Food-Processing-Plant-Design-layout

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Food Processing Plant Design & layoutadoption of some new process /replacement of some existing equipmentmodernization / automation of the existing facilityexpansion of the plant capacityrelocating the existing plant at a new site because of new economic, social, legal orpolitical factors1.3 Differences in the design of food processing and non-food processing plantsMany of the elements of plant design are the same for food plants as they are for otherplants particularly those processing industrial chemicals. However, there are manysignificant differences, basically in the areas of equipment selection and sizing, and inworking space design. These differences stem from the ways in which the processing offoods differs from the processing of industrial chemicals. Such differences occur because ofthe following considerations:The storage life of foods is relatively limited and strongly affected by temperature,pH, water activity, maturity, prior history, and initial microbial contamination levels.Very high and verifiable levels of product safety and sterility have to be provided.Foods are highly susceptible to microbial attack and insect and rodent infestation.Fermentations are used in producing various foods and bio chemicals. Successfulprocessing requires the use of conditions, which ensure the dominance of desiredstrains of microorganisms growth or activity.Enzyme-catalyzed processes are used or occur in many cases. These, like microbialgrowth and fermentation are very sensitive to temperature, pH, water activity andother environmental conditions.Many foods are still living organisms or bio chemically active long after harvest orslaughter.In some cases foods (e.g. ripening cheeses) contain active living micro organisms,which induce chemical transformations for long periods of time.Crop-based food raw materials may only be available in usable form on a seasonalbasis. Therefore, plant design may involve the modelling of crop availability.Food raw materials are highly variable and that variability is enhanced by the ageingof raw material and uncontrollable variations in climatic conditions.The biological and cellular nature and structural complexity of foods causes specialheat-transfer, mass-transfer and component separation problems.Foods are frequently solid. Heat and mass-transfer problems in solids have to becreated in ways that are different than those used for liquid and gas streams. Thekinetics of microbe and enzyme inactivation during thermally induced sterilizationand blanching and heat-transfer in the solids being sterilized or blanched arestrongly linked.6 www.AgriMoon.com
Food Processing Plant Design & layoutFood processing generates wastes with high BOD loads.Foods are often chemically complex systems whose components tend to react withone another. Certain types of reactions, e.g. Maillard reactions, oxidativerancidification, hydrolytic rancidification and enzymatic browning tend to occurwith a high degree of frequency.The engineering properties of foods and biological material are less well known andmore variable than those of pure chemicals and simple mixtures of chemicals.Vaguely defined sensory attributes often have to be preserved, generated ormodified. These require sensory testing. Raw material variation, minor processingchanges and trace contaminants leached from processing equipment and packagescan often cause significant changes in these attributes. Frequently, we do not havemechanistic bases for linking these attributes to processing conditions andequipment design. Much current food engineering and food science research activityat universities is designed to provide such linkages.In the case of foods, prototype products have to be consumer tested so as to assuremarket acceptability before plants for large scale production are built.Mechanical working is sometimes used to induce desired textural changes. Examplesinclude kneading and sponge mixing during the making of bread, the calendaring ofpastry dough, shearing during extrusion texturization.Packaging in small containers is often used or required; and strong-package-productinteractions exist. Packaging often requires care to maintain integrity of closure,reproducibility of fill elimination of air from head spaces and prevention ofsubsequent moisture and oxygen transfer. Segregation often causes problems in thepackaging of powdered foods. Aseptic packaging is starting to be widely used.Food processing techniques and formulations are sometimes constrained bystandards of identity and good manufacturing practice regulations and codes.Food processing is an art to a certain extent. Engineers and technologists arefrequently uncertain as to weather portions of that art are really justified ornecessary. It is sometimes difficult for them to translate the necessary portions ofthat art into quantifiable heat-transfer and chemical reaction processes on whichrational designs can be based.1.4 General design considerationsFood plant designs must provide necessary levels of sanitation, means of preventingproduct and material contamination and means of preventing or limiting product, rawmaterial, and intermediate product deterioration due to naturally occurring processes.Great care must be exercised to achieve high levels of product purity and preserve productintegrity. A brief description of some of the design considerations follows.1.4.1 Food processing unit operationsFood processing involves many conventional unit operations but it also involves manywhich differ greatly from those usually encountered in the production of industrialchemicals. These include: freezing and thawing and other temperature-induced phase7 www.AgriMoon.com
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