Professional Documents
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OF AGRICULTURAL PRODUCTS 1
INTRODUCTION
One of the most important durables in the Philippines is the wheat. Having an important
place in world’s rice and corn production, Philippines are a consumer country for wheat.
Philippines, who cannot realize grain-based agricultural product export, is among the world’s
leading wheat importers. The country cannot produce wheat due to its climatic features, thus, it
imports the entire wheat amount that it needs from abroad as wheat or flour. Today, wheat
covers more of the earth’s surface than any other grain crop and it is the staple grain food for
much of the earth’s population. Even in areas where there is a long tradition of rice eating, as in
North and Southeast Asia, there is extensive use of wheat flour for making noodles, steamed
The first flour mill in the Philippines was established in the late 1950s, and the industry
has grown into a modern, sophisticated sector. As of late 1999, the Philippines had 13 millers,
with the newest entrant, Nissin Biscuits, starting operations in 1999 in Laguna. The industry's
total rated annual production capacity is 2.2 million tonnes. Capacity utilization was as high as
76.7% in 1995, with the average through the 1990s at or above 65%, according to a study by
A. PRODUCTION
The Philippines does not produce any wheat and imports everything it needs. The
country is expected to buy about 2.0 million to 2.5 million tons of milling wheat in the
coming year. The industry's total rated annual production capacity is 2.2 million tonnes.
Capacity utilization was as high as 76.7% in 1995, with the average through the 1990s at
or above 65%. Philippines is considered as the fifth biggest importer of wheat from the
United States.
The figure shows the annual imports of wheat in the Philippines. In the last five years, the
import of wheat is decreased in the year 2012 and 2013. The highest import of wheat is recorded
in the year 2014.
Growth
Market Year Imports Unit of Measure
Rate
2011 4075 (1000 MT) 26.40%
2012 3645 (1000 MT) -10.55%
2013 3482 (1000 MT) -4.47%
2014 5099 (1000 MT) 46.44%
2015 4800 (1000 MT) -5.86%
Table 1. Philippine import of wheat during the last five years
The table shows the import of wheat in the Philippines in the last five years. The highest
growth rate is recorded in the year 2014.
B. SUPPLY
Growth
Market Year Imports Unit of Measure
Rate
2011 4733 (1000 MT) 21.39%
2012 4689 (1000 MT) -0.93%
2013 4358 (1000 MT) -7.06%
2014 5880 (1000 MT) 34.92%
2015 6056 (1000 MT) 2.99%
Table 2. Supply of wheat in the Philippines during the last five years
The table shows the supply of wheat in the Philippines during the last five years. The data
shows that in the year 2013, the supply of wheat decreases and the highest supply in the
Philippines is recorded in the year 2015.
C. CONSUMPTION
Growth
Market Year Imports Unit of Measure
Rate
2011 3650 (1000 MT) 14.06%
2012 3785 (1000 MT) 3.70%
2013 3545 (1000 MT) -6.34%
2014 4575 (1000 MT) 29.06%
2015 4900 (1000 MT) 7.10%
Table 3. Consumption of wheat in the Philippines during the last five year
II. General Specifications of Processing Center
For Employees
The two owners will be in charge in the over-all operation of the processing center
50 employees will be given respective position and will be in-charge to the following
field of work:
Storing
Cleaning
Tempering
Milling
Sifting
Flour
Total Supply Deficit = Demand – Supply (*Demand is 15% of the total import)
= 2.2 million T (0.15) – 6056 T
= 330,000 – 6056 T
= 323,944 T/year (WHEAT GRAINS)
Wheat Bread (50% of the total milled flour)
= 171896.8964 T (0.50)
= 85,948.44822 T/year
Pizza (40% of the total milled flour)
= 171896.8964 T (.40)
= 68,758.75856 T/year
Total Product to be produced/year (90% of the total milled flour)
= 85,948.44822 T/year + 68,758.75856 T/year
= 154,707.2068 T/year or 155,000 T/year
B. Output Computations
Total duration of Operation = 2064 hours/year including legal holidays
Target Output = (155000 T/year) / (2064 hrs/year)
= 75 T/hr or 1802 T/day
Wheat Bread:
= (85,948.44822 T/year) / (2064 hrs/year)
= 42 T/hr
Pizza:
= (68,758.75856 T/year) / (2064 hrs/year)
= 33 T/hr
UNIT OPERATIONS IN PROCESSING FLOUR TO BREAD
Dividing Storage
Baking Depanning
SPECIFICATIONS OF EQUIPMENTS PER UNIT OPERATION OF PROCESSING
WHEAT BREAD
AUTOMATIC MIXER
The Tweedy™ T170 is designed for small to medium sized bakeries. It provides high-
energy mixing giving mix times as low as three minutes. It is suitable for a wide variety of
dough types. It combines simplicity, ease of use and hygienic operation with consistent dough
quality.
