CHAPTER I INTRODUCTION

In fiestas and parties, the common gel dessert is always served. Some of these gels are soft and wriggle when shaken, while some are hard and brittle. Some gels need refrigeration or cooling to prevent them from melting. Others can withstand the heat. These dessert gels are served with or without fruit. These desserts gel are usually called gelatins and locally known as gulaman. In the Philippines, they are recognized as one product but naturally, they are not the same in terms of texture and properties. While gelatin is a protein, gulaman is a carbohydrate sourced from a plant, specifically seaweed, which is also known as agar. Recently, there have been objections to the use of gelatin that brought its price down in the world market, aside from oversupply. The controversial hoof and mouth disease and mad cow disease made the consumers wary of any products that come from farmed animals. Since gelatin is an animal protein from cattle or hogs, our vegetarian friends and Muslim brothers and sisters also have objections to its use in food and medicines. One of the used replacements as gelling ingredient is seaweed-based. Unlike gelatin, agars, alginates and carrageenans are complex carbohydrates. Agar, as a dessert gel ingredient known locally as gulaman, is usually sold as wafer bars in the Philippines. It is also sold in powder and wafer strip forms. One has to boil the water in order to dissolve the wafer before allowing it to set as a gel. Because the gelling temperature is high, refrigeration is not necessary to obtain the gel. The industry is finding a growing use of processed seaweeds (gulaman) as evidenced by the increasing demand in both domestic and international

markets. The domestic market is full of unexplored opportunities. Its inception in the 70's had been geared to the world market for survival. Local factories which produce gulaman bars are located in Caloocan City, San Juan, Malabon. This study aims to explore the business opportunity in the Philippine Gulaman Manufacturing Industry. This study also provides the proponents aim to study and meet a high production rate. And to increase the customers demand the product will be introduced low price in sales. 1.1 General Introductory Statement The company shall be named Batangas Gulaman Manufacturing Company, gulaman manufacturing company which aims to satisfy the different customers needs .The company name was derived from the location of the plant since the plant location will be on San Roque, Batangas. Mrs. Gulaman shall be the brand name of the product which has four (4) colors, white, red, yellow and green. The colors have chosen according to the

costumers interests and preference. And, in order to satisfy their necessities. The project aims to introduce a low price brand of dried gulaman. A strong market penetration scheme like an introductory low price for the product as compared to existing brands would be a very good start. Ten years from now, Batangas Gulaman Manufacturing Industry will become one of the main producers of dried gulaman for the company will involve. It is expected also to be one of the main contributors of economic success in the Philippines through its long range plan of production expansion. The product is to be offered in different sizes and will have appropriate packagings which are important factors to the marketing of the product. The company is looking forward to export its product and conquers the global market.

1.2 Subject of the Report This part discusses the different and chronological stages of the design. The group did before the completion of the design project.

Inception Stage In this stage the proponents had come up with the decision to design a gulaman manufacturing plant. The industry is finding a growing use of processed seaweeds as evidenced by the increasing demand in both domestic and international markets. Certain factors were considered in the choice of the industrial plant to design, which includes the plant location, plant layout, materials of construction, structural design, utilities, buildings, storage or warehouse, material handling, safety, waste disposal and local laws of code.

Research Stage After finalizing the decision of the selection of industrial plant to design, the group did the next step in the completion of the design project, which is researching for sufficient data and information needed for the design project. The group also made inquiries on specifications of the equipments to be utilized, as well as the parameters for plant location, such as land area, price of the land, accessibility to roads, proximity to the target market, and concerns regarding the ownership, operation and construction of the gulaman manufacturing plant, to be set by the government.

Design Stage At this point, sharing of ideas and information were done by the group to ensure the effectiveness of the design of the gulaman manufacturing plant. Factors considered in the design stage were the proper design layout of the gulaman manufacturing plant, proper selection of the equipments to be used and utilized in the installation and operation of the plant, source of raw materials and water treatment process and facilities. The group used much needed skills learned from previous subjects of the curriculum. From design concepts to design plates, the group combined the knowledge learned in specifying the appropriate equipment for selection and the skills to put together the selected equipments to form a functioning and reliable system.

