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Planta Procesadora de Galletas
Planta Procesadora de Galletas
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https://agriexchange.apeda.gov.in/Weekly_eReport/Biscuit_%20Report.pdf
4.1 CHOICE OF EQUIPMENT
In any production process, the choice of the equipment from the different types is
very important, so as to meet the production capacity target, ensure good quality of
product, maximise cost, durability, safety to life and property and cost of production.
Equipment are built with different sizes and shapes, they are designed on different
working principle or operation, which are therefore characteristic of the use to which it will
be applied. It is therefore important to know the nature of the material in the process and
Dough and paste are mixed in machines, which have of necessity, to be heavy and
powerful. Because of the large power requirements, it is particularly desirable that the
motor posses reasonable efficiency; as the power dissipated in the form of heat may cause
substantial heating of the product. Such machines may require jacketing mixer to remove
as much heat as possible with cooling water (Richardson and Peacock, 1994).
The most commonly used mixers for these heavy material are the
(3) The Kneader, which employs two contra rotating arms of special shape, which fold and
shear the material across a cusp, or division, in the bottom
The blade of these mixers rotates at differential speeds, often in the ratio of 3:2.
Mixing action of the Z-blade mixers combines shearing and kneading which is brought
about by the specially shaped blades enabling it to mix, whip and knead materials ranging
modern continuous mixers consist of an interrupted screw which oscillate with both rotary
and reciprocating motion between pegs in an enclosing cylinder. The important principle in
these machines is that the material has to be divided and folded and also displaced so that
fresh surfaces recombine as often as possible (Meyer, 1992; Perry and Green, 1997).
4.3 EXTRUDER
heavy walled cylindrical container is forced to flow through an orifice (die or mould) at
one end of the container as a result of pressure applied to the material by a piston (ram)
acting at the other end of the container. The process is often successful on materials, which
are too brittle to work by other shaping methods such as rolling. The instruments for this
process are generally called extruders. They may come in many shapes and work with
different principles e.g. the extrusion mixer, presses the material via a kneader.
Extrusion is well suited to producing long bars of constant cross section. The shape
of the cross section, which is determined by the die opening, may be quite complex. The
force required for extrusion may be supplied by a hydraulic cylinder, which drives the ram.
The material to be extruded must have sufficient plasticity so that it begins to flow through
the die at a pressure less than the breaking point of the material. The ram pressure should
not be above 180,000lb/m2. The die is another limiting feature of the process since it may
lose its shape if pressure and temperature becomes excessive and abrasive wear may occur.
The pressure (force/area) required for extrusion is a function of the stiffness of the
material, surface friction and changes in cross sectional are from the billet to the rod or
Where R = Ratio of the initial to final cross sectional areaPowerful presses up to 15,000 tonnes capacity are used for extrusion, but the
most
common size is about 2,500 tonnes. Suitable lubricants (ground nut oil) must be used to
reduce extrusion force, increase die life and give better surface on the extruded product. In
general the force required to overcome friction, even in well-lubricated operation is about
improve the surface finish and to get greater dimensional accuracy or desired thickness.
mixture that yields a solid product (biscuit). Dryers are classified by:
(1) HEATING METHOD: The manner whereby the moist material removes heat i.e. by
conduction heating from the sheets or very wet material. Convective heating is the most
common, where mild heating is necessary to avoid heavy degraded product, and radiation
(2) PROCESS CONDITION: The pressure and temperature of operation which are
constrained however by the nature of the materials to be dried. The thermal sensitivity of
the material fixes the maximum temperature to which the material may be heated. The
temperature rises with the time the material is held in the dryer.
(3) CONVEYING METHOD: The way the material is loaded or supported in the dryer.
The outward appearance of the dryer depends largely upon the way the drying material
moves through the equipment. Free flowing granules can be handled in many ways
(conveyor, rolling, trays etc), but more awkward materials often require special techniques.
Most modern dryers are operated continuously or semi-continuously over the working tray,
as a continuous dryer will require less labour, fuel and floor space than the batch dryers.
Certain factors are considered in the selection of dryer for particular purpose, they are:
In this type the solids are fed onto the endless, perforated conveyor belt, through
which hot air is forced. The belt is housed in a long rectangular cabinet, which is divided
into zones, so that the flow pattern and temperature of the drying air can be controlled. The
relative movement through the dryer of the solids and drying air can be parallel or more
This type of dryer is clearly only suitable for materials that form a belt with an
open structure. High drying rate can be achieved with good product quality control.
Thermal efficiency are high and with steam heating, steam usage can be as low as 1.5 per
Kg of water evaporated.
The main raw materials for the production of biscuit are flour, sugar, additives,
water, baking powder and yeast. Wheat flour and sugar are produced locally and this will
reduce the overall cost of production. Additives include; flavouring, shortening, colourants
and modifiers, which are also obtained locally while water, baking powder and yeast, are
readily available.
Most of these materials are locally produced (although most of them are still
imported to meet the demand of the populace) and thus help reduce the overall cost of
production and consequently produce biscuit at a cheaper rate, but putting into
consideration that they must of necessity be good food grade and hygienic.
