About the designe of Food plant layout

1. A Brief Discussion on Bakery Industr
Group : c
Included id: 1605035,
1605036, 1605037, 1605040, 1605042, 1605043, 1605044, 1605045, 1605046, 1605048, 1605049,
1605050

2. Conclusion ID: 1605050
• Due to modernization, westernization, industrialization demand for
bakery has increased
• Due to changing consumption pattern there is a lot of scope for
bakery industry
• Good opportunity to emerge as a national brand
• As the industry continues to evolve, bakers should remember that
growth doesn’t just happen in the bricks and mortar; it extends far
beyond the walls of a facility, and growth for the bakery means
growth for the community at large, as well.

3. Objectives ID: 1005035
• Types of Factories
• Location Selection
• Food plant layout
• Labor facilities
• General design consideration
• Processing
• Safety
• Maintenance
• Modernization
• Transportation

4. What is Bakery ? ID: 1605036
• A Bakery is an Establishment That Produces and Sells Flour-based
Food Baked in an Oven Such as Bread, Cookies, Cakes, Pastries,
and Pies.
• The Foods Produced in The Bakery are Mainly Sweet Based
Products That People Usually Have as Snacks.
• Some Popular Baked Products are Cake, Bread, Biscuit, Donut,
Muffin Etc.

5. TYPES OF BAKERYS
There Are Mainly Two Types Of Bakery's
• 1. Commercial Bakery Or Large Scale Bakery
• 2. Private Bakery Or Small Scale Bakery

6. Location selection: ID: 1605037
For a good plant should follow this
conditions:
(a)Good marketing environment.
(b)Place of workship.
(c)Medical service etc.
(d)Need to have good waste disposal system.
(e)Need to have good transportation facilities.
(f)High proportion of skilled employes.
(h)Availability of labour force.

7. Layout of food plant. ID: 1605040
• Facility layout and design is an important component of a
food plant.
• The basic objective of layout is to ensure a smooth flow
of work, material, and information through a system.
• The basic meaning of facility is the space in which
activities take place.
• cleaning sector, maintenance, sanitation, processing
sector, packaging ,storing ,labour room, official room, bio-
security is the key point of a layout design .

8. Labor facilities ID: 1605042
• Workers in food processing plants are exposed to many potential
hazards and dangers instruments knife cuts, falls and exposure to
infectious disease and hazardous chemicals.
• They need security and medical facilities .
• its important to regulate minimize these dangers and create a safe
working environment in plants.
• The plant and all workers must comply with these regulations to
maintain safe surroundings and avoid fines.
• Workers must follow regulations to maintain a safe environment.

9. General Design Consideration ID: 1605043
• Maximize site location
• Availability of labors, water supply and energy
• Proper ventilation system
• Floor drains
• Manage traffic flows
• Protect against infestation and contamination
• Install durable wall and ceiling materials
• Design system to maintain sanitation
• Choose well-designed, cleanable process
equipment

10. Production Methods ID: 1605044
• The principles of baking bread have been established for thousands of
years. The basic ingredients are flour, yeast, salt and water.
• All bread making processes rely on four key steps:
• Mixing
• Proving/Fermenting
• Baking
• Cooling
• There are two main methods of making bread:
• Bulk Fermentation Process (BFP)
• Chorleywood Bread Process (CBP)

11. • BFP
• BFP is a traditional method. Ingredients are mixed together to form a dough and left to
ferment for up to three hours. During fermentation the dough changes from a short dense
mass into an elastic dough. The time taken to reach this state largely depends on the amount
of yeast and the dough temperature.
• CBP
• The modern commercial process used in large bakeries is known as the Chorleywood Bread
Process and was developed in the early 1960’s by the Flour Milling and Baking Research
Association (BBIRA) at Chorleywood. CBP uses mechanical energy in the form of high speed
mixing to develop the dough for proving and baking. It is essentially a rapid form of kneading
helping to develop the gluten (protein) structure within the dough (this means that the
lengthy bulk fermentation of traditional processes is not needed). To achieve this, a flour
treatment agent (ascorbic acid) and a little fat or emulsifier need to be added, usually in the
form of a bread improver.

12. • Other than mixing and bulk fermentation, all other parts of the bread making process – dough
dividing, proving, baking, cooling and slicing are the same as any other way of making bread.
• The plant bread production process takes around 4 hours from end to end.
• Other methods of bread making include:
• Activated Dough Development (ADD)
• Straight Dough Method
• Delayed Salt Method
• Sponge and Dough Process (S&D)
• Ferment Dough Process

13. Safety in Bakeries: ID: 1605045
Main Types of Risks:
Slips, trips and falls
40% of major accidents are due to slips on wet floors or spillage of dough or other wet ingredients.
Uneven and obstructed floor surfaces also lead to tripping accidents.
Many accidents occur when staff fall from a height, e.g. when loading/unloading vehicles, or when
accessing stores.
Machinery
Bakeries contain many items of dangerous machinery where staff can
come into contact with moving blades, conveyor belts and other traps leading to serious cutting and
crushing injuries
of the limbs. For example, dough
brakes, pie and and tart machines, mixers, roll plant and dividers.

