PLANT

LAYOUT
 PLANT LAYOUT FOR BAKERY INDUSTRY
INTRODUCTION:
Bread is major product for bakery industry, because which is major
consumption by people. Commercially bread manufactured by three types like
S2, S4 and family type bread.
INGREDIENTS: Wheat flour, Yeast, Sugar, Salt, Water, Shortening, Milk solids.
PROPORTION OF INGREDIENTS:
Flour:
The flour should be of good quality prepared from hard wheat with a
protein content of at least 11 %. It should prove quite satisfactory in laboratory
bread making tests. It is customary to give the other ingredients for 100-gram
flour.
Fat:
The quantity of fat(shortening) used can be varied from 2-6%. Shortening
improve the loaf volume. Fat imparts a velvety and softer crumb and improves
the grain of bread.
Water:
The optimal quantity of water required for making a good varies with
the hydration capacity of gluten in the flour. 100grams of good quality flour
will require about 60-64 ml of water.
Sugar:
The quantity of sugar used in bread making may vary widely from 2-6%.
It has been reported that a part of the cane sugar is fermented by yeast
producing CO2 .
Yeast:
Baker’s yeast is usually incorporated at level of 2-3%. Yeast is made into
a slurry and added to the flour before making the dough. The dough is allowed
to undergo fermentation for 3-4 hours.
Salt:
Salt is added at 1.5-2.0% level in bread formulation.
The function of salt in bread is three:
1. Improve the taste and flavor,
2. Stabilizes the fermentation process,
3. To give strength to the gluten.
Fermentation takes place rapidly when salt is added.
Milk solids:
Fluid milk is often used in bread made in homes or in small industries.
Skim milk powder (SKMP) is used in large industries. The quantity of SKMP used
varies from 3-8% for 100 gram of flour.
EFFECT OF BREAD QUALITY:
The number changes occur in bread when stored for a few days. These
change known as staling of bread and are briefly described below:
Crust staling:
The principle reaction, which occurs in crust staling, is the transfer of
moisture from the interior of the loaf to the crust. The crust processes
considerable hygroscopic properties and so it absorbs moisture and becomes
soft and leathery. The wrapping of bread on waxed paper or moisture proof
films favors the staling of crust as it prevents loss of moisture from the crust. It
losses the original aroma and flavors and develops an off odor and bitter taste.
Crumb staling:
The crumb becomes harder and more crumbly due to loss of moisture.
There is marked deterioration in flavor. Bread stored at low temperature (0°C)
hardened to a greater extent then that stored at 43°C but the bread stored at
43°C developed an off flavor and the crumb turned brown.
Ropy bread:
This rapiness in bread is caused by contamination of dough with
B.mesentericus. The spores of this bacterium are not destroyed by heat during
baking of bread. A sticky, gummy material, which can be pulled into threads,
develops in the center of the loaf 1 to 3 days after baking. The bread also
develops a strong off-flavor.
MANUFACTURE OF BREAD:
The stages involved in the manufacture of bread are:
1. The preparation if the dough,
2. Fermentation of the dough,
3. Baking.
METHODS FOR PREPARATION OF DOUGH:
Three methods are commonly used for the preparation of the dough:
1. Straight line method,
2. Sponge and dough method,
 3. Mechanical dough method

1. Straight-line method:
• It is a batch process
• Mixing is conducted until the dough attains the desired
smoothness and elasticity.
Advantages:
 Minimum labor requirement
 Less fermentation time
 Better flavor
Disadvantages:
 Inflexibility require fixed fermentation time
 Ripe-ready dough must be baked when ready.

2. Sponge-dough method:
This method consists of two stages;
a) Formation of sponge,
b) Development of dough

a) Formation of sponge:
The sponge contain about 50-60% of total flour to be used, the
total quantity of yeast and malt and sufficient water to yield slightly
stiff dough.

b) Development of dough:
The sponge is mixed with remaining quantity of flour and water
and allowed to ferment for a short time
3. Mechanical method:
• It is continuous method,
• No bulk fermentation and consequent losses are avoided,
• Allows addition of extra water and produces better bread from
weaker flours
COMPOSITION OF BREAD:
Ingredients Straight dough Sponge-dough method (parts)
Method (parts)
Sponge Dough
Flour 100.0 65.0 35.0
Water 65.0 45.0 25.0
Yeast 3.0 2.5 -
Yeast food 0.2-0.5 0.2-0.5 -
Salt 2.25 2.25
Sugar 8.0 8.0
Fat 3.0 3.0
skmp 3.0 3.0

