Feasibility Study of Rice Milling Plant

Submitted to:

ENGR. ANACLETO CORTEZ JR.

Professor

In Partial Fulfillment of the Requirements in the

Subject

ME-427

(INDUSTRIAL PLANT ENGINEERING)

Leading to the Degree of Bachelor of Science in Mechanical Engineering

Submitted by:

Name

Name

June 16, 2023

 Management Study

A. Pre-Operating Period
a. Project Activities
i. Management Aspect
1. Conceptualization and Identification of the project
2. Preparation of the project study
3. Sourcing for possible investors
4. Identification and hiring of personnel for preparation: marketing
programs, engineering specifications, quality control personnel,
and etc.
5. Selection and hiring of top management personnel & Department
Managers
6. Recruitment and training of company personnel
ii. Marketing Aspect
1. Distribution channels
2. Promotional activities
iii. Technical Aspect
1. Calculation of Plant Capacity
2. Identification of Plant Location
3. Determination of Milling Process
4. Designing of Plant Layout
5. Waste disposal methods
6. Plant site acquisition and construction of land improvement (if
there’s any)
7. Building Construction and preparation of specification
8. Machinery
9. Raw materials and utilities
10. Operation: trial run, normal rice milling operation, full capacity
rice milling operation
 iv. Financing Aspect
1. Seeking for possible investors (both local and foreign)
2. Survey for possible sources of financing
3. Sounding out of prospective investors, both stockholders and
creditors, and preliminary negotiations
4. Preparation of formal documents (project studies, application
forms), and filing of applications
5. Follow-up of financing application
6. Fulfillment of conditions required by the financiers
7. Receipt of funds from the financiers
8. Payment for: plant site; building construction; and machinery
b. Project construction: the project construction will start as soon the finance
sourcing phase is successful.
c. Project Scheduling
i. See PERT chart in Appendix A.

B. Form of organization: Corporation

C. Ownership: the plant will be 60% Filipino-owned
D. Internal structure
a. Function
i. Marketing Department: The function of the marketing is to promote the
company's products and services, identify potential customers, and
develop and execute marketing strategies to increase sales and revenue
ii. Quality Control Department: The quality control department is responsible
for ensuring that the rice products produced meet the required standards
and specifications. They are responsible for inspection of the rice to ensure
that it is free from impurities, properly processed, and packaged correctly.
They will also monitor the milling process to ensure that the product meets
the required quality standards.
iii. Finance and Administrative Department: The finance and administrative
department is responsible for managing the financial resources of the
 company and ensuring that administrative processes run smoothly. They
will oversee budgeting, financial reporting, payroll, and accounts payable
and receivable. They may also be responsible for purchasing supplies and
managing inventory.
iv. Maintenance Department: The maintenance department is responsible for
ensuring that the machinery and equipment used in the milling process are
properly maintained and in good working condition. This department will
carry out routine maintenance and repairs, perform preventive
maintenance, and troubleshoot any equipment malfunctions. They will
also oversee the installation and commissioning of new equipment.
b. Organizational Chart
i. See appendix B for the organizational chart by function
E. Personnel
a. Requirements
i. General Manager: At least a bachelor's degree in Business
Administration/Management, with a minimum of 5 years of experience in
a similar industry.
ii. Plant Manager: A degree in Agricultural Engineering or a related field,
with a minimum of 3 years of experience in rice milling operations.
iii. Quality Control Manager: A degree in Food Science or a related field,
with a minimum of 3 years of experience in food quality assurance.
iv. Sales and Marketing Manager: A degree in Business
Administration/Marketing, with a minimum of 3 years of experience in
sales and marketing in the food industry.
v. Finance and Accounting Manager: A degree in Finance/Accounting, with
a minimum of 3 years of experience in financial management and
accounting.
vi. Human Resources Manager: A degree in Human Resource Management,
with a minimum of 3 years of experience in personnel management.
 Marketing Study
A. Demand
a. Past demand
 Graph 1.0 Shows the local production and importation of rice from the past 20 years from
2001-2021.

b. Projected demand based on past demand (straight line; linear)

Year Actual Demand (Y) X X² XY Yc
in million metric tons
2011 12.41 -9 81 -111.69 10.53
2012 12.94 -7 49 -90.58 11.56
2013 12.86 -5 25 -64.3 12.59
2014 12.96 -3 9 -38.88 13.62
2015 12.81 -1 1 -12.81 14.65
2016 12.57 1 1 12.57 15.69
2017 13.97 3 9 41.91 16.72
2018 14.21 5 25 71.05 17.75
2019 15.3 7 49 107.1 18.78
2020 15.18 9 81 136.62 19.81
2021 16.49 11 121 181.39 20.84
13 21.87
15 22.90
17 23.93
19 24.96
21 25.99
23 27.02
25 28.05
27 29.08
29 30.11
31 31.14
151.7 231 451 232.38
 Table 1. Linear projected demand based on Past Demand

c. Local production

Table 2. Production of Rice in Capiz from 2010 – 2022.

