SECTION 1

INTRODUCTION
NAME OF COMPANY : GÜNEŞ

MAIN ADDRESS : MANİSA /ORGANIZATION INDUSTRIAL ZONE

CAPACITY : FRESH GRAPE 22 TONS/DAY

OPERATING TİME : 16 HOURS

NUMBER OF EMPLOYEES :40

TOTAL AREA : 8600 M2

TOTAL CLOSED AREA : 4000 M2

PROCESS TYPE :CONTINUOUS

PEKMEZ
-Pekmez is a traditional Turkish food made by using different fruits such as grape, mulberry, fig, apple, and sugar beet.

-There are two different kinds of pekmez, either liquid pekmez or solid pekmez, produced in Turkey.

-It is estimated that aproximately 18% of grapes produced in Turkey is processed into pekmez.

-Pekmez is the concentrated form of grape juice.It is obtained by boiling the juice without addition of sugar or other
food additives.Pekmez is a healthful food due to its nutritional content and is used as a main source of energy based on
its chemical composition.
-The product can be considered to be a natural food containing natural sugars glucose, fructose and minerals.Pekmez
is a natural source of energy due to its high carbohydrate content (65-68%). Pekmez contains approximately 293
kcal/100g of energy also important source of organic acid and minerals.It contains valuable minerals such as calcium
(0.084-0.086%) and iron (0.005-0.01%).In addition, B1 and B2 vitamins add extra value to the product.
-The structure of liquid grape pekmez is concentrated and fluid.
According to TS 3792, the sensory properties of Pekmez are as follows;
Pekmez must have its own fragrance, color and taste, and it should not have burnt taste and foreign smell.
The appearance of Pekmez must be unique and homogeneous.
Pekmez must be unsedimented and uncrystallized
Pekmez should not contain the core and fiber particles of other fruits (such as figs, mulberries and dates).
RAW MATERIAL
• Grape fruit is rich in nutrients- carbohdrates,fat,protein, vitamins and minerals. Raw grapes are 81% water, 18%
carbohydrates, 1% protein.

• Grapes can be eaten fresh as table grapes or they can be used for making wine, jam, juice, jelly, grape seed
extract, raisins, vinegar, and grape seed oil.

• Approximately 71% of world grape production is used for wine, 27% as fresh fruit, and 2% as dried fruit.

• Grape production of Turkey is fifth rank in the World.

• Raw material must be ; Uncrushed,ripeness,unspoilt for good quailty pekmez.

• The grape with less water content is preferred. Because, we want to get more final products.
Components (per 100 gr) Fresh grape

Water 81
Carbohydrates(g) 18.1
Protein(g) 0.7
Fat 0.2
Calcium(mg) 10
Iron(mg) 0.4
Potassium(mg) 191
Energy (kcal/100 gr) 69
Vitamin C (mg) 3.2
 ORGANIZATION CHART
General
manager

Production Purchasing and Quality control Administrative Finance Health

Department sale department department department department department

Production Purchasing Quality control Human Official

Doctor
manager manager manager resources accountant

Workers Sale personel Food engineer Secretary Accountant

Food technician Security system

Repair technician
PROCESS FLOW CHART

FRESH GRAPE
WASHING
STALK SEPERATION
CRUSHING GRAPES
PRESSING
SEPARATION
HEATING AND DEACIDIFICATION
(CaCO3 ADDITION)
COOLING
 CLARIFICATION
(Tannin-Gelatin Addition)

FILTRATION

TRIPLE EFFECT EVAPORATION

PASTEURIZATION

COOLING

PACKING
STORAGE
PROCESS AND EQUIPMENT
DESCRIPTION
BELT CONVEYOR
• Capacity: 2-7 Ton/hr
• DIMENSION: L1000mm*W5000mm*H1000mm

-One of the most important means of

transport is the belt conveyors, which are
especially used for the transportation of solid
materials in a continuous way to long
distances in horizontal or within certain
limits.
WASHING • Capacity:6 Ton/hr
• DIMENSION:L3000*W1000*1300mm

-The first stage of pekmez production is washing the

harvested fruits.

-At this stage the aim is to remove dust, soil, pesticide

residue and live/dead insects in the fruits to be processed
and to reduce the microbial load of the fruit.

-While cleaning the residues on the grapes by washing,

certain amount of stum and sugar are also lost due to
washing. Therefore, it is necessary to be carefull in this
process. Using of cold water can help to reduce the amount
of sugar wasting by washing process.
CRUSHING
• Capacity:4-5 Ton/hr
• DIMENSION:3000L*1130W*1900mm

-Crushing process is the process of separating the

parts such as grape pulps and waste.
-In addition, since the phenolic substances and
chlorophyll found in grape stems negatively affect
the taste and color of molasses, it is important to
separate grape grains from their stems and
garbage before pressing.
PRESSING
Capacity:4-6 Ton/hr
• DIMENSION:1836L*630W*1352mm

-The grapes are pressed to obtain the must.

