Name Orion, Gene Laser Andrew Industry Focus # 1

Student Number 2015-12624 Date of Submission March 22, 2021

Section & Schedule MQRUV, Monday, 7 AM -1 PM

1. Resource Material Topic: Ice Cream [Ice Cream Sandwiches, https://www.youtube.com/watch?v=Vlb4mfQv6-s]

Process Summary List of Essential
● 200(min) – 300(max) words Equipment and
● Single space
● Justified corresponding Process Flow Diagram Productivity and Efficiency General
● Font Type: Time New Roman Font performance (Based on your own understanding.) Formula
Font Size: 8
●
● Font Color: Black
parameters.
● Medium: English

The whole process of producing ice cream treats starts with 1. Mixer - RPM 𝑂𝑢𝑡𝑝𝑢𝑡
𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
fresh cream, which is initially stored at silos. Then, it goes 2. Pumping system - 𝐼𝑛𝑝𝑢𝑡
to a high speed mixer which blends the cream with other Pressure 1 Preparation and Mixing
ingredients such as powdered skim milk, plant based 3. Pasteurization tanks - Input: Water (kg), ingredients (kg), fuel (liters)
stabilizers and emulsifiers. Sugar and corn syrup are also Temperature Mixing
Output: Mixture of ingredients (kg), spillage, steam
added in the mix. After that, it goes to a pumping system 4. Homogenizing machine -
which moves the mixture to pasteurization tanks to kill Pressure 2. Filling and toppings (crunchy and liquid)
bacteria and activate stabilizers. The factory now 5. Cooling Equipments / Pasteurization
homogenizes the mixture to obtain a smooth texture. This Storage freezers - Input: Ice cream, toppings, cones, wafers
mixture is then cooled. Then, concentrated flavors are Temperature [quantity(number), mass(kg)],
added. The mixture is chilled and whipped, for the mixture 6. Whipping Equipment – Homogenization
to blend with air which transforms the liquid to soft solid. RPM, time, temperature Output: Ice cream product
On a connected line, a filling machine is used to feed two 7. Filling Machine – Speed [quantity(number), mass(kg)], waste
lines of wafers toward the injection pipe. In here, ice cream and Timing (Computer Cooling
is injected in between the pipe’s head as the wafers come Controlled) Cone Production 3. Packaging
together. These ice cream sandwiches now go to the 8. Packaging Machine Speed x
packaging system which raises each ice cream to a wrapper, and Timing (Computer Input: product, packaging material
which then folds and tucks the ends for it to be perfectly Controlled) Whipping Filling of Cones [quantity(number), mass(kg)]
sealed. A machine then, counts the ice cream and inserts
them into boxes. Once sealed, they directly go to a storage Output: Product, spillage, waste (defects in packaging
freezer. Filling of Chocolate wafers Injection of Fillings process), excessive package-boxes or wrappers
On a another line, ice cream cones are produced. In here, [quantity(number), mass(kg)]
the feeder drops prewrapped sugar cones into holders on a
conveyor belt. Sprayers coats the inside of the cones. Then, Packaging Adding of Liquid and Crunchy Toppings
a nozzle squirts the ice cream to each cone. An injection of 𝑂𝑢𝑡𝑝𝑢𝑡
liquid fillings is done afterwards. Then, liquid and crunchy 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
𝐼𝑛𝑝𝑢𝑡
toppings are added. Then, a lid dispenser produces wax Input: Time to produce these set of ice cream (hrs)
coated paper lids on top of the ice cream. A heating element Freezing Packaging
Output: Number of ice creams produced on one specific
melts the wax concealing the lids to the cones paper sleeves. variant (quantity or mass)
Again they are inserted to boxes which then goes to a
storage freezer. Storage Freezing
 2. Resource Material Topic: Beer [How Its Made – 012 Beer, https://www.youtube.com/watch?v=3d-MsQlUpnQ]
Process Summary List of Essential
● 200(min) – 300(max) words Equipment and
● Single space
● Justified corresponding Process Flow Diagram Productivity and Efficiency General
● Font Type: Time New Roman Font performance (Based on your own understanding.) Formula
Font Size: 8
●
● Font Color: Black
parameters.
● Medium: English