14. • Hazardous Substances
• Some chemicals used for cleaning can be harmful.
• Burns and Scalds
• Hot ingredients such as syrups can cause burns and scalds, as can other heated
• surfaces and objects, e.g.trays, ovens etc
• Manual Handling
• Handling heavy loads such as bags of flour or trolleys and trays result in injuries of the back and
muscles.
• Health Problems
• Flour dust exposure is a major problem in the bakery industry causing asthma and nose, throat
and eye disorders. The handling of dough and other ingredients can cause dermatitis.

15. Figure: Wastage from Bakery
Maintenance and Waste Management
ID:1605046

16. BAKERY INDUSTRY WASTE SOURCES: Facing increasing stringent wastewater discharge regulations and cost
of pretreatment, more bakery manufacturers have turned to water conservation, clean technology, and
pollution prevention in their production processes.
addition, other types of pollution resulting from production are noise pollution and air pollution.
1.Noise
2.Air Pollution
3.Wastewater
Wastewater in bakeries is primarily generated from cleaning operations including equipment cleaning and
floor washing. It can be characterized as high loading, fluctuating flow and contains rich oil and grease
BAKERY WASTE TREATMENT:
Generally, bakery industry waste is nontoxic. It can be divided into liquid waste, solid waste, and gaseous
waste. In the liquid phase, there are high contents of organic pollutants including chemical oxygen demand
(COD), BOD5, as well as fats, oils, and greases (FOG), and SS. Wastewater is normally treated by physical
and chemical, biological processes. Some prosses are as follows.
1.Pretreatment system:
Pretreatment or primary treatment is a series of physical and chemical operations, which precondition the
wastewater as well as remove some of the wastes. The treatment is normally arranged in the following
order: screening, flow equalization and neutralization, optional FOG separation, optional acidification,
coagulation–sedimentation, and dissolved air flotation

17. 2.Flow Equalization and Neutralization
In bakery plants, the wastewater flow rate and loading vary significantly with the time as illustrated in Table 8.4 [8,9].
It is usually economical to use a flow equalization tank to meet the peak discharge demand. However, too long a
retention time may result in an anaerobic environment. A decrease in pH and bad odors are common problems during
the operations
3.Screening
Screening is used to remove coarse particles in the influent. There are different screen openings ranging from a few
mm (termed as micro screen) to more than 100 mm (termed as coarse screen). Coarse screen openings range from 6–
150 mm; fine screen openings are less than 6 mm. Smaller opening can have a better removal efficiency; however,
operational problems such as clogging and higher head lost are always observed.
4. Acidification:
Acidification is optional, depending on the characteristics of the waste. Owing to the presence of FOG, acid (e.g.,
concentrated H2SO4) is added into the acidification tank; hydrolysis of organics can occur, which enhances the bio
treatability.
5.Coagulation:
Coagulation is used to destabilize the stable fine SS, while flocculation is used to grow the destabilized SS, so that the
SS become heavier and larger enough to settle down. The Coagulation–flocculation process can be used to remove
fine SS from bakery wastewater. It normally acts as a preconditioning process for sedimentation and/or dissolved air
flotation

18. Modernization of food plant ID: 1605048
• Modernization is the term used for development purpose of food plant
industry.
• It could be included in infrastructural , equipmental, technical
development.
• Main purpose of modernization of food plant is to improve the qualities of
food and services .
• Sanitation is one of the important part of modern food plant

19. Transportation Id no:1605049
Transportation- is the movement of humans, animals and
goods from one location to another.
Mode of transportation include-
Air, land (rail and road), water, cable, pipeline and space.
The field can be divided into-
• infrastructure, vehicles and operations.
The Role of Transportation in Service Quality
• Goods could be sent to the right place at right time in order to satisfy
customers’ demands.
• It brings efficacy, and also it builds a bridge between producers and
consumers.
• It is the base of efficiency and economy in business sector.
• A good transport system brings benefits not only to service quality
but also to company competitiveness  Raw material >transport > factory> transport >market

20. Conclusion ID: 1605050
Due to modernization, westernization, industrialization demand for bakery has increased
Due to changing consumption pattern there is a lot of scope for bakery industry
Good opportunity to emerge as a national brand
As the industry continues to evolve, bakers should remember that growth doesn’t just happen in
the bricks and mortar; it extends far beyond the walls of a facility, and growth for the bakery means
growth for the community at large, as well.

21. Thank You All