-The must obtained as a result of pressing is
cloudy and acid in character.
-The degree and quality of the turbidity varies
according to the variety of the grape, whether
it is fresh or kept.
-%18 of product is lost as grape pulp
SEPARATION

Capacity:3 ton
Dimension:L3500*W1100*H1510

-The must obtained from press contains fruit

pulp and shell particles of various sizes.
-Grape must is passed through a separator in
order to separate it from coarse substances.
(2500-3000 rpm)
HEATING AND DEACIDIFICATION
• Capacity:6 ton/hr
• DIMENSION:L1800*W2300*H2000

After the grape juice syrup is acidified and crushed, the heating process is
applied.
• Grape juice contains tartaric acid, protein and pectin, which do not have
a positive effect on molasses.
• Therefore, the main treatment methods, heat application, cold leave,
tannin-gelatin application should be done.
• Deacidification is mostly applied with marl. Marl contains 50-90%
CaCO3 and is white or whitish in color.The syrup is heated at 55-60 ° C
for 10-15 minutes.
• 66 g calcium carbonate (CaCO3) should be added to reduce the acidity of
100 liters of must by 0.1%.
• It is very important how much acidity regulator is used. Using less acidity
regulators than necessary causes the taste of molasses to be sour and the
formation of high amounts of HMF as a result of Maillard Reaction
during the thickening of the must due to the acidity that cannot be
reduced. In addition, it causes the color to be dark due to caramelization.
When using too much acid corrector, clarity decreases, color and
consistency become too dark, taste and odor are adversely affected.
PLATE HEAT EXCHANGER
• Dimension:L1190*H2930*L1650
We use plate heat exchanger to transfer
heat between two fluids or to cool.
CLARIFICATION
• Capacity:4-7 Ton
• DIMENSION:L1000*W900*H1500mm

-In order to completely clarify the grape must

and eliminate the bitter flavors, the must is
clarification.Clarification can be achieved by
application of heat, tannin-gelatin application
or enzymatically or a sufficient clarification, it
is sufficient to add 10 g / hl of tannins and
gelatin to the must with 41% dry matter and 5
g / hl to the must with 17% dry matter.
VACUUM EVAPORATION
Capacity:6 Ton
• DIMENSION:L4000*W3500*H5200mm

-Heat treatment applied to remove acidity. Heat energy is

used to concentrate the molasses.
-The clarified must is finally concentrated to the desired dry
matter level by means of evaporation.
-Evaporation is continue until it reaches 68% of dry matter.
-Combustion and caramelization can occur at very low levels
or even be eliminated.
-While the vacuum method produces molasses in the desired
concentration, color, taste and odor, non-caramelized, HMF
formation is minimized and nutritive components are
produced. It is highly protected and it is possible to produce
healthier molasses by preventing metal contamination.
PASTEURIZATION
Capacity:3 Ton/hr
Dimension:L2000×W2000×H2000

-The product is heated to the specified

temperature by means of hot water (82ºc) and
delivered to the filling machine at this
temperature for a specified period of time.
FILLING

• Capacity:5 Ton
• DIMENSION:L1440*W850*H1600mm
Filling operations of all dense and high
viscosity products, including molasses, can
be made.
PACKING

• DIMENSION:L75*W36*H70 inch
After the concentration process, molasses is
left to cool. Molasses is put on the market
by filling in tin cans, glass jars, plastic or
other packages.
WATER TANK

• Capacity:15 Ton
• DIMENSION:L4750*W1950*H2500mm

• Provides the storage of water for use in

many applications such as drinking water,
fire fighting, food preparation and many
other applications.
RESTING

Capacity: 5 Ton

DIMENSION: L:1800*W:2300*H:1500
PLANT LAYOUT
MATERIAL BALANCE
 22.000 kg/h Fresh grape 20° Brix

44.000 kg water /h WASHING 44.000 kg

WATER/h

22.000 kg/h Fresh grape

TMB STALK
6%(waste) SEPARATION AND Waste (capsterm)
22.000 kg = (22.000)*(0.06)+ P CRUSHING
W
P=20.680 kg/h 1320 kg/h
W=1320 kg/h
P
 20,680 kg/h 20° Brix

TMB , F=W+P Grape Pulp

18%(grape pulp) PRESSING
(seeds, shells, etc.)
20,680 kg/h= (20,680 kg/h)*(0.18) + P
W=3722 kg/h
P= 16,958 kg/h
W= 3722 kg/h
Grape Juice 20° Brix (P)

16,958 kg/h
TMB , F=W+P
2%(grape pulp) Grape Pulp (W)
16,958kg = (16,958 kg)*(0.02)+ P SEPERATION

P= 16,621 kg/h W=339,16

W=339,16 kg/h kg/h

Must 20° Brix

 16,621 kg 20° Brix (F)

in normal 66 gr CaCO3 c
use for 100 liters HEATING (70°C) and
molesses. Therefore we DEACIDIFICATION
used 10,96 kg=11 kg for
our product. TMB,
F+C=P
16,958 kg+11 kg=16,969/h
P
16,969 kg/h 20° Brix

COOLING(25°C)
 16,969 KG /h 20° Brix
(F)
If dry matter is %17 we should add 5
gr tanen-gelatin..

0.006 kg tanen-gelatin CLARIFICATION

P
16,969.006 kg /h 20° Brix
TMB, 1%(waste)
F=W+P

W=169.69006
FILTRATION Sediment (waste) kg/h

16,799 KG /h
(p)
 16,799 KG/h 20° Brix (F)

WATER
DS MB, EVAPORATION
16,799*0.20=W*0+(P*0.68)
P= 4940 KG/H PEKMEZ Water =11859
kg/h

P
4940 kg/h
68° Brix kg
68° Brix
PASTEURIZATION

(82°C/15 sec)

grape molasses = 4940

kg /h 68° BRIX(P)

FILLING

grape molasses = 4940

kg /h 68° BRIX(P)

