BSC Thesis

Soy milk process development and optimization 2016
1. INTRODUCTION
1.1. BACKGROUND
Milk is a nutritive drinkable food obtained from various animals and consumed by humans. Most
milk is obtained from dairy cows, in the United States, and in many industrialized countries, raw
cow's milk is processed before it is consumed. Milk is also produced from goats, water buffalo, and
reindeer in various parts of the world. During processing the fat content of the milk is adjusted,
various vitamins are added and potentially harmful bacteria are killed. In addition to being
consumed as a drinkable food, milk is also used to make butter, cream, yogurt, cheese, and a variety
of other products. [1]
The use of milk as a beverage probably began with the domestication of animals. Goats and sheep
were domesticated in the area now known as Iran and Afghanistan in about 9000 B.C and by about
7000 B.C. The first milk processing plant in the United States to install pasteurizing equipment was
the Sheffield Farms Dairy in Bloomfield, New Jersey, which imported German-made pasteurizer in
1891. [2]
The term milk is also used for white colored, non-animal beverages resembling milk in color and
texture (milk substitutes) such as soy milk, rice milk, almond milk, and coconut milk. In addition, a
substance secreted by pigeons to feed their young is called" crop milk" and bears some resemblance
to mammalian milk, although it is not consumed as a milk substitute.[3]
Soybeans are an important source of protein and oil. On average, over one-third of the soybean mass
is protein and about 20% is oil. One of the most common types of soy product for food applications
sold in the Western marketplace is soymilk. Soymilk is the pasteurized extract of soaked ground
soybeans, and soy protein isolates are purified fractions containing greater than 90% protein.
Soy protein isolate is extensively used as a food ingredient in many fabricated foods such as
comminuted meat products. The recent increase in soy protein products consumption is the result of
advances in achieving improved taste and recognition of health benefits. [4]
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Currently, a number of researchers are doing their scientific and technological work to diversify and
enhance soya bean products. This paper work is mainly concentrate on process development for
soymilk production using hot and cold extraction method. Then, based on the developed process,
laboratory based soymilk produced and characterized. Lastly, large scale production process
designed and optimized to get a better product yield.
1.2. PROBLEM OF THE STATEMENT

Our land is one of large cattle owner countries over the world. It is the 10th in the world and the first
in Africa. However, our milk production yield is poor and traditional. Even if the milk utilization
technologies were rare in the past, currently there is a radical booming. But, most of the emerging
milk processing technologies gave emphasis on cow milk processing. Although large number of
cattle the country has, the cost of milk is increasing extraordinarily in the last few years. The
probable reason for this may be many but milk product diversification and industrialization could be
the major causes. Besides the high demand for milk, during fasting time large numbers of Ethiopian
people do not use cow milk. Moreover, some people have milk allergic naturally.
To supplement the high demand of milk soya milk is an ideal solution. There is currently a large and
growing market for soymilk in the Ethiopia, as a dairy alternative, as a nutritious sweetened soft
drink. But there is no production of soymilk in our country. Dairy alternatives are attracting an
increasing interest for a number of powerful reasons, including health concerns, the growth in
vegetarianism, interest in organic foods, regulatory pressures, concerns about genetically modified
foods and animal welfare issues. Soymilk is low in fat, sugar and in gluten. It does not contain any
cholesterol or lactose, but it is high in fiber, contains calcium and is known to promote bone health.
Therefore, it is little wonder that it appeals strongly to a great many people.
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1.3. OBJECTIVES OF THE STUDY

1.3.1. General objective
The main objective of this study work is to develop production process for milk production from
soya bean and to optimize the designed process.
1.3.2. Specific objective
To identify production process of soymilk
To produce soymilk and to characterize some physical and chemical composition of the
soymilks.
To design and sizing of basic equipments.
To evaluate the economic feasibility of the developed process
1.4. OUTCOME OF THE RESEARCH

It is expected that the result of this research work contributes both for researchers as well as the
agricultural sector. For the researchers it can creates an opportunity to conduct further research work
on yield maximization and product quality escalation. If the concerned bodies applied the proposed
products from soya bean, the need of the seed increases and it inspire the farmers to be engaged in
its cultivation massively. This will make possible the agricultural product transformation to
industrial product and intern it plays its own role on import substitution. Beyond all, this research
work has enabled us to have exposure on real research work and its outcome has motivated us to
think further work on the sector including as a business work.
1.5. THE SCOPE OF THE STUDY

This research work is mainly emphasized on determining the optimum process for soya milk
production and to make it’s by product valuable. From this ground, the different processes by taking
different operation conditions are tried and the better one is taken. Once, the production is possible,
the byproducts make to have different uses. Lastly designing the major equipments and sizing the
rest are made and its plant economics analyzed in preliminary level.
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1.6. LIMITATION
It is obvious that our University has a big problem on Internet access and unfortunately our
department has no Laboratory instruments and equipments. Nowadays without these two utilities
thinking research work is meaningless. For examples chemical used for characterization of our
product like protein content with the help of Kejeldah method, viscosity, color, carbohydrate,
mineral content, proper heating medium and also other related things were not measured due to un
availability of material in laboratory.
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2. LITRATHURE REVIEW
2.1. INTRODUCTION
Soya bean, a member of the family leguminoceae and the genus Glycine Max (L) Merril, has been
receiving attention as a source of food capable of increasing the available protein supplies.
Consequently, interest in the production, processing and utilization of the crop has been growing.
[5]Soybean grows in tropical, subtropical, and temperate climates.
It was domesticated in the 11th century BC around northeast of China. It is believed that it might
have been introduced to Africa in the 19th century by Chinese traders along the eastern coast of
Africa. [6]Soybeans were first grown in Ethiopia in 1950 and a grower’s manual was published in
Amharic. [7]
There are more than 1, 500 varieties of soybean with a growth period that ranges from
75 to 200 days. Different varieties are distinguished according to the size and color of the seeds, the
end use and the length of the growing season. Generally, soybeans can be classified into two major
types, namely the commercial field type and the edible garden type. [8]
The beans are mostly round in shape, like ordinary peas, with considerable size variation within and
between varieties. The color of the seeds may be yellow, green, brown or black and a striped or
spotted combination of all these colors. [8]
Traditional soy foods are classified into two categories: non-fermented and fermented. Typical non-
fermented soybean products are soy milk, tofu, tofu skin, soy meat alternatives, etc., while
fermented products include soy sauce, fermented bean paste, natto, sufu, miso, tempeh, etc. [9]
2.2. SOY PRODUCTS

Soy based foods were developed in Asian countries and accepted in Western countries within
decades. Soy foods become popular due to two reasons: the first is that soy foods contain many
nutrients, and the second is that a high percentage of populations in Western countries have allergic
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reactions to dairy. Around 2.5% of children younger than three years old are allergic to milk in the
USA and approximately 80% of these children with milk allergy will not outgrow the allergic
reaction until the age of sixteen. [10]
2.2.1. Health Benefits from Soya bean Consumption:

Consumption of foods containing soya bean and soya bean constituents has been associated with
reduced heart disease risk factors, reduced osteoporosis, alleviation of menopausal symptoms,
reduced cancer risk and in a limited number of studies, reduced diabetes. It also helps people to stay
lean (reduced obesity). Iso-flavone compounds found in soya bean, especially genistein may help to
stay lean by causing us to produce fewer and smaller fat cells. [11] Soya bean works in the
prevention or minimizing the conditions through controlling cholesterol, blood pressure, vascular
function and direct effects on the cells of the artery wall. [12]
Soya bean has also been shown to promote serum insulin production. [13] It has been demonstrated
that soya protein helps persons with diabetes prevent kidney diseases and improve the cholesterol
profile. [14] There is evidence that soya foods may help reduce bone loss that typically occurs after
menopause. Soya Iso-flavone can help women with low bone mineral content prevent hip fractures
in postmenopausal years. [15] Soya bean is thus particularly important in postmenopausal years
because it prevents hip fractures, reduces fat development especially abnormal fat and blood
pressure. [16]
Soya foods contain calcium, magnesium and phosphorus, which help to strengthen teeth and prevent
nerve disorder. Soybean consumption on regular basis delays the ageing process.
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2.3. SOYMILK AND SOYMILK PROCESSING METHODS

2.3.1. Soymilk
Soymilk is a creamy, milk-like product made by soaking and grinding soybeans in water. Soymilk is
used in various food products such as tofu, fruit flavored puddings, calcium and protein rich
soymilk. It contains about the same proportion of proteins cow’s milk: around 3.6%; also 2% fat,
2.9% carbohydrate, and 0.5% ash besides being rich in protein, vitamins and minerals. [17]
Soymilk is very economical, lactose free, highly digestible and nutritious alternative of dairy and
meat centered diet. It is cholesterol free product, has a very low fat content and is rich in
polyunsaturated fatty acids of phospholipids. Generally soymilk contains around 7-8% TSS in it.
Adding 3-4% sugar and about 0.05% salt brings it to a sugar, salt and total solid level approximately
identical to toned (2% fat) cow’s milk, i.e. about 12-13% TSS. [18]
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Table 2.1compositions of cow milk and soy milk

Item / 100g Soy milk Cow’s milk
Calorie 44 59
Water 90.8 88.6
Protein 3.6 2.9
Fat 2.0 3.3
Carbohydrates 2.9 4.5
Ash 0.5 0.7
Vitamins(mg) 0.03 0.04
Thiamine(B1) 0.02 0.15
Riboflavin(B2) 0.05 0.20
Niacin
Saturated fatty acids (%) 40-48 60-70
Cholesterol(mg) 0 9.24-9.9
Minerals (mg)
Calcium 15 100
Phosphorus 49 90
Sodium 2 36
Iron 1.2 0.1
Source: taken from Liu (1997), adapted from Chen (1989).
2.3.2. soymilk processing methods

Soymilk is essentially a water extract of soybeans, and the basic steps of preparation are: selection of
soybeans, adding water, wet grinding and separation of soymilk from fiber (okra), cooking to
inactivate lipoxyygenase and trypsin inhibitors, formulation, and packaging of the soymilk. [19]
Soybeans host a large population of micro flora. Because the microorganisms found in soybeans get
transferred and increase in numbers during the soaking and grinding process, soymilk must be
treated to inactivate spoilage microorganisms and extend its shelf-life. [20]
Proper processing of soybeans into soymilk is very important because soybean contains some
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undesirable properties which include the presence of trypsin inhibitors and lipoxygenase
enzymes. These disadvantages can be overcome by proper cooking (Blanching) and
dehydration (Soaking) of soybeans because it deactivates the enzyme system responsible for the
odor. [21] Boiling, the application of wet heat loosens soybean seed to ease de-husking and
tenderizes bean cells.
Blanching also enriches soymilk because if soybeans are properly blanched, half of the protein
remains soluble in the liquid extract and will not separate with the residue after filtration.
However, long blanching times should be avoided in the final soymilk product. [21] Boiling whole
beans in water for 20 minutes also deactivates the enzyme system and most of trypsin
inhibitors. [23]
The degree of milling influences digestibility and palatability. [22]

