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Food factory design - process design
This is a mind map about food factory design - process design, including process flow, material balance, etc. The introduction is detailed and the description is comprehensive. I hope it can help interested friends learn.
Edited at 2023-11-19 15:55:51
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Food factory design - process design
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- Outline
technological design
in principle
in accordance with
Approved feasibility study report
Combined with specific circumstances
Raw materials and power supply
Water quality
Environmental health
in principle
The process flow, equipment selection, and production workshop layout of various products are tailored to local conditions.
Process design strives to be technologically advanced, mature, reliable, and economically reasonable
Design subject - production workshop
Canning factory: full can workshop, empty can workshop and comprehensive utilization workshop
Dairy factory: fresh milk workshop, milk powder workshop, yogurt workshop
Beverage factory: juice workshop, filling workshop
Meat products: sausage workshop, Western-style ham workshop
significance
Affects technical rationality, factory construction costs, product quality, cost, and labor intensity
The remaining workshops and auxiliary departments are designed around the production workshop
Process design provides the basic data basis required for non-process design
Requirements for location in the overall layout
Civil engineering, lighting, ventilation, heating, sanitation facilities
Illumination lx: light intensity, the degree to which an object is illuminated, the energy of visible light received per unit area
Initial processing console＞220, other processing areas＞110, food testing console greater than 550
Water, electricity and steam consumption load
electrical load
Level 1 load: When the power supply is suddenly interrupted, it will cause personal casualties, major equipment damage or significant losses to the national economy.
Secondary load: A sudden power outage will produce a large amount of waste products, or stop production and cause large economic losses.
Level 3 load: Anyone who does not belong to Level 1 or Level 2 - food industry
Water quality requirements, drainage and wastewater treatment requirements
General technical specifications for pretreatment of microbial samples in wastewater treatment systems; technical specifications for advanced treatment of refractory organic wastewater
Calculation of area and volume of various warehouses and requirements for temperature and humidity
Product plan confirmed
aka production program, the types of products produced by food factories throughout the year, Planning and arrangement of quantity, production cycle and production shift
necessity
Necessary for continuous and planned production of food products
Objective and realistic requirements of seasonality and imbalance in the supply of food raw materials
It is a macro-control method to solve the problem of reasonable allocation of labor force caused by unbalanced production, and to maintain the relative stability of employees in the factory and prevent excessive fluctuations in technical quality.
Four satisfactions
Meet product output requirements
Comprehensive utilization of raw materials
Balanced production during off-peak and peak seasons
Economic benefits
five balances
Product output and raw material supply
Product Seasonality and Labor
production shift
Equipment production capacity
Water, electricity and steam load
in principle
Meet the shift output and packaging specifications of major products
Meet 5 balances
According to the requirements of the mission statement and the supply of raw materials, combined with the actual utilization rate of each workshop, and considering the characteristics and commonalities of various varieties, the number of production workshops, processing lines, and new packaging quantities are determined.
25 days per month, 300 production days per year. Considering the supply of raw materials and other reasons, it should not be less than 250 days, with 1 to 2 production shifts per day; 3 shifts during the peak period of seasonal products
According to factory technology, raw material characteristics and equipment production capacity
The normal supply of raw materials or cold storage rooms and semi-finished product processing equipment can extend the production period and eliminate the need to suddenly open more shifts. Conducive to labor balance and full utilization of equipment
Formulation of product plans
According to the requirements of the mission statement, determine the product type and clarify the product packaging, specifications, and varieties.
According to the design scale, combined with raw material supply, supply cycle, etc., determine the proportion and output of various products in the total output
Determine the production time of the product based on the production season and storage time of the raw materials
Determine the shift output and the number of production shifts based on the design output
Determination of shift output
Under normal working environment and conditions, the total output that can be completed in one shift
The most important calculation basis, directly affects the workshop layout, equipment matching, floor area, specifications of public facilities, auxiliary facilities, labor capacity and product economic benefits.
The larger the shift output, the lower the unit product cost.
The most suitable shift output is the scale with the best economic benefits.