 Technical Study
A. Manufacturing Process
a. Choice of process
i. Regular milled Rice
 Regular milled rice, also known as brown rice or
unpolished rice, undergoes minimal processing where only
the husk is removed, leaving the bran and germ intact. This
type of rice is considered to be more nutritious than well-
milled rice because it contains more fiber, vitamins, and
minerals.
ii. Well-milled Rice
 Well-milled rice, also known as white rice or polished rice,
is processed to remove the bran and germ layers, leaving
only the endosperm. This results in a more refined and
polished appearance and a longer shelf life compared to
regular milled rice.
b. Description of Process
 Figure 1.0 Diagram flow of Rice Milling Process
Figure 1.0 shows the diagram flow of Rice Milling Process. The process can be
segmented into eight (8) parts namely: Paddy Cleaning System, Paddy Husking, Paddy
Separation, Rice Whitening, Rice Polishing, Rice Grading, Color Sorting, and Rice
Packaging System.
Paddy Cleaning System
Paddy Cleaning System consist of drum sieve, vibratory sieve and destoner. The
paddy that is delivered to the plant goes several processes before it is packed and can be
sold. It first comes into the drum sieve which remove coarse impurities, such as large
stones, sticks, straw, and other oversized particles, from the rice grains. It consists of a
rotating cylindrical drum with perforated screens or mesh. As the drum rotates, the rice
passes through the perforations, while the larger impurities are retained and discharged
separately. Drum sieves are typically used in the initial stages of the rice milling process
to achieve a preliminary cleaning and ensure the quality of the incoming paddy.
It then passes the vibratory sieve that separate smaller impurities and broken rice
grains from the main product stream. It uses vibration to agitate the rice grains, causing
the smaller particles to pass through the sieve while retaining larger particles. Vibratory
sieves are commonly used in the later stages of the rice milling process, such as after
whitening or polishing, to remove any remaining broken grains, fine bran, or other small
impurities. They contribute to achieving a higher level of purity and consistency in the
final rice product.
Lastly, it passes through a destoner which remove stones and heavy impurities
from the raw paddy or rice grains. Its purpose is to improve the quality and purity of the
rice by eliminating foreign materials that could affect the taste, appearance, and
processing efficiency.
Paddy Husking Process
The cleaned paddy is passed through a paddy husker which remove the outer husk
layer from the paddy, which is the unprocessed rice with its protective covering
resulting in brown rice.
Paddy Separation Process
In the paddy separation process, the paddy separator machine is used. The paddy
separator separates unhusked paddy from brown rice. It uses a combination of sieving
and air aspiration to achieve the separation.

Rice Whitening Process

The brown rice is passed through a rice whitener to remove the bran layer and
produce polished white rice. The rice whitener is a machine that removes the bran layer
from brown rice, resulting in polished white rice. It uses abrasive rollers to rub against
the rice grains and remove the bran.
Rice Polishing Process
The polished white rice may undergo further polishing in a rice polisher to give it
a glossy appearance. The rice polisher is used to give the white rice a glossy appearance
by removing the remaining fine bran particles and providing a smooth surface.
Rice Grading Process
The polished rice is graded based on size and shape using a rice grader. The rice
grader sorts the polished rice into different grades based on the size and shape of the
grains. It typically uses a series of sieves or screens to achieve the grading.
Color Sorting Process
After grading, a color sorter can be used to remove any discolored or defective
grains. The color sorter is an optional component that uses optical sensors to detect and
remove any discolored or defective grains from the polished rice.
Rice Packaging Process
The final product, polished and graded rice, is packed into bags or containers
using a packaging machine for distribution and sale. The packaging machine is used to
pack the polished rice into bags or other containers for distribution and sale.

B. Machinery & Equipment

a. Plant Capacity: The Plant Capacity of the plant is 200 Tons per Day
b. Supplier: Henan Chengli Grain and Oil Machinery Co., Ltd
c. Machinery Specification:
Equipment Specification
 100T Rice Mill Production Line

Capacity: 100 Tons per Day

Power Required: 249 kW
Overall Dimension: 26m x 10m X 7m
Equipment Quantity
1. TQLZ150*200 PADDY CLEANER 1
2. TQSZ120*2 DESTONER 1
3. MLGT51 RICE HULLER 1
4. MGCZ60*20*2 PADDY SEPARATOR 1
5. MNML40 EMERY ROLLER RICE WHITENER 3
6. MMJP125*4 RICE GRADER 1
7. KPM150D RICE POLISHER 2
8. RICE LENGTH GRADER 3
9. RICE PACKING MACHINE 3
10. BUCKET ELEVATOR 13

Table 3. Specification of 100T/D Rice milling equipments

C. Plant Location
 The plant site of the proposed rice milling plant is located at Lanot, Roxas City
Capiz. At 11°31’36’’N 122°45’35’’E. It is along the National road and can be
accessed by neighboring municipalities, towns, and barangays. Also, this site is near
the National Food Authority (NFA) which is located in Bolo, Roxas City, Capiz
D. Layout
a. Ground layout: See Appendices
b. Building layout: See Appendices

Material Balance Calculations

The material balance, which is also called “mass balance”, is the application of the law of
conservation of mass. This means that in the analysis of physical systems, the material entering
and leaving the system is equal. This can be expressed in through:
 𝑚𝑖𝑛 = 𝑚𝑜𝑢𝑡
Where:
𝑚𝑖𝑛 = mass in
𝑚𝑜𝑢𝑡 = mass out

In the case of rice, mass in is the total amount of raw materials (paddy rice) fed into the
system and mass out are the specific components that comprise the total mass which includes the
product (milled rice) and waste (bran and husk). Equation 1.1 can then be expounded further to:

𝑚𝑅𝑎𝑤 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠 = 𝑚𝑃𝑟𝑜𝑑𝑢𝑐𝑡 + 𝑚𝑊𝑎𝑠𝑡𝑒

According to Dhankar (2014), Rice kernels are composed of 20% rice husk, 11% rice
bran, and 69 % starchy endosperm (milled rice).
Material Balance:

100 kg of Paddy Rice

Rice Husk
Rice Husk
(20%)

Rice Rice Bran

Whitener (11%)

69 kg of Milled Rice
Considering the milling process, 20% of the total mass is loss due to the husk, and 11% is
Figure
due to the rice bran.2.0:
ThisMass
sumsbalance
up of aoftotal
Ricewaste
as undergone milling
of about 31 process
%. This leaves 69% of milled rice.
This gives us:
𝑚𝑅𝑎𝑤 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠 = 𝑚𝑃𝑟𝑜𝑑𝑢𝑐𝑡 + 𝑚𝑊𝑎𝑠𝑡𝑒
100 kg = 69 kg + 31 kg

Figure 1.2: Mass balance of Rice as undergone milling process

 For every 100 kilograms of paddy rice fed, we lose 31 kg and have a product output of 69
kg, or 69% of the paddy rice fed as output. For the monthly capacity of the rice milling plant, we
will consider 22 working days (excluding holidays and weekends) and the capacity of the
machine of 100 tons per day, we have:
Cmonthly = Cdaily x 22 days
Cmonthly = 100 Tons / day x 22 days
Cmonthly = 2200 Tons
The monthly capacity of the milling plant is 2200 Tons per month for a daily capacity of
the machine which is 100 Tons per day.

