150 mm squared. Figure 6.6 shows the modules and its dimensions.
Following some adjustments to the MatLab programme in order to accommodate the new layout of
the structure, it was ready to run again. Now that the table was fixed at the floor, the displacements
felt at table level were reduced dramatically to 8 mm. This is now a much more acceptable distance.
If an equivalent sized table which is now supported by four legs (i.e. a normal table) is given the same
impulse force, it will displace by up 1000 mm, assuming that the table in on a level polished wooden
floor. Also from the programme it is clear that stress felt within the bottom module, when a worst
case scenario point load is applied to the edge of the table, is well below the yield stress of mild steel.
In fact it has a factor of safety of 10. The bottom module was chosen to model as it is under the
greatest load, and therefore would be the first to fail.
23
Detail Design
6.3.1 Assembly
To reach the desired height of the restaurant the modules can be stacked from the floor one of top of
another. Each module has eight 10mm diameter holes on its top and bottom plates. These are to
accommodate the M10 bolts that are used to fasten each module together, as shown in figure 6.7.
By using eight of these bolts, the amount of shear stress felt by each individual is reduced when the
system is under torsion. Furthermore in the bottom of figure 6.7 it is possible to make out the Lbrackets that are used to connect the dispensing system to the structure. As the dispensing system is
spread out over four plates and four L-brackets are used per plate, a total of 16 of these brackets are
fastened to the module that will house the dispensing system.
To fasten the table top to the module, a 3mm thick support plate with eight 10 mm diameter hole in
the same location as that of the modules, as well as having 12 smaller holes around its circumference,
asused.Thisplateisthe sa d i hed et ee t o odules efo etheeightM oltsa eput
into place. The table top can then be placed over the top module and secured to the support plate
using screws which pass through the 12 smaller holes. Figure 6.8 an exploded view while figure 6.9
shows it assembled.
24
It is obvious that the height of the modules are most likely not going to fit evenly into the height of
the ceiling of the restaurant, and therefore a method was needed to deal with this. The solution was
to use 10 mm diameter rods attached to standard adjustable floor flange fixings. These would be
fastened to the ceiling of the restaurant using four screws and four plugs. The flange can then be
adjusted to accommodate the 10 mm diameter rods. As these rods have the same diameter as the
holes in the top of the modules, they slide right through. Figures 6.10 and 6.11 show this.
These rods not only offer a small amount of additional support, but they act as guide rods to aid in the
installation of the modules.
6.3.2 Aesthetics
Although the dispensers are no longer hanging from the ceiling, the dramatic appearance does not
have to be compromised. It was decided to use standard column cases to coat the structure. These
not only have a beautiful finish which attracts the eye, but also have the added benefit that they are
very easy to install and remove. This makes getting at the working parts for maintenance much less
complex. On top of this they are also finished in an array of different coatings which means that
restaurants can select a style to fit to their needs.
These column cases are fastened to the structure with the use of four T-brackets above the table and
two below the table with an additional two L-brackets. The L-brackets are only used because the
bottom module is sitting on the floor of the restaurant and therefore there is no room for the T to
extend downwards. After the T and L-brackets are aligned with the holes in the casing two M4 bolts
per bracket are used to secure the two together. Figure 6.12 shows these T-brackets whilst figure 6.13
shows the two M4 bolts in place. It is also important to note that the column case will extrude all the
way up to the ceiling, with the exception of a small cut out to allow the pipes to flow into the structure.
Hence the guide rods used to aid the installation process will be hidden. This creates a smooth change
from casing to ceiling.
25
26
27
Valve System
In order for the dispenser to operate, flow control of the individual beverage lines are required as this
dictates whether a drink is being poured. Therefore a control valve is needed on each line to activate
the flow when the beverage is requested and cease the flow once it has fully dispensed. This process
has to be automated without any physical input form the user.
7.1.1
Design Concepts
Figure 7.12: The valve configuration when (a) the linear actuator is at rest and (b) when the linear actuator is
activated
28
plunger is depressed, stopping the flow of the beverage in the line. However when the actuator
activates the plunger rises, allowing flow of the beverage.
This configuration poses some issues:
Regarding the first point, the total height was approximately 0.4m (Amazon Supply, 2015) (Linak,
2015). As this is quite large, installation will pose an issue as it would be difficult to reach so far within
the hollow section, especially with tools. The square section could not have an access panel cut out of
it as it would compromise its structural integrity, so if the valves were installed maintenance would
still pose a concern.
Secondly the speed and response times of the actuator were quite slow, typically in the range of
17mm/s. This speed is susceptible to change as the pressure in the pipe will always fluctuate which
would have an influence on this. This is not ideal as the amount of time the valve is open will require
calibration to take this into account.
Lastly the cost for this valve assembly was approximately 177 (RS, 2015) and since there are ten of
these per dispenser, the cost will rise considerably. It is clear that that the configuration may also be
vulnerable to mechanical failure as there are moving parts which could fail within the dispenser.
7.1.1.2 Solenoid Valve System
An improvement on the previous idea was to use an array of solenoid valves. These are essentially the
above configuration engineered into one device however instead of a linear actuator moving a
plunger, a solenoid will energize resulting in the movement of a diaphragm which would then allow
flow. This is shown in figure 7.2 (Refrigeration Blogspot, 2015).
In order to fit ten valves into the dispenser, they would have to be mounted on a tiered structure and
be raised into the dispenser from below. Each tier would have to be 0.15m x 0.15m to fit within the
dispenser body. Since the chosen valves have dimensions 0.025m x 0.02m, four will easily fit in the
desired area and so three tiers would be sufficient for ten. The structure would then be secured into
place.
29
The MOPD is the difference between inlet pressure and outlet pressure of the nozzle, as shown in
equation (7.1)
=
(7.1)
MOPD (kPa)
15.8
The flow factor, usually denoted in metric terms by Kv, is used to compare the capacity of different
valves in order to specify the correct one for use in a system. This is because the flow factor correlates
to the flow rate within the valve; it is defined as the flow rate in m3/h of water at 16o Celsius with a
pressure drop across the valve of 1 bar. (Valvias, 2015) The flow factor is calculated using equation
(7.2)
=
(7.2)
Where Kv is the flow factor in m3/h, is the flow rate of the beverage in m3/h, SG is the specific gravity
of the beverage and is the pressure drop across the valve in bar. It is clear that for a constant flow
rate, the pressure drop across the valve, , will be lower for a higher flow factor, Kv. The equation
also suggests that if the pressure drop across the valve is 1 bar, then the flow factor, Kv will just equal
the flow rate of the water, .
For the dispenser the pressure drop is 0.158 bar (15.8 kPa) and the flow rate is 0.204574 m3/h
(5.6826E-5 m3/s) for soft drinks and beer and 0.184115 m3/h (5.1143E-5 m3/s) for wine. These flow
rates were decided in the initial stage of the design process as they delivered the beverage to the
customer in an acceptable time. The specific gravity or all beverages are assumed to be the same as
that for water, which is simply 1. Using equation (7.2), the flow factor can be calculated and the results
are shown in table 7.2 with the other properties for each type of beverage.
Thepipi gusedth oughoutthes ste issta da d
/ dia ete PVCpipi ga dideall this
would be the orifice diameter for the chosen solenoid valve. In addition to this, solenoid valves
commonly are made from brass, stainless steel or plastic. Brass is an unacceptable material for use in
this design as it is not food safe and cannot be used for transporting beverages. Stainless steel and
certain plastic valves are suitable for this purpose, however the stainless steel has to be grade 304 or
30
higher to prevent contaminating the red or white wines. Lower grade stainless steels contain too much
sulphur which would taint the wine. (Micromatic, 2015)
Soft Drink
1.77
1.01
0.518
0.204574
0.5086
Beer
1.77
1.01
0.518
0.204574
0.5086
Wine
1.77
1.01
0.518
0.184115
0.4577
The solenoid valve chosen is a type 6011 2/2 way miniature solenoid valve (Burkett, 2015) shown in
figure 7.3 and its operating specification is shown in table 7.3. It can be seen that the valve possesses
a greater maximum flow factor than any of the types of beverage listed in table 7.2 and the valve can
operate at a pressure higher than used in the dispenser. This particular solenoid valve is known as a
o all losed NC al e ea i gthatthe al eis losed he thesole oid al eis ote e gised.
Maximum MOPD (bar)
Maximum Flow factor (m3/h)
Port/pipe diameter (mm)
Material
Dispenser Properties
0.158
0.20
10
Plastic or stainless steel
It is clear that this valve meets the required specifications, however the port diameter for this
particular valve is significantly less. The piping used throughout the system has an internal diameter
of 10mm and therefore they will not fit into the valve. A larger valve could be used but the cost of
each one would severely increase the materials cost for a single dispenser; this is further discussed in
section 7.1.4. It is necessary for the piping diameter to change in the dispenser either at the entrance
to the valve or beforehand and use fixed piping of the correct diameter. It was decided that mounting
fixed piping into the valves would be the optimal solution as the entire valve assembly can be treated
as a single component with the 10mm piping entering and leaving it. This is elaborated in section
7.1.2.2.
7.1.2.2 Fixed Piping and Relevant Connectors
In order for the chosen valves to work with the current design, narrower pipe diameters were
required. In order to treat the whole assembly of 10 solenoid valves as one component, fixed piping
of the correct diameter would be installed into the inlet and outlet of each valve. This allows for the
10mm trunking to pass through the top of the dispenser, and have each line connect to the fixed
piping in the valve system. The end of the valve system would then have a similar arrangement where
the fixed piping would adapt back to the 10mm used throughout the dispenser.
The chosen piping diameter for the valves was chosen to be 3mm and the piping would be made from
flexible PVC which is suitable for food use. This type of piping is already standard for current bar
systems as it is the same piping that are used in soft drink soda guns. In order to implement these
pipes, two connectors are needed: a connector to fit the pipe into the valve, and an adapter to reduce
the working pipe diameter from 10mm to 3mm. Both of these components have to be made out of
stainless steel to avoid any wine contamination.
31
Figure 7.4 shows the end fitting which will connect the 3mm piping into the valve port. It is made of
stainless steel grade 316 so it is acceptable for use in the design. The threaded end would simply
tighten into the valve and the barbed end would be pushed into the 3mm piping. A pipe clamp would
be used to secure the fitting into place.
An adapter to reduce the pipe diameter is also used to connect the valve and piping assembly to the
dispenser system. The component is shown in figure 7.5. It can be seen that the 10mm piping will
enter the adapter and tighten into place, and the 3mm piping will slot over the narrow extrusion
before being clamped. Both of these components allow the control valve system to simply slot into
the current dispenser design without any modification to it.
32
The structure is fabricated from 3mm mild steel sheets and uses 10mm steel threaded rods with
locking nuts to separate each tier by 100mm. There is a rectangular hole, which is 80x50mm, in each
tier and this allows the fixed piping to run through the support structure from the top towards the
usto e sglass.Thehole illalsoallo a ele t i al i estopasstolo e tie ed al esf o the
microcontroller situated near the top of the dispenser. Each tier has four 5mm holes drilled into
opposite sides. The dispenser frame will have L brackets with 5mm holes drilled into them welded
along it. This allows the structure to be mounted into the dispenser using M5 bolts and locking nuts.
