Engr. Edwin Richard R.

Ortiz

Comments/ Actions Taken Page number

Recommendations

1O.) How is Heinz Heinz vinegar was initially to be used as a source 29

vinegar used in the of the acetobacter aceti (A.aceti) bacteria.
process? Which part is However, after further consideration, Heinz will no
Heinz added to? longer be used and the A.aceti bacteria starting
culture will be obtained from DOST. DOST has
Is it added constantly in expressed their willingness to help starting
the process? If so, companies in vinegar production (DoST-ITDI
inherent its cost in the teaches vinegar-making in ‘TekPinoy.biz’ series,
process. 2020). This would also mean that there will be no
cost for the A.aceti.

The A aceti bacteria will be used during the acetic

acid fermentation stage where it is inoculated on
the packings inside the acetator. This bacteria will
facilitate the conversion of ethanol into acetic acid
(acetification).

The fermentation stage will operate for 9 months

annually and the inoculation will only be done at
the start of the operation. Thus the bacteria will
only be added once per year. However, if
monitoring of the acetification process indicates
flooding of the system, then re-inoculation will
need to be done. Flooding of the system occurs
when the gas velocity is too high, it entrains the
flow of the liquid which causes the liquid to fill up
the packed column.

2O.) What is the monthly The source of the raw materials are based on the 14, 24-28
production of mangoes? proposed location of the plant, which is in
What is the percentage Sinawal, General Santos City, South Cotabato in
of rejects? the SOCCSKSARGEN region.

According to a publication by the Philippine

Statistics Authority (PSA) on the production of fruit
crop of SOCCSKSARGEN in the year 2017-2018,
South Cotabato has produced 13,372.81 metric
tonnes of mango in the year 2018. This data was
 used since there were no recent publications on
the same topic that was found.

A compilation of the published reports of the PSA

on the quarterly fruit crop production of
SOCCSKSARGEN has showed that the peak
harvest of mango happens on the second quarter
of the year (April to June) which comprises 84.9%
of the annual mangoes produced and based on
(Nuevo and Apaga 2011), 2-33% loss is incurred
during harvesting of mangoes however, only 10%
of the mangoes produced is considered for the
calculations on this report.

Using all these references, 10% of the 84.9% of

the 2018 mango production was considered as
rejects. This effectively uses 8.49% of the 2018
mango production as the plant’s annual raw
mango feed. 8.49% is equal to 1,135,351.57 kg.

3O.)Modify the process The design and schedule of operations are largely 77-78
considering the different based on the availability of the raw materials. The
percentages of mangoes whole operation is divided into three (3) stages
and pineapples used. namely the Preparation stage, the alcoholic
(100% mangoes, 100% fermentation stage and the acetic acid
pineapples, and the fermentation stage. The preparation stage is
percentages in between) where juice extraction from the fruit happens and
because of the different availability of the raw
materials, this stage is further divided into the
mango preparation stage and pineapple
preparation stage.

Since reject mango availability is based on the

peak mango production which is from April to
June, then the mango preparation stage will only
operate for 3 months. The juice will then be
pasteurized and stored in tanks. According to
(Arampath and Dekker 2019), pasteurized juice
can only be stored for 6 months. Because of this,
release from the storage tanks will be controlled
so that the fermentation stages (both alcoholic
and acetic) will operate for an additional 6 months
after the stop of the preparation stage.This means
 that the fermentation stages will operate for a total
of 9 months.

On the other hand, since pineapple is available

all-year round, the pineapple preparation stage
will operate for 9 months.

From this, the plant will operate for a total of 9

months annually.

4O.)The washer for The pineapple washer has already been replaced. 54-55
pineapple is not
indicated.

Dr. Shierlyn S. Paclijan

Comments/Recommendations Actions Taken Page number

1P.)Ethical considerations After further consideration, Heinz will no 29

when Heinz vinegar is used as
the mother vinegar.
longer be used as a source of the
acetobacter aceti (A.aceti) bacteria. Since
DOST has expressed their willingness to
help starting companies in vinegar
production, the A.aceti bacteria starting
culture will instead be obtained from DOST
(DoST-ITDI teaches vinegar-making in
‘TekPinoy.biz’ series, 2020).