Economic Analysis Stage After the selection of the proper location as made, the market study, and feasibility of the location was done next. The existing demand for gulaman through commercial and household use was carefully analyzed and served as the basis for the design capacity of the gulaman manufacturing plant. The initial costing includes land cost, construction cost, cost of main plant components and auxiliaries and miscellaneous expenses were justifiably estimated. Design costs were negated because of the ability of the proponents to use their knowledge in Industrial Plant Design as thought in their undertaken field of Engineering. Future operation and maintenance cost throughout the life of the plant were also forecasted. Marketing strategies like providing the needs for all kinds of ice were also studied.

Review of Related Literature The group researched on a project which is considered the demand of Filipino people using gulaman in their daily lives. Through extensive studies, the group realized that the demand on processed seaweed goes higher every year in the global market due to the discoveries of new use for seaweed extracts for industrial use as well as consume commodities. Statistic show that the international demand for this has grown much more rapidly.

Based on BFAR information on Philippine marine algae, the country is already at a stage where it can easily utilize and proceed to industrialize the highly commercial useful seaweeds. Only 1% of the total production is consumed commercially as food. The local market for industrial seaweed producer is practically limited to the producers of the "gulaman" bar.

Gulaman

Gulaman, in Filipino cuisine, refers to the bars of dried seaweed used to make jellies or flan, as well as the desserts made from it. The gulaman jelly bars are used in the various Filipino refreshments or desserts such as sago at gulaman (commonly shortened to sago't gulaman), buko pandan, agar flan, halohalo, different varieties of Filipino fruit salads, black gulaman, and red gulaman.

Seaweeds Seaweeds or macroalgae are multicellular eukaryotic algae. They are classified as algae because they are plants in the sea that have no true roots, stems and leaves. They are widely distributed in the ocean at various depths either free-floating or attached to sand, mud, rocks, shells, coral and others.

Classification of Seaweeds Red algae (Rhodophycae) is a very large class, encompassing approximately 4,000 species. Some of these are found in northerly latitudes, but most are found further south. Color varies among the red algae and is certainly not always red. A number of red algae are used as food. Brown algae (Phaeophycae) are often rooted to a stationary structure such as a rock, shell or dock by a structure called a holdfast, although species in the genus Sargassum are free-floating. Many species of brown algae have air bladders which help the blades of the algae float toward the ocean surface, allowing for maximum sunlight absorption. Green algae (Chlorophycae), as the name indicates, the algae of this class are green in color. The pigments of the chloroplasts include the two types of chlorophyll, a and b, and the various carotinoids. The yellow and orange of the latter pigments are masked by the abundance of the green chlorophyll. In contrast to the chitinous cell wall of the blue-greens, these plants produce walls that are largely cellulosea carbohydrate as opposed to the nitrogenous product, chitin. Some green algae of the sea for example, Halimeda of the Siphonalesbecome incrusted with calcium carbonate, and thus may contribute materially in some places to the formation of lime deposits in warmer seas. The joints of the plant remain uncalcified, and thus allow flexibility in the moving water. Harvesting

Seaweed is harvested on a weekly basis after 6 or 8 weeks of growth depending on the culture method you use.

It is the responsibility of the seaweed farmer to harvest the crop, dry the harvested seaweed and keep it in a well-protected place such as a storage shed

until the buyer comes to the village to collect it. Harvesting is a simple work to perform. It involves removing of the mature seaweed plants from the lines by unfastening the raffia knots, or by breaking off the plants; spreading the seaweed plants over a drying rack; and then removing raffia and other unwanted materials.

Eucheuma seaweed can be harvested after 8 weeks of growth. During the year, it is possible to achieve at least 5 harvests; one every 2 months.

If weather remains favorable, an additional harvest can be obtained unless it is necessary to commit some time for social and/or traditional activities.

At maturity (8 weeks), about 30 kg of wet seaweed can be harvested from each line planted with 30 seeds. After drying the seaweed, from each line you can obtain about 3 kg of dried seaweed.

In a realistic situation, as experienced by many seaweed farmers, you will not be able to harvest on a regular basis, rainy weather sometimes last several days or weeks. In this condition it will be a problem to find a shade to protect your harvest form rain and dry the seaweed. You might then decide not to harvest during this time. The seaweed will keep growing and as a result at the harvest, you will be able to obtain more than 3 kg from each line.

Drying

The drying rack should be built in such a way, keeping in mind that air should easily circulate through the seaweed to assure good ventilation and quick drying.

The simplest way to dry seaweed is by spreading the harvested wet seaweed over a net, a tarpaulin or over coconut leaves on the ground. However, in this way only the seaweed exposed directly to the sun will dry efficiently and the remaining will stay wet.

