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Food Plant Design
Department of Food Technology
Faculty of Chemical Engineering
University of Technology, VNUHCM
Email: lqdat@hcmut.edu.vn
1
Lai Quoc Dat, Dr
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 2
Introduction
 Content of Subject:
- Chap. 0: Introduction of Food Plant Design
- Chap. 1: Analysis of feasibility of the food plant project
1.1. Situation of Market
1.2. Trends of Market
1.3. Own capacity
1.4. Threats
1.5. Scientific and technological context
1.6. SWOT Methods for feasibility study
1.7. Product Design
1.8. Capacity estimation
1.9. Location and site
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 3
Introduction
 Content of Subject (cont.):
- Chap. 2: Process design
2.1. Principles of Process Design
2.2. Materials
2.3. Mass balance
2.4. Energy balance
2.5. Equipment for Food Production
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 4
Introduction
 Content of Subject (cont.):
- Chap. 3: Facilities in Food Plant
3.1. Steam
3.2. Water
3.3. Cooling system
3.4. Electricity
3.5. CIP
- Chap. 4: Waste and waste treatment in food factory
4.1. Waste water
4.2. Solid water
4.3. Air pollution
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 5
Introduction
 Content of Subject (cont.):
- Chap. 5: Lay out and industrial building
5.1. Principles of lay out design in food plant
5.2. General lay out of plant
5.3. Industrial building
5.4. Ventilation
5.5. Lighting
5.6. Drainage
5.7. Floor, door, window and roof
5.8. Warehouse
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 6
Introduction
 Content of Subject (cont.):
- Chap. 6: Organization, operation and safety
6.1. Gant chart
6.2. Organization of plant
6.3. Human resource
6.4. Safety
- Chap. 7: Economic analysis of food plant
7.1. Capital
7.2. Revenue, Expense, and Profit
7.3. Cash flow
7.4. Sensitivity in Economic analysis
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 7
Introduction
 References:
1. Zacharias B. Maroulis and George D. Saravacos, Food Plant
Economics, CRC Press, 2008, 352 pages
2. Antonio López-Gómez and Gustavo V. Barbosa-Cánovas, Food
Plant Design, CRC Press, 2005, 372 pages
3. Zacharias B. Maroulis and George D. Saravacos, Food Process
Design, CRC Press, 2003
4. Joseph Irudayaraj, Food Processing Operations Modeling: Design
and Analysis, Marcel Dekker Inc., 2002
5. Jasim Ahmed and Mohammad Shafi ur Rahman, Handbook of
Food Process Design, Wiley – Blackwell, 2012, 1470 pages
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 8
Introduction
 References:
6. G. D. Saravacos and A. E. Kostaropoulos, Handbook of Food
Processing Equipment, Kluwer Academic/Plenum Publishers,
2002
7. D. R. Heldman and R. W. Hartel, Principles of Food Processing,
Aspen Publishers, 1998
8. Perry, R.H. and Green, D.W., Perry’s chemical engineers’
handbook, 7th edition, New York McGraw-Hill
9. D.R. Heldman and D.B Lund, Handbook of Food Engineering,
CRC Press, 2007
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 9
Chap.0: Introduction of Food Plant
 Characteristics of Food Plant
- Storage of materials, fresh materials
- Season of materials
- Diversity of materials: Engineering Properties, Chemical
Compositions, Ripen…
- Scale up: Bench scale  Pilot  Practical scale
- Contamination of impurities and microorganism.
- The change of microorganism and enzyme in products
- Sensitive attributes of products in storage and distributions
- Role of distribution system: B2B, B2C products
- Consumer behaviors
- Scale
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 10
Chap.0: Introduction of Food Plant
 Food Plant Design
- Food Plant:
+ Material zone
+ Manufacturing
+ Distribution
+ Marketing
+ Trading
+ R&D
+ Cash flow
….
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 11
Chap.0: Introduction of Food Plant
 Food Plant Design
- Steps of Design:
+ Step 1: Get idea,
+ Step 2: General Feasibility Study
* Economic Context
* Science and Technological Context
* General estimation
* Social issues
+ Step 3: Deciding investment
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 12
Chap.0: Introduction of Food Plant
 Food Plant Design
- Steps of Design (Cont.):
+ Step 4: Technical Design
* Location and site, capacity, products
* Process design, mass and energy balance
* P&ID design
* Energy, electricity, water, fire fighting
* Waste treatment
* Facilities
* Industrial building, ware house, general lay out
* Operation
* Economic analysis
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 13
Chap.0: Introduction of Food Plant
 Food Plant Design
- Steps of Design (Cont.):
+ Step 5: Deciding on investment
+ Step 6: Master plan for investment
+ Step 7: Mobilization of capital, tendering, contracting…
+ Step 8: Installation
+ Step 9: Trial operation and evaluation
+ Step 10: Official operation and launch.
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 14
Chap.0: Introduction of Food Plant
 Food Plant Design
- Master Plan for Design Activities:
+ Human resource
+ Data resource
+ Facility resource
+ Financial resource
+ Gantt chart
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 15
Chap.0: Introduction of Food Plant
 Food Plant Design
- Documents of Design activities:
+ Preliminary design: reports and drawing
+ Technical design: revised reports and drawing, legal
documents…
+ Installation design: drawing of construction and installation,
legal documents for construction…
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 16
Chap.0: Introduction of Food Plant
 Food Plant Design
- Drawings:
+ Vietnamese Standards of Drawings (TCVN).
