ARBAMINCH UNIVERSITY

SAWLA CAMPUS

DEPARTMENT OF FOOD TECHNOLOGY AND PROCESSING ENGINEERING

INDIVIDUAL PROJECT

PLANT DESIGN AND ECONOMICS

DESIGN AND LAYOUT FOR A SOFT DRINK PROCESSING PLANT

NAME: GETU MIRIKAT

ID: 878/11

FEBRUARY 2023

SAWLA ETHIOPIA
 CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND
The term soft drink originated to distinguish the flavored drinks from hard liquor, or distilled
spirits. Soft drinks were recommended as a substitute in the effort to change the hard drinking
habits of early Americans. Indeed, health concerns of modern consumers led to new categories of
soft drinks emphasizing low sugar, low calorie count, low sodium content, no caffeine, and “all
natural” ingredients. (Cayabyab, 2022)

1.1.1 Definition and Classification of Carbonated Beverages

A carbonated beverage is a product filled with carbon dioxide gas under certain conditions.

It is a kind of soft drink (non-alcoholic beverage).

Its main ingredients are sugar, color, sweetener, acidifier, spices and carbonated water, Etc. It
generally does not contain vitamins or minerals. According to the classification standard of
Chinese soft drinks, carbonated drinks (soft drinks) are divided into fruit juice carbonated drinks,
fruit-flavored carbonated drinks, cola carbonated drinks, and other carbonated drinks.

Juice type

The original juice content of not less than 2.5% of carbonated beverages, it has the
corresponding fruit color, aroma, taste, but also contains a certain amount of nutrition, is
conducive to health. Such as orange juice soda, lemon soda, etc.

Fruit flavor type

Edible flavoring as the primary flavoring agent, edible coloring agent coloring, the original juice
content of less than 2.5% of carbonated beverages, giving a specific fruit flavor and color, such
as orange soda, pineapple soda, Etc.

Cola-type

Refers explicitly to carbonated beverages containing caramel color, cola flavoring or similar cola
fruit and fruit flavoring pungent, fruity mixer.
The aroma is coordinated and soft; the taste is pure and refreshing, with a cool and braking taste.
Due to the unique taste, products containing caffeine also have a refreshing effect. On people
often, prefer these products, especially Coca-Cola, Pepsi, Very Cola, and other well-known
brand products that have guided consumption.

Other types

In addition to the above three types of carbonated beverages, such as soda water, saltwater and
carbonated beverages containing non-fruit plant extracts or non-fruit edible flavors.

1.1.2 History of Soft drinks manufacturing

First artificially made carbonated water and drinks were made in late 1700s, but the origins of
those drinks can be found even 2 thousand years ago in ancient Greece and Roman empires who
started noticing beneficiary medicinal effects of natural springs that produced carbonated water.
Because of these medicinal effects, many inventors tried to emulate this effect of carbonization
in chemical laboratories. First two men who managed to do that were Swedish chemist Torbern
Bergman and English scientist Joseph Priestley in second half of 18th century. (Cayabyab, 2022)

After their discovery, other inventors started developing their processes, many patents were
issued and manufacture started, and general population of United States and Europe got the
chance to taste first new products carbonated water and soft drink products. It is important to
mention that one of the reasons why sugary soft drinks managed to become so popular was not
only because they were initially targeted as a “fun summer drink”, but also because pharmacist
infused early soft drink recipes with powerful stimulants that actively tried to change the
emotional state of the user. Most popular of these stimulants were coffee, cola nuts and coca
leaves, all able to ward off fatigue and clear mind for brief moments. (Cayabyab, 2022)

Beverage industry in Ethiopia

Ethiopia is the second most populated country in Africa; it represents a largely untapped
consumer market. There is growing demand for carbonated soft drink as well as bottled water;
although the majority of Ethiopians still drink home brewed beer branded, alcoholic beverages
are becoming increasingly popular amongst upwardly mobile members of society.
During the past five years, foreign companies have made substantial investments in the Ethiopian
beverages industry and several manufacturers have expanded their installed capacity in an effort
to meet growing demand

1.2 Statement of the problem

A smooth manufacturing process can be achieved if the plant layout is flexible in flow of
workers, materials and machines. This flexibility can bring about desire goal of minimizing
production cost with little or no industrial accident.