Specifications:
DIVIDER
Accuracy, reliability and low cost of ownership are the hallmarks of the Accurist™ 3000,
5000 and 9000 dough dividers. They are durable, easy to operate and easy to maintain; there is a
wide range of piece-weight and output combinations available, covering applications as diverse
as small breads and pizza bases up to large loaves.
ROUNDER
The Baker Perkins Conical Rounder combines efficiency with hygienic, non-stick
operation. It accepts divided dough pieces and forms them into ball shapes for easier handling
and better presentation to the First Prover and final moulder. It is a fully integrated part of Baker
Perkins’ dough forming system for high output plant bakeries.
WEIGHT CHECKER
Specifications
Through 80 p/min
put
Max. 6 kg(13.23lb)
load
capacity
2 g(0.07 oz)
Accuracy
MOULDER
The Multitex4™ Moulder combines gentle dough handling with high efficiency panning
for consistent quality and low production costs. Hygenic operation and rapid repeatable
changeovers contribute to exceptionally high operational efficiency and very few stoppages.
Dough structure is optimized to enable ingredient costs to be reduced or loaf quality to be
improved.
BAKING
Item Code: RRO-36
Our Rotary Rack Oven has various provisions like firing chamber, heat circulation and
temperature controllers. These are widely used in FMCG and baking industries. This oven is
fabricated using quality tested raw material to ensure long service life. We also provide
customization on ovens as per the specification detailed by clients.
DEPANNING
Specifications
220V, 60HZ
Power
500 pans/hr
Capacity
BREAD COOLING
Specifications
Bread vacuum cooler:
1. CE certificate
2. Sanitary without bacteria contamination
3. Stainless-steel material
BREAD SLICER
Item Code: SBS-20
FEATURES:
1. Dual frequency conversion control, bag length can be set and cut in one step, saving time and
film.
2. Interface features easy and quick setting and operation.
3. Self-failure diagnosis, clear failure display.
4. High sensitivity photoelectric eye color tracing, numerical input of cutting sealing position for
extra accuracy.