2P.)What is the basis of the
target production capacity? Is it
based on the supply of raw
materials or based on the
demand of vinegar?
What is the assumed
percentage of the supply for
mangoes and pineapple
rejects.
The production capacity is based on the 14, 24-28, 51
amount of raw materials available. Analysis
of the quarterly fruit crop production of
SOCCSKSARGEN in 2020 has shown that
pineapples are largely available all-year
round while mangoes have a peak harvest.
Thus the amount of raw materials available
is largely based on the mango production.
According to a publication by the Philippine
Statistics Authority (PSA) on the production
of fruit crop of SOCCSKSARGEN in the
year 2017-2018, South Cotabato has
produced 13,372.81 metric tonnes of
mangoes in the year 2018. This data was
used since there were no recent
publications on the same topic that was
found.

A compilation of the published reports of the

PSA on the quarterly fruit crop production of
SOCCSKSARGEN in 2020 has showed that
the peak harvest of mangoes happens on
the second quarter of the year (April to
June) which comprises 84.9% of the annual
mangoes produced and based on (Nuevo
and Apaga 2011), 2-33% loss is incurred
during harvesting of mangoes however, only
10% of the mangoes produced is
considered for the calculations on this
report.

Using all these references, 10% of the

84.9% of the 2018 mango production was
considered as rejects. This effectively uses
8.49% of the 2018 mango production as the
plant’s annual raw mango feed. 8.49% is
equal to 1,135,351.57 kg mangoes per year.

According to (Othman, 2011 ) and (Fruits

and Sugars, n.d.), mangoes have more
fermentable sugars present in the fruit than
in pineapples. Since sugars are converted
into ethanol which in turn is converted into
acetic acid, this means that more sugar in
the process would yield a higher acetic acid
composition. Because of this, more
mangoes will be used than pineapples.

A ratio of 3:1 mangoes to pineapples is

used for the annual raw feed. This would
mean that 378,450.52 kg reject pineapples
is used annually which is 0.05% of the 2018
pineapple production of South Cotabato.

