Cebu Institute of Technology –University

College of Engineering and Architecture

Department of Mechanical Engineering

MANUFACTURING AND INDUSTRIAL PROCESSES

WITH PLANT VISITS
ME468 – P1 C2

Assignment No. 1
Manufacturing of Rice Cookers and Ice Creams

Submitted to:
ENGR. RAY H. MALONJAO

Submitted by:
HOYUMPA, CHRISTIAN ARNUL C.
BSME - 4
 MANUFACTURING OF RICE COOKERS

I. Product Description

Figure. 1.1. Tatung Rice Cooker

Rice cookers are machines that are designed to steam rice to perfection by using
indirect heat to circulate steam around rice and water from the outer pot to an inner pot.
Preparing rice in an electric cooker is easier than cooking rice on the stove because the cooking
process in the rice cookers took only half an hour.

II. Raw Materials

1. Aluminum Ingots - are aluminum non-ferrous product that is produced by pouring
molten aluminum into special molds.
2. Stainless Steel Disc - is a form of steel containing chromium, resistant to tarnishing
and rust.
3. Thermal Insulation Sheet - this consists of two-layer aluminum foil and inside
polyethylene foam and is used to prevent the heat gain inside of buildings.
4. Porcelain Plate - a nearly translucent ceramic material used to make plates, bowls, and
cups.
5. Steel Shells – it is a connecting piece between middle plate and base of rice cooker and
baked in an oven for about 15 minutes at 390 ℉ for the paint can set.
6. Fuse – it prevents the rice cooker from overheating.
III. Equipments
1. Automated Drilling Machine - which punctures 18 holes through the bottom.
2. Pad Printer - which makes possible the company logo is applied to the shell.
3. Press Machine- where the disc of stainless steel is placed and will mold the steel to
form the inner cooking pot.
4. Pot - which is loaded onto an automated drilling machine.
5. Thermometer – which is used to test the temperature after starting for the approval.
6. Robotic Arm – which scoops ip the required amount of molten aluminum with a ladle.
7. Furnace – where the aluminum ingots are melted.
8. Mold – forms the outer cooking pot.
9. Computer Guided Lathe – used to refine the form of the molded pot.
10. Automated Booth – which paints the rice cooker’s steel shells
11. Oven – where the shells are baked.
12. Hand Drill – which fastens the bolts and screws.

IV. Manufacturing Process Diagram

Fig.1.2. Manufacturing Process Diagram of Rice Cooker.

The figure 1.2 above is a block diagram for manufacturing of pot and assembly the
electric rice cooker is shown. Workers first process aluminum ingots into aluminum disks
which will be stamped to form the exterior pot for the electric rice cooker. Then, press the
aluminum disk into the form for the cooker's outer pot. After metal punching, chrome plating
or spray decoration procedure follows to shiny or decorate the exterior of outer pot. The inner
pot is mad from higher grade aluminum and coated with Teflon for a non-stick surface
 The cooker's heating element is dye cast on site from lower grade aluminum alloy.
After all the parts are manufactured, the electric rice cookers are then partially assembled.
Following assembly, each electric rice cooker is tested for quality assurance prior to
packaging. Legs are screwed into the bottom of the electric rice cooker before the final
packaging. And in the end, the electric rice cookers are packaged and then transported to
the destination.

V. Health and Safety Practices

• Lack of Personal Protective Equipment – the machine operator needs to wear gloves
when operating the mold and drilling machine and wear a face mask in operating the
pad printer to protect him from inhaling small metal particles.

VI. Quality Assurance System

The rice cooker undergoes a temperature test wherein it measures the cooking
temperature using a thermometer.

VII. Current Packing Process

Once approved, the rice cookers are manually packed where a corrugated packaging
material is used to protect the container of the rice cookers because their packaging structure
have an excellent cushioning property.

VIII. Definition of Terms

• Work – measure of energy transfer when an object is moved over a distance by an
external force. In the manufacturing process, work is applied in the lathe and drilling
machines as they move to cut some part of the shell of the rice cooker.
• Power – it is defined as the time rate of doing work or simply the equivalent to the rate
of the energy transfer. In manufacturing process, the equipment’s used are utilizing
electrical power for them to operate.
• Amperage – it is the strength of electrical current needed to make a piece of electrical
equipment work which is measured in terms of amperes or amps. Current is a function
of power, therefore each equipment used in the manufacturing process has its own
current rating to deliver the rated power.
 • Kilowatts – it is a unit of electrical power which determines on how much power is
required for the equipment to operate during manufacturing process.
• BTU – it is an approximate amount of energy needed to heat one pound of water by
1°F at the temperature that water has its greatest density.
• Latent Heat – it is defined as the amount of thermal energy need to change the phase
of a substance without changing its temperature. In the manufacturing process, the
aluminum ingots undergo latent heating.
• Sensible Heat – is defined as the amount of thermal energy needed to change the
temperature of a substance without changing its phase. In the manufacturing process,
steel shells undergo sensible heating which are heated in the oven for 15 minutes at
390°F.
• Enthalpy – sum of the internal energy and the flow work of the system. Enthalpy is
present during the heating process of the manufacturing plant such as melting of
aluminum ingots and heating of steel shells.
• Potential Energy – stored energy by virtue of the body’s position relative to the datum.

