PLANT
LAYOUT
PLANT LAYOUT FOR BAKERY INDUSTRY
INTRODUCTION:
Bread is major product for bakery industry, because which is
major consumption by people. Commercially bread manufactured by
three types like S2, S4 and family type bread.
INGREDIENTS: Wheat flour, Yeast, Sugar, Salt, Water, Shortening,
Milk solids.
PROPORTION OF INGREDIENTS:
Flour:
The flour should be of good quality prepared from hard wheat
with a protein content of at least 11 %. It should prove quite
satisfactory in laboratory bread making tests. It is customary to give
the other ingredients for 100-gram flour.
Fat:
The quantity of fat(shortening) used can be varied from 2-6%.
Shortening improve the loaf volume. Fat imparts a velvety and softer
crumb and improves the grain of bread.
Water:
The optimal quantity of water required for making a good varies
with the hydration capacity of gluten in the flour. 100grams of good
quality flour will require about 60-64 ml of water.
Sugar:
The quantity of sugar used in bread making may vary widely
from 2-6%. It has been reported that a part of the cane sugar is
fermented by yeast producing CO2 .
Yeast:
Baker’s yeast is usually incorporated at level of 2-3%. Yeast is
made into a slurry and added to the flour before making the dough.
The dough is allowed to undergo fermentation for 3-4 hours.
Salt:
Salt is added at 1.5-2.0% level in bread formulation.
The function of salt in bread is three:
1. Improve the taste and flavor,
2. Stabilizes the fermentation process,
3. To give strength to the gluten.
Fermentation takes place rapidly when salt is added.
Milk solids:
Fluid milk is often used in bread made in homes or in small
industries. Skim milk powder (SKMP) is used in large industries. The
quantity of SKMP used varies from 3-8% for 100 gram of flour.
EFFECT OF BREAD QUALITY:
The number changes occur in bread when stored for a few days.
These change known as staling of bread and are briefly described
below:
Crust staling:
The principle reaction, which occurs in crust staling, is the
transfer of moisture from the interior of the loaf to the crust. The crust
processes considerable hygroscopic properties and so it absorbs
moisture and becomes soft and leathery. The wrapping of bread on
waxed paper or moisture proof films favors the staling of crust as it
prevents loss of moisture from the crust. It losses the original aroma
and flavors and develops an off odor and bitter taste.
Crumb staling:
The crumb becomes harder and more crumbly due to loss of
moisture. There is marked deterioration in flavor. Bread stored at low
temperature (0C) hardened to a greater extent then that stored at
43C but the bread stored at 43C developed an off flavor and the
crumb turned brown.
Ropy bread:
This rapiness in bread is caused by contamination of dough with
B.mesentericus. The spores of this bacterium are not destroyed by
heat during baking of bread. A sticky, gummy material, which can be
pulled into threads, develops in the center of the loaf 1 to 3 days after
baking. The bread also develops a strong off-flavor.
MANUFACTURE OF BREAD:
The stages involved in the manufacture of bread are:
1. The preparation if the dough,
2. Fermentation of the dough,
3. Baking.
METHODS FOR PREPARATION OF DOUGH:
Three methods are commonly used for the preparation of the
dough:
1. Straight line method,
2. Sponge and dough method,
3. Mechanical dough method
1. Straight-line method:
It is a batch process
Mixing is conducted until the dough attains the desired
smoothness and elasticity.
Advantages:
Minimum labor requirement
Less fermentation time
Better flavor
Disadvantages:
Inflexibility require fixed fermentation time
Ripe-ready dough must be baked when ready.
2. Sponge-dough method:
This method consists of two stages;
a) Formation of sponge,
b) Development of dough
a) Formation of sponge:
The sponge contain about 50-60% of total flour to be used,
the total quantity of yeast and malt and sufficient water to yield
slightly stiff dough.
b) Development of dough:
The sponge is mixed with remaining quantity of flour and
water and allowed to ferment for a short time
3. Mechanical method:
It is continuous method,
No bulk fermentation and consequent losses are avoided,
Allows addition of extra water and produces better bread
from weaker flours
COMPOSITION OF BREAD:
Ingredients Straight
dough
Method
(parts)
Sponge-dough method
(parts)
Sponge Dough
Flour 100.0 65.0 35.0
Water 65.0 45.0 25.0
Yeast 3.0 2.5 -
Yeast food 0.2-0.5 0.2-0.5 -
Salt 2.25 2.25
Sugar 8.0 8.0
Fat 3.0 3.0
skmp 3.0 3.0
Ingredient
s
Mechanical
method
(parts)
Flour 100.0
Water 60.3
Yeast 2.8
Yeast food 0.5
Salt 2.1
Sugar 7.6
Fat 3.0
skmp 3.0
FIRST MIXING:
The ingredients are placed in the mixing bowl of capacity of 200
kg. The mixer is working under the double crank mechanism. The
ingredients are properly mixed by the action of double machine. The
time for mixing is 30 minutes. The resultant product is called as dough.