Ingredients Mechanical
method
(parts)
Flour 100.0
Water 60.3
Yeast 2.8
Yeast food 0.5
Salt 2.1
Sugar 7.6
Fat 3.0
skmp 3.0

FIRST MIXING:
The ingredients are placed in the mixing bowl of capacity of 200 kg. The
mixer is working under the double crank mechanism. The ingredients are
properly mixed by the action of double machine. The time for mixing is 30
minutes. The resultant product is called as dough.
FERMENTATION:
The fermentation is done for 1 hour and the quality of bread depends
upon fermentation period. Yeast plays a major role in fermentation process.
SECOND MIXING:
The purpose of the second mixing is to incorporate the air particles into
the dough. The mixing time is 20 minutes.
DIVIDING:
In the dividing sector, the twin pocket divider was used. The divider has
twp pockets. The size and shape of the boxes are adjustable. So we get the
required shape and size of the dough.
ROUNDING:
In the rounding process, the dough from the dividing unit through the belt
conveyor and enter into the rounding machine. Inside the machine the spiral
blades are provided to make round size. In the process the heat is liberated
and the temperature of dough is increased.
INTER MEDIATE PROOFING:
In this process, the heat is removed from the dough, which is generating
during the dividing and rounding process. The intermediate proofed has 75
trays and completion of one cycle requires 7 minutes.
MOLDING:
It is the final shaping and sizing operation. In this process, three pairs of
rollers are rolled with different directions. The vanaspathi and sunflower oil
was used as a lubricant for the roller. Then the thin molded dough is sent to
the final proofer.
FINAL PROOFER:
In the proofer, the steam is passed over the bread at the temperature of
200c with 16-kg/cm2 pressures. Horizontal tube boiler produces the steam. The
proofing time is 1-1.5 hours.
BAKING:
Baking is done in the large capacity oven. The baking temperature is 215°c
for 27-32 minutes.
COOLING:
After the baking was over, then the bread was cooled into the room
temperature. The taken for cooling is one hour.
SLICING AND PACKAGING:
The action of slicer slices the cooled bread and then the breads are packed
in polythene bags each.
PROCESS FLOW CHART FOR BREAD:

Selection of ingredients

First mixing (Maida+ sugar +yeast)

Fermentation

Second mixing

Dividing

Rounding

Inter proofing

Molding

Final proofing

Baking

Cooling

Slicing

Packaging
LIST OF MACHINERIES

MACHINERIES NUMBER CAPACITY POWER SPACE

REQUIRED REQUIRED, m2
Dough mixer 2 250 kg/hr 3 hp*2 (4*4) 2
Divider 250 kg/hr 1 hp (3*3) 2
Rounder 1 250 kg/hr 3 hp (3*3) 2
Moulder 1 250 kg/hr 3 hp (3*3) 2
Proofer 1 75 box/cycle 1 hp (4*4)
Baking oven 1 75 box/cycle 3 hp (4*4)
Cutter&slicer 2 250 loaf/hr 1 hp*2 (1.5*1.5)

ABSTRACT:

Location : Sangrur
Product : bread
Total area : 1000 m2
Building area : 700 m2
Water source : Bore well
Labours : 22
Power requirement : 16 hp
 PLANT LAYOUT FOR BREAD INDUSTRY
05 0500
09 01. Raw material storage

01 10. Proffing section,

11 02. Office room
03. Restroom,
06 08 10 12 04. Reception,
05 mixing,
06 fermentation section,
07. Dividing section,
17 07 08. Rounding section,
09. Moulding section,
02 13 10. Proofing section,
11. Baking oven,
12. Cooling section,
14 13. Cutting and slicing section,
14. Packaging section,
03 04 15 15. Finished products storage,
16. Toilet,
16 17. Water tank,
 PLANT LAYOUT FOR BISCUIT INDUSTRY
INTRODUCTION:
Biscuits are common baked items available in shops. Biscuits vary in size,
shape, filling and type of recipes. Biscuits require care, attention and good procedure
to get a better product. The materials required are maida, sugar, salt, and milk,
shortening and leavening agents. Variations can be introduced by altering of
ingredients; manipulation of ingredients and care should be taken in preparation of
dough. Occasionally egg is added to increase the volume, taste, and flavor of biscuits.
MIXING OF INGREDIENTS:
Biscuits can be classified into hard and soft dough. Hard dough can be further
classified into
 Fermented dough
 Puff dough
 Semisweet dough