The base of each solenoid valve is flat and so it the base of the support structure. In order to mount
the valves securely to the support structure, heavy duty adhesive felt pads can be cut to size and
applied between the valve base and the structure. The shear force between the valves and the base
of the structure was minimal and these pads can withstand up to 445N of shear force before failing,
therefore they would be able to hold the solenoid valves firmly in place. Figure 7.8 shows the full valve
system with the 3mm piping entering and exiting each valve shown in red. It is clear that each 3mm
beverage line will pass through a single valve before passing through the remaining tiers to the end of
the valve system.
7.1.2.4 Check Valve
In an ideal situation, the beverage would directly leave the valve and enter the nozzle so it can be
dispensed. However due to some valves being positioned at most 30mm away, there would be
stagnant fluid in the piping between the valve outlet and the nozzle inlet. This could potentially lead
to the beverage trickling out of the nozzle into the drip tray. This must be avoided as a leaking
dispenser might spoil the customer experience. In order to prevent this, a small plastic check valve
was installed in the piping system just before the nozzle inlet. The aim of this is to hold back any
33
stagnant fluid until the beverage is requested. This essentially works as a diaphragm which only opens
when a certain pressure is reached.
To specify the check valve required, the stagnant fluid can be modelled as a tower supported by the
check valve. Equation (7.3) calculates the pressure the fluid will apply on the check valve.
=
(7.3)
Where is the pressure difference in Pa, is the density of the beverage kg/m3, is the acceleration
due to gravity in m/s2 and is the change in height in m. Taking the datum to be level with the check
valve and the density to be 1000 kg/m3, the pressure due to the stagnant fluid can be calculated as
2.943kPa. When the fluid flow is activated, the pressure due to the fluid above the check valve will be
114.5kPa. Therefore a check valve is required that possesses an opening pressure greater than
2.943kPa but less than 114.5kPa. The check valve specified for this purpose has an opening pressure
between 20-30kPa. This is ideal for use in the dispenser design.
7.1.3 Design for Manufacture and Sustainability
For the valve system, most of the components are standard parts that do not require manufacturing
and can be bought from a retailer. The only components which are manufactured are the steel plates
and rods which make the valve support structure.
The 3mm thick 150x150mm steel plates are manufactured from a larger 180x180mm plate. A 5x5mm
square will be cut from each corner and the edges will fold down forming a single tier. A diagram of
this is shown in figure 7.9. The cross hatching indicates a region to be cut out and the dotted line
indicates a fold. A more detailed drawing of the steel tier is found in appendix 2.
The threaded rods will fit into the four holes in each corner of the plate and two locking nuts on either
side of the plate will secure it into place. The thread rod can be bought and cut to size as required.
34
Nozzle Assembly
O e the flo has passed th ough the al e, it has to e di e ted i to the usto e s glass. This
requires a set of nozzles for soft drinks, lagers and wines to be mounted securely onto the frame of
the dispenser. It is a requirement that alcoholic drinks avoid contact with one another to avoid
contamination and so each alcoholic beverage line will be independent of each other. It is also
necessary that a dispensed lager should generate 1- 2cm of head after a pint has been delivered.
7.2.1
Design Concepts
35
Figure 7.21: A diffuser used in current soda guns. This has been removed using an
appropriate solvent.
It was decided that designing and manufacturing a new soft drink nozzle would be the best step
forward. The nozzle would need to have:
Figure 7.11 shows an initial sketch of the design concept and how a 10mm pipe section may clamp on
to the nozzle. Section 7.2.2.1 details the development of the design.
36
beer will not be released and the pint does not look as appetising. Too much head and the customer
will be unsatisfied with not receiving a full pint.
Quantifying this pe fe t pi t was important so that the nozzle could be designed to this specification.
The opinion on how much head a pint should have varies between different parts of the world but
since the design is aimed at the English market we went with what a typical good English pint would
look like. Our perfect pint would have 1.5cm of head. This would vary slightly depending on what beer
is being dispensed as different beers react slightly differently and some will fizz slightly more creating
a little more head than others. The universally agreed way to pour a perfect pint is to angle the glass
at a 45-degree angle (Carlsberg Ltd, 2015) and then pour in the beer aiming for halfway down the
glass. While the beer is being poured in, the glass is slowly straightened up until vertical so the flow
would stop hitting the side of the glass and enter straight into the beer already in the glass to prevent
too much head building up.
To decide the way to design the nozzle so that the best possible pint was consistently achieved in a
cost effective way, several design concepts were drawn up and the best design was chosen using a
Pugh matrix, shown in table 7.4. A description of each criteria is included in appendix 7.1. Each design
was scored against certain parameters:
How much head would be produced
Space efficiency. It was vital to keep the design small so that the dispenser would not become
a bulky piece of equipment in the middle of the table
Cost
Perfect Pint
Space Efficient
Cost
TOTAL
Angled Nozzle
1
2
1
4
Rotating Base
1
4
3
8
Widget Design
1
2
2
5
Lowered Nozzle
2
3
3
8
Table 7.7: Pugh matrix of different design concepts for the alcoholic nozzle
The first concept included the nozzle being mounted at an angle so the flow of lager would come out
at an angle and hit the side of the glass halfway down creating head. As the glass fills up the flow
would go straight into the already dispensed beer preventing too much head from build-up. This is
shown in figure 7.12.
The second concept design includes a motor-driven rotatable base so the glass could be set an angle
to begin with. The flow would hit the side of the glass and as the glass fills up the glass could be rotated
to a vertical position much like a bartender would do manually when dispensing a pint. This design
would take up a lot of space as there would need to be space for a little motor and space for the
Figure 7.1232: An alcoholic nozzle design concept showing the nozzle mounted at an
angle
37
rotating base to rotate in. The complexity of this design also meant to would be more expensive than
other options. This concept is shown in figure 7.13.
Figure 7.13: The second concept showing the glass on a rotating tray
The third design includes a little widget place under the pint glass. The pint glass would be placed on
top of this widget angling the glass so again the flow would hit the side of the glass. As the glass fills
up it becomes heavier so when it reached a certain weight with the glass half-full it would be heavy
enough to overcome the force of the spring pushing the widget up and the widget would be pushed
down lowering the glass to a vertical position. A second part of the widget would then push the glass
out in a sideways direction to keep the glass placed under the nozzle. This design would work very
well, but the widget and spring would have to be manufactured accurately and to very small tolerances
to make sure the system would work. This drove the cost of this design up. Figure 7.14 highlights this
concept. Figure 7.15 shows the operation of this, where the red arrows show the forces acting
between the glass and widget.
38
The final design included a movable nozzle that could be lowered down into the glass so that the beer
could be dispensed vertically. At first the beer would hit the bottom of the glass creating head then as
the glass filled up the nozzle would be down under the beer so the newly dispensed beer would be
dispensed under the fluid. When it is dispensed in this fashion no more head is created so you would
not get a glass only full of head. This design is slightly more unpredictable to the amount of head
created may vary slightly and is also more costly and needs more space as a motor is needed to drive
the nozzle up and down. This design concept is shown in figure 7.16.
39
The angle at which the nozzle was set was calculated using equations (7.4) and (7.5)
=
s = ut +
(7.4)
(7.5)
40
Using these equations it was calculated that the nozzle should to be inclined at an angle of 70 to the
vertical. This would result in the flow hitting the glass halfway down at an angle of 36.3 to the glass.
This is not the ideal angle of 45. The reason for this is that it is more important that the flow hits
halfway down the glass so that was prioritised. This is because it is important that the flow stops hitting
directly onto the glass and enters straight into the fluid within the glass halfway through pouring so
that no more head is created from this point onwards. The fact that the flow does not hit at a 45
angle has less of an effect on the head produced. The effect of a change in angle was measured in an
experiment where several pints were dispensed into glasses set at different angles to record the
differences in head. The results are presented in Table 7.5.
Angle (o)
30
35
40
45
50
55
60
Head (cm)
1.2
1.2
1.3
1.3
1.3
1.4
1.5
Head (cm)
0.1
0.1
0.0
0
0.0
0.1
0.2
The results show that decreasing the angle of the flow to the glass only has a small effect on head
produced with 0.1cm difference. This was judged to be acceptable.
The angle the trajectory of fluid makes with the glass could have been increased by increasing the
velocity of the fluid. The flow rate would have to be greatly increased for the desired result. This in
itself would create the problem of the fluid striking the glass at a much higher velocity meaning the
that the beer would fizz a lot more thereby creating a lot more head than would be desired.
Another option was to further increase the angle of the nozzle. With an angle of 70 the nozzle will be
situated 7.52cm from the side of the glass and increasing the angle further will mean the nozzle will
have to be situated outside the rim of the glass. This opened up two issues. The first is that the flow
would be in danger of hitting the outside of the glass on its path to the middle of the opposite side of
the glass. The other issue is when the first and last bit of lager is dispensed it does not follow the full
trajectory that the constant flow would follow. There is a little bit of liquid that will not flow as far as
the constant flow trajectory meaning it would miss the glass. Therefore, the nozzle had to be kept
within the boundaries of the glass rim.
7.2.2.3 Mounting Plate
The mounting plate is used to secure the valves into place so they are angled correctly, which is
important to generate the correct amount of head from a dispensed lager. It is also a method of
attaching the nozzle assembly to the frame of the dispenser. The dimensions of the mounting plate
are similar to that of the valve support plate being 150x150mm and 3mm thick. There are also four
5mm holes drilled into opposite sides of the plate in order to secure the assembly to the dispenser
frame using four M5 bolts and locking nuts.
41
The main difference is that the nozzle plate features five large bores which will be used to hold the
two types of nozzle. This is shown in figure 7.20.
Figure 7.29: The nozzle mounting plate. It contains four bores for alcoholic beverages and one central bore
for soft drinks
Each bore contains an indentation which accommodates the pins on each nozzle and locks them into
pla e.This e ha is isk o asa t ista dlo k s ste ,a dis o
o l fou di household
appliances such as food processors. A closer view of the twist and lock indent for the soft drink nozzle
is shown in figure 7.21.
Each pin on the each nozzle is 2mm in diameter and in length, and the depth of the indentation is
3mm, allowing for a comfortable fit. The soda drink nozzle has three equally spaced pins around its
circumference and so the corresponding bore on the nozzle plate has three indentations. The alcoholic
drink nozzles only have two pins around its circumference, each 180o apart. It follows that the four
bores for this nozzle type only have two indentations. Figure 7.22 shows the mounting plate with all
five nozzles locked into place.
42
All three designs possess complex geometries. This is because the base plate contains fine
indentations and the nozzles contain a cavity.
The material cost for plastic instead of metal is considerably cheaper.
Replacement parts are readily available as they can be moulded easily and quickly.
The nozzle has to be made from a food safe material which can be easily shaped. It was decided to
use a plastic such as polyethylene terephthalate (PET) to manufacture the nozzle as it is completely
food safe. Since the nozzle design possesses a complex geometry, due to the cavity present within it,
they can only be manufactured by plastic injection moulding.
It is worth noting that other manufacturing options were considered such as 3D printing the
components, but this could not be used as there will always be small voids where bacteria can thrive.