5. Temperature independent PID control, more suitable for packaging different materials.
6. Positioned stop function, without sticking knife or wasing film.
7. Simple driving system,reliable working,conwenient maintenance.
8. All control is realized through software,esay for function adjusting and technical upgrade.
METAL DETECTOR
Features
Automatic rejection of contaminated products
Comprehensive self-design system
Noiseless in operation
High sensitivity to all metal
100% detection and rejection for product with very high speed
Designed to suit all application
Compact design
Effective shielding to prevent leakage of flux or powder
On line stability
Cow belt type and y type flap rejection system
Available in different size
User friendly machine
Microcontroller Based
High Sensitivity Detection
Digital Touch Control System
Print Option
Password Protection
CE Marking (Applied)
The production starts with the automated handling and storage of raw materials using
silos and stainless steel bins that make up its computerized material handling system. Only the
highest quality ingredients are stored in the silos and used in making bread. According to the
guide, the wheat flour used in the production of the bread was imported while other raw
materials were produced locally. The next step would be the sponge mixing where the specially
formulated flour, sugar, milk, whey, and other raw materials are added together to form the
sponge. Fifty per cent of sponge dough is then kept in a fermentation room, under controlled
temperature and humidity for four hours, so that carbon dioxide is released, and the sponge can
rise. This fermentation process helps the sponge to develop a unique bread, texture, aroma, and
taste. The dough mix was then produced by mixing the sponge again with the remaining
ingredients. Depending on the type of bread to be baked, these can include skimmed milk
powder, vegetable shortening, wheat germ, bran, malt, or honey. The dough is then divided into
the required weight for each loaf and conveyed to a rounder. At the rounder, each piece of dough
is kneaded so that carbon dioxide can be trapped and the bread can develop a soft texture when
baked. The dough pieces then go through the check weigher. Here, pieces of dough that are over
and under the required weight are automatically rejected. After checking the weight, the dough is
then left to rest in the intermediate proofer for ten minutes before being moulded and placed into
the baking pans. During moulding, the dough is shaped according to the desired configuration
and then automatically placed into the pans. The pans are then lidded automatically to give the
bread its uniform rectangular shape. At the final proofing stage, the yeast is allowed to rise
further under controlled temperature and humidity. Once the dough has risen, it is finally ready
for baking. The loaves of bread are then baked through the thirty three meter-long tunnel oven
for about twenty minutes at approximately two hundred degrees Celsius. Hot from the oven, the
freshly baked loaves are then removed by vacuum suction before being conveyed to a bread
cooler where the loves travel through massive spiral cooling towers where thousands of loaves
are cooled on a moving conveyor at any given time. When the loaves are sufficiently cooled, the
bread is mechanically sliced and bagged, then travels through metal detector system to ensure
that there is no metal contaminant.
Automatic Mixing
Dividing
Rounding
Weight Checking
Moulding
Automatic Lidding
Baking
Depanning
Bread Cooling
Automatic Slicing
Packing
Metal Detecting
UNIT OPERATIONS IN PROCESSING FLOUR TO PIZZA
Raw Materials
Baking
Filling
Forming/shaping
Cooling
Packaging
Making the pizza crust
A small amount of baker's yeast, about 1 tbsp. is mixed with a cup or so of warm
water. It is left in a warm place until the mixture becomes foamy.
Several cups of sifted flour are poured into a bowl. The yeast and water mixture
along with 1 tbsp. of olive oil is poured into a well-made in the center of the flour.
The liquids are mixed into the flour with the hands and then kneaded on a floured
surface until smooth and elastic. The kneading time is approximately 10 minutes.
The kneaded dough is formed into a ball, dusted with flour and then placed in a
bowl and covered with a damp kitchen towel. The bowl is placed in a warm place
until the dough has doubled in size. This occurs in approximately one to two
hours.
The dough is kneaded again for about one minute and then rolled out onto a
floured surface into a circle. The standard pizza is approximately 10 in (25 cm) in
diameter. The edges of the circle are raised by pushing up on the dough with the
thumbs.
A half cup or so of tomato sauce is spooned over the pizza dough. The sauce is
spread over the surface of the pie to within 0.5 in (1.3 cm) of the rim. The
shredded cheese may be added before the toppings or on top of them.
Using a wide metal pizza peel, a long-handled flat shovel, the pizza is eased onto
a metal pan or clay stone. Pizza pans feature a flat, circular bottom set into a
round metal frame. After the pizza is baked, the outer frame is removed. Pizza
stones are made of clay similar to that of old-fashioned brick ovens. Because the
clay is porous, it absorbs moisture. The thickness of the stone, usually about 0.75
in (2 cm), radiates heat evenly.
The pizza is baked at 450°F (230°C) for about 15 minutes or until the cheese is
bubbling. The pan or stone is removed from the oven with the peel. The pizza is
allowed to sit for approximately five minutes before cutting it into slices with a
pizza wheel.
Packaging
The completed pizzas are placed on trays for movement to the counter or packed
into boxes for custom orders.
