Auto Ceiling Tap

Final Design Report

Group 2
Dr G. Ingram & Prof D. Cartwright
06/03/2015

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

Restaurant Sizing (Iason)................................................................................................................. 2

Piping System (Iason and Shaun) .................................................................................................... 3

Design Process ........................................................................................................................ 3
3.1.1

Design Requirements ...................................................................................................... 3

3.1.2

Normal Bar Setup ............................................................................................................ 3

3.1.3

Method............................................................................................................................ 4

3.1.4

Calculations and Results ................................................................................................. 6

3.1.5

Analysis ........................................................................................................................... 7

Detailed Design ....................................................................................................................... 7

Installation .............................................................................................................................. 9
4

Cooling (Shaun) ............................................................................................................................. 10

Beverage Cooling .................................................................................................................. 10
Beverage Temperature Maintenance ................................................................................... 12
4.1

Trunking ................................................................................................................................ 14

4.2.1

Glycol Coolant Flow Rate .............................................................................................. 15

4.2

Dew point .............................................................................................................................. 16

4.3

Costings ................................................................................................................................. 16

Cleaning (Shaun) ........................................................................................................................... 17

Structural Considerations (Dominic, James and Iason) ................................................................ 18

Design Concepts .................................................................................................................... 18
Design Development ............................................................................................................. 18
6.2.1

Displacement ................................................................................................................ 18

6.2.2

Torsion .......................................................................................................................... 19

6.2.3

Stress Analysis ............................................................................................................... 20

6.2.4

Vibration........................................................................................................................ 20

6.2.5

Modelling ...................................................................................................................... 20

6.2.6

Modular Design ............................................................................................................. 22

Detail Design ......................................................................................................................... 24

6.3.1

Assembly ....................................................................................................................... 24

6.3.2

Aesthetics ...................................................................................................................... 25

Design for Manufacture ........................................................................................................ 26

ii

Design for Sustainability ....................................................................................................... 26

7

Dispensing System (Murtaza and Martin) .................................................................................... 28

Valve System ......................................................................................................................... 28
7.1.1

Design Concepts ............................................................................................................ 28

7.1.2

Design Development and Detail Design........................................................................ 29

7.1.3

Design for Manufacture and Sustainability................................................................... 34

7.1.4

Commercial Considerations .......................................................................................... 35

Nozzle Assembly ................................................................................................................... 35

7.2.1

Design Concepts ............................................................................................................ 35

7.2.2

Design Development and Detail Design........................................................................ 39

7.2.3

Design for Manufacture and Sustainability................................................................... 43

7.2.4

Commercial Considerations .......................................................................................... 43

Overview of Dispensing System ............................................................................................ 44

8

Control system (Iasbel) ................................................................................................................. 45

Design concepts .................................................................................................................... 45
Design development ............................................................................................................. 47
8.2.1

Control operation.......................................................................................................... 47

8.2.2

Communication ............................................................................................................. 47

8.2.3

Tablet ............................................................................................................................ 48

8.2.4

User Interface and software ......................................................................................... 49

Design detail.......................................................................................................................... 51

9
10

8.3.1

Control feedback ........................................................................................................... 51

8.3.2

Microcontroller and relay ............................................................................................. 52

8.3.3

Wiring ............................................................................................................................ 53

Installation (Martin) ...................................................................................................................... 55

Finance and Business Plan (James and Shaun) ......................................................................... 57
Value to the Restaurant ........................................................................................................ 57
Cost of Production ................................................................................................................ 58
10.2.1

Location Strategy .......................................................................................................... 59

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

Flow velocities, flow rates, Reynolds Numbers ............................................................ 73

14.3.2

Darcy-Weisbach coefficient .......................................................................................... 73

14.3.3

Pipe Loss ........................................................................................................................ 74

14.3.4

New pipe loss (large) ..................................................................................................... 75

14.3.5

Solubility of Carbon Dioxide in Beer, Pressure-Temperature Relationships ................ 76

14.3.6

Pipe drawings ................................................................................................................ 77

Beverage Cooling .................................................................................................................. 78

14.4.1

Required Mass Flow Rate.............................................................................................. 78

14.4.2

Beverage and Trunking Surface Temperatures and System Losses.............................. 78

14.4.3

System Heat exchanger rate calculations ..................................................................... 79

14.4.4

Coolant Flow Rates ....................................................................................................... 80

14.4.5

Flash Cooler ................................................................................................................... 80

14.4.6

Glycol Chiller ................................................................................................................. 81

14.4.7

Dew Point ...................................................................................................................... 83

Cleaning Procedure ............................................................................................................... 84

Structures .............................................................................................................................. 85
14.6.1

Matlab Codes ................................................................................................................ 85

Dispensing System ................................................................................................................ 87

14.7.1

Pugh Nozzle ................................................................................................................... 87

Control System ...................................................................................................................... 88

Operation .............................................................................................................................. 89
14.9.1

Location Strategy .......................................................................................................... 89

14.9.2

Fixed Costs .................................................................................................................... 92

Operational Cost ............................................................................................................... 93
Bill of Materials ................................................................................................................. 94
Quotes ............................................................................................................................... 95

14.12.1

Tablet ........................................................................................................................ 95

14.12.2

Alcoholic Nozzle ........................................................................................................ 96

14.12.3

Soft Drink Nozzle ....................................................................................................... 97

14.12.4

Nozzle Plate ............................................................................................................... 98

Company Costing .............................................................................................................. 98

Waiter Timesheet.............................................................................................................. 99

iv

Nomenclature and Abbreviations

Second Moment of area
Outer Depth
Outer Breadth
Inner Depth
Inner Breadth
Force applies
Length
You g sModulus
Twist Angle
Torque
Polar Second Moment of Area
Shear Modulus
Rotational Stiffness
Bending Stress
Resulting Bending Moment
Elastic Section Modulus
Torsional Stress
Resulting Torsion
Normal Stress
Resulting Normal Force
Cross-sectional area
Tensile Stress
Equivalent Mass
Damped Natural Frequency
Un-damped Natural Frequency
Zeta
Time
Flow Rate
Pressure
Flow Velocity
Height
Density
Gravitational Acceleration
Pressure loss
Pipe Diameter
Darcy-Weisbach Friction Coefficient
Minor Loss Coefficient
Reynolds Number
Kinematic Viscosity
Absolute Roughness
Voltage Drop
Current
Wire Resistance
Rate of Heat Transfer
Specific Heat Capacity
Temperature Difference
Heat Transfer with the Environment
Temperature of the fluid
Ambient Temperature of the Environment

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

Diameter of Pipe Insulation

Surface Heat Transfer Coefficient
Thermal Conductivity of Insulation
Maximum operating pressure differential
Factor Flow
Flow rate
Specific Gravity
Number of months since inception
Fraction of the profits
Number of months passed
Number of dispensers installed
Upfront cost
Interest
Outstanding negative balance
Monthly warehouse cost
Monthly office cost
Monthly site cost
Monthly materials cost
Monthly transport cost
Monthly maintenance cost
Distance
Velocity
Initial velocity
Time
Acceleration
BIB
PVC
VESA
MOSFET
emf
FMEA
LDR
PoS
GPIO
MCB
URS
LGV
HGV
LLP
MIG
MOPD

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.