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 17
Chap.0: Introduction of Food Plant
 Science vs. Engineering vs. Technology
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 18
Chap.0: Introduction of Food Plant
 Science vs. Engineering vs. Technology
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 19
Chap.0: Introduction of Food Plant
 Science vs. Engineering vs. Technology
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 20
Chap.0: Introduction of Food Plant
 Engineer in Food Industry: Capable of R&D:
- Process
- Products
- Plant (factory)
- System
 Assignment to:
- R&D
- Design sector
- Manufacturing
- Trading
- …
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 21
Chap. 1: Analysis of feasibility
of the food plant project
1.1. Situation of Market
- Volume and demands
- Necessity of the related products
- Relationship of quality – price
- Possibility of export
- Possibility of distribution system
- Efforts of sales
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 22
1.2. Possibility of market development in future
- Increasing in demands and amount of consumers
- Increasing in acceptance of consumer
- New products on market
- Trends in society, economy and politics
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 23
1.3. Strengths of price and distribution system
- Material cost
- Labor cost
- Distribution and saling cost
- Efficiency of process
- Patents and copyright
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 24
1.4. Threats
- Stability of economy
- Risks of technologies
- Competition from import
- Capacity of competitors
- Risks on quality and consumer belief
- Capital
- Possibility of attacks
- Laws and policies of government
- Time to obtain the profit
- In stock
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 25
1.5. Scientific and Technological context
- Achievement of science and technology
- Equipment
- Supporting industry: packaging, transportations…
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 26
1.6. SWOT method for feasibility study
- SWOT
STRENGTHS
1.
2.
WEAKNESSES
1.
2.
OPPORTU-
NITIES
1.
2.
3.
Opportunity-Strength (OS)
Strategies
Use the strengths to take
advantage of opportunities
1.
Opportunity-Weakness (OW)
Strategies
Overcome weaknesses by taking
advantage of opportunities
1.
THREATS
1.
2.
Threat-Strength (TS)
Strategies
Use strengths to avoid threats
1.
Threat-Weakness (TW) Strategies
Minimize weaknesses and avoid
threats
1.
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 27
1.7. Capacity Estimation
- Where to play?
- Who are consumers?
- Source of materials
- Capital
- Human resource
- Limitation of technology
- Policies of governmental authority (national, local….)
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 28
1.8. Product Design
Quality:
- Nutrition elements
- Food Safety and Hygiene
- Sensory Properties
- Convenience for using
- Service
- Level of technology: hand made, mechanization, automation…
Specifications:
- Brand and Label
- Packaging
- Size
- Storage and transport
- Shelf life
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 29
1.8. Product Design
Method of product design:
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 30
1.8. Product Design
Method of product design:
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 31
1.8. Product Design
Method of product design:
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 32
1.8. Product Design
Method of product design:
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 33
1.8. Product Design
Method of product design:
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 34
1.9. Location and Site
- Material sources
- Market
- Labor resource (cost, capacity, amount…)
- Transport system
- Supporting services: public transport, internet, banking…
- Infrastructure: electricity, water supply, waste water treatment,
- Characteristics of site: shape of area, geological characteristics
- Climate (temperature, typhoon, storm, drain, flood…)
- Policies and plans of local and central governments
Note: Consider the priority of factors and forecast the changes
in these factors in future.
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 35
1.9. Location and Site
Steps of selection:
- Step 1: Determine the purposes of food plant
- Step 2: Figure out the factors influencing on the operation of
Plant
- Step 3: Determine the requirements of these factors
- Step 4: Seek the sites satisfying the requirements
- Step 5: Preliminarily evaluate and choose some sites most
satisfy the requirements
- Step 6: Set up the method for eligibility of sites
- Step 7: Evaluate the sites which are preliminarily selected.
- Step 8: Select the optimized site.
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 36
1.9. Location and Site
Methods for selection: SWOT analysis
- Analyze the SWOT of sites
- Select the site satisfying the requirements
- Strategies for plant compatible with the sites (solutions for
problems of site).
- Select the site suitable for the factory
 This method is simple, however, it depends on the capacity of
people in charged of selection work. Normally, apply for SMEs.
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 37
1.9. Location and Site
Methods for selection: Optimize the cost of transportation
- Estimate the cost for transport of materials and products
- Select the site at lowest cost
 This method suitable for factories in which, the cost of
transportation is remarkable.
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 38
1.9. Location and Site
Methods for selection: Factors analysis
- Step 1: Determine the factors influencing on selection of site
- Step 2: Determine the important coefficient of each factor
- Step 3: Make score for each factor for each site (note: scale of
score)
- Step 4: Summarize score, evaluate and select the optimized site
with highest scored.
- In case of two or more sites have the same score at highest,
investor decide the site.
 This method requires the experts with high capacity, apply for
big project.
Chap. 1: Analysis of feasibility
of the food plant project
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 39
1.9. Location and Site
Methods for selection: Factors analysis
Chap. 1: Analysis of feasibility
of the food plant project
No. Factor
Important
coefficient
Scale of
score
Score
Standardized
score
Score of
Contribution
1 F1 k1 m1 s1 g1=
𝑠1
𝑚1
C1=k1*g1
i Fi ki mi si gi=
𝑠𝑖
𝑚𝑖
Ci=ki*gi
n Fn kn mn sn gn=
𝑠𝑛
𝑚𝑛
C1=kn*gn
Total score
1
𝑛
𝐶𝑖
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 40
2.1. Principles of process design
What is food engineering
- Food Engineering is a relatively new profession and a scientific
field involved with food manufacturing and the processing of
refined foods. It encompasses the practical application of food
science to develop efficient industrial production, packaging,
storage, and physical distribution of nutritious and convenient
foods that are uniform in quality and safe.
- Food Engineering: integrate physical, chemical engineering and
bioengineering
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 41
2.1. Principles of process design
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 42
2.1. Principles of process design
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 43
2.1. Principles of process design
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 44
2.1. Principles of process design
Components of food technology
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 45
2.1. Principles of process design
Process system
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 46
2.1. Principles of process design
Some basic principles of food process design
- Including physical engineering, chemical engineering, biological
engineering process.
- Base on chemical process: mass transfer, heat transfer, fluid mechanic…
- Optimization in food process: Maximize the yield, minimize the loss of
quality and hazards to human health.