Pasteurization is the most common practice used to extend soymilk shelf-life because it inactivates
most known vegetative pathogens and spoilage bacteria. [24] When soymilk is heat-treated it
develops brown color and cooked flavor. Consumers are readily able to assess color and flavor so it
is of great importance to the industry to remove any unacceptable characteristics.
Processed soymilks prepared by various manufacturing methods were examined for quality by
physical and chemical methods. Viscosity, pH, soluble solids, total solids, fat and protein content
were used as indicators of quality. Processing methods have an effect on the nutritional value of
soymilks. Lack of proper processing may give rise to unpleasant digestive responses. The most
important factor is the heat treatment. There are several "anti-biological factors" present in the raw
soymilk which are heat labile.
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Shi and Ren (2000) observed that heat treatment apparently helps to stabilize soymilk emulsion. The
protein molecules unfold and the hydrophobic regions located on the inside become exposed to the
outside when soymilk is heated. In the presence of soy lipids, the stability of the soymilk emulsion is
improved due to increased interaction of proteins with lipids.
The traditional Chinese method for soymilk production is soaking the soybeans for 8-12 hours in
cold water, wash, grinding, filtering and then cooking. Heating, in soymilk is an important step
because it helps in the flavor development, pasteurization, and improving the nutritional quality. [25]
Soymilk has a strong off-flavor that is unpleasant to most western consumers. The benefits of
utilizing soy as food products prompted researcher’s to develop new ways of processing soy to
improve its flavor. Several methods have been proposed to improve the flavor of soymilk, through
processing modifications or modifying the raw ingredient of soymilk. Some examples of processing
modifications are Cornell, Illinois, Rapid Hydration Hydrothermal Cooking (RHHTC), cold-grind
under vacuum (Pro-Soya), deodorization, antioxidant addition and alkali treatment methods. [8]
In Illinois method, the soybean was first soaked for 12 h in 0.5% NaHCO3 solution, drained and
then boiled in fresh 0.5% NaHCO3 solution for 30 min, drained again and ground in water at room
temperature. The soy-slurry was heated to 90C and filtered to remove okra. The soymilk thus
produced has bland flavor. [8]
In RHHTC method, the Soybean was ground into flour and made into slurry using hot water and
then pressure-cooked for 30 sec, cooled and adjusted to 9% solid with water and centrifuged to get
the soymilk. [8]
The Illinois and the RHHTC method incorporate all of the soybean parts into the resulting soymilk
due to high shear of the process. However, the RHHTC method uses a higher temperature (154 C
for 3 s) than the Illinois method (90C). [8]
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The Pro Soya and the Cornell method is a modification of the traditional methods. In the Pro-Soya
method, the soybeans are ground with cold water under vacuum to prevent the incorporation of
oxygen into the fatty acid by lipoxygenase. [8]
In the Cornell method, the soybeans were cleaned in order to remove dirt’s and also some impurities
like other seed stalks etc. The beans were blanched in hot water for 30 minutes for the following
reason; to soften the seeds and aid in see coat removal to remove, to reduce the beany flavor and
eliminates the anti-nutritional factors. The beans were the de-hauled and milled with water using the
Kenwood blender, about 3 parts of water was added to the slurry and filtered using a Muslin cloth,
the filtrate was allowed to simmer on fire about 10 minutes it was then bottled and allowed to cool.
Enzyme inactivation is accelerated by inactivation of the enzyme using heat (80 C and above)
during grinding. [26]
Even though it was reported that the processing modifications reduced off-flavor development, each
method has its own advantages and disadvantages in terms of protein and solids recovery. The
traditional and Cornel1 method yield the lowest % solid extraction (55- 65% wt/wt), where the
Illinois and the RHHTC method yield the highest % solid extraction (86-89% wt/wt).
For protein extraction the traditional, Cornell and the Pro-Soya method extracted about 70-80 %
(wt/wt) of protein and the Illinois and RHHTC method extracted about 90-93 % (wt/wt) protein. In
the Illinois and the RHHTC method, all of the soybeans including the okra are included in to the
soymilk and therefore increases its % solid and % protein extraction [27] In the Illinois method,
where soybeans are blanched for 30 minutes, Johnson and Snyder (1978) showed that the initial
blanching step would heat fixed the protein bodies in the soybeans and make it insoluble even after
the grinding step. If the soybeans are ground with hot water, such as in the Cornell method, the
protein fixation does not occur and better extraction can be obtain. Another disadvantage of the
Illinois and RHHTC method is that the suspended insoluble solids may settle out.
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Some research suggest that modifying the processing methods by the addition of extra ingredients
such as antioxidants, sodium bicarbonate, oxidize enzymes or masking agents can improve the
flavor of soymilk.
The other application of sodium alkali is by adding it into the soymilk itself. [28] In this case,
Bourne reported that the pH change in soymilk was not the one responsible for the improvement of
flavor but instead it was the concentration of the sodium ions.
The addition of an oxidize enzyme was suggested for flavor removal through oxidation. The
addition of the enzyme would oxidize the already present off-flavor to reduce the amount of off-
flavor (aldehydes to carboxylic acids). Currently, many research works are being done to increase
the yield and productivity of milk and it’s by products from soya and related seeds.
2.3.3. By products of soy milk

The main byproducts of soy milk from soya bean are okra and skin. Every kilogram of dry beans
made into soymilk generates about 1.1 kg of okara, which contains 76–80% moisture. [29] Most
okara is sold as animal feed. However, okara contains about 27% protein (dry basis), 10 -15% oil,
42% insoluble fiber and 12% soluble fiber. [30] But little starch or simple carbohydrate. [31]
It is a suitable dietary additive in biscuits and snacks because it reduces calorie intake and increases
dietary fiber. Okara protein has good nutritional quality and a superior protein efficiency ratio. The
protein can be extracted from okara at alkaline pH; [32] Ma et al reported that the protein recovery
obtained at pH 9 and 80 °C was significantly higher than when incubated at 25°C. With its high
moisture content, fresh okara is very easily spoiled by microorganisms. In the factory, okara is
usually dried to reduce the low moisture content prior to sale as animal feed. [33]
Okara is dried and then milled in to powder. The okara powder is then mixed with baking powder
and other ingredients and baked for about 170c.
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Okra used for different purpose such as animal feed, fermentation substrate, fertilizer and food
products. This paper mainly concerns on the use of okara for oil and flour processing.
On this research work, the attention is mainly given to produce milk, to develop the production
process of milk from soya bean and to optimize its production as a whole using hot and cold
extraction processing method.
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3. MATERIAL AND METHODS

3.1. MATERIAL AND INSTRUMENTS
For the production of soya milk using hot extraction process, the following materials are basically
used.
 Soybeans
 pH meter
 water
 Muslin cloth
 Measuring cylinder
 Beaker
 Volumetric flask
 Thermo meter
 Holding tank
 Water bath
 Digital balance
3.2. METHOD OF PREPARATION OF SOY MILK, OIL AND FLOUR
3.2.1. Production of soy milk

Soybean was purchased from market and kept at ambient temperature prior to usage. They were
analyzed within a day of purchase. Once the materials and chemicals used for the process prepared,
the following lists of procedure are used:
They were analyzed within a day of purchase. Soybean was sorted to remove stones and damaged,
deformed seeds. The soybean was washed and soaked in water (300 g in 1 Liter) for 6 and 10 hours.
The soybean was washed, manually de-hulled and rinsed. The soybean seeds were hot ground with
water at 91°C in blender (Kenwood) and expressed in the ratio of 5:1 to remove the okra and then
through a holding tank at 85°C to inactivate the LOX enzyme. Further it was passed through a
decanting centrifuge for separation of the insoluble residue (okra). The soymilk thus obtained was
held at 91°C for 20 minute to inactivate approximately 80% of the Kuntz trypsin-inhibitor (TI) and
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there-by improving the soy protein digestibility flash-cooled to 75°C and further cooled to 25°C.
The cooled soymilk was subjected to packaging unit.
Soymilk produced using soybean : below four different methods was analyzed for its physico-
chemical, proximate, lipoxygenase visual assay, and other parameters using standard procedures.
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Table 3.1 flow chart four methods of soy milk production

Whole soybean Whole soybean Whole soybean Whole soybean
washing and sorting Washing and sorting Washing and sorting Washing and sorting
Soaked with water for Blenching for 20 minute Soaked with water for 6 Soaked with water for
10 hour hour 10 hour
De hulled Soaked with water for 6 Blanching for 20 minute Bleaching for 20 minute
hour
Wet milling De-hull soybean De-hull soy bean De-hull soy bean
Holding for 20 minute Wet mill by hot water at Wet mill by hot water at Wet mill by hot water at
to inactivate LOX 91C 91C 91C
Separation of milk from Holding for 20 minute Holding for 20 minute Holding for 20 minute
okara to inactivate LOX to inactivate LOX to inactivate LOX
Cooking for 20 minute Separation of milk from Separation of milk from Separation of milk from
at 90C to inactivate TI okara okara okara
Flash cooling 75C Cooking for 20 minute Cooking for 20 minute Cooking for 20 minute
at 90C to inactivate TI at 90C to inactivate TI at 90C to inactivate TI
Cooling 25C Flash cooling 75C Flash cooling 75C Flash cooling 75C
Packaging Cooling 25C Cooling 25C Cooling 25C
Packaging Packaging Packaging
Cold extraction (A) Hot extraction Hot extraction Hot extraction
blenching before blanching after socking blanching before
socking (B) time 6 hour (C) socking time 10 hour
(D)
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A. analytical methods
 pH Value
The pH value of four soymilk samples was determined with a pH meter. Soymilk samples were
placed in room temperature for 2 h before measured.
 Color
The color of four soymilk samples was observed by eye at room temperature. Land py represent
lightness and pale yellow respectively.
 Total Solids Content

The total solids content of soymilk samples was determined by drying 8 g of samples in an air oven
at 105ºC for 12 h. Total solids content was calculated as follows:
Total solid (%) = ([weight (dish + dry sample) – weight dish]/ [Weight (dish + wet sample) – weight
dish]) * 100
B. proximate analyses
 moisture
About 8 g sample was weighed into a clean dried dish. This was placed on an oven maintained at
105C for 6 hours. The dish was cooled to room temperature and then this was re-weighed and
recorded. Weight of moisture was calculated by subtracting the weight of dried samples from
the fresh.
% Moisture = [fresh weight – dried weight]/ [weight of fresh sample] x 100.
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 ash (by furnace method)

Sample was weighed into a porcelain crucible which was previously pre-heated and weighed. The
crucible was inserted into a muffle furnace and regulated to a temperature of 630C. This
was heated for 3hours and allowed to cool.
 lipid (by sox let extraction method)

About 40g sample was placed into a sox let extractor. The extractor was placed into a pre weighed
dried distillation flask. Then the solvent (hexane) was introduced into the distillation flask via the
condenser end attached to the sox let extractor. The setup was held in place with a retort stand
clamp. Cooled water jet was allowed to flow into the condenser and the heated solvent was refluxed
as a result, the lipid in the sox let chamber was extracted in the process of continuous refluxing.
When the lipid was observably extracted; to concentrate the lipid; the flask was then dried with
the air oven to constant weight and re-weighed to obtain the weight of lipid.
% lipid = [weight of flask and extract –weight of flask]/ [weight of sample extract] x100.
3.2.2. Production of oil and flour from okara

A. Oil production process from okara and physical characterization
The okra was obtained from soy bean after it has been processed to make soy milk and 40 gram of
okara were prepared then placed in to sox let apparatus. After this the solvent mainly hexane (300
ml) was filled in to the distillation flask via the condenser end attached to sox let extractor. The
extracted oil was heated in water bath at 75oC in order to remove the hexane then cool to room
temperature.
Physical characterization of edible oils

 Determination of pH Value:
Edible oil (0.5g), 50ml of hot distilled water was added and both samples were then cooled in a cold-
water bath to 25°C. The pH electrode was standardized with Buffer solution and the electrode
immersed into the samples and the pH value (5.6) was recorded.
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 Determination of Specific gravity:

First of all measure 20 ml of oil and 20 ml of water. Then, weigh each sample after this determine
the specific gravity of the oil.
𝜌𝑜𝑖𝑙
𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑔𝑟𝑎𝑣𝑖𝑡𝑦(𝑆𝐺) =
𝜌𝑤𝑎𝑡𝑒𝑟
 Determination of color:
The color of the edible oil determined using observation and compared with the standard.
 Determination of odor:
The product was smell physically and compared with standard odor.
B. Making of bread from okara flour

The okra was obtained from soy bean after it has been processed to make flour. Okara flour are good
source of Ca, P the vitamin B complex and protein and also used in the backing industry to improve
the crust of bread ,retain moisture and improve flavor . Cookies, crackers, cake mixes and cereal
products are superior in nutritive quality when okara flour is added. Analyze the effect of okara flour
combined with wheat flour and alone have done.
Physical characterization of okara flour

 Colure
 Taste
 Flavor
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4. DESIGN AND ECONOMICAL EVALUATION OF SOYA MILK PRODUCTION