2 Restaurant Sizing (Iason)

Since restaurant sizes and structures vary and restaurants have different amounts of large or small
tables the design should be as flexible as possible. However, for exact calculations and discussions and
to depict the product, there is the need to define samples of the product based on the number of
dispensers and therefore tables. Three different sizes, with 10, 15 and 21 dispensers, because the
number of tables and seat capacity is common. Based on that, sample floor plans were created to
allow exact analysis. In the following section they will be referred to as small, medium and large. The
figures below highlight the layout for small, medium and large restaurants respectively.

Figure 2.1: Small, 10 dispensers

Figure 2.2: Medium, 15 dispensers

Figure 2.3: Large, 21 dispensers

3 Piping System (Iason and Shaun)

Design Process
3.1.1 Design Requirements
To get the drinks from the cellar along the ceiling and into the dispensers, a piping system has to be
designed that fits the following requirements:

Dispense ten different drinks at each dispenser

The product specification states that the dispenser provides ten different drinks, which
include lagers, wines and soft drinks. Therefore, the piping system has to consist of ten pipes
that are distributed across the desired number of dispensers. The distribution has to be
achieved with a series of manifolds. Each drink dispensed at each dispenser must dispense
identically, regardless of how many dispensers are operating.

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.

Use standard equipment

Although the required piping system will be bigger and more complex than a piping system in
a normal bar setup, it is aimed to consist of standard bar equipment. That is going to reduce
design and manufacture complexity and costs, and make the equipment supply simple.

3.1.2 Normal Bar Setup

The diagram below shows how a normal bar setup with beer and wine kegs and dispensable syrup
bags operates.

Figure 3.1: Cellar bar setup

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

Minor Loss Coefficient

0.5
2.3
2
Table 3.1 Minor Loss Coefficients

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.

Figure 3.2 Flow rate in the T-Connectors

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.

Figure 3.4 Flow rates as a multiple of Q1

3.1.4 Calculations and Results

3.1.4.1 Pressure Losses
The pressure losses are calculated with the equation (3.2) for every restaurant size. The biggest
diameter for bar equipment is 10mm, which is used to calculate the flow rates (see appendix 3.1).
Table 3.2 shows the results of the dispenser, a full calculation can be found in appendix 3.3:
Part
Small
Medium
Large

Major loss [bar]

1.61
2.58
6.05

Minor Loss [bar]

0.65
1.00
1.19

Total loss [bar]

2.26
3.58
7.24

Table 3.2: Pressure Losses 1

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

Major loss [bar]

1.32
2.18

Minor Loss [bar]

0.45
0.70

Total loss [bar]

1.77
2.88

Table 3.3: Pressure Losses 2

3.1.4.2 Tap Pressure

The tap pressure is the pressure that has to exist at the nozzle inside the system. It corresponds to the
desired flow rate and therefore to the flow velocity of v1=0.798 m/s. It is calculated ithBe oulli s
equation (3.1) before the valve and after the nozzle. It also regards the properties of the drinks and
therefore minimum required pressures. They can be found in various tables, depending on the drink
(see appendix 3.5) and its CO2 concentration. Exact figures for specific drinks can be obtained by the
drink supplier.
Fluid
Lager
Wine
Syrup
Water

Tap pressure [bar]

1.12
1.03
1.12
1.12
Table 3.4: Tap Pressures

3.1.4.3 Operating Pressure

The operating pressure is the pressure which is set at the primary and secondary gas regulators in the
cellar. It has to be high enough so the fluid overcomes the maximum pressure losses throughout the
system and it still has an overpressure which is equal to the tap pressure.

Fluid
Lager
Wine
Syrup
Water

Small
3.38
3.27
3.38
3.38

Operating pressure [bar]

Medium
4.70
4.61
4.70
4.70

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

Pipe length [m]

46
64
84
Table 3.5: Pipe System Lengths

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

Figure 3.5: T-Connector

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

Table 3.7: Number of Pressure Regulators

Figure 3.6: Pressure Regulator

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:

Remove existing piping in the cellar

Install the new pipes at the keg and pumps and the cooling in the cellar
Direct the pipe trunking to the restaurant area
Direct the pipe trunking to the ceiling
Fix the trunking at the ceiling with U-clamps
Direct the trunking to the dispensers using the T-Connectors were they are needed
Direct the trunking through the hole in the column casing

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)

is the rate of heat transfer (W)

is the mass flow rate (kg/s)
is the specific heat capacity of the beverage
is the difference in original and required beverage temperature

The workings for this can be found in appendix 4.1.

Installation
Required Flash Cooler
Capacity [kW]

Small
3.5

Medium
5.3

Large
7.6

Table 4.1: Required Flash Cooler Capacities

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:

It would have to meet the maximum heat exchange rate

Ideally it would need to utilise existing cooling equipment
Ideally it would be universal for all types of drink
Ideally it would have to be cost effective

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.

Figure 4.1: Typi al Cella to Ba Cella E uip e t

Figure 4.2: Indicative Example of Additional Flash Cooler Installation

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.

Beverage Temperature Maintenance

Due to the increased pipe length required compared to a sta da d ella to a s ste t pi all fou d
in existing pubs and restaurants, concerns regarding the warming of the beverages in the pipework
were raised. These were based on the increased time fluid would remain in the beverage lines after
already being pre-cooled to their desired temperature in the cellar. By treating the overall length of
the system as a compound cylinder and the beverages contained within as being static the worst case
scenario for the heat exchange rate between the beverages and the ceiling space was calculated using
equation S2 for each installation type. The resulting system heat transfer rates are shown in table ST2
below.

Where:

(4.2)

is the rate of heat transfer with the environment (W)

is the temperature of the fluid (oC)
is the ambient temperature of the environment (oC)
is the diameter of the pipe insulation (m)
is the pipe outer diameter (m)
is the surface heat transfer coefficient (W/(m2. oC))

The workings for the above can be found in appendix 4.2.

Installation
Rate of Heat Transfer [W]

Small
215

Medium
315

Large
383

Table 4.2: Rate of Heat Transfer of Pipework System with Environment

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

is the length of pipework accommodated by 0.568 litres of fluid (m)

is the mass flow rate (kg/s)
is the specific heat capacity of the beverage
is the difference in original and required beverage temperature

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

Figure 4.3: Indicative Installation of Glycol Cooler

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

i sulatio thi k ess is used as a o p o ise

between bundle thickness and insulation capacity. A thicker bundle would better insulate the pipe but
it would be unmanageable when installing. Finally a vapour barrier is used to ensure moisture does
not reach the colder beverage and coolant lines within, therefore considerably reducing any
condensation build-up within trunking.