FERMENTATION:
The fermentation is done for 1 hour and the quality of bread
depends upon fermentation period. Yeast plays a major role in
fermentation process.
SECOND MIXING:
The purpose of the second mixing is to incorporate the air
particles into the dough. The mixing time is 20 minutes.
DIVIDING:
In the dividing sector, the twin pocket divider was used. The
divider has twp pockets. The size and shape of the boxes are
adjustable. So we get the required shape and size of the dough.
ROUNDING:
In the rounding process, the dough from the dividing unit through
the belt conveyor and enter into the rounding machine. Inside the
machine the spiral blades are provided to make round size. In the
process the heat is liberated and the temperature of dough is
increased.
INTER MEDIATE PROOFING:
In this process, the heat is removed from the dough, which is
generating during the dividing and rounding process. The intermediate
proofed has 75 trays and completion of one cycle requires 7 minutes.
MOLDING:
It is the final shaping and sizing operation. In this process, three
pairs of rollers are rolled with different directions. The vanaspathi and
sunflower oil was used as a lubricant for the roller. Then the thin
molded dough is sent to the final proofer.
FINAL PROOFER:
In the proofer, the steam is passed over the bread at the
temperature of 200c with 16-kg/cm2 pressures. Horizontal tube boiler
produces the steam. The proofing time is 1-1.5 hours.
BAKING:
Baking is done in the large capacity oven. The baking temperature
is 215c for 27-32 minutes.
COOLING:
After the baking was over, then the bread was cooled into the
room temperature. The taken for cooling is one hour.
SLICING AND PACKAGING:
The action of slicer slices the cooled bread and then the breads are
packed in polythene bags each.
PROCESS FLOW CHART FOR BREAD:
Selection of ingredients
First mixing (Maida+ sugar +yeast)
Fermentation
Second mixing
Dividing
Rounding
Inter proofing
Molding
Final proofing
Baking
Cooling
Slicing
Packaging
LIST OF MACHINERIES
MACHINERIES NUMBER CAPACITY POWER REQUIRED
SPACE REQUIRED, m2
Dough mixer 2 250 kg/hr 3 hp*2 (4*4) 2
Divider 250 kg/hr 1 hp (3*3) 2Rounder 1 250 kg/hr 3 hp (3*3) 2Moulder 1 250 kg/hr 3 hp (3*3) 2Proofer 1 75
box/cycle1 hp (4*4)
Baking oven 1 75 box/cycle
3 hp (4*4)
Cutter&slicer 2 250 loaf/hr 1 hp*2 (1.5*1.5)
ABSTRACT:
Location : Sangrur
Product : bread
Total area : 1000 m2
Building area : 700 m2
Water source : Bore well
Labours : 22
Power requirement : 16 hp
17
16
01
02
03 04 15
05 0005
06
07
08
09
10 12
13
14
11
PLANT LAYOUT FOR BREAD INDUSTRY
01. Raw material storagesection,02. Office room 03. Restroom, 04. Reception, 05 mixing, 06 fermentation section, 07. Dividing section, 08. Rounding section, 09. Moulding section,10. Proofing section,11. Baking oven,12. Cooling section,13. Cutting and slicing section,14. Packaging section,15. Finished products storage,16. Toilet,17. Water tank,
PLANT LAYOUT FOR BISCUIT INDUSTRY
INTRODUCTION:
Biscuits are common baked items available in shops. Biscuits vary in
size, shape, filling and type of recipes. Biscuits require care, attention and
good procedure to get a better product. The materials required are maida,
sugar, salt, and milk, shortening and leavening agents. Variations can be
introduced by altering of ingredients; manipulation of ingredients and care
should be taken in preparation of dough. Occasionally egg is added to
increase the volume, taste, and flavor of biscuits.