PLANT
4.1. MARKET STUDY
A. Past Supply and Present Demand
Soya bean milk, a nutritious product produced from soya bean, can be used as a substitute for cow
milk. Accordingly, the demand for cow milk is used as a proxy for estimating the demand for soya
been milk traditionally processed milk is supplied to the market, albeit there is no quantitative data.
In the absence of data on domestic production and consumption of milk, the Revised Report on the
1995/96 Household Income, Consumption and Expenditure Survey is analyzed in estimating the
demand for the product. Table 4.1 depicts the average consumption of milk by different expenditure
groups in urban and rural areas according to the survey finding.
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Table 4.1 domestic consumption of milk
Average
Number of Annual Total Annual
Income Individuals in Consumption of Consumption
Group the Group milk (ml) of milk (liter)
< 600 17,253 255 4,400
600 - 999 125,904 653 82,215
1000-1399 432,547 3,198 1,383,285
1400-1999 580,104 4,938 2,864,554
2000-2599 4,217,465 4,302 18,143,534
2600-3399 6,498,555 6,118 39,758,159
3400-4199 7,844,772 7,746 60,765,604
9000-12599 5,114,961 12,950 66,238,745
12600-16199 1,765,555 10,603 18,720,180
16200-19999 673,706 11,160 7,518,559
> 20000 972,722 12,864 12,513,096
Total 55,954,227 526,761,355
Source: CSA, Revised Report on the 1995/96 Household
Income Consumption and Expenditure Survey, 2001
As can be seen from Table 4.1, the total consumption requirement of households for milk is
526,761,355 liters. Given a total population of 55,954,227 at the time the survey was conducted, the
per capita consumption of milk is computed to be 9.4 liters.
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Table4.2.Soy bean Production and area coverage in Ethiopia (2000/01-2011/12)

Production Year Area coverage Tone Productivity
(Hectare) (ton/ha)
2001/02 1,769 1620.5 0.92
2003/04 1,027 457.4 0.45
2004/05 2,606 833.5 0.32
2005/06 3,326.52 3811.89 1.15
2006/07 6,352.46 5848.95 0.92
2007/08 7,807.40 8400.64 1.08
2008/09 6236.04 7898.9 1.27
2009/10 5,678.69 7205 1.27
2010/11 11261 15824.42 1.41
2011/12 19397 35880.29 1.85
Source: Central Statistical Agency
Table 4.3 Demand Projection (tons)

Year Domestic Demand Export Demand Total Demand
2014 8,670 2,674 11,344
2015 9,103 2,942 12,045
2016 9,559 3,236 12,795
2017 10,037 3,559 13,596
2018 10,538 3,915 14,453
2019 11,065 4,306 15,371
2020 11,619 4,737 16,356
2021 12,200 5,211 17,411
2022 12,810 5,732 18,542
Source: Central Statistical Agency
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B. Demand Projection
The current population of Ethiopia in 2016 is 101,577,251 from this 19.4% urban (i.e. 19,705,986)
the demand for soya bean milk is assumed to be associated with the urban population. Therefore, a
rate of growth of 4% that corresponds to the rate of urbanization in the country is considered in
projecting the demand for the product. The projected demand for the product is shown in Table 4.4
Table4.4. Projected demand for soya bean milk (liters)

Year Projected
Demand
2017 20,494,225
2018 21,313,994
2019 22,166,554
2020 23,053,216
2021 23,975,345
2022 24,934,358
2023 25,931,733
2024 26,969,002
C. Pricing and Distribution
Based on the retail price of cow milk, a price of Birr 12 per liter is recommended for the product of
the envisaged plant.
Distribution of the product could be undertaken through the existing wholesale and retail network
that include department stores, supermarkets, and retail shops catering establishments
BSC thesis Page 23

D. Site selection
The following are site selection criteria’s that should be considered:
 Availability of raw material

 Market competency in terms of distribution
 Accessibility of infrastructures like electricity, communication and water
 Amount of consumers i.e. demand and supply gap
Generally the plant can be constructed in Addis-Ababa where a large amount of people is found, which
help us for advertising our product, because it is new for country and people can understand within a
fraction of time due to approaching to modern based style. The next reason of constructing our plant in
Addis- Ababa is, our product is perish able and it can be spoiled during long transportation from country
side were raw material can be found.
4.2. PLANT CAPACITY AND PRODUCTION PROGRAMME

I. Plant Capacity
The following assumptions are employed in estimating the capacity for soya bean milk
- soya bean milk can substitute about 10% of the projected demand for cow milk(2019)
- based on annual productivity of soya bean
- the consumption of soya bean milk will remain limited to urban areas
Based on the market study and assumption the capital requirement and minimum economy of scale,
the Soya milk processing plant will have a capacity of 2,216,655 liters of Soya milk per annum. A
capacity of 7,388 liters per day is considered on the basis of double shifts of 16 hours per day and
300 working days per annum.
II. Production Program
The annual production program is formulated based on the proposed plant capacity. Considering the
problem of market penetration and skill development of production at the initial stage of the production
period, it is planned that the plant will start production at 75% and 85% of its rated capacity in the first
and second year of production, respectively. Full production shall be attained in the third year and then
after. The detailed production program is shown on Table 4.5
BSC thesis Page 24

Table 4.5production program
Production Year
Description Unit
2019 2020 2021-20
Soya bean milk Lit 1,662,491 1,884,156 2,216,655
Utilization of rated capacity % 75 85 100
III. Raw and auxiliary materials
The major raw material required for producing Soya bean milk is food-grade Soya bean.
Other materials such as detergents and salts are also required in relatively small quantity. In addition to
raw materials, auxiliary materials like, sugar.
Annual requirement of each of these auxiliary materials at full production capacity is given in Table 4.6
the estimated annual cost of the raw and auxiliary materials at full production capacity is about Birr
8,383,300.
Table4.6. Annual requirement of raw and auxiliary materials and their estimated cost
Cost, [ '000 Birr]
No. Description Unit Qty.

1. Food-grade Soya bean Tones 470 9400
2. Sugar Tones 80 1,240
3. Detergents tones 0.6 2.3
4. Plastic bags (0.5 liter per Pcs 5 million 955
bag
Grand Total 11,597.3
BSC thesis Page 25

IV. Utilities
The major utilities required by the plant are electricity, water for cleaning, steam, diesel oil, compressed
air, lubricating oil and grease. The annual consumption of these utilities is shown in Table 4.7.
Table 4.7Annual requirement of utilities and cost
No. Description Unit Quantity Birr

1 Electricity KWH 605,146 242,058
2 Water M3 300 450
3 Diesel oil Lit 18,000 54,000
4 Lubricant oil Lit 25 14,000
5 Grease Kg 6 250
6 Total 262,158
4.3. MATERIAL BALANCE
The data obtained and recorded from the laboratory will be analyzed and interpreted by
using measured data. This will be done by evaluating the material balance on each
equipment /steps in the process. The determination of materials that exits and enters to the
process equipment/ unit will help us to determine the scale up of material balance to
industrial level.
4.3.1. Experimental/laboratory material balance
 Sorting
Raw soya bean (Rs) =340g waste=40g
Clean soya bean (Cs)
Input=output
BSC thesis Page 26

Rs=Cs+40, Cs=300g
 Washing CSin=300g
Water in (win) =900ml water out (Wout) =900ml
CSout=300g
Input=output
 Soaking
CS out=300g
Water in =900ml remove water
Soaked or expand soya bean=658g
Input=output
Removed water= (900g+300g)-658g
=542g
 dehulling 658g of soaked soya bean
Husk or skin
Pulp=542g
In put=output, Husk or skin=116g (wet basis)
 Grinding
soaked soya bean=542g
Hot water=5Cs
Grind soya bean (Gs)
In put =out put
Gs=5Cs+542g, Cs=300g
=2,042g
BSC thesis Page 27

 Filtration
Gs=2,042g
Okara=718g (wet basis)
Filtered soy milk
In put=out put
Filtered soy milk=1,324ml
 Holding tank
Filtered soy milk=1,324ml
Sugar=77.6g homogenized soy milk
Input=out put
Homogenized milk=1,401ml
 Destnor
Waste=40g
Stone
Under size soy bean and other grains=30g
In put= out put
Stone=10g
BSC thesis Page 28

 Dryer for husk
Wet husk=116g
Dry husk=42g
Moisture
In put=out put
Moisture=74g
 Dryer for okra
Wet okara=718g
Dry okra=127g
Moisture
In put = out put
Moisture= 591g
BSC thesis Page 29

Raw soybean (Rs) Sorting 11.76%RS Destone (2.94% RS)

r
Clean soybean (CS) other grains and soybean
Water in (3CS) Washing Water out (3CS)
CS
Water (3CS) Water removed (1.8067CS)

Soaking
SCK
17.63%SCK 6.383%SCK
DE hulling
Drying of husk
Pulp
Water=5CS (277%pulp) Moisture

Grinding
GS (11.25%SCK)
35.16%GS
Filtration
Drying of okra 2.18%GS
Sugar FSM Moisture
25.867%CS (5.86%FSM) Homogenization (10.17%GS)
Soymilk product
Figure4.1. Flow diagram of material balance on each unit operation
BSC thesis Page 30

4.3.2. Industrial scale production

Assumptions:
Capacity = 2,216,655 lit/yr.
Batch process
300 operating days per year
4 operating hours per batch and 4 batches per day
Number of cycle per year = 300*4 = 1,200
soy milk production per batch = 2,216,655/1,200 = 1,848lit
 Material balance on homogenization tank
Sugar (5.86%FSM) FSM
2,216,655lit soy milk

Input=out put
FSM=2,093,950lit where: FSM=filtered soy milk
Sugar=0.0586*2,093,950
=122,705kg
 Material balance on filtration
GS
Okara (35.16%GS)
FSM=2,093,950lit
Input=out put
GS=3,229,410kg
Okara=0.3516*3,229,410=1,135,460kg (wet basis) where: GS=grained soy bean
BSC thesis Page 31

 Mass on dryer for okara

Okara=1,135,460kg (wet basis)
83.8%Okra (dry okara)
Water removed (Wr)

In put=out put
Wr=1,135,460kg-0.838*1,135,460kg
=183,944kg
Dry okra=951,515kg
 Mass balance on grinder
Pulp
Hot water (277%pulp)
GS=3,229,410kg
In put=out put
Pulp=3,229,410/3.77
=856,607kg
Hot water=2.77*856,607kg
=2,372,801 Lit (kg)
 Mass balance on De hulling
SCK
Wet skin (17.63%SCK)
Pulp=856,607kg
In put =out put
SCK (soaked soya bean) =856,607/0.8237
=1,039,950kg
Wet skin =0.1763*1,039,950
=183,343kg
BSC thesis Page 32

 Mass balance on dryer for skin
183,343kg wet skin dry skin (6.385SCK)
Water removed
In put =out put
Dry skin =0.06385*1,039,950
=66,400kg
Water removed=183,343-66,400
=116,942 Lit
 Mass balance on soaking
Clean soya bean (CS)

Water in (3CS) water removed (1.8067CS)
SCK=1,039,950kg
In put=out put
CS+3CS+1.8067CS=1,039,950
CS=179,095kg
Water in=3*179,095
=537,284 Lit
Water removed=1.8067*179,950
=323,570 Lit
BSC thesis Page 33

 Mass balance on sorting
Row soya bean (RS)
Unwanted grain and stones (11.76%RS)
Clean soya bean =179,095kg
In put =out put

RS=179,095/0.8824
=202,964kg
Unwanted grains and stone (Un) =0.1176*202,964
=23,868kg
 Mass balance on destnor
Stone (2.94%RS)
Un=23,868kg
Grains free from stone

In put=out put
Amount of stone=0.0294*202,964
=5,967kg
Grains free from stone=23,867-5,967
=17,899kg
BSC thesis Page 34

4.4. ENERGY BALANCE
 Energy balance on jacketed vessel

674kg soy bean (at 25oc)
1,127 lit (at 55oc) Steam at 120oc
Boiled soy bean at 90oc

Assumption where: Ms=flow rate of steam
Qin=Qouts=Latent heat of vaporization
Mss = Mf cp ∆T Mf=mass flow rate of feed
Ms*2202.6KJ/Kg=1,801kg*3.778KJ/Kgk* (90-35) kCP=Average specific heat capacity
∆T=change of temperature
Ms= (374,230KJ/day)/ (2202.6KJ/Kg)
=170Kg/day
 Energy balance on hot water tank
Water in at 25oc Steam at 120oc
Hot water out at 95oc
Qin=Qouts=2202.6KJ/Kg
Mss = Mf cp ∆T Mf=2,372,801kg/yr=7,909kg/day
Ms*2202.6KJ/Kg=7,909kg*4.18KJ/Kgk* (95-25) k
Ms= (2,314,271KJ/day)/ (2202.6KJ/Kg)
=1,050Kg/day
BSC thesis Page 35

 Energy balance on cooker

Grinded soy solution at 65oC steam at 120oC
Hot grinded soy solution at 85oC

Qin=Qouts=2202.6KJ/Kg
Mss = Mf Cp ∆T Mf=3,229,410kg/yr=10,764kg/day
Ms*2202.6KJ/Kg=10,764kg*4KJ/Kgk* (85-65) K
Ms= (861,120KJ/day)/ (2202.6KJ/Kg)
Ms=391Kg/day
 Energy balance on pasteurizer
Steam out at 92C
o o
Soy milk in at 60oc soy milk out 120 C
o
Steam in at 150 C
Flow rate of soy milk in=7,389lit/day