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)

is the rate of heat transfer of the system (W)

is the mass flow rate of the coolant(kg/s)
is the mass flow rate of the beverage(kg/s)
is the specific heat capacity of the coolant (J/kg.K)
is the specific heat capacity of the coolant (J/kg.K)
is the coolant input temperature (oC)
is the coolant output temperature (oC)
is the beverage input temperature (oC)
is the beverage output temperature (oC)
Installation
Required flow rate of
glycol coolant at -1.7C

Small
0.012 ltrs/s

Medium
0.018 ltrs/s

Large
0.021 ltrs/s

Table 4.3: Required Glycol Coolant Flow Rates

Workings can be seen in the appendix 4.4.

As statedea lie i the epo t eusedall ofthegl ol oola tli es ithi thet u ki gfo the hot
etu flo of the oola t. To odel this e app o i ated the oola t li es as si gle la ge
coolant line and the outer beverage lines were approximated as a large concentric pipe around the
coolant line. This is shown in figure 4.4 above. This simplified the required process of calculating the
resulting heat transfers rates between the coolant, beverages and the ambient ceiling space
temperature.

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.

4.2 Dew point

Checks were also performed regarding the dew point and surface temperature of the trunking to avoid
a o de satio fo i go thet u ki g ssu fa e hi h ould ause ate da agetothe oofspa e
and other components within the dispenser units, as well as to avoid dripping on electronics or
customers. After looking at standard operating temperatures and humidity levels of restaurants and
using the logarithmic mean temperature gradient in equation (4.6) todete i ethet u ki g ssu fa e
temperature, it was confirmed that during normal operation of the system there should be no
condensation build up as the trunking surface temperature should not fall below 17.9oC (above the
16oC dew point temperature for a comfortable environment taken from the psychrometric chart and
accompanying table in the appendix 4.7).
=

Where:

(4.6)

is the rate of heat transfer with the environment (W)

is the temperature of the fluid (oC)
is the surface temperature of the trunking (oC)
is the diameter of the pipe insulation (m)
is the pipe outer diameter (m)
is the thermal conductivity of the insulation (W/m.k)

Workings can be seen in the appendix 4.3.

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.

Figure 5.1: Funnel and Drainage Tap Components

17

6 Structural Considerations (Dominic, James and Iason)

Design Concepts
Before a design could be taken forward into the design development stage of this project it had to
first meet some certain requirements. Firstly to agree with the original criteria the design must be
attached to the ceiling of the restaurant. Along with this, all of the pipes had to flow along the ceiling
and then down through the structure to where the dispensing system will be located. Below are the
criteria points that the structure design had to meet:

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.

Figure 6.1: Original design

Figure 6.2: Cross-section of Structure

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

6.2.3 Stress Analysis

Once MatLab was able to compute the deflection and torsion of the structure, the forces and stresses
within the material were considered. To carry out these calculations a worst case force of 1000N was
applied to the table to simulate a person standing on it.
The resulting forces inside the structure can be calculated by regarding it as a static problem. The
resulting stresses are calculated with the following equations respective of their local geometries:

Bending stress: =

, where

is the inside resulting bending moment and

, where

is the inside resulting torsion and

the

elastic section modulus

Torsional stress: =
Normal stress: =

where

is the resulting normal force and

the plastic modulus

the cross-sectional area

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)

where is the response to a generic impulse,

is the equivalent mass, is the damped natural
frequency, is the damping constant, is the undamped natural frequency and is the time from
the impulse applied. The displacement is then modelled by multiplying by the magnitude of the
impulse force. MatLab was then used to create two parallel arrays, one with time increasing in
increments of 0.0001 seconds and the other housing the corresponding displacements. These were
plotted in a graph to give a visual impression of the vibration that the table would experience. Here it
is important to note that the effects of air resistance, although very small, where include within the
design. Hence for these calculation equalled 0.025.
6.2.5 Modelling
Once the MatLab programme could output all of the above information about the structure to the
user, it was time to start putting values into the code. All variables that were not structural parameters
were taken as their worst case scenario. For example the point force used within the stress analysis
was located at the edge of the table where it would have most effect, as well as being equivalent to
the force that would be applied if a large person stood on top of the table.

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.

Figure 6.3: Graph showing Displacement Vs Time

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.

Figure 6.4: Tuned Vibration Absorber

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.

Figure 6.5: Displacement Vs Time for the thicker structure

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.

Figure 6.6: Initial Module Design with 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.

Figure 6.7: Assembly of two Modules

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.

Figure 6.8: Exploded view of the Table Top

Support

Figure 6.9: Table Top Secured in Place

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.

Figure 6.10: Module before Insulation

Figure 6.11: Module and Guide Rods in place

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.

Figure 6.12: Two T-Brackets Fastened to the top

Module

Figure 6.13: Cladding Secured in place

25

Design for Manufacture

Once the structure had been fully designed how the modules would be fabricated was considered. As
some of the material sizes are reliant on the fastening techniques a full list of dimensions is needed
first. For a completely secure weld, the plate that is being welded onto must be of equal thickness as
that of the material you are fastening. As the square vertical rods of the structure had to be 30mm
squared to withstand buckling when fully loaded, it meant that the top and bottom plate of the
module also had to be 30 mm thick. On top of this, 5 mm every side around the square rod needed to
be allowed for the fillet weld to be carried out (Australian Institute of Steel Construction, 1996). As a
result the top and bottom plate have to be 230 mm wide, as this is equal to the sum of the other
leading factors (i.e. 150mm for the cavity, two 30mm thick square rods and then the room for the fillet
weld (5mm x 4)). Furthermore as the height of each module is set to 750 mm, it becomes clear that
the vertical rods must be of length 690 mm.
As previously stated, the fabricators are only manufacturing one type of model and therefore they
could choose to use jigs. These would speed up the process as the fabricator would not have to keep
measuring out each length of material.
For convenience, all the prices of materials are taken from one website, themetalstore.com which
supplies mild steel at grade CR4, bar the top and bottom plate. This is due to the fact that the metal
store can only cut sheet metals up to a thickness of 18 mm, which is less than the 30 mm thick plates.
To generate the price for the top and bottom plate a CAD drawing was sent to
.i dust ial etal. o.uk .Thep i es for this are supplied within the appendix 11. To obtain a price
for cutting the remaining the materials, the entire length that was going to be cut needed to be
calculated first. Then using the quoted cutting price from the same supplier of 1.20/m (The Metal
Store, 2015) it is possible to find out the price to cut the material to size. The outcome of this is also
shown within the appendix 11.
Once all the materials had been cut to size, how the modules would be assembled was researched. To
secure all of the brackets to the modules a MIG welder (metal inert gas welding) using 6013 electrodes
was sufficient. However as most of the remaining structural parts are thicker than 18mm it was no
longer safe to use 6013 electrodes and therefore 7018 electrodes are to be used. As stated by, the
thicker the steel the more stresses and strains are produced by the heat of welding. 7018s produce a
cleaner, more ductile and stronger weld metal better equipped to withstand these higher stresses.
Also the thicker the plate the greater the chance of hydrogen induced cracking. 7018s are low
hydrogen and as such are less prone. (Mig welding - The DIY guide, n.d.)
The cost of welding was calculated in a very similar way to that of the cutting cost. A quote that was
received from PSP architectural gave the price of 50/m. This was then multiplied by the total weld
length to give the price of fabrication. This information can again be seen in the appendix 11.

