Basic concepts of plant layout and

design
 Plant design
• Plant design refers to the overall design of a
manufacturing enterprise / facility.
 Plant design specifies
• Flow charts and plant layouts
• spell out interconnections and raw material flows,
permanent/temporary storage, shop facilities, office spaces,
delivery and shipping facilities, access ways
• Equipments, utilities and services to be used
• Required instrumentation and interconnections for process
monitoring and controls
• Strategic site location, plan and elevation
• They also often provide economic analyses of plant
profitability in terms of various product demand and price
and material cost scenarios.
 Plant design situations
• design and erection of a completely new plant
• design and erection of an addition to the existing plant
• the facility or plant operations and subsequent expansion restricted by a
• poor site, thereby necessitating the setting up of the plant at a new site
• addition of some new product to the existing range
• adoption of some new process /replacement of some existing
equipment
• modernization / automation of the existing facility
• expansion of the plant capacity
• relocating the existing plant at a new site because of new economic,
social, legal or political factors
 Design considerations for plant design
• Acquisition of capital
• Product design
• Sales planning
• Selection of production process
• Make or buy
• Plant size
• Product prize range
• Plant location
• Plant layout
• Building type selection
• Diversification
• Organization development
 Acquisition of capital
• Primary sources of capital are
– Personal savings
– Loans
– Sale of bonds/sale of stocks
– Trade credit
• Capital needs fall into three categories
– Capital for initial establishment
– Funds for covering the operating cost
– Securing funds for expansion
 Product design
• Product design is to determine and specify products
that will be profitable to manufacture and distribute
and that will give human satisfaction
• Product design has three aspects
– Design for function
– Design for making
– Design for selling
 Sales planning
• Early phase in plant design is the planning
requirements by the sales department
• Volume of production by market survey
• Nature of demand for the product and expected
seasonal variants
 Selection of production process
• Determination of specific type of equipment for a
given operation
• Determination of optimum type of raw material for a
given product
• Rate of return on an investment proposal
 Make or buy
• Problems of plant design are mostly depend on the
make or buy decision
• Determination of unit cost of the product is the first
step in it
– Reducing the unit material cost and processing
costs
– Minimizing the cash investment
– Improving the product mix
 Plant size
• Determination of size of the plant is dependent upon
the volume of product proposed.
• Break even chart is helpful in determining the plant
size
– Number of dollars versus production capacity
– Number of units a concern must produce in order
to break even
 Product prize range
• Similar to make or buy
• Its an early decision that management must make for
products to compete.
• Product prize will influence the basic quality of the
product and manufacturing process
• Low priced products are usually produced in larger
volumes than higher priced ones
 Plant location
• Selecting a location involves
large commitments of
capital
• It involve selecting a region
as well as specific site
within that region
• Difficult part is determining
the plant location is the
criteria by which various
location alternatives can be
evaluated
 Plant layout
• Plant layout is a plan of optimum arrangement of
facilities including personnel, equipment’s, storage
space, material handling equipment and all other
supporting services along with the decision of best
structure to contain all these facilities.
 Plant layout
• Plant layout is very complex in nature; because it
involves concepts relating to such fields as
engineering, architecture, economics and business
management.
• After the site for plant location is selected; it is
better to develop the layout and build the building
around it – rather than to construct the building first
and then try to fit the layout into it.
 Objectives of plant layout
• Streamline flow of materials through the plant
• Minimise material handling
• Facilitate manufacturing progress by maintaining
balance in the processes
• Maintain flexibility of arrangements and of operation
• Maintaining high turnover of in-process inventory
 Objectives of plant layout
• Effective utilisation of men, equipment and space
• Increase employee morale
• Minimise interference (i.e. interruption) from
machines
• Reduce hazards affecting employees
• Hold down investment (i.e. keep investment at a
lower level) in equipment.
 Building type selection
• For an existing building, building should be selected
that best suits the overall requirements of the layout
plan.
• For new construction, building type should be
selected only after the plat layout is fairly well
developed
 Diversification
• Diversification is an act of an existing entity
branching out into a new business opportunity. This
corporate strategy enables the entity to enter into a
new market segment which it does not already
operate in.
 Organization development
• Once the overall objectives of the enterprise are
clearly defined, the objectives of the various
subdivisions must be determined and clearly
specified.
 Special features of food industry
• Many of the elements of plant design are the
same for food plants as they are for other
plants particularly those processing industrial
chemicals.
• Differences,
• basically in the areas of equipment selection
and sizing, and in working space design
 Food plant design considerations
• Food processing unit operations
• Prevention of contamination
• Sanitation
• Deterioration
• Seasonal production
 Food processing unit operations
• involves many conventional unit operations
• involves many which differ greatly from usual process
• freezing and thawing, freeze drying,
• pasteurization and sterilization, blanching, baking, cooking
• leavening, puffing, and foaming
• slaughtering, tenderization
• slicing and dicing, peeling and trimming,
• component separation, filling and packaging, canning and
bottling, coating and encapsulation
• stuffing, controlled atmosphere storage, fumigation
 Prevention of contamination
• provision or use of filtered air, air locks, piping
layouts that ensure complete drainage and
prevent cross stream
• contamination of finished products by
unsterilized or unpasteurized raw material and
cleaning solutions
• Contamination from water; washing products
and containers
• pest entry, mould growth
 Sanitation
• CIP systems
• equipment which can be readily disassembled for
cleaning if necessary
• clearances for cleaning under and around
equipment,
grouting to eliminate crevices
• Air flow and human traffic flow patterns
• impermeable coated or tiled floors and walls, at least
one floor drain per every 40 m2 of wet processing area
 Deterioration
• refrigerated and controlled environment
storage areas
• space and facilities for product inspection and
for carrying out quality assurance tests
• equipment for pre-cooling material
• standby refrigeration and utility arrangements
in case of power interruptions
 Seasonal production
• plants have to be sized to accommodate peak
seasonal flows of product without excessive
delay,
• have to be highly flexible so as to handle
different types of fruits and vegetables
• Modelling of crop and animal growth
processes for scheduling production and
adequately sizing plants.