PACKING and STORAGE

SECTION 3
CONVEYING SYSTEM
CALCULATIONS
1- CONVEYOR POWER CALCULATION FROM STORAGE TO WASHING
T = a*b*v
T: carrying capacity, (mass/time, t/h, kg/s….)
a: average crossescional area of the material, (m 2)
b: bulk density of material, (t/m3, g/cm3…)
v: speed of conveyor belt, (m/s)
T = 0.38 kg/s
a = 0.04 m2
b = 0.400 k g/cm3
v =?
T = a*b*v  0.38 kg/s= (0.04 m2 ) x (400 kg/m3) x v
0.38 kg/s = (0.04 m2 ) x (400 kg/m3) x v

V = 0.023 m/s
 Power required to convey material, Wm:
Theoretical power necessary
Wm = mm*lt*g*µm *v
The total power required (WT) = We + Wm ± Wr
Wm = T*lt*g* µm,
The force required to move the empty belt, Ne:
(µm ~ 0.3 – 0.4).
Ne = mi*lt* g* µe
Wm= (0.38 kg/s)*(5 m)*(9.81m/s2)*(0.4)
lt = conveyor length, (m) = 5 meter
Wm = 7.455 (kg* m2)/s3 = 7.45 watt
mi = F6/1EU02N/UOFDA
Wr=0
1 kg/m2*1m=1 kg/m
The total power required (WT) = We + Wm ± Wr
µe = friction coefficient of ball bearing idlers: ~ 0.4
Wt= 0.49+ 7.45 + 0 = 7.94 W
Approximation: if precise information is not available, then,
(Motor efficiency = % 90)
Ne = mi*(lt + 0.10lt)*g*µe
Motor power : 7.94 / 0.9 = 8.82 W
Power required,
We = 1 kg/ m *(5m+0.1*5m) * 9.81 m/s 2
*0.4* 0.023 m/s ≌ 0.012 hp
We = Ne*v = mi*(lt + 0.10lt)*g* µe *v
We = 0.49 (kg* m2)/s3 = 0.49 watt
POSITION NUMBER OF BELT W total (kW) hp

CONVEYOR POWER 1 7.94 W 0.012 hp

CALCULATION FROM
STORAGE TO WASHING

CONVEYOR POWER 1 7.94 W 0.012 hp

CALCULATION FROM
WASHING TO
CRUSHING
ENERGY CONSUMPTION
PIPING AND PUMPING
CALCULATION
CALCULATION FROM WATER TANK TO WASHING  Di(opt) = 3,0 * (qf)0.45 * (μ) 0.18
qf = Fluid Flow Rate = mflow /ρwater Di(opt) = 3.0 * (0.406)0.45 * (9.1 x10 -4)0.18
ρwater = 997 kg / m3 = 61.8 Ibm/ft3 Di(opt) = 0.567 inch
Qf= 0.012 KG/S Sch = 40 For Liquid;
mflow = 44,000 kg/h Di (opt) = 0.0293 m

qf = 44,000 x x 0.01497 x Area = 0.0034

qwater flow = 0.406 Velocity = =

NRE = (ρ*v*D)/M
=((997 kg/m3 * 0.352 m/s * 0.0293)/ (0.00091))
= 11.298 > 2100 turbulent
 MECHANICAL ENERGY BALANCE FOR FROM WATER TANK TO WASHING

-WS=1/2α × (V22-V12) +g (Z2-Z1) + (P2-P1 /ρ ) + ΣF (α = 1)

Fconst=0.55× "V22" /2α Fconst=0.55× (0.3522/2) = 0.034 J/kg

Fenlarg.=hx× "V22" /2α Fenlarg.=1× (0.3522 / 2 ) = 0.001352 J/kg

Felbow=kf× "V22" /2α Elbow, 90° Felbow (2) =0.75 × (0.3522 / 2) = 0.046 J/kg = 2 x 0.046 J/kg = 0.092 J/kg

Fvalve=kf× "V22" /2α

Fvalve (2) =6× (0.3522 / 2) = 0.371 J/kg = 2X0.371 J/kg = 0.742 J/kg
Ftee=kf× "V22" /2α
Ftee=1 × (0.3522 / 2) = 0.001352 J/kg
Fpipe=4×F×L/D× "V22" /2α
ΣF
Fpipe==4×1.41×4/0.622×0.352
0.034 + 0.001352 + 0.092
2 + 0.742 + 0.001352 + 2.24= 3.11 j/kg
/2 =2.24 J/kg
1/2(0.352² - 0)+9.81(2.5-2.0)+(997-0)/997+3.11=0
Ws= 18.883j/s
Ws=n * Wp n=0.65
Wp= 17.603/0.65 = 29.05 watt
29.05watt*(1kW/1000watt)*(1hp/0.745kW)=0.038hp
SECTION Di (opt ) Velocity (m/s) Turbulent or Laminar

Water tank - washing Sch = 40 For Liquid; 11.298 > 2100 turbulent
Di (opt) = 0.567 m

Crushing-pressing Sch = 80 for solid; 30481 > 2100 turbulent

Di(opt)= 0.00546 m

Pressing-seperation Sch = 40 for solid; 17.609> 2100 turbulent

Di(opt)= 0.02093 m

Seperation-heating and Sch = 40 For Liquid; 15.297 > 2100 turbulent

deacidification Di(opt) = 5.047 m

Heating and deacidification- Sch = 40 For Liquid; 78.3 < 2100 laminar
cooling Di(opt) = 0.02664 m

Cooling- clarification Sch = 80 for solid 1.02 x 10^(-3) m/s 17.966 > 2100 tubulent
Di(opt) = 0.1223 m
SECTION Di(opt) Velocity (m/s) Turbulent or Laminar

Clarification-filtration Sch = 40 For Liquid; 1.18 x 10^(-5) m/s 0.044 < 2100 laminar
Di(opt) = 0.02664 m

