Food Plant Design

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ISBN: 9781574446029 | 1574446029
Cover: Hardcover
Copyright: 5/6/2005

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Balancing coverage of chemical engineering and food technology issues, this text discusses the design of the food processing system and the industrial food plant. Including modeling procedures for food processing systems and auxiliary systems, the authors discuss synthesis techniques and procedures to structure information and data on different food processing alternatives. They also cover food factory optimization and experimentation in the food plant. The book outlines solutions to plant design problems in the context of overall optimization of an agro-industrial system and corresponding food chain. It provides the work procedures and techniques needed to solve design problems.

Chapter 1 Economic and Technical Context of Food Plant Design

(30)

1.1 Food Science, Technology, and Engineering

(9)

1.1.1 Historical Evolution

(8)

1.1.2 The Design Engineer in Food Engineering

(1)

1.2 Socioeconomic and Technical Context

(18)

1.2.1 Agro-Industrial System and the Food Chain

(4)

1.2.2 Food Processing Systems, Auxiliary Systems, and Food Plants

(14)

References

(3)

Chapter 2 Mathematical Modeling of Food Processing Systems and Food Plant Simulation

(122)

2.1 Transfer Phenomena and Property Balance

(34)

2.1.1 Transfer Phenomena

(5)

2.1.2 Macroscopic Balances and Physical Properties

(12)

2.1.2.1 Mass Balance

(1)

2.1.2.2 Energy Balance

(5)

2.1.2.3 Momentum Balance

(5)

2.1.2.4 Physical Properties

(1)

2.1.3 Microscopic Balances and Transfer Phenomena

(17)

2.1.3.1 Microscopic Mass Balance: Fick's Laws

(4)

2.1.3.2 Momentum Balance: Newton's Law

(6)

2.1.3.3 Energy Balance: Fourier's Law

(6)

2.2 Transfer Properties: Viscosity, Conductivity, and Diffusivity

(6)

2.2.1 Viscosity

(3)

2.2.2 Thermal Conductivity

(1)

2.2.3 Diffusivity

(2)

2.3 Heat Transfer in Fluids

(6)

2.3.1 Individual Coefficients of Heat Transfer by Convection

(1)

2.3.2 Heat Transfer Coefficients in Newtonian Fluids

(3)

2.3.3 Heat Transfer Coefficients in Non-Newtonian Fluids

(2)

2.4 Mathematical Model of a Unit Operation: Hot Air Drying

(16)

2.4.1 Equations for General Model

(1)

2.4.2 Equations from This Model

(4)

2.4.3 Results of Experiment

(3)

2.4.4 Nomenclature

(1)

2.5 Mathematical Modeling of Refrigeration and Thermal Storage Systems

(34)

2.5.1 Modeling the Components of a Refrigeration System

(21)

2.5.1.1 Compressor

(6)

2.5.1.2 Condenser

103

(3)

2.5.1.3 Evaporator

106

(6)

2.5.1.4 Expansion Valve

112

(4)

2.5.2 Trends in Refrigeration Systems Modeling

116

(1)

2.5.3 A Case Study

117

(10)

2.5.3.1 Model Formulation

117

(3)

2.5.3.2 Heat Transfer Coefficients Analysis

120

(1)

2.5.3.3 Experiment Validation

121

(6)

2.6 Food Plant Simulation

127

(14)

2.6.1 Malting Plant

127

(4)

2.6.1.1 Knowledge-Based System Development

128

(3)

2.6.1.2 Simulation Results

131

(1)

2.6.2 Winery

131

(8)

2.6.2.1 Refrigeration Requirements Profile for Wineries

133

(1)

2.6.2.2 Thermal Behavior of the Fermentation Process

134

(1)

2.6.2.3 The Use of Thermal Storage Systems

135

(1)

2.6.2.4 The Use of Advanced Control Systems in Fermentation

136

(3)

2.6.3 Frozen Vegetables Plant

139

(2)

References

141

(12)

Chapter 3 Documentation of Food Plant Design

153

(60)

3.1 Introduction

153

(1)

3.2 Preliminary Studies of Food Products and Raw Materials

154

(1)

3.3 Literature Review and Laboratory Studies on Food Processing Technology and Engineering

155

(1)

3.4 Pilot Plant Studies

156

(1)

3.5 Food Processing Systems and Food Plant Preliminary and Final Projects

157

(14)

3.5.1 The Food Processing Plant Preliminary Project

157

(5)

3.5.2 The Food Processing Plant Final Project

162

(9)

3.5.2.1 Food Processing System Final Project

163

(3)

3.5.2.2 Auxiliary System Final Project

166

(2)

3.5.2.3 Buildings and Services Final Project

168

(3)

3.6 Information Handling in Flowchart Form

171

(23)

3.6.1 Basic Modules General Flowchart

171

(1)

3.6.2 Flowcharts

172

(4)

3.6.3 Mass Balance in the Process

176

(11)

3.6.4 Energy Balance in a Food Processing System

187

(28)

3.6.4.1 Energy Accounting in Food Processing Plants

187

(2)