This totals to 1,513,802.09 kg of reject fruits

annually.
3P.)Check production
scheduling based on the
chosen design basis.
4P.)Improve PID with table of
summary and description.
5P.)Justification of the use of
storage tanks. Provide
The design and schedule of operations are 77-78
largely based on the availability of the raw
materials. The whole operation is divided
into three (3) stages namely the Preparation
stage, the alcoholic fermentation stage and
the acetic acid fermentation stage. The
preparation stage is where juice extraction
from the fruit happens and because of the
different availability of the raw materials,
this stage is further divided into the mango
preparation stage and pineapple
preparation stage.
Since reject mango availability is based on
the peak mango production which is from
April to June, then the mango preparation
stage will only operate for 3 months. The
juice will then be pasteurized and stored in
tanks. According to (Arampath and Dekker
2019), pasteurized juice can only be stored
for 6 months. Because of this, release from
the storage tanks will be controlled so that
the fermentation stages (both alcoholic and
acetic) will operate for an additional 6
months after the stop of the preparation
stage.This means that the fermentation
stages will operate for a total of 9 months.
On the other hand, since pineapple is
available all-year round, the pineapple
preparation stage will operate for 9 months.
From this, the plant will operate for a total of
9 months annually.
The PID has been improved together with 47-48
the stream descriptions table. Streams
indicated in the PID are according to kg/d
flow rates.
Since mango fruits are seasonal, the mango 79-81
juice will only be prepared for 3 months in a
 computation and scheduling.
6P.)Cost estimation part. What
is your total product cost per
Liter?
How did you come up with the
price?
Compute price based on costs
of manufacturing.
7P.)Finalize facilities layout.
Dr. Maria Theresa I. Cabaraban
Comments/Recommendations
1C.)Raised during the defense:
How is inoculation done? Time
it will take to completely
inoculate the packings.
year, which coincides with its peak season.
To anticipate maximum capacity to be
stored, the mango juice storage tanks are
expected to hold, at maximum 90 m3 of
mango juice.
The annual total product cost is Php 145, 146-148,
78,655,335 and the plant is expected to 155-156
produce 550,508 liters of the vinegar
product per year. Thus the total product cost
per liter is Php 142.88
A sensitivity analysis was performed to
determine at what mark-up will the project
be profitable. The criteria to determine
profitability was the NPV and PVR. The
base price used was the product cost per
liter which is 142.88.
The sensitivity analysis performed used a
per 20% mark-up interval. The results
showed that the plant became profitable
starting at 80% mark-up. At this mark-up,
the selling price will be Php 257.18 with an
NPV of 33.97 million Php and PVR of 1.19.
The facilities layout has been finalized, and 35-36
the extra facilities layout figure has been
removed.
Actions Taken Page number
The inoculation is done by adhering the A. 70
aceti bacteria on the packing’s surface prior
to the acetification process where the
vinegar mother culture is allowed to
recirculate in the acetators for a period of 1
week until a clear biofilm forms on the
surface (Vazquez, et al.).
2C.) The Design Problem:
What is your design problem?
For questions to answer to be
able to generate the design
problem statement:
Who is affected? consuming
public? fruit rejects
generators? the vinegar
industry?
What is the problem? Is it the
amount of waste fruit
generated? Or the low supply
of vinegar in the market?
Where does it happen? A
particular area in the
Philippines? All over the
Philippines? Worldwide?
Why does it matter?
3C.) The Design Bases:
What is the product currently in
the market that the cider
vinegar product is expecting to
replace or be an alternative to?
Apple cider? Cane vinegar?
Coconut vinegar? Balsamic
vinegar?
What are the specifications of
the cider vinegar product, vis a
vis the product that it is
expected to replace (partially)
in the market?
14-15
The SOCCSKSARGEN region is estimated
to have approximately 17.3 thousand metric
tons of mangoes and 199 thousand metric
tons of pineapples in a year that are
considered wastes/rejects because they do
not meet with the standard requirements for
fresh fruits. To address this, the proposed
plant shall manufacture cider vinegar from
the reject mangoes and pineapples. A total
of 1135 metric tons of mangoes and 378
metric tons of pineapples are to be
processed by the plant, thereby producing
550,508 liters of vinegar annually.
The production of vinegar does not only
solve the massive generation of fruit wastes
in the region but also help in the increasing
demand of vinegar in the market.
Aside from that, the plant also addresses
the slow reaction and expensive production
of vinegar by using rPBBR with cooling and
recovery units to solve the evaporative loss
of ethanol during fermentation.
15-18
The cider vinegar produced from reject fruits
is expected to replace the commercial apple
cider vinegar in the market.
The specifications of the cider vinegar
product are the following:
%(v/v) acetic acid = 7.32 pH = 2.94
Color = Light yellow Density = 1007 kg/m3.
The parameters are then compared to the
commercial cider vinegar, wherein the
values are within the expected values.
4C.) So what is your target
market? Local? Global?
5C.) You will have to obtain
permission to use their product
for purposes of your
manufacturing!
6C.) Is the chosen location not
for industrial use?
7C.) The chosen location does
not account for the facts that:
(1) the lot is NOT ideal for
industrial use
(2) it is expensive at Php
1,500/sq m
8C.) used as fuel? or platform
chemical?
since this by product is to be
marketed, its properties vis a
vis the properties of the
product currently in the market
that will be replaced by
bioethanol should be
presented.
With the fast growing market of cider 16-17
vinegar and vinegar in general, the plant will
target the local and global market.
After further consideration, Heinz will no 29
longer be used as a source of the
acetobacter aceti (A.aceti) bacteria. Since
DOST has expressed their willingness to
help starting companies in vinegar
production, the A.aceti bacteria starting
culture will instead be obtained from DOST
(DoST-ITDI teaches vinegar-making in
‘TekPinoy.biz’ series, 2020).
Barangay Morales will no longer be chosen 29-32
as the plant location due to being
established for commercial use. The new
plant location is in Barangay Sinawal,
General Santos City, which is an ideal
location for manufacturing and is not
situated in a residential area.
The new plant location is in Brgy. Sinawal, 30
General Santos City, which is an ideal
location for manufacturing and is not
situated in a residential area. It costs Php
8,000,000, which is much cheaper than the
previous chosen location, which costs
around Php 85 million.
37 - 38
The initial profitability assessment using
profit margin is now edited.
Since vinegar is mainly produced through
oxidative fermentation of ethanol, the stage
1 initial profitability assessment was used to
assess the profitability of using bioethanol
for the production of vinegar. The bioethanol
indicated here is not going to be marketed
as a product but rather was used to indicate
the raw material in the oxidative
fermentation. This value of bioethanol was
used solely for the purpose of the stage 1