Many industries today are recognized because their products are in high demand and in large
quantity in the market. In these industries, there is good relationships among staff, managements
and the located communities. Within the industries, there are fewer or no record of accidents.
Jobs done comfortably. There is enough working space for various machines, facilities and the
employees. They enjoy a safe and comfortable environment during work. Any industry that is
operating under aforementioned conditions will surely be profitable. All these and more are the
dividends of a carefully planned production layout. Therefore, this project aims to develop a
design for a soft drink processing plant, which will help in production and profit for the
investors.

Therefore, this project aims to select a suitable site and produce design for a soft drink
processing factory.
1.3 Objectives
1.3.1 General objectives
The general objective of this project is to develop a design for a beverage (soft drink) processing
plant

1.3.2 Specific objectives

 To develop plant design and layout for a soft drink processing plant
 To perform site selection for the beverage plant
 To do economic analysis of the plant
 To identify factors that affect the site selection process

1.4 Location selection

Comprehensive site selection process for freight facilities systematically translates the strategic
goals of the company into a business plan for a new operation; and continues the process of
identifying appropriate candidate areas.

Evaluating those areas determining the financial impacts of the move and implementing any
resulting decisions many corporate officials have a stake in the process and each shapes the
process and the relative importance of key factors at different stages in the decision.

While some small or regional companies will make location decisions based upon the
idiosyncratic market and supply chain knowledge of specific individuals many others construct a
more robust site selection process that will result in the application of analytic discipline to the
stated business. Such a process explicitly identifies the key success factors for the new facility
meets the operational requirements verifies financial payback and ultimately supports the
executive decision making process.

This section explores the most common approaches to site selection while noting differences and
alterations that sometimes occur for differing facility or company type.
The location selection process typically begins with an examination of the overall business needs
for the distribution network as a whole or for the new facility in isolation and then follows a
process similar to that shown below to narrow the range of alternatives

Factors determining the location choice for the soft drink processing factory are

 Availability of sufficient land

 Cost of the land
 Availability of raw materials
 Access to transport
 Availability of skilled man power
 Power requirements
 Waste disposal and treatment
 Government regulations

Three different locations were selected as possible sites for the plant. These locations were
selected for different reasons. The three locations were compared and measured using equal
weights method to identify the best plant site.
These locations are

1. Addis Ababa
2. Ambo
3. Sawla

Factors Site A.A Site Ambo Site Sawla

F1 2 4 5
F2 2 4 5
F3 5 3 2
F4 5 4 2
F5 5 4 2
F6 5 4 3
F7 3 3 4
F8 2 4 5
Total 29 30 28

As it can it be seen from the result of the comparison the site that got the highest score was
Ambo. This means that the soft drink processing factory will be located in ambo town;
proceeding further this project takes into consideration the result of the site selection process.
 CHAPTER TWO

2 LITERATURE REVIEW

2.1 Soft drinks manufacturing process

Materials Receiving and Storage

When the facility gets the compounding ingredients, the quality-control staff begins inspecting,
sampling, and analyzing the substances. In the concentrate manufacturing process, only materials
that have passed the testing will be employed. Some of the raw materials are delivered in tank
trucks and need to be handled differently. In the same way as raw materials are received,
evaluated, and analyzed, packaging materials are also received, evaluated, and analyzed.

Water Treatment

Impurities such as suspended particles, organic matter and bacteria may degrade the taste and
color. They are removed through the traditional process of a series of coagulation, filtration and
chlorination (Figure 2). Coagulation involves mixing a gelatinous precipitate, or floc (ferric
sulphate or aluminum sulphate) into the water. The floc helps in absorbing suspended particles,
thus making them bigger in size so that they are easily entrapped by filters. The clarified water is
then made to pass through sand filter aiding the removal of fine floc particles.