Due to the ease and cost of the manufacturing process, if any of these components fail, a replacement
can be ordered and delivered immediately.
7.2.4 Commercial Considerations
The cost of plastic injection moulding these components is relatively minor compared to the overall
materials cost. This can be seen in appendix 11 and the cost per unit is given in table 7.6. However, in
order to generate these components using plastic injection, a tool is required to be manufactured.
The price for each is considerably high, but since it is only a single cost which will benefit the company
in the long run, it was deemed acceptable. The quotes for the individual tooling costs are shown in
appendices 12.2, 12.3 and 12.4, however they are summarised in table 7.7 The reason for the cost of
each tool is due to the complexity of each component; the nozzles each have a cavity running through
them and the mounting plate has to have the correct indentations for the twist and lock mechanism
to operate.
43
Component
Soft drink nozzle
Alcoholic drink nozzle
Nozzle mounting plate
Cost (/unit)
1.60
1.44
4.59
Table 7.9: Cost per component of each item in the nozzle assembly to be plastic injection moulded
Cost ()
4301
3114
7418
Table 7.10: Cost to create the tool required to plastic injection mould each component
Diagram Index
Component
1
10mm to 3mm pipe adapter
2
3mm piping
3
Pipe to valve connector
4
Solenoid valve
5
10mm piping
6
Check valve
7
Nozzle (soft drink)
Figure 7.32: An exploded view of each component within the dispenser for a single beverage line
There is a requirement for passing the beverages back to 10mm piping once it has passed through the
solenoid valve. This is because the nozzle will only accept 10mm pipes and also if the lager were to be
dispensed through a 3mm pipe, its velocity would be very high resulting in it being very frothy. This
would certainly dissatisfy the customer.
44
Easy to use
Robust
Touch
screen
Functions
Accessible
by all
Payment
Cash/card
Order
recording
Secure
registered
payment
Cost effective
Drinks
control
Food
ordering
Extras
Entertainment
The control device also had to withstand the regular customer use and any spillages you might expect
within a restaurant environment. Several concepts for the type of docking system were established as
shown in figure 8.2.
(a)
(b)
(c)
The table top design in figure 8.2a is a touchscreen device embedded and situated flush within the
table top. The design had to withstand heat contact as well as having a toughened glass touch screen.
It therefore consisted of an open-frame industrial screen or tablet, typically found in retail advertising
and kiosk housing, such as that shown in figure 8.3. (Axiomtek, 2015) These are robust and can easily
be embedded in the table top either using the open frame mount or the VESA connection. Whilst the
design concept results in a striking appearance, these are very high performance computers, due to
their typical application, and were found to not be cost effective.
45
The second concept consists of a hand held tablet, which can be positioned on a stand, as shown in
Figure 8.2b or housed and wired to a power supply. There are several types of fixed housing for
commercial tablets specifically design for retail/ kiosk environments, such as that in figure 8.4
(Bouncepad, 2015), which is housing an iPad. This includes a durable casing, wiring through the centre
and a lock so the tablet is secure. The housing typically costs around 250, which is of a similar figure
to a consumer based tablet itself.
Finally, the concept in figure 8.2c consists of a tablet wired and housed on a docking rail from the
drinks dispenser. Commercial based tablets can include VESA mounts which could be used to mount
each tablet to the rail, however they often have a much larger screen size. There are different types
of standard screen wall mounts available for the tablet; but the rail design would have had to be
adapted to be compatible to enable this attachment.
A Pugh matrix, in table 8.1, evaluates the design concepts against these criteria.
Criteria
Weight
Table top
Bar Docked
Hand Held
Tablet
3
Unobtrusive size/
design
Accessible position
Ease of installation
Cost effective
Aesthetics
Robust
Power accessible
Total
10
8
7
10
8
7
6
4
1
1
4
4
3
167
4
4
3
3
3
4
189
2
2
3
2
3
2
139
It can be seen that the hand held device is the best solution for meeting the design criteria.
46
Design development
8.2.1 Control operation
The solenoid valves require an electrical excitation to be activated. This needs to be controlled in
o ju tio iththe usto e ssele tio ;the efo eas it h/digitallogi s ste as e ui ed.
A microcontroller would enable the processing of information from the customer input, and translate
this to a logic output to activate the valves. This user input would be via touch screen control. The
order needs to be sent both to the server for processing, as well as to the microcontroller in order to
control the dispenser. The order needs to be billed before the drink is dispensed, to ensure that there
is a reliable recording. Figure 8.5 shows that upon ordering, the tablet will send the order to the server.
The server will then send a digital logic signal to a microcontroller, found within each dispenser.
The solenoid valves for each pipe line are activated under an excitation current. Each valve is
connected to an output pin on the microcontroller. When the microcontroller receives a signal from
an order, the microcontroller outputs logic high on a corresponding output pin. The connecting valve
will be activated and opened.
Tablet
Order
Server
Feedback
Digital
logic
Microcontroller
Continuous check for
serial logic from server
Relay/
Transistor
12V, 2A
Valve
A typical digital logic output pin supplies tens of milliamps of current. The solenoid valves required
V a ti atio t pi alfo sole oid al es . The efo e if the output of the i o o t olle is t
sufficient it cannot activate the valves alone, therefore there are several cases that need to be
considered:
47
Tablet Microcontroller
Tablet Main server
Main server microcontroller
The communication methods need to be able to transfer the data at the correct speed. For drink
orders the data will include the table reference and which drink has been requested. There are 10
drinks options available and up to 21 tables. This requires 16-bits with bits 0-3 referencing the drink
and 4-10 referencing the table. The food orders depend on the number of options available, the
number of people at each party, and whether the restaurant offers side and customisation options. A
typical restaurant, from research, has a total of over 40 different options from starter to desert. The
maximum party size for our restaurant is 12. This will result in around 80bits of data per food order.
There are several options for communication. With the distance required to travel being the length of
a restaurant, all of the following meet this criteria.
Equally the server needs to make connection to up to 21 Tablets and 21 microcontrollers. Cable
connections are the most reliable and secure, with wireless connections sometimes being
u p edi ta le. The desig e ui es o
u i atio ith a ta let. ta let t pi all does t ha e
connections for data or Ethernet cables, but often has wireless capabilities. A server can permit both
wireless and cable connections, typically connecting up to hundreds of devices. A microcontroller can
be used in conjunction with additional modules to facilitate these connections, such as
ZigBee wireless module. Given the restraints of the tablet connections, the most practical option is
to communicate over Wi-Fi. This provides a high speed connection. The server selected runs a
windows server operating system which enables a wireless connection to both the tablet and
microcontroller, and it has an enough capacity to serve a small business.
8.2.3 Tablet
Following the chosen concept it needed to be determined whether the device was to be housed and
therefore wired at all times or a cable free battery powered device. The typical working hours of a
restaurant are 11am until 10pm, totalling 11hours1. Typically these tablets have a battery life of a
maximum of 8-10 hours (Tabletmonkeys, 2015), which, despite only performing low performance
functions, will diminish over time, particularly with continuous usage. This would result in the need
for these tablets to be replaced frequently over time.
Alternatively, there are specific retail and kiosk designed tablets which have a larger battery life,
extending 20hours. These also have detachable batteries for easy charging. This would mean the
tablet is portable and cable free. A Pugh matrix was populated to determine the best tablet to meet
required memory, processing speed, aesthetics and cost for both a customer based and retail tablets,
as shown in table 8.2. The cost took into account additional costs required for table mounting and
battery replacement where appropriate.
48
Criteria
Robust
Battery capacity
Stand/case
compatible
Sleek
all,<
Expansion
Cost effective
Wifi
Memory
Processing speed
MTBF
TOTAL:
Weight
3
4
1
4
4
3
3
2
249
4
4
3
3
4
3
2
2
272
4
4
2
4
4
2
2
2
268
This resulted in the battery powered tablet being the most suitable solution. The tablet includes a
removable external battery pack and charger, in addition to the internal battery.
Tabletkiosk runs a windows operating system, making it easy to implement a windows overlay
interface. It has a 1.6GHz Intel Atom processer and 64gb solid state flash drive, which makes it a high
performing tablet computer and is therefore able to run any operating software at a fast response
rate.
8.2.4 User Interface and software
It is essential that the dispenser is easy to use by all age groups with different abilities. In light of this
a simple and clear interface is required. Whilst the interface would be customisable to fit with
restaurant branding needs, a simple generic interface design was produced as an outline to
demonstrate how the customer would interact with the dispenser. This is shown in figure 8.7 and
includes clear selection buttons.
A flow map was developed to show the full operation processes, also including several control loops
which the Failure Mode and Error Analysis identified. This is shown in figure 8.8. Upon being seated
49
and after ID checks, staff can turn alcoholic drink options on or off accordingly. Under license, it is an
offence to allow alcohol to be sold to anyone who is heavily under the influence of alcohol, and
therefore restaurant staff must be able to monitor and refuse alcohol consumption (Gov, 2015).
Therefore within the user interface design, a notification is sent to a staff bar console once a prespecified number of alcoholic drinks have been ordered by any table. This will have to be confirmed
by a member of staff on the bar console before the customer can continue to order their alcoholic
drink at the dispenser.
Finally, the customer has to not only confirm their order, but also confirm that their glass is in place
and that they ready for the drink to be dispensed. This is there to avoid accidently orders and spillages,
and hence customer dissatisfaction under error. A future development for this would be to have
either a pressure or light sensor, such as a LDR (light dependant resistor), to detect that a glass has
been placed, thus further avoiding customer error.
The software package will include the aforementioned ordering interface as well as backend software.
This will operate to meet the requirements of typical existing restaurant management software. This
includes:
50
Menu alteration
PoS (Point of Sale)
Employee scheduler
Design detail
8.3.1 Control feedback
Once the valves are opened, and the drink is being dispensed, there needed to be a detection
mechanism for controlling how much fluid should be dispensed, in order to determine when flow
should terminate. Whilst the pressure regulator at the top of each dispenser should ensure that flow
rate is be fairly regular, slight variations would result in different volumes of fluid being released over
a set time. Hence a sensor was required to monitor the fluid dispensed. A flow sensor could be
positioned just before the valves to monitor flow rate of the fluid - the volume of fluid dispensed was
be calculated.
With a removable drip tray required in the base of the dispenser, installing and implementing a
pressure sensor beneath the glass would be difficult, hence a flow rate sensor, providing the same
result, was a more suitable solution. The flow sensor will monitor the flow, which will be read
continuously by the microcontroller. Once the desired amount of fluid dispensed has been reached
the microcontroller will operate a logic low, deactivating and hence closing the valve. This is shown in
figure 8.9.
Tablet
Order
Server
Digital
logic
Microcontroller
Continuous check for
serial logic from server
12V, 2A
Relay/
Transistor
Valve
Flow sensor
Figure 8.8: Control Operation with Feedback Loop
The flow sensor was required to fit a 10mm pipe diameter, needed to read a high accuracy of order
0.0568l/s (3.4 l/min) reading (1pint in 10seconds). This is in order to ensure that volume error is kept
to a minimum. It is also required to be manufactured from stainless steel grade 304 and above or of a
food-safe standard plastic. The flow metre needed to carry carbonated fluids. There are several
different types of flowmeters, but for the required specifications, particularly diametre and the type
of fluid, meant that either an electromagnetic or turbine flow metre were required. Sensors such as
ultrasonic sensors are effected by bubbles, and venturi flow sensors have a minimum diameter of
25mm (Engineering, 2015).
