ARBAMINCH UNIVERSITY

SAWLA CAMPUS

INDIVIDUAL PROJECT

COURSE NAME: PLANT DESIGN AND LAYOUT

DESIGN AND LAYOUT FOR A BISCUIT PROCESSING PLANT

NAME: ABRHAM ANLEY

ID: RAMIT/1211

FEBRUARY 2023

SAWLA, ETHIOPIA
Table Contents
CHAPTER ONE........................................................................................................................................3

1. INTRODUCTION...................................................................................................................................3

1.1 BACKDROUND....................................................................................................................................3

1.2 Statement of the problem.................................................................................................................4

1.3 Objectives..........................................................................................................................................4

1.3.1 General objective......................................................................................................................4

1.3.2 Specific objectives.....................................................................................................................4

1.4 Location selection..............................................................................................................................4

 CHAPTER ONE
1. INTRODUCTION
1.1 BACKDROUND
The word 'Biscuit' is derived from the Latin words 'Bis' (meaning 'twice') and 'Coctus' (meaning cooked
or baked), history evidence is that biscuits are made since 17th century. Typically, biscuits are small
baked products made principally from flour, sugar and fat. They typically have a moisture content of less
than 4% and when packaged in moisture proof packing material has a long shelf life, perhaps six months
or more. The appeal to consumers is determined by the appearance and eating qualities. Biscuits are
mainly of two types: hard dough and soft dough biscuits depending on water activity of dough. Biscuits
are made in many shapes and sizes with or without embossed designs or logos. They are of different
flavors as well they may be coated with chocolate, sandwiched with a fat-based filling. Biscuit making is
a conventional activity in India and in many other countries. The biscuits are produced by organized
sector in large quantities, however, unorganized sector having prominent share in market. Despite the
advent of modern, large capacity and automatic biscuit making plants, large section of people especially
in semi-urban and rural areas still prefer fresh biscuits from local bakery as they are cheap and offer many
varieties. These manufacturers are able to cater to some typical local palate as well. Thus, they are able to
withstand competition from organized sector units.
Biscuits is a truly worldwide food. They are manufactured in almost every country with similar
equipment and process. Biscuit are the first and best convenience food: Biscuit have a long shelf life; are
eaten straight from the pack; and are nutritious and available in many forms both sweet and savory.
Biscuits have many functional forms, enriched with calcium, iron and vitamins and formulated for
infants, children and the elderly and for those with special needs such as gluten free foods. Biscuits
broadly fall in to four categories, distinguished by their recipes and process: crackers; hard sweet and
semi-sweet biscuits; short dough biscuits; and cookies, including filled cookies. Each category and each
product type require a particular mixing, forming and baking process. In general, the biscuit making
process has the following main steps. Mixing and fermentation or dough standing time is usually a batch
process.
The forming, baking, oil spraying, cooling are continuous operations with a high degree of automation. It
will be seen that biscuit production equipment must meet a wide range of process requirements to
produce the structure, texture, volume, appearance, color, and moisture content required by each product.
The abilities to mix and form the dough’s and to control heat transfer, baking temperature profile, time
and humidity are critical factors in producing good quality products. Require no preparation eaten straight
from the pack, have along shelf life, 6–12 months, Nutritious, providing protein and energy and can carry
vital minerals and vitamins. Biscuit making is a conventional activity in many parts of the country.
Despite the advent of modern, large capacity and automatic biscuit making plants, large section of people
especially in semi-urban and rural areas still prefer fresh biscuits from local bakery as they are cheap and
offer many varieties. These manufacturers are able to cater to some typical local palate as well. Thus; they
are able to with stand competition from organized sector units. Baking industry is the most stable sector
in the food manufacturing industries. The principal basis for most products in this range is wheat flour.
Addition of water and various other ingredients give us variety of products like cookies, crackers, cakes,
pastries and biscuits. Biscuits are flat, crisp, baked good, whereas cookies are softer and thicker. Cracker
means biscuits of a low sugar and fat content, frequently bland or savory. These types of flour confections
are palatable, easy to carry and don’t require further preparation before consumption and thus they are
considered as staple snacks. Biscuits are one of the most popular snack foods around the world and liked
and enjoyed by people of all 3 age groups. The thing that most people enjoy about a biscuit’s that it can
be taken with anything from a cup of tea or coffee to milk or just nibbled alone.
1.2 Statement of the problem
Globally, it has been estimated that least 251 million children of preschool age are at risk of vitamin A
deficiency (VAD) and 2.8 million children are at risk of VAD and an estimated 1.04 million of these have
clinical signs of the deficiency.
Therefore; the use of pro vitamin A maize flour in substituting VAD. Every year, 250000-500000
children become partially or totally blind from VAD and two-thirds of these children die within a few
months of going blind.
Biscuits constitute an important component of the diet, as such using biscuits as dietary intervention in
combating vitamin A deficiency will produce good result, because it is highly consumed by people of all
age group. Research into the use of tropical crops has shown that biscuits and other pastries such as meat-
pie, cookies, cake etc., could be produced from flours of locally available crops such as sweet potato,
cassava, maize, rice, millet, sorghum etc. Biscuits are one of the most popular bakery products, widely
consumed due to their ready-to-eat nature, good nutritional quality, now cost and longer shelf life and
they are also rich in dietary fibre.
1.3 Objectives
1.3.1 General objective
The general objective of this project is to develop a design and layout for a biscuit processing factory