Design for Sustainability

In a bid to make the product more sustainable, the waste material that was created to allow the
module to slide through the centre of the table was reused in a different component. To facilitate this
module in the centre of the table-top a hole of 230mm x 230mm was created. This waste material was
then take to make the support for the drip tray. When In place, this not only reduced the amount of
waste material, but created a seamless blend table to drip tray. This is shown in figure 6.14.

26

Figure 6.14: Drip Tray

27

7 Dispensing System (Murtaza and Martin)

The dispensing system comprises of two components: the valve system and the nozzle assembly. Both
of these are housed within the body of the dispenser and are used to effectively deliver any of the ten
beverages available to the customer as soon as a request is made.

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

7.1.1.1 Plunger Valve and Linear Actuator

Initially, the dispenser body was made using a hollow steel square section which had an internal area
of 0.0225cm2 and so the ten control valves would have to be housed within this small area. However,
since there is limited access to the inside of the section, a solution was required which allowed for
simple installation and ease of access to the valves for maintenance.
The first solution was to use a 10mm stainless steel plunger valve powered by a linear actuator which
would open or close the valve as required. The linear actuator would have to again be small enough
to fit within the confines of the hollow square section but be powerful enough to move the plunger
against the force of the fluid above.
The desired configuration of this solution is shown in figure 7.1; where the yellow component shows
a cross section of the linear actuator and the blue component shows the cross section of the plunger
valve. The red arrows show the direction of flow. It is clear that when the linear actuator is at rest, the

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:

Its dimensions are very large

Slow response time
High cost

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.

Figure 7.13: Operation of a

solenoid valve
7.1.2 Design Development and Detail Design
Ultimately, the second concept was decided upon as a solenoid would provide a better solution to the
problem of controlling beverage flow.

7.1.2.1 Valve Specification

In order to specify a valve, certain parameters of our system would have to be calculated and
compared to the values on its datasheet to see if the valve is capable of handling the system. These
parameters include the:

29

Maximum operating pressure differential (MOPD)

Flow factor, Kv
Port diameter
Material choice

The MOPD is the difference between inlet pressure and outlet pressure of the nozzle, as shown in
equation (7.1)
=

(7.1)

Where MOPD is the maximum operating pressure differential,

is the pressure at the inlet of the
solenoid valve, and
is the pressure at the outlet of the valve. All units are in kPa. The MOPD is
the pressure the solenoid operator has to overcome to open the valve. If the solenoid valve selected
has a quoted MOPD lower than the pressure drop in the actual system, the solenoid coil will burnout
and the valve will be permanently damaged. To prevent this from occurring, it is imperative that the
chosen valve will meet desired criteria. Table 7.1 shows the pressure values for each beverage line
within the dispenser, with the MOPD being calculated using equation (7.1)
Inlet Pressure (kPa)
116.8

Outlet Pressure (kPa)

101

MOPD (kPa)
15.8

Table 7.4: Calculated MOPD for each beverage line

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

Inlet Pressure (bar)

Outlet Pressure (bar)
MOPD (bar)
Flow rate (m3/h)
Flow factor (m3/h)

Beer
1.77
1.01
0.518
0.204574
0.5086

Wine
1.77
1.01
0.518
0.184115
0.4577

Table 7.5: Flow properties for each type of beverage

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

Solenoid Valve Specification

6
0.78
5
Stainless steel

Table 7.6: Solenoid valve specification

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 7.15: This design is typical of type 6011 solenoid

valve

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.

Figure 7.14: 10mm to 3mm pipe

adapter

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.

Figure 7.16: 3mm pipe to valve

connector

32

7.1.2.3 Support Structure and Valve Mounts

The ten solenoid valves with their correct connectors must be securely supported within the frame of
the dispenser. To support the valves, a tiered structure was used on to which each valve could be
secured into place. The frame of the dispenser is made from hollow modules with a cavity in the centre
to which the tiered structure can be attached. The entire structure can pass though the frame of the
dispenser allowing for simple installation. A render of the structure can be seen in figure 7.6.

Figure 18.6: Render of the valve support structure

with 3 tiers

Figure 18.7: Render of the valve support structure with

valves

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.

Figure 7.19: The completed valve system, with 3mm piping

shown in red

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

7.1.4 Commercial Considerations

A full list of materials and manufacturing costs are provided in appendix 11. Each steel plate costs
approximately 1.07 to buy and 0.85 to manufacture. This was done by buying in mild large mild
3mm thick mild steel sheets with dimensions 2500x1250mm and cutting them to the necessary size.
Since each dispenser requires 3 tiers, the total cost for the steel tiers would be 5.76.
The same method was used for the threaded rods. 3m long M10 rods would be bought and cut to the
correct size. The total cost per steel rod is approximately 1.02, however four rods are required for
the support structure and so the total cost for the rods would come to 4.08 per dispenser.

Figure 7.20: View of a 180x180mm steel plate before being

manufactured

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

7.2.1.1 Soft Drink Nozzle

Ideally, sourcing nozzles from manufactures would be ideal for the dispenser because this would
greatly reduce manufacturing costs as nozzles could be ordered in. In most bar systems, the piping is
fed into a diffuser, shown in figure 7.10 (John, 2015), which is glued into the soda gun. This essentially
acts as a hub which receives the end of each drinks line. A generic soft drink nozzle would simply screw
onto the end of the soda gun body to complete the assembly. However, if standard nozzles were to
be used, it would require the design and manufacture of a new diffuser with the capability to allow
multiple pipes to enter it, allow the nozzle to screw onto it and have a method of mounting itself to
the dispenser body. This would increase the manufacture cost of the nozzle assembly, and as well as
this, the cost of buying standard nozzles would have to be included in the price.

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:

At least 6 inlets that accept 10mm diameter piping and 1 outlet,

A method of securing the nozzle to the dispenser body.

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.

Figure 7.22: Initial design concept of the soft drink

nozzle

7.2.1.2 Alcoholic Drink Nozzle

The beer nozzle is the most complicated design. Unlike wine and soft drinks, the nozzle cannot simply
be vertically set into the glass because a pint of beer needs to have a certain height of head, the froth
created when the beer is poured into the glass. Too little head and the important aromas from the

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.

Figure 7.1424: The glass supported by a small widget

38

Figure 7.15: The operation of the widget

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.