Filtration-evaporation Sch = 40 For Liquid; 0.158 m/s

Di(opt) = 0.0901 m 8.708 > 2100 turbulent

Evaporation-pasteurization Sch = 40 For Liquid; 0.158 m/s 8.708 > 2100 turbulent
Di(opt) = 0.0901 m

Pasteurization-cooling Sch = 40 For Liquid; 0.158 m/s

Di(opt) = 0.0901 m 8.708 > 2100 turbulent

Cooling-resting tank Sch = 40 For Liquid; 0.158 m/s

Di(opt) = 0.0901 m 8.708 > 2100 turbulent

Resting tank-filling Sch = 40 For Liquid; 0.158 m/s

Di(opt) = 0.0901 m 8.708 > 2100 turbulent
From To F cons F enlargment
j/kg F pipes Felbow F valve F tee ∑F Ws Wpower W hp
machine machine (j/kg)
j/kg j/kg j/kg j/kg Friction
j/s watt pump(wp
(%65
loss j/kg efficiency)

WATER TANK WASHING

0.034 0.001352 2.24 0.092 0.742 0.001352 3.11 17.603 29.05 0.65 0.038
(1)
(2) (2)
CRUSHING PRESSING 0 0 0 0 0 0 0 49.0 75.3 0.65 0.101

PRESSING SEPARATION 0 0 0 0 0 0 0 59.0 90.84 0.65 0.121

SEPARATION HEATING AND
DEACIDIFICATI 0.198 0.361 2.991 1.083 8.43 0.361 13.42 19.67 30.27 0.65 0.0406
ON (4) (5)

HEATING AND
DEACIDIFICATI
COOLING 0.0121 0.0205 2.18 0.01653 0.02646 0.0205 4.36 10.25 15.77 0.65 0.021
ON (2)

COOLING CLARIFICATION
0.0121 0.0205 7.12 0.0117 0.0187 0.0220 7.123 8.114 12.48 0.65 0.016
(3)
CLARIFICATION FILTRATION 0.00382 0.0059 2.62 0.00885 0.00354 0.00059 2.72 4.71 7.26 0.65 0.0578
(2)
FILTRATION EVAPORATIO
N
0.00686 0.0124 35.59 0.744 1.488 0.0124 37.85 43.02 66.18 0.65 0.0888
(8) (2)
EVAPORATION PASTEURIZATI
ON
0.00686 0.0124 11.86 0.279 3.72 (5) 0.0124 15.89 24.153 37.15 0.65 0.0498
(3) (1)
PASTEURIZATI
ON
COOLING
0 0 0 0 0 0 0 5.17 7.95 0.65 0.0106
COOLING RESTING
TANK 0.0068 0.0124 11.86 0.279 0.0744 0.0124 12.24 13.38 20.58 0.65 0.0276
SECTION NUMBER OF FRICTION LOSS(J/kg) PUMP(watt and hp)
PUMP

Water tank - washing 1 6.707 34.5 watt = 0.0463hp

Crushing-pressing 1 0 75.3 watt=0.101hp

Pressing-seperation 1 0 90.84 Watt=0.121hp

Seperation-heating and 1 17.23 36.13 watt=0.048hp

deacidification

Heating and deacidification- 1 13.00 29.07 watt=0.390hp

cooling

Cooling- clarification 1 10 16.92 watt=0.0227hp

SECTION NUMBER OF FRICTION LOSS(J/kg) PUMP(watt and hp)
PUMP

Clarification-filtration 1 12.00 16.92 watt=0.0165 hp

Filtration-evaporation 1 32.15 57.41 watt=0.0770 hp

Evaporation-pasteurization 1 15.05 31.10 watt=0.0417 hp

Pasteurization-cooling 1 0 7.95 watt=0.0106 hp

Cooling-resting tank 1 11.05 24.96 watt=0.0335 hp

Resting tank-filling 1 21.05 40.34 watt=0.0541 hp

NUMBER OF TANK FOR ACIDIFICATION
Height of each tank;
Resting time for acidification is 4 hours. (4h*14400s)
Q=16641 kg/h*1h/3600s*1m3/1080 kg =4*10^-3
V= ×D2×H H= D
Trest = 14400 s = V= 61.63
V= ×D2×D = D3= 8.55 m3 D = 1.03 m H=
1.03 m
Vtank =61.630 *

Head space = 0.2×(7.13)+ 7.13=8.55 m3

# of Tank = = 8 TANKS
TANK CALCULATION
• WATER TANK FOR WASHING
Water (V) =( (44000 kg)/(997 kg/m3) ) Vw=44.13 m3
Safety Factor(20%)=( ( S+44.13)*0.2 ) = S S=11 m3
Vtotal=55.13 m3

Vtank=(πD3)/3 D=1.87
Htank=(4D/3) H=2.5
EQUIPMENT HEIGHT(m) DIAMETER(m) VOLUME OF VOLUME OF TOTAL VOLUME
PRODUCT(m*3) SAFETY (m*3)
FACTOR(20%)
(m*3)

Water Tank (x3) 2.5 1.87 44.13 11.0 55.13

Resting Tank (x2) 1.5 1.12 12.7 3.1 15.8

Clarification Tank 1.5 1.12 43.6 10.9 54.5

Heating And 2.0 1.5 43.6 10.9 54.5

Deacidification
Evaporation 5.2 3.9 12.7 3.1 15.8

Acid Detergent 4.0 3 27.77 6.94 34.71

Caustic Detergent 4.0 3 27.77 6.94 34.71

Sterilent 4.0 3 27.77 6.94 34.71

PLATE HEAT EXCHANGER
CALCULATIONS
PLATE HEAT EXCHANGER CALCULATION

Mass transfer of grape molasses (mc)= 4940 kg/h

Mc = (4940 kg/h) * 1h/3600sec = 1.37 kg/sec
Q = (mh * c ph * ∆Th ) = (mc * cpc * ∆Tc) (total heat capasity)
We assumed the out of steam temperature is 50 °C
(mh ) * (4.18 kJ/kg*K) * (70-50°C ) = 1.37 kg/sec * 2.31 kJ/kg*K * (55-20 °C )
mh = 1.2441 kg/s

