1. Introduction - the rationale and the economic importance of the product/technology.

Butter is a semi-solid fat-rich product, principally in the form of an emulsion of the water-in-oil type with
complex rheological properties, and its structure and consistency are determined bynumerous factors
(Rønholt, Kirkensgaard, Pedersen, Mortensen, & Knudsen, 2012; Truong, Palmer, Bansal, Bhandari, &
Hub, 2018;Vithanage, Grimson, & Smith, 2009; WHO/FAO, 2018). Butter contains more than 80% milk
fat, which exerts a decisive influence on its properties (Wright & Marangoni, 2006). Triacylglycerols
(TAGs) account for more than 96% of milk fat in butter (Fontecha, Goudjil, Ríos, Fraga, & Juarez, 2005 ).
Milk fat is one of the most complex edible fats in terms of its fatty acid composition. More than 400 fatty
acids (FAs) have been identified in milk fat (Butler, Stergiadis, Seal, Eyre, & Leifert, 2011; Collomb,
Bütikofer, Sieber, Jeangros, & Bosse, 2002). However, only 16 FAs have been detected in large
quantities, and they are chiefly responsible for the main physical properties of butter, including melting
and solidification temperature, solid phase content and, consequently, butter hardness (Chen et al.,
2004).

Butter as a food appears to be as old as history. We have record of its use as early as 2,000 years before
Christ. The Bible is interspersed with references to butter, the product of milk from the cow. In the field
of nutrition, butter has many qualities that explain its preeminence as a food fat. Along other points, its
distinctive, appealing flavor contributes to the ease and completeness with which it is digested. Butter
has a pleasing aroma with its equally pleasing flavor. Agreeable odors and flavors of foods stimulate
natural digestive activity, according to W. B. Cannon of Harvard Medical School. He as well as other
eminent authorities emphasize the importance of good flavor at all times for normal digestion of foods.
Butter has long been recognized as a rich source of the fat-soluble vitamin A and its precursor, carotene,
from which vitamin A originates. Butter also contains some vitamin D, which is significant inasmuch as
this vitamin occurs in but few commonly used foods.

2. Technical Description of the product/technology – agronomic description, physical and thermo-

chemical properties, and the required environmental conditions during processing and storage.

3. Plant Size - desired rated capacity, floor and space requirement, and market disposal schedule.

4. Process Flow - unit operations involved and material balance if possible.

5. Product Data - specific heats, density, working temperatures, relative humidity, etc.

Zone A. Processing Area

1. Before Re-heat part:

a. Air supply; T 1 = 12°C, RH 1 = 30%.

b. Read; pd 1 = 1.4014 kPa, h g 1 = 2523.6 kJ/kg, v g 1 = 93.84m3 /kg.

c. Solve: ps 1 = pd 1 RH 1 = 1.4014(0.30) = 0.42042 kPa.

0.622∗Ps 1 0.622∗0.42042
d. Solve; W 1= = =0.002592 kg/kg
P t−P s 1 101.3−0.42042
e. Solve: h1 = c p T 1 + W 1 h g 1 = 1.0062(12) + 0.002592(2523.6) = 18.6156 kJ/kg

2. After Reheat to Zone-A;

a. Supply temperature: T s 2 = 16°C

b. Read: pds 2 = 1.1818 kPa, h gs 2= 2530.8 kJ/kg, v gs 2= 73.33 m3 /kg

c. Solve: RH s 2, W s 2 = W 1 = 0.002592 kg/kg; ps 2 = ps 1= 0.42042 kPa.

ps 2 0.42042
RH s 2= = =0.3557( 35.57 %)
p ds 2 1.1818

d. Solve: h s 2 = c p T s 2 + W s 2 h gs 2 = 1.0062(16) + 0.002592(2530.8) = 22.6593 kJ/kg

e. Design room conditions: T 2 = 20°C; RH 2 = 60%; u, air velocity = 0.25 m/s.

f. Read; pd 2 = 2.337 kPa, h g 2 = 2538.2 kJ/kg, v g 2 = 57.84 m3 /kg.

g. Solve; ps 2= pd 2 ( RH 2) = 2.337(0.60) = 1.4022 kPa.