Qin=Qout
MsCps ∆T = Mf cpf ∆t
Ms*4.31(150-100) =7,389kg*4KJ/Kgk* (120-60) k
Ms= (1,773,360KJ/day)/ (216KJ/Kg)
Ms =8,229Kg/day
BSC thesis Page 36

 Energy balance on dryer
Wet solid (okra) =3785kg/day hot air in=120oc

Weight percent of water=20%
Temperature of the feed=30oc
Exit air Product contain
With 90oc 5%moistur content
Tp=80oc
Water amount in the feed=0.2*3,785

=757kg/day
Solid amount in the feed=0.8*3,785
=3,028kg/day
Water leaving with product= (0.05*3,028)/(1+0.05)
=144kg/day
Water evaporated into gas stream=757-144
=613kg/day
Energy required raising the product to discharge temperature.
=3,028*3.778(80-30) +144*4.18(80-30)
=602,085KJ/day
Energy required removing the water
=613[2.01(90-30) +4.18(120-80) +2308.8]
=1,591,715KJ/day
Total energy needed= (602,085+1,591,715) KJ/day
= 2,193,800KJ/day
= 25.4KW
BSC thesis Page 37

4.5. EQUIPMENT SIZING AND SELECTION
Assumption
 Assume four batch in a day
 Assume 4 hrs operating time (i.e., four batch in a day)
 volume on Boiling tank
mmix (597+1,194)kg
Vmix= ρmix = kg = 1.95𝑚3 = 1,950lit
(1000∗0.67+753∗0.33) 3
m
1,950
Vmix = = 488lit/cycle
4
If the boiling tank is 80% full in each cycle the volume of the boiling tank is estimated as follows.
488
Vbt = = 610 lit/cycle
0.8
So, we select 600lit

 volume on soaking tank
mw mcs 1,791kg 597kg

Vmix = + = + = 2.55m3
ρw ρcs 1000 ∗ 0.75 kg 753 ∗ 0.25 kg
m3 m3
2,550
Vmix= =637.5lit/cycle
4
If soaking tank is 80% full in each cycle the volume of the soaking tank is estimated as follows:
637.5
Vst= =796.875lit
0.8
So, we have selected 800lit

 volume on De hulling
msoaked soy bean 3,466kg
Vde = = kg
= 4.6m3=4,600lit
ρsoaked soy bean 753 m3
4,600
vde= =1,150 lit/cycle
4
If de-hulling is 80% full in each cycle the volume of the dehulling tank is estimated as follows:
1,150
Vst = 0.8
=1,438 lit
So, we have selected 1,400lit
BSC thesis Page 38

 volume on grinding
mw mpulp 7,909kg 2,855kg

vmix = + = kg
+ kg
= 11.86m3
ρw ρpulp 1000 ∗ 0.73 753 ∗ 0.27 m3
m3
11,860
vmix= =3,706lit/cycle
4
If grinding is 80% full in each cycle the volume of the grinding tank is estimated as follows:
3,706
Vgr = =4,632lit
0.8

 volume on homogenization tank
mfilterd soy mik msugar 6,979kg 409kg

vmix = + = kg
+ kg
= 7.26m3
ρfsm ρsugar 1,025 ∗ 0.94 1590 ∗ 0.055 m3
m3
7,260
vmix= =1,815lit/cycle
4
If homogenizer is 80% full in each cycle the volume of the homogenizer tank is estimated as
follows:
1,815
Vgr = =2,268lit
0.8
BSC thesis Page 39

4.6. DESIGNING OF SELECTED EQUIPMENTS
 Design of batch storage tank
s α a
Figure 4.2 conical cylindrical tank
Assuming
Operating temperature = 90 0c
Where D – the diameter of cylindrical section
H- The fluid height measured from the center of the bottom of the tank to the surface of the fluid
in the tank
a-The depth the bottom extends below the cylindrical section of the vertical tank
R- The radius of the cylindrical section of a vertical tank
α-half of the angle of the cone
S-The hypothnuios of the conical section
Assuming the storage tank is a cylindrical
BSC thesis Page 40

𝑉𝑜𝑙𝑢𝑚𝑒𝑜𝑓𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 (𝑉𝑅) = πr 2 H… …… … (1)
Where
R- Radius of the cylinder= D/2
VR = 0.6𝑚3 (With 20% safety factor)
Assume height to diameter ratio 1-6 and take H/D =2
H = 2D and r = D/2 substitute to eqn. 1
D 2
VR = π ( ) ∗ 2D
2
3 2VR
D= √
π
D = 0.73m
𝐻 = 2 ∗𝐷 = 2∗ 0.73𝑚 = 1.46𝑚
Angle of the cone
𝐿𝑒𝑡𝑎 = 0.1𝐻 = 0.1 ∗ 1.46 = 0.146𝑚
𝑅 = 𝐷/2 = 0.73𝑚/2 = 0.365𝑚
s 2 = a 2 + R2
𝑆 = 0.393m
BSC thesis Page 41

a
cosα =
s
α = cos −1 (0.371)
α = 68.20
𝐴𝑛𝑔𝑙𝑒𝑜𝑓𝑡ℎ𝑒𝑐𝑜𝑛𝑒 = 2𝛼 = 2 ∗ 68.2 = 136.40
Storage tank Thickness where:

Po = Pa + ρgh Po=operating pressure
=101,325+918.5*9.81*1.46 Pa=atmospheric pressure
𝑁 𝑁
=114,480𝑚2 =0.115𝑚𝑚2 Pd=designed pressure
f=design stress
Take 10 % pressure allowance j=joint factor
N
Pallowance = 0.1 ∗ 0.115=0.0115mm2
Pd = Po + Pallowance
N
=0.1265mm2 = 126,500pa
Thickness of storage tank

Pd ∗ Di
t=
2fj − Pd
Design stress f = 150 N/mm2constant from table typical design stress 50 to 100oCand material made
from stainless steel,
0.1265 ∗ 0.73
t= = 0.36mm
2 ∗ 150 ∗ 0.85 − 0.1265
Corrosion allowance=2mm
Minimum thickness of storage tank=0.36mm+2mm=2.36mm
BSC thesis Page 42

Top cover
It required resisting for only the atmospheric pressure
Pd ∗ Di
t=
2fj − Pd
0.101 ∗ 0.73
t= = 0.29mm
2 ∗ 150 ∗ 0.85 − 0.101
By taking corrosion, allowance 2mm
t=2mm+0.29mmt=2.29mm
 The calculated thickness for storage tank and its top cover is out of the range, from the given
table below. However, take the nearby standard that is D=1m, t storage and t top cover = 5mm
Table4.8. Vessel diameter with minimum thickness

Vessel diameter(m) minimum
thickness(mm)
1.0 5mm
1 to 2.0 7mm
2.0 to 2.5 9mm
2.5 to 3.0 10mm
3.0 to 3.5 12mm
 Plate Heat Exchanger Design on (Pasteurization)
High temperature short Time

Data
Assumptions: All fluids approximated as water. Additional 15% plate area allowance for fouling and
inefficiencies. Smallest pressure drop assumed to give most conservative estimate. Each plate is 0.55mm
thick and is constructed of stainless steel.
BSC thesis Page 43

Plate Thickness = 0.55 mm
kg
Viscosity of Water = 0.002822 m.s at 100oc
kg
Viscosity of Milk = 0.004m.s
w
K of soy milk = 0.526 m.kat room temperature
w
K of water = 0.598 m.k
𝑤
K of Stainless Steel = 17.5𝑚.𝑘
Density of soy Milk = 1,050 kg/m3 at 120oc degrees

Density of Water = 958 kg/m3 @100oc degrees
kj
Cp of soy milk = 4kg k
kj
Cp of water = 4.31kg k
Pr No. soy Milk = 20.34

Pr No. water = 30.4
Known
Mass flow rate of water = 8,229 kg/day = 342.875 kg/hr=0.0953kg/s

Mass flow rate of soy milk = 7,389 kg/day = 307.875 kg/hr=0.08586kg\s
Justification
1. choose Stainless Steel

• Corrosion resistant.
• High Temp Resistant.
• Easy to clean.
• No contamination of products.
• Fouling Resistant.
• Availability.
• Economical.
BSC thesis Page 44

2. choose Plate Heat Exchanger type

• Maintainability.
• Flexibility.
• Suitable For Viscous Materials
• Low approach temp can be used
• easy to cleaning
Solution.
1. Calculating for heat load.

Q=m (soy milk) Cp (milk) ∆T
Q= (0.08586) (4) (120-60)
Q=20.6kw, Take 15% allowance
Q=24kw
Q=m (water) Cp (water) (T1-T2)
24kw= (0.0953) (4.31) (150-T2)
T2= 92oc
2. Log Mean Temperature, Number of transfer units and Mean Temperature.
∆TLM= (T1 − t2) − (T2 − t1)/ ln [(T1 − t2)/ (T2 − t1)]

= (150-120)-(92-60)/ln [(150-120)/ (92-60)]
∆TLM = 31
NTU = ∆t/∆TLM
NTU=60/31
NTUcold=2
∆Tm = Ft *∆TLM Where Ft= correction factor.
∆Tm = 0.945 * 31
∆Tm = 30
BSC thesis Page 45

3. Required Area and Effective plate area

Determination heat transfer coefficient
w
H hot= 13,000m2 .k
w
H cold=7,500m2 .k
Determination of Overall Heat Transfer Coefficient:
1 ∆x 1 −1
U=[ + + ]
hhot kss hcold
𝑤
=2700 𝑚2 .𝑘
Area req. = Q/U x ∆TLM

Area req. = 24,000/ (2700) (0.945) (31)
Area req. =13m2
Assuming L=0.8m and W=0.3m

A (ef) =LxW
BSC thesis Page 46

A (ef) = 0.8 x 0.3

A (ef) =0.24 m2
4. Total No. of plates and No. of channels.
N = Area req. /A (ef)

N = 13/0.24
Nt = 54.2 =55
Nt−1
Nc= 2
Nc = 27
5. Channel Cross sectional Area and Hydraulic Diameter.
Taking Plate Spacing as 3mm

Ac = W x Plate spacing
Ac = 0.3 x 0.003 =0.0009 m2
De = 2 x Plate Spacing
De = 2 x 0.003
De = 0.006 m
 Design of dryer
Selection criteria
 characteristics of the raw material
 quality requirements on the dry
 Economic analysis or cost estimation
 safety and environmental consideration
Based on criteria rotary dryer selected and It has high capacity, simple in operation, and continuous.
BSC thesis Page 47

Table4.9: Rotary dryer’s practical ranges of dimension and operating parameters

Shell i.d. : D = 1 to 10 ft. Length, L = 4 D to 15 D
Radial flight height: D/12 to D/8; shell rpm: 4 Peripherals shell speed: 50 – 100 ft/min
to 5
The flight count per circle: 2.4D to 3 D
Inclination of the shell to the horizontal: up to Avg. solid retention time: 5 min to 2h
8cm/m
Mass flow rate of the drying gas: 300 to 5000 Drying capacity: 0.4 to 2.5 lb moisture/(h)
lb/h.ft2 (ft3 dryer volume)
Number of heat transfer units in the dryer Solid hold up m(i.e. fraction of the shell
(NT): 1.5 to 2 volume occupied by the solid at any time): 5-
15%
The soya bean okara at 30oC is to be dried from 20 % initial moisture to 5% final moisture in a rotary
dryer at a rate of (Mso) 127kg/h. The hot air enters the dryer at 120oC with a humidity of (Y2) 0.015.
With condition that the temperature of the solid leaving the dryer must not exceed 105oC and the air
velocity must not exceed 1.5 m/s in order to avoid dust carry over.
CPokra= 3.77 kJ/kg.K.
 Wet solid flow rate in to the dryer=158𝑘𝑔/ℎ𝑟
Basis of calculation is 1 hour operation
 Moisture in the wet solid (𝑋1) = 0.2/0.8 = 0.25