In a beer production plant, it all starts with water filtration 1. Water Filtration System – 𝑂𝑢𝑡𝑝𝑢𝑡
Water treatment 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
to eliminate chlorine. Then, it is transferred to a tank that temperature, pH, turbidity 2 Hours Preparation 𝐼𝑛𝑝𝑢𝑡
will hold water, malt and grain. After prepped for two 2. Agitator - RPM Input: Malt (kg), Grain (kg), Water (L), Hops (kg), Yeast
hours, the agitator prevents any particles to settle at the 3. Pumps - Pressure Sample Testing (kg), Bottles/Cases (quantity or mass), Caps (quantity or
bottom of the tank. As soon as it is transferred, the 4. Filtration Tank - Mixing of Water, Malt, and Grain mass)
Agitation
turbulence from the pumps creates a formation of protein temperature, pH, turbidity
foam. Now, the wort is in the process being extracted and 5. Wort heater - Temperature Output: Bottles or cases of beer (quantity or mass), liters
boiled inside a heater. During this process samples are 6. Brewing Machine – Data Wort Heating Filtration Sample Testing
of beer, wastes (broken bottles (quantity or mass), caps
obtained to create control test at various stage of brewing. Control System (quantity or mass), beer (L))
In filtration tanks, the wort is separated from the malt. 7. Fermentation Tank –
Again, another sample is taken to verify the quality of wort Computer controlled Brewing
and density of sugar. Hops is then added to the wort heater 8. Conveyor Belts – Speed Hops
to provide bitterness and aroma particular to beer. After and Timing (Computer 𝑂𝑢𝑡𝑝𝑢𝑡
this, brewing can now start. In a control room, an operator Controlled) Add yeast 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
𝐼𝑛𝑝𝑢𝑡
handles the data control system of the brewing process. 9. Packaging System – Input: Time to produce a set of bottles/cases of beer (hrs)
Yeast is added to start the fermentation process which Speed and Timing Washing of bottles Output: Number of bottles/cases produced in one
usually lasts in seven to ten days. Now, sugars will (Computer Controlled) Fermentation Bottles manufacturing cycle (quantity or mass)
transform to alcohol. The fermentation tank will be
controlled by a computer to maintain a specific temp. After Sterilization
being aged for 3 weeks, the beer is filtered once more to get Aging
rid of the components that makes it cloudy.

In another line, the bottles to be used for storing the bear to

Filtration Bottling
be consumed in the market are prepared. The bottles are
washed and sterilized first which then arrives to the plates
ready to be filled. Then, it goes to a capper mechanism
Capping
before being sent to the pasteurizer. Labels are attached and
are sent by the conveyer for them to be put into cases.
Pasteurization

Labeling Packaged to Cases

 3. Resource Material Topic: Tequila [TEQUILA – How Its Made, https://www.youtube.com/watch?v=dmAZ0aH0P9o]
Process Summary List of Essential
● 200(min) – 300(max) words Equipment and
● Single space
● Justified corresponding Process Flow Diagram Productivity and Efficiency General
● Font Type: Time New Roman Font performance (Based on your own understanding.) Formula
Font Size: 8
●
● Font Color: Black
parameters.
● Medium: English