0.622∗Ps 2 0.622∗1.402
h. Solve: W 2= = =0.008729
P t−P s 2 101.3−1.402

i. Solve: h2 = c p T 2 + W 2 h g 2 = 1.0062(20) + 0.008729 (2538.2) = 42.2803 kJ/kg.

j. Cooling Load:

a) Transmission load: Q = A(T f – T i) / R; T ¿ = 20°C.

Material R, therm. Resistance Area T f– T i Q1

2
m2 -K/W m °C kJ/s
A. Wall Conduction
1) Outside air film 0.029
2) Face brick, 50 mm 0.038
3) Concrete,120 mm 0.066
4) Gypsum board, 10mm 0.080
5) Inside airfilm 0.120
0.333 240 8 5.765
B. Ceiling Conduction
1) Outside airfilm 0.029
2) Sheating fiber
board,13mm 0.232
3) Gypsum board,10mm
4) Inside airfilm 0.080
0.120
0.461 120 8 2.082
Sub-total 7.847
b) Infiltration load: Heat gain due to the entry of outdoor air through door opening/closing is assumed
8% of the transmission load.

Q 2 = 0.08 (7.847) = 0.62992 kJ/s

c) Internal load:

1) Lights: Lighting requirement is 10 watts/m 2, 12 hrs per day, for a total floor area, 200 m 2:

10∗240∗12
Q a= =1.2 kJ /s
24∗1000
2) Conveyor motors: 5-units 3 hp each, 8% radiation/kW.

Qb=5∗3∗0.746∗0.08=0.895 kJ /s

3) Workers: 12 laborers to stay 8 hrs/day. Activity- standing and working.

Qc =305 J / s− person∗12 persons∗8 /24 /1000=1.220 kJ /s

Q3=1.2+0.895+ 1.220=3.315 kJ /s

d) Solar Load: Minimal effect due to complete shading at all wall-sides.

e) Sensible heat load of the product:

Q 5 = m p c p(T p– T i)

= 150,000 kg * 3.95 kJ/kg°C (22 – 20) °C/6/3600

= 54.8611 kJ/s

f) Latent heat load of the product:

Heat gain due to respiration rate of protein and fats–15% of

Q 6 = 0.15 (54.8611) = 8.2292 kJ/s

g) Total Load

Qt =Q1+ Q2+Q 3+Q 5 +Q6 =74.8822 kJ / s

For 50 % safety factor;

Refrigeration load: QL2 = 1.5 (74.8822) = 112.3233 kJ/s.

k. Needed mass of air: m a 2

Energy balance about the meat packing area:

ma2(h2 – hs2) = QL2 … (Total heat load)

QL 2 112.3233
ma2 = = =5.7246 kg/s
(h 2−hs 2 ) (42.2803−22.6593)
l. Volume of air; Va2

Va2 = ma vgs2 = 5.7246kg/s(73.33 m3/kg)

= 419.788 m3/s (25187 m3/min)

Use 25,000 m3/min blower capacity.

3. Main duct area; us2 = 75 m/s.

V a 2 419.788.3527 2
Va2 = A2us2; A2 = = =5.5971m
u s2 75
4. Heating Load at the Reheat:

Qr2 = ma2 (hs2 – h1) = 3.6434 kg/s(22.6593 – 18.6156) kJ/kg

= 14.7328 kJ/s

5. Moisture Removed in this Zone:

Mr2 = ma2 (W2 – Ws2) = 3.6434 kg/s(0.008729 – 0.002592) = 0.02236 kg/s (22.36 gm/s)
Zone B. Packaging & Storage Area

1. After Reheat to Zone-B;

a. Supply temperature: T s 3 = 16°C

b. Read: pds 3 = 1.1818 kPa, h gs 3= 2530.8 kJ/kg, v gs 3= 73.33 m3 /kg

c. Solve: RH s 3, W s 3 = W 1 = 0.002592 kg/kg; ps 2 = ps 1= 0.42042 kPa.

ps 3 0.42042
RH s 3= = =0.3557 (35.57 %)
p ds 3 1.1818

d. Solve: h s 3 = c p T s3 + W s 3 h gs 3 = 1.0062(16) + 0.002592(2530.8) = 22.6593 kJ/kg

e. Design room conditions: T 3 = 18°C; RH 3 = 60%; u, air velocity = 0.25 m/s.

f. Read; pd 3 = 2.064 kPa, h g 3 = 2534.4 kJ/kg, v g 3 = 65.038 m3/kg.

g. Solve; ps 3 = pd 3 ( RH 3) = 2.064 (0.60) = 1.2384 kPa.