PROCESSING OF WHEAT GRAINS TO FLOUR W/ MATERIAL BALANCE
323,944 T/year
CLEANING
MILLING
80% Efficiency
252,789.5536 T/year
214,871.1206 T/year
SIFTING
80% Efficiency
307,746.8 T/year
CLEANING
DEHULLING
85% Efficiency
PADDY SEPARATOR
DESTONING
1% stones
253,789.5536 T/year
POLISHING
Cleaning
= (323,944 T/year) (0.05)
= 307,746.8 T/year of cleaned wheat
Impurities = 16197.2 T
Milling
= (307,746.8 T/year) (0.80)
= 252,789.5536 T/year
Unmilled =54,957.2464 T
Grinding
= (252,789.5536 T/year) (0.85)
= 214,871.1206 T/year
Losses = 37918.433 T
Sifting
= (214,871.1206 T/year) (0.80)
= 171,896.8964 T/year
Losses = 42974.2242 T
Automatic Mixing
= (85,948.414822 T/year) (0.88)
= 75,634.60504 T/year (dough)
Unmixed = 10313.80978 T
Rounding
= (75,634.60504 T/year) (.85)
= 64,289.41428 T/year
Reject = 11345.19076 T
Automatic slicing
= (64,289.41428 T/year) (.88)
= 56,574.68457 T/year
Reject = 7715.25823 T
Packaging
= [(56,574.68457 T/year) (0.01)] – 56,574.68457 T/year
= 56,008.93777 T/year
Scattering loss = 565.7468 T
Mixing
= (68,758.75856 T/year) (0.88)
= 60,507.70753 T/year
Unmixed = 8251.05103 T
Moulding
= (60,507.70753 T/year) (0.88)
= 53,246.78263 T/year
Reject = 7260.9249 T
Packaging
= [(53,246.78263 T/year) (0.01)] – 53,246.78263 T/year
= 52,714.31483 T/year
Reject = 532.4678 T
REPAIR AND MAINTENANCE
The machines must be maintained so that too much loss will be prevented to increase productivity
and generate more income. In order to maintain the machines used for each unit operations, weekly
check-up are made by the repair and maintenance team of the processing center.
Maintenance must be for every 3 months including all necessary need that was seen and recorded
in everyday check-up of the machines for every unit operations.
Building Maintenance electricians perform electrical repair and preventive maintenance in campus
facilities. These services are considered normal operational costs for buildings allocated through
general maintenance funds. Items serviced include lighting, HVAC systems, circuit breakers,
exhaust fans, incubators, fume hoods, and water heaters.
The hydronics crew maintains and repairs closed-loop hot water systems on campus. They test and
treat system water, facilitate chemical balance in the system, and maintain and repair systems
corroded by excess particles.
Overheating in mechanical spaces costs the campus in lost energy efficiency. The heat and frost
insulators add recyclable insulating materials to pipes and equipment to provide energy
conservation and burn protection, and prevent unnecessary wear and tear on other mechanical room
equipment.
Laborers provide support services for numerous crafts and trades including plumbers, electricians,
carpenters, cement finishers, and brickmasons. They also provide emergency response to exterior
drain stoppages and plugged sanitary lines.
Machinists handle upkeep of equipment, and maintain and repair fans, pumps, and compressors,
bearing assemblies, hydraulic systems, and power transmissions. They can also manufacture new
and replacement parts.
Cleaning of machines and facilities in the processing center is from 4pm – 6 pm.
Wastewater treatment plant was designed so that wastewater used in maintenance of the building
will be treated to dispose properly or to reuse. This was also designed so that standards for a processing
plant must meet. The total consumption of water for maintenance was assumed to be 15000 L/day and the
water to be treated at the WTF was assumed to be around 10000 – 15000 L/day.
COST ANALYSIS
The costing in making a processing plant is divided into two: the fixed costs and operating costs
which are taken annually. Fixed cost includes the cost in the building, land, vehicles, equipment and other
charges. On the other hand, operating cost includes electricity, water, labor, supplies of refrigerant, oil,
packaging, office supplies, and specialize clothing for workers and for maintenance.
CORPUZ, P., VERZANI, M., (n.d.). Philippine Grain and Situation and Outlook. Retrieved 02 March
2016.
HASHMI, IRFAN (n.d.). Step by Step Wheat Farming, Milling, and Quality Requirements. Retrieved 02
March 2016.
Building And Maintenance (n.d.) Retrieved 31 March 2016 from: https://www.fs.illinois.edu
Specifications for Machines (n.d.) Retrieved 31 March 2016 from: http://www.bakerperkins.com