Figure 7.25: A concept showing a lowering nozzle

7.2.2 Design Development and Detail Design

7.2.2.1 Soft Drink Nozzle
The final soft drink nozzle design was based upon the initial concept shown in figure 7.11. The top of
each nozzle will feature seven inlets onto which a 10mm pipe can be clamped to the nozzle as shown
in figure 7.17. There is a gap between the centres of each inlet to the centre of the adjacent inlet of
15mm. Since the thickness of the 10mm trunking used throughout the design is 2mm, this allows for
plenty of space to attach the piping and install the pipe clamps. This results in the diameter of the
head of the nozzle being 50mm and the outlet diameter being 20mm. The thickness of the nozzle was
chosen to be 4mm as this is standard in current soft drink nozzle designs.
Around the outside of the nozzle, there are 3 pins 120o apart which are 2mm in diameter and 2mm in
length. These will be used to mount the soft drink nozzle into place. Figure 7.18 shows the nozzle
alongside a standard pint glass for scale.

39

Figure 7.27: Design of the soft drink nozzle. It can be

seen that they have 7 inlets and 1 outlet

Figure 7.27: The soft drink nozzle shown

with a standard pint glass

7.2.2.2 Alcoholic Drink Nozzle

The design that was chosen was to angle the nozzle itself, as it was by far the cheapest design. The
flow would exit the nozzle with a horizontal component. This meant that the flow would hit the pint
glass halfway down and as the glass filled up, the flow would start to go straight into the already
dispensed beer so not too much head would be created. A detailed drawing of this can be found in
figure 7.19.

Figure 28: The final design concept

The angle at which the nozzle was set was calculated using equations (7.4) and (7.5)
=

s = ut +

(7.4)
(7.5)

40

Where id the displacement in m, is the horizontal velocity in m/s,

m/s, is the time in s and is the acceleration in m/s2.

is the initial vertical velocity in

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

Table 7.8: The results table showing an investigation of head

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.

Figure 30: A closer view of the 'twist and lock' mechanism

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

Figure 31: The completed nozzle assembly

7.2.3 Design for Manufacture and Sustainability

The two types of nozzle and the mounting plate are required to be made from a food safe material
which can be easily shaped. It was decided that a plastic such as polyethylene terephthalate (PET) was
an acceptable material to use as it is completely food safe. Plastic injection moulding each of these
three parts was agreed to be the best method of manufacture because:

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

Tool for Component

Soft drink nozzle
Alcoholic drink nozzle
Nozzle mounting plate

Cost ()
4301
3114
7418

Table 7.10: Cost to create the tool required to plastic injection mould each component

Overview of Dispensing System

In this section, both the valve assembly and the nozzle assembly have been fully defined. This section
explains how both of these fit together within the frame of the dispenser in order to deliver a
beverage. Figure 7.23 shows an exploded view of a single drink line from the top of the dispenser to
the outlet of the nozzle.

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

8 Control system (Iasbel)

Design concepts
The control of the dispenser from the customer order to the eventual dispensing of the desired drink
is an important aspect of the design. Keeping in line with the self-se i e a keta d ithtoda s
technology, the design operates from a touch screen. Traditionally in a restaurant environment all
party members are looking at the menu at once. Therefore the design requires multiple or easily
accessible screens. With the dispenser occupying the central spa eo ea hta le,thes ee ssize
and position also needed to remain unobtrusive to the dining environment. It was important that the
touch screen device was cost effective, meeting the functions required from the device, and not
beyond the scope of design criteria. In order to ensure this an objective tree was developed as shown
in figure 8.1.
Ordering
System

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

Figure 8.1: Touchscreen Objective Tree

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)

Figure 8.2: Design concepts

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

Figure 8.3: Open Frame Touchscreen Display

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.

Figure 8.4: Kiosk Mount for Tablet

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

Table 8.1: Pugh Matrix for Touchscreen Design Concepts

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

Read flow rate

Figure 8.5: Control System

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:

1. The output voltage is 12V, the current is <2A.

A circuit array, such as a MOSFET (Metal Oxide Semiconducting Field Effect Transistor), which
is a transistor based switch driven by voltage, can boost the current supply. Given the circuitry
contains a solenoid; a diode would have to be connected across the transistor to protect it
against back emf.
2. The output current and voltage both not in the correct range.
A relay is required to boost the voltage and current. Relays contain an electromagnetic coil
that, when energised, connects to the load to drive the valves. There are two subcases as a
result:
a) The microcontroller output current can drive the relay.
The relay is connected directly.
b) The microcontroller output current is insufficient drive.
A relay driver such as a transistor array is required similar to above.
These cases need to be considered under the choice of microcontroller.
8.2.2 Communication
In order for the system to work and clearly from figure 8.5, there needs to be communication between
several components in the control system. These are:

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.

Ethernet cables can transfer up to 100Gbits/s (arstechnica, 2015)

Wireless up to 6.75Gbits/s (N, 2015)
CAN (Controller Area Network) chip up to 500kbits/s (Motion Engineering, 2015)
Data cables such as an RS-232, up to 20kbits/s (ARC Electronics, 2015)

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.

Based on Wagamamas and Nandos

48

Criteria
Robust
Battery capacity
Stand/case
compatible
Sleek
all,<
Expansion
Cost effective
Wifi
Memory
Processing speed
MTBF
TOTAL:

Weight

Acus VevoTab iPad Mini 3

Samsung Galaxy Tab 3.0
8
2
2
2
7
1
2
2
9
2
4
4
6
10
5
10
10
9
8
7

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

Table 8.2: Pugh Matrix for Tablet Design

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.

Figure 8.6: Generic Interface

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.

Figure 8.7: User Interface Flow Map

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:

Table management and booking

Inventory
Kitchen communication
Order management

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

Read flow rate

Flow rate recorded

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:

reading data continuously from the server

outputting a logic high on the correct output pin
reading the flow metre
outputting logic low at desired volume

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

Table 8.3: Pugh Matrix for Microcontrollers

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.

Figure 8.9: Wiring Diagram

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

is the voltage drop, is the current and

(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

AWG (American Wire Gauge)

24
14
30

Table 8.4: Wiring Sizes

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

Clear Existing Pipe work

1 hour

None

Structures

1 per dispenser

None

Fit Pipes

0.5 per dispenser

Structures and clearing

existing pipework

Fit Out Dispenser

0.3 per dispenser

Pipes

Electrical Work

0.5 per dispenser

Fit

Set up Tablet

0.16 per dispenser

Electrical Work

Table 9.1: Tasks

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

10 Finance and Business Plan (James and Shaun)

This section discusses the way the company will turn a profit. There are several facets to this decision:
1. The value of the dispensers to the restaurants
2. The cost of producing and delivering the dispensers
3. The demand for the dispensers
These three will be analysed in order to determine the best way to charge each restaurant for the
product, in order that the product is as attractive and competitive as possible, but also that the
company is profitable and attractive to investors and lenders.