MANUFACTURING OF ICE CREAM

I. Product Description

Figure 2.1. Ice Cream

The ice cream sandwich wafers are ice cream filled in chocolate sandwich wafers. The
ice cream cones are wafer cones filled with chocolatey barriers and a filling of a variety of
 flavors such as vanilla, chocolate, fruit flavors, etc. Inside the cone’s core was an injection
of liquid caramel/strawberry/chocolate topped with chocolate-flavored liquid topping and
chocolaty-coated puffed rice.

II. Raw Materials

1. Fresh Cream mixed with powdered skim milk – improves the body and texture of ice
cream and produces a thicker and less ice product.
2. Plant – Based Stabilizers - helps bind together the complex mixture of fats, sugars, air,
and tiny ice crystals present in ice cream and give it a smooth texture.
3. Emulsifiers – which allows the mix to bond with air during the whipping process and sugar
corn syrup.
4. Sugar Corn Syrup – consists mostly of glucose.
5. Concentrated Vanilla Flavoring – is a premium flavoring.
6. Liquid Caramel – a dark liquid prepared from caramelized corn syrup which is used to
add a rich brown color.

III. Equipments
1. Refrigerated Silos – which stores the fresh cream.
2. Half Speed Mixer – which blends the cream with other ingredients.
3. Pumping System – which moves the mixture into pasteurization tanks.
4. Pasteurization Tanks – which heats the mixture to 162°C.
5. Filling Machine – which feeds two lines of wafers toward an injection pipe.
6. Packaging System – which packs the ice cream sandwiches.
7. Feeder – which drops the ice cream cones.
8. Sprayers – which coats the insides of the ice cream cones.
9. Nozzles – which squirts ice cream filling.
10. Injector – Injects the liquid caramel.
11. Hot Dispenser – which applies a wax-coated paper lid.
IV. Manufacturing Process Diagram

Figure 2.2. Manufacturing Process Diagram of Ice Cream.

V. Health and Safety Practices

The production plant adheres to health and safety regulations by practicing proper
hygiene and appropriate protective equipment for the personnel. The plant also maintains a
proper ventilation which is important in preventing microorganisms from growing and
contaminating the ice cream.

VI. Quality Assurance System

The quality assurance system in the making of an ice cream sandwich involves the
quality of the dairy ingredient and flavorings utilized. Also, proper maintenance of the
condition of the storage and manufacturing equipment. The ice cream sandwich water and the
ice cream cone were sealed entirely in the packaging process to prevent the ice cream from
melting in the box.

VII. Current Packaging Process

For the ice cream sandwiches, the packaging system raises each sandwich into a
wrapper, then it folds and tucks the end. The machine counts the sandwiches and inserts them
in the box. For the ice cream cones, the lid dispenser applies paper lid to each cone then the
ice cream cones are transported to the boxes.
VIII. Definition of Terms
• Kinetic Energy – form of energy that an object has by reason of its motion. It is a
property of a moving object of an ice cream.
• Acceleration – rate at which velocity changes with time. Acceleration is present in the
manufacturing process specifically in the transport equipment which moves the
products.
• Momentum – the product of the mass of a particle and its velocity. The ice cream
sandwiches and cones possess momentum as they are being transported by the transport
equipment.
• Energy – the ability to do work. In the manufacturing process, the mixer equipment
applies energy to the fresh cream to blend it with other equipment.
• Reaction Heat – energy that is released or absorbed when chemicals are transformed
in a chemical reaction. The manufacturing process heavily relies on refrigerating the
products to maintain good quality.
• Water Hammer – pressure surge caused when a fluid in motion stops or suddenly
changes direction. During the transport process water hammer can occur from the silos
to the pasteurization tanks.
• Mole of Gas – the molar volume of gas is the volume of one mole of gas at standard
temperature and pressure. Mole of gas is applied during the whipping process which
mixes the mixture with air.
• Molecular Weight – mass of a molecule of a substance. The manufacturing process
involves mixing of different substances with different molecular weights.
• Gas Laws – laws that relates the pressure, volume, and temperature of a gas. Gas laws
can be applied when the mixture is mixed with air during the whipping process.
• Absolute Pressure – pressure that is relative to the zero pressure. To conserve the
properties of the mixture, the silos and pasteurization tanks are at the designed pressure.