Grape juice (cold) Water (Hot Stream)

m (mass transfer) Mc=1.37 kg/s Mh=1.2441 kg/s
T İnlet temperature Tci =20 °C Thi = 70 °C
T (Out temperature) Tco =55 °C Tho = 49.7 °C
µ (Viscosity) 2.267x10 -3 0.483x10 -3
ρ (Density) 1,070 kg/m3 1,000 kg/m3
Pr (Prandl Number) 4.55 3.09
Cp (heat capasity) 3.650 kJ/kg*K 4.2 kJ/kg*K
k (heat transfer coefficient) 0.62 0.656
The heat transfer coefficient between plates is;
hp : heat transfer coeffi cient
Re : Reynolds number
ρ = density
up = linear velocity of the fluid in the channel, m/s
de =, m
Re = ( ρ*up * de ) / µ

Plate heat exchanger dimention

L (lenght of Plate) 1.5 m
W (width of plate) 0.47 m
b (space between two plate) 0.005 m
a (Hydraluic area) W*b = 0.00235 m2
de (hydraulic diameter) b.w/2(b+w)=0.0025
𝑚 1.37 kg/s
up (linear velocity of the fluid in the up = = kg =0.545 m/s
ρ ∗de 1,070 ∗0.00235m2
channel, m/s) m3

Re = (1,070 kg/m3)* (0.545 m/s)*(0.0025m)/ 2.267x10 -3kg/m*s

Re= 643  Re<1800 Laminar flow for grape juice

Nu = hp *de /k = 0.026 (Re)0.65 * (Pr)0.4* (µ/ µw )0.14 = 0.023 (643)0.65 * (0.45)0.4*(2.267 / 0.483 )0.14
Nu= 0.023*66.88*0.73*1.24 = 1.394 = (h p * 0.048m)/0.62

hp = 18 W/(m2*°C )
Number od transition units (NTU);
Q = (mh * c ph * ∆Th ) = (mc * c pc * ∆Tc)
ሺThi −Tco ሻ−(Tho −Tci )
∆TLM = (LMTD values)
ln⁡( ሺThi −Tco ሻ/(Tho −Tci ))

= 14.07 °C
ሺ70 −48 .7 ሻ−(48 .7−40 ) 12 .6
∆TLM = ሺ =
ln ⁡( 70 −48 .7 ሻ/(48 .7−40 )) 0.8954
NTU = (Thi - Tho ) / ∆TLM (NTU value)
NTU = (70-48.7) /14.07 = 1.51

Temperature of grape molasses (T g) = 40 °C = (313.15K)

Grape molasses flowing at a 1.37 kg/sec countercurrent plate heat exchanger at 40 °C (313.15K)
and is heated by hot water stream entering at 75 °C (348.3K).

Density of grape molasses (ρg) = 1.40 kg/m3

Brix of grape molasses = 68°
Cp of grape malosses = 2.31 kJ/kg*K
A t = Q / UFt *∆TLM = 110.76 / 0.97*14.07 = 8. 11 m² (total heat transfer area)

A plate = L X W =1.5 X 0.47= 0. 705 m² (plate area selection)

N = A t / A plate = 8.11 / 0.705 m² = 11.50 plates (number of plates)

m hc = mh / (N+1 / 2 / N hg) = 1.2441 / (11.50 + 1 / 2 / 1.00) = 0.1990kg/s

(mass velocities passing through a channel)
m cc = mc / (N+1 / 2 / N cg) = 1.37 / ( 11.50 + 1 / 2 / 1.00) = 0.2192kg/s

u hc = m hc / (ρ h * A c ) = 0.1990 / ( 1,000 *0.00235) = 84.68m/s

(linear velocities through a channel)
u cc = m cc /( ρ c * A c ) = 0.2192 / ( 1,000 *0.00235) = 93.27m/s

N RE,h = ρ h * u hc * De / μ h = 1,000 *84.68* 0.0025 / 0.483*10^(-3) = 438.30

( N RE numbers)
N RE,c = ρ c * u cc * De / μ h = 1,070 *93.27* 0.0025 / 2.267*10^(-3) = 110.056
 N NU,h = h h * De / k h = 4.2 * 0. 0025 / 0.50 = 0.021
(heat transfer coefficients)
N NU,c = h c * De/ k c = 3.650 * 0.0025 / 0.50 = 0.018

Δx= plate thickness

1/u = 1/hc + Δx / k + 1/ hi = 1/ 3.650 + 0.00/ 45.00 + 1/ 70 = 0.014 (total heat transfer coefficient)

% deviation =(( ui – u i+1 ) / ui ) X 100 =71,42 x 100 = 7.14 (control)

(pressure drop
ΔP c = 8*(0.6 N RE ^( -0.3))*(L/Dc)*(ρuc² /2) = 8*(0.6*643^(-0.3))*(1.5/1193.00)*(0.00260/2)= 1.127N/m²
in the channel)
ΔP p = 1.3*(ρup /2)*Ng = 1.3*(1.070/2)*(1.00) = 0.69 N/m²
(pressure drop at main flow port)
up =m / ρ Ap = 11.61/0.0079 =1.46 m²