MIXING OF INGREDIENTS:
Biscuits can be classified into hard and soft dough. Hard dough can be
further classified into
Fermented dough
Puff dough
Semisweet dough
Fermented dough: It is prepared by the addition of yeast to flour.
Fermentation results in softening and mellowing effect on gluten.
Puffed dough: It requires very strong flour with high gluten content. The
dough contains flour, water and salt. Other ingredients like hard fat
(margarine), nuts, flavors (essence) are added to the puffed dough to enrich
the dough.
Semisweet dough: Soft flours are used for the preparation of semisweet hard
biscuits. The addition of corn flour and potato flour helps to reduce the
strength of gluten in this type of biscuits.
Soft dough is prepared with the flour containing less amount of gluten. Soft
dough can be prepared by two methods.
Creaming
All in one
Creaming: In this method, fat and sugar are blended to form a smooth
homogeneous cream. The creaming helps to develop uniform mixing of
ingredients. This adds air to the product. In this, mixing is continued till the
dough is developed.
All in one: All the ingredients are blended together. The aerating chemicals,
salt, color and essence are mixed in water and added. The mixing varies with
the type of biscuits.
PROCESS FLOW CHART:
MIXING PROCESS
Selection of ingredients
Addition
Mixing process
Dough
MANUFACTURING PROCESS
Short dough
Dough feed conveyor
Metal detector
Molders
Panned web (it transfer to band)
Baking
Q.C.inspection
Cooling
INGREDIENTS / RECIPES USED FOR VARIOUS BISCUITS:
Ingredients Quantity
Maida 100
Sugar 30-40
Fat 15-25
Salt 1-1.25
Milk powder 2-3.3
Liquid glucose 2-30
Ammonium bicarbonate 0.75-1.0
Sodium bicarbonate 0.75-1.0
Lecithin 0.3-0.5
Water 5-9
Flavors as desired
MIXING:
In the preparation of biscuits, mixing is very critical. The dough has to
be mixed for a minimum period to obtain a tender and crisp biscuits. At the
same time, mixing should be such that all the ingredients are well dispersed
and the dough become cohesive enables shaping of biscuits in a mould.
Mixing is done in two stages, Creaming and Mixing stage. All the
ingredients except flour and acetic ingredients are mixed first at gentle speed
and it forms a cream. The flour is then added to the cream and mixing
proceeds until uniform depression of cream over the flour takes place.
Horizontal type of mixer is used.
MANUFACTURING:
Manufacturing is the important operation where the dough after mixing
is moulded, baked and cooled. The most important aspect of molding is to
create biscuit of uniform weight both in line and across the over band. Hard
dough varieties are molded in different way. They are made into laminators,
sheeted and molded.
The dough then passes through cutters and gets reduced in size. The
cutter roller rolls over the dough sheet and gets cut with the support of
rubber roller, which is placed below the canvas.
BAKING:
Baking is another stage of operation where the following changes take
place,
Development of rigid porous structures
Reduction in moisture
Surface coloration
Gelatinisation of starch
Liberation of gases
Loss of water vapor
Expansion of gases.
COOLING:
During cooling, interchange of moisture between the product and
atmosphere occurs. Generally, the cooling time is 1.5 times that of baking.
LIST OF MACHINERIES:
MACHINES NO CAPACIT
Y
POWER
REQD
SPACE
REQD
TOTAL
SPACE
REQD
Weighing
balance
1 1.5*1.5 2*2
Dough mixer 1 250 kg/hr 3 hp 3*3 4*4
Dough sheeter 2 250 kg/hr 3 hp 2.5*2.5 3*3
Molder cutter 1 250 kg/hr 1 hp 3.5*3.5 4*4
Baking ovens 1 250 kg/hr 3 hp 5*4 5*5
Cooling
conveyor
1 3 hp 5*3 5*4
Packing
machine
1 3 hp 5*5 6*6
Storage 1 10 t/day 10*10 12*12
Office 1 4*3 5*5
Lab 2 5*5 4*4
Rest room 1 3.5*3.5 5*5
Toilet 1 5*5 4*4
ABSTRACT:
Name of the industry : BISCUIT INDUSTRY
Total area : 600 m2
Total building area : 300 m2
Total power required : 16 hp
Total water required : 1 litre/kg of the product
Total investment : Rs. 50,00,000
Profit percentage : 50%
PLANT LAYOUT FOR PRODUCTION OF BOTTLED BEER
INTRODUCTION:
ALCOHOLIC BEVERAGES
Alcoholic beverage is a drink that contains ethyl alcohol. Alcoholic
beverages are made chiefly from such grains as barley, maize, and rye, or
from grapes or other fruit. There are two main groups of alcoholic beverages,
fermented drinks and distilled drinks. Fermented drinks contain from 5 per
cent or less to 20 per cent ethyl alcohol. The principal fermented beverages
are beer and wine. Distilled beverages, also called spirits or liquor, contain
from 12 to 55 per cent or more ethyl alcohol. They include brandy, gin, rum,
vodka, and whisky.