 Moisture in the dry solid (𝑋2) = 0.05/0.95 = 0.053
 Water evaporated (ms, evaporated) = ms, dry solid(𝑋1−𝑋2)
= 25𝑘𝑔/ℎ𝑟
Given data in the form of symbolical
𝑇f= 30℃, Tair in=120℃ and 𝑌air in=0.015
Let us assume the exit temperature of the gas is
𝑇air exit= 65oC𝑎𝑛𝑑𝑓𝑜𝑟𝑠𝑜𝑙𝑖d okra 𝑇p=80℃
Now enthalpy of different streams suppose reference temperature is 0℃
BSC thesis Page 48

HS1 = [𝐶pokra + 4.18×𝑋1] × [Tf–T Reference]

HS1 = [3.77+4.18 × 0.2] × [30 − 0]
= 138.2KJ/ Kg of dry air
HS2= [𝐶pokara + 4.18 × 𝑋2] × [𝑇air in –𝑇 Reference]
HS2 = [3.77 + 4.18 × 0.053] × [80 − 0]
=368.5KJ/Kg dry solid
Hg2 = [𝐶𝑃𝑎𝑖𝑟 + 1.88 × 𝑌air in] × [T air in−T Reference] + Yair in× 𝜆
Hg2 = [1.005+1.88 × 0.015] × [120−0] + 0.015 × 2206.2𝐾𝐽/𝑘𝑔
=157 KJ/Kg
Hg1 = [𝐶𝑃𝑎𝑖𝑟 + 1.88 × 𝑌air exit] × [T air exit−T Reference] + 𝑌air exit × 𝜆
Hg1 = [1.005+1.88 × 𝑌air exit] × [65 − 0] ℃ + 𝑌air exit × 2206.2KJ/𝑘𝑔
Hg1=65.33+2,328.4Yair exit
Over all mass balance;
GS × (𝑌air exit−𝑌air in) =ws × (𝑋1−𝑋2) =𝐺𝑆 × (𝑌air exit−0.015)
Gs (Y1 – 0.015) = 25𝑘𝑔/ℎ𝑟
GS = 25/ (Yair exit– 0.015)……………. (1)
MSo[HS2 – HS1] = GS [Hg2 – Hg1]
127 [368.5 – 138.2] = [25/ (Y air exit– 0.015)] × (157– 65.33-2,328.4Yair exit)
By rearranging the above equation Yair exit = 0.0312, Gs = 1,540kg/hr andHg1=138KJ/kg

And the theoretical amount of heat needed for taking away the amount of water W dry is (temperature of
dried material is practically Twt=wet bulb temperature=41℃) and at 41℃ the latent heat of evaporation
(𝜆=2394.8𝑘𝑗𝑘𝑔)
Shell diameter design

Volume of humid inlet (120 ℃=393K and Y air in=0.015)
22.4 T 22.4 × ℋ T
VH2= 29 (273) + (273)m3/kg
18
22.4 393 22.4 × 0.015 393
= 29 (273) + 18
(273 )m3/k
= 1.1388m3/kg dry air
BSC thesis Page 49

The volume of exit gas (air) 65oC = 338K and Yair exit = 0.0312
22.4 𝑇 22.4 × ℋ 𝑇
VH1 = 29 (273) + (273)m3/kg
18
22.4 338 22.4 × 0.0312 338
= 29 (273) + (273)m3/kg
18
= 1.0043m3/kg
The maximum volumetric gas flow rate =GS ×VH2 =1,540Kg/hr∗1.1388m3/Kg= 0.4872m3/sec
Working velocity = 1.2m/s
maximum volumetric gas flow rate

Area = working velocity
0.4872
= = 0.3747m2≈ 0.41m2
1.2
Area = 𝜋D2/4
4A
D=√π
= 0.723m
Heat transfer unit
Dryer is divided into three zones and therefore, the stage wise calculation of temperature and humidity
of the stream can be obtained by material and energy balance.
Figure 4.4. Different section of dryer
BSC thesis Page 50

Stage III
Very less water left for vaporization in stage III. Consider solid is at TSB, the wet bulb temperature of
the air at location between III & II.
Assume TSB = TSA = 410C
 Enthalpy of solid at the inlet to stage III
𝐻𝑆𝐵= [3.77+4.18 ×0.053] (41 − 0)

=163.65𝑘𝑔/𝑘𝑔𝑑𝑟𝑦𝑠𝑜𝑙𝑖𝑑
 Humid heat of gas entering stage III
(𝐶HB)= CP air +CP𝐻2 (Yair in)

=1.005 + 1.88 × 0.015
=1.0332𝐾𝐽/𝑘𝑔𝑘
 Heat balance over stage III
𝑀𝑆× [𝐻𝑆2−𝐻𝑆𝐵] =𝐺𝑆× (𝐶𝐻𝐵) × (120−𝑇𝐺𝐵)

104.6(368.5– 163.65) = 1,540× (1.0332) × (120 –𝑇𝐺𝐵)
TGB = 106.53 ℃
Adiabatic saturation temperature of air entering stage II (106.53 ℃ and humidity of 0.015) is 41℃
At the boundary B, Δ𝑇B = 106.53− 41
=65.53 ℃
At end two Δ𝑇2= 120−85
= 35 ℃
65.53 − 35
(𝐿𝑀𝑇𝐷)III= (ΔT) m= 65.53 =48.7 ℃
ln( )
35
Calculating Number of transfer unit:

𝑇2−𝑇𝐺𝐵 120−65.53
(𝑁t𝐺)= = =1.1
ΔTM 48..7
Stage II
Use heat balance equation over stage IIto calculate the value of TGA. The calculated TGA value can be
used to estimate the number of transfer units. Since Yair in= 0.015
BSC thesis Page 51

𝐻𝐺𝐵= [1.005+1.88 × 𝑌air in] × [67.75 − 0] +2500 × 𝑌air in

𝐻𝐺𝐵= [1.005+1.88 × 0.015] × 67.75 + 2500 × 0.015
=107.49𝐾𝐽/𝑘𝑔 of dry solid
𝐻𝐴𝑆= [3.77+4.187 × 𝑋1] × (𝑇𝑆𝐴−𝑇𝑅ef)
= [3.77+4.18 × 0.25] (41 − 0)
= 197.42kJ/kg of dry solid
Enthalpy balance
𝑚𝑠 [𝐻𝑆𝐵−𝐻𝑆𝐴]=𝐺𝑆× [𝐻𝐺𝐵−𝐻G𝐴]
101.6[163.65−197.42] = 1,540 × [107.49−𝐻𝐺𝐴]
= 154.2𝐾𝐽/𝑘𝑔
Once 𝐻𝐺𝐴value is known then 𝑇𝐺𝐴can be calculated using the following equation.
𝐻𝐺𝐴=154.2kj/kg=[1.005+1.88×𝑌air exit] × [𝑇𝐺𝐴−𝑇ref] +𝑌air exit×2500
159.21kj/kg = [1.005 + 1.88 × 0.0312] × [𝑇𝐺𝐴 − 0] + 0.0312 × 2500
𝑇𝐺𝐴=72 ℃
At section “A” temperature difference Δ𝑇𝐴=72− 41= 31 ℃
Δ𝑇𝐵= 106.53 – 41 = 65℃
65 −31
Δ𝑇𝑀= 65 =
ln( )
31
= 46 ℃
106.53 − 72
Calculating Number of transfer unit 𝑁𝑇𝐺II= (𝑇𝐺𝐵−𝑇𝐺𝐴)/Δ𝑇𝑀= 46
= 0.751
To validate the assumed value of exit gas temperature that is 𝑇𝐺1=65 ℃ first do an energy balance over
stage one;
GS (𝐻𝐺2−H𝐺1) =Ms (𝐻𝑆2−𝐻𝑆1)
1,540(157–HG1) = 101.6(368.5−197.42)
𝐻G1= 115kj/kg
𝐻𝐺1= 115= [1.005+1.88 × 𝑌air exit] [𝑇𝐺1−30OC] +𝑌air exit× 2500𝑘J/𝑘𝑔
115 = 1.064TG1 + 46
TG1=HG1=64.84
BSC thesis Page 52

STAGE 1
(∆T)I= 64.84 – 30 = 34.8OC
(∆T)A= 31oC
34.8−31
(∆T) m = 34.8 = 33oC
ln( )
31
72−64.84
Number of transfer unites, NtG1 = = 0.2057
34.8
Number of transfer unite, NtG = 1.1 + 0.751 + 0.2057

= 2.1
Length of transfer unit;
Average mass flow rate = [Gs(1 + Yair exit) + Gs(1 + yair in)]/2
1,540(1+ 0.0312) + 1,540(1 + 0.015)
= 2
= 1,603kg/hr. = 0.45kg/s
The gas mass flow rate, G = 0.45/ (𝜋/4×0.7232)
= 1.096 kg/m2.s
Volumetric heat transfer coefficient,
Ua = 237(G)0.67/d
= 237(1.096)0.67/0.723
= 348.7W/m3.k
Humid heat at the ends

CH2 = 1.005 +1.88 × 0.015
= 1.033kJ/kg.k
CH1 = 1.005 + 1.88 × 0.0312
= 1.063kJ/kg.k
Average humid heat,
1.033+1.063 1.048𝑘𝐽
CH = =
2 𝑘𝑔.𝐾
BSC thesis Page 53

Length of transfer unite,

𝐺 ×𝐶𝐻 1.096 ×1.048
LT = =
𝑈𝑎 348.7
= 3.3m
Length of dryer, L = NtG × LT
= 2.1 × 3.3
= 6.93m
d = 0.723m and L = 7m
Thickness of the drier shell;
𝑃𝑖𝐷𝑖
ts = 2𝑓𝐽 − 𝑃𝑖
Known parameters are;

Pi = design pressure or internal pressure,
Pi = 𝜌𝑔ℎ
= 753 × 9.81 × 7
= 51,708pa
Since the working pressure is less than atmospheric pressure, the internal pressure should include
atmospheric pressure.
Pi = 51,708 + 101,325
Pi = 153,033pa or 0.153N/mm2
f = design stress of construction material (carbon steel) = 135N/mm2
j = welded joint efficiency (double butt equivalent) = 0.85
Di = internal diameter = 0.723m
ts = thickness of the drier
0.135 ×1150
ts = 2 ×135 ×0.85−0.135 = 0.677𝑚𝑚
For the shell minimum thickness is given as 8mm. consider corrosion allowance of 25% therefore,
including the corrosion allowance the thickness can be taken as 10mm.
BSC thesis Page 54

The outer diameter of the drier ;( Do)

Do = Di + 2ts
Do = 1.15 + 2 × 0.01
Do = 1170mm or 1.17m
To find the diameter of feed pipe first find the mass flow rate of air entering
water evaporated in the outlet stream
Y1 = mass flow rate of air entering
water in
0.015 × G +water evaporated into gas stream
(the outlet ) = G
stream
0.015 ×𝐺+42
0.0337 = 𝐺
G = 2246kg/hr or 0.624kg/s
Mass flow rate of feed = 316kg/hr
Density of feed = 454kg/m3
𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑓𝑒𝑒𝑑
Volumetric flow rate of feed = 𝑑𝑒𝑚𝑠𝑖𝑡𝑦 𝑜𝑓 𝑓𝑒𝑒𝑑
316
= 454 = 0.696m3 or 0.7m3
Assume the velocity of the feed is to be 50m/s
 Cross-sectional area of the feed pipe(A)

𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑓𝑒𝑒𝑑
A= 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑓𝑒𝑒𝑑
0.7
A= = 0.014m2
50
 Diameter of the feed pipe(D)

4 ×𝐴
D=√ 𝜋
D = 0.134m
With 20% corrosion allowance D = 0.16m
BSC thesis Page 55

To find the diameter of the air inlet and outlet pipe

Inlet pipe
Humidity of inlet air = 0.015kg of water/kg of air
Mass flow rate of air entering = 0.624kg/s or 2246kg/hr.
And density of air = 30.61kg/m3
m
Volumetric flow rate of air (Vair) = ρair
0.624
= = 0.0207m3/s or 73.37m3/hr.
30.61
Velocity of entering air is = 1.2m/s
 Cross-sectional area of the inlet air pipe (A)

volumetric flow rate of air
A= velocity of air
0.0207
A= = 0.017m2
1.2
 Diameter of the inlet pipe (D)

4 ×𝐴
D=√ = 0.14m
𝜋
With 20% corrosion allowance, D = 0.168m

Outlet pipe
Humidity of out let air = 0.0337kg of water/kg of air
Volumetric flow rate of exit air = V inlet air + V evaporated
41.9𝑘𝑔/ℎ𝑟
V of evaporated = 1000𝑘𝑔.𝑚3 = 0.042m3/hr. 0r 0.0000116667
V of exit = 0.0207 + 0.000011667