Value to the Restaurant

Firstly, the profit generated by the dispensers must be evaluated. There are two means by which the
dispensers increase profit:
1. Employing fewer waiting staff
2. Increasing drink sales
The first means is analysed by working out how many waiters would be needed for a 21-table
restaurant that uses the dispensers. Table 10.1 demonstrates how much time is spent with each table
if dispensers are installed.
Task
Set up and demonstrate dispenser
Gap for food to be ordered and prepared
Deliver food
Gap for food to be eaten
Clear table
Gap for dessert to be ordered and prepared
Deliver Dessert
Gap for dessert to be eaten
Clear table
Gap
Bring bill
Set up and demonstrate dispenser

Time [min]
3
~ 20
2
~ 20
2
~ 17
2
~12
2
~ 12
1
3

Table 10.1: One Table Waiter Timesheet

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:

129575 0.35 0.747 0.1 3,389.49

(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

Beer price as percentage of cost price

Soft drink price as percentage of cost price
Wine price as percentage of cost price
Gross Profit / Unit (wine)
Gross Profit / Unit (beer)
Gross Profit / Unit (soft drinks)

450%
1000%
170%
41%
77%
90%

Increase in turnover / month (drinks sales)

Average gross profit margin
Profit increase/month (drinks sales)

4,535.13
75%
3,389.49

Total Loss Due to Setup

Monthly Gross profit increase
Price for Restaurant

62,957.50
7,389.49
50,000.00

Percentage of profit taken by the company

Monthly net profit increase per restaurant

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

Table 10.3: Expenditure overview

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.

Number of Sales per

month

Graph of Projected Increasing Demand

5
4
3
2
1
0
1

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:

Low level of debt

No burden of maintenance for the company
No risk of a change in fashion. (Since the company sold the dispensers, they are no longer our
responsibility, so if a better method of serving drinks is invented in the next ten years the
company does not lose any earnings)
Disadvantages

Lower level of profit

Very unattractive to the market, few restaurants can raise 100,000 to pay upfront.

Option 2: Ten-year financing

Advantages:
Far higher profit to the company
Easier for the restaurant to pay as there is no upfront cost
Disadvantages

Burden of maintaining dispensers

Very high level of debt before income catches up with expenditure
Risk that a newer product will be released and the restaurant will get rid of ours, paying us
nothing past this point
Risk that the restaurant goes bust.

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:

Table 10.4: Pugh Matrix for Costing Method

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

Figure 10.4: Graph showing the effects of bad debt

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

Number of Sales /month

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

Net loan drawdown

113,770.39

1,085,974.06

0.00

0.00

0.00

0.00

Table 10.5: Summarized projected Cash Flow

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.

Figure 10.5: Cumulative profit

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:

It would be installed at each table within a restaurant

Give customers the ability to independently order, dispense and collect their drink
Have the ability to dispense lager, wine, water and soft drinks
Include a food ordering system

To fulfill the above requirements and ensure that a robust, cost effective and efficient product was
produced many refinements were made. These included:

The use of overhead beverage trunking

Optimal beverage line pathing
Efficient Glycol Cooling to maintain beverage temperatures
Effective delivery nozzle system
Compact and responsive electronic dispensing valve package
Accurate fluid control system
Intuitive UI hardware and software package
Flexible modular solution of the dispenser structure

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

13 References
Amazon Supply, 2015. Robert Manufacturing R900 Series Bob Red Brass Float Valve with Fluted
Plunger, 3/8" NPT Male Inlet x 3/8" NPT Male Outlet, 13 gpm at 85 psi Pressure. [Online]
Available at: http://www.amazonsupply.com/robert-manufacturing-series-plungerpressure/dp/B008OMH7IY
[Accessed 2015].
Anon., n.d. [Online].
ARC Electronics, 2015. RS232 Data Interface. [Online]
Available at: http://www.arcelect.com/rs232.htm
[Accessed 2015].
arstechnica, 2015. Speed atte s: how Ethe et we t f o
M ps to
G ps a d eyo d.
[Online]
Available at: http://arstechnica.com/gadgets/2011/07/ethernet-how-does-it-work/
[Accessed 2015].
Australian Institute of Steel Construction, 1996. Costing of steelwork from Feasibility Through To
Completion Steel Construction, Vol 30, No 2. s.l.:s.n.
Axiomtek, 2015. 5" XGA TFT Ope F a e Pa el Co pute with I tel Ato p o esso N 7 .
[Online]
Available at:
http://axiomtek.com/Default.aspx?MenuId=Products&FunctionId=ProductView&ItemId=845&upcat
=252
[Accessed 2015].
Bouncepad, 2015. Bouncepad Static 60. [Online]
Available at: http://www.bouncepad.com/product/ipad-kiosks-static60/
[Accessed 2015].
Burkett, 2015. Type 6011. [Online]
Available at: http://www.burkert.co.uk/en/type/6011
[Accessed 2015].
Business, R. f. B. -. E. o., 2015. Location Strategy. [Online]
Available at: http://www.referenceforbusiness.com/management/Int-Loc/Location-Strategy.html
[Accessed 5 March 2015].
Caglar, L., 2015. Fira - Ergonomics of Tables and Desks. [Online]
Available at: http://www.fira.co.uk/technical-services/ergonomics/bs-en-527-1-2011
[Accessed 2015].
Carlsberg Ltd, 2015. Carlsberg - Perfect Beer. [Online]
Available at: http://www.carlsbergwedelivermore.co.uk/uploads/1c356399-82b8-c154-a56ff537d0d4e932.pdf
[Accessed 2015].
EC&M, 2015. The basics of calculating voltage drop. [Online]
Available at: http://ecmweb.com/content/basics-calculating-voltage-drop
[Accessed 2015].