- Overall goals of optimization of process is profit.
- Food safety and hygiene
- From the process design  characteristics of equipment forprocessing
- Process design: Fundamentals of process  modeling  simulation 
optimization  select facilities for process
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 47
2.1. Principles of process design
Some basic principles of food process design
- Activities of process design: select process, estimate mass balance and
energy, estimate capacity and specifications of equipment, design lay out of
equipment in factory, estimate cost for investment and operation,
technological and economic assessment.
- Factors influence on the design: HSE, policies, regulation, disaster, quality
of production, food safety, operation…
- Food Quality Management: ISO, HACCP, TQM, GMP…
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 48
2.1. Principles of process design
Some basic principles of food process design
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 49
2.1. Principles of process design
Optimization in Food Process
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 50
2.1. Principles of process design
Block Diagram of process
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 51
2.1. Principles of process design
Process Diagram with Equipment
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 52
2.1. Principles of process design
P&ID
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 53
2.1. Principles of process design
2D process Diagram
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 54
2.1. Principles of process design
3D process Diagram
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 55
2.1. Principles of process design
3D Process Diagram
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 56
2.2. Materials in Foods
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 57
2.2. Materials in Foods
Roles of materials:
- Influence on quality and price of product
- Input data for process design
- Contribute to determination of economic efficiency
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 58
2.2. Materials in Foods
How to select materials and suppliers:
- Roles of materials in process and product
- Plant capacity
- Requirements on quality of materials
- Price
- Stability of quantity and quality
- Prestigious suppliers
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 59
2.3. Mass balance
Mass and energy flow in food factory:
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 60
2.3. Mass balance
Mass and energy flow in food factory:
- Used for preparation of formulas, final compositions of products,
yields  estimate the rate and size of equipment, economic
efficiency, operation and planning…
- Based on the principles of the law of “conservation of mass”:
Mass can neither be created or destroyed
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 61
2.3. Mass balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 62
2.3. Mass balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 63
2.3. Mass balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 64
2.3. Mass balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 65
2.3. Mass balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 66
2.3. Mass balance
Preparing the mass balance estimation:
- Prepare the diagram of process flow
- Determine the boundaries of the system (process)
- Describe the system with a boundary (real or imaginary, stationary or movable)
- A system boundary may even enclose an entire food processing system.
- Choose the basis capacity (kg/hour, kg, ton….)
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 67
2.3. Mass balance
Conducting the mass balance estimation:
- Collect all data on mass and composition of an inlet and exit streams from the
references or experiments
- Analysis the changes in process
- Draw a process flow diagram, indicating the process, with inlet and exit streams
property
- Draw the system boundary
- Write all available on the flow diagram, select the basic
- Determine the loss
- Write total and components mass balance.
- Solve the material balance to determine the unknowns.
- Notes: All unknowns ≥0, adding some components for solution of problems
(maltodextrin, butter…)
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 68
2.3. Mass balance
Loss and yield:
- Depends on properties of material
- Depend on process
- Depend on storage and transportation
- Depend on equipment
- Depend on skill of staffs
- …
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 69
2.3. Mass balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 70
2.3. Mass balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 71
2.3. Mass balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 72
2.3. Mass balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 73
2.3. Mass balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 74
2.4. Energy balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 75
2.4. Energy balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 76
2.4. Energy balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 77
2.4. Energy balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 78
2.4. Energy balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 79
2.4. Energy balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 80
2.4. Energy balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 81
2.4. Energy balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 82
2.4. Energy balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 83
2.4. Energy balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 84
2.4. Energy balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 85
2.4. Energy balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 86
2.4. Energy balance
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 87
2.4. Energy balance
Saving energy in food plant
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 88
2.5. Equipment for food production
Criteria
- Advance technology
- Automation
- Friendly with environment.
- Satisfy the capacity, synchrony and technological parameters…
- Capital cost
- Operation cost
- Safety
- Durability
- Sanitation
- Cleaning
- Match the requirements of food safety
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 89
2.5. Equipment for food production
Criteria
- Method of manufacture
- Structure:
+ Low weight
+ Easy to maintain and repair
+ Easy to cleaning
+ Safety and convenient in operation
+ No leakage
+ Able to update (capacity and specification)
+ Standardize elements
- Material:
+ Durable
+ Easy to process
+ No corrosion
+ Easy to cleaning
+ Low cost
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 90
2.5. Equipment for food production
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 91
2.5. Equipment for food production
Chap. 2: Process design
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 92
3.1. Steam
Using of Steam
- Heating, drying, pasteurization, sterilization, steaming…
- State of steam: P, T, Enthalpy…
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 93
3.1. Steam
Estimate of The consumption of Steam
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 94
3.1. Steam
Estimate of The consumption of Steam
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 95
3.1. Steam
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 96
3.1. Steam
Selection of Boiler
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 97
3.1. Steam
Selection of Boiler
- Codes and standards of requirements
- State of steam
- Boiler load
- Number of boiler
- Performance considerations
- Special considerations
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 98
3.1. Steam
Fuel for boiler
- Fossil: coal, DO, FO..