PROOF OF ALCOHOL
As is well known, all alcohol used for beverage purposes is subject to a
very high excise tax. This tax is based on the strength of the particular
alcoholic solution, such strength being ascertained by a specific gravity
determination.
"Proof Spirit" is used to express the strength of alcoholic solutions. In
the United States, any alcoholic solution containing 50% alcohol and 50%
water by volume is said to be proof spirit, or 100 degrees proof, or simply 100
proof. For example, ordinary 95% (by volume) commercial ethyl alcohol is
95/50 x 100 = 190 degrees proof, or 90 over proof.
The two terms to remember then are O.P. (overproof) and U.P.
(underproof). 100 litres of 190 degrees proof alcohol would be taxed as 190
litres of proof spirit.
The British system is in use in Canada and is more complicated.
According to this system, any alcoholic solution containing 57.09% (by
volume) alcohol and 42.91% water is said to be proof spirit or 100 degrees
proof.
BEER
COMPOSITION OF BEER
Water
More than 90% of beer is water. There are many salts and minerals in
the water, the quantity and variety of which affect the ultimate flavour of the
beer.
The minerals in the water will also influence the head formation.
Malt
Malt is the sugar to be fermented that comes from the grain. Grain
cannot ferment by itself. When the grain is left in water, allowed to germinate
and then dried, fermentable sugar is released. This procedure is called
malting. Barley malt is by far the most important sugar-containing raw
material for producing beer. Only malted barley can be used in the brewing
process.
Sugar
In addition to the malted grain, sugar is often also added to help the
fermentation.
Hops
Hops give beer its bitter flavour and are also a natural preservative.
Only the flowers from the female hops are used for beer. The hop flowers
contain lupulin, a resinous substance that gives the typical bitter flavour.
Hops also contain substances that make the beer last longer. Hops also
contain isoflavons with phyto-oestrogens these substances are of more
importance in functional nutrition.
Yeast
Yeast is a single cell micro-organism. It is needed in the brewing
process for converting fermentable sugars into alcohol and carbon dioxide.
When converting sugar into alcohol many types of aromatic substances are
formed that also determine the character of the beer.
NUTRITION IN BEER
Water : 90%
Sugar : 3%
Protein-Less than : 0.5%
Fat : Nil
Vitamin B2 : 0.07mg
Vitamin B1 : 0.01mg
Vitamin B6 : 0.12mg
Minerals : Fe,Cr,Cu,Si,k
BEVERAGE SUBSTRAT
ES
ALCOHOL(
%)
Beer
Wine
Cidar
Champagne
Brandy
Cereals
Grape
juice
Apple juice
Grape
4-8
10-22
8-12
12-13
43-57
Whiskey
Rum
Gin
Rectified
spirit
juice
Wine
Cereals
Molasses
Cereals
Cereals
51-59
51-59
51-59
95.0
SAFE LEVEL OF DRINKING FOR PER DAY CONSUMPTION:
Category BEERml
WINEml
DISTILLED BEVERAGES
ml
MEN 672 280 84
WOMEN 336 140 42
AGED FEW FEW FEW
FLOW DIAGRAM OF BEER PRODUCTION
RECEIVING OF MALTED GRAINS
CLEANING
WORT PRODUCTION
BOILING OF MASH
PRIMARY FERMENTATION
MATURATION
FILTRATION
YEAST+ SUGAR
HOPS
BOTTLING
PASTEURIZATION
COOLING
LABELLING
STORAGE
PROCESS EXPLANATIONS
In our industry, we are purchasing only malted barley because we
procure the malted barley proximity to the unit. The purpose of procuring
malted is to prepare the starch in the barley for easy degradation during
mashing, whereby it is transferred into easily fermentable sugar.