Air ventilation is very limited when seaweed is dried on the ground. If it is convenient and handy to dry the seaweed on the ground, be sure that the seaweed is at least partially dried. Fresh wet seaweed, just harvested, cannot be placed directly on tarpaulin for proper drying.

Moreover, if the seaweed is dry on the ground, sand, soil and other rubbish can mix with the wet seaweed. The seaweed buyers will not buy a dirty product.

The best way to dry seaweed, is to use a drying rack with the drying area made of sarlon netting. The rack can be constructed on shore or near your farm

In some cases it might be difficult to find the netting which can also be expensive. You can use reeds or bamboo instead.

Just to give you an idea, consider that in an area of 100 square meters (20 meter by 5 meter) of sarlon netting, you can dry approximately 80 lines of mature seaweed at one time or more.

With plenty of sunshine, assuming of 8 to 9 hours a day, the drying process will take you 3 to 5 days. Seaweed should be frequently tedded or turned for proper and quick drying. Also, for efficient drying, make sure the seaweed is thinly and evenly spread.

If the seaweed weighs before and after drying, you will find out that the original weight has decreased by approximately 10 times. So, 10 kg of wet seaweed after 3 to 5 days of sun drying, it will weigh only 1 kg. This is called 10 to 1 wet to dry ratio.

The minimum moisture content which is required by the seaweed buyers, is about 35 %. You do not need to measure the moisture content of your

seaweed before selling it. Just make sure that seaweed is properly dried as suggested.

Well dried seaweed is covered with plenty of salt crystals and has rubberlike texture when you squeeze it and no water should drip from it.

It is wise to cover the drying seaweed during rainy weather or at night with a tarpaulin or anything that can prevent the seaweed from getting wet. You might have unexpected showers at night! If seaweed is rain-washed, it will take more time to dry and you will face a further weight loss. This is a disadvantage for the seaweed farmer as the moisture content will be lower and the seaweed will become partially rigid and very difficult to pack. Rain-washed seaweed will give you less money than you might expect.

Uses of the Product Gulaman is used to make one of the popular dessert or sweet drinks called as Sago at gulaman. It is prepared by cutting the gelatin in cubes. The cooked sago or tapioca pearls are placed in the base of a tall glass. Boiling both together makes a syrup of half water and half sugar. This syrup is streamed over the sago or tapioca pearls and the gelatin cubes are added to it along with ice. Gulaman is also used to make flan. The gelatin-like characteristics help in making of flan in an easy and less expensive manner. The flan does not melt or get soggy when served at room temperature because of the use of gulaman.

There are a few dessert recipes which can be easily made by combining gulaman with milk, cream or coconut milk or cream. This gives the dessert a rich flavor. In some recipes gulaman needs to be cooked and the reconstructed and then the sugar and milk or coconut is added. When the mixture is allowed to cool, it is set and can be cut into squares which can be eaten as snacks or used as garnish for other dishes.
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Types of Driers 1. Flat Bed Box Dryer Dryers have a very simple design, grain is laid out on a perforated screen, and dried by forcing air from below. The air fan that provides the drying air is usually a simple axial flow fan that is powered by a diesel engine or by an electric motor. A kerosene burner or a biomass stove provides drying heat. Generally the drying floor is flat although dryers with reclining sections (to facilitate unloading) or vibrating sections (to facilitate stirring) exist as well. The four main components of a flatbed dryer are the fan for blowing the air coming from the atmosphere, the oven for heating the air coming from the fan, the drying bin for holding the grain, this grain is contained in a rectangular box which is called drying box and placed on a perforated floor and lastly the shedding for covering all these parts against rain.

Figure 1.0 Flat Bed Box Dryer

2. Continuous, Band Type Through-Flow Drier This drier serves to layer materials up to 30 to 100 mm in thickness on the band comprised of wire mesh or perforated sheet and perform drying by feeding hot air from the top or the bottom at right angles to the materials layered. This drier is used to dry formed materials, enabling you to get homogeneous products with uneven drying diminished. Extended contact time makes it possible to dry materials of high internal moisture up to considerably low moisture content. Materials are dried in a state of packed layer, enabling you to
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get products with minimized particle destruction. Compared to concurrent-flow compartment driers, you are able to finish drying step in far shorter period of time. Materials can be layered thick in a state of packed bed for shorter drying time, reducing the floor space required for drying as well as the volume of the equipment. Materials are dried as they are left at rest to diminish their flying, enabling you to cut the costs of flue gas treatment.