= 0.0207m3/s
Velocity of outlet air is 1.2 m/s
 Cross-sectional area of pipe is;
𝜋𝐷2 0.0207
A= =
4 1.2
A = 0.017m2
BSC thesis Page 56

 The outlet diameter of the pipe;

4 ×𝐴
D=√ = 0.148m
𝜋
To find the diameter of the air inlet and outlet pipe

Inlet pipe
Humidity of inlet air = 0.015kg of water/kg of air
Mass flow rate of air entering = 0.624kg/s or 2246kg/hr.
And density of air = 30.61kg/m3
𝑚
Volumetric flow rate of air (V air) = 𝜌𝑎𝑖𝑟
0.624
= = 0.0207m3/s or 73.37m3/hr.
30.61
Velocity of entering air is = 1.2m/s
 Cross-sectional area of the inlet air pipe (A)

𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑎𝑖𝑟
A= 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑎𝑖𝑟
0.0207
A= = 0.017m2
1.2
 Diameter of the inlet pipe (D)

4 ×𝐴
D=√ = 0.14m
𝜋

Outlet pipe
Humidity of out let air = 0.0337kg of water/kg of air
Volumetric flow rate of exit air = V inlet air + V evaporated
41.9𝑘𝑔/ℎ𝑟
V of evaporated = 1000𝑘𝑔.𝑚3 = 0.042m3/hr 0r 0.0000116667
V of exit = 0.0207 + 0.000011667

= 0.0207m3/s
Velocity of outlet air is 1.2 m/s
BSC thesis Page 57

 Cross-sectional area of pipe is;

𝜋𝐷2 0.0207
A= =
4 1.2
2
A = 0.017m
 The outlet diameter of the pipe;
4 ×𝐴
D=√ = 0.148m
𝜋
The thickness of insulation

From the heat balance it is clear that there is some heat lost into the atmosphere to limit the heat loss to
the same figure insulation is to be given to the drier. The insulation material can be chosen as asbestos.
𝑘𝑔
𝜌𝑎𝑠𝑏𝑒𝑠𝑡𝑜𝑠 = 577
𝑚3
𝑤
𝑘𝑎𝑠𝑏𝑒𝑠𝑡𝑜𝑠 = 681.4 ∗ 10−3
𝑚2 𝑘
𝑤
𝑘𝑐𝑎𝑟𝑏𝑜𝑛 𝑠𝑡𝑒𝑒𝑙 = 51
𝑚2 𝑘
𝑤
Convective heat transfer coefficient=56.78𝑚2 𝑘
But let us assume that 15% of the total heat supplied to the drier is loss to the environment i.e
 Heat loss from the drier=15% 25.4kw=29.21kw
 Inner diameter of the drier shell,D1=0.723m
 outer diameter of the drier shell,D2=1.17m

 thickness of the drier shell(ts)=10mm
 length of the drier (L)=7m
Let’’ Y’’ be the thickness of insulation
D3=D2+2Y, T1=120oc and T2=90OC
BSC thesis Page 58

We have from continuity equation

(𝑇1 − 𝑇2)
𝑄= 𝑡1 𝑌 1
(𝑘1𝐴1) + (𝐾2𝐴2) + (ℎ𝐴3)
(𝐷1+𝐷2)
But, A1=𝜋 ∗𝐿
2
0.723𝑚+1.17𝑚
=3.14 ∗ ( ) ∗ 7 = 21𝑚2
2
𝐷2+𝐷3
A2=𝜋 ∗ ( )∗𝐿
2
𝐷2+𝐷3
=𝜋 ∗ ( )∗𝐿
2
1.17𝑚 + 𝐷3
=𝜋∗( )∗𝐿
2
1.17 + (𝐷2 + 2𝑌)
= 𝜋∗( )∗𝐿
2
1.17 + (1.17 + 2𝑌)
= 3.14 ∗ ( )∗7
2
= (25.74 + 22𝑌)𝑚2
A3=𝜋 ∗ 𝐷3 ∗ 𝐿
= 𝜋 ∗ (1.17 + 2𝑌) ∗ 7
= (25.74 + 44𝑌)𝑚2
Insert A1, A2 and A3 into the above equation and re arranging it gives Y=12mm then,
𝐷3 = 𝐷2 + 2𝑌
= 1170 + 2 ∗ 12
= 1,194𝑚𝑚 = 1.194𝑚
Weigh of dryer (W) = volume of shell material*density
(𝐷22 −𝐷12 ) 𝐾𝑔
=𝜋𝐿 ∗ ∗ 7830 𝑚3
4
1.172 − 0.7232 𝑘𝑔
= 3.14 ∗ 7 ( ) 𝑚2 ∗ 7830 3 = 36,402𝑘𝑔
4 𝑚
BSC thesis Page 59

𝑓𝑡
 Peripheral shell speed :50-100𝑚𝑖𝑛
 Solid hold up (i.e. fraction of the shell volume occupied by the solid at any time ) 5-15%
 NTU from1.5 up to 2
𝜋∗𝐿𝐷12
 Volume of drier filled with material= ∗ 0.1
4
3.14 ∗ 7 ∗ (0.723)2
= ∗ 0.15 = 8𝑚3
4
 Weight of material in drier at any time ,w = volume*density
𝑘𝑔
= 5.0265𝑚3 ∗ 753 = 3,784𝑘𝑔
𝑚3
𝑣𝑜
𝐷33 −𝐷22
 Volume of the insulating material= 𝜋 ∗ 𝐿 ( )
4
1.1942 − 1.172
= 𝜋∗7∗( ) = 0.3117𝑚3
4
 Weight of the insulating material=volume*density
𝑘𝑔
= 0.3117*167.1𝑚3 =52kg
Total weight (W) =weight of dryer +weight of insulation +weight of material

=36,402kg+52kg+3,784kg
=40,238kg=88,630Ib
To find the power to drive the drier
𝑟(4.75𝑑𝑤 + 0.1925𝐷𝑊 + 0.33𝑊
𝑝𝑜𝑤𝑒𝑟 =
100,000
Where: r –rpm of the drier
w- Live load, Ib
D- Riding ring diameter, ft. (d+2)
d- shell diameter, ft
W- Total rotating load, Ib
1𝐼𝑏
w=live load=weight of the material=3,784kg*0.454𝑘𝑔 = 8,334 𝐼𝑏
D=riding ring diameter=d1+2=0.723m+2ft

3.281𝑓𝑡
= 0.723𝑚 ∗ + 2𝑓𝑡 = 4.37𝑓𝑡
1𝑚
BSC thesis Page 60

Assume the peripheral speed of rotation to be 25ft/min

𝑓𝑡
𝑝𝑒𝑟𝑖𝑝ℎ𝑒𝑟𝑎𝑙 𝑠𝑝𝑒𝑒𝑑 25
𝑚𝑖𝑛
𝑟 = 𝑟𝑝𝑚 = = = 4rpm
𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 6.2𝑓𝑡
The revolution of the drier various between 2 and 5.therefore the above can be accepted.
4.75∗0.723∗8,334+0.1925∗4.37∗88,630+0.33∗88,630
BHP=4 ( ) = 5.3𝐵𝐻𝑃
100,000
33.62𝐾𝑊
5.3BHP*45.08𝐵𝐻𝑃 = 3.95𝐾𝑊
BSC thesis Page 61

4.7. FLOW SHEET OF SOY MILK PRODUCTION FROM SOY BEAN
Raw soybean
P-23
Destiner
V-7 V-9 V-13
V-8 V-10 P-26
P-23
Water tank
E-43
Washing tank
E-14
E-15 Soaking tank

Boiling tank
E-33
E-18
E-22
Waste
grinding
V-11 DE hulling
P-27
E-36
P-27
Dry okara
filter E-34 Bagging

V-14 Drier
E-40
Plate heat exchanger

Homogenizer
Bottling
V-17
Figure 4.5. Flow sheet of production of soy milk from soya bean
BSC thesis Page 62

4.8. CLEANING OF DAIRY EQUIPMENT
4.8.1. Aspects of cleaning

The arrangements for cleaning equipment that comes in contact with products are an essential
part of a food processing plant. It must be kept in mind that food manufacturers are always
obliged to maintain high hygienic standards; this applies both to the equipment and, naturally, to
the staff involved in production.
4.8.2. Objectives of Cleaning

As concerns of cleaning results, the following terms are used to define the degree of cleanliness:
• Physical cleanliness – removal of all visible dirt from the surface;
• Chemical cleanliness – removal not only of all visible dirt but also of  microscopic residues which
can be detected by taste or smell but are  not visible to the naked eye;
• Bacteriological cleanliness – attained by disinfection;
• Sterile cleanliness – destruction of all micro-organisms.
It is important to note that equipment can be bacteriologically clean without necessarily being
physically or chemically clean. However, it is easier to achieve bacteriological cleanliness as a
matter of routine if the surfaces in question are first rendered at least physically clean.
In dairy cleaning operations the objective is nearly always to achieve both chemical and
bacteriological cleanliness. The equipment surfaces are therefore first thoroughly cleaned with
chemical detergents and then disinfected.
BSC thesis Page 63

4.8.3. Cleaning procedures
Circulatory cleaning-in-place (CIP) systems adapted to the various parts of a processing plant have
been developed to achieve good cleaning and sanitation results.
Cleaning operations must be performed strictly according to a carefully worked out procedure in
order to attain the required degree of cleanliness. This means that the sequence must be exactly
the same every time.
The cleaning cycle in a dairy comprises the following stages:
• Recovery of product residues by scraping, drainage and expulsion with  water or compressed air;
• Pre rinsing with water to remove loose dirt;
• Cleaning with detergent;
• Rinsing with clean water;
Disinfection by heating or with chemical agents (optional); if this step is  included the cycle
ends with a final rinse, if the water quality is good. Each stage requires a certain length of time
to achieve an acceptable result.
4.8.4. Cleaning-in-place systems

Cleaning-in-place means that rinsing water and detergent solutions are circulated through tanks,
pipes and process lines without the equipment having to be dismantled. CIP can be defined as
circulation of cleaning liquids through machines and other equipment in a cleaning circuit. The
pas- sage of the high-velocity flow of liquids over the equipment surfaces generates a
mechanical scouring effect which dislodges dirt deposits. This only applies to the flow in pipes,
heat exchangers, pumps, valves, separators, etc.
BSC thesis Page 64

4.8.5. Programs
Dairy CIP programs differ according to whether the circuit to be cleaned contains heated surfaces or not.
We distinguish between:
• CIP programs for circuits with pasteurizers and other equipment with  heated surfaces (UHT,
etc.).
• CIP programs for circuits with pipe systems, tanks and other process equipment with no heated
surfaces.
The main difference between the two types is that acid circulation must always be included in the
first type to remove encrusted protein and salts from the surfaces of heat-treatment equipment.
A CIP program for a pas- teuriser, "hot components", circuit can consist of the following stages:
1. Rinsing with warm water for about 10 minutes.