Microbiological quality of water is also taken into consideration. The presence of bacteria and
organic compounds hamper the organoleptic quality of water. For disinfecting, water is treated
with small quantity of chlorine and kept in the tank for at least two hours to complete the
reaction. After that it is passed through activated carbon filter which helps in de-chlorinating the
water and also the remaining organic matter. This is followed by deaeration of water by pumping
it through vacuum pump. The water which is to be used should be either soft (Chaudhary, 2021)

Deaeration

Carbonated beverages are very sensitive to the amount of oxygen dissolved in water. Retention
of vitamins, appearance, taste and the storage life of carbonated beverage is influenced by the
dissolved oxygen. In addition to it, dissolved oxygen negatively affects the performance of filler
and also trigger causes excess filler foaming, thus hampering the fill-volume control. Higher the
amount of air in water more difficult it becomes to hold carbon dioxide in the beverage.

Various processes employed for deaerating are

 By pressure
 Vacuum
 Both

In the process of deaeration by using pressure, nitrogen and oxygen are removed from water by
addition of carbon dioxide. Pressure deaeration is used when the levels of dissolved carbon
dioxide content of water is low. Deaeration of water for soft carbonated beverages can also be
done by creating vacuum in the deaeration tank. Water is injected by spraying in the deaeration
tank held under vacuum, whereas the gases nitrogen and oxygen are wheedle out from the water
and drawn out of the deaerator. Deaeration by pressure and/or vacuum can be performed in one
line with the use of liquid ring pump. In this process, water is introduced in a horizontal tank by
spray valves over the perforated plates, thus increasing the surface area which enables proper gas
transfer. The horizontal tank is kept under low pressure so as to remove oxygen. In single stage
de-aeration oxygen levels of 0.5 ppm can be achieved, but in dual stage processes, in which we
use two de-aeration tanks, oxygen level up to 0.03 mg/l or less can be attained. In dual stage,
carbon dioxide or nitrogen can be added for stripping the oxygen. (Chaudhary, 2021)

Preparation of Syrup

Basic ingredient of most of the soft carbonated beverages is sugar syrup, which can be prepared
by combining cane sugar or beet sugar with water. Sugar used may be in granulated or liquid
form. Liquid sugar dissolves directly in water however if it is granulated then it require special
conditions for dissolution such as increased temperature which hasten the rate of solubility. Cane
or beet sugar Soft Carbonated Beverages 103 can also be replaced by high fructose corn syrup
(HFCS). HFCS is a sweetener derived from enzymatically treated corn starch so as to increase its
fructose content. Syrup is produced in concentrated form in the syrup rooms. It includes mixing
of all the ingredients in proportions either manually or automatically with required ratio of water.
Finally the syrup is diluted with addition of carbonated water and bottled.
Mixing –

In this stage, taste and dissolved sugar concentrates are fed into the dosing station in a preset
order based on compatibility. Because the ingredients are carried into batch tanks and too much
agitation can create undesirable aeration, the ingredients are properly blended. The syrup will be
sterilized in the tanks using flash pasteurization and UV radiation in order to swiftly heat and
cool the combination. Fruit-based syrups usually go through a pasteurization process.

Designed soda soft drink devices called “Proportions” to regulate the ratios and flow rates of the
liquids carefully blend the syrup and water. The vessels are pressured with CO2 to prevent the
mixture from aerating (Carbon Dioxide). (Cayabyab, 2022)

Carbonation

Carbonation is the process of impregnating liquid with carbon dioxide. During carbonation the
temperature of the liquid should be low as the solubility of carbon dioxide increases with
decreasing temperature. The gas which is injected into the beverage should be free from
microorganisms and dust particles. The level of carbonation differs with the type of beverage and
the perceived flavor (Table 8). For example fruit drinks require low carbonation as compared to
drinks which are meant to be diluted. During carbonation, carbon dioxide is added to the
beverage in a carbonator, where vaporized carbon dioxide is mixed under pressure with
temperature controlled beverage mix. The flow rate of the beverage and the pressure of CO2 are
significant for required level of carbonation. Greater the surface area of the beverage higher will
be the rate of solubility of CO2. When carbon dioxide is imbibed in the beverage the CO2
bubbles start rising to the surface causing some of the gas to dissolve in beverage. The un-
dissolved portion of CO2 outflow from the surface of the beverage and changes its state from
liquid to gas. The gas fills the space above the beverage. Equilibrium is set between the rate of
release of gas and the rate of dissolution of gas in the beverage. However, the equilibrium
pressure fluctuates with augmentation in temperature or decline in pressure. This equilibrium
breaks with opening of can or bottle and causes the gas to be released spontaneously and the
process is known as foaming. (Chaudhary, 2021)
Filling and Packaging