The selected flow sensor, the 300-010 Beverage meter, based on this criteria is specifically designed
for drinks dispensing units and suitable for dispensing wine and beer. It is a turbine based sensor and
has a reading range of 0.6-10l/min and an accuracy of 1% full scale deflection (TITAN ENTERPRISES
LTD, 2015). The sensor outputs a digital pulse at 235Hz which can be read by the microcontroller. The
output is a NPN signal, which refers to the transistor connection. The connection requires an pull-up
resistor when connected to a microcontroller.
51
The valves operate at a reaction time of 60ms. The dispenser is assumed to be operating at an average
of 0.0568l/s (1 pint in 10seconds). With the accuracy of the flowmetre taken into account results in a
deviation of 0.00167l/s. Therefore within this period the dispenser will have dispensed 3.5ml. This
is the tolerance the drinks dispenser.
8.3.2 Microcontroller and relay
There were several factors that were required from the microcontroller for our design. As discussed
previously, the output supply from the output pins needed to be considered. With 10 lines of drink,
10 GPIO pins are required to be connected to each corresponding valve. As discussed, in order to be
connected to the tablet and server, the microcontroller also was required to have a wireless
connection. This meant an additional shield, such as ZigBee or a similar RF product modules needed
to be considered. These are additional modules which allow microcontrollers to connect to a wireless
network. These were considered in the costs if the microcontroller alone was unable to provide
wireless connection. A ZigBee microchip costs around 15. The microcontroller is also required to
have a flash memory to record the flow at a frequency of 237Hz therefore requires a operating speed
greater to manage this data. The memory capacity only needs to store the measured flow rate
temporarily; therefore the memory required is small. Whilst the program to control the
i o o t olle has t ee oded,it o sistsofthefollo i gsteps:
The program is relatively simple but needs to be expandable for future developments. Therefore the
programmable memory needs to be sufficient.
A Pugh matrix in table 8.3 was populated against these weighted criteria, comparing several
microcontrollers, resulting in the Arduino Yun as the best solution for the design requirements.
Criteria
>10 GPIO
12V output
Light weight
Cost effective
Low power
Wifi capable
Processing speed
Flash Memory
Programmable memory
Total
Weight
10
5
4
10
7
9
8
5
6
LPC1200
4
1
4
3
4
1
4
3
3
193
ATXMEGA256A3B-AU
4
1
3
4
4
1
1
2
2
164
Arduino Yun
4
1
3
2
4
4
3
4
2
197
The Arduino Yun is the combination of two boards: the ATmega32u4 and the Wi-Fi module Atheros
AR9331, automatically connected via a bridge communication. It has a flash Memory of 16MB and
operates at a speed of 16MHz.
The output current on the Arduino Yun pin is 40mA, 5V. This corresponds to case 2 in section 8.2.1
therefore a relay board is required. A relay is required for each of the 10 valves. Relay boards are
found with 2, 4, 8, and 16 channels. A 16-channel relay board was sourced to be driven by the Arduino
52
Yun directly, driven by a 20mA 5V supply, preventing the need for a separate relay drive such as a
transistor array. This results in case 2a in section 8.2.1
Additionally, the Arduino Yun has an inbuilt pull-up resistor, meaning the flowmeter can be connected
directly.
8.3.3 Wiring
With numerous connections and different power supplies to a large number of dispensers, it was
important that the system was powered and connected in an efficient way. Figure 8.10 shows how
each part of system is connected and powered. There is a switch board which consists of a consumer
unit and a Mini Circuit Breaker (MCB) for each dispenser, in order to isolate each supply. All electronics
are low power DC therefore the MCB units are rated at a max of 6A 60V. They are Type B characteristic
which it offers instantaneous short circuit response level of 3-5 times the normal rated current, making
it suitable for circuits with moderate inrush currents most domestic/small building protection
applications. The relay board is not connected to the MCB units, as without supply through the main
i uit,thuse e gisi gthe oils it h,the ela is t o e tedto ai ssuppl .Gi e thedispe se
casing is made of metal, a ground wire has been included to ground the system. A full wiring diagram
can be found in the appendix 8.
As with the pipe work to supply the drinks to the dispensers, the length of the power lines to each
dispenser will result in substantial voltage drops across the length of the wire due to the resistance.
As identified in our FMEA, this poses a potential risk - if the cable is far too small, the cable can
overheat. Undersized cables also waste energy. Equally as it is not cost effective to use cables which
53
are too large, as copper is an expensive metal. Typically, it is advised to have a maximum of 3% voltage
drop across a line (EC&M, 2015). There are three sets of wiring required: 50mA 5V; 2A, 12V and a
100mA 24V to power the microcontroller, solenoid valves, and flow meter respectively. Assuming a
3% voltage drop, the required resistance of the wire was calculated using equation (8.1):
Where
(8.1)
is the wire resistance. Taking the resistivity,
of the copper to be 1.68 x10-8 the cross section area, A for each length of wire, L can be calculated
using equation (8.2):
(8.2)
=
Assuming a maximum line of 20m, for this length yielded the following results, in table 8.4.
Supply
50mA 5V
2A 12 V
100mA 24V
Area mm2
0.11
1.87
0.047
Tinned copper is used to increase the lifespan of copper, in high humidity or high temperature
environments. It is also used in soldering applications. However it is considerably more expensive.
Therefore the wiring connections contained within the dispenser body, connecting the flow sensor,
relays and valves will be made of tinned copper. Similarly the correct wire cross section was calculated.
All the electronics will be pre-manufactured and connected inside the main valve module. There will
be power connections free at the top of these pre-manufactured modules ready to be attached to
power supplies during installation. This is to make installation as efficient as possible.
54
9 Installation (Martin)
When deciding how best to install the drinks dispensing system there were many factors that needed
to be taken into account.
A process was gone through to find out exactly what tasks need to be completed to install a dispenser
and how long they each take. Table 9.1 shows the different tasks, how long they take and how many
people would be employed to do each.
Task
Time (hours)
Numbers of workers
needed
Dependency on
1 hour
None
Structures
1 per dispenser
None
Fit Pipes
Pipes
Electrical Work
Fit
Set up Tablet
Electrical Work
The structures consist of the under-table support, table and dispenser structure. They would be
installed using the following method.
The first module would be fastened to the floor support and both attached to the floor of the
restaurant. On top of this module the table support is sandwiched between the first and another
module. Eight M10 bolts secure these three components. After this the four flanges are fastened to
the ceiling along with the four guide rods to aid in the installation of the top modules. However before
the last module can be put into place the table top has to be passed over the second module and then
slide down until it sits on top of the table support. The twelve 38mm wood screws are then used to
fix the table top in place. Once this has been completed the last module can be fastened to the rest of
the structure. The casing can then be attached using two M4 bolts per bracket to secure it. The final
part to be put in place is the drip tray. As this is removable for cleaning it can be installed at any time.
For the restaurant, it is vital that the installation is completed as quickly as possible. Each day the
restaurant is closed they lose business, and since large restaurants turnover over 4,300 a day then
that is big loss for them. For this reason, we decided to employ more people to work at once rather
than a fewer people over a longer period of time, so we will have two teams working on the structures
at once and employ two electricians at once to do the electrical work as this will half the time it takes
to complete these two tasks. In total it was managed to cut the installation time down from 5 days to
3.
The installation schedule for a typical large restaurant installation is shown in table 9.2. First some of
the existing pipework in the cellar will need to be removed to make space for our pipework. Since
there is not very much existing pipework this is a very quick job. The first thing to be fitted in the
restaurant is the dispenser structures. This is because the positions of these cannot be changed once
the system is in place. Therefore, it is vital to make sure the tables are in the right positions with
enough space around them for chairs etc. Installing all the structural parts will take one day. Once the
dispensers are in place, the pipework can be fitted from the cellar out to all the dispensers. The next
job is to fit out the dispensers and connect the pipes leading out from the cellar to the dispensers.
Along with this the electrical connections need to be put in place. The server also need to be installed,
this will usually be situated in the bar area or in the cellar. Finally the tablets need to be setup and
55
synced with the server so the ordering system works. All the valves can then be opened and the drinks
will be ready to be dispensed.
Day 1
1
Day 2
7
1
0
1
1
1
2
1
3
1
4
1
5
1
6
Day 3
1
7
1
8
1
9
2
0
2
1
2
2
2
3
2
4
2
5
2
6
2
7
2
8
2
9
3
0
Unload Truck
Clear Pipework
Structures
Fit Pipes
Fit out Dispensers
Electrical Installation
Tablets
Table 9.2: Installation Schedule
56
Time [min]
3
~ 20
2
~ 20
2
~ 17
2
~12
2
~ 12
1
3
Using this table, a timesheet can be made for a certain number of waiters to serve 21 tables with no
double bookings. This sheet can be found in the appendix 14. It shows that three waiters will be
sufficient for a restaurant of this size. An average restaurant of 21 tables will have seven waiting staff,
so the wages of four staff members will be saved. This equates to an increase in profitability of 48,000
a year, or 4,000 a month.
The second means by which the dispenser increases profitability is by increasing drink sales. Drinks
account for around 35% of the ave age estau a t stu o e .The a ealsosoldata e highp ofit
margin, with beer sold at around 500% of cost price and soft drinks around 1000% of cost price. Wine
is less than this, usually around 170%. It is worth noting that this is aimed at lower quality wines as a
customer might expect higher-class wines to come from a bottle. Typical mark-ups increase as the
cost of the wine increases, so while many wines are sold at as high as a 300% mark-up, this would
probably be too high for the type of wine served through the dispensers. Assuming that soft drinks
make up 50% of drinks sales, and wine and beer 25% each, the average profit from drink turnover is
74.7%. The Wagamama chain makes 129,575 per month in turnover from each of its 110 seat
restaurants. Of this, 35% will be from drinks. Table Tap, a company that produces a similar product
57
which pumps beer up into a tap onto each table, claim that their product increases drinks sales by
10%. Using these numbers, the total profit provided from extra drinks can be worked out:
(10.1)
Therefore, the total monthly profit generated by our dispensers is 7,389.49. These calculations are
shown in full in table 10.2.
Task
Restaurant Closure time (months)
Number of customers / month
Annual Waiter Salary
Number of Waiters Laid Off
Turnover / restaurant / month
Time [min]
0.1
40000
12,000.00
4
129,575.00
450%
1000%
170%
41%
77%
90%
4,535.13
75%
3,389.49
62,957.50
7,389.49
50,000.00
20%
5,911.59
Payback /months
Total Loss Due to Setup
10.65
62,957.50
Table 10.2: Value added for the Restaurant
Cost of Production
Secondly, it is necessary to ascertain the cost of the product to manufacture and install, as well as
company running costs. The costs can be divided into five main areas:
1.
2.
3.
4.
5.