Machine Foundation Calculation

Dimension of the machine (L x W x H) : 26 000 mm x 10 000 mm x 7 000mm
Weight of the machine: 10 Tons or 10, 000 kg
Machine Foundation Formulas
The following formulas are used in the calculation of the machine foundations, where:
L = length of the foundation
LB = length of the bedplate
c = clearance
a = upper width of the foundation
w = width of the bedplate
Wf = weight of the foundation
Wm = weight of the machine
Vf = volume of the foundation
ρ = density of building material
Sb = soil bearing capacity
N = factor of safety
h = depth of the foundation
WSB = weight of the steel

Length of the Foundation

𝐿 = 𝐿𝐵 + 2𝑐
 Where:
L = length of the foundation
LB = length of the bedplate
c = clearance
The clearance or the distance between the edge of the foundation and the baseplate must
be at least 120 mm to 300 mm to secure the belts imbedded within the foundation. This machine
foundation design will make use of the 200 mm clearance.
𝐿 = 26, 000 𝑚𝑚 + 2(200 𝑚𝑚)
𝑳 = 26, 4𝟎𝟎 𝒎𝒎 𝒐𝒓 26.4 𝒎
Upper Width of the Foundation
𝑎 = 𝑤 + 2𝑐
Where:
a = upper width of the foundation
w = width of the bedplate
The clearance or the distance between the edge of the foundation and the baseplate must
be at least 120 mm to 300 mm to secure the belts imbedded within the foundation. This machine
foundation design will make use of the 200 mm distance.
𝑎 = 𝑤 + 2𝑐
𝑎 = 10, 000 𝑚𝑚 + 2(200 𝑚𝑚 )
𝒂 = 10, 400 𝒎𝒎 𝒐𝒓 10.4 𝒎

Weight of the Foundation

𝑊𝑓 = 5(𝑊𝑚)
Where:
Wf = weight of the foundation
Wm = weight of the machine
 Calculations:
𝑊𝑓 = 5(𝑊𝑚)
𝑊𝑓 = 5(10, 000 𝑘𝑔)
𝑾𝒇 = 𝟓0, 𝟎𝟎𝟎 𝒌𝒈

Volume of the Foundation

Table 4: Approximate Weights of Building Materials.
Building Material Density (kg / m3)

Plain Concrete, stone 2323-2403

Plain Concrete, slag 2082

Plain Concrete, cinder 1602

Reinforced Concrete, stone 2403

Brick Masonry, pressed 2243

Brick Masonry, common 1922

Ashlar Masonry, granite 2643

Ashlar Masonry, limestone 2563

Ashlar Masonry, sandstone 2243

Sand gravel 1602-1762

Cinder fill 641-721

Approximated weight of different building materials is shown in Table 1.3 in terms of

density (kg/m3). The volume of the foundation can be calculated through:

𝑊𝑓
𝑉𝑓 =
𝜌
Where:

Wf = weight of the foundation

Vf = volume of the foundation

ρ = density of building material

Where the material to be used for the machine foundation is reinforced concrete and its density
is derived from Table 1.3.

Calculations:

50,000 𝑘𝑔

𝑉𝑓 = 2403 𝑘𝑔/𝑚3

𝑽𝒇 = 𝟐0. 𝟖𝟎𝟕 𝒎𝟑

Lower Width of the Foundation

𝑁(𝑊𝑚 + 𝑊𝑓)
𝑏=
𝑆𝑏𝐿
Where: b = lower width of the foundation
Sb = soil bearing capacity
N = factor of safety
Wm = weight of the machine
Wf = weight of the foundation
L = length of the foundation

Table 5: Safe Bearing Power of Soil

Safe Bearing Power of Soils
Soil Safe Bearing Power (tonnes/m2)
Native Rock 1950 – above
Ashlar Masonry 245 – 290
Best Brick Masonry 145 -195
Common Brick Masonry 50 – 98
Clay, compact 50 -78
Clay, soft 9.5 – 19.5
Gravel and sand 78 – 98
Sand 19.5 – 58.5
Quicksand, Loam 5 – 9.5

Table 5 shows the different safe bearing power of soils depending on its type. For
common brick masonry: 𝑆𝑏 = 98 𝑡/𝑚²
Since this is a machine foundation, the safe bearing power of soil will be halved given an
allowable unit of soil stress as follows:
ton 1000 kg
98 ×
𝑆𝑏 = m
2
1ton = 49,000 𝑘𝑔/m2
2
 Note that if b < a, then let b = a, which means that the foundation is a rectangular cross
section. According to PSME Code, the appropriate factor of safety for machine foundations is 5.
Calculations:
5(10,000+50 , 000)
N (Wm+Wf )
𝑏= = kg
SbL 49,000 2 × 26.4 m
m
= 𝟎. 23 𝒎
Since b < 10.4 m), then b= 10.4 m.
Depth of the Foundation

𝑎+𝑏
𝑉𝑓 = ( ) ℎ𝐿
2

2𝑉𝑓
ℎ=
(𝑎 + 𝑏)𝐿

Where:
h = depth of the foundation
Vf = volume of the foundation
a = upper width of the foundation
b = lower width of the foundation
L = length of the foundation

Calculations:

2𝑉𝑓 2 (20.807 𝑚3)

ℎ= = 0.076 m
(𝑎 + 𝑏)𝐿 (10.4 𝑚 + 10.4 𝑚) × 26.4 𝑚
Concrete Mixture

Based on the table below, the ratio of Cement to Sand to Stone for Reinforced Concrete Floors
is 1:2:4.
Table 6: Data on Concrete Mixes to Yield 1 m3 Concrete
Mixture Cement Sand Stone Application Weight Safe
Comp.
(sacks) (m3) (m3) (ton/m3)
Stress