9C.) could we not present this
here? this only causes
confusion.
10C.) confusing. how many
liters do you expect to produce
for every 45 kg of mango and
45 kg of pineapple?
11C.) bases for these
assumptions?
initial profitability assessment and will not be
used in further calculations in the report.
In this stage, 1 kmol of ethanol is used as a
basis and the calculation results in 75.26 L
vinegar can be produced.
Calculations can be found on the page
indicated.
Removed N/A
The initial profitability assessment using 40 - 43
profit margin is now edited.
On the stage 2 initial profitability
assessment, the profitability of using reject
mangoes and pineapples as source of
ethanol was investigated. 1 kmol of ethanol
was kept from stage 1 as a basis and it was
determined how many reject mangoes and
pineapples are required (in kilograms) and
how much vinegar can be produced (in
liters).
The calculation results in 494.51 kg reject
mangoes and 281.5 kg reject pineapples
are required to produce 1 kmol of ethanol.
From this, 71.05 L vinegar is expected to be
produced.
Calculations can be found on the page
indicated.
The washer is used to clean any dirt that is 51
on the surface of the raw reject fruits. There
were no studies found indicating the exact
mass percentage of the dirt on the fruit thus
an assumed value of 1% mass percentage
of the fruit was used for the amount of dirt

12C.) Use label consistently.
Mango pulper or juice
extractor?
13C.) what is the mechanism
in the pineapple crusher? how
can it separate the peels from
the pulp (and juice)?
14C.) this is already a juicer.
why add another one (below)?
Not a scientific journal article!
Perhaps, to provide the
scientific basis for these
calculations, show
thermodynamic proof/evidence
that this 70% conversion could
be achieved at the temperature
(25 C) and pressure (1 bar?) of
your design. That is, calculate
for extent of reaction from data
on standard enthalpy and
gibbs energy of formation.
glucose?
on the fruit. This was used to indicate the
minimal change in mass due to the removal
of the dirt.
Although there was no reference to the 1%
dirt, it is important to consider that there will
be dirt on the fruits since they are grown on
farms and that these dirt should be removed
before processing.
Mango Juicer 56-58
The proposed equipment for the pineapple 58
juicer is a juicing equipment specialized for
pineapple. In this equipment, the feed
hopper is connected to a crusher. Thus the
whole pineapple fruit is crushed when it falls
to the feed hopper. The crushed pineapple
then goes to the attached rotating drum filter
to extract the juice.
This specialized equipment is already
available commercially.
Extra equipment is removed N/A
Culled a valid scientific journal article which 63, 66
indicates a 95% conversion of the total
sugars into ethanol and carbon dioxide
(Balamaze and Wambete, 2017).
The fermentable sugars considered in the 64-66
 calculation were sucrose, glucose, and
fructose. Ethanol fermentation is a biological
process which uses microbes - most
commonly Saccharomyces cerevisiae - to
convert sugars such as glucose and
sucrose into cellular energy ATP, producing
ethanol and carbon dioxide as by-products.

values do not match with The values in this table have been 67
calculation shown. corrected.

what are these values here?
standard heats of formation?
where did we get these
values?
The values of the standard heats of 68, 86-89
formation are sourced from NIST Standard
Reference Database 69: NIST Chemistry
WebBook.

if process is exothermic, the The alcoholic fermenter will be incorporated

design of equipment should
include a cooling mechanism!
with a jacket where cooling water is used as
the jacket fluid to maintain a temperature of
25°C since the reaction is exothermic. A
spirally baffled jacket is used for a high heat
transfer rate (Sinnot, 2005).

how did you get from the The annual energy requirement was 68
previous line to this line? calculated by multiplying the values of the
heat load, the number of batches and
fermentation time.

in the initial/start up stage of The packings will have to be sterilized 70

the process, how is this done? before placed in the acetator. Once the
how often should this be done? packings are placed, mother vinegar will be
generated in the acetator for one week for
inoculation until a biofilm has been formed.
Reinoculation of the packings will be done
once a year (Vinegar Making Processes,
2020).