Soft carbonated beverage prepared according to specifications is filled in bottles or cans. Initially
thick walled, reusable glass bottles were used. In recent years glass bottles are being replaced by
PET bottles which are thin walled and easier to handle during processing and storage. Filling is
done under gravity, in which the flow rate depends on the difference between the container to be
filled and filler basin. Flow rate of beverage increases with increase in the overhead pressure.
Two types of fillers are generally used i.e. gravity fillers and counter pressure filler. Now a days,
volumetric and capacitance probe fillers are also used. The later uses a capacitance probe to
check the point at which filling should be stopped. In the former i.e. volumetric fillers exact
amount of carbonated beverage is introduced in the container. It has a disadvantage that no two
containers will have the exactly same amount of carbonated beverage.
 CHAPTER THREE

3 DETAILS OF THE PROJECT

3.1 Plant layout

Plant layout refers to the arrangement of physical facilities such as machinery, equipment,
furniture etc. Within the factory building in such a manner so as to have quickest flow of
material at the lowest cost and with the least amount of handling in processing the product from
the receipt of material to the shipment of the finished product.

According to Riggs, “the overall objective of plant layout is to design a physical arrangement
that most economically meets the required output – quantity and quality.” According to J. L.
Zundi, “Plant layout ideally involves allocation of space and arrangement of equipment in such a
manner that overall operating costs are minimized.

After analyzing all the factors that affect the following layout was developed for the soft drink
processing plant to be built:
-+

Figure 3-1Plant layout

3.2 Processing flow diagram

Figure 3-2 Soft drink production process

3.3 Equipment Layout

This is the part where a decision is made about where equipment and vessels will fit into the
space. The right layout can make a huge difference to the efficiency, the quality of the product
and the vibe of the plant’s venue.

There are many things to take into account when designing the equipment layout like:

A. Cost reduction

There are so many measures that can be taken to reduce costs in the design of any processing
plant. These are some of our methods:

 Design a layout which flows with the production process to increase efficiency and avoid
redundant tasks and movements
 Utilize vertical space by stretchy vessels out to maximize floor for either better flow or
easier expansion
 Plan for additional space ahead of time this will preemptively save costs of having to
redesign equipment layout later.
 B. Sustaining quality through cleanliness

Steps should be taken to ensure that the facility is clean and the processing equipment is
designed to be cleaned quickly, easily, and effectively, you will be free of contamination
ultimately saving time and money. It will also ensure product quality.

C. Energy efficiency

The plant layout can play a pivotal role in saving energy costs. For example:

 Shortening the distances between steps means a decrease in the amount of required
pumping. Less pumping requires less energy
 Building in heat recovery systems for reuse of heat within floor plan.
 Placing utilities near vessels to reduce piping runs and possible energy loss
Figure 3-3 soft drink processing plant equipment layout

3.4 Equipment’s and Construction Materials Selection

The processing equipment for this soft drink manufacturing plant were selected by referring to
the internet and collecting all the necessary information about the equipment, all the selected
equipment were made from stainless steel and their price and capacity was determined from the
internet.

3.5 Economy of the project

3.5.1 Production capacity
This soft drink processing plant will have the capacity of producing four different drinks, with an
annual production capacity of 868000hl per year or 86800,000 liter per year.

The company works all of the days in the year except Sunday and international calendars from
these the plant will operate for 300days per year without total down time.
From the project demand, the factory will start in 2017 with 23.725% of the present market
demand (4000tons/year)

300days/year*16hr/day=4800hr/year

Basis chosen is in ton/hr.

Plant capacity is 950ton/year

Productivity per day is 950ton/yr*1yr/300days=3.16 ton/day

Converting this in to kg/hr.3.16ton/day*1day/16hr*1000kg/1ton=197.5 kg/hr.