0.622∗Ps 2 0.622∗1.2384
h. Solve: W 3= = =0.007698kg /kg
P t−P s 2 101.3−1.2384

i. Solve: h3 = c p T 3 + W 3 h g 3 = 1.0062(18) + 0.007698 (2534.4) = 37.62 kJ/kg.

j. Cooling Load:

a) Transmission load: Q = A(T f – T i) / R; T ¿ = 20°C.

Material R, therm. Resistance Area T f– T i Q1

2
m2 -K/W m °C kJ/s
A. Wall Conduction
1) Outside air film 0.029
2) Face brick, 50 mm 0.038
3) Concrete,120 mm 0.066
4) Gypsum board, 10mm 0.080
5) Inside airfilm 0.120
0.333 128 8 3.075
B. Ceiling Conduction
1) Outside airfilm 0.029
2) Sheating fiber
board,13mm 0.232
3) Gypsum board,10mm
4) Inside airfilm 0.080
0.120
0.461 120 11 2.863
Sub-total 5.938
b) Infiltration load: Heat gain due to the entry of outdoor air through door opening/closing is assumed
8% of the transmission load.

Q 2 = 0.08 (5.938) = 0.47504 kJ/s

c) Internal load:

1) Lights: Lighting requirement is 10 watts/m 2, 12 hrs per day, for a total floor area, 128 m 2:

10∗128∗12
Q a= =0.64 kJ /s
24∗1000
2) Conveyor motors: 5-units 3 hp each, 8% radiation/kW.

Qb=5∗3∗0.746∗0.08=0.895 kJ /s

3) Workers: 12 laborers to stay 8 hrs/day. Activity- standing and working.

Qc =305 J / s− person∗20 persons∗8/24/1000=2.0333 kJ / s

Q3=0.64+0.895+2.0333=3.5683 kJ /s

d) Solar Load: Minimal effect due to complete shading at all wall-sides.

e) Sensible heat load of the product:

Q 5 = m p c p(T p– T i)

= 150,000 kg * 3.95 kJ/kg°C (22 – 18) °C/24/3600

= 27.43 kJ/s

f) Latent heat load of the product:

Heat gain due to respiration rate of protein and fats–15% of

Q 6 = 0.15 (54.8611) = 8.229165 kJ/s

g) Total Load

Qt =Q1+ Q2+Q 3+Q5 +Q 6 =45.6405 kJ /s

For 50 % safety factor;

Refrigeration load: QL3 = 1.5 (45.6405 ) = 68.46075 kJ/s.

k. Needed mass of air: m a 2

Energy balance about the meat packing area:

Ma3(h3 – hs3) = QL3 … (Total heat load)

QL 3 68.46075
ma3 = = =4.5760 kg /s
(h3 −h s3 ) (37.62−22.6593)
l. Volume of air; Va3

Va3 = ma vgs3 = 4.5760 kg/s(73.33 m3/kg)

= 335.5609 m3/s (20133.66 m3/min)

Use 20,000 m3/min blower capacity.

3. Main duct area; us3 = 65 m/s.

V a 2 335.5609 2
Va3 = A3us3; A2 = = =5.1625 m
u s2 65
4. Heating Load at the Reheat:

Qr3 = ma3 (hs3 – h1) = 4.5760 kg/s(22.6593 – 18.6156) kJ/kg

= 18.504 kJ/s

5. Moisture Removed in this Zone:

Mr3 = ma3 (W3 – Ws3) =4.5760 kg/s(0.007698 – 0.002592) = 0.02236 kg/s (22.36 gm/s)
Zone C. Administration Building