(ton/m2)
1:2:3 9.2 0.51 .077 roofs, sills, 2.66 382.78
tanks,
tunnels
1:2:4 7.8 0.44 0.88 R. C. 2.66 328.1
floors,
beams,
columns
1:2.5:4 7.3 0.52 0.83 building 2.66 273.42
walls
1:3:5 6.2 0.52 0.86 foundations 2.66 218.73
and
footings
1:2:4 8.6 0.49 cinders cu. R.C. floors 1.99 153.11
yd. 0.98

Based on the identified cement:sand:stone ratio from Table 6, the following equations are
used:
7.8 sacks
𝐶𝑒𝑚𝑒𝑛𝑡 = 𝑉𝑓 ( 3
)
1m
 3
0.44 m
Sand = 𝑉𝑓 ( 3
)
1m

0.88 m3
Stone = 𝑉𝑓 ( )
1 m3

Calculations:

7.8 sacks
𝐶𝑒𝑚𝑒𝑛𝑡 = 20.807m3 ( 3
) = 162. 3 or 163 sacks
1m

0.44 m3
Sand = 20.807m3 ( ) = 9.155 m3
1 m3

3
0.88 m
Stone = 20.807m (
3
3
) = 18.31m3
1m

Weight of Steel Bar Reinforcements

𝑊𝑆𝐵 = 0.01(𝑊𝑓)
Figure 1.7: Steel Bar Reinforcements in Machine Foundation

Figure 1.7 visualizes the cross-sectional area of the machine foundation with the
reinforcement steel bar.

Calculations:

𝑊𝑆𝐵 = 0.01(50,000 𝑘𝑔) = 𝟓𝟎0 𝒌𝒈

Fire Protection System Design

A. General
According to Section 10.2.6.555 or Automatic Sprinklers and other Extinguishing Equipment of
the Fire Code of the Philippines Implementing Rules and Regulations of 2008,
 “1. Automatic sprinklers if required by Division 8 through Division 17 of this Chapter
shall be in accordance with NFPA 13, Standard for the Installation of Sprinkler
Systems
2. All automatic sprinkler and standpipe systems required by this code shall be
inspected, tested, and maintained in accordance with NFPA 25, Standard for the
Inspection, Testing, and Maintenance of Water-Based Fire Protection Systems.
Records of conducted maintenance and testing should be maintained and submitted
together with FALAR 3.
3. Where a required automatic sprinkler system is out of service for more than 4
hours in a 24-hour period, the owner shall notify the nearest fire station
immediately upon discovery but not later than 24 hours and a fire watch shall be
assigned until the sprinkler system has been returned to service.
4. Sprinkler impairment procedures shall comply with NFPA 25, Standard for the
Inspection, Testing, and Maintenance of Water-Based Fire Protection Systems.”
Table 7 NFPA 13 Occupancy Classification

OCCUPANCY DESCRIPTION
CLASSIFICATION

Light Hazard Low combustibility of contents and low heat release expected from a fire.

Ordinary Hazard Group 1: Low combustibility, moderate amount of combustible

materials, stockpiles are not taller than 8 feet, and moderate heat release
is expected from a fire.
Group 2: The combustibility and amount of contents ranges from
moderate to high. Contents with a moderate heat release are not stacked
taller than 12 feet, and contents with a high heat release are not stacked
taller than 8 feet.

Extra Hazard Group 1: The combustibility and amount of contents is very high, and
there are compounds like dust or lint present, which can accelerate a fire
if it occurs. The rate of heat release from a fire is high, but combustible
and flammable liquids are only present in small amounts or not present at
all.
 Group 2: Moderate to large amounts of flammable or combustible
liquids.
Also includes occupancies with ample shielding of combustibles.

Table 7 shows the occupancy classification of buildings according to the content and
combustibility of materials. For a tomato processing plant with only one major equipment
handling most of the process and the rest being handled manually, the rightful classification is
ordinary hazard with group 1. This is because washing, drying, packing and storage of
tomatoes do not emit enough heat or are not stacked taller than 8 feet.
B. Supervision
Supervisory Signals – since the industrial plant will be installed with an automatic
sprinkler system, supervisory attachments shall be installed and monitored for integrity in
accordance with NFPA 72. Supervisory signals include monitoring of control valves, fire
pump power supplies and running conditions, water tank levels, and temperatures, tank
pressure, and air pressure.
C. Sprinkler System
According to NFPA 13, Standard for the Installation of Sprinkler Systems, wet pipe sprinkler
systems have their piping permanently filled with pressurized water. This has a purpose: if
any individual sprinkler head opens in response to heat, water flows immediately and at a
moderately high pressure. For this reason, wet pipe installations have the fastest response
among all sprinkler system configurations - reaction time does not depend on distance
between the activated sprinkler head and the water supply. This is the ideal sprinkler system
for the plant.
Also, it specifies that each sprinkler has a maximum operating area of 130 square feet (12.1
square meters) and there should be a maximum space of 15 feet (4.6 meters) between each
sprinkler. It is important to note that the minimum spacing between sprinklers must be sufficient
to ensure that nearby sprinklers are adequately wetted when they are in operation. The
determination of the number of sprinkler heads will be based on a spacing of 12.1 square meters
per sprinkler.