how was this obtained? from
the literature, the acid product
obtained was 21 g/L starting
with 100 g/L of ethanol.
To provide the scientific basis
for these calculations, show
94.4% conversion was achieved through 70, 73,
high ethanol concentration (HIE) 104-107
acetification process with 45 g/L and 55 g/L
initial concentrations of acetic acid and
ethanol respectively (Krusong, Yaiyen and
Pornpukdeewatana 2015).
thermodynamic proof/evidence
that this (94.4%) conversion
could be achieved at the
temperature (29 C) and
pressure (1 bar?) of your
design. That is, calculate for
extent of reaction from data on
standard enthalpy and gibbs
energy of formation.
at what temperature should
this process be maintained?
endothermic or exothermic?
on what basis? how was this
achieved?
but some go (6.99 kg) with the
air stream?
The process will be maintained at 25°C 107
From the energy balance calculation, the 73, 104-107
reaction is exothermic.
70-72
28% of ethanol mass is carried by the rising
air to the condense at an aeration rate of
0.434 vvm (Pham & Mata, 1992).
The premise of this report is that the use of 70-72
a packed bed bioreactor process for the
generator method of vinegar production has
been known to be susceptible to
evaporative losses of ethanol. This claim is
based on the studies of (Caro, Perez,
Cantero, & Webb, 1992) and (Wollan,
Pham, & Wilkinsion, 2016).
In the study of (Pham & Mata, 1992), the
effects of aeration on the continuous
fermentation of acetic acid were studied.
The aeration rates used were 1.348 vvm,
0.842 vvm and 0.434 vvm. The initial
ethanol concentration was 40 g/L and the
dilution rate was 0.03 h-1 at 30 °C. The
results indicated a 28% evaporative loss of
ethanol. Although the exact parameter of
their study was not applied to this report,
there were no other studies that were found
that indicated an exact value of the
evaporative loss of ethanol. Since the
percentage of ethanol evaporated is

since the reaction is
endothermic, what mechanism
is included in this design to
keep the temperature at 29 C?
needs heating medium!
Is the cost of the wwtp
included in the cost estimates?
projected impact, considering
that the area is commercial
area?
cost of wwtp?
Dr. Hercules R. Cascon
Comments/Recommendations
Describe inoculation steps.
How is it done? When does
reinoculation happen? If
reinoculation does occur,
incorporate the cost.
Change the source of the
mother vinegar. The potential
source can be obtained from
DOST. Add references
important for the premise of this report, the
28% value was used instead.
From the energy balance calculations, the 73, 104-107
reaction is exothermic. The acetator will be
incorporated with a conventional jacket
where cooling water is used as the jacket
fluid to maintain a temperature of 25°C
since the reaction is exothermic.
The cost of the wastewater treatment plant 119-121, 139
is inclusive of the service facilities which
are part of the ISBL Direct Costs.
The plant location is changed, which is not 29-32
anymore located in a commercial area.
The cost of the wastewater treatment plant 119-121, 139
is inclusive of the service facilities which
are part of the ISBL Direct Costs. The
estimated cost of wwtp is around Php 543k,
which is covered by the estimated service
facilities, which is around Php 13M.
Actions Taken Page number
The packings will have to be sterilized 70
before placed in the acetator. Once the
packings are placed, mother vinegar will be
generated in the acetator for three days for
inoculation until a biofilm has been formed.
Reinoculation of the packings will be done
once a year (Vinegar Making Processes,
2020).
After further consideration, Heinz will no 29
longer be used as a source of the
acetobacter aceti (A.aceti) bacteria. Since
DOST has expressed their willingness to
help starting companies in vinegar
 production, the A.aceti bacteria starting
culture will instead be obtained from DOST
(DoST-ITDI teaches vinegar-making in
‘TekPinoy.biz’ series, 2020).

What is the treatment of juice Flash pasteurization will occur before 61-62
in order for it to be stored storing, making the fruit juice to last up to 6
longer? months at most. (Arampath and Dekker
2019)

Project scheduling The production scheduling has been 77-78

modified to operate for 9 months (270 days)
in a year. In these nine months, only 3
months shall the mango juice be prepared
before stored in storage tanks. Pineapple
juice will be processed daily, followed by the
alcoholic fermentation, and acetification
respectively, giving a total number of 262
batches a year.

Decide on the proper diagram The pre-existing PID has been replaced. 47
to be used in the PID.

Correct the material of The material of construction was changed 79-81,

construction for storage tanks. from carbon steel to stainless steel. 131-132
Adjust cost.