No Processing equipment Cost ($) Capacity

1 Washing Filling Capping Machine 24,000 7500b/hr max
2 RO treatment system 20,000 100tn/hr
3 Carbonator 13,000 100/yr
4 Manufactory and Trading Combo Powder Dissolver 10,000 1000/yr
5 Blender 15,000 1000/yr

3.5.2 Material balance

Mass balance on RO

Hard water treated water 100tn/hr

RO

Water

Using overall mass balance;

There is no change in mass in homogenization process

Mass balance on carbonator

Mev3=?
Evaporator4
Mev4=217kg/hr

Mwater=15%of Mev3

Mass of ev3=mass of milk ev4+ mass of water evaporated

Milk ev3=15%of Mev3 + Mev4

Mev3=0.15Mt +217 kg/hr Mev3=255kg/hr. The mass of evaporated water =38kg/hr

Mev2 Mev3=255kg/hr
Evaporator3

20%of Mev2

Mass of ev2=0.2Mev2+255kg/hr Mass of ev2=318kg/hr

Mass of water evaporated=63.75kg/hr

Mev1 Evaporator2 318kg/hr

20%Mev1

Mass of ev1= 20%Mev1 +318kg/hr

Mass of ev1=397.5kg/hr Mass of water evaporated=79.5kg/hr

 M treated 397.5kg/hr
Evaporator1

72.5%Mtreated

M treated=72.5%Mtreated +397.5kg/hr

M treated=1446kg/hr Mass of water evaporated=1048kg/hr

Mass balance on standardizer

Clarified milk=?Mt=1446kg/hr Clarified milk=3.9%of clarified

Standar
milk +1446kg/hr

Fat=3.9%of clarified milk

SM=0.039Cm+1446kg/hr

SM=1505kg/hr Mfat removed=59kg/hr

The amount of milk input (raw material) to produce 197.5kg/hr of milk powder is 1505kg/hr

Daily milk consumption

Milk required (daily) =milk required/hr*working hour/day

Mwm (daily) = kg/hr*16 hr/day

The daily milk required is 24080 kg

3.6 5.2 Energy balance

The assumptions required for the system are described as follows:

1. No accumulation of material in the system (inlet stream=outlet stream).

2. The type of process takes place is continuous.

3. There is No change in density of material along the process line.

4. The liquids in the process are incompressible.

Based on the temperature profile of the system described from the above:

 Inlet temperature of raw milk to the cooler =20⁰C

 Outlet temperature of raw milk from cooler = 5⁰C
 Boiling temperature of milk is 1200C
 Steam temperature to the first effect of evaporator = 800C
 Specific heat capacity of milk = 3.9 kj/kg. k

Energy balance in the milk cooler

The temperature of raw milk is about 20⁰C inlet to the cooler and the outlet temperature of raw
milk about 5⁰C

T1 (raw milk) = 200C

T2 (coolant) =40C, T2 (raw milk) = 5⁰C
T1 (coolant) =20C

Then we can calculate the amount of heat energy in the cooler by;

Q=M ∗CPΔT

From material balance: M =1505kg/hr= 0.42Kg/sec then;

Q=0.42 Kg/ sec∗3.9 Kj /kg k∗(20−5)=24.5 Kw

from thermodynamic and equilibrium relationship we can calculate the mass flow rate of the
coolant from theseQcold=Qhot

Qcold=M∗Cpw∗ΔTcold

So, Mass flow of coolant (M) = Q/Cpw* ΔTcool where the temperature of coolant T1=2⁰C, T2 =
4⁰C and specific heat of water (Cpw) = 4.18
 M =24.5 /4.18∗(4−2)=2.93 Kg/ sec