- Wood,
- Biomass
- Notice: Air pollutions from boiler operation
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 99
3.2. Water
Source of water
- Surface water
- Ground water
- Water from suppliers
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 100
3.2. Water
Using of Water in Food Factory
- Technical water
- Non –technical water:
+ Cleaning equipment, floor
+ Fire distinguish
+ Irrigation of greenery area
+ For staff activities
+ Boiler
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 101
3.2. Water
Quality of Water
- Depend on the purpose of using
- Quality for technical water
- Quality for non-technical water
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 102
3.2. Water
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 103
3.3. Cooling system
- Carnot cycle
- Estimation of power
- Estimation of electrical consumption
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 104
3.3. Cooling system
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 105
3.4. Electricity
- Electricity for motors
- Electricity for heating
- Electricity for lighting
- Electricity for pumps
- Electricity for fans
- Electricity for ventilation
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 106
3.4. Electricity
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 107
3.5. Cleaning in place (CIP)
Benefits of CIP
- Substantial increase in processing capacity
- Reduce losses through application of CIP cleanable automated
valves and highly automated process
- Improve quality of all products and significant improvement in the
shelf – life of perishable products
- Reduce labor for both processing and cleaning
- Refer Handbook of CIP
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 108
3.5. Cleaning in place (CIP)
CIP system
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 109
3.5. Cleaning in place (CIP)
CIP system
Chap. 3: Facilities in Food Plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 110
4.1. Waste water
Chap. 4: Waste treatment in Food Factory
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 111
4.1. Waste water
Chap. 4: Waste treatment in Food Factory
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 112
4.1. Waste water
Chap. 4: Waste treatment in Food Factory
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 113
4.1. Waste water
Chap. 4: Waste treatment in Food Factory
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 114
4.1. Waste water
Chap. 4: Waste treatment in Food Factory
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 115
4.1. Waste water
Chap. 4: Waste treatment in Food Factory
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 116
4.2. Solid Waste
Chap. 4: Waste treatment in Food Factory
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 117
4.3. Air pollution
Chap. 4: Waste treatment in Food Factory
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 118
5.1. Principles of lay out design in food plant
Chap. 5: Lay out and industrial building
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 119
5.1. Principles of lay out design in food plant
Chap. 5: Lay out and industrial building
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 120
5.2. General lay out of food plant
Chap. 5: Lay out and industrial building
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 121
5.2. General lay out of food plant
Chap. 5: Lay out and industrial building
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 122
5.2. General lay out of food plant
Chap. 5: Lay out and industrial building
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 123
5.3. Industrial building
Chap. 5: Lay out and industrial building
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 124
5.3. Industrial building
Chap. 5: Lay out and industrial building
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 125
5.4. Ventilation
Chap. 5: Lay out and industrial building
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 126
5.5. Lighting
Chap. 5: Lay out and industrial building
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 127
5.6. Drainage
Chap. 5: Lay out and industrial building
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 128
5.7. Floor, door, window and roof
Chap. 5: Lay out and industrial building
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 129
5.8. Warehouse
Chap. 5: Lay out and industrial building
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 130
6.1. Gantt chart
Chap. 6: Organization, operation and safety
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 131
6.2. Organization of plant
Chap. 6: Organization, operation and safety
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 132
6.3. Human resource
Chap. 6: Organization, operation and safety
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 133
6.4. Safety
Chap. 6: Organization, operation and safety
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 134
7.1. Capital
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 135
7.2. Factors influencing on price
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 136
7.2. Factors influencing on price
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 137
7.2. Factors influencing on price
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 138
7.2. Factors influencing on price
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 139
7.2. Factors influencing on price
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 140
7.2. Factors influencing on price
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 141
7.2. Factors influencing on price
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 142
7.2. Factors influencing on price
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 143
7.2. Factors influencing on price
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 144
7.3. Cash flow
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 145
7.3. Cash flow
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 146
7.3. Cash flow: In Operation
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 147
7.3. Cash flow
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 148
7.3. Cash flow
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 149
7.3. Cash flow
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 150
7.3. Cash flow
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 151
7.4. Sensitivity in Economic Analysis
Chap. 7: Economic analysis of food plant
LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 152
7.4. Sensitivity in Economic Analysis
Chap. 7: Economic analysis of food plant

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Food Plant Design ver 2022.pptx

  • 1. Food Plant Design Department of Food Technology Faculty of Chemical Engineering University of Technology, VNUHCM Email: lqdat@hcmut.edu.vn 1 Lai Quoc Dat, Dr
  • 2. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 2 Introduction  Content of Subject: - Chap. 0: Introduction of Food Plant Design - Chap. 1: Analysis of feasibility of the food plant project 1.1. Situation of Market 1.2. Trends of Market 1.3. Own capacity 1.4. Threats 1.5. Scientific and technological context 1.6. SWOT Methods for feasibility study 1.7. Product Design 1.8. Capacity estimation 1.9. Location and site
  • 3. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 3 Introduction  Content of Subject (cont.): - Chap. 2: Process design 2.1. Principles of Process Design 2.2. Materials 2.3. Mass balance 2.4. Energy balance 2.5. Equipment for Food Production
  • 4. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 4 Introduction  Content of Subject (cont.): - Chap. 3: Facilities in Food Plant 3.1. Steam 3.2. Water 3.3. Cooling system 3.4. Electricity 3.5. CIP - Chap. 4: Waste and waste treatment in food factory 4.1. Waste water 4.2. Solid water 4.3. Air pollution
  • 5. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 5 Introduction  Content of Subject (cont.): - Chap. 5: Lay out and industrial building 5.1. Principles of lay out design in food plant 5.2. General lay out of plant 5.3. Industrial building 5.4. Ventilation 5.5. Lighting 5.6. Drainage 5.7. Floor, door, window and roof 5.8. Warehouse
  • 6. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 6 Introduction  Content of Subject (cont.): - Chap. 6: Organization, operation and safety 6.1. Gant chart 6.2. Organization of plant 6.3. Human resource 6.4. Safety - Chap. 7: Economic analysis of food plant 7.1. Capital 7.2. Revenue, Expense, and Profit 7.3. Cash flow 7.4. Sensitivity in Economic analysis
  • 7. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 7 Introduction  References: 1. Zacharias B. Maroulis and George D. Saravacos, Food Plant Economics, CRC Press, 2008, 352 pages 2. Antonio López-Gómez and Gustavo V. Barbosa-Cánovas, Food Plant Design, CRC Press, 2005, 372 pages 3. Zacharias B. Maroulis and George D. Saravacos, Food Process Design, CRC Press, 2003 4. Joseph Irudayaraj, Food Processing Operations Modeling: Design and Analysis, Marcel Dekker Inc., 2002 5. Jasim Ahmed and Mohammad Shafi ur Rahman, Handbook of Food Process Design, Wiley – Blackwell, 2012, 1470 pages
  • 8. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 8 Introduction  References: 6. G. D. Saravacos and A. E. Kostaropoulos, Handbook of Food Processing Equipment, Kluwer Academic/Plenum Publishers, 2002 7. D. R. Heldman and R. W. Hartel, Principles of Food Processing, Aspen Publishers, 1998 8. Perry, R.H. and Green, D.W., Perry’s chemical engineers’ handbook, 7th edition, New York McGraw-Hill 9. D.R. Heldman and D.B Lund, Handbook of Food Engineering, CRC Press, 2007
  • 9. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 9 Chap.0: Introduction of Food Plant  Characteristics of Food Plant - Storage of materials, fresh materials - Season of materials - Diversity of materials: Engineering Properties, Chemical Compositions, Ripen… - Scale up: Bench scale  Pilot  Practical scale - Contamination of impurities and microorganism. - The change of microorganism and enzyme in products - Sensitive attributes of products in storage and distributions - Role of distribution system: B2B, B2C products - Consumer behaviors - Scale
  • 10. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 10 Chap.0: Introduction of Food Plant  Food Plant Design - Food Plant: + Material zone + Manufacturing + Distribution + Marketing + Trading + R&D + Cash flow ….