Fermented dough: It is prepared by the addition of yeast to flour. Fermentation results

in softening and mellowing effect on gluten.
Puffed dough: It requires very strong flour with high gluten content. The dough
contains flour, water and salt. Other ingredients like hard fat (margarine), nuts,
flavors (essence) are added to the puffed dough to enrich the dough.
Semisweet dough: Soft flours are used for the preparation of semisweet hard biscuits.
The addition of corn flour and potato flour helps to reduce the strength of gluten in
this type of biscuits.

Soft dough is prepared with the flour containing less amount of gluten. Soft dough can
be prepared by two methods.

 Creaming
 All in one

Creaming: In this method, fat and sugar are blended to form a smooth homogeneous
cream. The creaming helps to develop uniform mixing of ingredients. This adds air to
the product. In this, mixing is continued till the dough is developed.

All in one: All the ingredients are blended together. The aerating chemicals, salt,
color and essence are mixed in water and added. The mixing varies with the type of
biscuits.
PROCESS FLOW CHART:
MIXING PROCESS

Selection of ingredients

Addition

Mixing process

Dough

MANUFACTURING PROCESS

Short dough

Dough feed conveyor

Metal detector

Molders

Panned web (it transfer to band)

Baking

Q.C.inspection

Cooling
INGREDIENTS / RECIPES USED FOR VARIOUS BISCUITS:

Ingredients Quantity
Maida 100
Sugar 30-40
Fat 15-25
Salt 1-1.25
Milk powder 2-3.3
Liquid glucose 2-30
Ammonium bicarbonate 0.75-1.0
Sodium bicarbonate 0.75-1.0
Lecithin 0.3-0.5
Water 5-9
Flavors as desired

MIXING:
In the preparation of biscuits, mixing is very critical. The dough has to be
mixed for a minimum period to obtain a tender and crisp biscuits. At the same time,
mixing should be such that all the ingredients are well dispersed and the dough
become cohesive enables shaping of biscuits in a mould.
Mixing is done in two stages, Creaming and Mixing stage. All the ingredients
except flour and acetic ingredients are mixed first at gentle speed and it forms a
cream. The flour is then added to the cream and mixing proceeds until uniform
depression of cream over the flour takes place. Horizontal type of mixer is used.

MANUFACTURING:
Manufacturing is the important operation where the dough after mixing is
moulded, baked and cooled. The most important aspect of molding is to create biscuit
of uniform weight both in line and across the over band. Hard dough varieties are
molded in different way. They are made into laminators, sheeted and molded.
The dough then passes through cutters and gets reduced in size. The cutter
roller rolls over the dough sheet and gets cut with the support of rubber roller, which
is placed below the canvas.
BAKING:
Baking is another stage of operation where the following changes take place,
• Development of rigid porous structures
• Reduction in moisture
 • Surface coloration
• Gelatinisation of starch
• Liberation of gases
• Loss of water vapor
• Expansion of gases.

COOLING:
During cooling, interchange of moisture between the product and atmosphere
occurs. Generally, the cooling time is 1.5 times that of baking.
LIST OF MACHINERIES:

MACHINES NO CAPACIT POWER REQD SPACE REQD TOTAL SPACE

Y REQD
Weighing balance 1 1.5*1.5 2*2
Dough mixer 1 250 kg/hr 3 hp 3*3 4*4
Dough sheeter 2 250 kg/hr 3 hp 2.5*2.5 3*3
Molder cutter 1 250 kg/hr 1 hp 3.5*3.5 4*4
Baking ovens 1 250 kg/hr 3 hp 5*4 5*5
Cooling conveyor 1 3 hp 5*3 5*4
Packing machine 1 3 hp 5*5 6*6
Storage 1 10 t/day 10*10 12*12
Office 1 4*3 5*5
Lab 2 5*5 4*4

Rest room 1 3.5*3.5 5*5

Toilet 1 5*5 4*4

ABSTRACT:
Name of the industry : BISCUIT INDUSTRY
Total area : 600 m2
Total building area : 300 m2
Total power required : 16 hp
Total water required : 1 litre/kg of the product
Total investment : Rs. 50,00,000
Profit percentage : 50%
 PLANT LAYOUT FOR PRODUCTION OF BOTTLED BEER