Restricted by factors such as raw material supply, equipment production capacity and market sales
Raw material supply and market conditions
Production season length
Conditions for extending production period
Production capacity and operation of supporting equipment
Food variety matching and factory automation level
production shift
1 class in off-season, 2 classes in intermediate level, 3 classes in peak season
The production process requirements, raw material characteristics and equipment production capacity should be taken into consideration
The number of shifts can be reduced by extending the production period
determining factors
Raw material supply and market conditions
Production season length
Conditions for extending production period
Production capacity and operation status of supporting equipment
Food variety matching and factory automation
Production capacity expression method
Dairy products: production capacity - daily processing capacity of fresh milk. Milk powder: spray drying tower; Condensed milk: vacuum concentration pot; liquid milk: filling machine
Cannery: Shift capacity or amount of raw materials processed per hour. Tomato paste: vacuum concentrating pot; Mushrooms: pre-cooking machine; luncheon meat: quantitative filling machine; manual operation: can sealing machine
Beverage factory: filling line
Brewery: Daily wort production - mash tun volume, daily batches
Low temperature food factory: hourly quick freezing capacity
Pastry factory: production capacity of the oven
In order to facilitate mechanized production, products strive to be streamlined; in order to improve raw material utilization, edible value, and meet consumer demand - one raw material is produced into several specifications of products (variety matching)
Comparison and analysis of product solutions
Combined with the actual situation, consider actual production, technological advancement, feasibility and economic rationality
content
Comparison of annual output value of major products
Comparison of labor required for production per ten days
Labor productivity comparison: annual output/number of workers
Comparison of the difference between the maximum and minimum labor required for production per ten days
Comparison of average annual output per person
Comparison of production seasonality
Equipment usage balance
Water, electricity and steam consumption
Difficulties in organizing production
Infrastructure investment
Social benefits, economic benefits
Process flow
main content
Determine the number of production lines
Determine the degree of automation
Design of process flow diagram
Process instructions can be attached
The main processes and equipment of food factories of the same type are basically similar, and the same process equipment can be shared
Selection of process flow: Determine the specific content, sequence and combination of each production process in the production process to achieve the purpose of processing and producing high-quality, high-quality products. That is, the choice of production method is the key to determining product quality, as well as the key to determining equipment selection and investment. The same raw materials, methods, different processes and processing conditions, the product quality is also very different.
in principle
Advanced and scientific
Formulated based on the properties of raw materials, product specifications and relevant national standards
Choose a process with low investment, low energy consumption, low cost and high product yield.
Specialties and traditional famous products are not allowed to change the production process at will.
Scientific research results must be amplified through pilot testing before they can be used in design.
Arrange according to the assembly line to reduce the time that raw materials, semi-finished products and finished products stay in the production process to avoid discoloration, odor and deterioration.
Concentration uses vacuum concentration; sterilization uses continuous sterilization and high-temperature instant sterilization.
Less three wastes and meets emission standards
Develop process flows in strict accordance with the requirements of the food quality and safety market access system
Argument: theoretical rationality and practical feasibility
step
According to the product plan and production scale, the actual production situation and the size of the investment are combined to determine the production line and the number of production lines. If the output is large, several production lines can be used
Determine the degree of automation. According to the production characteristics and technological maturity, combined with the production scale. Adopt advanced, economical and reasonable automated production lines. High-quality products are equipped with automated online testing to ensure product quality.
The demonstrated process flow is represented by a process flow diagram
Process flow block diagram
Process name, process operation means, material flow direction, process conditions
Arrows indicate flow direction, thick arrows: raw materials to finished products; thin solid lines: intermediate products, auxiliary materials, waste materials
Process equipment flow chart
The basic appearance of the equipment (marked with the name or number of the equipment), the name of the process, the flow of materials, and the diameter and direction of various media pipelines. Mark the controls if necessary.
Necessary text description can be attached, and there is no proportion requirement.
Equipment selection
in principle
Meet production process requirements and ensure product quality
Factory size
Large-scale - high technical level and high degree of automation
Lower to medium-depending on your own situation, choose a machine with a higher degree of mechanization and continuity.
Small – simpler devices
Make full use of raw materials, can produce less energy, high efficiency, small size, easy maintenance, low labor intensity, and one machine can be used for multiple purposes
Comply with food hygiene requirements, easy to clean and disassemble, materials in contact with food are not easy to corrode, and will not cause contamination to the product
The equipment structure is reasonable and the material properties can adapt to various working conditions.
There are reasonable control systems for temperature, pressure, vacuum, concentration, time, speed, flow, liquid level, counting and procedures, etc., and automatic control is adopted as much as possible
Comprehensively consider factors such as output, production period, and equipment utilization to determine the key difference between the production capacity and the number of equipment.
It can be divided into units according to the process flow. Determine the production capacity of the equipment and select the appropriate model and quantity based on the material calculation results and the unit time output of processed products (t/h). In order to prevent the backlog of materials, the production capacity of the subsequent process should generally be slightly larger than that of the front process, and should be matched with each other as much as possible.
Hygiene requirements
Industry regulations
Ensure adequate cleaning, disinfection and maintenance
Ensure that the required temperature can be reached quickly
Non-toxic, odorless, corrosion-resistant, non-absorbent, non-deformable
Reasonable layout
Process hygiene requirements
Avoid dead corners and blind ends
Equipment flow chart
1:50, 1:100, 1:200
content
Basic appearance of equipment
Device name/number
Process name
Material flow
pipeline
control point
If necessary, indicate relative position, spacing, and height.
express
Thick solid line
Material flow
Logistics process
thin solid line
Equipment diagram
Process number
pipeline
Auxiliary boredom
double thin line
floor floor line
elevation
main valve
Control instruments and pipeline accessories
Necessary text comments
Three wastes treatment
The destination of by-products
Art style
from left to right
Device relative position
Pipelines with different media flow directions do not cross
The codes and symbols of media, valves and pipe fittings are drawn according to the national drawing standards.