Fire Fighting System (Sprinkler and Fire Extinguisher)

Source was taken from National Fire Protection Association (NFPA)
ROOM FLOOR AREA, (m2)
FPS Room 42.87
Storage Room 81.74
AHU Room (1) 81.74
Multi-Purpose Room 81.74
Main Office 83.75
T/D Automatic Rice Mill 260
AHU Room (1) 49.27
CR (Men) 48.125
CR (Women) 45.82
Utility Room 31.04
Clinic 60.59
Worker’s Room 93.94
Main Control Room 93.94

Floor Area
Sprinkler Head=
Sprinkler Spacing Requirement
According to the National Fire Protection Association or NFPA, the sprinkler spacing
requirement for light hazards that can be found in offices, restaurants, clubs, theaters, etc. needs
to be around 200𝑓𝑡2 or 18.58 𝑚2 ℎ𝑒𝑎𝑑 while the sprinkler spacing requirement for ordinary
hazards which can be seen in machine shops, processing areas, mills, and many more needs to be
around 130𝑓𝑡2 or 12.08 𝑚2 ℎ𝑒𝑎𝑑.
Solving for FPS Room,
Floor Area
Sprinkler Head=
Sprinkler Spacing Requirement
42.87
Sprinkler Head=
12.08
Sprinkler Head=3.55 heads ≈ 4 heads

Solving for Storage Room,

 Floor Area
Sprinkler Head=
Sprinkler Spacing Requirement
81.74
Sprinkler Head=
12.08
Sprinkler HeadSprinkler Head=6.77 heads ≈ 7 heads
Solving for AHU (1),
Floor Area
Sprinkler Head=
Sprinkler Spacing Requirement
81.74
Sprinkler Head=
12.08
Sprinkler Head=7 heads
Solving for Multi-Purpose Room,
Floor Area
Sprinkler Head=
Sprinkler Spacing Requirement
81.74
Sprinkler Head=
18.58
Sprinkler Head=4.3 heads ≈ 4 heads
Solving for Main Office,
Floor Area
Sprinkler Head=
Sprinkler Spacing Requirement
83.75
Sprinkler Head=
18.58
Sprinkler Head=4.5 ≈5 heads
Solving for AHU (2),
Floor Area
Sprinkler Head=
Sprinkler Spacing Requirement
49.27
Sprinkler Head=
12.08
Sprinkler Head=4.07 ≈ 4 heads

Solving for CR (MEN),

Floor Area
Sprinkler Head=
Sprinkler Spacing Requirement
48.125
Sprinkler Head=
18.58
 Sprinkler Head=2.59 ≈ 3 heads

Solving for CR (WOMEN),

Floor Area
Sprinkler Head=
Sprinkler Spacing Requirement
45.82
Sprinkler Head=
18.58
Sprinkler Head=2.4 ≈2 heads
Solving for Utility Room,
Floor Area
Sprinkler Head=
Sprinkler Spacing Requirement
31.04
Sprinkler Head=
12.08
Sprinkler Head=2.56 ≈ 3 heads
Solving for clinic,
Floor Area
Sprinkler Head=
Sprinkler Spacing Requirement
60.59
Sprinkler Head=
18.58
Sprinkler Head=3.26 ≈ 3 heads
Solving for Worker’s Lounge,
Floor Area
Sprinkler Head=
Sprinkler Spacing Requirement
93.94
Sprinkler Head=
18.58
Sprinkler Head =5.0 heads

Solving for Main Control Room,

Floor Area
Sprinkler Head=
Sprinkler Spacing Requirement
93.94
Sprinkler Head=
12.08
Sprinkler Head=7.77 ≈ 8 heads
 Solving for production area,
Floor Area
Sprinkler Head=
Sprinkler Spacing Requirement
750
Sprinkler Head=
12.08
Sprinkler Head=62 heads

ROOM FLOOR AREA, (m2) Spacing Actual No. of

Sprinkler head
FPS Room 42.87 12.1 4
Storage Room 81.74 12.1 7
AHU Room (1) 81.74 12.1 7
Multi-Purpose Room 81.74 12.1 4
Main Office 83.75 12.1 5
Production Area 750 12.1 62
AHU Room (2) 49.27 12.1 4
CR (Men) 48.125 12.1 3
 CR (Women) 45.82 12.1 2
Utility Room 31.04 12.1 3
Clinic 60.59 12.1 3
Worker’s Lounge 93.94 12.1 5
Main Control Room 93.94 12.1 8

Lighting Calculation
According to the Occupational Safety and Health Standards issued by the Department of
Labor and Employment, artificial lighting shall be provided when daylight fails or where the
daylight illumination is insufficient. The general lighting should be of uniform level, widely
distributed to avoid harsh shadows or strong contrast and free from direct or reflected glare.
In section 1075.04 entitled Intensity, the standard provides for the minimum luminous
flux or lux for spaces.

Table 8: OSHA Illumination Levels

Area of Operation Minimum Luminous Flux (lux)
Cutting cloth
Sewing cloth 2000 and above
Finish inspection (200 foot candles)
Fine assembly
Color grading
Fine Machining
Inspection and assembly
Clay enameling and glazing 1,000
Electric motor insulating (100 foot candles)
Coil winding and testing
Chipping Grinding Fine core making
Machine shop benchwork
Transcribing handwriting
Indexing references
Accounting Pattern making
Drafting
Welding
Automotive frame assembly 500
Chemical laboratory (50 foot candles)
Foundry molding
Metal pouring
Sorting
Core making
Rubber extrusion and tire making
Punch press
Shearing
Stamping
Spinning
Woodworking
Sizing
Planning
Rough Sanding
Medium quality machine and benchwork
First aid station/Clinic
Packaging
Barrel Washing 300
Turbine (30 foot candles)
Clay molding and pressing
Chemical furnace
Tank
Dryer
Evaporator
Extractor
Cleaning and annealing furnace
Plating
Drop-forge shop
Lunch room
Locker room 100
Rest room (10 foot candles)
Shower room
Office Work Room
Tunnels, shaft and general
underground work areas, 50
concrete placement, excavation (5 foot candles)
and waste areas, access ways,
active storage areas, loading
platforms, refueling, and field
maintenance areas, indoors,
warehouses, corridors
hallways and exit ways

In calculating the needed number of bulbs as well as the total illuminations for the
industrial layout, each area must have a recommended bulb with its watts and illumination.
Table 9 specifies the bulb required for the processing area. The bulb highlighted in table 10
specifies the required watts and illumination for the rest of the areas in the industrial layout.
Table 9 Bulb Specifications for Processing Area
Table 10 Bulb Specifications for Areas aside from Processing Area