INTRODUCTION:

ALCOHOLIC BEVERAGES
Alcoholic beverage is a drink that contains ethyl alcohol. Alcoholic beverages
are made chiefly from such grains as barley, maize, and rye, or from grapes or other
fruit. There are two main groups of alcoholic beverages, fermented drinks and
distilled drinks. Fermented drinks contain from 5 per cent or less to 20 per cent ethyl
alcohol. The principal fermented beverages are beer and wine. Distilled beverages,
also called spirits or liquor, contain from 12 to 55 per cent or more ethyl alcohol.
They include brandy, gin, rum, vodka, and whisky.
PROOF OF ALCOHOL
As is well known, all alcohol used for beverage purposes is subject to a very
high excise tax. This tax is based on the strength of the particular alcoholic solution,
such strength being ascertained by a specific gravity determination.
"Proof Spirit" is used to express the strength of alcoholic solutions. In the
United States, any alcoholic solution containing 50% alcohol and 50% water by volume
is said to be proof spirit, or 100 degrees proof, or simply 100 proof. For example,
ordinary 95% (by volume) commercial ethyl alcohol is 95/50 x 100 = 190 degrees proof,
or 90 over proof.
The two terms to remember then are O.P. (overproof) and U.P. (underproof).
100 litres of 190 degrees proof alcohol would be taxed as 190 litres of proof spirit.
The British system is in use in Canada and is more complicated. According to
this system, any alcoholic solution containing 57.09% (by volume) alcohol and 42.91%
water is said to be proof spirit or 100 degrees proof.
BEER
COMPOSITION OF BEER
Water
More than 90% of beer is water. There are many salts and minerals in the
water, the quantity and variety of which affect the ultimate flavour of the beer.
The minerals in the water will also influence the head formation.
Malt
Malt is the sugar to be fermented that comes from the grain. Grain cannot
ferment by itself. When the grain is left in water, allowed to germinate and then
dried, fermentable sugar is released. This procedure is called malting. Barley malt is
by far the most important sugar-containing raw material for producing beer. Only
malted barley can be used in the brewing process.
Sugar
 In addition to the malted grain, sugar is often also added to help the
fermentation.
Hops
Hops give beer its bitter flavour and are also a natural preservative. Only the
flowers from the female hops are used for beer. The hop flowers contain lupulin, a
resinous substance that gives the typical bitter flavour. Hops also contain substances
that make the beer last longer. Hops also contain isoflavons with phyto-oestrogens
these substances are of more importance in functional nutrition.
Yeast
Yeast is a single cell micro-organism. It is needed in the brewing process for
converting fermentable sugars into alcohol and carbon dioxide. When converting sugar
into alcohol many types of aromatic substances are formed that also determine the
character of the beer.
NUTRITION IN BEER
Water : 90%
Sugar : 3%
Protein-Less than : 0.5%
Fat : Nil
Vitamin B2 : 0.07mg
Vitamin B1 : 0.01mg
Vitamin B6 : 0.12mg
Minerals : Fe,Cr,Cu,Si,k

BEVERAGE SUBSTRATES ALCOHOL(%)

Beer Cereals 4-8
Wine Grape juice 10-22
Cidar Apple juice 8-12
Champagne Grape juice 12-13
Brandy Wine 43-57
Whiskey Cereals 51-59
Rum Molasses 51-59
Gin Cereals 51-59
Rectified spirit Cereals 95.0

SAFE LEVEL OF DRINKING FOR PER DAY CONSUMPTION:

Category BEER WINE DISTILLED
ml ml BEVERAGES ml
MEN 672 280 84
 WOMEN 336 140 42
AGED FEW FEW FEW