Figure 2.0 Continuous, Band Type Through-Flow Drier

It is use for Fibrous materials, Solids forming of sludgy materials, Calcium carbonate and magnesium carbonate, Titanium oxide, white carbon, and carbon black and Synthetic resin pellets. The above figure shows an example of sludgy materials forming and drying system. Materials formed through the pelletizer are stacked in layers on the conveyor screen to enter the drying chamber, where the materials, while passing to the outlet, are dried with hot air forcibly ventilated from the top through the bottom of the material layers.

3. Rotary Drier Rotary dryers feature a slowly revolving cylinder tilted to one side. The wetted solid feeds in on one side of the cylinder and the dry product exits on the other. The rotary dryer is a type of industrial dryer employed to reduce or minimize the liquid moisture content of the material it is handling by bringing it
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into direct contact with a heated gas. The dryer is made up of a large, rotating cylindrical tube, usually supported by concrete columns or steel beams. The dryer slopes slightly so that the discharge end is lower than the material feed end in order to convey the material through the dryer under gravity. Material to be dried enters the dryer, and as the dryer rotates, the material is lifted up by a series of internal fins lining the inner wall of the dryer. When the material gets high enough to roll back off the fins, it falls back down to the bottom of the dryer, passing through the hot gas stream as it falls. This gas stream can either be moving toward the discharge end from the feed end (known as co-current flow), or toward the feed end from the discharge end (known as counter-current flow). The gas stream can be made up of a mixture of air and combustion gases from a burner, in which case the dryer is called a direct heated dryer.

Figure 3.0 Rotary Drier

4. Spray Drier For spray drying, it is usual to pump a concentrate of the liquid product to the atomizing device where it is broken into small droplets. These droplets meet a stream of hot air and they lose their moisture very rapidly while still suspended in the drying air. The dry powder is separated from the moist air in cyclones by centrifugal action. The centrifugal action is caused by the great increase in air speed when the mixture of particles and air enters the cyclone system. The dense powder particles are forced toward the cyclone walls while the lighter, moist air is directed away through the exhaust pipes. The powder settles to the
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bottom of the cyclone where it is removed through a discharging device. Sometimes the air-conveying ducts for the dry powder are connected with cooling systems which admit cold air for transport of the product through conveying pipes. Spray dryers can dry a product very quickly compared to other methods of drying. They also turn a solution or slurry into a dried powder in a single step, which can be advantageous for profit maximization and process simplification.

Figure 4.0 Spray Drier

5. Drum Drier The Drum dryer consists of a cylindrical drum, having provision for cooling drum surface. One end of the drum shaft is connected to a gear box which is driven by a motor. The heating cooling media will be circulated in drum during operations; the drum rotates at a slow speed. These have a heated drum or set of 2 drums where the product is distributed on the outside of the drum and dries as it rotates slowly toward a scraping blade which scrapes the dry product off the outside of the drum. A thin layer of the product to be dried / cooled, adheres to the outside of the rotating, drum and internally cooled drum. The product gets solidified and is after an almost complete rotation, scrapped off drum surface and at the same instant granulated in the form of flakes, falls on screw conveyor. At
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the bottom of conveyor, filling point is provided to fill the bag. The entire process is continuous operation, does not require manpower except bag filling. These are good for milk drying, and cereals.

Figure 5.0 Drum Dryer

6. Freezer/Dryer

This is a low temperature batch dryer that has a vacuum rated housing with heated or cooled shelves inside. The product is spread onto trays that are inserted onto the shelves. Once the shelves are full the door to the dryer is closed until the drying process is complete. The identical to a shelf dryer except the product is processed under low temperatures. Many times vials filled with a pharmaceutical injectable medicine and a stopper on top are process in this dryer. When the process is complete the shelves compress to press the stoppers into to vials to completely seal them before leaving the dryer for sanitary reasons.

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Figure 6.0 Freezer/Dryer

1.3 Location of Selected Plant Site In CALABARZON, most of the seaweed nurseries established and beneficiaries identified are located in the provinces of Quezon and Batangas. Existing seaweed farming areas are located in the municipalities of Balayan and Calatagan, Batangas, and in Quezon in the municipalities of Agdangan, Burdeos, Jomalig, Mauban, Padre Burgos, Panukulan, Patnanungan, Perez, Polillo, Tagkawayan, and Unisan.