Office/Warehouse
Site
Maintenance
Materials
Transport
The office and warehouse costs will be a monthly expenditure, whereas the rest will depend on how
many dispensers are installed. The site costisthe ostofla ou o the lie t ssitefo thei stallatio
process, the maintenance cost is the cost of replacing the components with a shorter warranty than
the dispenser lifetime, the materials cost is simply the cost of all materials and components used, and
58
the transport cost is the cost of hiring a large van for a day to carry these materials to the site. Table
10.3 shows the total cost of these areas.
Cost per restaurant
Office/ Warehouse
Site
Maintenance
Materials
Transport
Total
2,097.40
6,159.68
70,750.39
275.00
79,282.47
Monthly cost
17,587.00
17,587.00
A full breakdown of these costs can be found in the appendix 11. On top of these there will also be
initial start-up costs. These are the purchase of the software for the tablets, enough materials to cover
an unexpected jump in demand as well as office supplies like computers and furniture. All of this
amounts to a setup cost of 96,183.39.
10.2.1 Location Strategy
Bei gi the ightlo atio isake i g edie ti a usi ess'ssu ess.Ifa o pa sele tsthe o g
location, it may have adequate access to customers, workers, transportation, materials, and so on.
Consequently, location often plays a significant role in a company's profit and overall success. A
location strategy is a plan for obtaining the optimal location for a company by identifying company
needs and objectives, and searching for locations with offerings that are compatible with these needs
and objectives. Generally, this means the firm will attempt to maximize opportunity while minimizing
ostsa d isks. (Business, 2015)
It was decided that the main factors needing to be optimised with regards to our operating location
would be our proximity to our customers, a suitable work force, transport routes and the cost and size
of units available. The results of each are discussed below.
Firstly, using the NHS map of restaurant densities, in appendix 9.1.1, and the Ordinance Survey map
of population density, in appendix 9.1.2, an obvious relationship between restaurant/population
density and cities could be seen. To ensure a nationwide coverage the midlands offered a compromise
between each of the city locations. This ensured good proximity to both the co pa s usto e sa d
workforce.
Secondly, considering transport links between the major cities and using the Google Map image of the
UK s major roads, in the appendix 9.1.4. A location local to the A1/M1 was deemed suitable due to its
central location to the surrounding cities and the easy access it would offer for subcontract LGVs and
HGVs.
Finally, considering the unit costs for both purchase and rent using the Zoopla Property Heat-map (in
the appendix 9.1.3) a more exact location for the operating location was highlighted between Sheffield
and Derby. By selecting the location highlighted in the red circle on our final location map (in the
appendix 9.1.5) we could optimised the cost of the unit along with the above factors, ensuring
opportunities for trade are maximised and cost and risk are minimised.
From the location criteria above and from our operation strategy in the business plan of this report a
suitable unit was chosen, see appendix 9.1.6, at a cost of 11280 per annum. The unit would allow
loading and unloading access and site access for LGVs and HGVs. It would also offer enough shop floor
59
space for the storage and assembly of the dispenser units and accompanying accessories whilst also
offering enough office space for the initial seven employees and additional employees as and when
they are required. The site also offered a high level of security and portrayed a desirable professional
ambiance.
Demand
The final facet is to work out the demand. This is difficult to predict but it is estimated that the demand
will increase at a decaying rate up until four are being installed every month i.e. 1 per week. The
market for this product is a predominantly lower end chain restaurant. These often feed the largest
number of people, as well as being able to raise the capital to afford the product. Being a chain, they
are also likely to be a repeat customer, the ideal scenario for a small business. Four a month is the
capacity of the company, though if demand increases steadily beyond that then the company could
expand to double capacity and therefore profits. The formula used to predict the demand is:
=
(10.2)
Where N is the number of months since the inception of the company. This figure is rounded down to
the nearest integer, to give the graph shown in figure 10.1. The total number of restaurants fitted
using this model after ten years would be 424. This is not unrealistic, especially if a large chain of
restaurants can be persuaded to use the product. The Wagamama chain has 110 stores in the UK, so
apa t e ship iththe ouldgua a teeo e a ua te ofthetotalp edi tedde a d, hileNa do s
has 315. Since these are lower end restaurants, they are likely to serve mostly cheap wine and beer,
which customers will accept being served from a dispenser rather than a bottle. This means that our
product will not detract from the service expected by the customer, and so will not decrease the
number of customers using each restaurant.
13
25
37
49
61
73
85
97
109
121
Month
Figure 10.1: Graph of Demand
The final part of the business analysis is to ascertain how the restaurants will be charged for the
dispensers. There are two options: either charge the restaurant upfront for the cost of installing the
dispensers or loan the dispensers to the restaurant in exchange for a share of the predicted extra
monthly profit every month for the lifetime of the product (10 years). Between the two of these are
60
compromises. The restaurant might be charged for a proportion of the cost of the installation as well
as a smaller proportion of the monthly profit. The projected profits of these two options are shown in
figures 10.2 and 10.3. Both options have advantages and disadvantages, which are explained below,
then analysed in the decision matrix in table 10.4.
Option 1: Upfront charge
Advantages:
Figure10.3:
10.2:Financed
Upfront by
Cost
Profits
Figure
Profits
only
These graphs explain the above point. The above graph showing the model of paying upfront leaves a
very small period of slight debt before a steady profit is turned. However, within ten years the total
profits are only 8.5 million. By contrast, the second graph shows a long period of heavy debt (peaking
61
at above 3 million) yet the total profits within ten years are over 50 million and rising far more
sharply than the first model. This is clearly preferable in the long term, though the large amount of
debt will prove a stumbling block.
It should be noted at this point that the monthly profit would be projected and agreed upon
beforehand; otherwise the restaurant might manipulate their accounts to show no profit generated
by the dispensers. A decision matrix is shown is table 10.4 that analyses the finance options.
Completely
rented
Weight
3
4
Installation
costs + finance
Half installation
cost and finance
4
1
1
4
4
2
4
3
4
40
1
43
3
43
2
46
All upfront
Factors
Loan ceiling
Benefit to buyer
Total cash benefit to
company
Risk of
default/shutdown
Maintenance
burden on company
Risk of new
fashions/ideas
Total:
A justification for these scores can be found in the appendix. Charging the restaurant for half the
installation and then extracting 20% of the profits is the optimal solution. This would mean that the
restaurant would have to raise 50,000, though this would be repaid within 11 months. The company
would also recoup the cost of installation after ten months. This ameliorates the issue of the
restaurant either going bust. These events would have to happen within 10 months of the dispensers
being installed for the company to lose money on the installation, something that is very unlikely. If
this does happen, the 423 other, extremely profitable dispenser systems will cover this loss. However,
it is worth considering what might happen should 10% of restaurants fail to come good on their loans,
an extraordinarily high figure, especially considering that this would mean that 1 in 10 restaurants go
bust immediately after having had the dispensers installed. Figure 10.4 shows this eventuality.
It is clear that even a terrible rate of debt repayment leaves the company richly rewarded after ten
years.
The company would still have the burden of maintenance, something that will cost 6,159.68 over the
p odu t s -year lifetime. However, 1,477.90 a month will be easily enough to cover this, since it
only happens after five years, by which time the company will have collected 88,673.85 in monthly
fees from the restaurant.
62
Cash Flow
The projected cash flow of the company takes into account all of these factors. The monthly income
is calculated by summing the number of dispensers put in up to that month and multiplying that by
the income from one dispenser (i.e. 15% of the increased restaurant profit). This is added to the
number of restaurants serviced that month multiplied by the upfront charge.
(10.3)
Where p is the fraction of the profits, t is the number of months passed, nt is the number of dispensers
installed that month and c is the upfront cost.
The monthly costs are then calculated by summing the fixed monthly expenditure and the installation
costs multiplied by the number of restaurants in which the dispensers have been installed. Please note
that for simplicity, only the large restaurants have been considered. These costs are added to the
interest on the outstanding balance from the bank. The interest is calculated using the following
formula:
= .
(10.4)
Where
is the outstanding negative balance (i.e. it will be discounted when the company
is no longer in debt) and the interest rate is 0.0083 (a 10% annual interest rate divided into 12 months).
This ea sthatthei te est o pou dsasti egoeso e ausethep e ious o th si te estis
added to the outstanding balance. This type of deal is known as a loan facility agreement. Rather than
taking out a large sum of money all at once and paying it back over time, the banks allows a negative
balance to build up and interest is only paid on the money used. The agreement will have a ceiling,
beyond which no more can be borrowed. It is far easier to agree to a lower ceiling, as it is less risky to
the a k, hi his h itisi po ta tthatthe o pa does t di etoodeepl i tode t efo e
becoming profitable.
However, a bank is still unlikely to agree to this since the company is not putting up any stake, so in
case of bankruptcy, only the bank bears any loss. As such, capital must be raised by the company to
put up as collateral against this loan agreement. Such capital would be secured by offering equity in
63
this potentially extremely profitable company in exchange for money. A deal of 1% of the company in
exchange for 50,000 would return a projected 200,000 within ten years. Selling 10% of the company
to a variety of investors at this price would amount to half the proposed debt, and would therefore
make the bank far more likely to invest.
A large number of the components have only a five-year warranty, so must be replaced after five of
the ten years that the company is responsible for the dispensers. This is factored into the expenditure
by multiplying the cost of the new components (the people fitting them will be permanent employees
so will not need extra payment) by the number of restaurants fitted five years previously, nt-5years.
With this in mind, the total expenditure every month is calculated as:
=+
+ +
(10.5)
Where w is the monthly warehouse cost, o the office cost, s the site cost, m the materials cost, tr the
transport cost and ma the maintenance cost. The full version of this spreadsheet can be found in the
appendix 13. However, it is summarized in the graph in figure 10.5.
Jan-16
Jan-18
Jan-20
Jan-22
Jan-24
Jan-26
Month counter
25
49
73
97
121
Increasing Demand
0.00
3.69
4.01
4.16
4.26
4.32
0.00
3.00
4.00
4.00
4.00
4.00
Setup
96,183.39
Office
17,587.00
17,587.00
17,587.00
17,587.00
17,587.00
17,587.00
Materials
0.00
212,251.17
283,001.56
283,001.56
283,001.56
283,001.56
Transport
0.00
825.00
1,100.00
1,100.00
1,100.00
1,100.00
Site
0.00
6,292.20
8,389.60
8,389.60
8,389.60
8,389.60
Maintenance
0.00
0.00
0.00
18,479.05
18,479.05
24,638.73
Monthly income
0.00
241,629.64
400,994.05
542,872.21
684,750.36
826,628.52
9,013.62
0.00
0.00
0.00
0.00
Interest
Net monthly profit
113,770.39
4,339.35
90,915.89
214,315.00
356,193.15
491,911.62
Balance
113,770.39
1,085,974.06
174,738.13
3,970,044.63
10,887,081.46
21,122,958.46
113,770.39
1,085,974.06
0.00
0.00
0.00
0.00
64
The inflation that our performance is measured against is calculated using the Bank of England target
inflation rate of 2%, and uses the money that the bank loans us, i.e. the largest debt that the company
accumulates, which is 1,085,974.06. This shows that after four years the money loaned to the
company is more valuable than it would have been if it had been left in the bank to accumulate
interest.
The Partners
This is a seven-person project, with fixed wages of 25,000 annually factored into the costs for the
seven fixed roles (1 accountant, 2 sales reps, 1 production manager, 2 packing/distribution managers
and one marketing director). However, the company is a limited liability company (LLP) so the net
profits will also be paid to the seven partners when the company reaches profitability.