Matured blue agave plants are manually harvested. When 1. Shredder - RPM 𝑂𝑢𝑡𝑝𝑢𝑡
𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
harvested, the whole greenery surrounding the huge core 2. Stone wheel machine – Agave Plants Harvested 𝐼𝑛𝑝𝑢𝑡
(pina) is removed. A person will then measure the starch RPM, fuel (liters) Input: Agave plants (quantity or mass), Yeast (kg), Bottles
content of the pina if its sufficient, before bringing it to the 3. Distillation Tanks - (quantity or mass), Corks (quantity or mass)
distillery. The pinas are now chopped to quarters for them Temperature Measuring of starch content
to be manageable for baking. They are now transferred to a 4. Conveyer belts Speed and Output: Bottles of tequila (quantity or mass), liters of
brick cover, in preparation for steaming. Steam baking Timing (Computer tequila, wastes (broken bottles (quantity or mass), corks
transforms agave starch to sugar. The agave is now placed Controlled) Cut into Quarters (quantity or mass), alcohol (L))
into a shedder to turn the fruit into fibers. The fibers land 5. Bottling Line Speed and
into a conveyer, then to a pit wherein a stone-wheel Timing (Computer
Steam Baking 𝑂𝑢𝑡𝑝𝑢𝑡
machine is used to squeeze out the agave nectar. The juice Controlled) 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
are now placed into wooden tanks. Yeasts are added for 𝐼𝑛𝑝𝑢𝑡
fermentation which usually lasts up to 72 hours. But for Input: Time to produce a set of bottles/cases of beer (hrs)
drinks with more complexity, they are aged for two or more Shredding Output: Number of bottles/cases produced in one
months. The fermented liquid are now transferred copper manufacturing cycle (quantity or mass)
stills to boil off the alcohol. It takes 2 distillation cycles for
the technician to measure 55% of alcohol content. Now, the Squeezing of Agave Juice
tequila is transferred to a steel tank wherein a purified well
Yeast
water is used to dilute the whole alcohol content down to
40%. Now going to the bottling line, bottles are placed Fermentation
upside down in a revolving carousel for them to be rinsed
and filled easily. The employees manually corks the bottles
before putting the label. 2 Distillation Cycles

Diluting alcohol with water

Bottling Line

Sealing and Labeling

 4. Resource Material Topic: Soft Drinks [How It’s Made – Soft Drinks, https://www.youtube.com/watch?v=fWXPgC86EXE]
Process Summary List of Essential
● 200(min) – 300(max) words Equipment and
● Single space
● Justified corresponding Process Flow Diagram Productivity and Efficiency General
● Font Type: Time New Roman Font performance (Based on your own understanding.) Formula
Font Size: 8
●
● Font Color: Black
parameters.
● Medium: English

A soft drink is basically, just a combination of filtered 1. Carbonator – pressure of 𝑂𝑢𝑡𝑝𝑢𝑡

𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
water, and syrups from carefully selected ingredients both CO2 𝐼𝑛𝑝𝑢𝑡
natural and artificial. These syrups are used for the drink 2. Bottling and Packaging Input: Filtered water (L), Natural and Artificial syrups (L),
coloring and flavoring, since it has glucose or fructose line – Speed and Timing Bottles (quantity or mass), Caps (quantity or mass), Label
extracted from corn or cane. A machine releases right (Computer Controlled) stickers (quantity)
proportion of syrup and filtered water to create the final soft 3. Rinsing Machine/Jets -
Filtered water Uncaser
drink. But before it travels to the bottling machine, the drink Pressure Output: Bottles/cases of soft drink (quantity or mass),
Mixing Room
travels first to a pressurized tank called the carbonator. The liters of tequila, wastes (broken bottles (quantity or mass),
Syrup
carbonator injects carbon dioxide to the drink which will Caps (quantity or mass), Softdrink (L), Label stickers
result to the formation of gas bubbles which is observed in Case Washing Machine
Carbonator (quantity))
all soft drinks. This carbonated drink now goes to the
reservoir of the bottling machine. But before this happens,
Bottle Washing Machine 𝑂𝑢𝑡𝑝𝑢𝑡
the bottles are rinsed and cleaned first, and then drained 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
Bottling and Filling 𝐼𝑛𝑝𝑢𝑡
upside down before going to the filling station. When the
Station Input: Time to produce a set of bottles/cases of soft drinks
bottle arrives an travels its carousel, a machine will remove
the air before filling it with the carbonated soft drink. Then, Eon Inspection Light (hrs)
Capping Output: Number of bottles/cases produced in one
it goes to the capping machine where the caps come down for Damaged Bottles
a chute. A machine twists the cap on the part of the bottle manufacturing cycle (quantity or mass)
on the crimp of the bottle. In here, the threads of the crimp Labeling
and the cap intertwines tightly to seal the bottle. Then, it
now goes to the labeling machine wherein a machine roller
applies cold glue to one metal plate after another. This metal
Packaging
plate grabs a label and applies it to a bottle. A brush smooth
the edges down to ensure that the labels adhere well.
 5. Resource Material Topic: Bacon [BACON | How It’s Made, https://www.youtube.com/watch?v=GAqIynamBMY]
Process Summary List of Essential
● 200(min) – 300(max) words Equipment and
● Single space
● Justified corresponding Process Flow Diagram Productivity and Efficiency General
● Font Type: Time New Roman Font performance (Based on your own understanding.) Formula
Font Size: 8
●
● Font Color: Black
parameters.
● Medium: English

