Grafilo, Laumar Alan Dave R.

AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

AENG 95 - PROCESSING, HANDLING AND STORAGE

OF AGRICULTURAL PRODUCTS 1

“Design of a Processing Center for Wheat”

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 is 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

bread, and other foods (Miller Magazine, 2014).

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

economists at the University of Asia and the Pacific.

Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

PHILIPPINE MARKET

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.

Figure 1. Philippines wheat imports by year

Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

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%
Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

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

UNIT OPERATIONS INVOLVED IN PROCESSING OF WHEAT

Raw Materials (Wheat grains)

Storing

Cleaning

Tempering

Milling

Sifting
Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

Flour

PROCESSES
Bread (ProductAND
1) MACHINES INVOLVE IN PROCESSING OF(Product
Pizza WHEAT 2)

1.) CLEANING SYSTEM

Once in the processing plant, the wheat is separated from foreign matter with
machinery that consists of mesh, magnetic separators and aspiration channels. The
system consists of:
a. Sieving machine
b. Metal/Magnet Separator
c. Stone Separator/Destoner
d. Dumping Station
e. Bucket elevator
f. Screw conveyor
g. Centrifugal blower
h. Platform
2.) TEMPERING SYSTEM
The conditioning takes place before milling to produce uniform moisture content
throughout the grain. The system consists of:
a. Bucket elevator
b. Platform
c. Scanner
3.) MILLING SYSTEM
After the wheat is conditioned, grinding takes place. This is done by a sequence of
breaking, grinding and separating operations.
a. Bucket elevator g. Collecting vessel
b. Screw conveyor h. Transporting system
Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

c. Pre-grinding
d. Intermediate-grinding
e. Fine grinding
f. Sieving machine
UNIT OPERATIONS IN PROCESSING FLOUR TO BREAD

Automatic Mixing Distribution

Dividing Storage

Rounding Metal Detecting

Weight Checking Packing

Moulding Automatic Slicing

Automatic Lidding Bread Cooling

Baking Depanning
Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

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
Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

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
Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

 Rounding

 Weight Checking
Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

 Moulding

 Automatic Lidding
Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

 Baking

 Depanning
Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

 Bread Cooling

 Automatic Slicing
Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

 Packing

 Metal Detecting
Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

UNIT OPERATIONS IN PROCESSING FLOUR TO PIZZA

Raw Materials

Mixing and Kneading

Sheet and laminating

Baking

Filling
Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

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.

Filling the pizza

 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.
 Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

Baking the pizza

 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.

Table 4. Material Balance on Unit Operation

O
Unit Operation INPUT Losses/Recovery/Eff.
UTPUT
Amount Amount
(kg/hr) Item (kg/hr) Item
WHEAT GRAINS
Cleaned wheat
1.) Cleaning 37672.00 Wheat grains 0.99 37295.28 grains
Milled wheat
2.) Milling 37295.28 Cleaned grains 0.80 29836.22 grains
3.) Grinding 29836.22 Milled grains 0.90 26852.60 Flour
4.) Sifting 26852.60 Flour 0.80 21482.08 Flour
WHEAT BREAD
5.) Automatic
Slicing 21482.00 Flour 0.98 21052.36 Dough
6.) Rounding 21052.36 Dough 0.95 19999.74 Dough
7.) Automatic
Slicing 19999.74 Dough 0.98 19599.75 Bread
PIZZA
8.) Mixing 21482.00 Flour 0.98 21052.36 Dough
9.) Moulding 21052.36 Dough 0.99 20841.84 Dough
 Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

Computations:

Inpur/hr = 15% of the total production/year x 1 year/365 days x 1 day/24 hrs

= 2200000000kg (.15) /8760 hrs
= 37672 kg/hr

Input/hr : 37672 kg/hr

 Cleaning
= (37672 kg) (0.99)
= 37295.28 kg/hr of cleaned wheat
Impurities = 376.72kg

 Milling
= 37295.28kg (0.80)
= 29836.224kg/hr
Unmilled =7459.056kg

 Grinding
= 29836.224kg (0.90)
= 26852.6kg/hr
Losses = 2983.62kg

 Sifting
= 26852.6kg (0.80)
= 21482.08kg/hr
Losses = 5370.52kg

 Automatic Mixer
= 21482kg (.98)
= 21052.36kg/hr (dough)

 Rounding
= 21052.36kg (0.95)
= 19999.742kg/hr

 Automatic slicing
= 19999.742kg (0.98)
= 19599.75kg/hr
Reject = 399.992kg/hr
 Grafilo, Laumar Alan Dave R. AENG 95 01 March 2016

Processing, Handling and Storage 03 March 2016

BSAE 5-1 of Agricultural Products I Dr. M.M. Escobar

 Mixing
= 21482kg (0.98)
= 21052.36kg/hr

 Moulding
= 21052.36kg (.99)
= 20841.84 kg/hr

REFERENCES

AZADUN, N., (n.d.). The Milling Process. Retrieved 02 March 2016.

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.