  • 11. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 11 Chap.0: Introduction of Food Plant  Food Plant Design - Steps of Design: + Step 1: Get idea, + Step 2: General Feasibility Study * Economic Context * Science and Technological Context * General estimation * Social issues + Step 3: Deciding investment
  • 12. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 12 Chap.0: Introduction of Food Plant  Food Plant Design - Steps of Design (Cont.): + Step 4: Technical Design * Location and site, capacity, products * Process design, mass and energy balance * P&ID design * Energy, electricity, water, fire fighting * Waste treatment * Facilities * Industrial building, ware house, general lay out * Operation * Economic analysis
  • 13. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 13 Chap.0: Introduction of Food Plant  Food Plant Design - Steps of Design (Cont.): + Step 5: Deciding on investment + Step 6: Master plan for investment + Step 7: Mobilization of capital, tendering, contracting… + Step 8: Installation + Step 9: Trial operation and evaluation + Step 10: Official operation and launch.
  • 14. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 14 Chap.0: Introduction of Food Plant  Food Plant Design - Master Plan for Design Activities: + Human resource + Data resource + Facility resource + Financial resource + Gantt chart
  • 15. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 15 Chap.0: Introduction of Food Plant  Food Plant Design - Documents of Design activities: + Preliminary design: reports and drawing + Technical design: revised reports and drawing, legal documents… + Installation design: drawing of construction and installation, legal documents for construction…
  • 16. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 16 Chap.0: Introduction of Food Plant  Food Plant Design - Drawings: + Vietnamese Standards of Drawings (TCVN).
  • 17. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 17 Chap.0: Introduction of Food Plant  Science vs. Engineering vs. Technology
  • 18. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 18 Chap.0: Introduction of Food Plant  Science vs. Engineering vs. Technology
  • 19. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 19 Chap.0: Introduction of Food Plant  Science vs. Engineering vs. Technology
  • 20. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 20 Chap.0: Introduction of Food Plant  Engineer in Food Industry: Capable of R&D: - Process - Products - Plant (factory) - System  Assignment to: - R&D - Design sector - Manufacturing - Trading - …
  • 21. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 21 Chap. 1: Analysis of feasibility of the food plant project 1.1. Situation of Market - Volume and demands - Necessity of the related products - Relationship of quality – price - Possibility of export - Possibility of distribution system - Efforts of sales
  • 22. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 22 1.2. Possibility of market development in future - Increasing in demands and amount of consumers - Increasing in acceptance of consumer - New products on market - Trends in society, economy and politics Chap. 1: Analysis of feasibility of the food plant project
  • 23. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 23 1.3. Strengths of price and distribution system - Material cost - Labor cost - Distribution and saling cost - Efficiency of process - Patents and copyright Chap. 1: Analysis of feasibility of the food plant project
  • 24. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 24 1.4. Threats - Stability of economy - Risks of technologies - Competition from import - Capacity of competitors - Risks on quality and consumer belief - Capital - Possibility of attacks - Laws and policies of government - Time to obtain the profit - In stock Chap. 1: Analysis of feasibility of the food plant project
  • 25. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 25 1.5. Scientific and Technological context - Achievement of science and technology - Equipment - Supporting industry: packaging, transportations… Chap. 1: Analysis of feasibility of the food plant project
  • 26. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 26 1.6. SWOT method for feasibility study - SWOT STRENGTHS 1. 2. WEAKNESSES 1. 2. OPPORTU- NITIES 1. 2. 3. Opportunity-Strength (OS) Strategies Use the strengths to take advantage of opportunities 1. Opportunity-Weakness (OW) Strategies Overcome weaknesses by taking advantage of opportunities 1. THREATS 1. 2. Threat-Strength (TS) Strategies Use strengths to avoid threats 1. Threat-Weakness (TW) Strategies Minimize weaknesses and avoid threats 1. Chap. 1: Analysis of feasibility of the food plant project
  • 27. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 27 1.7. Capacity Estimation - Where to play? - Who are consumers? - Source of materials - Capital - Human resource - Limitation of technology - Policies of governmental authority (national, local….) Chap. 1: Analysis of feasibility of the food plant project
  • 28. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 28 1.8. Product Design Quality: - Nutrition elements - Food Safety and Hygiene - Sensory Properties - Convenience for using - Service - Level of technology: hand made, mechanization, automation… Specifications: - Brand and Label - Packaging - Size - Storage and transport - Shelf life Chap. 1: Analysis of feasibility of the food plant project
  • 29. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 29 1.8. Product Design Method of product design: Chap. 1: Analysis of feasibility of the food plant project
  • 30. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 30 1.8. Product Design Method of product design: Chap. 1: Analysis of feasibility of the food plant project
  • 31. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 31 1.8. Product Design Method of product design: Chap. 1: Analysis of feasibility of the food plant project
  • 32. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 32 1.8. Product Design Method of product design: Chap. 1: Analysis of feasibility of the food plant project
  • 33. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 33 1.8. Product Design Method of product design: Chap. 1: Analysis of feasibility of the food plant project
  • 34. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 34 1.9. Location and Site - Material sources - Market - Labor resource (cost, capacity, amount…) - Transport system - Supporting services: public transport, internet, banking… - Infrastructure: electricity, water supply, waste water treatment, - Characteristics of site: shape of area, geological characteristics - Climate (temperature, typhoon, storm, drain, flood…) - Policies and plans of local and central governments Note: Consider the priority of factors and forecast the changes in these factors in future. Chap. 1: Analysis of feasibility of the food plant project