In estimating the labour requirement and cost for plant personnel, a one eight hour
shift was assumed for the direct production workers. The indirect production workers will
also operate a single shift for eight hours. The full labour requirement which are detailed in
waste management, modifications are applied to biscuit plant operation and manufacturing
processes. These modifications reduce the amount of solid and liquid wastes, recover more
product and by-products, often reduce energy consumption and exhibit other benefits. In
reducing both the amount of waste solids generated and the volume of the waste water
The following are examples of modifications, which can be made to biscuit plant
operations:
[2] collecting culls and other solid wastes into containers rather than discharging to the
floor drain,
[5] using less or no water in plant operations that formerly used a fair to a large amount of
water.
Good manufacturing practices that reduce water usage and waste require good
discouraged.
Recycling of water in the same plant operation can be achieved by treating spent
process water with activated charcoal or sand filter or by ion-exchange columns, chemical treatment, pH adjustment, temperature
adjustment, pasteurisation, or a combination of
Counter currents water reuse systems can be established in many plant operations.
For example, spent wash water can be used again to initiate wash down of dirty floors or to
The location of the plant can have a crucial effect on the profitability of a project,
and the scope for future expansion. The principal factors are:
(8) Climate
For a product such as biscuit in which case the product per tonne is low the plant
The availability of suitable raw materials will often determine the site location. A
plant that will produce biscuit should be sited close to where the major raw materials are
available.
6.2.3 TRANSPORTATION
The transport of materials and products to and from the plant is an overriding
consideration in site location. The plant should be located close to at least two major forms
of transport: road, rail, waterway (canal and river) or airport. Choosing at least two will be
an added advantage for the two cannot be out of service at the same time.
Labour will be needed for construction of the plant and its operation. Skilled
workers will be brought in from outside the site area, but there should be an adequate pool
of unskilled labour locally and labour suitable for training, to operate the plant. Skilled
6.2.5 UTILITIES
A biscuit plant invariably requires large quantities of water for its operation
(process and general use). Hence the plant must be located near a source of water of
suitable quality. Process water may be drawn from borehole or purchased from local
authority. Electrical power will be needed for the plant production process (mixer, electric
Full consideration must be given to the difficulties and cost of disposal of biscuit
plant's by-product.
6.3 LAND (SITE) CONSIDERATION
Sufficient suitable land must be available for the proposed plant and for future
expansion, the land should be ideally flat, well drained and have suitable load bearing
characteristics.
6.4 CLIMATE
Since weather in Nigeria is neither too hot nor too cold, the site consideration in
form of climate can be neglected since the raw materials will not degrade in quality over
the little time for storage and production. Also the country is not situated within the
Capital grants and other inducement are often given by government to direct new
investment to preferred area or locations such as high unemployment prone zone. The
The biscuit industry and ancillary building should be laid out to give the most
economical flow of material and personnel around the site. Consideration must also be
given to the future expansion of the biscuit factory. The ancillary buildings and services
required on a site in addition to the main processing units (buildings) will include:
When roughing out the biscuit factory layout the process unit will normally be sited
first and arranged to give a smooth flow of material through the various processing steps,
The location of principal ancillary buildings should then be decided. They should
pipe alleys and drains. Access roads will be needed to each building for construction,
operation and maintenance. Utility buildings should be sited to give the most economical
runs of pipes to and from the process units. The main storage area should be placed
The composition of the feed is as listed in chapter three. From the material balance
carried out it can be seen that to get a product of 1000 kg (1 tonne) of biscuit, a feed mass
of 1357.15 kg of the raw material is required. This will require the following mass of feed:
Taking a basis of 1000 kg of feed; the masses of the feed based on the composition
is:
=1000-263.16 =736.84 kg
Working backward,
T(0.3-0.0368) = 357.15 kg
T= 357.15/0.2632=1356.95 kg
The difference (1356.95-357.15)= 999.8 kg of biscuit, this value is 0.2 short of the
expected 1000kg. This means that the original feed must be (1356.95 + 0.2)= 1357.15 kg.
= Heat energy to raise temp. to 100oC + Latent heat to vaporise water = m1Cp0 + m2L
= 525827.77+806132.69 = 1331960.46 kJ
Since 10% of moisture is lost the overall heat balance over the oven is:
m1=(1357.15-(1357.15x10)/100 = 1221.44 kg
From the material balance carried out, to get a product of 1000kg (1 tonne) of
biscuit we will need to feed a mass of about 1492.96 kg of the raw material. This will
In a hourly basis:
Mass in
Mass out
3.1.2.1 MIXER
Mass in
1492.96 kg = 1492.96 kg
On an hourly basis:
3.1.2.2 EXTRUDER
Mass in
Water in = 447.84 kg
Solid in = 1045.12 kg
Mass out
Losses = 186.71 kg
On a hourly basis:
3.1.2.3 DRYER
Water in = 261.25 kg
Solid in = 1045.00 kg
Water out = 55 kg
On a hourly basis:
Most of the energy balances were done using the computer program developed (Appendix
D)
3.2.2.1 MIXER
Heat in = 80568 kJ/hr
3.2.2.2 EXTRUDER
3.2.2.3 DRYER
= 25629.565 kJ/hr