PLANT DESIGN

PLANT
 Plant is a complex having several buildings,
where workers manufacture goods or
operate machines processing one product
into another.
DESIGN

 Design is the creation of manufacturing

process to fulfill a particular need.

 The need may be public need or commercial

opportunity.
PLANT DESIGN
 Total overview of the industrial plant
 Totality of the plant
 Plant layout
 Plant site
 Plant location
 Costing
 Can be a new project, modification, a new
process or expansion
GENERAL CONSIDERATIONS
IN A PLANT DESIGN
1. Plant location
2. Plant layout
3. Plant operation and control
4. Utilities
5. Structural design
6. Storage
7. Materials handling
8. Waste disposal
9. Health and safety
10. Patents
PLANT LOCATION

 Plant location refers to the choice of the

region where men, materials, money,
machinery and equipment are brought
together for setting up a business or factory.
PLANT LOCATION
 The geographical location of the final plant
can have a strong influence on the success
of an industrial enterprise.

 The plant should be located where the

minimum cost of production and distribution
can be obtained.
PLANT LOCATION
 The choice of the final site should first be
based on a complete survey of the
advantages and disadvantages of various
geographical areas.

 An approximate idea for the plant location

should be obtained before a design project
reaches the detailed estimate stage.
PLANT LOCATION
 Identifying an ideal location is very crucial, it
should always maximize the net advantage,
must minimize the unit cost of production and
distribution.

 Plant location decisions are very important

because once the plant is located at a
particular site then the organization has to
face the pros and cons of that initial decision.
FACTORS AFFECTING PLANT
LOCATION
 Raw Materials
 Markets
 Energy Availability
 Climate
 Transportation Facilities
 Water Supply
 Waste Disposal
 Labor Supply
 Taxation and Legal Restrictions
 Site Characteristics
 Flood and Fire Protection
 Community Factors
RAW MATERIALS
 The source of raw materials is one of the
most important factors influencing the
selection because location near the raw
materials source leads to reduction in
transportation and storage charges.
RAW MATERIALS
Attention should be given to the;
 purchased price of the raw materials

 distance from the source of supply

 freight or transportation expenses

 availability and reliability of supply

 purity of raw materials

 storage requirements
MARKETS
 The location of markets or intermediate
distribution centers affects the cost of product
distribution and the time required for
shipping.

 It should be noted that markets are needed

for by-products and end products as well as
for major final products.
MARKETS
ENERGY AVAILABILITY

 Power and steam requirements are high in

most industrial plants and the fuel is ordinarily
required to supply these utilities.
Consequently, power and fuel can be
combined as one major factor in the choice of
a plant site.
ENERGY AVAILABILITY

 In addition, the presence and cost of

electricity is an important consideration for
plant location. In industrial areas the cost,
voltage and availability of electricity is
different than in living areas.
CLIMATE

 Excessive humidity or extremes of hot or cold

weather can have a serious effect on
economic operation of a plant and these
factors should be examined when selecting a
plant site.
TRANSPORTATION
FACILITIES

 The common means of transportation used

by major industrial concerns are roads,
highways, railroads and water.

 For selection careful attention should be

given to “freight rates”.
TRANSPORTATION
FACILITIES

 In food industry, raw materials and food

products are in huge amounts and not very
durable.

 Therefore, transportation should be done with

a great care and should be fast.
WATER SUPPLY
 The process industries use large quantities of
water for cooling, washing, steam generation,
immobilized conveying and as a raw material.
Therefore, the plant must be located where a
dependable supply of water is available.
WATER SUPPLY

 Water sources can be tab water, rivers,

lakes, deep wells and artesian wells. If own
sources are to be used the level of existing
water, seasonal fluctuations, chemical,
bacteriological content and cost for supply
and purification must be considered.
WASTE DISPOSAL
 The site selected for a plant should have
adequate capacity and facilities for correct
waste disposal.

 In recent years many legal restrictions have

been placed on the methods for disposing of
waste materials from the process industries.
WASTE DISPOSAL
 In choosing a plant site, the permissible
tolerance levels for various methods of waste
disposal should be considered carefully and
attention should be given to potential
requirements for additional waste treatment
facilities.
LABOR SUPPLY
 The type and supply of labor available in the
vicinity of a proposed plant site must be
examined.

 Consideration should be given to prevailing pay

rates, restrictions on number of hours worked per
week, competing industries that can cause
dissatisfaction or high turnover rates among the
workers, the ethnic distribution and variations in
the skill and intelligence of workers.
TAXATION AND LEGAL
RESTRICTIONS
 Tax rates, health insurance rates and property tax
rates do not change depending on position in our
country.

 However, being a governmental policy some places

are promoted for the development (as reduced tax
and interest rates). In industrial regions permissions
to be taken are important in cost and time delays.

 For the abroad enterprises local tax rates and

promotions should be considered.
SITE CHARACTERISTICS
 The characteristics of the land at a proposed
plant site should be examined carefully
(topography and soil structure).

 The cost of land is important as well as local

building costs and living conditions. Future
changes may make it desirable or necessary
to expand the plant facilities.
SITE CHARACTERISTICS
 The buildings that are constructed as a result
detailed land analysis, soil analysis and
structural calculations are very resistant to
aging as well as natural disasters like
earthquakes.
FLOOD AND FIRE PROTECTION
 Before choosing a plant site, the regional
history of natural events like floods or
hurricanes should be examined.

 Protection from losses by fire is another

important factor for selection of plant location.
In case of a major fire, assistance from
outside fire departments should also be
available as well as fire protection systems.
COMMUNITY FACTORS
 The character and facilities of a community
can have effects on the location of the plant.

 Cultural facilities as schools, shops,

mosques, cafeterias, kindergartens, cinemas
are important for a progressive community. If
these facilities are not present it becomes for
the plant as a necessity to provide such
facilities.