Loads of pork belly are tossed into a big rotating tumbler to 1. Big rotating tumbler - 𝑂𝑢𝑡𝑝𝑢𝑡
Big Rotating Tumbler Pork Belly 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
soften them for the skin to be easily removed. Each pork RPM 𝐼𝑛𝑝𝑢𝑡
now goes to a conveyor belt, skin side down for a long 2. Long automated blade - Input: Pork belly (kg), Liquid smoke (L), Flavorings (L),
automated blade to slice the skin away from the meat. The Speed Water (L), Packaging wrappers (quantity)
skin drops down to another conveyor belt to be processed 3. Conveyor belt – Speed Automated Blade Slicer Skin Processed to Pork Rinds
into pork rinds while the meat goes to a flipping device that and Timing (Computer Output: Bacon (mass), waste (broken pieces of bacon
turns it back side up so that employees down the line can Controlled) (mass), packaging wrappers (quantity))
trim off remaining pieces of the skin. Now, they mix up a 3. Flipping device – Speed Meat
brine solution that will the cure pork. So, as soon the pork and
𝑂𝑢𝑡𝑝𝑢𝑡
belly pass under an injector head, its needles inject the 4. Oven - Temperature 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
solution into each pork belly. Metal hangers are pressed to 5. Blast Freezer and Storage Flipping Devices 𝐼𝑛𝑝𝑢𝑡
each pork belly so that they can be hanged on a rack. Then, - Temperature Input: Time it takes for one manufacturing cycle of bacon
this meat is showered with liquid smoke to add color and 6. Metal detector – Detection (hrs)
flavor to the meat surface. Then, the pork belly is Height, Width, Sensitivity Trimming off of remaining pieces of skin Output: Mass of bacon produced in one manufacturing
transferred to a big oven which allows the flavoring to 7. Tracking machine – cycle (quantity or mass)
permeate through the meat. It then goes to a blast freezer for Detection Height, Width, Salt
a quick chill down and then, stored to another cooler for a Sensitivity Injector Head
couple of days. This makes the meat easier to slice as it goes Liquid Smoke
to the slicing station for a quick trimming of the sides. It Brine Solution Tank of Water
then goes to a metal detector so that no piece of metal
hanger is lodged into the meat. Then, they are stacked, Flavorings
wrapped, and stored into a freezer until it’s ready to be Pressing of Metal Hanger to Pork Belly
sliced into bacon sized pieces. Now, the bacon are now
cooked to a browning microwave wherein after being
cooked it goes to a watchful eye of an inspector to disregard Liquid Smoke Shower Slicing (Bacon-size) Cooking
broken pieces. Then, a tiny electronic eye keeps track of the
number of pieces before being stacked for packaging.
Low Temp Cooking Storing Quality Control