Further Work
More possibilities to be considered in the business plan are patents: because each dispenser is worth
148,065.22 to the provider company, a chain of restaurants with high capital reserves might decide
to do this for themselves, and therefore keep this large profit. The company would need patents that
cover the design concept, focusing particularly on the central beam that is the cornerstone of the
design.
Another possibility is future expansion into other markets. Similar restaurants overseas are the most
obvious market, with a large fast food culture in the USA and a natural affinity for machines and
robotics in Japan the most likely targets.
65
11 Discussion
The uto Ceili g Tap s losest o petito is Ta le Tap LLC, hi h solel dispe ses ee . The uto
Ceiling Tap offers customers an array of different drinks, from soft drinks to a small alcoholic range,
all of which are dispensed automatically. Table Tap, primarily found in specialised ale and beer houses,
relies on the customer having the ability to pour their own pint, thus restricting their market. This
includes carefully angling the glass to reduce the amount of head. The Auto Ceiling Tap dispensing
system will repeatedly pour drinks to the same requirements, thus eliminating customer
dissatisfaction with badly poured drinks. With a large array of drinks available with no pre-existing
drinks pouring knowledge required, the Auto Ceiling Tap targets the mass restaurant market.
After cross-referencing the final product against the original specification, it was concluded that the
design fully met all requirements. However there are certain aspects of the design which could be
taken further in future developments. These include:
Reducing the size of the dispenser body in order to reduce the obstruction to the dining
environment
Implement a pressure or light sensor to detect the presence of the glass before dispensing
Enable a self-service payment facility at each table
Offer further drinks options such as half pints
Implement an automated cleaning system
The main assumptions that have been made are regarding the software development and program
coding. Whilst the required functions have been determined, without sufficient coding or software
knowledge an accurate quote for timing and cost of production has been estimated. Secondly, it has
been assumed that any restaurant wanting to implement the Auto Ceiling Tap system will already
operate a cellar to bar system, therefore will already have standard cellar equipment.
66
12 Conclusion
The project resulted in the design of a drinks dispenser that could be situated at each table in a
restaurant giving customers the ability to independently order, dispense and collect their drink. It
would have the ability to dispense lager, wine and soft drinks and would also include a food ordering
system.
The project resulted in the design of a drinks dispenser that fulfilled the following design parameters:
To fulfill the above requirements and ensure that a robust, cost effective and efficient product was
produced many refinements were made. These included:
The product was designed to be profitable both for the company and the restaurants in which the
system would be installed. It would be profitable for the restaurant by increasing the amount of drinks
sold and because the restaurant would save money on wages, as they would be able to lay off several
existing waiters as the dispenser replaces some of the jobs done by a waiter. The restaurants monthly
profit would be increased by 5911. The restaurant would pay off the initial cost of the installation
and be in profit after 11 months.
The product would be sold to the restaurant in the form of an upfront cost of 50,000 and then a
monthly rent of 1477. Over 10 years this would make the company 148065 per installation. It would
take 3.3 years for the company to be out of debt and after 10 years the company would 19,633,818
to the good.
67
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[Accessed 2015].
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http://axiomtek.com/Default.aspx?MenuId=Products&FunctionId=ProductView&ItemId=845&upcat
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[Accessed 2015].
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[Accessed 2015].
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[Accessed 5 March 2015].
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[Accessed 2015].
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Engineering, P., 2015. Flow Meter Types Based on Measurement Techniques. [Online]
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69
70
December
10th
17th
24th
1st
8th
W6
W7
W8
W9
W10
January
13th Dec - 11th Jan 12th
Chirstmas
W11
February
March
19th
26th
2nd
9th
16th
23rd
2nd
W12
W13
W14
W15
W16
W17
W18
All
All
Initial Drawings
Shaun
Market research
All
Key
All
Task duration
Shaun
Martin
Deadline
Martin
Optional task
Murtaza
Develop URS
All
All
All
All
All
Piping system
Shaun/Iason
Shaun/Iason
Shaun
Murtaza/Isabel
Martin
Beer Nozzle
Martin
Glass holder
Martin
Delivery/valve system
Murtaza
James/Dom
James/Dom
Design of Joint
Design of Supports
Dom
James/Dom
Iason/Dom
Iason/Dom
Shaun
Valve System
Murtaza
User Interface
Isabel
Isabel
Isabel
Martin
All
Shaun
All
Marketing strategy
James
Business Model
James
Pricing Strategy
James
Isabel
Sauce dispenser
PRESENTATION
Draft presentation structure
All
All
All
Rehearsal
All
Presentation
FINAL REPORT
Draft structure
All
All
Compile Report
All
Formatting
All
Report Hand-in
10
20
150
10
50
10
10
80
M10 THREAD
150
150
20
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
DATE
TITLE:
DRAWN
CHK'D
APPV'D
MFG
Q.A
REVISION
A4
DWG NO.
SCALE:1:5
SHEET 1 OF 1
9
12
51
.9
R1
.65
131
40
47
4.
83
.44
1.90
DETAIL A
SCALE 1 : 1
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
ALL DIMENSIONS IN MM
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
DATE
CHK'D
MFG
Q.A
REVISION
TITLE:
DRAWN
APPV'D
DWG NO.
SCALE:1:2
SHEET 1 OF 1
30
219.76
20
11
150
500
75
150
ALL DIMENSIONS IN MM
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
DATE
REVISION
TITLE:
DRAWN
CHK'D
APPV'D
MFG
Q.A
A4
DWG NO.
SCALE:1:5
SHEET 1 OF 1
20
25
150
20
10
25
150
ALL DIMENSIONS IN MM
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
DATE
TITLE:
DRAWN
CHK'D
APPV'D
MFG
Q.A
REVISION
A4
DWG NO.
SCALE:1:2
SHEET 1 OF 1
6
50
1.50
15
R1
2
58
R10
R10
26.91
1.90
Fillet
Radius 0.1mm
A
DETAIL A
SCALE 1 : 1
ALL DIMENSIONS IN MM
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
DATE
CHK'D
MFG
Q.A
REVISION
TITLE:
DRAWN
APPV'D
DWG NO.
SCALE:1:2
SHEET 1 OF 1
116
150
90
SECTION A-A
120
ALL DIMENSIONS IN MM
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
DATE
TITLE:
DRAWN
Drip Tray
CHK'D
APPV'D
MFG
Q.A
REVISION
A4
DWG NO.
SCALE:1:5
SHEET 1 OF 1
7.50
50
20
150
17.50
20
12
20
150
20
150
1.50
1.50
SECTION A-A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
DATE
TITLE:
DRAWN
CHK'D
APPV'D
MFG
Q.A
REVISION
A4
DWG NO.
SCALE:1:5
SHEET 1 OF 1
230
40
230
11
40
60
690
30
20
85
30
30
11
5
20
30
SECTION A-A
30
150
230
85
ALL DIMENSIONS IN MM
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
DATE
TITLE:
DRAWN
CHK'D
APPV'D
MFG
Q.A
REVISION
Module
A4
DWG NO.
SCALE:1:10
SHEET 1 OF 1
Piping System
14.3.1 Flow velocities, flow rates, Reynolds Numbers
73
74
75
76
77
Beverage Cooling
14.4.1 Required Mass Flow Rate
Installation Type
Number of drinks to be
dispensed simultaneously
Mass Flow Rate
Cooling Capacity Required
Small
10
Medium
15
Large
21
5.682 kg/s
3.5 KW
8.524 kg/s
5.3 KW
11.933 kg/s
7.6 KW
0.000568261
m^3 /s
4193
J/Kg.K
20
Degrees Celsius
Degrees Celsius
Fluid density
1000
Kg/m^3
78
79
80
450 ft.
Capacity
15 gal.
Dedicated Circuit
20 Amps.
Voltage
115/60 volt/Hz.
Compressor Power
3/4hp
Pump Type
Procon-100gl
100 Gal/hr.
81
Refrigerant
R134a
Dimensions
Height
32"
Width
20"
Depth
25"
Weight
Unit Weight
120 lbs.
Shipping Weight
120 lbs.
http://www.beveragefactory.com/draftbeer/glycol-chiller/EG-3_4P.shtml
82
Dew point
Human perception[1]
Over 26 C
2426 C
62%
2124 C
5260%
1821 C
4452%
1618 C
3746%
1316 C
Comfortable
3841%
1012 C
Very comfortable
3137%
Under 10 C
Psychrometric chart
http://en.wikipedia.org/wiki/Dew_point
83
Cleaning Procedure
1. Motorised valve in cellar that will switch between the beverage, cleaning fluid and clean
water lines.
2. Turn off flash chillers
3. Turn CO2 gas connector to beverages off
4. Drip tray removed exposing catch funnel leading to outlet valve.
5. Drainage container/hose placed at/on outlet valve located on the lower table support.
6. Switch Beverage to Cleaning Fluid
7. Fill lines with cleaning fluid whilst also purging lines of beverage (dispenser valves are open).
8. Once cleaning fluid begins to be dispensed and the beverage is purged from the lines close
the dispensing vales and leave the cleaning fluid for X minutes.
9. After 15 minutes open dispensing valves and dispense cleaning fluid sample (1 pint worth)
and inspect.
10. Ifthe lea i gfluid s olou i di ato has ha ged i di ati g o ta i ated e e ageli es .
11. Purge lines of old cleaning fluid with new cleaning fluida d epeatu tilfluidsa ple s olou
indicator has not changed (indicating clean lines).
12. Clea i gfluidsa ple s olou i di ato has ot ha ged.
13. Switch Cleaning to Clean Water
14. Dispense water out of each dispense until there is no visible sign of cleaning fluid. Then
proceed to dispense another 10 litres of clean water out of each dispenser.
15. Switch Clean Water to Beverage
16. Purge water out of the system using beverage.
17. When the clean water has been purged and the beverage begins to appear at the dispensing
end proceed to dispense a further half pint of the beverage to ensure that any dilution of
the beverage served to the customer is kept to a minimum.
