1.

The manufacturing process

2. Raw materials required and their sources

1. Determining the Manufacturing Process

Production Planning
To determine the manufacturing process, a production planning must be conducted.  This plan
should indicate how the different stages in a process are linked together, identify any 'bottle-necks' in the
process, the equipment that is required for each stage and where quality assurance procedures should be
used. The data that has been found from market surveys is added to the process chart to indicate the
scale of production that is required.
The chart is also used for planning a number of different aspects of the production process, including:
1) the weights of raw materials and ingredients that should be scheduled each day,
2) the number of workers and their different jobs,
3) the size of equipment required to achieve the planned throughput of product
4) the number of packages that are required each day.
In the example, the market information for chutney sales indicated that a minimum production
rate of 36 kg per day would be needed to meet the anticipated initial market share. Assuming that
production takes place for 8 hours each day for 20 days per month, the average throughput would be 4.5
kg per hour (36/8 kg). This throughput figure is critically important in all subsequent planning and every
effort should be made to ensure that it is as accurate as possible by checking all assumptions carefully. In
particular, the number of assumed working days may fall below twenty if there are regular power failures
or if production planning is inadequate. The different stages of production planning are described below.
Modified process chart showing scale of operation and daily requirements for mango chutney
production
Processing % Weight of Batch size Processing No. of Minimum
stage losses mangoes (kg) time (minutes) workers equipment size
(kg) from Figure (kg/hr)
33.

Mangoes 0 60

Wash 14 60

Sort 45 51.6 90 2 Table for 2

workers

Peel/destone 0 28.4

Cut 28.4 120 3 Table for 3

workers, 3 knives

Mix 0 27 27 kg sugar
+ 13.51
vinegar for
batch of
 60.7 kg.

Boil 34* 40 180 1 Boiling pan for 10

kg batches. Two
filters and heat
Fill/seal 10 36 180 2 sealers. Table for
2 people

Cool/label 0 36 120 1

Store 0 36

Weight of 36
product
* evaporation losses during boiling. 

Notes on calculations:
Boiling results in weight losses of 34% as water is evaporated and the solids content increases to
70%. If each batch takes 20 minutes to boil, there are 2 batches per hour and in 3 hours there are 6
batches of 10 kg each to meet production target of 60 kg of raw materials, yielding 36 kg of product per
day. Therefore the boiling pan should have 10 kg working capacity (that is a 12-15 litre pan).
Each worker fills and seals 40 bags per hour = 120 bags per day x 2 workers = 240 bags of 150g net
weight = 36 kg per day
Calculation of boiling losses:
The solids content in the mix of ingredients before boiling is found as follows:
Ingredient Weight (kg) Solids content (%) Weight of solids (kg)

Mangoes 27 15 4.05

Sugar 27 100 27

Vinegar 13.5 0 0

Total 67.5 31.05

Total weight after 10% losses 60.7 kg 28

% solids in batch before boiling = (28/60.7) x 100 = 46%

So 28 kg equals 46% of the batch before boiling. After boiling there is no loss of solids (only water is
removed) but the solids content has been increased to 70%.
Therefore 70% still equals 28 kg.
Therefore the total weight of the batch after boiling = (100/70) x 28 = 40 kg

What you have to do:

1. Do production planning.
2. Create a chart as a result of your production planning. Your chart must look like the example
above. It must show the different stages of manufacturing process; and each stage, it must have-
mass of raw material, number of laborers per stage, size of equipment required, number of
products/packages produced that is required.
 Processing %Losses Weight of Batch Processing Number of Minimum
Stage Raw Material SIze Time Workers Equipment Size