1.3.2 Specific objectives .

 To identify factors that affect the location selection process
 To develop a biscuit processing plant design and layout
 To perform a location selection operation
1.4 Location selection
Location is primarily influenced by the nature of the product manufactured. The general location and the
specific site should be selected with the aim of attaining as nearly as possible the ideal over-all economic
situation for the particular enterprise, may it be a fluid biscuit plant or biscuit product biscuit. The most
favorable location is one that attains the lowest unit cost in producing and distributing the product or
service to consumers.

1.4.1 Plant Location Selection

This section presents the basic ideas of plant location selection considering the unstable supply of food
raw materials. In the food industry, unexpected conditions, such as natural disasters, abnormal climate, or
the abandonment of cultivation, sometimes lead to shortfalls in the supply of raw materials. In this case, a
food manufacturer should search for alternative sources for food raw materials in other regions. We take
this supply shortage situation into account for a supply vulnerability factor, that is, the possibility of
replacing raw material feedstock using alternative sources. It can be said that if the possibility is small,
the supply vulnerability is high. The plant location selection procedure is illustrated by a case study of
semi processed kimchi production. The case study was chosen upon the request of our research partner,
World Institute of Kimchi, who are aiming to construct a new kimchi processing plant in a suitable
location.
The locations for the sites are:-
1. Bahrdar (site A)
2. Addis Ababa (site B)
3. Adama (site U)
4. Debrezeyt (site Y)`
For the selection process of the best suitable site for the biscuit plant the potential sites are evaluated
against each factor using weight-cum-rating method. Variable weights are assigned to each factor and at
the same time each factor is rated on a scale of 1-5;
1. Very poor
2. Poor
3. Good
4. Very good
5. Excellent
 1. Accessibility and availability of raw materials
2. Accessibility of market
3. Adequacy & availability of labor
4. Adequacy of transportation facilities
5. Volume of power and fuel
6. Water supply and its quality
7. Market Potential
8. Sewage and effluent discharge.
factors Potential sites
Site A BD Site B AA Site U ADAMA Site Y DZ
F1 5 3 4 3

F2 5 5 4 5
F3 4 4 4 4
F4 5 5 5 5
F5 5 5 5 5
F6 5 4 4 5
F7 4 5 4 4
F8 5 3 4 4
Site rating 38 34 34 35
As shown in the above table the sample calculation reveals that site A (Bahrdar) is the best site to locate
the biscuit processing plant.
CHAPTER TWO