18. Reverse steps 1 and 2
84
Structures
14.6.1 Matlab Codes
function modules
clc;
% this function will model a dispenser supported by braced column modules
% Maximum force applied horizontally, either perpendicular
F=400;
to table or to table hypotenuse
% Young's Modulus
E=200000000000;
L1=0.69;
%
Height
of
table
/
module
(http://www.hillcrossfurniture.co.uk/blog/2011/08/how-to-choose-the-rightsize-of-restaurant-table/)
n = 3;
% number of modules above table
% square rod side length
D=0.03;
B = 0.18;
% distance between rods
density=0.63*(10^3);% Density of table
x=1.45;
% long side of table
% short side of table
y=0;
% Depth of tabletop
z=0.05;
G=75000000000;
% shear modulus
zeta = 0.025;
% damping ratio
steeldensity=8000;
dt=0.0001;
t_total = 1;
plthi = 0.03;
h = 0.05;
%diameter of hole
% 3EI/L3
% 3EI/L3
* 4
* 4
% springs in parallel
85
% volume of table
% mass of one rod
( (B^2) - ( pi * (h^2) / 4 ) ); % mass of
);
% mass of one module
% mass of support above table
% mass of below table support
meq = mt + (1 - ( 2 / pi )) * ( ma + mb );
% system characteristics
wn=(K/meq)^(1/2);
wd = wn*(1-(zeta^2))^0.5;
%graph
i=1;
for (time = 0: dt: t_total)
h(i) = (1/(meq*wd))*(exp(-zeta*wn*time))*sin(wd*time);
s = F*h(i);
time_data(i) = time;
time = time + dt;
s_store(i) = s;
i = i + 1;
end
plot(time_data,s_store);
title(' Horizontal Displacement of the Mass with Time');
xlabel('Time /s');
ylabel('Displacement /m'
86
Dispensing System
14.7.1 Pugh Nozzle
Perfect Pint
Space Efficient
Cost
TOTAL
Angled Nozzle
1
2
1
4
Rotating Base
1
4
3
8
1
No variation
2
Slight variation
~ 1-3mm in
Head
Space Efficient
No increase in
size from basic
design
Increase in size
of base of cup
holder by < 3cm
Cost (per
dispenser)
No extra cost
from basic
design
Cost of extra
design part
(10)
Perfect Pint
Widget Design
1
2
2
5
Lowered Nozzle
3
Medium
variation
~ 3-5mm in
Head
Increase in size
of nozzle head
by including
space for a
motor
Cost of a motor
(21.99)
4
Large Variation
>5mm in Head
2
3
3
8
Large Variation
>5mm in Head
Cost of a motor
and cost of
extra design
part (31.99)
87
Control System
88
Operation
14.9.1 Location Strategy
89
90
91
92
Building/Office
Rent
Business Rates
Electricity
Public Utilities
Monthly
One Off
17587
22433
Lease Payments
Lights
100
Heating
300
Telephone (Landline)
35
Mobile Phones
25
Internet
35
BT
4
100
Orange
BT
Water
Wages
Administrative/Accounts
25000
25000
Sales
25000
50000
Production
25000
25000
Packing/Distribution
25000
50000
Marketing
25000
1
total
Computer Equipment
Computers
350
1050
Laptops
350
1050
Monitors
80
240
Accessories
20
120
Printers/Photocopier
25 per month
Telephone System
Office Supplies/Furniture
Storage
Company Cars
Tooling Costs
Advertising/Marketing
25000 monthly
175000
Stationary
Dell
Dell
Currys
Currys
http://www.absdigital.co.uk/photocopiers_hire.htm
540
http://www.thetelecomshop.co.uk/panasonic-kx-tda15-telephone-system-with-4-phones?gclid=CIav6uzX5sMCFUvLtAodgmkA5g
20
20
Desks
150
900
Viking Direct
Chairs
40
240
Viking Direct
Filing Cabinets
80
480
Viking Direct
Racking System
150
10
1500
100
per 50
Forklift
http://www.barloworld.co.uk/New-Equipment/Special-Offers/NEW-Hyster-electric-forklift-trucks-and-pallet-trucks-offer_17.htm
Sales Rep
880 upfront
https://www.allcarleasing.co.uk/car-leasing/vauxhall-insignia-20_cdti_%5B140%5D_ecoflex_tech_line_4dr_%5Bstart_stop%5D-car-leasing-64316#.VOI32y7LJH8
https://www.allcarleasing.co.uk/car-leasing/vauxhall-insignia-20_cdti_%5B140%5D_ecoflex_tech_line_4dr_%5Bstart_stop%5D-car-leasing-64316#.VOI32y7LJH8
Viking Direct
http://www.idhdirect.co.uk/shelving-1/heavy-rivet-shelving-from-51-including-delivery-up-to-600kg-per-level/heavy-duty-shelving-system-orange.html
www.kitepackaging.co.uk/scp/heavy-duty-cardboard-boxes/enviro-box/?sfpartno=CSW-EBOX-161616&gclid=CN_T6_yL58MCFfDKtAodPUwAhQ
4301
Murtaza
3114
Murtaza
7418
Murtaza
Website (Creation)
Website (hosting)
wishdesign.co.uk
10 per month
Host Gator
Advertising
Depreciation
14583
Computer Equipment
3000
0,2
50
Office Furniture
1620
0,2
27
Part
Cellar Equipment
Dispenser Body
Cleaning
Ceiling Joints
User Interface
Electronics
Manufacturing Costs
Running Costs
Source
http://www.abbeychart.co.uk/shurflo-syrup-pump-166-296-28
Syrup Pump
62,04
Small
Medium Large
Small
Medium
Large
310,20
310,20
310,20
256,29
Carbonator
256,29
http://www.sodadispenserdepot.com/pics/Carb7004.htm
256,29
256,29
Cleaning Pump
76,00
http://www.sprayingequipmentsupply.com/pumps/diaphragm-pump.html
76,00
76,00
76,00
Flash Chiller
830,00
10
http://www.hotfridges.ca/content/flash-chillers/best-for-beer/6/T160F-12T6
2.490,00
4.150,00
5.810,00
1,02
http://www.sodadispenserdepot.com/pics/7123hose.html
5,10
5,10
5,10
36,34
10+
http://www.sodadispenserdepot.com/pics/Reg5125.htm
36,34
36,34
36,34
29,20
10+
http://www.sodadispenserdepot.com/pics/Reg7129L.htm
29,20
29,20
29,20
CO2/N2 Regulator
59,15
10+
http://www.micromatic.com/draft-keg-beer/wine-regulators-pid-842-15.html
118,30
118,30
118,30
35,01
10+
http://www.micromatic.com/draft-keg-beer/keg-taps-couplers-pid-7485S.html
70,02
70,02
70,02
Motorised Valves
20,00
http://www.flow-controls.com/Automated-Electric-Brewing-valve.html
160,00
160,00
160,00
7,75
10+
http://www.sodadispenserdepot.com/pics/Bib3200.html
31,00
31,00
31,00
34,81
10+
http://www.divinity-systems.com/Trunk_Line_p/cdi1034-x.htm
46
64
122
1.601,26
2.227,84
4.246,82
Coolant
93,00
http://www.beveragefactory.com/draftbeer/glycol-coolant/gl-5g.html
93,00
93,00
93,00
Glycol Chiller
1.300,00
10+
http://www.beveragefactory.com/draftbeer/glycol-chiller/EG-3_4P.shtml
1.300,00
1.300,00
1.300,00
Manifold
3,36
http://www.overclock.co.uk/product/Alphacool-Plugin-Y-connector-for-10mm-hoses_1777.html
90
140
210
302,40
470,40
705,60
Tertiary Regulator
4,81
http://www.bes.co.uk/products/060.asp
80
120
160
384,80
577,20
769,60
U-bend Tubing
2,64
http://www.harrymason.co.uk/index.php?route=product/product&product_id=267
40
60
84
105,60
158,40
221,76
Glycol Line
16,60
http://www.beveragefactory.com/draftbeer/glycol-cooling/glycol-trunkline/bf_1445.shtml
27
37
45
448,20
614,20
747,00
Module Plate
8,50
10+
http://www.industrialmetal.co.uk/categories/6/products/21
60
90
126
510,00
765,00
1.071,00
Module Rod
12,60
10+
http://www.themetalstore.co.uk/products/mild-steel-black-square-bar
120
180
252
1.512,00
2.268,00
3.175,20
T - section Bracket
0,34
10+
http://www.themetalstore.co.uk/products/steel-t-section
40
60
84
13,60
20,40
28,56
0,06
10+
http://www.themetalstore.co.uk/products/6-metre-lengths-3mm-angle
60
90
126
3,60
5,40
7,56
0,09
10+
http://www.themetalstore.co.uk/products/6-metre-lengths-3mm-angle
120
180
252
10,80
16,20
22,68
Table Top
59,99
20
http://www.fiestafurniture.co.uk/store/table-tops/laminate-table-tops/round-laminate-table-top-1000mm-(25mm-thick)
10
15
21
599,90
899,85
1.259,79
Aluminum Casing
68,00
60+
http://www.alibaba.com/product-detail/Pvdf-coating-decorative-aluminum-column-cladding_783803181.html
30
45
63
2.040,00
3.060,00
4.284,00
M10 Bolts
0,56
99
http://www.screwfix.com/p/bolts-a2-stainless-steel-m10-x-90mm-pack-of-10/44460
240
360
504
134,40
201,60
282,24
M4 Bolts
0,06
99
http://www.screwfix.com/p/bzp-pan-head-machine-screws-m4-x-30mm-pack-of-25/50074
440
660
924
25,87
38,81
54,33
M10 Nuts
0,04
99
http://www.screwfix.com/p/hex-nuts-bzp-steel-m10-pack-of-100/19879
160
240
336
7,02
10,54
14,75
68,77
10+
http://www.themetalstore.co.uk/products/5mm-thick-mild-steel-sheet
10
15
21
687,70
1.031,55
1.444,17
Woodscrews 20mm
0,01
99
http://www.screwfix.com/p/goldscrew-yellow-zinc-plated-woodscrews-double-countersunk-4-x-20mm-pack-of-200/11192
120
180
252
0,82
1,22
1,71
Drip tray
67,20
60
http://www.alan-courtenay.co.uk/driptrays.html
10
15
21
672,00
1.008,00
1.411,20
453,75
C-Section (Cladding)
8,25
60
http://www.themetalstore.co.uk/products/2m-aluminium-channel
26
39
55
214,50
321,75
Funnel
3,24
10+
http://uk.rs-online.com/web/p/funnels/8459539/
10
15
21
32,40
48,60
68,04
Funnel Plate
34,60
10+
http://www.themetalstore.co.uk/products/3mm-thick-mild-steel-sheet
10
15
21
346,00
519,00
726,60
Hose
0,30
10+
http://www.homebase.co.uk/en/homebaseuk/garden/hoses-and-reels/homebase-tough-anti-kink-50m-garden-hose-045699
10
15
21
3,00
4,50
6,30
Tap
3,56
10+
http://www.screwfix.com/p/jg-speedfit-15esotp-emergency-shut-off-tap-15mm/13133
10
15
21
35,60
53,40
74,76
Screws 38mm
0,01
99
http://www.screwfix.com/p/easydrive-phosphate-phillips-twin-thread-drywall-screws-3-5-x-38mm-pk1000/12984
160
240
336
1,04
1,56
2,18
Guide Rod
0,36
99
http://www.wickes.co.uk/Wickes-Threaded-Rod-M10x500mm-Pack-2/p/511123