NOTE: This can be further modified

3. Make a detailed description  of the manufacturing process, and include a workflow diagram.

2. Identify weights of raw materials and ingredients

There are two stages involved in planning the amounts of materials that are needed to produce
the required weight of product: first, it is necessary to calculate the amount of each ingredient that will be
needed to formulate a batch of product and secondly, it is necessary to calculate the amount of losses
that can be expected during preparation of fruits and vegetables.
The processor should experiment with different mixes of ingredients (the 'formulation' or 'recipe')
to produce a product that has the colour, flavour, appearance etc. that consumers say they prefer from
market research. Skill and flair are needed to achieve this, using the combination of ingredients that has
the lowest cost. It is important to weigh each ingredient carefully and make sure that all weights are
recorded for each formulation that is tried.
Otherwise, the inevitable result is a successful trial product, but no information is recorded to
enable it to be repeated. Once a formulation has been successfully developed, great care is needed to
ensure that it is made in exactly the same way on every occasion. This requires staff training, especially
for those staff involved in batch preparation, the implementation of quality assurance procedures and
careful production control. These may arise from peeling or de-stoning, from unsatisfactory fruits and
vegetables that are thrown away during sorting, from spillage during filling into packs or from food that
sticks to equipment and is lost during washing. Different types of fruit and vegetables have been found in
practice to have different levels of wastage and examples of some of these are given in Table 17. Typical
losses from other sources in a well-managed production process are shown in Table 18. However, it is
necessary for an entrepreneur to do trials to calculate the actual amount of wastage experienced with the
particular varieties of fruit or vegetable and with the particular process that are being used.
Clearly, it is in the interests of the processor to reduce losses as much as possible. Contracts with reliable
suppliers  help to ensure lower levels of poor quality raw materials and therefore reduce losses.
Additionally, a well-managed processing operation, having good quality assurance procedures , also
reduces wastage, especially during later stages of a process when the product has a higher added value.
Using the data from experimental production trials, or less desirably estimates based on data in Tables 17
and 18, it is necessary to calculate the amount of raw materials and ingredients that are needed to
produce the required weight of product each day. This will also enable the true cost of raw materials to be
calculated for use in financial planning 
Using mango chutney as an example. The  figure shows losses during each stage of the process.
The amount of mangoes that need to be bought to produce the required weight for each day's production
can then be calculated. The result indicates that only 45% of incoming raw materials were actually used in
the product (27 kg of the 60 kg bought). If mangoes were bought for $0.2 per kg in season, the true cost
of the fruit is calculated as $0.44 using the following formula:

Other ingredient costs are estimated as follows: sugar $0.6/kg, vinegar $1.25 per litre and total spice
costs of $1.3 per day. This data is used to calculate operating costs.

Typical losses during the preparation of selected fruits and vegetables

Fruit or vegetable Typical losses during preparation (%) Notes

Apples 23 peeled & cored

Apricot halves 12 destoned

Bananas 41 peeled

Cabbages 30

Carrots 4 (bought without leaves)

Cauliflowers 38

Currants 3 seeds & skins removed

Figs 2

Grapes 19 skins & pips removed

Guava 22

Lemons 40 peel & seeds removed

Mangoes 45 peeled & destoned

 Melons 42 peel & seeds removed

Okra 12

Onions 3

Oranges 25 peel & seeds removed

Passion fruits 58 peel & seeds removed

Pawpaws 38 peel & seeds removed

Peas 50 bought in pods

Peppers - chilli 15 seeds & stalk removed

Peppers - green 14 seeds & stalk removed

Pineapples 48 peeled & cored

Plantains 39 peeled

Tomatoes 4 seeds & skin removed

(Adapted from data in The Composition of Foods by Paul and Southgate, and from field
data collected by the author)

Packaging

Similar considerations apply when ordering packaging materials as there is a very wide range
available and there are a number of considerations that should be taken into account by the producer.
These include the technical requirements of the product for protection against light, crushing, air, moisture
etc. , the promotional and marketing requirements and the relative cost and availability of different types
of packaging. Selection of packaging materials frequently causes the largest problems for small
producers and is often the main cause of delay in getting a business established. Professional advice
should be sought from a food technologist or in some countries, packaging specialists or agents of
packaging manufacturers

What you have to do:

1. Create a description of the product or each product of the product line.
2. Describe the packaging of the product. Make sure to detail all the considerations-
technical, promotional, and marketing,  in choosing the packaging, and how it was given a
solution
3. After the description, identify the raw material needed for the required amount of product.
4. Make a chart that shows the percentage loss of the raw material, and calculate for the true
material cost.
5. Indicate the price and the cost of the raw material for each product in the product line.