ΔPt =ΔPc + ΔPp = 1.127 + 0.69 = 1.817N/m (total pressure drop)

UNIT OPERATION-I
• CRUSHING

Bond Equation ( From Geankoplis Size Reduction Formulas )

= 1.46 Ei ( (initial)

Ei=0.97
(assume for bond equation)
T =2500 kg/h
= 1.46 *0.97 ( P = 2503.5 W = 2.50 kW
SECTION 4
MULTIPLE EFFECT EVAPORATION
 V2
V1 V3
F=16799
Xf =0.20 T1 T2 U2 T3 U3
U1 80 65
95
Steam
Tsteam=110
Psteam=143.27 kPa
CONDENSER

L1 L2 L 3=4940 Xp=0.68

P1=84.55 kPa P2=47.39 kPa P3=25.03 kPa

T1 =95 T2=80 T3=65

Effect 1 Effect 2 Effect 3

Tsteam=110 Tsteam2=95 Tsteam3=80 Tcondenser=65
T1= 95 T2=80 T3=65
 OVERALL MATERIAL BALANCE

W=11859 kg/day

16799 kg/day EVAP. 4940 kg/day

20S 68S

OVERALL BALANCE (We Assume V1=V2=V3=V)

F= (V1+V2+V3) +L3
16799 kg/day =(3V)+4940 V=3953 kg/day
ENTHALPY BALANCE AROUND EACH EVAPORATOR EFFECT 3:
EFFECT 1:
L2*H+V2hg=L3hf+V3hg+V2hc
Ms(hg-hc)=V1hg
(L1-L2)2309=(L2-4940)2618
Ms=V1hg/hfg
2309L1-2309L2=2618L2-12932920
2230Ms=(16799kg/day-L1)2668
5601=2.13L2-L1
Ms = 200982-119L1
Ms=4770kg/day
EFFECT 2:
L2=6287kg/day
L1*H1+V1hg=L2hf2+V1hc+V2hg
L1=10700kg/day
V1(hg-hc)=V2hg
(16799-4)(2270)=(L1-L2)2644
38124650-2270L1=2644L1-2644L2
4914L1-2644L2=38124650
1.86L1-L2=14419
 COMPONENT BALANCE FOR EACH EFFECT
MATERIAL BALANCE
1)
FIRST EFFECT:
F=VF=L1*X1+V1*Xw
F=V1+L1
16799(0.20)=6099(X1)+0
16799=V1+10700
X1=0.55
V1=6099
2)
SECOND EFFECT:
L1=V2+L2 L1*X1=L2*X2+V2*Xw
10700=V2+6287 10700(0.55)=6287(X2)
V2=4413
THIRD EFFECT: X2=0.93
L2=V3+L3
6287=V3+4940
3)
V3=1347 L2*X2=L2*X3+V3*Xw
6287(0.93)=6287*X3
X3=0.93

STEAM ECONOMY
Vtotal/Ms = 11859/4770=2.48
 1-) 95
𝟏
𝟒
U=

k=16.3 for stainless steel

k=0.680 hb=2.55

𝟏
𝟒
𝒘
hs=1293.7 𝟐
℃ .𝒎

hb=2.55 𝟖𝟒 . 𝟓𝟓 hb = 9088.4 𝒘
𝟏𝟓𝟓𝟏 𝟐
℃ .𝒎
U 1=
𝑤
2
℃ .𝑚
2-) 80
𝟏
𝟒
𝒘
hs=1238.4 𝟐
℃ .𝒎

hb=2.55 𝟒𝟕 . 39 hb = 8873.2
𝒘
𝟏𝟓𝟓𝟏 𝟐
℃ .𝒎
U 2=
𝒘
𝟐
℃ .𝒎

3-) 65
𝒘
hs=1191.1 𝟐
℃ .𝒎
𝒘
hb=8746.2 ℃ .𝒎
𝟐

𝒘
U3=984.9 ℃ .𝒎
𝟐
Q

A1 = A1 = 18.40 m²
𝒘
𝟐
A₂=17.77 m² ℃ .𝒎

A₃=17.46 m²

n₁= 234.4 = 235 pipes

~
n2= 226.28 = 227 pipes

n3= 222.3 = 223 pipes ~

~
 PASTEURIZATION
Pasteurization ( 85 and 30 sec ) for fruit juice

V = 0.52 m/s each pipe 1 m

1-effect 235 pipes

t = = 452 s * = 7.53 min

 First effect is enough for pasteurization.

 Heat Requirement
The heat is supplied to the vacuum evaporator at a pressure of 143.27 kPa from the
steam generator in 110° C. Natural gas is used for production of steam.

Also we use hot water (70°C) for double pipe heat exchanger from evoparation of condensation
water (2nd and 3rd effect) .
STEAM CONSUMPTION:

110 =hfg= 2230.2 𝒌𝒋 Ms = 5946.25 𝒌𝒈

𝒌𝒈 𝒉

. 𝒌𝒈
5946.25
𝒌𝒋 𝒌𝒋
Q=m x 1 𝒙 𝟐𝟐𝟑𝟎. 𝟐 1329756.75
𝒉 𝒌𝒈 𝒉

𝒌𝒋 𝟏 𝒌𝒄𝒂𝒍 𝒌𝒄𝒂𝒍
1329756.75 𝒙 =𝟑𝟏𝟕𝟖𝟏𝟗 .𝟓
𝒉 𝟒 .𝟏𝟖 𝒌𝒋 𝒉

317819.5 𝒌𝒄𝒂𝒍 𝒙
𝟏𝒎 𝟑 𝟏 𝑻𝑳
𝒙x 92.45
𝒉 𝟖𝟐𝟓𝟎 𝒌𝒄𝒂𝒍 𝟎 .𝟖 𝒉
 Energy and Material Balance Around Barametric Condenser