Summary of Lighting Calculations

 Bulb Actual
No. of
Place Area, ( ) Lux Illumination Watts Illuminat No. of
Bulbs
ion Bulbs
FPS Room 42.87 50 2,144 20 1200 1.78625 2
Storage Room 81.74 50 4,087 40 2500 1.6348 2
AHU Room (1) 81.74 50 4,087 40 2500 1.6348 2
Multi-Purpose Room 81.74 100 8,174 40 2400 3.40583 3
Main Office 83.75 100 8,375 36 2500 3.35 3
Production Area 750 500 375,000 400 32000 11.7188 12
AHU Room (2) 49.27 50 2,464 40 2500 0.9854 1
CR (Men) 48.125 100 4,813 20 1200 4.01042 4
CR (Women) 45.82 100 4,582 20 1200 3.81833 4
Utility Room 31.04 50 1,552 20 1200 1.29333 1
Clinic 60.59 300 18,177 40 2500 7.2708 7
Worker’s Room 93.94 100 9,394 20 1200 7.82833 8
Main Control Room 93.94 300 28,182 36 2500 11.2728 11
The formulas used in calculating the number of bulbs is shown below. The number of
bulbs needs to be rounded up to the whole number in order to get the actual number of bulbs for
a certain area.
 Illumination=(Lux)( Area)
Illumination
 No . of Bulbs=
Bulb Illumination

AIR CONDITIONING AND REFRIGERATION DESIGN

Door and Window Schedule

Wall Composition

Assuming that heat gain is equally distributed through the premises except the production floor.

Table 2.1: Building Composition

ITEM STRUCTURE MATERIAL t R 𝑅 1

(in.) 1/K 1/C 𝑈=
𝑅
(hr- (hr-
( Btu
ft2°F/Btu ft2°F/Btu)
/hr-
ft2-
 °F)
ROOF 1 Outside 0.25 4
surface
(7.5 mph
wind)
2 Cement 1 0.20 5
mortar, 1
in.
3 Blanket 11 0.09
and Batt 3
insulation,
3 in.
4 Primer 0 0
5 Concrete 6 0.19 0.88
sand and
gravel, 6
in. 120
lb/ft3
density

6 Inside 0.92 1.09

surface
(still air)
TOTAL 11.06
EXTERNAL 1 Outside 0.25 4
WALL surface
(7.5 mph
wind)

2 Cement 0.08 12.5

plaster,
0.375 in.
 3 Cement 0.20 5
mortar, 1
in.

4 Concrete 0.91 1.10

block,
sand and
gravel
Aggregate,
6 in.
5 Cement 0.20 5
mortar, 1
in.

6 Cement 0.08 12.5

plaster,
0.375 in.
7 Inside 0.68 1.47
surface
(still air)
TOTAL - 36.5
DOORS Exposed 1.13
glass door,
¾ in.
herculite

TOTAL 1.13
WINDOW Clear 1.10
S single
glass,
Without
storm
windows
TOTAL 1.10

Table 11 shows the different materials used for the building and their corresponding R and U
values.

Heat Load Calculations

Design Criteria

LOCATION OF SITE:

a) Place: Barangay Lanot, Roxas City, Capiz

b) Latitude: 11°31’36’’N 122°45’35’’E
c) Summer Climate Condition Outdoor 92°F DB; 81 °F WB; 40%RH
d) Summer Indoor Design Condition
INDOOR 78°F DB; 50 °F WB; 40 % RH
 e) Mean Daily Range: 80°F

Cooling Load Temperature Difference Calculations

𝐶𝐿𝑇𝐷𝑐𝑜𝑟𝑟 = (𝐶𝐿𝑇𝐷 + 𝐿𝑀) ∗ 𝐾 + (78 − 𝑇𝑅) + (𝑇𝑂 − 85) ∗ 𝑓

Where:

LM = Latitude – Month Correction = 0 (ASHRAE Handbook, Table 9)

K = Color adjustment factor = 1

Indoor Design Temp. Condition = (78 – TR)

Outdoor Design Temp. Condition = (To – 85)

ƒ = Factor for the Attic Fan and/or Ducts = 1.0 (no attic/duct)

From table 5 of ASHRAE 1985 Fundamentals Handbook, with a roof construction of 4 in

heavyweight concrete with 1-in insulation, without suspended ceiling, and at solar time 12,
𝐶𝐿𝑇𝐷𝑟𝑜𝑜𝑓 = 23. A sample computation for 𝐶𝐿𝑇𝐷𝑐𝑜𝑟𝑟 of the roof is provided.
𝐶𝐿𝑇𝐷𝑐𝑜𝑟𝑟 = (23 + 0) ∗ 1 + (78 − 78) + (92 − 85) ∗ 1

𝐶𝐿𝑇𝐷𝑐𝑜𝑟𝑟 = 21.75

Additional design requirements:

Latitude: 11
Month: May
Wall type: Group B Walls
Roof Type: Roof Type 12
Solar time: 12:00 PM
For sunlit walls, ASHRAE Table 7 is used.

Table 2.3: CLTD Corrected Summary of Results

Exposure CLTD LM k 78 Tr To 85 f CLTDcorr

N 8 4 1.0 78 78 92 85 - 18

W S 11 -7 1.0 78 78 92 85 - 10
A
E 19 -1 1.0 78 78 92 85 - 24
L
L W 15 -1 1.0 78 78 92 85 - 20
S

Roof 23 0 1.0 78 78 92 85 - 21.75

Table 12 shows the corrected CLTD which is derived by multiplying the values to the
left.