Furthermore, the malting and drying gives taste and colour to the beer.
The raw materials are received and cleaned with vibrator and then
stored in a silo. For Wort production, the cleaned malted barley is ground by
using with hammer mill. The ground malt is collected in a grist bin or a
hopper before being mixed with water in a pre-masher during the mashing
process. The mash is heated to a high temperature in the mash-tun to
activate the enzymes built up during malting.
The next step is the separation of the grist residues. This takes place
at the lauter tun.When the first wort (the extract from the water and the
malt) is separated, the remaining extract is washed out of the spent grains by
spargings: that is, spraying hot water over the grains.
The last extract (last runnings) are used in the mashing of the next
brew. The spent grains are used as animal feed.The wort is brought into the
pre-run vessel and then to the wort kettle, where it is boiled together with the
hops.
During the boiling, proteinous substances coagulate and fall out,
together with hop residues and tannins.The so-called trub also named hot
break is separated from the wort in the whirlpool (which has a tangential
inlet), circulating the whole inflowing batch at speed. The result is that the
hot break settles like a cone at the bottom of the whirlpool about 25 minutes
after wort pumping is finished.
The hot break is collected and pumped back into the lauter tun to be
added to the next brew. The wort is cooled down from its 95°C to
approximately 8°C in a heat exchanger (a wort chiller), transferred into the
gauging vessels, and then passed to the fermenters.
Wort cooling produces hot water, which is normally returned to a hot
water tank in the brewhouse and used for brewing/spargings and for
cleaning. All vessels and pipes in the brew house are cleaned using the CIP
(Cleaning-in-Place) system.
The cooled wort is aerated, yeast pitched by a metering pump, and
fermentation is started in the conical fermenters. Fermentation normally
takes seven days.During fermentation, the yeast settles in the cone of the
fermenter.
The most active yeast is taken out of the fermenter for re-utilization in
another batch. As the yeast is multiplied by approximately six or seven times,
there is a considerable amount of excess yeast from each fermenter. The
surplus yeast has widespread uses, from animal feed to pharmaceutical
purposes, but can also be discharged to the sewer.
When the main fermentation is finished, the green beer is pumped into
storage tanks for maturation. During the maturation, a second fermentation
takes place under high pressure, building up dissolved carbon dioxide in the
beer, while the remaining yeast settles out.
This deposit yeast is used for animal feed or is discharged. The
maturation can also take place in an unitank, which is used for both primary
fermentation and maturation.
The finished beer is prepared for bottling or kegging by filtration and
addition of carbon dioxide. To ensure a standard quality, some batches of
beer are blended and colour may be added. Before filtration, the beer is
cooled down to 0-1°C to minimize the risk of it foaming in the filters. The beer
is normally filtered in a coarse filter and a fine filter. To avoid too high a filter
resistance, kieselguhr is used as a filter medium.
The beer is bottled under counter pressure and the bottles are sealed.
A spraying device takes foam residues away. After passing a fill height
inspector, the bottled beer is pasteurized, labelled and packed
The bottles (new or returned) are passed through the bottle washer for
cleaning. The bottles are alternately soaked and sprayed in the washer; first
with warm water, then with a hot caustic solution, thirdly sprayed and rinsed
in hot and cold water, and finally a last cold rinse before they are conveyed to
the bottling machine.
After bottling, the beer goes to the pasteurizer. The bottles pass
slowly through different zones with increasingly hot water (up to 62°C), and
then slowly cooled down to approximately 25°C. The water in the tunnel
pasteurizers is circulated and thus used repeatedly. Any breakage is normally
collected in containers and returned to the glass manufacturers for recycling.