W,T1 (Cold Water) V=3004 kg/day

T1 = 25℃
T2 = 60
V,Hs Hs = 2346.24
Cp=4.18 kj/kg

P,T2 (Hot Water)

Total material balance V+W=P

Heat Balance = V.Hs+W.Cp (T1-273)= (V+W) x Cp (T2-273)

VACUUM

• Effect 3 = 25.03 kPa (Vacuum Pressure )

• (101.325-25.03) kPa =76.3 kPa = 0.75 atm = 11 psia

COLD STORAGE ROOM
• Properties of room
• Tin = 10
• Tout =35 ( for summer average temperature in Manisa)
• Height of cold storage r = 10m
• Width of cold storage r = 20 m
• Length of cold storage r = 26 m
• Volume of cold room = 5200 m^3
• Properties of fruit box
• Each fruit box= 50kg
• L= 52cm, W=36cm, h=31cm
• 3 days=22ton*3=66 ton
• Required the fruit box=1344
• 1344*0.52*0.36*0.31=77.995 need volume
• hi =9.3W/ h0= 25W/ k1=Polysacyanature
• Tin=35 Tout=10 k2=Polyurethane board
• X1=3cm X2 =10cm
• k1 = 0.027 W/ k2=0.023 W/
• U= >>> >>>0.18 W/
• Q=U.A. T >> 0.18*520m^2*29= 2.71 W
• NORT-NORM
• Q=0.18*520*(35+3-10)= 2620.8 W
FLAT ROOF
• Tflat=35 + 9
• Q=4118 W
• İnfiltration load from door opening
• Qf=(0.125V+27) T or Qf=(0.7V+2) T
• V=5200m^3
• Qf=18.564
• PRODUCT LOAD (Raw material)
• Tin=10 m=22 ton/day
• Tout=35 m=0.381 >>> Q=34.29 Kw
• Cp=3.6kj/kg.
INTERNAL LOAD
• Heat given off by light
• Number of flouresence lamp=100
• Watt of each lamp=100 watt
• Qwatt=wattag*hours/24hr
• Q=100W*10lamp*16h/24h
• Q=660W
Heat given off by electrical motor
• Electrical motor=3415 Btu/hr.Kw
• Power motor=0.25kW
• Q=34.15Btu/hr.kW*1kj/Btu*1h/3600s*0.25= 238W
• FOR FORKLIFT
• Q=m.r*t/(m*24)
• Where Mr=motor rating(W) For 900 kg fork capacity=4100W
• 1800 kg fork capacity=6150W
• 2700 kg fork capacity=6750W
• 22.000kg/16h=1375kg/h
• T=time use per day (hr)
• M=motor efficiency (%80 battery and %33 internal combustion)
• Q=6750W*16h/(0.8*24h)=5625 W
For people
• Qp=(272-6)*T() or
• Qp=number of people*heat equivalent(table 5)*hours(24)
• Qp=3*246*16h/24h=492W
• TOTAL
• Transmission load=7009.8 W
• Infiltration load=18.564 W
• Product (raw) Load=34.290 W
• Internal load=7015W
• TOTAL=66.8kW
SECTION 5
CLEANING IN PLACE ( CIP )
 CLEANING

Cleaning and sanitization of process plant is one of

the most critical aspects of food processing to ensure
the health and safety of the consumer.

Proper cleaning is essential for the production of

high quality food products especially those with
extended shelf life.

A key part of safe food manufacturing is cleanliness,

which is why solid cleaning-in-place (CIP) and
cleaning-out-of-place (COP) systems are essential.
WHAT IS THE CIP SYSTEM ?
CIP is a process that uses water rinses,caustic and/or acid
recirculation, precise temperatures, and turbulence to clean soils and
bacteria from the inside surfaces of food production equipment—such
as, pipes,tanks, pumps,valves, storage vessels, and other equipment.

ADVANTAGES
Much faster than manual cleaning
Less labor intensive, no disassembly or reassembly
Highly repeatable results
Documentation
Safer for workers, less chemical exposure
Effectively helps to manage water and chemical costs
CIP SYSTEMCIP SYSTEM
 CLEANING IN PLACE (CIP) OPERATION

CIP OPERATION FACTORS AFFECTING CIP

Pre-rinse Time
Mechanical removal of soil
Detergent
Temperature
Cleaning of remaining soil
Caustic acid or both
Final-rinse
Wash residual detergent/soil
Sterilant/Sanitizer
Cold or Hot
 TYPICAL CIP TIMES

VESSEL CIP MAIN CIP

Pre-rinse 10 to 20 mins 5 to 10 mis

Caustic Detergent 30 to 45 mins 20 to 30 mins

Rinse 10 to 15 mins 5 to 10 mins

Acid Detergent 20 to 30 mins 15 to 20 mins

Rinse 15 to 20 mins 10 to 15 mins

Sterilant 10 to 15 mins 5 to 10 mins

 WHAT IS THE COP SYSTEM ?
COP systems are used to clean pieces of equipment that would not be
touched by the CIP system. Equipment could include fittings, clamps,
product handling utensils, tank vents, pump rotors, impellers, casings,
hoses, etc. One might also employ this type of system in situations where
process equipment needs to be disassembled for cleaning, typically
equipment that is small, complex, or difficult to clean. COP systems can also
be used in conjunction with manual cleanings when a CIP system isn’t in the
budget.