Bureau of Fisheries and Aquatic Resource (BFAR) 4A has actively conducted expansion of seaweed farming areas thru these established nurseries and dispersal of seedlings to farmers and fisherfolk. Farming paraphernalia are also distributed to assist the farmers in the initial establishment of their farming area. Trainings and seminars are also conducted prior to dispersal especially to beneficiaries who are first time farmers.

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Figure 7.0 Proposed Plant Location

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CHAPTER II DESIGN PROPER Seaweeds undergo several processes before they become dried gulaman. Gulaman is a plant-derived carbohydrate. Gulaman are bars of dried seaweed used to make jellies or flan, as well as the desserts made from it. Seaweeds are freshly harvested early in the morning or during low tide. After gathering, the seaweeds are washed with fresh water and drained thoroughly. They are spread into thin layers over wooden trays or in any clean container and dry under the sun for one week. Following, seaweeds are resoaked in fresh water and to be dried again until they turn into dirty yellow. After several procedures, they are cooled before packing and storing.

Figure 1 Seaweeds

Figure 2 Dried Seaweeds

Figure 3 Gulaman Bars

2.1 Scope of the design of selected Industrial Plant This part would include certain scope and limitations of the design project. Initially, it would only be limited on the design, calculation and selection of the equipments involved in the process, but for certain consideration in looking up to the feasibility of the design, economic analysis would also be included. The specific scope and limitations of the proposed dried gulaman manufacturing plant are: a) The design would mainly cover the entire gulaman making process, operation and production starting from the gathering of raw materials up to the production of finished products. The industrial plant design project
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relied solely on engineering concepts and engineering works relative to the chosen plant. Due to limited time constraint, other construction

aspects and respective building services were excluded and disregarded. b) The design would include only the required or desired plant capacity and other essential parameters in the operation, process and production as the bases for the selection of necessary equipments. Since the equipments incorporated in the design of a dried gulaman plant were not tackled in this semestral course, this imposed a limitation in the project study. Thus, detailed calculations for particular equipment were not presented as the groundwork leading to machinery and equipment selection. c) Using the manufacturers catalogue, the project would also inco rporate the design of primary machineries and equipments taking into consideration the various specifications. d) The industrial plant layout would likewise be presented, including structural building arrangements on the site and equipment installation and set-up. Economic analysis was also employed in the study.

2.2 Introduction to the Dried Gulaman Plant Design The company shall produce dried gulaman using the latest technology the Philippine has. The technology uses the largest and most economical in terms of energy needed. They will manufacture gulaman bars in different colors. Gelidium corneum (most edible seaweed) is the main raw materials used and they will be chosen in accordance with certain specifications the company will establish to ensure the quality they want to be well known for. This raw material is very accessible because it can be found at the sea during low tide.

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2.3. Design Basis Dried gulaman manufacturing starts in the harvesting of fresh seaweeds. They are carefully inspected to determine their moisture content. Washing and draining is the next step. Then after that is drying them to achieve the desired moisture content; then they are re-soaked in fresh water and drying them again. Bleach them with weak acids like vinegar until the color turns olive green. A one-tenth kilo of dried seaweeds is either soaked in a solution of 3.5 liters of water an 90 ml of 0.1N sulfuric acid or soaked in a solution of half a liter water and 2.5 grams of commercial sodium thiosulfate. Drain the bleached seaweeds and dry them until achieved the light brown color. Boil the dried seaweed in the solution (water and vinegar); boiling rangers from 30 to one hour while constantly stirring the solution. Boiling can be repeated until the solidification of the extracted agar is difficult to achieve. Strain the

seaweeds after boiling. Separate the liquid portion from the plant residue. After extraction, allow the filtered extract to cool and solidify. Once it is hard enough, cut into strips or to any desired form. Pack the gulaman strips or bars into an ice box with dry ice; keep the bars intact for 2-3 days. Thaw the gulaman bars by placing them on bamboo matting or wire screen and allow them to dry at room temperature. Allow the extracted thawed agar to dry under the sun until the desired texture is obtained. Cool the gulaman bars before packing and storing.