68

Engineering, P., 2015. Flow Meter Types Based on Measurement Techniques. [Online]
Available at: http://www.piping-engineering.com/flow-meter-measurement-techniques-types.html
[Accessed 2015].
Gov, 2015. Licensing of Alcohol. [Online]
Available at: http://www.cps.gov.uk/legal/l_to_o/licensing_of_alcohol/#sale
[Accessed 2015].
John, C. S., 2015. Soda gun. [Online]
Available at: https://wiki.ece.cmu.edu/ddl/index.php/Soda_gun
[Accessed 2015].
Linak, 2015. Linear Actuator LA22. [Online]
Available at: http://www.linak.co.uk/products/linear-actuators.aspx?product=LA22
[Accessed 2015].
Micromatic, 2015. Key Elements to Dispensing Wine. [Online]
Available at: http://www.micromatic.com/Wine_On_Tap-cid-16163.html
[Accessed 2015].
Mig welding - The DIY guide, n.d. Mig - welding. [Online]
Available at: http://www.mig-welding.co.uk/mild-steel.htm
[Accessed 2015].
Motion Engineering, 2015. CAN Bit Rate. [Online]
Available at: http://support.motioneng.com/software-mpi_03_04/docs/CAN/Topics/bit_rate.htm
[Accessed 2015].
N, S., 2015. For Multi-Gigabyte-Per-Second WPAN and WLAN. [Online]
Available at: http://arxiv.org/ftp/arxiv/papers/1211/1211.7356.pdf
[Accessed 2015].
Refrigeration Blogspot, 2015. Refrigeration. [Online]
Available at: http://refrigerationnew.blogspot.co.uk/2014/07/refrigeration-solenoid-valveworks.html
[Accessed 2015].
RS, 2015. SKF 500N ACME Screw Drive Electric Linear Actuator, 24V dc, 16mm/s, 200mm Stroke.
[Online]
Available at: http://uk.rs-online.com/web/p/electric-linear-actuators/7643480/
[Accessed 2015].
Tabletmonkeys, 2015. Tablet Comparison Chart: List of Tablets. [Online]
Available at: http://tabletmonkeys.com/tablet-comparison/
[Accessed 2015].
The Engineering Toolbox, 2015. Major loss in Ducts, Tubes and Pipes. [Online]
Available at: http://www.engineeringtoolbox.com/major-loss-ducts-tubes-d_459.html
The Engineering Toolbox, 2015. Minor Loss Coefficients in Pipes and Tubes Components. [Online]
Available at: http://www.engineeringtoolbox.com/minor-loss-coefficients-pipes-d_626.html

69

The Metal Store, 2015. The Metal Store. [Online]

Available at: http://www.themetalstore.co.uk/products/misc
[Accessed 2015].
TITAN ENTERPRISES LTD, 2015. Beverage meter. [Online]
Available at: http://www.flowmeters.co.uk/pdf/turbine_meters/Beer_Meter/beverage-meter.pdf
[Accessed 2015].
Valvias, 2015. Flow Coeffiecient. [Online]
Available at: http://www.valvias.com/flow-coefficient.php
[Accessed 2015].

70

14.1 Introduction, Project Plan

November

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

INITIAL IDEAS STAGE

Generate possible projects

All

Choose a project to go with

All

Initial Drawings

Shaun

Market research

All

FEASIBILITY BUSINESS REPORT

Develop concepts for the project
Further drawings

Key

All

Task duration

Shaun

Pugh Matrix to decide on final concept

Martin

Deadline

Initial Project Plan

Martin

Optional task

Start costing estimates

Murtaza

Develop URS

All

Develop report structure

All

First draft report

All

Write final report

All

Feasibility Report hand-in

DESIGN
Review feedback

All

Piping system

Shaun/Iason

Fluid Flow calculations

Shaun/Iason

Beverage Cooling System

Dispenser nozzle/head design

Shaun
Murtaza/Isabel

Beer Dispensing Method

Martin

Beer Nozzle

Martin

Glass holder

Martin

Delivery/valve system

Murtaza

Bending moment/torsion of beam

James/Dom

Design of Dispenser Unit

James/Dom

Design of Joint
Design of Supports

Dom
James/Dom

Deatailed Drawings of Structure

Table Design
Cleaning system

Iason/Dom
Iason/Dom
Shaun

Valve System

Murtaza

User Interface

Isabel

Tablet, POS design

Isabel

Wiring Data Lines

Isabel

Installation Procedure in Restaurant

FMEA
Operations Costs
Full List of Costs

Martin
All
Shaun
All

Marketing strategy

James

Business Model

James

Pricing Strategy

James

Final design finshed

EXTRAS
Payment system
Food ordering system

Isabel

Sauce dispenser
PRESENTATION
Draft presentation structure

All

Produce idividual slides

All

Put together Final presentation

All

Rehearsal

All

Presentation
FINAL REPORT
Draft structure

All

Write individual sections

All

Compile Report

All

Formatting

All

Report Hand-in

10

20

150

10

50

10

10

80
M10 THREAD
150

150

20

UNLESS OTHERWISE SPECIFIED:

DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME

DEBUR AND
BREAK SHARP
EDGES

FINISH:

SIGNATURE

DATE

DO NOT SCALE DRAWING

TITLE:

DRAWN

VALVE SUPPORT PLATE

CHK'D
APPV'D
MFG
Q.A

REVISION

SolidWorks Student Edition.

For Academic UseMATERIAL:
Only.
WEIGHT:

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

DO NOT SCALE DRAWING

SolidWorks Student Edition.

For Academic UseMATERIAL:
Only.
WEIGHT:

Alcoholic Drink Nozzle

A4

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

DO NOT SCALE DRAWING

REVISION

TITLE:

DRAWN

Table Support Plate

CHK'D
APPV'D
MFG
Q.A

SolidWorks Student Edition.

For Academic UseMATERIAL:
Only.
WEIGHT:

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

DO NOT SCALE DRAWING

TITLE:

DRAWN

Drip Tray Cover

CHK'D
APPV'D
MFG
Q.A

REVISION

SolidWorks Student Edition.

For Academic UseMATERIAL:
Only.
WEIGHT:

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

DO NOT SCALE DRAWING

SolidWorks Student Edition.

For Academic UseMATERIAL:
Only.
WEIGHT:

Soft Drink Nozzle

A4

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

DO NOT SCALE DRAWING

TITLE:

DRAWN

Drip Tray

CHK'D
APPV'D
MFG
Q.A

REVISION

SolidWorks Student Edition.

For Academic UseMATERIAL:
Only.
WEIGHT:

A4

DWG NO.

SCALE:1:5

SHEET 1 OF 1

7.50

50

20

150

17.50

20

12

20

150
20

150

CIRCLE RADIUS 2MM

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

DO NOT SCALE DRAWING

TITLE:

DRAWN

Nozzle Mounting Plate

CHK'D
APPV'D
MFG
Q.A

REVISION

SolidWorks Student Edition.

For Academic UseMATERIAL:
Only.
WEIGHT:

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

DO NOT SCALE DRAWING

TITLE:

DRAWN
CHK'D
APPV'D
MFG
Q.A

SolidWorks Student Edition.

For Academic UseMATERIAL:
Only.
WEIGHT:

REVISION

Module
A4

DWG NO.