Blast Freezing and Cooling Stacking and Wrapping Packaging

Sizing Metal Detection

 6. Resource Material Topic: Smart Poultry [Incredible modern chicken processing factory. Amazing automatic poultry egg harvesting technology,
https://www.youtube.com/watch?v=uvHHHZjDQOk]
Process Summary List of Essential
● 200(min) – 300(max) words Equipment and
● Single space
● Justified corresponding Process Flow Diagram Productivity and Efficiency General
● Font Type: Time New Roman Font performance (Based on your own understanding.) Formula
Font Size: 8
●
● Font Color: Black
parameters.
● Medium: English

The broiler chickens to be processed all grew from a farm 1. Slaughter/Conveyor line – 𝑂𝑢𝑡𝑝𝑢𝑡
Broiler Chickens Hanging Stunning Slaughter 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
or facility where they are fed and taken care of until they Speed Feather 𝐼𝑛𝑝𝑢𝑡
are ready to be slaughtered. When deemed ready, they are 2. Stunner – Concentrations Removal Input: Broiler Chicken (quantity or mass), packaging
brought to a poultry processing facility, where first, they are of CO2 Vent Cutter Evisceration Hock and Feet Cutter wrappers (quantity), egg trays (quantity)
hanged in a moving slaughter line. As they move forward, 3. Double knife killer - RPM Veterinarian
they are stunned using carbon dioxide. They are then 4. Feather puller - RPM Opening Machine Egg harvesting Evisceration (2) Output: Processed chicken (quantity or mass), eggs
Inspection
stunned again using a water bath before sticking them using 5. Feet and Hock Cutters - (quantity), processed hock and feet (mass), harvested
a double knife killer. Then, it undergoes the process of RPM gizzard (mass ), waste (chicken innards (mass), packaging
Washing inside and out Cropping Machine Head and
scalding and feather troughing, as well as tail weather 6. Cropping Machine - RPM wrappers (quantity), egg trays (quantity), rejected chickens
pulling and plucking. The feet are then cut. After that, is the 7. Jet stream Scalding Trachea and eggs (mass and quantity))
hock cutter slaughtering and evisceration. After removing Machine - Pressure Recharge Chilling Sorted and Removal
Packaging
the viscera, they are sent to a vent cutter and an opening 8. Spin Chiller - RPM Weighed
𝑂𝑢𝑡𝑝𝑢𝑡
machine for the eggs to be harvested. It again undergoes an 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
evisceration process for everything inside to be removed. On different lines, 𝐼𝑛𝑝𝑢𝑡
For a quality control, a veterinarian inspector checks the Input: Time it takes for one manufacturing cycle of
fowls one by one as they pass by. Now, the head and trachea (A) (B) (C) chicken broilers (hrs)
are removed. After going to a cropping machine, which Output: Quantity or mass of chicken produced in one
cleans the loose skin inside the chicken. Then they are Dropped innards Hock and feet Processing Egg Processing manufacturing cycle (quantity or mass)
washed inside and out. They are chilled to prevent cross
contamination within the birds which is the sorted and Input: Time it takes for the chicken eggs to be packed
weighed. After that they are dropped, for the worker to wrap Gizzard harvesting Feet scalder and deskinner Sorting and processed.
it using a machine. Output: Quantity of eggs (in trays or individually)
Quality Control
Now, the ejected parts from the chicken’s body are checked produced in one manufacturing cycle (quantity)
since the chicken’s gizzard are manually peeled and Spin Chiller
harvested. On another line, the removed hock are processed.
It goes through a feet scalder and deskinner before going to Packaging
a spin chiller.
On another line, eggs are processed using computer
controlled machines so that the eggs that are packed into
trays are all clean and are not leaking. Basically in this
process, eggs that do not pass there standards are not
included in the packaging.