Machineries Required:
Equipment CapacityKg/hr
No. Power Reqd. Hp/V
Area Reqd m2
Total space m2
1. Vibrator 2000 1 5 /440 0.595 1
2. Hammer mill 200 1 5/440 0.365 0.6
3. Solar Dryer 300 kg/day 2 - 0.45 1.6
4. Pasteurization vat
30,800 bottles
1 - 10 12
5. Fermenter 1 lakh litres
7 2/220 2.25 20
6. Boiler 1 ton/day 1 - 4 7
7. Filter 5000 1 - 0.3 0.8
8. Bottle washer 15500 bottles/hour
1 2/220 3 5
9. Vacuum filler 1 5/440 4 6
10. Generator 15 Hp 1 - 4 7
11. Conveyor 1000 kg/hr 1 1/220 2.5 5
12. Storage Bin 50000 kg 2 - 17.5 40
13. Maturation Tank
25000 kg 4 - 8 35
ABSTRACT
Location : Punjab
Industry : Brewery
Product : Bottled Beer
Capacity : 3,08,000 Bottles per day
Total Power : 20 Hp
Total Water : 90,000 litres per day
Building area : 250 m2
Total Area : 500 m2
Total Investment : Rs.10,75,00,000
No. Working days : 200
No. Labour reqd. : 18 (6 skilled, 12 unskilled)
Total Profit : Rs.40,00,000/day (Before Tax)
LAY OUT OF BEER PRODUCTION UNIT
1 2 3 4
12
13
14
11
567a8
10
8a
0
9
19
7
15 15a
17
18
16 2021
22
SECTIONS OF LAYOUT:
0 - Security office
1 - Cleaning section
2 - Storage of malted barley
- Belt conveyor
3 - Wort production
4 - Fermentation
- Fermenter
5 - Maturation section
- Maturation tank
6 - Filtration
7 - Bottle preparation (bottle washing, bottle sterilization)
7a - Bottle filling
8 - Pasteurization
8a - Cooling
9 - Labeling and Storage
10 - Administrative block
11 - Collection of yeast strains and Drying section
12 - Parking
13 - Canteen
14 - Recreation
15 - Gents toilet
15a - Ladies toilet
16 - Fuel storage
17 - Boiler
18 - Co2 tank
19 - ETP
20 - Water tank
21 - Generator
22 - Quality Control Lab
LAYOUT FOR NATURAL MINERALWATER PLANT
Introduction:
The first recorded history of discovery of natural mineral waters
was as early as 400 B.C.
Mineral rich waters are created by the flow of water through
rocks and soil where mineral salts are dissolved.
Many of the renowned springs were touted for their miracle
medicinal cures, and promotion of good health.
In 1767, the waters of Jackson's Spa in Boston were bottled and
sold.
1820- SARATOGA SPRINGS Mineral Water was first bottled and
sold
There was a rapidly growing demand for its therapeutic
miracles.
In the early days of mineral waters, the closure of choice was
the cork stopper.
Regulations very later emphasized on the bottling and
packaging of natural mineral water.
This resulted in the Purification of water obtained from natural
sources.
Reverse Osmosis:
Reverse osmosis (Nano filtration) filters with a pore size of about
0.001 to 0.005 microns is used for this purpose.
R.O is a high pressure, energy efficient separation Process
wherein pressures of about 15 – 60 KSC are applied.
This allows monovalent salts and retains divalent salts like
carbonates and sulphates and solutes having molecular wt. >
300.
Efficient process with least MWCO that filters out all micro
organisms.
ABSTRACT
Industry : Natural Mineral Water Plant
Product : Bottled Natural Mineral Water
Capacity : 30,000 litres/day(8 h)
(15,000 one ltr Btls, 600 – 25 lts cans)
Total Power : 15 Hp
Total Water : 35 kilo litres/day
Building area : 250 m2
Total Area : 500 m2
Total Investment : Rs. 82,00,000
No. Working days : 200
No. Labour required : 15
Total Profit : Rs. 78,00,000 – 95%
Pay Back period : 1.1 years
Break Even point : 15 %
Natural mineral water in its packaged state shall contain not more
than the following amounts of the substances indicated hereunder:
Antimony 0.005 mg/l
Arsenic 0.01 mg/l, calculated as total As
Barium 0.7 mg/l
Borate 5 mg/l, calculated as B
Cadmium 0.003 mg/l
Chromium 0.05 mg/l, calculated as total Cr
Copper 1 mg/l
Cyanide 0.07 mg/l
Lead 0.01 mg/l
Manganese 0.5 mg/l
Mercury 0.001 mg/l
Nickel 0.02 mg/l
Nitrate 50 mg/l, calculated as nitrate
Nitrite 0.02 mg/l as nitrite 2
Selenium 0.01 mg/l
MACHINERIES AND SPACE REQUIRED:
Equipment Capacity No. Power Reqd. Hp/V
Area Reqd m2
Total space m2
1. Storage Tanks 1lac ltrs 2 - 25 50
2. R.O Membrane tanks
5000 ltrs/hr
2 5/220 9 20
3. Blow Molder 2500 btls/hr
1 2/220 1 1.5
4. Integrated Filler 2500 btls/hr
1 2/220 2 3
5. Bi-Directional Table
1000 btls 2 - 2.25 5
6.Trine Labeler 2500 btls/hr
1 1/220 0.5 1
7.Multi packer 250 cartons/hr
1 1/220 2 3
8.Palletizer 25 stacks/hr
1 2/220 2 3
9. Volumetric filler 15,000 ltrs/hr
1 2/220 2 3
10. Product Storage 30,000 Bottles
1 - 10 12
Case Packager / Multi packer
Integrated Filling Machine
Trine Labeler Constant Volume Filler
Natural mineral water should contain no parasites and should meet
the following criteria:
n: number of sample units from a lot that must be examined to satisfy a
given sampling plan.