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2.3.1 Below is the Tabulated Processes Involved in the Production of Dried Gulaman

Loading of Fresh Seaweeds

Inspection

Weighing

Washing

Drying

Soaking

Drying

Bleaching

Drying

Boiling

Straining

Drying

Cooling

Packing

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Process Description The following are process in making dried gulaman:

1. Loading Delivering of the raw materials which will be needed for the process of production. 2. Weighing After the seaweeds are carefully inspected, they are weighed directly in the platform balance. This is to determine whether the seaweeds contains the right amount, and to determine the right weight that must be use. 3. Inspection Upon delivery of the raw materials samples of seaweeds are inspected using the moisture meter to determine if they possess the allowable moisture content. It is important to determine the moisture content of the seaweeds to gauge the drying needed. 4. Washing Washing the seaweeds to remove its fishy odor. 5. Drying The main purpose of drying is removing the desired moisture content of the seaweeds and arrived with the desired color. 6. Soaking Immersing the seaweeds in fresh water for 5-10 minutes until it turns to dirty yellow 7. Bleaching Bleaching the seaweeds with weak acid (vinegar) until the color turns olive green; one-tenth kilo of dried seaweeds is either soaked in

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a solution of 3.5 liters of water an 90 ml of 0.1N sulfuric acid or soaked in a solution of half a liter water and 2.5 grams of commercial sodium thiosulfate. 8. Boiling Boil the dried seaweeds into 3-5 liters of water and a diluted solution of vinegar until slightly acidic to taste while continuously stirring it; boiling can be repeated until the solidification of the extracted agar is difficult to achieve. 9. Straining Separation of the liquid portion from the plant residue. 10. Cooling Allow the filtered extract to cool and solidify; once it is hard enough, cut into strips or to any desired form. 11. Packing Packing the gulaman strips or bars into an ice box with dry ice or wrap them in cheesecloth with ice and salt.

List of Equipments The following are the list of the equipments use for the process production of dried gulaman: 1. Weighing Scale 2. Tray Dryer 3. Square Water Tank 4. Belt Conveyor 5. Hoist 6. Water Tank with Stirrer 7. Strainer

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2.3.2 Below is the Specification of the Equipment Involved in each of the Processes 1. My Weigh - Ultraship 55 Maximum capacity is 25kg with dual range accuracy. When weighing less than 1kg accuracy is to 0.1, then above 1kg accuracy is to 0.5. Weighing modes include pounds, pound: ounces, grams, and kilograms. 2. Double Chamber Batch Dryer Most of the experiences to date have been with drying herbs and fruits. Typical drying temperature for herbs like seaweeds is at 55C. Output Capacity is 240 kg per 24 hour. 3. Innovative Square Water Tanks Square water tanks are made from Bluescope Aquaplate steel with an internal polymer food grade lining and are available in all Colorbond colors. Each tank is hydraulically tested before it leaves the factory and is quality checked through each stage of the manufacturing process. It supplied with the standard 400mm inlet, 90mm overflow and 25mm outlet and gate valve. 4. GRAVITY TAKE-UP Belt Conveyor Depending on the specific conveyor requirements, design changes may be made to accommodate them. Specification standard is : belt width 18 in, pulley diameter 16 in, shaft diameter 3 7/16 in and weight capacity is 440 lbs. 5. LMHA Hand Chain Hoist Designed for portability and easy installation; compact gear housing provides low headroom. Meets or exceed minimum 4:1 design factor and all requirements of ASME/ANSI Standard B-30.16. All units tested at 125% of rated load. Rated capacity of - 20 ton.

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2.5 EQUIPMENT SPECIFICATION Equipments for the dried gulaman manufacturing plant where all based on manufacturers catalogue. Related computations where only made in order to justify the use of these equipments and know if it will be suitable to attain the desired plant output. The computations are given in details as follows:

DRYING PROCESS 1st Dryer

MODEL: Double Chamber Batch Dryer (Tray Dryer) MANUFACTURER: ITDG South Asia

CAPACITY: 240kg per 24 hour

P = 101. 325KPa T = 25CDB 17CWB %mf = 82%

Air Out

T = 45C

DRYER
T = 55C

%mp = 18%

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25C

45C

55C

@ entering condition he = 47.918 KJ/kg 47.918 = 1.0062 (25) + W e (2547.3) We = 0.0089 kg/kg @ state point 1 We = W 1 = 0.0089 kg/kg h1 = 1.0062 (55) + 0.0089 (2600.95) h1 = 78.489 kJ/kg @ leaving condition h1 = h L 78.489 = 1.0062 (45) + W L (2583.3) WL = 0.0129 kg/kg BDM analysis F (1 0.82) = 320 (1 0.18) F = 1457.78 kg/8hr mwv = F P mwv = (1457.78 320) kg/8hr mwv = 1137.78 kg/8hr
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mair = mwv (W L W 1) mair = 1137.78 kg/8hr (0.0129 0.0089) mair = 284,445 kg/8hr Qair = mair (h1 he) Qair = (284,445 kg/8hr x 1hr/3600s) (78.489 47.918) Qair = 301.94 KW