Production capacity calculation
See courseware for details
use
Metering and storage equipment
Special equipment for shaping
General machinery and equipment
Non-standard professional equipment
Way
Special for styling
Process throughput
Equipment label rated output
General Equipment
Determined by materials, product varieties, and process conditions
Material Accounting
Amount and quantity of raw materials, intermediate products, by-products, finished products, and packaging materials
Technological and economic quota index method
Empirical data on inputs and outputs of raw materials and products
Basic basis - technical and economic quota indicators
Regional differences
degree of mechanization
Raw material varieties
Maturity
Freshness
operating conditions
Calculation basis - shift output
Calculation of raw materials, auxiliary materials and packaging consumption per shift
One raw material → multiple products
The sum of the raw material dosage of different products
material utilization method
Most used
criteria
A certain process: input = output loss
The whole process: entry = exit loss
Raw material utilization rate = cost/input
conservation of materials
step
Select the calculation basis for accounting
Collect relevant data parameters
Production scale → shift output, raw material utilization rate
Each process
Material quantity
concentration
Moisture content
According to input = output loss, each process is calculated
Known raw materials: along the process
Known output: reverse flow
Fill in the material balance sheet/chart
Principle: Conservation of materials (write more
Material main direction: solid line
Material branch flow direction: thin solid line
workforce capacity
effect
Factory staffing establishment
Calculation of living facilities area
Domestic water and gas consumption calculation
Proper use of industrial and commercial equipment and staffing
Product output and quota indicators
in accordance with
Relevant national laws, regulations and rules
Factory construction scale
Production operation complexity and automation level
Organizational structure and production management system
Personnel quality and labor rate requirements
The situation of similar factories at home and abroad
type
Production staff
essential worker
Auxiliary workers
non-production personnel
manager
Technical staff
service personnel
administration staff
Calculation method
Labor productivity
Calculated based on production tasks and production personnel efficiency
Each production process
Less automated
Labor workers required to produce unit weight varieties
Higher degree of automation
Labor required for each piece of equipment
production workshop
In actual production, two processes coexist
equipment
Calculated based on the quantity of mechanical equipment, manual operation equipment quota, production shifts, etc.
labor quota
workload, production tasks
post
Each operating position and the number of people required for each position
Proportion
Service staff ratio
Organizational Responsibilities
manager
Precautions
Productivity depends on
Freshness and maturity of raw materials
Worker proficiency
Equipment mechanization and automation
implement
Determine the labor productivity of each product with reference to old factories with similar production conditions
Use shift output as much as possible to adjust labor force
If there is strong seasonality, temporary workers will be hired during peak periods; during normal production, the basic number of employees will be balanced.
The quantity should be accurate and reasonable
Automation is the general trend and should be based on new labor productivity and labor production quotas.
Water, electricity and gas balance calculation
Water consumption and steam consumption quota index method
Water and steam consumption per unit product
The temperature in the south is high, so the cooling water consumption should be a larger value.
The technical level of food factories is uneven and lacks specific and unified technical and economic indicators.
Produces multiple products and lacks independent calculation of individual products
It cannot reflect the actual water consumption and steam consumption at local locations such as each piece of equipment and each process.
Production scale
The greater the shift output, the lower the consumption
Major equipment
Places with large and concentrated usage are individually connected to main pipelines
Process parameter calculation method
Water Consumption
Amount of water added to product
Cleaning and washing dosage
Cooling water consumption
Condensed secondary steam consumption
Amount of floor washing
Steam consumption
Calorie calculation to determine total heat consumption
Material heating
solid dissolution, melting phase change
liquid evaporates
Heating equipment
Equipment convection heat radiation
Heat → steam consumption
Water and steam consumption load curve
Calculated value without loss correction value
Each device may not be used at the same time
Water and steam conformity-time curve
Determine peak production usage – peak load
Main equipment of different factories
cannery
Conveying equipment
Cleaning and raw material pre-treatment equipment
Heat treatment equipment
Sealing and filling equipment
Finished product packaging machinery and equipment
Empty tank equipment
dairy factory
Jacket pot
Cream separator
Homogenizer
Vacuum concentration pot
Drying equipment
Spray drying - milk powder
pressure
centrifuge
airflow
Microwave drying
Infrared drying
vacuum drying
Sublimation drying
Bottle washing machine
heat exchanger
Beverage factory
water treatment equipment
Bottle washing machine
Juicer
Filter
Separator
mixer
Saccharifier
Canning, capping, packaging
bakery
mixer
Dough dicing machine
Bread rounding machine
baking oven