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

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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

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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

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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.