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Primitive Process Creation <9 July 07>copyright zain/PSE- FKKKSA, UTM PPC - 1
“Process Creation by Intuition”
(Dr. Zain’s Primitive Process Design)
Man learn in three ways….1st, through imitation, that’s the easiest,2nd, through experience, that’s the hardest,3rd, through meditation, that’s the noblest
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Why did you choose Chemical Engineering?
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Chemical Engineering Concerns You !!!
Challenge:Bringing chemical
engineering to your doorstep
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Each of us have some chemical engineering (i.e., process design)
experience!!!
Dr Zain’s….Believe it, or not…
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Primitive Process Creation <9 July 07>copyright zain/PSE- FKKKSA, UTM PPC - 5
Basic Needs: Any example?• E.g. Food? • Shelter? • Clothing?• Medication?• Transportation • Cosmetics• …….
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Basic Needs (Physical)• Food •Clothing
•Shelter
Health & Medication
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Other Needs• Transportation
• Cosmetics/Cosmeceuticals
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How to get them?
Buy,
Let’s try to make all the things that we could make!……
Make !
or
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Let’s start with the most basic need!
• Food!
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Key Terminology-Chemical Engineering
..is the field of study thatinvolves the process ofconverting resources intovalue-added products
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What is Chemical Engineering?..is the field of study that involves the process ofconverting resources into value-added productsthrough the application of basic sciences (math,chemistry, physics and biology) and engineeringprinciples for the development, design, operation andmaintenance of processes
MathematicsChemistry
PhysicsBiology
Economics
Natural Gas
Air Energy
Minerals
Plants/Crops
Petroleum
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Let’s start with the most basic need!
Example of food as a basic need: Rice….Let’s make “Biryani Rice”
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Primitive Process Creation <9 July 07>copyright zain/PSE- FKKKSA, UTM PPC - 13
The 5M of Converting Resources to Value Added Products in
Chemical Engineering
Mini Project: Create a Process to Produce e.g. Biryani Rice, Bread,
cookies, cakes and etc
Using…..
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Dr Z’s 5M’s of Chemical Engineering
• Materials – ingredients and the product (what,how much, where, cost) ?
• Method (steps...any recipe? Own recipe?...orprocess (of making..))
• Machinery/Tools/Equipment (what, how big?,how many, where, cost, any tools alreadyavailable?, any new one? limitations)
• Manpower (skill required? how many? who?, whoto do what (job-spec)?
• Money (net income?)
We need 5M to convert resources into VA products!
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Some Key Terminologies• Create Steps = Synthesise/Design a Process• Recipe/Steps = Methods, Processes/Operating
Procedure• Tools = Equipment, Unit Operations• Variables = Process Conditions• Net income = Gross Profit/Profitability Analysis• Recipe Improvement = Debottlenecking, Process
Improvement, Optimisation
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Methods (Recipe)
• Steps involved – e.g. wash, heat, mix, stir, cool)• Key variables for each step
– Amount of each material…i.e composition– Temperature? Pressure? Additives? Colour? Smell?, – Duration?
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The 5M of Chemical Engineering
Student Project:Create a Process
Manufacture Bahulu Kemboja
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“Bahulu Kemboja”
• Introduction– Also known as “Kuih Bakar’ – Traditional ‘kuih’– Pandan flavour– Home based business – Market demand wide; morning breakfast,
gathering, official function etc.– Prod. development; how to make the ‘kuih’ last
longer, taste good with competitive price.
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M1-Materials
Raw Materials: Pandan Leaf Sesame Seed Flour Sugar Coconut Milk EggsWater
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STANDARD OPERATING PRACTICE FOR BAHULU KEMBOJA
PROCESS METHOD
BLENDING- Crushing
- Filtration
-Pandan leafs to be cut to small pcs-Transfer cut pandan leaf into blender jar- Pour 700ml water into blender jar- Blend few minutes until all pandan leaf crushed- Pour the blended pandan leaf into plastic container by pass through plastic filter
M2-Methodology
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PROCESS METHOD
MIXING- Pre-Heating
-Mixing
-Transfer pandan jus and coconut jus until steel bowl- If mixed pandan and coconut become light green, add 1-2 tea spoon of green color flavor. - Heat until its boil- Pour the heated pandan extract and coconut milk into the blender jar and transfer all the flour, sugar and eggs- Blend few minutes until its properly mix-Transfer into plastic bowl
M2-Methodology
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M2-Methodology
PROCESS METHOD
MOULDING- Mould Pre-heating
- Pour 1 tea spoon of cooking oil until the steel mould.- Heat on gas oven until oil boil- Pour mixed cake ingredient into the mould using plastic jar until mould level- Distribute sesame seeds evenly on the surface
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M2-Methodology
PROCESS METHOD
HEATING (BAKING)
- Switch on oven and set oven temperature knob at desired temperature.- Transfer all the mould into the oven- Set oven timer knob at desired time for bottom heating- Switch on top heater once bottom heating complete.- Heat top surface until its turn to brownish color.- Transfer all the mould out from oven when the top heating complete.
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Knife Blender Plastic filter Steel bowlMould Oven Spoon
M3- Machinery/Equipment
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M4-Manpower
MAN POWER QUANTITY PRICE COST / UNIT
Wages 1 man RM60. 00/day 3.85
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M5-Money: Costing
RAW MATERIAL QUANTITY (5 units OF CAKE)
PRICE, RM COST/UNIT(5 units OF
CAKE)Flour 350g 1.30/kg 0.455
Sugar 500g 1.50/kg 0.750
Pandan extract 20-30leaf 1.00/100leafs 0.20 – 0.30
Coconut milk 700ml 1.00/L 0.70
Eggs 4nos 0.2/nos 0.80
Sesame Seeds 10-15g 3.00/kg 0.03 – 0.045
Oil 5-10ml 9.00/5kg 0.009 – 0.018
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UTILITIES QUANTITY PRICE COST / UNIT(5units OF
CAKE)Electricity 3.33KW 0.218/KWH 0.72594Fuel Gas (LPG) 50 – 100g 18.50/14kg tank 0.06 – 0.13Water 700ml 0.57/m3 0.0004
Selling price = RM2.70/nos x 5 units = RM13.50GROSS PROFIT MARGIN
= RM5.7257 (73.65%)
TOTAL COST, RM(5units OF CAKE)
7.7743
M5-Money: Costing
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Semi-Batch ProcesApplication: Intermediate scale of production
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Continuous (Automatic) Process
Application: Large scale production
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“A radical improvement can materialise through paradigm shift”
- dr.zain -
“A paradigm is like a map. Getting to a place quicker is not a
matter of technique. It is a matter of getting the right map”
- Covey -
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“Process Synthesis is paradigm.
Process Design, Process Control and Optimisation are merely
techniques.”
- dr.zain -