Conductive Heat Gain Calculations

Table 13: Conductive Heat Gain

 Conduction Heat Gain: Hc = U * A * (CLTDcorr)
U A CLTD CLTDCorr Hc
WALL (NORTH)
Main Office 0.52 3155.168 - 11.5 18867.90464

Multi-purpose Room 0.52 3079.44 - 11.5 18415.0512

Storage Room 0.52 3079.44 - 11.5 18415.0512

WALL (SOUTH)

Main Control Room 0.52 3539.03 - 1.5 2760.4434

Worker’s Lounge 0.52 3539.03 - 1.5 2760.4434

Clinic 0.52 2282.646 - 1.5 1780.46388

CR (men) 0.52 1813.044 - 1.5 1414.17432

CR (women) 0.52 1726.207 - 1.5 1346.44146

WALL (EAST)
Main Office 0.52 3155.168 - 29.5 48400.27712
Main control room 0.52 3539.063 - 29.5 54289.22642
ROOF
Main Office 0.42 3155.168 - 21.5 28491.16704

Multi-purpose Room 0.42 3079.44 - 21.5 27807.3432

Storage Room 0.42 3079.44 - 21.5 27807.3432

Main Control Room 0.42 3539.063 - 21.5 31957.73889

Clinic 0.42 2282.646 - 21.5 20612.29338

Utility Room 0.42 1169.39 - 21.5 10559.5917

Total Conduction Heat Gain
Main Office 95759.3488

Multi-purpose Room 46222.3944

Storage Room 46222.3944
Main Control Room 86246.96531

Clinic 22392.75726
Utility Room 10559.5917
Total Conduction Heat Gain 307403.4519

Table 13 presents the conductive heat gains of the building. A total of 307, 403.4519 Btu/hr is
experienced.

Convective Heat Gain Calculations

 Conductive heat gain calculations are presented in the following sections.

Moisture Content Difference

Wo [Outdoor (92 °F DB 81 °F WB)] = 0.0205 lbmoisture / lbdry air

Wi [Indoor (78 °F DB 68 °F WB)] = 0.0124 lbmoisture / lbdry air
ΔW = 0.0081 lbmoisture / lbdry air
ΔT = 92 °F - 78° F
ΔT = 14°F

Table 14: Convection Heat Gain

Convection Heat Gains
Hv=1.1 cfm ΔT+4840 cfm ΔW

Sensible (BTU/hr) Latent (BTU/hr)

Windows 0 0

Doors • [1.1( 7.4*216)14°F] [4,840( 7.4*216) 0.0081lb/lb]

Infiltration =24,615.36 BTU/hr =62,663.67 BTU/hr

Air Conditioner [1.1(15*44) 14°F] [4,840( 15*44) 0.0081 lb/lb]

• Ventilation = 10,164 BTU/hr = 25,874 BTU/hr

Sensible Hv=34779.36 Btu/hr Latent Hv=88573 Btu/hr

Table 14 shows the computation of heat gain through convection. The sensible and latent
heat gain values are identified.

Solar Heat Gain Calculations

Table 15: Solar Heat Gain

 Solar Heat gain Hs=A(SHGF)(SC)(CLF)

A(s.f.) SHGF SC CLF Hs

1) Windows (May-11 degrees lat)

a.) North 24 52 0.94 0.7 821.184

b.) South 48 41 0.94 0.52 961.9584

c.) East 36 215 0.94 0.39 2837.484

d.) West 72 215 0.94 0.14 2037.168

2.) Doors

a.) North 36 52 0.94 0.7 1231.776

b.) South 0

c.) East 72 215 0.94 0.39 5674.968

d.) West 108 215 0.94 0.14 3055.752

Total Hs= 16620.29 Btu/hr

Table 15 presents the heat gain due to solar radiation from the doors and windows.

Internal Heat Gain Calculations

Table 16: Internal Heat Gain

Internal Heat Gains
Hs = (Sensible Load) * (CLF) + (Latent Load)

Computations Sensible CLF His (Btu/hr) Latent Hil (Btu/hr) Hi Total

Load Load (Btu/hr)
(Btu/hr) (Btu/hr)

Lights 1.18 watts/s.f. x 27763.06 1 27763.06 0 0 27763.06

3.14
Btu/watt-hr x
7493 sq. Ft

Computers 6 x 450 Btu/hr 2700 1 2700 0 0 2700

Office 1 x 10,000 10,000 1 10,000 0 0 10,000

Machines Btu/hr

Total, Hi = 40463.06 Btu/hr

Table 16 shows the heat gain due to internal heat produced by lights, computers, and other
office machines.

People Heat Gain Calculations

Table 17: People Heat Gain

People Heat Gains
Hsp = Ps * n * CLF
Hlp = Pl * n

Persons Activity No. of Ps CLF Hsp Pl Hlp

Persons Btu/hrperson (sensible) Btu/hrperson (latent)
Btu/hr Btu/hr

Moderately Active office 20 250 1.0 5000 200 4000

work

Walking 3 mph; light 45 375 1.0 16875 625 28125

machine work

TOTAL 65 21875 32125

Hp = Sensible + Latent
Hp = (21875 + 32125) Btu/hr
Hp = 54000 Btu/hr

Table 17 shows the cooling load due to people heat gain.

Summary of Heat Gain Calculations

Table 18: Heat Gain Summary

Sensible Heat Gain Latent Heat Gain TOTAL HEAT GAIN (Btu/hr)

Conduction 307, 403 0 307, 403

 Convection 191,204.86 486752.94 677,958
Solar 16,620.2904 0 16,620
Internal 40463.06 0 40,463
People 21875 32125 54,000
TOTAL 577, 566.06 518, 877.94 1, 096, 444

Table 18 summarizes the cooling load due to heat gains of the building. The sensible and
latent heat gains are also presented in Btu/hr. Solving for the ton refrigeration, we have:

𝑏𝑡𝑢 1 𝑡𝑜𝑛
1, 096, 444 x = 91.37 𝑡𝑜𝑛𝑠
ℎ𝑟 12,000 𝑏𝑡𝑢
ℎ𝑟

Air Conditioning Design

A single centralized Air Handling Unit will be utilized to supply for the air conditioning
of the whole industrial plant. Solving for the cfm of the AHU is presented below:

𝐻𝑣 = 1.1 ∗ 𝑐𝑓𝑚 ∗ Δ𝑇

𝐻𝑣
 𝑐𝑓𝑚

Where Hv = sensible heat gain, therefore.

