Noodles Production in Chaudhary Food Complex: A Case Study

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Rajeev Thapaliya (66053)

Saubhagya Joshi (66066)

Sushil Dahal (66077)

ABSTRACTGet knowledge about the industrial automation

Performance of industrial components was seen

Knowledge about industry production

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ORGANIZATIONAL BACKGROUNDCG is the first Nepali conglomerate with over 40 companies

Established in 1935

FUDCO offers a wide range of products of true international quality

Nepal’s first noodles production company to be awarded ISO 9002

FUDCO has 2 sub units: NEPAL THAI FOODS (NTF) KWIKS FOOD NEPAL (KFN)

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OBJECTIVESTo provide the finest quality products

Maintaining consistency in taste

Meet the changing needs by using modern manufacturing practice

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CURRENT STATUS FUDCO Produces the following products: “WAI WAI TENZ”, in the NTF unit “KWIKS” CHEESE BALLS in the KFN unit

Production is done for 16 hours a day

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PRODUCTION DETAILS NOODLES:

1. Brown Noodles◦ WAI WAI 123◦ WAI WAI QUICK ◦ WAI WAI MINI ◦ WAI WAI TENZ

2. White Noodles◦ WAI WAI X PRESS◦ WAI WAI X PRESS MASALA DELIGHT ◦ SOALTEE

3. Snack Noodles◦ MIMI

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PRODUCTION DETAILS (continued…) BHUJIA & SNACKS

◦ MIMI CHEESE RING◦ KWIKS CHEESE BALLS◦ MAMA BHUJIA

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EXISTING SYSTEM’S BLOCK DIAGRAM

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DESCRIPTION OF UNITSMIXING UNIT:

Required amount of raw material is measured Mixing of flour with other ingredients Dough is prepared and fed to the unit manually

THICKNESS CONTROL UNIT: Thickness of the dough is maintain through the pair of rollers

SHAPING UNIT: Noodle shape is maintained

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DESCRIPTION OF UNITS (continued…)STEAMING UNIT:

Temperature setting is done by operator manually. Shaped noodle comes out from the shaping unit which is half cooked

at around 90 to 95 0 c

CUTTING UNIT: Unit noodles grooved are cut in the actual size Weight of the noodle is determined

FLAVORING UNIT: Soup is used to provide flavor in noodles

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DESCRIPTION OF UNITS (continued…)FRYING UNIT:

Noodle is fried in the palm oil at 1700 to 1800 c

DRYING UNIT: Dry noodle to remove oil

PACKING UNIT: Noodle is packed using digital technology

QUALITY CONTROL UNIT: Quality of the product is checked manually

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CASE STUDY: OBJECTIVETo acquire knowledge regarding the existing system

Giving suggestion on how to improve the current status of the industry

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PROBLEMS IN THE EXISTING PLANTMixing manually, consumes a lot of time

Thickness controlled using motors requires large maintenance and is least efficient

Manually control temperature causes errors

Manually checking final product is time consuming

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PROPOSED SYSTEM’S BLOCK DIAGRAM

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WORKING PROCEDURESMIXING UNIT:

Weight of the flour is detected by weight sensor. E.g.: LVDT Level of liquid ingredients is sensed through the level detector.

THICKNESS CONTROL UNIT: Thickness controlled by the use of width sensors

FRYING UNIT: Temperature sensor controls temperature of noodle Output from the thermocouple is fed as input to ADC Microcontroller further processes the digital value

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WORKING PROCEDURES(continued…)PACKAGING UNIT:

Consists of printer which prints the manufacturing date Counter for counting no of products

QUALITY CONTROL: Weight of the instant noodle is taken Prints weight in packets and are forwarded for packing

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CONCLUSIONKnowledge about microprocessor based system

Gained knowledge about industry automation

Knowledge about sensors

Suggestion on recommended design

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RECOMMENDATIONSThe steam from the steam plant can be stored so that it can be reutilized.

The defective packets of noodle can be detected automatically.

The seasoning ingredients packets can be added to the noodle packets automatically.

The use of above recommended design having a microprocessor would minimize the human effort to a great extent and errors can also be reduced which helps in the better manufacturing process.

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~~~THANK YOU~~~