LMTD=( Δt 1 – Δt 2)/ ln (Δt 1/ Δt 2) Δt 1=20−4=16⁰ C , Δt 2=5 – 2=3⁰ C

LMTD = (16 – 3)/ ln (16/3) = 7.76⁰C

Energy balance on preheater

According the given data milk is heated up from 10°C to a boiling temperature in the 1st
evaporator effect; to 70°C. Milk heating is done step by step with vapors leaving individual
evaporator’s effects. In the last step heating steam is used.
Q HE = Msm*Cpm*(Tevp - Tsm).
QHE = 1505kg/hr*3.9kj/kg. k* (700C – 100C)
QHE=352170KJ/hr*hr/3600s
QHE=97.83kw
Energy balance on evaporator
Almost all chemical plantsuse fourth effect evaporator for optimum desired product. Falling film
evaporator is used for this system with forward flow sequence. Operating parameters for fourth
effect system
Effect I: mf H f +msHs = (mf -ms1) H1+ms1Hs1 +msHl1
If the sensible heat of the steam is neglected this equation can be rewritten as
Mf Hf +ms λ+ (mf -ms1) H1+ms1Hs1
Effect II: (mf -ms1) H1+ms1λ + (mf -ms1-ms2) H2+ms2Hs2
Effect III: (mf -ms1-ms2) H2 +ms2λ = (mf -ms1-ms2 -ms3) H3 +ms3Hs3
Where,
msk is the rate of vapor generated in the k th effect
mfand ms are the feed and steam flow rate respectively.
Hk is the enthalpy of the solution leaving the kth effect at Ts and Ps
Hsk is the enthalpy of vapor (steam) generated in the kth effect.
Specific heat steam consumption of the evaporator is given as 0.28 and the amount of water
evaporated in the evaporator obtained from the mass balance is 1229kg/hr furthermore the latent
heat at each temperature are as follows;

λ1 @ 00C =2500kj/kg
λ2 @ 1000C=2256kj/kg

Qeva=0.28*Wevap*λ 1

= 0.28*1229 kg/hr *2500kj/kg*hr/3600

Q eva= 239kw

Qev= λ 2*Msteam

Msteam=QEv/λ 2 =239kw/2256kj/kg

Msteam = 0.102kg/s*3600s/hr =381.3 kg/hr

Energy balance on the dryer

Data’s of drying process are shown below;

 In let steam temperature ………………………………………….180o c

 Humidity of in let air…………………………………………….0.011
 Humidity of out let air……………………………………………0.0405
 Out let steam temperature………………………………………….85o c
 Steam velocity must not exceed 2.5m/s in order to avoid dust carries over.
 Cp Solid……………………………………………………………3.9kg/kg. k
 In let temperature of the wet solid…………………………….45o c
 The concentrated milk content… ………………………….45% dry matter.
 Final dry matter of milk……………………………………….0.97
 Final milk powder moisture content………………………….0.03
 The initial moisture content of the Entering milk is…………...55%
 Wet solid flow rate in to the dryer……………………………….217 Kg
Assumptions
Basis of calculation is 1hr operation.
Mass of dry solid Ms = 217 Kg(1-0.55)
Ms = 97.6kg
fraction of wet solid
Moisture in the wet solid X1 = =55/45 = 1.222
fractionof dry solid
Moisture in the dry solid X2 = 0.03/0.97 = 0.03
Ms evaporated = Ms(X1 - X2) = 97.6kg (1.222 – 0.03)
Ms= 116.4kg/hr
If temperature of the feed = 40 oc Temperature of air = 180oC; Y2 = 0.011 It is assumed TG 1 =
85o c (out let temperature)
For solid out let temperature Ts2 = 100o c
Total enthalpy of an air – water vapor mixture
From litratureY1 (humidty of out let air) = 0.0405
Amount of drying air is calculated on this premise. 1kg of dry air with given temperature is able
to take away (y1 – y2) of moisture from a material (milk).
In the dryer it is necessary to take away W DRY = 97.6kg/hr water. Then the theoretical amount of
drying air is. Gs = WDRY/y1 – y2 = 97.6/ (0.0405 – 0.011) = 97.6/0.0295
Gs (mass of air) = 3308 kg/hr
The theoretical amount of heat needed for taking away the amount of water W DRY is (temperature
of dried material is practically T = 44oC). For the temperature, the latent heat of evaporation λ =
2397 kj/kg.k
Q needed for drying = WDRY* λ = 97.6*2397kj/kg,
Q DRYT = 233947KW

3.6.1 RAW MATERIALS AND UTILITIES COST

3.6.2 Equipment and machinery cost

3.6.3 Land building and civil work cost

3.6.4 Man power requirement