c: the maximum acceptable number, or the maximum allowable number of
sample units that may exceed the microbiological criterion m. When this
number is exceeded, the lot is rejected.
m: the maximum number or level of relevant bacteria/g; values above this
level are either marginally acceptable or unacceptable.
M: a quantity that is used to separate marginally acceptable quality from
unacceptable quality foods.
Process Flow Diagram:
Reception of water from springs
Storage
Blow Molding Reverse osmosis
Integrated Filling constant volume Filling
Labeling
Manual labeling
Case packing
Palletizing storage/Dispatch
G
A
T
E1
Raw Water Storage Tank 1
Office
Raw Water Storage Tank 2
R.O Tank 1
R.O Tank 2
Bottling Unit
Storage Unit
G
A
T
E
2
PLANT LAYOUT FOR SPICE PROCESSING INDUSTRY
INTRODUCTION
Nowadays people are living a very fast life is which they don't even find
time for cooking.In this stage ready made foods like masalas play amajor
role &very important role in our day to day life. these readymade produts
are very much helpful in making various delicious recipes for our daily
food
needs.
SITE SELECTION:
_ Should be nearer to production area and farms.
_ Ample water supply.
_ Sufficient labour.
_ Availability of finance.
_ Economic and social supports
_ road and railway facilities.
_ eco friendly.
_ ample power supply.
_ readily available raw materials.
_ marketing facilities and publicity.
Products:
l.Turmeric powder
2.chilly powder
3.Chicken masala
4.Mutton masala
5.Fish masala
PROCESS FLOW CHART:
RAW MATERIAL
CLEANING
ROASTING
MIXING
MILLING
PACKING
DESPATCH
Raw Material Section:
All ingredients used for masalas preparation are purchased and stored
here. The ingredients are purchased from wholesale markets. The raw
materials are ordered depending on their requirements. The storage
section is well furnished with insect guards and sufficient ventilation. It is
large enough to store up to 300 tonnes. All ingredients (except chilly and
turmeric) are stored here. Chilly and turmeric are stored separately in
another room specially built for that. (Capacity: 300 tonnes)
Cleaning Section:
Redgram, gram dhal, coriander, are cleaned with the use of specific
gravity separator (destoner). Experienced persons handle it. It has a
capacity of 1 tonne per hour.
Roasting Section:
All ingredients are fried here. Red gram dhal, coriander, horse gram,
Bengal grams, mustard are fried in the roasting machine. The roasting
machine is a dual drum machine designed like a feed mixer in which the
ingredients are constantly mixed while frying. This avoids over heating
and White gingely, poppy seeds, cashew, curry leaf, sombu, garlic,
groundnut etc are fried manually because these materials require different
temperatures and different duration of frying and also they need more
personal care. The required amount of material for each masalas product
is roasted here before grinding, except chilly and turmeric product.
Pouch packet roll storage room:
Pouch packet rolls are obtained in the printed state from Namakkal and
Chennai. The information about the product, ingredients, address of
manufacture (except manufacture date and M.RP) is printed in these rolls.
These pouches packets are made of polypropylene. These pouch packet
rolls are stored in a separate room with racks built in for this purpose.
Kitchen:
kitchen is situated in the centre portion of the industry. Sensory &
organoleptic evaluation of the prepared masalas & other products is done
here.
Pouch packet roll storae:e room:
Pouch packet rolls are obtained in the printed state from Namakkal and
Chennai. The information about the product, ingredients, address of
manufacture (except manufacture date and M.R.P) is printed in these rolls.