 Food Plant Design Process
• all projects follows the same stages of
development.
• extent and detail of the activities behind each
stage are different with every project.
• A sequence of plant design activities is
outlined in flow chart
 Types of manufacturing processes
• A layout is primarily determined by the type of process it
supports.
• Industrial processes and their layouts vary so widely. So it
is desirable to classify them based on common
characteristics.
• Continuous process industry
• Repetitive process industry
• Intermittent process industry
 Continuous
• In this type of industry raw material are fed at one end and the
finished goods are received at another end.
• A continuous industry may either be analytical or synthetic
• A analytical industry breaks up the raw material into several parts
during the course of production process or changes its form, e.g.
oil and sugar refineries.
• A synthetic industry on the other hand mixes the two or more
materials to manufacture  one product along with the process of
production or assembles several parts to get finished product.
Cement and automobiles industries are the examples of such
industry. Line layout is more suitable in continuous process
industries.
 Repetitive
• Repetitive industry is one where the product is processed
in lots.
• The product moves through the process in specific
quantities, called lots.
• It also involves series of operations, but not so rigid as in
case of continuous process.
  Intermittent
• Intermittent type of industries is those, which
manufacture different component or different machines.
Such industries may manufacture the parts, when
required according to the market needs.
• Examples of such industries are shipbuilding plants. In
this type of industry functional layout may be the best.
 International Organization
for Standardization
• Of the more than 21 500
International Standards
and related documents,
ISO has more than 1 600
related to the food
sector, with many more
in development. These
cover:
• ISO 9001
• ISO 14001
• OHSAS 18001
• ISO 22000
• HACCP
• Prerequisite ProGrames
– (Food safety)Basic conditions and activities necessary to
maintain a hygienic environment throughout the food supply
chain which is suitable for production, handling, and provision
of safe end products and safe food for human consumption.
• ISO 9001:2008 Quality Management System standard, which is
widely implemented in all sectors but does not itself
specifically address food safety.
• ISO 14001- Environmental Management Systems: This
standard helps an organisation to address its environmental
risk by identifying the aspects of its business that impact the
environment and assessing those impacts to determine how
best they can be managed in the context of the organisation.
• OHSAS 18001- Occupational health and safety: Provides a
framework for managing occupational health and safety in the
workplace and holds great potential for saving on costs related
to health and safety failures and routinely reduces insurance
premium costs for business owners.
• ISO 22000 is a certifiable standard that sets out the overall
requirements for a food safety management system. It
defines the steps an organization must take to
demonstrate its ability to control food safety hazards and
ensure that food is safe for human consumption.
• HACCP (Hazard Analysis and Critical Control Points) and
ISO certifications serve different purposes, but are also
complementary.
• HACCP focuses on the sanitation of facilities, equipment
and products, all of which must meet government and
municipal standards.
 ISO 22000
• In fact, ISO 22000 is a new standard that specifies the
requirements for a food safety management system. ISO 22000
incorporates all the elements of HACCP and of Good
Manufacturing Practices (GMP).
• International
• Applicable to the entire food chain
• Auditable and can be used for certification and registration
• Structured / aligned with the 8 clauses of ISO 9000:2000
• Require the implementation of relevant industry GMP's,
Standards and prerequisite measures
 HACCP
• HACCP is an internationally recognised system used to
identify and manage risk.
• HACCP stands for Hazard Analysis and Critical Control Point.
• The principles of HACCP are:
• hazard analysis
• identifying critical control points
• establishing critical limits
• monitoring
• taking corrective action
• keeping records, and
• verifying results.
 HACCP Plan Implementation
• Describing the food and its intended use.
• Developing a flow diagram for the production, processing and
preparation of food.
• Performing the hazard assessment.
            a) Ingredients prior to any processing step.
            b) Processing steps.
            c) End product.
• Selection of CCP.
            a) entering in flow diagram.
            b) listing of CCP’s by numbers.
• Establishing the Critical Limits.
   
• Establishing monitoring requirements.
• Establishing corrective action to be taken when there is
a deviation identified by monitoring of a CCP .
• Establishing effective record-keeping systems that
document the HACCP plan .
• Establishing procedures for industrial and governmental
verification that the HACCP system is working properly.
• Verification measures may include physical, chemical and
sensory-organoleptic methods and the establishment of
microbiological criteria .
 Fruit Products Order (FPO), 1955
• Aims at regulating sanitary and hygienic conditions in
manufacture of fruit & vegetable products. 
• Licensing under this Order lays down the minimum
requirements for:
– Sanitary and hygienic conditions of premises,
surroundings and personnel.
– Water to be used for processing.
– Machinery and equipments
– Product standards.
 Meat Food Products Order 1973
• Specifies sanitation and hygiene requirements for
slaughterhouses and manufacturers of meat products.
• Contains packing, marking and labeling provisions for
containers of meat products.
• Defines the permissible quantity of heavy metals,
preservatives, and insecticide residues in meat products.
Milk and Milk Products Order 1992
• The order sets sanitary requirements for dairies,
machinery, and premises, and includes quality control,
certification, packing, marking and labeling standards for
milk and milk products.