2. Circulation of an alkaline detergent solution (0.5 – 1.5%) for about  30 minutes at 75°C.
3. Rinsing out alkaline detergent with warm water for about 5 minutes.
4. Circulation of (nitric) acid solution (0.5 – 1.0 %) for about 20 minutes at  70°C.
5. Post-rinsing with cold water.
6. Gradual cooling with cold water for about 8 minutes.
A CIP program for a circuit with pipes, tanks and other “cold components" can comprise the following
stages:
1. Rinsing with warm water for 3 minutes.
2. Circulation of a 0.5 – 1.5% alkaline detergent at 75°C for about  10 minutes.
BSC thesis Page 65

3. Rinsing with warm water for about 3 minutes.
4. Disinfection with hot water 90 – 95°C for 5 minutes.
5. Gradual cooling with cold tap water for about 10 minutes (normally no  cooling for
tanks). [10]
4.9. ECONOMIC ANALYSIS
4.9.1. Capital cost estimation
Total capital investment of any plant can be including in its side both fixed capital
investment and working capital investment. Total capital investment = fixed capital
investment + working capital investment. To estimate fixed capital investment of the plant,
first find the cost of each purchased equipment cost.
4.9.2. Equipment cost
The installation of equipment involves costs for labor, foundations, supports, platforms,
construction expenses, and other factors directly related to reelection of purchased
equipment. There is general range of installation cost as a percentage of the purchased-
equipment cost for various types of equipment. Installation labor cost as a function of
equipment size shows wide variations when scaled from previous installation estimates.
Table 4.10 shows the cost of selected pieces of equipment.
BSC thesis Page 66

Table 4.10: Purchased equipment’s cost

No Equipment’s Quantity Material of Capacity Cost(birr)
construction
1 DE stoner 1 Carbon steel 4m2 174,000
2 Washing tank 2 Carbon steel 1m3 164,000
3 Soaking tanks 2 Carbon steel 1m3 164,000
4 Cooking vessel 2 Carbon steel 1m3 164,000
5 Holding tank 2 Stainless 2m3 2,228,000
steel
6 Soy bean grinder 1 Cast iron 200-500kg/hr 192,000
7 Soy milk storage 2 Stainless 2.5m3 3,260,000
tank steel
8 DE huller 1 Rubber roller 200-1500kg/hr 230,000
9 Centrifugal pump 4 Cast iron 5 Gpm 190,000
10 Slurry pumps 2 Cast iron 4 Gpm 146,400
11 Boiler 2 Carbon steel 3m3 2,426,400
12 Homogenization 1 Stainless 2.5m3 1,630,000
tank steel
13 Soy milk filter 1 Cast iron 5.76m2 120,000
14 Water cooler 1 Stainless 13m2 848,000
steel
15 Pasteurizer 1 Stainless 13m2 268,000
steel
16 Drier 1 Cast iron 26m2 6,880,000
PEC= 19,084,400ETB
Source: http:// www.mathes.com/
BSC thesis Page 67

4.9.3. Fixed capital investment estimation
Capital investment is the total amount of money needed to supply the necessary plant and manufacturing
facilities plus the amount of money required as working capital for operation of the facilities. This
project considers the proportional costs of each major component of fixed capital investment as outlined
below determination technique of the cost factors presented here are based on a careful study and
associates plus additional data and interpretations. Purchased equipment cost is 40% of fixed capital
investment cost.
𝑃𝐸𝐶 19,084,400
FCI = = = 47,711, 𝐸𝑇𝐵
0.4 0.4
Fixed capital investment values for direct and indirect cost

A. Direct cost (DC)
Direct cost is the type of fixed capital investment costs that directly applicable for plant
erect. It can take 70-85% of FCI range. But used for calculation, 80%. The part of direct
cost listed table 5.2 with range and selected percentage.
The range is on the basis of FCI.
Table 4.11: Direct cost
Direct Range Assumed Cost(birr)
component % FCE
cost
Total 15-40 40% FCE 19,084,40

purchased- 0
equipment
Piping 3-20 6 2,862,660

(installed
Instrumentati 2-8 4 1,908,440

on and
BSC thesis Page 68

controls
Electrical 2-20 6 2,862,660

installed and
lab
Building 3-18 11 5,248,210

including
service
Yard 2-5 4 1,908,440

improvement
Service 8-20 9 4,293,990

facilities
Land 1-2 2 954,220
Total direct cost 33,947,06

0
(Source: max s.peters, kalusd.timmerhaus, 1991).
BSC thesis Page 69

B. Indirect cost
Indirect cost is another type of fixed capital investment cost that aicable for plant erect indirectly.
The table shows categories of indirect cost p art with ranges and selected percentage.
Table 4.12 Indirect cost
Direct Range Assumed Cost(birr)
component % FCI
cost
Engineering 4-21 5 2,385,550

and
supervision
Construction 4-16 5 2,385,550

expense
Contractors 2-6 3 1,431,330

fee
Contingency 5-15 10 4,771,100
Total indirect cost 13,763,940
(Source: max s.peters, kalusd.timmerhaus, 1991).
Therefore:
FCI = DC + IC =33,947,060+ 13,763,940
FCI = 47,711,000ETB
4.9.4. Total capital investment
The total capital investment = fixed investment + working capital investment

In most plants working capital investment takes (10-20) % of total capital investment. In this
plant, it is assumed that 15% of total capital investment.
BSC thesis Page 70

Therefore, Total capital investment = fixed capital investment + working capital investment
TCI = FCI + 0.15TCI
𝐹𝐶𝐼 47,711,000
TCI = 𝑇𝐶𝐼 = (1−0.15) = 0.85
TCI = 56,130,588birr and working capital will be the difference of total capital investment and fixed
capital investment
WCI = TCI – FCI = 56,130,588-47,711,000
WCI = 8,419,5871birr
4.9.5. Total operational cost estimation
Determination of the necessary capital investment is only one part of a complete cost estimate. Another
equally important part is the estimation of costs for operating the plant and selling the Products. These
costs can be grouped under the general heading of total product cost. The latter, in turn, is generally
divided into the categories of manufacturing costs and general expenses. Manufacturing costs are also
known as operating or production costs. Further subdivision of the manufacturing costs is somewhat
dependent upon the interpretation of direct and indirect costs. Fixed charge is 10-20%TPC
I. Manufacturing Cost=Fixed charges +Direct production costs +Plant overhead costs

A. Fixed charges
Expenses are always present in industrial plant whether or not the manufacturing process
in operation.
1. Depreciation
The annual depreciation rate for machinery and equipment ordinarily is about 10% of the
tied-capital investment.
Depreciation=0.1*47,711,000=4,771,100birr/year
2. Currently in Ethiopia each region is voluntary to provide local tax (LT) and land rent (LR) freely for
the investor as result no cost is estimated for them.
3. Insurance (I) = 1% of FCI

= 0.01*47,711,000
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= 477,110birr
Subtotal of fixed charges = d + I + LT +LR
= 4,771,100+477,110+ 0 + 0
=5,248, 210birr
(Subtotal of fixed charges)=15% of the total product cost (TPC)
5,248,210 birr=0.15*TPC
TPC=28,988,066birr
B. Direct production cost

1. Raw material cost (RM) = (10-50) %of TPC, take 20%
=0.2*28,988,066
=5,797,613 birr
2. Operating labor (OL) = (10-20) % of TPC, take10%
OL= 0.1*28,988,066=2,898,806 birr
3. Direct supervisory and clerical labor (10-25) of TPC, taking 12%
0.12*28,988,068=3,478,567birr
4. Utilities (U) = (10-20) of TPC, take 13%
0.13*28,988,066=3,768,448 birr
5. Maintenance and repairs= (10-20) of FCI, take10%
0.1*47,711,000=4,771,100birr
6. Operating supplies= (0.5-1) of FCI, Take 0.5%
0.005*47,711,000=238,555 birr
7. Laboratory charges= (10- 20) % of operating labor, take 10%
0.1*2,898,806=289,880birr
8. Patents and royalties= (0-6) % of TPC take 2%
0.02*28,988,066=579,761birr
Subtotal direct production cost is the sum of from
(1-8) listed above will be = 17,822,363birr
C. Plant-overhead costs
= (5- 10) % of TPC, take 5%
0.05*28,988,066=1,449,403birr
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Manufacturing cost = A + B + C =24,519,976 birr

II. General expenses
General expenses=administrative cost+ distribution and selling costs +research and development costs
a. Administrative costs
= (2-6) % of TPC, take 2%
=0.02*28,988,066
=579,761birr
b. Distribution and selling costs
= (2-20) % of TPC, take 3%
=0.03 * 28,988,066
=869,641birr
c. Research and development costs
= 5% TPC
=0.05*28,988,066
=1,449,403 birr
d. Financing (interest) = (0-10) of TCI, take 3%
=0.03*47,711,000birr,
=1,431,330birr
Subtotal of general expenses is the sum of from (a-d) listed above will be=4,330,135birr
Total income and expense

Total annual product of the plant is 2,216,655lit milk/year (this determines from market study) which
yieldsokra of amount 951,515kg/yr and with a corresponding grains and fiber of 82,299kg/yr. The
selling pricesof okra is 8birr/kg and for fiber and other grains=2kg/yr.
𝑡𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑐𝑜𝑠𝑡

The minimum unit cost for soy milk= 𝑎𝑛𝑛𝑢𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡
28,988,066
= 2,216,655 = 12birr/lit
Therefore the unit price for soy milk is =15birr/lit (this already determine from market study)
BSC thesis Page 73

Income from milk=annual capacity *unit price

=2,216,655*15
=33,249,825birr/year
Income from okara=8*951,515
=7,612,120birr/year
Income from grains and fibers=2*82,299
=164,598birr/year
Total income=41,026,543birr/year
Total expense= Manufacturing costs + General expenses
=24,519,976+4,330,135
=28,850,111birr/year
Breakeven point (volume)
TPC= annual sales

28,988,066 = 𝑄 ∗ 15
Q=1,932,537lit/year
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4.9.6. profitable analysis

A. Gross profit
Gross profit= total income –total expenses
= 41, 026,543-28,850,111
=12,176,432birr
B. Net profit
Net profit=gross profit (1-income tax)
Recent tax in Ethiopia (30-40) % we take we take the average = 35% income tax.
Net profit= 12,176,432(1-0.35)
=7,914,683birr
C. Payback period
Now taking the minimum acceptable rate (Mar) = 12%

Taking the percentage of fixed capital investment to total capital investment
𝐹𝐶𝐼 47,711,000
%= = = 0.85
𝑇𝐶𝐼 56,130,588
0.85 0.85
𝑃𝐵𝑟𝑒𝑓 = 0.85 = 0.85 = 4.5𝑦𝑒𝑎𝑟
𝑚𝑎𝑟 + 0.12 +
𝑛 12
𝐹𝐶𝐼 47,711,000
𝑃𝐵𝑝 = = = 2.1 𝑦𝑒𝑎𝑟
𝑁𝑝 + 𝑑 7,914,683 + 4,771,100
Since PBP <PBref, The project is feasible
Where PBref = pay back reference

PBP = Payback period
Mar=minimum acceptable rate
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n=12(life of project)
d= depreciation
D. Rate of return on investment (ROI)

𝑁𝑝
𝑅𝑂𝐼 = ∗ 100
𝑇𝐶𝐼
7,914,683
∗ 100 = 24%
56,130,588
Since 24% >12% so, the project is feasible
E. Annual cash flow
Annual cash flow = NP + d
= 7,914,683+4,771,100
=12,685,783 birr
F. net present worth (NPW)
The service life is, n=12yr
I=12%, d = 4,771,100birr
Annual cash flow(R) =12,685,783birr
Now convert to present value (i = 12%, discount rate)

𝑅((1+𝑖)𝑛 −1)
𝑃= + 𝑟𝑒𝑐(1 + 𝑖)−𝑛 , 𝑏𝑢𝑡 𝑟𝑒𝑐 = 0 Where rec= recovery
𝑖(1+𝑖)𝑛
12,685,783((1+0.12)12 −1)
= p=present worth of an annuity
0.12(1+0.12)12
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36,737,723
= = 78,580,487𝑏𝑖𝑟𝑟
0.46
𝑝 =78,580,487birr
Therefore:
NPW = P
= 78,580,487 – 56,130,588
= 22,449,899 birr, therefore the value of NPW is positive the project is acceptable and feasible.
G. Discount cash flow rate of return (DCSRR or

IRR)
NP = 7,914,683birr and d =4,771,100birr
Annual cash flow(R) = 12,685,783birr
∑18
1 𝑁𝑃𝑊 = + Recovery ( - TCI
Recovery (rec) = 0
12
∑ 𝑁𝑃𝑊 = 0
1
The return obtained from an investment in which all investment and cash flow are discounted.
𝑅((1 + 𝑖)𝑛 − 1)
= 𝑇𝐶𝐼
𝑖(1 + 𝑖)𝑛
12,685,783((1 + 𝑖)12 − 1)
= 56,130,588
𝑖(1 + 𝑖)12
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((1 + 𝑖)12 − 1)
= 4.423
𝑖(1 + 𝑖)12
From appendix I, the approximate value of “I” is 0.2016.
Therefore the discount cash flow rate of return (DSRR) is 20.2%; DSRR is greater than minimum
acceptable rate (mar) so, the project is acceptable
Cumulative
Cash flow
Breakeven Point ( BP )
Payback period = 2.1 Year

year
0 project life 12
Figure 4.6 commulative cash flow
BSC thesis Page 78

5. RESULT AND DISCUSSION
5.1.SOYMILK
An experiment was conducted to study the effect of different methods used for preparation of
soymilk.. To conduct the research work four samples prepared as follows. In this study, Process A was
cold extraction of Soymilk, Process B was hot extraction of Soymilk treated with blanching before
socking for 6 hour, Process C was hot extraction of Soymilk treated with blanching after socking for 6
hour, Process D was hot extraction of Soymilk treated with blanching before socking for 10 hour.
Soymilk from the four processes were evaluated for their physio-chemical parameters and proximate
composition and summarized as shown in table 5.1 and table 5.2.
Table 5 .1: proximate composition of soy milk
Proximate method A Method B Method C Method D
composition
Ash (%) 0.3 0.45 0.5 0.4
Fat (%) 1.9 1.65 1.85 1.6
Moisture (%) 1.01 1.00 1.02 1.0
Tss 8.25 7 7.40 6.25
Table 5.2: sensory tests panel scores of soy milk processing techniques
Quality attribute Method A Method B Method C Method D
Color Light Pale yellow Pale yellow Pale yellow
Flavors Strongly Beany weakly beany Slightly beany Slightly beany
Taste Strongly rancid Clean milky Less rancid Less rancid
Mouth-feel Less Normal Slightly less Medium
PH 6.5 6.4 6.68 6.62
The experimental data analysis result of the soymilk on the four different samples taken indicate some
variation in their solid yield (%), total solid, fat and ash content as shown on table 5.1 and table 5.2. The
solid content of soymilk for all the samples varied from 6.38% to 8%. The highest solid content is found
in sample A and it is due to limitation of solubility at the time of grinding.
BSC thesis Page 79