These pouches packets are made of polypropylene. these pouch packet
rolls are stored in a separate room with racks built in for this purpose.
All prepared masalas products are packed here. SOgm, 100gm pouches
are packed by automatic packaging machine. 2S0gm, SOOgm, 1000gm
pockets are prepared manually. Vadagam and vatthal, payasam mixes are
packed by continuous packaging machine.
Machinery in Packing Section
As we all know the packing section is the very important unit of any
industry, in this industry also this section is given utmost care .In the
packing section they use both automated machines with least manual
intervention in operations and total manual packaging. The former is used
for all ground powders like masalas and the latter is used for the
packaging of larger sized solids like Vadam, Curd chilly etc.
Manual Packaging:
This is the most traditional method of packaging adopted for those items
that are not produced in very large scale. Many labours are employed for
this purpose and they weigh the required quantity o(the materials and
pack then manually inside polythene bags and seal them either manually
or by using a continuous sealing machine.
Continuous sealing machine:
This machine is used for sealing the polythene bags, which are manually
packed.
Descrintion:
This machine has a belt conveying unit driven by a motor over which there
is a set of eight pulleys in four pairs arranged in series. The outer two
pulleys are used for the movement of the packets over the belt drive at
the bottom in a vertical position and feed the packets to the heat-sealing
machine. The heating coil is insulated using Teflon belts driven
between the inner pulleys, which prevents the polythene from melting,
and sticking to the heating coil because of their non-stick property. Next to
the heating coil is the cooling coil, which is actually circulated with cold
water in its inner side, which cools the sealed packets in the sealing area
thereby, strengthening the seal.
The Teflon belt runs over the cooling also in order to serve the same
purpose as above and thereby making the entire sealing operation
smooth.
Material and temperature balance sheet:
Material of plastic
bags
Temperature of
sealing, C
Polyethylene 180- 225
Poly propylene 180- 21O
Moist proof poly paper 200- 225
Poly paper 220- 240
Poly styrene 200- 225
Polyvinyl acetate 200- 225
Hard PVC 200- 235
Polyvinyl fluoride 200- 255
Aluminum 200- 235
Auger Filler:
This is a fully auto mated pouch packing machine with all sorts of
automations and electronic controls possible. It is only used in the pouch
packing of all masalas for the fixed weights of 50gms and 100gms in
pouches. This filling process in the auger filler is taken care by the screw
auger by which the set quantity of masalas is fed into the pouches.
Grinding Section:
Chilly and turmeric are produced in a much larger scale than all other
products hence they are stored separately and ground separately in the
pulveriser. All other masalas are ground using three attrition mills each.
After grinding the chilly and turmeric powder from pulverizing unit, are
mixed together with masalas powder. After that, that is allowed for cooling
for some time. The details of the pulveriser and attrition mills are as
follows.
Attrition mills:
There are four attrition mills which work on the principle of friction and
shear forces developed during the rotation of the criss cross hatched disc
against the fixed the disc thereby bringing size reduction of the particles.
These have a capacity of 1 ton per day. All the controls in this particular
milling section are fully manual and operated skilled and experienced
workers.
Despatch section:
Here, all finished goods are temporarily stored and despatched to dealers.
They own many vehicles like vans, tempos and goods carrier autos mainly
for the marketing and despatch of these goods.
ABSTRACT
INDUSTRY : Chilly powder plantCAP ACITY : 4t/dayBUILDING AREA : 0.6 acre(70x42)=2940 m2
COST OF BUILDING : Rs 11,76,000TOATAL AREA : 1 acre(80x50)=40000m2
MACHINERY COST : Rs 16900000TOTAL INVESTMENT : 4466000+20000000=Rs.646600NO.OF MACHINES : 17WATER REQUIREMENT : 3000 litres /dayPOWER REQUIREMENT : 16.5hp
CONCLUSION:Spice studies is necessary to provide new opportunities in the
diversification of trade in spices, spice blends, and their products and to
find new uses of spices in human physiology.
Our knowledge of spices in relation to evaluation of their flavor quality is
fragmentary. Flavor is a conglomeration of many contributing factors. We
know more about these factors now than we did yesterday.
However, further knowledge must be continuously acquired as a first
priority in the various disciplines engaged in this complex field of spice
favor, if we are to develop methods for its correct and rapid evaluation.