2nd Dryer MODEL: Double Chamber Batch Dryer (Tray Dryer) MANUFACTURER: ITDG South Asia

CAPACITY: 240kg per 24 hour

P = 101. 325KPa T = 25CDB 17CWB %mf =50.11 %

Air Out

T = 45C

DRYER
T = 55C

%mp = 11%

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25C

45C

55C

@ entering condition he = 47.918 KJ/kg 47.918 = 1.0062 (25) + W e (2547.3) We = 0.0089 kg/kg @ state point 1 We = W 1 = 0.0089 kg/kg h1 = 1.0062 (55) + 0.0089 (2600.95) h1 = 78.489 kJ/kg @ leaving condition h1 = h L 78.489 = 1.0062 (45) + W L (2583.3) WL = 0.0129 kg/kg

BDM analysis 320 (1 0.5011) = P (1 0.11) P = 179.3797753 kg/8hr mwv = F P mwv = (320 - 179.3797753) kg/8hr
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mwv = 140.6202247 kg/8hr mair = mwv (W L W 1) mair = 140.6202247 kg/8hr (0.0129 0.0089) mair = 35155.05618 kg/8hr Qair = mair (h1 he) Qair = (35155.05618 kg/8hr x 1hr/3600s) (78.489 47.918) Qair = 37.316848 KW

3rd Dryer MODEL: Double Chamber Batch Dryer (Tray Dryer) MANUFACTURER: ITDG South Asia

CAPACITY: 240kg per 24 hour

P = 101. 325KPa T = 25CDB 17CWB %mf = 36.4%

Air Out

T = 45C

DRYER
T = 55C

%mp = 8%

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25C

45C

55C

@ entering condition he = 47.918 KJ/kg 47.918 = 1.0062 (25) + W e (2547.3) We = 0.0089 kg/kg @ state point 1 We = W 1 = 0.0089 kg/kg h1 = 1.0062 (55) + 0.0089 (2600.95) h1 = 78.489 kJ/kg @ leaving condition h1 = h L 78.489 = 1.0062 (45) + W L (2583.3) WL = 0.0129 kg/kg

BDM analysis 179.3797753 (1 0.364) = P (1 0.08) P = 124.0060186 kg/8hr mwv = F P mwv = (179.3797753 - 124.0060186) kg/8hr
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mwv = 55.37375672 kg/8hr mair = mwv (W L W 1) mair = 55.37375672 kg/8hr (0.0129 0.0089) mair = 13843.4918 kg/8hr Qair = mair (h1 he) Qair = (13843.4918 kg/8hr x 1hr/3600s) (78.489 47.918) Qair = 14.69471456 KW

4th Dryer MODEL: Double Chamber Batch Dryer (Tray Dryer) MANUFACTURER: ITDG South Asia

CAPACITY: 240kg per 24 hour

P = 101. 325KPa T = 25CDB 17CWB %mf = 22.78%

Air Out

T = 45C

DRYER
T = 55C

%mp = 5%

30

25C

45C

55C

@ entering condition he = 47.918 KJ/kg 47.918 = 1.0062 (25) + W e (2547.3) We = 0.0089 kg/kg @ state point 1 We = W 1 = 0.0089 kg/kg h1 = 1.0062 (55) + 0.0089 (2600.95) h1 = 78.489 kJ/kg @ leaving condition h1 = h L 78.489 = 1.0062 (45) + W L (2583.3) WL = 0.0129 kg/kg

BDM analysis 124.0060186 (1 0.2278) = P (1 0.05) P = 100.7973132 kg/8hr mwv = F P mwv = (124.0060186 - 100.7973132) kg/8hr
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mwv = 23.20870538 kg/8hr mair = mwv (W L W 1) mair = 23.20870538 kg/8hr (0.0129 0.0089) mair = 5802.176344 kg/8hr Qair = mair (h1 he) Qair = (5802.176344 kg/8hr x 1hr/3600s) (78.489 47.918) Qair = 6.158969898 KW