FLOW DIAGRAM OF BEER PRODUCTION

RECEIVING OF MALTED GRAINS

CLEANING

WORT PRODUCTION

BOILING OF MASH

PRIMARY FERMENTATION HOPS

YEAST MATURATION
+ SUGAR
FILTRATION

BOTTLING

PASTEURIZATION

COOLING

LABELLING

STORAGE

PROCESS EXPLANATIONS

In our industry, we are purchasing only malted barley because we procure the
malted barley proximity to the unit. The purpose of procuring malted is to prepare the
starch in the barley for easy degradation during mashing, whereby it is transferred into
easily fermentable sugar. Furthermore, the malting and drying gives taste and colour
to the beer.
The raw materials are received and cleaned with vibrator and then stored in a
silo. For Wort production, the cleaned malted barley is ground by using with hammer
mill. The ground malt is collected in a grist bin or a hopper before being mixed with
water in a pre-masher during the mashing process. The mash is heated to a high
temperature in the mash-tun to activate the enzymes built up during malting.
The next step is the separation of the grist residues. This takes place at the
lauter tun.When the first wort (the extract from the water and the malt) is separated,
the remaining extract is washed out of the spent grains by spargings: that is, spraying
hot water over the grains.
 The last extract (last runnings) are used in the mashing of the next brew. The
spent grains are used as animal feed.The wort is brought into the pre-run vessel and
then to the wort kettle, where it is boiled together with the hops.
During the boiling, proteinous substances coagulate and fall out, together with
hop residues and tannins.The so-called trub also named hot break is separated from
the wort in the whirlpool (which has a tangential inlet), circulating the whole
inflowing batch at speed. The result is that the hot break settles like a cone at the
bottom of the whirlpool about 25 minutes after wort pumping is finished.
The hot break is collected and pumped back into the lauter tun to be added to
the next brew. The wort is cooled down from its 95°C to approximately 8°C in a heat
exchanger (a wort chiller), transferred into the gauging vessels, and then passed to
the fermenters.
Wort cooling produces hot water, which is normally returned to a hot water
tank in the brewhouse and used for brewing/spargings and for cleaning. All vessels and
pipes in the brew house are cleaned using the CIP (Cleaning-in-Place) system.
The cooled wort is aerated, yeast pitched by a metering pump, and
fermentation is started in the conical fermenters. Fermentation normally takes seven
days.During fermentation, the yeast settles in the cone of the fermenter.
The most active yeast is taken out of the fermenter for re-utilization in another
batch. As the yeast is multiplied by approximately six or seven times, there is a
considerable amount of excess yeast from each fermenter. The surplus yeast has
widespread uses, from animal feed to pharmaceutical purposes, but can also be
discharged to the sewer.
When the main fermentation is finished, the green beer is pumped into storage
tanks for maturation. During the maturation, a second fermentation takes place under
high pressure, building up dissolved carbon dioxide in the beer, while the remaining
yeast settles out.
This deposit yeast is used for animal feed or is discharged. The maturation can
also take place in an unitank, which is used for both primary fermentation and
maturation.
The finished beer is prepared for bottling or kegging by filtration and addition
of carbon dioxide. To ensure a standard quality, some batches of beer are blended and
colour may be added. Before filtration, the beer is cooled down to 0-1°C to minimize
the risk of it foaming in the filters. The beer is normally filtered in a coarse filter and
a fine filter. To avoid too high a filter resistance, kieselguhr is used as a filter
medium.
The beer is bottled under counter pressure and the bottles are sealed. A
spraying device takes foam residues away. After passing a fill height inspector, the
bottled beer is pasteurized, labelled and packed
 The bottles (new or returned) are passed through the bottle washer for
cleaning. The bottles are alternately soaked and sprayed in the washer; first with
warm water, then with a hot caustic solution, thirdly sprayed and rinsed in hot and
cold water, and finally a last cold rinse before they are conveyed to the bottling
machine.
After bottling, the beer goes to the pasteurizer. The bottles pass slowly
through different zones with increasingly hot water (up to 62°C), and then slowly
cooled down to approximately 25°C. The water in the tunnel pasteurizers is circulated
and thus used repeatedly. Any breakage is normally collected in containers and
returned to the glass manufacturers for recycling.
Machineries Required:

Equipment Capacity No. Power Area Reqd Total

Kg/hr Reqd. Hp/V m2 space m2
1. Vibrator 2000 1 5 /440 0.595 1
2. Hammer mill 200 1 5/440 0.365 0.6
3. Solar Dryer 300 kg/day 2 - 0.45 1.6
4. Pasteurization vat 30,800 bottles 1 - 10 12
5. Fermenter 1 lakh litres 7 2/220 2.25 20
6. Boiler 1 ton/day 1 - 4 7
7. Filter 5000 1 - 0.3 0.8
8. Bottle washer 15500 1 2/220 3 5
9. Vacuum filler bottles/hour 1 5/440 4 6