3.6.4.2 Measuring Energy Flow Rates

189

(5)

References

194

(19)

Chapter 4 Processing System Alternatives: Process Synthesis

213

(18)

4.1 Introduction

213

(2)

4.2 Synthesis Methods

215

(12)

4.2.1 Evolutionary Methods

215

(5)

4.2.1.1 Basic Modules Method

215

(3)

4.2.1.2 Evolutionary Design Method

218

(2)

4.2.2 Methods Based on Problem Solving

220

(3)

4.2.3 Heuristic Design Methods

223

(1)

4.2.4 Algorithmic or Mathematical Programming Methods

224

(3)

Nomenclature

227

(1)

References

228

(3)

Chapter 5 Food Processing System Alternatives Analysis

231

(54)

5.1 Outlining the Problem

231

(1)

5.2 Selecting Design Variables

232

(24)

5.2.1 Process Subsystems

233

(10)

5.2.1.1 Degrees of Freedom and Information Flow Diagram

233

(4)

5.2.1.2 Inversion of Information Flow

237

(3)

5.2.1.3 Algorithms for Selecting Design Variables

240

(3)

5.2.2 Process Systems

243

(14)

5.2.2.1 Information Flow through Subsystems

243

(6)

5.2.2.2 Inversion of Information Flow

249

(2)

5.2.2.3 Algorithm for Selecting Design Variables

251

(5)

5.3 Alternative Analysis by Means of Simulation

256

(1)

5.4 Design Economic Criteria

257

(6)

5.4.1 Static Criteria

257

(2)

5.4.2 Dynamic Criteria

259

(4)

5.4.2.1 Net Present Worth

260

(1)

5.4.2.2 Net Present Worth/Initial Investment Ratio

261

(1)

5.4.2.3 Payback Period

261

(1)

5.4.2.4 Internal Rent Share

262

(1)

5.5 Cost Estimation

263

(19)

5.5.1 Initial or Capital Investment Estimation

263

(6)

5.5.1.1 Cost Estimation of Food Processing Equipment

263

(6)

5.5.1.2 Auxiliary System Cost Estimation

269

(1)

5.5.2 Operating Cost Estimation

269

(13)

References

282

(3)

Chapter 6 Experimentation in Pilot Plant

285

(14)

6.1 Introduction

285

(1)

6.2 Size and Structure of the Pilot Plant

286

(2)

6.2.1 Basic Principles of Scaling

286

(1)

6.2.2 Minimum and Maximum Size

287

(1)

6.3 Types and Applications

288

(4)

6.4 Pilot Plant Design

292

(1)

6.5 Experimentation Strategies

293

(3)

6.6 Capital Investment and Operation Cost

296

(1)

References

297

(2)

Chapter 7 Materials for Construction of Food Equipment

299

(16)

7.1 Characteristics of Suitable Construction Material

299

(2)

7.2 Types of Materials and Applications

301

(13)

7.2.1 Stainless Steel

301

(10)

7.2.1.1 Surface Finish

303

(6)

7.2.1.2 Corrosion

309

(2)

7.2.2 Aluminum

311

(1)

7.2.3 Nickel and Monel

311

(1)

7.2.4 Plastic Materials

312

(2)

References

314

(1)

Chapter 8 Hygienic Design of Processing Systems and Auxiliary Systems

315

(36)

8.1 Basic Principles for Hygienic Design of Food Equipment

315

(3)

8.2 Hygienic Design of Auxiliary Systems in Contact with Foods

318

(15)

8.2.1 Tanks

318

(4)

8.2.2 Pumps

322

(3)

8.2.3 Valves

325

(3)

8.2.4 Pipes

328

(5)

8.3 External Design of Processing Equipment and Auxiliary Systems

333

(2)

8.4 CIP (Clean-in-Place) System Design

335

(15)

8.4.1 Single-Use or Single-Tank Systems

337

(3)

8.4.2 Multiple-Use or Multitank Systems

340

(1)

8.4.3 Compact Systems and Foam-Cleaning Systems

341

(4)

8.4.4 CIP System Design Details

345

(6)

8.4.4.1 Spray Distribution Devices

346

(3)

8.4.4.2 Pumps, Heat Exchangers, and Valves

349

(1)

References

350

(1)

Chapter 9 Food Processing Plant Design Considerations

351

(22)

9.1 Designing the Food Plant

351

(9)

9.1.1 Legal Aspects

352

(2)

9.1.2 Functional Aspects

354

(3)

9.1.3 Plant Layout

357

(3)

9.2 Selecting Food Plant Site

360

(2)

9.2.1 Land Conditions and Location

360

(1)

9.2.2 Distribution of Zones at the Site

361

(1)

9.3 Hygienic Design of the Food Processing Plant

362

(10)

9.3.1 Resistant Structure

362

(1)

9.3.2 Building Enclosure and Interior Divisions

362

(4)

9.3.3 Floors

366

(6)

References

372

(1)

Index

373

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Food Plant Design

Summary

Table of Contents

Supplemental Materials