The pH value varies from 6.4 to 6.68. The lower PH value is found in the second method, method B. As
it is shown on table 4.2, the quality of the produced milk is better for method B. the flavor, taste, mouth
fill and its shelf life characteristics of the milk produced using method B is better than the other three.
5.1.1. result justification

This is due to the lipoxygenase activity and trypsin inhibitor activity decrease with temperature increase
and decrease in pH value. Besides, the yield is also increases as the temperature increases. The milk
processed by cold process has beany flavor and light color that is not acceptable by customer. The best
process flow diagram of soy milk production is as follow.
Whole soybean water Hot water Water
Waste Sorting Washing Waste water

Boiling Soaking
Hot water
Grinding De hulling
At 910c (pulp) skin
Holding at
850c
Filtration Cooking at Flash cooling

910c To 750c
Okara
Packaging Soymilk pH Cooling to

6.4 250c
Figure5.1 flow diagram of soymilk production
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5.2.BYPRODUCT OF SOY MILK
 Edible oil
The experimental result indicated that the PH value (5.6), color and specific gravity approach to the
standard. From 60g of okara we got 20ml of edible oil and after oil extracted the bread prepared from
okara flour by proportionally mixing and the following result on table 5.3 obtained.
Table5.3 physical characteristics of okara with wheat flour
Sample Texture flavor Color
25 g okara with 75g wheat flour Soft sweetness Light white
50 g okara with 50 g wheat flour Hard salt Light yellow
100g okara alone Brittle Bitterness Deep yellow
From the above sample analyzed, 25g okara with 75 g wheat flour gives sweetness flavor, soft texture is
acceptable more.
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6. CONCLUSION AND RECOMMENDATION
6.1.CONCLUSION
Soy milk of different protein concentration was prepared from different water to bean ratios based on
hot and cold extraction, to investigate how this would affect various physical characteristics of soy
milk particles. The different methods of soy milk preparation are found to influence its protein
content. The differences in protein value might be due to the effects of heat treatments of blanching,
boiling and pasteurization.
The result of the research work shows that the best process of producing soy milk is boiling before
socking. This indicate that temperature have its own effect on the quality of soy milk production. In
addition, the use of soy milk as opposed to soy protein isolates provides a more efficient and direct
conversion of soy bean to edible food products like oil and flour.
Evaluating the economical aspect of the project which is intended to produce milk from soya bean
shows that it is very feasible with attractive working environment and has positive perception by
society with any background.
Lastly, from the experimental work as well as from the project evaluation, it is possible to conclude
that soy milk production by boiling before soaking yields a better product quality which has nearly
the same physical properties as cow milk but with additional benefits like low fat content,
consumable during fasting time and free from any allergic nature is highly feasible economically and
can contribute a lot in the industrialization process of the country.
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6.2.RECOMMENDATION
It is already agreed that soya bean is industrial crop with diversified uses. The need of soya food
products are emerging in our country. Investigating the appropriate chain between farmers, processers
and marketers will have high contribution for better quality products including unwanted chemical
formation during harvesting and distribution. In addition, studying the consumers feeling on soya
products is very crucial to make improvement on tastes and odor of the products. Based on the
observation and the research result we recommend that:
 Soy food processors and manufacturers selling soy-based products should tailor their products
to the tastes of the individuals who are most likely to buy their products to boost sales.
 The soy industry must endeavor to improve consumers’ motivation. Results from the study
shows that this variable act in conjunction with perceived soy health benefits construct to
determine the likelihood of participation and consumption of soy food products. This variable
which is related to diet-disease awareness suggests that an effective marketing tool may be to
highlight the disease element of poor nutrition. Marketers can therefore capitalize on this issue
in their advertising and promotion campaigns.
 Finally it is also recommended that government and other stakeholders interested in investing
in the soy industry should do so via the consideration of the producer price incentive
component purchasing, processing and utilization channels to boost the interest of producers
(farmers) to cultivate more, and to provide more employment avenues for the unemployed.
 This research work shows that the soy bean products are so diversified and investors who are
interested on then will have enormous opportunities in many aspects and giving attention for
the sector is very timely and prosperous.
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REFERENCE
[1].Giblin, James. Milk: The Fight for Purity.
[2]. ^”Food Outlook –Global Market Analysis” (pdf). Food and Agriculture organization of the United
Nations. May 2012. Pp. 8, 51-54
[3]. ^ Gussekloo, S.W.S. (2006). "Chapter 2: Feeding Structures in Birds". In Bels, V. Feeding in
Domestic Vertebrates: From Structure to Behavior. CABI Publishing. p. 22. ISBN 978-1-84593 063-9.
"A remarkable adaptation can be found in the crop of pigeons. During the breeding season the crop
produces a yellow-white fat-rich secretion known as crop milk that is used to feed the nestlings. … The
crop milk resembles strongly the milk produced by mammals, except for the fact that carbohydrates and
calcium are missing in crop milk."
[4]. Khaleque, A., W. R. Bannatyne and C.E. Wallace, (1970), Studies on the processing and
properties of soymilk I.—Effect of preprocessing conditions on the flavour and compositions of
soymilks. Journal of the Science of Food and Agriculture, 21: 579–583
[5]. (Osho, 1991).
[6]. (Shurtleff and Aoyagi, 2007).
[7].Laswai HS, Thonya N, Yesaya D, Silayo VCK, Kulwa K, Mpagalile JJ and WRW Ballegu.
2009. Use of locally available flavouring materials in suppressing the beany taste in soymilk.
African Journal of Food, Agriculture, Nutrition and Development; 9(7): 1548-1560
[8]. (Millie Miu-Yee Wong). Effect of Processing Methods on the Chemical and Physical Properties of
Soybean Milks.
[9]. Jacobs, Morris B. The chemistry and technology of food and food products, vol. 2. New York,
Interscience Publishers, 1951. 1769p.
[10]. American College of Allergy, Asthma and Immunology. 2010. Milk Allergy. Available from:
http://www.acaai.org/allergist/allergies/Types/food-allergies/types/Pages/milkallergy.aspx. Accessed
2013 Auguet 17.
[11]. (Naazetal., 2003).
[12]. (AHA, 2000).
[13]. (Fukushima, 2000).
[14]. (Teixeira et al., 2000).
[15]. (Chen et al., 2003).
[16]. (Anderson, 2003).
BSC thesis Page 84

[17]. Shurpalekar, S.R. Et al. Chemical composition and nutritive value of soya-bean and soya-bean
products. Food Science, Mysore 10:52-64. 1961.
[18]. Wilgus, H.S. Jr., L.C. Norris and G. F. Heuser. Effect of heat on nutritive value of soy bean
meal. Industrial and Engineering Chemistry 28:586-588. 1936.
[19]. Erickson (1995) and Lui (1999).
[20].Wilkens, W. F., Mattick, L. R. and Hand, D. B., Effects of processing method on oxidative off-
flavours of soybean milk. Food Technol., 1967, 21, 1630 –1633.
[21]. (Nelson et al., 1997).
[22]. (Liu, 2005).
[23]. (Weingartner, 1996).
[24]. (Kwok et al., 1995).
[25] .lson, Murphy and Gallagher 1992).
[26]. (WI (Kwok and Niranjan 1995).
[27]. (Golbitz 1995; Kwok and Niranjan 1995).
[28]. (Bourne, and others, 1976).
[29]. (Liu, 1997). Hackler et al (1963)
[30]. (O’Toole, 1999).
[31]. Characteristics and use of okara, the soybean residue from soy milk production. Agric. food
chem.., 1999, 47 (2), pp 363-371
[32]. (Khare et al., 1995).
[33]. Characteristics of Proteins from Fresh and Dried Residues of Soy Milk Production
YupornPuechkamut1,* and Woralak Panyathitipong2
[34]. Resource potential and opportunity study, project identification, selection and profile preparation-
done by Addis Ababa city administration investment authority
[35].Plant economics and design for chemical engineer by Max S.peters and Klaus D.timmerhaus,
1991
[36]. NTPEL-Chemical engineering Design –II(MODULE FOURE)
BSC thesis Page 85

Appendices
Appendix I:
Table a: Iteration method
I i +1 (i+1)12 (i+1)12-1 i(i+1)12
(𝒊 + 𝟏)𝟏𝟐 − 𝟏
𝒊(𝒊 + 𝟏)𝟏𝟐
1 2 4,096 4,095 4,096 0.9997
0.8 1.8 1,156 1,155 924.8 1.2489
0.6 1.6 281 280 168.6 1.6607
0.4 1.4 56 55 22.4 2.4553
0.28 1.28 19 18 5.32 3.606
0.2 1.2 8.9 7.9 1.78 4.4382
BSC thesis Page 86

APPENDEX II
SOYA MILK PRODUCTION FROM SOYBEAN PLANT LAY OUT
Boiling
Expansion area
house
Production
Raw material storage Area
Water
Storage tank
Product storage
n
atio
i n istr g
m in
Ad b u l i d
Water
Treatment area
By product
Clinic
storage
Cafeteria
Toilet
security
BSC thesis Page 87

APPENDEX III
Weighting of soy bean cleaning of soy bean boiling before soaking soaking after boiling
Clean soy bean Fiber after de hulling Grinding soy bean Temperature
After de hulling with hot water control after grinding
Filtration Okara after filtration Pasteurization of soy milk Soy milk after pasteurize
BSC thesis Page 88

Tray dryer okara flour Bread
Sox- let apparatus oil dry oven
BSC thesis Page 89

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Soy milk process development and optimization 2016

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1.2. PROBLEM OF THE STATEMENT

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1.3. OBJECTIVES OF THE STUDY

1.4. OUTCOME OF THE RESEARCH

1.5. THE SCOPE OF THE STUDY

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2.2. SOY PRODUCTS

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2.2.1. Health Benefits from Soya bean Consumption:

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2.3. SOYMILK AND SOYMILK PROCESSING METHODS

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Table 2.1compositions of cow milk and soy milk

Source: taken from Liu (1997), adapted from Chen (1989).

2.3.2. soymilk processing methods

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The degree of milling influences digestibility and palatability. [22]

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2.3.3. By products of soy milk

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3. MATERIAL AND METHODS

3.2. METHOD OF PREPARATION OF SOY MILK, OIL AND FLOUR

3.2.1. Production of soy milk

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Table 3.1 flow chart four methods of soy milk production

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 Total Solids Content

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 ash (by furnace method)

 lipid (by sox let extraction method)

3.2.2. Production of oil and flour from okara

Physical characterization of edible oils

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 Determination of Specific gravity:

B. Making of bread from okara flour

Physical characterization of okara flour

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4. DESIGN AND ECONOMICAL EVALUATION OF SOYA MILK PRODUCTION

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Table 4.1 domestic consumption of milk

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Table4.2.Soy bean Production and area coverage in Ethiopia (2000/01-2011/12)

Table 4.3 Demand Projection (tons)

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Table4.4. Projected demand for soya bean milk (liters)

C. Pricing and Distribution

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 Availability of raw material

4.2. PLANT CAPACITY AND PRODUCTION PROGRAMME

- based on annual productivity of soya bean

II. Production Program

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Table 4.5production program

III. Raw and auxiliary materials

Cost, [ '000 Birr]