10. Generator 15 Hp 1 - 4 7
11. Conveyor 1000 kg/hr 1 1/220 2.5 5
12. Storage Bin 50000 kg 2 - 17.5 40
13. Maturation Tank 25000 kg 4 - 8 35

ABSTRACT

Location : Punjab
Industry : Brewery
Product : Bottled Beer
Capacity : 3,08,000 Bottles per day
Total Power : 20 Hp
Total Water : 90,000 litres per day
Building area : 250 m2
Total Area : 500 m2
Total Investment : Rs.10,75,00,000
No. Working days : 200
No. Labour reqd. : 18 (6 skilled, 12 unskilled)
Total Profit : Rs.40,00,000/day (Before Tax)
LAY OUT OF BEER PRODUCTION UNIT

16 17 21 20

0 1 2 3 4

11

12 10
9 22
8a

7a 6 5
8
7
13

18 19
14 15 15a
SECTIONS OF LAYOUT:

0 - Security office
1 - Cleaning section
2 - Storage of malted barley
- Belt conveyor
3 - Wort production
4 - Fermentation
- Fermenter
5 - Maturation section

- Maturation tank

6 - Filtration
7 - Bottle preparation (bottle washing, bottle sterilization)
7a - Bottle filling
8 - Pasteurization
8a - Cooling
9 - Labeling and Storage
10 - Administrative block
11 - Collection of yeast strains and Drying section
12 - Parking
13 - Canteen
14 - Recreation
15 - Gents toilet
15a - Ladies toilet
16 - Fuel storage
17 - Boiler
18 - Co2 tank
19 - ETP
20 - Water tank
21 - Generator
22 - Quality Control Lab
 LAYOUT FOR NATURAL MINERALWATER PLANT
Introduction:

 The first recorded history of discovery of natural mineral waters was as

early as 400 B.C.

 Mineral rich waters are created by the flow of water through rocks and
soil where mineral salts are dissolved.

 Many of the renowned springs were touted for their miracle medicinal
cures, and promotion of good health.

 In 1767, the waters of Jackson's Spa in Boston were bottled and sold.

 1820- SARATOGA SPRINGS Mineral Water was first bottled and sold

 There was a rapidly growing demand for its therapeutic miracles.

 In the early days of mineral waters, the closure of choice was the cork
stopper.

 Regulations very later emphasized on the bottling and packaging of

natural mineral water.

 This resulted in the Purification of water obtained from natural sources.

Reverse Osmosis:

 Reverse osmosis (Nano filtration) filters with a pore size of about 0.001
to 0.005 microns is used for this purpose.

 R.O is a high pressure, energy efficient separation Process wherein

pressures of about 15 – 60 KSC are applied.

 This allows monovalent salts and retains divalent salts like carbonates
and sulphates and solutes having molecular wt. > 300.

 Efficient process with least MWCO that filters out all micro organisms.
ABSTRACT
Industry : Natural Mineral Water Plant
Product : Bottled Natural Mineral Water
Capacity : 30,000 litres/day(8 h)
(15,000 one ltr Btls, 600 – 25 lts cans)
Total Power : 15 Hp
Total Water : 35 kilo litres/day
Building area : 250 m2
Total Area : 500 m2
Total Investment : Rs. 82,00,000
No. Working days : 200
No. Labour required : 15
Total Profit : Rs. 78,00,000 – 95%
Pay Back period : 1.1 years
Break Even point : 15 %

Natural mineral water in its packaged state shall contain not more than the
following amounts of the substances indicated hereunder:
Antimony 0.005 mg/l
Arsenic 0.01 mg/l, calculated as total As
Barium 0.7 mg/l
Borate 5 mg/l, calculated as B
Cadmium 0.003 mg/l
Chromium 0.05 mg/l, calculated as total Cr
Copper 1 mg/l
Cyanide 0.07 mg/l
Lead 0.01 mg/l
Manganese 0.5 mg/l
Mercury 0.001 mg/l
Nickel 0.02 mg/l
Nitrate 50 mg/l, calculated as nitrate
Nitrite 0.02 mg/l as nitrite 2
Selenium 0.01 mg/l
MACHINERIES AND SPACE REQUIRED:

Equipment Capacity No. Power Reqd. Area Reqd Total

Hp/V m2 space m2
1. Storage Tanks 1lac ltrs 2 - 25 50
2. R.O Membrane tanks 5000 ltrs/hr 2 5/220 9 20
3. Blow Molder 2500 btls/hr 1 2/220 1 1.5
4. Integrated Filler 2500 btls/hr 1 2/220 2 3
5. Bi-Directional Table 1000 btls 2 - 2.25 5
6.Trine Labeler 2500 btls/hr 1 1/220 0.5 1
7.Multi packer 250 1 1/220 2 3
cartons/hr
8.Palletizer 25 stacks/hr 1 2/220 2 3
9. Volumetric filler 15,000 1 2/220 2 3
ltrs/hr
10. Product Storage 30,000 1 - 10 12
Bottles
 Case Packager / Multi packer

Integrated Filling Machine

Trine Labeler Constant Volume Filler

Natural mineral water should contain no parasites and should meet the following
criteria:

n: number of sample units from a lot that must be examined to satisfy a given
sampling plan.
c: the maximum acceptable number, or the maximum allowable number of sample
units that may exceed the microbiological criterion m. When this number is
exceeded, the lot is rejected.
m: the maximum number or level of relevant bacteria/g; values above this level are
either marginally acceptable or unacceptable.
M: a quantity that is used to separate marginally acceptable quality from unacceptable
quality foods.
Process Flow Diagram:

Reception of water from springs

Storage

Blow Molding Reverse osmosis

Integrated Filling constant volume Filling

Labeling

Manual labeling
Case packing

Palletizing storage/Dispatch
 Raw Water Raw Water
Storage Storage R.O
Tank 1 Tank 2 Tank 2

G
G
A
A
R.O T
T
Tank 1 Bottling
Unit E
E
1 2

Office

Storage Unit
 PLANT LAYOUT FOR SPICE PROCESSING INDUSTRY
INTRODUCTION
Nowadays people are living a very fast life is which they don't even find time for
cooking.In this stage ready made foods like masalas play amajor role &very
important role in our day to day life. these readymade produts are very much
helpful in making various delicious recipes for our daily food
needs.

SITE SELECTION:
 _ Should be nearer to production area and farms.
 _ Ample water supply.
 _ Sufficient labour.
 _ Availability of finance.
 _ Economic and social supports
 _ road and railway facilities.
 _ eco friendly.
 _ ample power supply.
 _ readily available raw materials.
 _ marketing facilities and publicity.

Products:
l.Turmeric powder
2.chilly powder
3.Chicken masala
4.Mutton masala
5.Fish masala
PROCESS FLOW CHART:

RAW MATERIAL

CLEANING

ROASTING

MIXING

MILLING

PACKING

DESPATCH

Raw Material Section:

All ingredients used for masalas preparation are purchased and stored here. The
ingredients are purchased from wholesale markets. The raw materials are ordered
depending on their requirements. The storage section is well furnished with insect
guards and sufficient ventilation. It is large enough to store up to 300 tonnes. All
ingredients (except chilly and turmeric) are stored here. Chilly and turmeric are
stored separately in another room specially built for that. (Capacity: 300 tonnes)
Cleaning Section:
Redgram, gram dhal, coriander, are cleaned with the use of specific gravity
separator (destoner). Experienced persons handle it. It has a capacity of 1 tonne
per hour.
Roasting Section:
All ingredients are fried here. Red gram dhal, coriander, horse gram, Bengal grams,
mustard are fried in the roasting machine. The roasting machine is a dual drum
machine designed like a feed mixer in which the ingredients are constantly mixed
while frying. This avoids over heating and White gingely, poppy seeds, cashew,
curry leaf, sombu, garlic, groundnut etc are fried manually because these
materials require different temperatures and different duration of frying and also
they need more personal care. The required amount of material for each masalas
product is roasted here before grinding, except chilly and turmeric product.
Pouch packet roll storage room:
Pouch packet rolls are obtained in the printed state from Namakkal and Chennai.
The information about the product, ingredients, address of manufacture (except
manufacture date and M.RP) is printed in these rolls. These pouches packets are
made of polypropylene. These pouch packet rolls are stored in a separate room
with racks built in for this purpose.
Kitchen:
kitchen is situated in the centre portion of the industry. Sensory & organoleptic
evaluation of the prepared masalas & other products is done here.
Pouch packet roll storae:e room:
Pouch packet rolls are obtained in the printed state from Namakkal and Chennai.
The information about the product, ingredients, address of manufacture (except
manufacture date and M.R.P) is printed in these rolls. These pouches packets are
made of polypropylene. these pouch packet rolls are stored in a separate room
with racks built in for this purpose.
All prepared masalas products are packed here. SOgm, 100gm pouches are packed
by automatic packaging machine. 2S0gm, SOOgm, 1000gm pockets are prepared
manually. Vadagam and vatthal, payasam mixes are packed by continuous
packaging machine.
Machinery in Packing Section
As we all know the packing section is the very important unit of any industry, in
this industry also this section is given utmost care .In the packing section they use
both automated machines with least manual intervention in operations and total
manual packaging. The former is used for all ground powders like masalas and the
latter is used for the packaging of larger sized solids like Vadam, Curd chilly etc.
Manual Packaging:
This is the most traditional method of packaging adopted for those items that are
not produced in very large scale. Many labours are employed for this purpose and
they weigh the required quantity o(the materials and pack then manually inside
polythene bags and seal them either manually or by using a continuous sealing
machine.
Continuous sealing machine:
This machine is used for sealing the polythene bags, which are manually packed.
Descrintion:
This machine has a belt conveying unit driven by a motor over which there is a set
of eight pulleys in four pairs arranged in series. The outer two pulleys are used for
the movement of the packets over the belt drive at the bottom in a vertical
position and feed the packets to the heat-sealing machine. The heating coil is
insulated using Teflon belts driven between the inner pulleys, which prevents the
polythene from melting, and sticking to the heating coil because of their non-stick
property. Next to the heating coil is the cooling coil, which is actually circulated
with cold water in its inner side, which cools the sealed packets in the sealing
area thereby, strengthening the seal.
The Teflon belt runs over the cooling also in order to serve the same purpose as
above and thereby making the entire sealing operation smooth.
Material and temperature balance sheet:

Material of plastic bags Temperature of sealing, °C

Polyethylene 180- 225
Poly propylene 180- 21O
Moist proof poly paper 200- 225
Poly paper 220- 240
Poly styrene 200- 225
Polyvinyl acetate 200- 225
Hard PVC 200- 235
Polyvinyl fluoride 200- 255
Aluminum 200- 235
Auger Filler:
This is a fully auto mated pouch packing machine with all sorts of automations and
electronic controls possible. It is only used in the pouch packing of all masalas for
the fixed weights of 50gms and 100gms in pouches. This filling process in the auger
filler is taken care by the screw auger by which the set quantity of masalas is fed
into the pouches.
Grinding Section:
Chilly and turmeric are produced in a much larger scale than all other products
hence they are stored separately and ground separately in the pulveriser. All other
masalas are ground using three attrition mills each. After grinding the chilly and
turmeric powder from pulverizing unit, are mixed together with masalas powder.
After that, that is allowed for cooling for some time. The details of the pulveriser
and attrition mills are as follows.
Attrition mills:
There are four attrition mills which work on the principle of friction and shear
forces developed during the rotation of the criss cross hatched disc against the
fixed the disc thereby bringing size reduction of the particles. These have a
capacity of 1 ton per day. All the controls in this particular milling section are fully
manual and operated skilled and experienced workers.
Despatch section:
Here, all finished goods are temporarily stored and despatched to dealers. They
own many vehicles like vans, tempos and goods carrier autos mainly for the
marketing and despatch of these goods.
ABSTRACT
INDUSTRY : Chilly powder plant
CAP ACITY : 4t/day
BUILDING AREA : 0.6 acre(70x42)=2940 m2
COST OF BUILDING : Rs 11,76,000
TOATAL AREA : 1 acre(80x50)=40000m2
MACHINERY COST : Rs 16900000
TOTAL INVESTMENT : 4466000+20000000=Rs.646600
NO.OF MACHINES : 17
WATER REQUIREMENT : 3000 litres /day
POWER REQUIREMENT : 16.5hp

CONCLUSION:
Spice studies is necessary to provide new opportunities in the diversification of
trade in spices, spice blends, and their products and to find new uses of spices in
human physiology.
Our knowledge of spices in relation to evaluation of their flavor quality is
fragmentary. Flavor is a conglomeration of many contributing factors. We know
more about these factors now than we did yesterday.
However, further knowledge must be continuously acquired as a first priority in the
various disciplines engaged in this complex field of spice favor, if we are to
develop methods for its correct and rapid evaluation.