Food-Processing-Plant-Design-layout

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Food Processing Plant Design & layout5.2 Food plant utilitiesThe principal plant utilities in a food plant are process water, process steam, electricpower for motors and lighting, and fuel.5.2.1 Process WaterProcess water is required for washing the raw materials and for various cooling operations.In fruit and vegetable processing plants, water may be used for transportation (fluming) ofthe raw materials from receiving to processing areas. Water used in steam boilers mayrequire ion exchange treatment to reduce its hardness. Total water requirement in fruit andvegetable processing may range from 5 to 15 m3 / ton of raw material.5.2.2 SteamSteam boilers are needed in most food processing plants to provide process steam, usedmainly in various operations, such as heating of process vessels, evaporators and dryers,sterilization, blanching, and peeling. A medium size food plant (80 tons / day raw material)may require a boiler producing about 10 tons/h of steam at 18 bar pressure.Two principal types of steam boilers are used in the food processing industry, i.e. the firetubeand the water-tube boilers. The fire tube boilers operate at relatively lower pressure(1–24 bar) and produce cleaner steam. The water- tube units operate at higher pressures(100–140 bar) and they are suited for co- generation, i.e. electrical power and exhaust steamof lower pressure for process heating. Co-generation is economical in large food plants,requiring large amounts of low-pressure steam, e.g., beet sugar plants.A standby steam boiler of proper capacity may be necessary to provide process steamduring any boiler failure or breakdown.Steam boilers are rated in Btu/h, kW or boiler HP (1 Btu/h = 0.293 W, 1 boiler HP = 9.8kW). The heat flux in the boiler heating surface is about 0.75 kW/ m2. The boiler efficiencyis about 85% with most of the thermal losses in the dry gases and the moisture. Steamgeneration is about 1.4 t/h per MW.In order to maintain the concentration of accumulated dissolved solids in steam boilersbelow 3500 ppm, periodic discharge of hot water (blow down) is practiced.Fuel is used in food plants mostly for generating process steam and process drying. Naturalgas and liquefied propane (LPG) are preferred fuels in food processing, because theircombustion gases are not objectionable in direct contact with food products. Fuel oil andcoal can be used for indirect heating, i.e. through heat exchangers.Culinary steam of special quality is used when steam is injected in food products. Thesteam must be free of objectionable chemicals used in boilers, which may be carried into thefood being heated. Culinary steam is usually produced from potable water in a secondarysystem of a heat exchanger heated with high pressure industrial steam.5.2.3 ElectricityElectrical power in food processing plants is needed for running the motors of theprocessing, control, and service equipment, for industrial heating, and for illumination. Fora medium size food plant processing about 100 tons/day raw materials, the power38 www.AgriMoon.com
Food Processing Plant Design & layoutrequirement may of the order of 500 kW. A standby power generator of about 200 k VA isrecommended for emergency operation of the main plant, in case of power failure orbreakdown.Single-phase or three-phase alternating current (AC) of 110 V (60 cycles) or 220 V (50 cycles)is used in food processing plants. The electrical motors are either single-phase or threephasesquirrel cage.Energy-efficient electrical motors should be used in various food processing operations. Ameasure of the efficiency of electrical power is the power factor (pf), defined as k W/ k VA,this which should be equal or higher than 0.85.Illuminating (lighting) of industrial food plants should utilize fluorescent lamps, which cansave significant amounts of energy.5.2.4 Plant EffluentsPlant effluents consisting mainly of wastewater, but including solids and gas wastes requirespecial handling and treatments to comply with the local laws and regulations.Food plants should be designed and operated so that a minimum pollution is caused to theenvironment. The Environmental Protection Agency (EPA) in the US has issued codes andregulations that ensure the quality of natural water bodies is not damaged by effluentdischarges from industrial plants. Similar regulations apply to atmospheric emissions ofobjectionable gases and dust. Environmental information needed to comply with EPAregulations for wastewater includes testing for pH, temperature, biochemical oxygendemand (BOD), fats oil and grease (FOG), and total suspended solids (TSS).Large amounts of waste are produced in the processing of fruits and vegetables, as incanning, freezing, and dehydration operations. Smaller waste volumes are produced indairy plants (with the exception of cheese and milk powder), and in dry-processing(milling) of grain (e.g., wheat flour).A medium size fruit or vegetable processing plant handling about 100 ton/day of rawmaterials may discharge about 1000 m3/day of waste water.Treatment of food waste water may involve one or more of the following operations:1. Simple screening out of the suspended solids,2. Gravel filtration,3. solids settling in sedimentation tanks,4. biological oxidation (aeration),5. spray irrigation,6. discharge into the local public sewer, and7. discharge into a waterway.Liquid wastes (waste water) can be disposed to the local waste (sewage) treatment plants,after removing some objectionable components, such as fat, oil, and grease to an acceptable39 www.AgriMoon.com
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