577, 566.06

𝑐𝑓𝑚

𝑐𝑓𝑚 = 37504.2896 cfm

To properly address the sizes of the room, a total if 12 diffusers will be distributed in the whole
area excluding the production area where it is not air conditioned. This gives us:

𝑐𝑓𝑚 37504.2896 𝑐𝑓𝑚

= = 3125𝑐𝑓𝑚/𝑑𝑖𝑓𝑓𝑢𝑠𝑒𝑟
𝑑𝑖𝑓𝑓𝑢𝑠𝑒𝑟 12 𝑑𝑖𝑓𝑓𝑢𝑠𝑒𝑟𝑠

𝐴𝐻𝑈 1 = 6 ∗ 3125 = 18750 𝑐𝑓𝑚 𝑜𝑟 31687.5 𝑚3/ℎ

𝐴𝐻𝑈 2 = 6 ∗ 3125 = 18750 𝑐𝑓𝑚 𝑜𝑟 31687.5 𝑚3/ℎ

List of Equipment

Table 19: List of Equipment

Equipment for AHU: Name: DDM AHU- QTY.

1819

Cooling 135 kW 2
Capacity
 Rated Flow 34, 445 cu. m
per hour

Dimensions Height = 2.2m

Width = 2.3 m
Panel
thickness =
50 mm

Table 19lists the air conditioning equipment to be acquired to supply for the cooling load.
A Double skin modular AHU is chosen for the industrial plant.

Financial Expenses

Table 20: Expenses

Item Unit Price/Unit Sub-total

DDM AHU-1819 2 ₱ 95,000 ₱ 190,000.00

TOTAL ₱ 190, 000.00

Table 20 presents the cost for acquiring the equipment for air conditioning.

Appendix A
Project Schedule:
PERT NETWORK
PATHS:
A-B Obtaining of Financing for Proposed Milling Plant
B-C Plant site acquisition
C-D Building Construction of Milling Plant
 A-F Milling Machinery supplier selection
F-D Order and receipt of Milling machinery
D-E Milling Machinery installation and test run & normal operation

B C
5 mos.

3 mos.
A F 12 mos.
D 5 mos.
E
START FINISH

Expected project completion: 24 Months

Operating Period:
PERT NETWORK
PATHS:
A-B: Receiving of Raw Materials
B-C: Cleaning and Sorting
C-D: Storage and Handling
D-E: Milling
A-F: Packaging and Labelling
F-G: Quality Control
G-H: Maintenance and Repair
E-H: Cleaning and Sanitation
H-I: Shipping and Distribution

B C D

A E

START
F G H I
Expected hours of Operation: 12hrs
FINISH

Appendix B

GENERAL MANAGER

FINANCE AND
CONSTRUCTION MARKETING QUALITY CONTROL MAINTENANCE
ADMINISTRATIVE
MANAGER MANAGER MANAGER MANAGER
MANAGER

MONITORING EQUIPMENT
PLANNING AND MARKET RESEARCH
FINANCIAL PLANING QUALITY CONTROL PLANNING AND
SCHEDULING AND PLANNING
ACTIVITIES SCHEDULING

BUDGET AND COST ADVERTISING AND CONDUCTING CALIBRATION OF

ACCOUNTING
CONTROL SALE PROMOTION QUALITY AUDITS MACHINERY
 HIRING & PROVIDES TRAINING
EQUIPMENT
MANAGING STAFFS BUDGETING AND AND SUPPORT
PROCUREMENT AND
(ENGIEERS, FORECASTING (RELATED TO
DISPOSAL
ARCHITECTS, & ETC.) QUALITY CONTOL)

COMMUNICATION FINANCING AND MANAGING ENSURING

(SUPPLIER- CAPITAL CONSUMER COMPLIANCE WITH
COSTUMER) MANAGEMENT FEEDBACK REGULATIONS

HIRING AND
ENSURING
DEPERTMENT MANAGING STAFFS
COMPLIANCE WITH ADMINISTRATION
COLLABORATION (MECHANICS &
REGULATION
TECHNICIANS)

ENSURING
CREDIT AND
COMPLIANCE WITH
COLLECTION
REGULATIONS

Appendix C
POSITION SALARY/MONTH
General Manager Php70,000
Department Manager Php47,500
Supervisors Php43,883
Team Leaders Php40,000
Staff Employees Php15,200
 Specialist Php19,493
Entry-level Employees Php15,000
Plant Manager Php36,834
Production Supervisor Php19,000
Maintenance Supervisor Php26,000
Production Workers Php14,881
Maintenance Workers Php15,333
Logistics and Warehouse Staff Php20,000
Safety and Environment Staff Php21,000
Quality Control Manager Php24,479
Quality Control Inspector Php17,000
Quality Control Technician Php15,099
Quality Assurance Analysts Php28,000
Compliance Specialists Php38,000
Documentation Specialists Php31,892
Training Coordinator Php27,822
Supplier Quality Engineers Php55,000
Sales and Marketing Manager Php45,000
Sales Representatives Php19,462
Marketing Specialists Php29,068
Product Managers Php49,000
Advertising and Promotions Staff Php19,000
Customer Service Representatives Php23,000
Market Research Analysts Php23,000
Sales Support Staff Php64,152
Finance and Accounting Manager Php65,000
Accountants Php35,662
Financial Analysts Php32,803
Auditors Php19,787
Budget Analysts Php32,659
 Tax Specialists Php45,409
Treasury Specialists Php32,659
Payroll Specialists Php30,000
Human Resource Manager Php46,621
Human Resource Generalists Php22,500
Recruitment Specialists Php15,837
Compensation and Benefits Specialists Php16,366
Training Development Specialist Php30,000
Employee Relations Specialists Php35,000
Human Resource Systems Specialists Php37,767
Diversity and Inclusions Specialists Php21,281
Legal Department Manager Php61,576
Attorneys Php55,000
Paralegals Php25,000
Compliance Officers Php33,000
Intellectual Property Specialists Php51,000
Contract Specialists Php48,000
Legal Operations Specialists Php48,000
Litigation Support Specialists Php43,000