  • 35. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 35 1.9. Location and Site Steps of selection: - Step 1: Determine the purposes of food plant - Step 2: Figure out the factors influencing on the operation of Plant - Step 3: Determine the requirements of these factors - Step 4: Seek the sites satisfying the requirements - Step 5: Preliminarily evaluate and choose some sites most satisfy the requirements - Step 6: Set up the method for eligibility of sites - Step 7: Evaluate the sites which are preliminarily selected. - Step 8: Select the optimized site. Chap. 1: Analysis of feasibility of the food plant project
  • 36. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 36 1.9. Location and Site Methods for selection: SWOT analysis - Analyze the SWOT of sites - Select the site satisfying the requirements - Strategies for plant compatible with the sites (solutions for problems of site). - Select the site suitable for the factory  This method is simple, however, it depends on the capacity of people in charged of selection work. Normally, apply for SMEs. Chap. 1: Analysis of feasibility of the food plant project
  • 37. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 37 1.9. Location and Site Methods for selection: Optimize the cost of transportation - Estimate the cost for transport of materials and products - Select the site at lowest cost  This method suitable for factories in which, the cost of transportation is remarkable. Chap. 1: Analysis of feasibility of the food plant project
  • 38. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 38 1.9. Location and Site Methods for selection: Factors analysis - Step 1: Determine the factors influencing on selection of site - Step 2: Determine the important coefficient of each factor - Step 3: Make score for each factor for each site (note: scale of score) - Step 4: Summarize score, evaluate and select the optimized site with highest scored. - In case of two or more sites have the same score at highest, investor decide the site.  This method requires the experts with high capacity, apply for big project. Chap. 1: Analysis of feasibility of the food plant project
  • 39. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 39 1.9. Location and Site Methods for selection: Factors analysis Chap. 1: Analysis of feasibility of the food plant project No. Factor Important coefficient Scale of score Score Standardized score Score of Contribution 1 F1 k1 m1 s1 g1= 𝑠1 𝑚1 C1=k1*g1 i Fi ki mi si gi= 𝑠𝑖 𝑚𝑖 Ci=ki*gi n Fn kn mn sn gn= 𝑠𝑛 𝑚𝑛 C1=kn*gn Total score 1 𝑛 𝐶𝑖
  • 40. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 40 2.1. Principles of process design What is food engineering - Food Engineering is a relatively new profession and a scientific field involved with food manufacturing and the processing of refined foods. It encompasses the practical application of food science to develop efficient industrial production, packaging, storage, and physical distribution of nutritious and convenient foods that are uniform in quality and safe. - Food Engineering: integrate physical, chemical engineering and bioengineering Chap. 2: Process design
  • 41. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 41 2.1. Principles of process design Chap. 2: Process design
  • 42. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 42 2.1. Principles of process design Chap. 2: Process design
  • 43. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 43 2.1. Principles of process design Chap. 2: Process design
  • 44. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 44 2.1. Principles of process design Components of food technology Chap. 2: Process design
  • 45. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 45 2.1. Principles of process design Process system Chap. 2: Process design
  • 46. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 46 2.1. Principles of process design Some basic principles of food process design - Including physical engineering, chemical engineering, biological engineering process. - Base on chemical process: mass transfer, heat transfer, fluid mechanic… - Optimization in food process: Maximize the yield, minimize the loss of quality and hazards to human health. - Overall goals of optimization of process is profit. - Food safety and hygiene - From the process design  characteristics of equipment forprocessing - Process design: Fundamentals of process  modeling  simulation  optimization  select facilities for process Chap. 2: Process design
  • 47. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 47 2.1. Principles of process design Some basic principles of food process design - Activities of process design: select process, estimate mass balance and energy, estimate capacity and specifications of equipment, design lay out of equipment in factory, estimate cost for investment and operation, technological and economic assessment. - Factors influence on the design: HSE, policies, regulation, disaster, quality of production, food safety, operation… - Food Quality Management: ISO, HACCP, TQM, GMP… Chap. 2: Process design
  • 48. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 48 2.1. Principles of process design Some basic principles of food process design Chap. 2: Process design
  • 49. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 49 2.1. Principles of process design Optimization in Food Process Chap. 2: Process design
  • 50. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 50 2.1. Principles of process design Block Diagram of process Chap. 2: Process design
  • 51. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 51 2.1. Principles of process design Process Diagram with Equipment Chap. 2: Process design
  • 52. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 52 2.1. Principles of process design P&ID Chap. 2: Process design
  • 53. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 53 2.1. Principles of process design 2D process Diagram Chap. 2: Process design
  • 54. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 54 2.1. Principles of process design 3D process Diagram Chap. 2: Process design
  • 55. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 55 2.1. Principles of process design 3D Process Diagram Chap. 2: Process design
  • 56. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 56 2.2. Materials in Foods Chap. 2: Process design
  • 57. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 57 2.2. Materials in Foods Roles of materials: - Influence on quality and price of product - Input data for process design - Contribute to determination of economic efficiency Chap. 2: Process design
  • 58. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 58 2.2. Materials in Foods How to select materials and suppliers: - Roles of materials in process and product - Plant capacity - Requirements on quality of materials - Price - Stability of quantity and quality - Prestigious suppliers Chap. 2: Process design
  • 59. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 59 2.3. Mass balance Mass and energy flow in food factory: Chap. 2: Process design
  • 60. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 60 2.3. Mass balance Mass and energy flow in food factory: - Used for preparation of formulas, final compositions of products, yields  estimate the rate and size of equipment, economic efficiency, operation and planning… - Based on the principles of the law of “conservation of mass”: Mass can neither be created or destroyed Chap. 2: Process design
