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10/3/2011 Pertegato Ing. Giancarlo 1
Feasibility studies and preliminary factory design
• To decide about an investment, the feasibility study is the first step that allows the estimation of the potential risks and the return of the investment in terms of time and income.
• Based on market research that considers the potential business growth, the competition, the distribution and sales possibilities as well the price levels, the capacity of the factory is estimated.
• From the capacity of the factory the land can be located and the factory preliminarily designed to obtain the budget cost for the building, and all the related mechanical and electrical plants. The running cost can also be estimated in relation to the production, the location and the services available nearby.
• Comparing the costs estimated in the previous steps plus the financial costs with the potential income from the sales, the return of the investment can be calculated and if satisfactory the project can start.
• The final project with tender documents is issued.• Suppliers are going to be selected and the quotation
checked to comply with the specifications. • When the suppliers selection is done construction
design can be provided and the works can start up to the testing and commissioning of the whole factory.
Return of investment
Feasibility Budget
Design & Tenders
Construction
YES
NO
10/3/2011 Pertegato Ing. Giancarlo 2
Summarizing:• The advising services are
provided step by step with the benefit that a wrong investment can be recognized from the beginning minimizing the wasted costs.
• The cost for the go ahead on any project is the best investment because a project on wrong assumptions or data could be catastrophic
• Generally speaking the engineering and advising costs can vary between 1.5 and 7.5% of the total investment inversely to the amount (the higher the investment the lower the %)
Contract with suppliers, construction design and project start up
Investment approval and final project with tender documents issuing
Preliminary project and lay-out
Feasibility study
Input
10/3/2011 Pertegato Ing. Giancarlo 3
Three working steps
PreliminaryPreliminary
DataData
Need
sNe
eds
Interconnections
Interconnections
Proj
ect
Proj
ect
FinalFinal
Fina
l Dat
a
Fina
l Dat
a
CheckingChecking
Tend
erin
gTe
nder
ing
TendersTenders
Construction
Construction
CheckingChecking
TargetTarget
Feas
ibili
tyFe
asib
ility
ImpactImpact
10/3/2011 Pertegato Ing. Giancarlo 4
Advantages• The design in several steps allows to modify the
project according to the data acquisition and strategies with minimal impact when changes occur.
• Any change in the design phase has a costs incomparably lower than in construction phase.
• Invest in engineering means to minimize changes and modification during construction reducing the wasted costs generated by such changes
Some projects are shown in the next slides
10/3/2011 Pertegato Ing. Giancarlo 5
Lanitis Bros. Ltd.
TANKER 4
TANKER 2
TANKER 3
TANKER 1
10/3/2011 Pertegato Ing. Giancarlo 6
Christis Dairies Ltd. Limassol Cyprus
-45°C Freezer
-25°C Store
LABORATORY
PROCESSED CHEESE
25-FUTURE FRESH MILK GRAVITY COLD STORE
4°
h=6.0m h=6.0m
STORE
COW 100T
SHIP 40T
GOAT 40T
COW 100T
22-COLD STORE FOR READY PALLETIZED GOODS FOR LOCAL
MARKET 4°
MILK FILLING/PAKING 22°
1-HALLOUMI PRODUCTION
4-FOLDING & SALTING
3-HALLOUMI COOKING
2-M
OU
LD
WA
SH
ING
/STO
RA
GE
BLAST COOLER
3-ANARI PRODUCTION
9-PACKING ROOM
RO
W M
ATE
RIA
L S
TOR
E
7-COLD STORE
10-PACKING IN BOXES
LIFT
LIFT
8-A
CC
ES
S F
RO
M
BA
SE
ME
NT
24-DRIVE IN YOGURT COLD STORE 4°
20-DRIVE IN EXPORT CHEESE STORE -18°
26-24TRADING AND DISPATCHING COLD STORES 1ST FLOOR
(FUTURE PROVISION)
LIFT
TRADING AND DISPATCHING COLD
STORES GROUND FLOOR (FUTURE PROVISION)
LIFTRECEIVING/DISPATCHING
OFFICES AND FACILITIES
21-FRESH MILK GRAVITY COLD STORE 4°
23-DRIVE IN COLD STORE 4°
h=4.9m
h=4.9m
h=3.7m
h=4.5m
h=3.7m
h=3.7m
h=4.9m
h=6.0m
h=6.0m
h=6.0mh=6.0m
h=6.0m
h=6.0m
h=6.0m
h=3.5m (lowered for technical space)
28-FUTURE PACKED CHEESE DRIVE IN COLD
STORE 4°HV TRANSFORMERS
MA
IN E
LEC
TRIC
BO
AR
D
POWER GENERATOR
CRATES WASHING
RAW MATERIAL BUFFER STORE
CANTEEN
CANTEEN STORECANTEEN STORE
RAW MATERIAL COLD STORE
RAW MATERIAL COLD STORE
RAW MATERIAL COLD STORE
16-FETTA PRODUCTION 22°
18-FETTA STORAGE 4°
19-HALLOUMI STORAGE 4°
DRY STORE (UHT) - DRIVE IN
17-FETTA MATURING 18°
PACKAGING STORE DISPTACHING 15°
SLICING
DRESSING ROOMS AND TOILETS RE-ADJUSTMENT
SUGGESTED TO AVOID CROSS CONTAMINATION
CRATES STORE
5bANARI
cold store
DRESSING ROOMS AND TOILETS
MILK RECEPTION
TANKER 1
TANKER 4
TANKER 2
TANKER 3
11-KEFALOTIRY PRODUCTION
13-KEFALOTIRY BRINING 10°
12-KEFALOTIRY PRESSING 10°
MILK MIXING ROOM
14-K
EFA
LOTI
RY
M
ATU
RIN
G 1
8°
C.I.P.
YOGURT RIPENING
YOGURT BLAST COOLER -1°
6-BRINING
MILK PASTEURIZATION
WORKSHOP
29-DISPATCHING GRAVITY COLD STORE
4°
30-BUFFER COLD STORE 4°
UNPACK ROOM 15°
RE-PACKING ROOM 15°(CLEAN ROOM)
h=6.0m
U.H.T.
U.H.T. FILLING
CHEESE PRODUCTION BUFFER TANKS
15-KEFALOTIRY STORAGE 4°
SEWAGE TANKER
DISPATCHING
Raw Material Store for:1. Straws for TBA 3 and TBA - 19 Prisma2. Carton Boxes for TBA 3 250/1000 & TBA 19 Prisma (for all different kinds)3. Schrink for TBA 19 line & TBA 3 line4. Glue for the carton Boxes and Straws5. Paper reels for the 3 machines, strip and aluminum strips for the pull tab6. Chemical liquids for the macines (Peroxide, external Cleaning, Acid, LFT)7. Trolley for lifting and turning the reels8. Raw materials needed for Mac Donalds9. Ready product storage
Operato r side
S eparat i ng wall
Mul ti vac exitcon veyor
V acu um p acked por t i ons (3 x 3)
T urni ng U nitD r iv en belt conve yor
Ex ist i ng bel t co nveyor w ithmet al det ec tor mount ed
C onverger
D i ver t in g poi nt (opti on)
Wei gh -p r ic e l abe ll i ng machineQ u eui ng conveyor D r i ven con veyor wi threj ect arm
S tan dard out l et
O ut le t fo r di ve rted p ro duct s
10/3/2011 Pertegato Ing. Giancarlo 7
Kasih Food Production Co.