40
60
84
14,40
21,60
30,24
Ceiling Flange
7,09
10+
http://www.signetfence.com/FFM-2-p/ffm-2.htm
40
60
84
283,60
425,40
595,56
99
http://www.burkert.co.uk/en/type/6011
100
150
210
3.665,00
5.497,50
7.696,50
Dispensing System
Quantity
Lifespan of
part (years)
Steel Plate
1,07
http://www.themetalstore.co.uk/products/3mm-thick-mild-steel-sheet
30
45
63
32,10
48,15
67,41
1,02
http://www.themetalstore.co.uk/products/3m-long-mild-steel-bzp-screwed-rod
40
60
84
40,80
61,20
85,68
0,30
10+
http://www.hilltop-products.co.uk/other-tubing-products/non-shrink-tubing/pvc-hose-tubing/pvc-tubing-hose-3mm.html#.VOyWtfmsV8E
100
150
210
30,00
45,00
63,00
5,00
10+
http://www.swagelok.com/search/find_products_home.aspx?part=SS-2-HC-1-2&item=50b243b0-8a71-45ac-8579-0f1d438b0b8c#
200
300
420
1.000,00
1.500,00
2.100,00
Check Valve
2,99
10+
http://www.advancedfluidsolutions.co.uk/nylon-10mm-straight-non-return-valve---38-fuel-check-valve-air-water-pipe-tube-hose-3090-p.asp
100
150
210
299,00
448,50
627,90
7,85
10+
http://www.swagelok.com/search/find_products_home.aspx?part=SS-3M0-R-6MBT&item=20b6dcb5-5a04-42f1-9df7-a5d3fd3672c3
200
300
420
1.570,00
2.355,00
3.297,00
96,39
Nozzle Plate
4,59
10+
http://www.protolabs.co.uk/protomold
10
15
21
45,90
68,85
1,60
10+
http://www.protolabs.co.uk/protomold
10
15
21
16,00
24,00
33,60
1,44
10+
http://www.protolabs.co.uk/protomold
40
60
84
57,60
86,40
120,96
42,00
10+
http://www.flowmeters.co.uk/pdf/turbine_meters/Beer_Meter/beverage-meter.pdf
100
150
210
4.200,00
6.300,00
8.820,00
0,39
10+
https://www.flexifelt.com/p-86-5006-2-industrial-strength-adhesive-felt-pads-of-3-x-3.aspx
100
150
210
39,00
58,50
81,90
Pipe Clamps
0,36
http://www.hcl-clamping.co.uk/Mini-Screw-or-Petrol-Pipe-Clip-Mollfam-P16
100
150
210
36,00
54,00
75,60
Tablet
485,00
10+
10
15
21
4.850,00
7.275,00
10.185,00
8 Channel Relay
13,68
http://www.sainsmart.com/16-channel-12v-relay-module-for-pic-arm-avr-dsp-arduino-msp430-ttl-logic.html
10
15
21
136,80
205,20
287,28
Server
607,48
http://www.dabs.com/products/hp-proliant-dl320e-gen8-e3-1220v2-3-1ghz-server-8MTT.html?src=2
607,48
607,48
607,48
Microcontroller
33,73
http://store.arduino.cc/product/A000008
10
15
21
337,30
505,95
708,33
Splitter
0,58
http://uk.rs-online.com/web/p/type-a-usb-connectors/6741325/
0,58
1,17
1,75
PSU
19,21
http://www.hms-electronics.com/BrightSign/bs_acc.htm
10
15
21
192,10
288,15
403,41
109,88
Wires 14AWG
27,47
http://uk.farnell.com/pro-power/4206/tri-rated-wire-14awg-black-100m/dp/2343970
54,94
82,41
Wires TC 30AWG
15,50
http://uk.farnell.com/alpha-wire/5851-rd005/wire-ul1213-30awg-red-30-5m/dp/1199097
15,50
15,50
31,00
Wires 24 AWG
34,92
http://uk.farnell.com/te-connectivity-raychem/44a0111-24-6/wire-24awg-blue-100m/dp/4175992
69,84
104,76
139,68
Wires TC 26 AWG
11,14
http://uk.farnell.com/alpha-wire/1853-bk005/wire-blk-26awg-7-34awg-30-5m/dp/2291040
11,14
11,14
22,28
DC Plug
1,89
http://www.maplin.co.uk/p/maplin-21-x-55-long-dc-power-plug-hh61r
20
30
42
37,80
56,70
79,38
MCB
7,67
http://uk.rs-online.com/web/p/mcbs/5398138/
10
15
21
76,70
115,05
161,07
34,90
http://uk.rs-online.com/web/p/consumer-units/8111906/
34,90
34,90
34,90
106,00
20
http://www.themetalstore.co.uk/products/misc
10
15
21
1.060,00
1.590,00
2.226,00
60,30
20
http://www.themetalstore.co.uk/products/misc
20
30
42
1.206,00
1.809,00
2.532,60
Valve Plate
0,85
20
30
45
63
25,50
38,25
53,55
Cleaning Fluid
17,71
0,082
http://www.themetalstore.co.uk/products/misc
http://www.nobleexpress.co.uk/cp/pipeline-purple-beer-line-cleaner-5litre/HP124?set_vat=true&referal=17253&gclid=Cj0KEQiAvKunBRCfsum9z6fu_5IBEiQAu4lg4jNQdMwPTpve15gYI81CoYUGhA6CnykILeZoqGEYFecaAsIi8P8HAQ
12
12
12
212,52
212,52
212,52
CO2/N2 Tank
20,00
http://www.adamsgas.co.uk/beer-cellar/trade/20l-cellar-beer-gas-30-70-mix-trade-only-detail
20,00
20,00
20,00
CO2 Tank
11,31
http://www.adamsgas.co.uk/beer-cellar/trade/carbon-dioxode-co2-gas-refil-6-35kg-trade-only2013-07-05-10-25-57-detail
11,31
11,31
11,31
Quotes
14.12.1 Tablet
Dear Isabel
Tha k ou e u hfo ou ki di te esti Go Mo ilit sTa letkioska
glad to provide you with all further information to take
As
per
your
inquiry
below,
we
have
quote
for
several
.We ould e
this further.
different
orders:
Limited Offer : If you pay on until 30th April 2015, we will provide you 10 % DISCOUNT.
We hope provided information will help. Let us know if you have any further queries or
comments.
Looking forward to your kind reply.
Kind regards,
Shaifta
Accounts
+31
(0)76
52
45
shaifta.saiyed@go4mobility.eu
95
96
97
Company Costing
98
Jan 16
Feb 16
Mrz 16
Apr 16
Month counter
1
2
3
4
Increasing Demand
0,00
1,25
1,84
2,19
Number of Sales /month
0,00
1,00
1,00
2,00
Setup
96.183,39
Office
17.587,00
17.587,00
17.587,00
17.587,00
Materials
0,00
70.750,39
70.750,39 141.500,78
Transport
0,00
275,00
275,00
550,00
Site
0,00
2.097,40
2.097,40
4.194,80
Maintenance
0,00
0,00
0,00
0,00
Monthly income
0,00
51.477,90
52.955,79 105.911,59
Interest
500.000,00
0,00
0,00
0,00
Net monthly profit
386.229,61
39.231,89
37.754,00
57.920,99
Balance
386.229,61 346.997,72 309.243,72 251.322,73
Net loan drawdown
0,00
0,00
0,00
0,00
Office/warehouse cost
17.587,00
transport cost per installation
275,00
Materials cost per installation
70.750,39
site cost per installation
2.097,40
maintenance cost
6.159,68
Loan Monthly Interest
0,0083
Upfront cost
50.000,00
setup cost
96.183,39
Loan Interest Rate
10%
fraction of projected profit taken
0,2
monthly fee
1.477,90
loan facility
(interest accrued only on used money)
Maximum Loan facility
493.994,92
Estimated rate of inflation
5%
(based on BoE target)
Monthly rate of inflation
0,004166667
total interest paid:
417.855,71
Inflation
496.053,24 498.120,12 500.195,62 502.279,77
investor
50.208,33
50.417,53
50.627,61
50.838,56
Mai 16
5
2,44
2,00
Jun 16
6
2,63
2,00
17.587,00
141.500,78
550,00
4.194,80
0,00
108.867,38
0,00
54.965,20
196.357,53
0,00
17.587,00
141.500,78
550,00
4.194,80
0,00
111.823,18
0,00
52.009,40
144.348,13
0,00
504.372,61
51.050,38
506.474,16
51.263,09
Jul 16
7
2,78
2,00
Aug 16
8
2,90
2,00
Sep 16
9
3,00
2,00
Okt 16
10
3,08
3,00
Nov 16
11
3,16
3,00
Dez 16
12
3,22
3,00
Jan 17
13
3,28
3,00
Jan 18
25
3,69
3,00
Jan 19
37
3,89
3,00
17.587,00
141.500,78
550,00
4.194,80
0,00
114.778,97
0,00
49.053,61
95.294,52
0,00
17.587,00
141.500,78
550,00
4.194,80
0,00
117.734,77
0,00
46.097,81
49.196,70
0,00
17.587,00
141.500,78
550,00
4.194,80
0,00
120.690,56
0,00
43.142,02
6.054,69
0,00
17.587,00
212.251,17
825,00
6.292,20
0,00
175.124,26
0,00
61.831,12
55.776,43
55.776,43
17.587,00
212.251,17
825,00
6.292,20
0,00
179.557,95
464,80
57.862,23
113.638,66
113.638,66
17.587,00
212.251,17
825,00
6.292,20
0,00
183.991,64
946,99
53.910,72
167.549,38
167.549,38
17.587,00
212.251,17
825,00
6.292,20
0,00
188.425,33
1.396,24
49.926,28
217.475,67
217.475,67
17.587,00
212.251,17
825,00
6.292,20
0,00
241.629,64
4.116,62
557,64
493.437,28
493.437,28
17.587,00
212.251,17
825,00
6.292,20
0,00
294.833,95
1.550,68
56.327,90
129.753,33
129.753,33
508.584,47
51.476,69
510.703,57
51.691,18
512.831,50
51.906,56
514.968,30
52.122,83
517.114,00
52.340,01
519.268,64
52.558,09
521.432,26
52.777,09
548.109,72
55.477,26
576.152,06
58.315,58
Jan 20
49
4,01
4,00
Jan 21
61
4,10
4,00
Jan 22
73
4,16
4,00
Jan 23
85
4,21
4,00
Jan 24
97
4,26
4,00
Jan 25
109
4,29
4,00
Jan 26
121
4,32
4,00
17.587,00
17.587,00
17.587,00
17.587,00
17.587,00
17.587,00
17.587,00
283.001,56 283.001,56 283.001,56 283.001,56
283.001,56
283.001,56
283.001,56
1.100,00
1.100,00
1.100,00
1.100,00
1.100,00
1.100,00
1.100,00
8.389,60
8.389,60
8.389,60
8.389,60
8.389,60
8.389,60
8.389,60
0,00
0,00
18.479,05
18.479,05
18.479,05
24.638,73
24.638,73
400.994,05 471.933,13 542.872,21 613.811,28
684.750,36
755.689,44
826.628,52
0,00
0,00
0,00
0,00
0,00
0,00
0,00
90.915,89 161.854,96 214.315,00 285.254,07
356.193,15
420.972,55
491.911,62
867.133,83 ######## ######## 7.695.324,29 ######### ######### #########
0,00
0,00
0,00
0,00
0,00
0,00
0,00
#########
605.629,09
61.299,12
636.614,22
64.435,30
669.184,62
67.731,93
703.421,37
71.197,23
739.409,74
74.839,81
777.239,35
78.668,76
817.004,39
82.693,60
Minute:
Table
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Set up and demonstrate Dispenser
Wait Staff:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
Deliver food
42 43 44 45 46
47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66
clear table
67 68 69 70 71 72 73 74 75 76 77 78 79 80
Deliver Dessert
81 82 83 84 85 86 87 88 89 90 91 92
clear table
93 94
95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113
bill