  • 61. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 61 2.3. Mass balance Chap. 2: Process design
  • 62. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 62 2.3. Mass balance Chap. 2: Process design
  • 63. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 63 2.3. Mass balance Chap. 2: Process design
  • 64. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 64 2.3. Mass balance Chap. 2: Process design
  • 65. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 65 2.3. Mass balance Chap. 2: Process design
  • 66. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 66 2.3. Mass balance Preparing the mass balance estimation: - Prepare the diagram of process flow - Determine the boundaries of the system (process) - Describe the system with a boundary (real or imaginary, stationary or movable) - A system boundary may even enclose an entire food processing system. - Choose the basis capacity (kg/hour, kg, ton….) Chap. 2: Process design
  • 67. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 67 2.3. Mass balance Conducting the mass balance estimation: - Collect all data on mass and composition of an inlet and exit streams from the references or experiments - Analysis the changes in process - Draw a process flow diagram, indicating the process, with inlet and exit streams property - Draw the system boundary - Write all available on the flow diagram, select the basic - Determine the loss - Write total and components mass balance. - Solve the material balance to determine the unknowns. - Notes: All unknowns ≥0, adding some components for solution of problems (maltodextrin, butter…) Chap. 2: Process design
  • 68. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 68 2.3. Mass balance Loss and yield: - Depends on properties of material - Depend on process - Depend on storage and transportation - Depend on equipment - Depend on skill of staffs - … Chap. 2: Process design
  • 69. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 69 2.3. Mass balance Chap. 2: Process design
  • 70. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 70 2.3. Mass balance Chap. 2: Process design
  • 71. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 71 2.3. Mass balance Chap. 2: Process design
  • 72. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 72 2.3. Mass balance Chap. 2: Process design
  • 73. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 73 2.3. Mass balance Chap. 2: Process design
  • 74. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 74 2.4. Energy balance Chap. 2: Process design
  • 75. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 75 2.4. Energy balance Chap. 2: Process design
  • 76. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 76 2.4. Energy balance Chap. 2: Process design
  • 77. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 77 2.4. Energy balance Chap. 2: Process design
  • 78. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 78 2.4. Energy balance Chap. 2: Process design
  • 79. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 79 2.4. Energy balance Chap. 2: Process design
  • 80. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 80 2.4. Energy balance Chap. 2: Process design
  • 81. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 81 2.4. Energy balance Chap. 2: Process design
  • 82. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 82 2.4. Energy balance Chap. 2: Process design
  • 83. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 83 2.4. Energy balance Chap. 2: Process design
  • 84. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 84 2.4. Energy balance Chap. 2: Process design
  • 85. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 85 2.4. Energy balance Chap. 2: Process design
  • 86. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 86 2.4. Energy balance Chap. 2: Process design
  • 87. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 87 2.4. Energy balance Saving energy in food plant Chap. 2: Process design
  • 88. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 88 2.5. Equipment for food production Criteria - Advance technology - Automation - Friendly with environment. - Satisfy the capacity, synchrony and technological parameters… - Capital cost - Operation cost - Safety - Durability - Sanitation - Cleaning - Match the requirements of food safety Chap. 2: Process design
  • 89. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 89 2.5. Equipment for food production Criteria - Method of manufacture - Structure: + Low weight + Easy to maintain and repair + Easy to cleaning + Safety and convenient in operation + No leakage + Able to update (capacity and specification) + Standardize elements - Material: + Durable + Easy to process + No corrosion + Easy to cleaning + Low cost Chap. 2: Process design
  • 90. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 90 2.5. Equipment for food production Chap. 2: Process design
  • 91. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 91 2.5. Equipment for food production Chap. 2: Process design
  • 92. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 92 3.1. Steam Using of Steam - Heating, drying, pasteurization, sterilization, steaming… - State of steam: P, T, Enthalpy… Chap. 3: Facilities in Food Plant
  • 93. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 93 3.1. Steam Estimate of The consumption of Steam Chap. 3: Facilities in Food Plant
  • 94. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 94 3.1. Steam Estimate of The consumption of Steam Chap. 3: Facilities in Food Plant
  • 95. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 95 3.1. Steam Chap. 3: Facilities in Food Plant
  • 96. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 96 3.1. Steam Selection of Boiler Chap. 3: Facilities in Food Plant
  • 97. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 97 3.1. Steam Selection of Boiler - Codes and standards of requirements - State of steam - Boiler load - Number of boiler - Performance considerations - Special considerations Chap. 3: Facilities in Food Plant
  • 98. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 98 3.1. Steam Fuel for boiler - Fossil: coal, DO, FO.. - Wood, - Biomass - Notice: Air pollutions from boiler operation Chap. 3: Facilities in Food Plant
  • 99. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 99 3.2. Water Source of water - Surface water - Ground water - Water from suppliers Chap. 3: Facilities in Food Plant
  • 100. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 100 3.2. Water Using of Water in Food Factory - Technical water - Non –technical water: + Cleaning equipment, floor + Fire distinguish + Irrigation of greenery area + For staff activities + Boiler Chap. 3: Facilities in Food Plant
  • 101. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 101 3.2. Water Quality of Water - Depend on the purpose of using - Quality for technical water - Quality for non-technical water Chap. 3: Facilities in Food Plant
  • 102. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 102 3.2. Water Chap. 3: Facilities in Food Plant