SCALE:1:10

SHEET 1 OF 1

Piping System
14.3.1 Flow velocities, flow rates, Reynolds Numbers

14.3.2 Darcy-Weisbach coefficient

73

14.3.3 Pipe Loss

74

14.3.4 New pipe loss (large)

75

14.3.5 Solubility of Carbon Dioxide in Beer, Pressure-Temperature Relationships

http://www.draughtquality.org/wpcontent/uploads/2012/02/Carbonation_Volumes_Pressure_Temperature_Chart.pdf
05.03.2015, 12:00pm

76

14.3.6 Pipe drawings

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

No of drinks dispensed simultaneously * Conversion between 1 pint in 10 seconds to volumetric flow

rate * Specific heat capacity of fluid * Stored fluid temperature * Required fluid temperature * Fluid
density
1 Pint in 10 seconds =

0.000568261

m^3 /s

Specific heat capacity of fluid

4193

J/Kg.K

Stored fluid temperature

20

Degrees Celsius

Required flow temperature

Degrees Celsius

Fluid density

1000

Kg/m^3

14.4.2 Beverage and Trunking Surface Temperatures and System Losses

78

14.4.3 System Heat exchanger rate calculations

79

14.4.4 Coolant Flow Rates

14.4.5 Flash Cooler

(3100 BTU/hr = 0.908520318 kilowatts)

(1595 CAD = 832.15 GBP)
http://www.hotfridges.ca/content/flash-chillers/best-for-beer/6/T160F-12T6

80

14.4.6 Glycol Chiller

Glycol Chiller Specs

Maximum Distance

450 ft.

Capacity

5500 BTU/hr. (1.61189089 kilowatts)

Glycol Tank Capacity

15 gal.

Dedicated Circuit

20 Amps.

Voltage

115/60 volt/Hz.

Compressor Power

3/4hp

Pump Type

Procon-100gl

Pump Flow Rate

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

14.4.7 Dew Point

Dew point

Human perception[1]

Relative humidity at 32 C (90 F)

Over 26 C

Severely high. Even deadly for asthma related illnesses

65% and higher

2426 C

Extremely uncomfortable, fairly oppressive

62%

2124 C

Very humid, quite uncomfortable

5260%

1821 C

Somewhat uncomfortable for most people at upper edge

4452%

1618 C

OK for most, but all perceive the humidity at upper edge

3746%

1316 C

Comfortable

3841%

1012 C

Very comfortable

3137%

Under 10 C

A bit dry for some

30% and lower

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

% stiffness of one module

% The vast majority of the bending will take place outside
% the braces, so these will be modelled, and any bending
% within the braces will be neglected
Ia = ( D ^ 4 ) / 12 ;
Ib = ( (D) ^ 4 ) / 12 ;
ka = 12 * E * Ia / ( L1 ^ 3 );
kb = 12 * E * Ib / ( L1 ^ 3 );
Ka = ka / n;
Kb = kb;
K = Ka + Kb;

% 3EI/L3
% 3EI/L3

* 4
* 4

% Identical springs in series

% springs in parallel

% equivalent mass of system

% the system will bend sinusoidally, and the springs have mass. therefore
% there must be a way to model the displacement of the spring mass,

85

% including it in the total mass of the system

vol=x*y*z;
mt=density*vol;
mrod = steeldensity * L1 * D^2;
mplate = steeldensity * plthi *
plate
mm = ( 4 * mrod ) + ( 2 * mplate
ma = n * mm;
mb = mm;

% 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;

fprintf('K = %0.1E\n', Kb);

%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

Table 14.1.1: Fast Food Outlets

Table 14.2.2: Population Density

89

Table 14.3.3: Heat map

Table 14.4.4: Major Road Map

90

Table 14.5.5: Final chosen Location

Table 14.6.6: Final chosen Unit

91

14.9.2 Fixed Costs

92

14.10 Operational Cost

Fixed

Building/Office

(ALL FIGURES ARE )

Rent
Business Rates

Electricity

Public Utilities

Monthly

One Off

17587

22433

11280 per year

940 per month

9500 per year

792 per month

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

Boxes & Packing Material

100

per 50

Forklift

240 per month

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

230 per month

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

Soft Drink Nozzle

4301

Murtaza

Alcoholic Beverage Nozzle

3114

Murtaza

Nozzle Mounting Plate

7418

Murtaza

Website (Creation)
Website (hosting)

600 one off

wishdesign.co.uk

10 per month

Host Gator

Advertising
Depreciation

14583

Computer Equipment

3000

0,2

50

Office Furniture

1620

0,2

27

14.11 Bill of Materials

275
Material costs

Part

Cellar Equipment

Piping, Cooling &

Pressure Eqipment

Dispenser Body

Cleaning

Ceiling Joints

Price per part

User Interface

Electronics

Manufacturing Costs

Running Costs

Source
http://www.abbeychart.co.uk/shurflo-syrup-pump-166-296-28

Syrup Pump

62,04

Small

Total cost for part

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

3/8" Braided Tubing

1,02

http://www.sodadispenserdepot.com/pics/7123hose.html

5,10

5,10

5,10

Primary CO2 Regulator

36,34

10+

http://www.sodadispenserdepot.com/pics/Reg5125.htm

36,34

36,34

36,34

Secondary CO2 Regulator

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

Wine Keg Couplers

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

BIB Pipe Connector

7,75

10+

http://www.sodadispenserdepot.com/pics/Bib3200.html

31,00

31,00

31,00

3/8" Insulated 12 Bundle

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

L - section Bracket (Small)

0,06

10+

http://www.themetalstore.co.uk/products/6-metre-lengths-3mm-angle

60

90

126

3,60

5,40

7,56

L - section Bracket (Large)

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

Table Support Plate

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

olenoid Valve and Electrical Conne 36,65

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

Threaded Steel Rod

1,02

http://www.themetalstore.co.uk/products/3m-long-mild-steel-bzp-screwed-rod

40

60

84

40,80

61,20

85,68

3mm Plastic Piping

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

Pipe to Valve Connector

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

Pipe Adapter (10mm to 3mm)

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

Soft Drink Nozzle

1,60

10+

http://www.protolabs.co.uk/protomold

10

15

21

16,00

24,00

33,60

Alcoholic Drink Nozzle

1,44

10+

http://www.protolabs.co.uk/protomold

40

60

84

57,60

86,40

120,96

Flow Rate Sensor

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

Heavy Duty Adhesive Pads

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+

Email

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

Switch Board Unit

34,90

http://uk.rs-online.com/web/p/consumer-units/8111906/

34,90

34,90

34,90

Central Dispnser Module

106,00

20

http://www.themetalstore.co.uk/products/misc

10

15

21

1.060,00

1.590,00

2.226,00

Normal Dispnser Module

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

Re: Pricing request - Tabletkiosk a7400 | Durham University

Shaifta Saiyed<shaifta.saiyed@go4mobility.eu>
Tue 18/02/2015 16:25
Inbox

To: BANISTER I.;

Cc: salesreply@go4mobility.eu;

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:

The pricing structure of the Tabletkiosk a7400 is as mentioned below:

US $1148.00 One Time Cost.

US $928.00 1-20 Tablets.
US $785.00 21-60 Tablets.
US $541.00 61+ Tablets.

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

Shaifta Suhel Saiyed

Client
Go4Mobility.
Phone
Email

Accounts

+31

(0)76

52

45

shaifta.saiyed@go4mobility.eu

95

14.12.2 Alcoholic Nozzle

96

14.12.3 Soft Drink Nozzle

97

14.12.4 Nozzle Plate

Company Costing

98

14.13 Company Costing

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

14.14 Waiter Timesheet

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