ADVANTAGE

Usually lower investment than CIP systems

Delivers consistent results

Provides a cost savings over manual cleanings, saves on time, chemical,

and water usage

Minimizes operator exposure to high temperatures and strong chemical

concentration
EQUIPMENT SYSTEM HOW EACH EVERY EVERY EVERY EVERY
SHIFT DAY WEEK MONTH SEASON

Evaporator Closed CIP ✓

Pipe&pump Closed CIP ✓
Conveyor Open Low alkaline ✓
cleaner
(Caustic)
Tanks Closed CIP & COP ✓
Heating Closed CIP ✓
Equipment
Crusher COP Low alkaline ✓
cleaner(Caustic
)
Hygiene Closed Washing ✓
coridor Chemical foam
Floor COP Washing with ✓
detergent
Toilets COP Washing with ✓
detergent
 COP (CLEANING OUT PLACE )
PLACES

All places are cleaned with floor washing machine for

every day .
And washed with chemical detergent for every week.

WALLS
All walls are cleaned every season.
 PERSONAL HYGENE
For good hygiene being a clean body,
clean hair and clean clothing.

Hairnets should be worn to assure

food product integrity.

Long-sleeve smocks should be worn

to cover arm hair.

Clean uniforms can help minimize

contamination.


 WASTE TREATMENT

• SOLID WASTE;
We use grape pulp(marc) as animal feed
Paper,glass collected at container and send to recycle center

LIQUID WASTE;
We convert the water that use for the evaporator and we use for heat exchanger and extraction again
COST ESTIMATION
MACHINE PROCESS UNIT COST(₺) TOTAL COST(₺)
EQUIPMENT
Washing 1 160.000, TL 160.000 TL
Belt Conveyor 3 40.480, TL 121.440 TL
Crushing 1 296.000, TL 296.000 TL
Pressing 1 160.000, TL 160.000 TL
Separation 3 360.000, TL 1.080.000 TL
Heating and Decadification 3 60.000,TL 180.000 TL
Plate heat exchanger 3 400.000, TL 1.200.000TL
Triple Effect Evaporator 1 3.500.000, TL 3.500.000 TL
Clarification 3 362.880, TL 1.080.640 TL
Filling Machine 1 640.000, TL 640.000 TL
Packing Machine 1 196.000, TL 196.000 TL
Water Tank(15 ton) 3 30.000, TL 90.000 TL
Water Storage(60 ton) 1 100.000, TL 100.000 tl
Resting Tank (2 ton) 2 14.000 TL 28.000 TL
MACHINE PROCESS UNIT COST(₺) TOTAL COST(₺)
EQUIPMENT
Clarification 1 14.000 TL 14.000
Tank(6ton)
CIP Tank(6 ton) 3 13.000 TL 39.000 TL

Pasteurization 1 130.000 TL 130.000 TL

machine
TOTAL 9.032.780 TL
SECTION 5
PURCHASED EQUIPMENT COST
PURCHASED EQUIPMENT COST = A + B + C

A. PROCESS EQUIPMENT COST =9.032.780TL

B. LABORATORY EQUIPMENT COST=473.456

C. AUXILLARY EQUIPMENT COST= 939.500 TL

PURCHASED EQUIPMENT COST = 10.445.736 TL

B. FIXED CHARGE
Depreciation =(V – VS) / n
V : Purchased equipment cost,
VS : Salvage value ( estimated as 5% of purchased
equipment cost)
n : Service life of equipments
(the average service life of equipment is 10 years )

V= 10.445.736 TL, n=10

Vs= 522.286 (%5)
Depreciation=992.345
MANUFACTURING COST
MANUFACTURING COST = A + B + C
A. Direct Production Cost
B. Fixed Charge
C. Plant Overhead Cost

Manufacturing Cost= 8.296.957 TL+ 1.396.440 TL+

915.510 TL

=10.608.907TL
 TOTAL PRODUCTION COST
• Total Production Cost = Manufacturing Cost + General Expenses

• Total Production Cost = 10.608.907TL + 2.652.096 TL

=13.261.003 TL
CUMULATIVE CASH
POSITION
• C.C.P =( Net profit + Depreciation ). X – Total
Capital Invensment
• Net Profit = 3.988.821 ₺ /year
• Depreciation =992.345TL
• Total Capital Investment 56.294.329 TL TL
• C.C.P = (3.988.821 TL + 992.345 TL )X –
56.294.329 =0

• X = 11.3 YEAR
BREAK-EVEN POINT
Total Product Cost = 13.240.958 TL /year
Total Product = 444.600 kg/year
Total Product Cost = (13.240.958 TL)/(444.600)
= 29.78₺ /kg
Total Income = (18.354.830 TL)/(444.600)
= 41,28 ₺ /kg
Total Income *(X) = T.P.C*(X )+T.F.C
41,28 *(X) = 29.78 *(X) + (1.376.395 TL)
(Break-Even Point)X = 119.686 kg
 Profitability
=
[(Total Income - Total Product Cost)/ Total Product Cost]*100

[(18.354.830 TL- 13.240.958 TL )/ 13.240.958

TL ]*100

= 38.62 %
 Our Project is Feasible
or not?
If we invest our total capital investment %10 in bank for
10 years.

In Bank annual interest=%10

TCI x (1+interest rate)time period

56.294.329 TL *(1+ 0.10)10=

145.802,312₺
Total net profit in bank =89.172.093
Net Profit*10= 3.988.821 ₺ *10=39.888.210 TL
• Our Project is not FEASIBLE