1. After Reheat to Zone-B;

a. Supply temperature: T s 4 = 20°C

b. Read: pds 4 = 2.339 kPa, h gs 4= 2538.1 kJ/kg, v gs 4= 57.791 m3 /kg

c. Solve: RH s 4 , W s 4 = W 1 = 0.002592 kg/kg; ps 4 = ps 1= 0.42042 kPa.

p s 4 0.42042
RH s 4 = = =0.1797 (17.97 %)
pds 4 2.339

d. Solve: h s 4 = c p T s 4 + W s 4 hgs 4 = 1.0062(20) + 0.002592(2538.1) = 26.7068 kJ/kg

e. Design room conditions: T 4 = 23°C; RH 4 = 40%; u, air velocity = 0.25 m/s.

f. Read; pd 4 = 2.81 kPa, h g 4 = 2543.5 kJ/kg, v g 4 = 48.574 m3/kg.

g. Solve; ps 4= pd 4 ( RH 4) = 2.81(0.40) = 1.124 kPa.

0.622∗P s 4 0.622∗1.124
h. Solve: W 4= = =0.006979 kg/kg
Pt −Ps 4 101.3−1.124

i. Solve: h 4 = c p T 4 + W 4 hg 4 = 1.0062(23) + 0.006979 (2543.5) = 40.8937 kJ/kg.

j. Cooling Load:

a) Transmission load: Q = A(T f – T i) / R; T ¿ = 20°C.

Material R, therm. Resistance Area T f– T i Q1

2
m2 -K/W m °C kJ/s
A. Wall Conduction
1) Outside air film 0.029
2) Face brick, 50 mm 0.038
3) Concrete,120 mm 0.066
4) Gypsum board, 10mm 0.080
5) Inside airfilm 0.120
0.333 134 8 3.129
B. Ceiling Conduction
1) Outside airfilm 0.029
2) Sheating fiber
board,13mm 0.232
3) Gypsum board,10mm
4) Inside airfilm 0.080
0.120
0.461 120 11 2.863
Sub-total 5.992
b) Infiltration load: Heat gain due to the entry of outdoor air through door opening/closing is assumed
15% of the transmission load.

Q 2 = 0.15 (5.992) = 0.8988 kJ/s

c) Internal load:

1) Lights: Lighting requirement is 10 watts/m 2, 8 hrs per day, for a total floor area, 134 m 2:

10∗134∗8
Q a= =0.4467 kJ / s
24∗1000
2) Office Equipment: A total of 5 hp, 8% radiation/kW.

Qb=5∗3∗0.746∗0.08=0.298 kJ /s

3) Workers: 10 laborers to stay 8 hrs/day. Activity- standing and working.

Qc =150 J / s− person∗10 persons∗8 / 24/1000=5 kJ / s

Q3=0.4467+0.298+5=5.7447 kJ /s

d) Solar Load: Minimal effect due to complete shading at all wall-sides.

e) Sensible and latent heat load of the occupants is included in internal

loads

g) Total Load

Qt =Q1+ Q2+Q 3=12.6355 kJ /s

For 50 % safety factor;

Refrigeration load: QL3 = 1.5 (12.6355) = 18.95325 kJ/s.

k. Needed mass of air: m a 4

Energy balance about the meat packing area:

Ma4(h4 – hs4) = QL4 … (Total heat load)

Q L4 18.95325
ma4 = = =1.336 kg /s
(h 4−hs 4 ) (40.8937−26.7068)

l. Volume of air; Va4

Va4 = mavgs4 = 1.336 kg/s(57.791 m3/kg)

= 77.2069 m3/s (4632.417 m3/min)

Use 5,000 m3/min blower capacity.

3. Main duct area; us4 = 40 m/s.

V a 4 77.2069 2
Va4 = A4us4; A4 = = =1.9302m
us4 40
4. Heating Load at the Reheat:

Qr4 = ma4 (hs4 – h1) = 1.336 kg/s(26.7068 – 18.6156) kJ/kg

= 10.8098 kJ/s

5. Moisture Removed in this Zone:

Mr4 = ma4 (W4 – Ws4) =1.336 kg/s(0.006979– 0.002592) = 0.005861 kg/s (5.86 gm/s)