  • 103. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 103 3.3. Cooling system - Carnot cycle - Estimation of power - Estimation of electrical consumption Chap. 3: Facilities in Food Plant
  • 104. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 104 3.3. Cooling system Chap. 3: Facilities in Food Plant
  • 105. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 105 3.4. Electricity - Electricity for motors - Electricity for heating - Electricity for lighting - Electricity for pumps - Electricity for fans - Electricity for ventilation Chap. 3: Facilities in Food Plant
  • 106. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 106 3.4. Electricity Chap. 3: Facilities in Food Plant
  • 107. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 107 3.5. Cleaning in place (CIP) Benefits of CIP - Substantial increase in processing capacity - Reduce losses through application of CIP cleanable automated valves and highly automated process - Improve quality of all products and significant improvement in the shelf – life of perishable products - Reduce labor for both processing and cleaning - Refer Handbook of CIP Chap. 3: Facilities in Food Plant
  • 108. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 108 3.5. Cleaning in place (CIP) CIP system Chap. 3: Facilities in Food Plant
  • 109. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 109 3.5. Cleaning in place (CIP) CIP system Chap. 3: Facilities in Food Plant
  • 110. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 110 4.1. Waste water Chap. 4: Waste treatment in Food Factory
  • 111. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 111 4.1. Waste water Chap. 4: Waste treatment in Food Factory
  • 112. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 112 4.1. Waste water Chap. 4: Waste treatment in Food Factory
  • 113. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 113 4.1. Waste water Chap. 4: Waste treatment in Food Factory
  • 114. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 114 4.1. Waste water Chap. 4: Waste treatment in Food Factory
  • 115. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 115 4.1. Waste water Chap. 4: Waste treatment in Food Factory
  • 116. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 116 4.2. Solid Waste Chap. 4: Waste treatment in Food Factory
  • 117. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 117 4.3. Air pollution Chap. 4: Waste treatment in Food Factory
  • 118. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 118 5.1. Principles of lay out design in food plant Chap. 5: Lay out and industrial building
  • 119. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 119 5.1. Principles of lay out design in food plant Chap. 5: Lay out and industrial building
  • 120. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 120 5.2. General lay out of food plant Chap. 5: Lay out and industrial building
  • 121. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 121 5.2. General lay out of food plant Chap. 5: Lay out and industrial building
  • 122. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 122 5.2. General lay out of food plant Chap. 5: Lay out and industrial building
  • 123. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 123 5.3. Industrial building Chap. 5: Lay out and industrial building
  • 124. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 124 5.3. Industrial building Chap. 5: Lay out and industrial building
  • 125. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 125 5.4. Ventilation Chap. 5: Lay out and industrial building
  • 126. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 126 5.5. Lighting Chap. 5: Lay out and industrial building
  • 127. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 127 5.6. Drainage Chap. 5: Lay out and industrial building
  • 128. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 128 5.7. Floor, door, window and roof Chap. 5: Lay out and industrial building
  • 129. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 129 5.8. Warehouse Chap. 5: Lay out and industrial building
  • 130. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 130 6.1. Gantt chart Chap. 6: Organization, operation and safety
  • 131. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 131 6.2. Organization of plant Chap. 6: Organization, operation and safety
  • 132. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 132 6.3. Human resource Chap. 6: Organization, operation and safety
  • 133. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 133 6.4. Safety Chap. 6: Organization, operation and safety
  • 134. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 134 7.1. Capital Chap. 7: Economic analysis of food plant
  • 135. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 135 7.2. Factors influencing on price Chap. 7: Economic analysis of food plant
  • 136. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 136 7.2. Factors influencing on price Chap. 7: Economic analysis of food plant
  • 137. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 137 7.2. Factors influencing on price Chap. 7: Economic analysis of food plant
  • 138. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 138 7.2. Factors influencing on price Chap. 7: Economic analysis of food plant
  • 139. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 139 7.2. Factors influencing on price Chap. 7: Economic analysis of food plant
  • 140. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 140 7.2. Factors influencing on price Chap. 7: Economic analysis of food plant
  • 141. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 141 7.2. Factors influencing on price Chap. 7: Economic analysis of food plant
  • 142. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 142 7.2. Factors influencing on price Chap. 7: Economic analysis of food plant
  • 143. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 143 7.2. Factors influencing on price Chap. 7: Economic analysis of food plant
  • 144. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 144 7.3. Cash flow Chap. 7: Economic analysis of food plant
  • 145. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 145 7.3. Cash flow Chap. 7: Economic analysis of food plant
  • 146. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 146 7.3. Cash flow: In Operation Chap. 7: Economic analysis of food plant
  • 147. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 147 7.3. Cash flow Chap. 7: Economic analysis of food plant
  • 148. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 148 7.3. Cash flow Chap. 7: Economic analysis of food plant
  • 149. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 149 7.3. Cash flow Chap. 7: Economic analysis of food plant
  • 150. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 150 7.3. Cash flow Chap. 7: Economic analysis of food plant
  • 151. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 151 7.4. Sensitivity in Economic Analysis Chap. 7: Economic analysis of food plant
  • 152. LAI Quoc Dat, Ph.D. HCMUT – Chemical Engineering Faculty 152 7.4. Sensitivity in Economic Analysis Chap. 7: Economic analysis of food plant