Summary of the Computed Values Dryer1-a Dryer1-b Dryer2 Dryer3 Dryer4 Total

Mass of 91.111kg/hr 91.111kg/hr 40kg/hr Feed kg/hr Moisture in Feed 82% 82% 50.11% 36.4% 22.78% kg/hr 22.422 15.501

Mass of 20 kg/hr Product kg/hr Moisture in Product 18% 18% 11% 8% 5% kg/hr kg/hr 20 kg/hr 22.422 15.501 12.5997

Mass of 17777.813 Air kg/hr Required kg/hr kg/hr kg/hr kg/hr kg/hr 17777.813 4394.382 1730.436 725.272 42405.716

Heat 150.597 Required KW KW KW KW 150.597 37.317 14.695 6.159 KW 359.365KW

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2.6 PLANT CAPACITY The following computations lead to the identification of plant capacity. The group aimed a desired output and considering the amount by percent required to achieve the target production of dried gulaman. The desired output are as follows: Dried gulaman bars = 12.5 kg/hr Qty of Gulaman bar per hour = 1250 2 Gulaman bar per pack; 625 pack In the first drying process, it was tested that fresh seaweeds generally contains about 82% moisture by mass; then it is to be dried up to moisture content of about 18%. After drying it was re-soak to fresh water which will have moisture content of 50.11% and to be dried up to 11%. It was then bleached to a solution which gives a moisture content of 36.4% to be dried to the desired moisture content of 8%. Lastly, it was to be boiled which gives moisture content of 22.78% and to be dried to the desired moisture content of 5%. Above computation shows the needed mass of seaweeds (kg) for the production of the desired production.

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CHAPTER III ECONOMIC ANALYSIS 3.1 Overview of the Design Project The size of the plant is normally determined by technical as well as economic considerations. The estimation of cost was from City Engineers Office. Summary I. Manufacturing Plant Concrete and Masonry Hardware Carpentry Doors and Windows Tile Works Plumbing Works Electrical Works Painting Works Excavation P 1,830,432 2,082,222 728,682 884,742 163,068 1,077,588 1,884,918 296,109 91,800 P 9,039,561 II. Fencing and Improvement Add: Labor P 1,353,924 2,888,320

Grand Total

P 13,281,805

Raw Material The raw material is mainly abundant in Calatagan, Batangas and Quezon Province. The company plans to get their supplies from these provinces at which will rapidly supply 40-45 tons per month of seaweeds.

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Seaweeds The type of seaweed use in the production of gulaman is Gelidium corneum. It is a genus of thalloid alga comprising 124 species. Its members are known by a number of common names. Specimens can reach around 2 to 40 cm in size. Branching is irregular, or occurs in rows on either side of the main stem. Gelidium produces tetraspores. Many of the algae in this genus are used to make agar. It is the one of the most edible alga, dehydrated and formed into foot-long dry a bar which is either plain or colored. The gulaman jelly bars are used in the various Filipino refreshments or desserts such as sago at gulaman (or gulaman at sago, commonly shortened to sago't gulaman), buko pandan, agar flan, halo-halo, different varieties of Filipino fruit salads, black gulaman, and red gulaman. It has also come to refer to the refreshment or dessert, sometimes referred to as samalamig or sago't gulaman, sold at roadside stalls and vendors. Utilities In every business, availability of utilities such as water, electricity and telephone are very vital. Without them, production would not be possible and so is the business. Sufficient electricity shall be applied by the Batangas Electric Company (BATELEC1) and the utilization of water shall be supplied by the Calatagan Water Supply. Installation of telephone lines shall be provided by Philippine Long Distance Telecommunications (PLDT). 1. Electricity Total Power Consumption KW-hr Total Cost per Year 2. Telephone Bill Php 700 per month
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3,620,243.01

P 34,899,142.62

Total Cost per Year 3. Water Php 51,000 per month Total Cost per year

P 8,400

P 7,344,000 ________________

Total 42,251,542.62

Php

Waste Disposal Production of gulaman bars will produce large volume of waste. Some of these wastes can be used as an organic fertilizer. These organic wastes can be allocated to the different farmers and will be used as fertilizers to their plantation. Sanitary Landfills can also be use for waste disposal; these landfills are large piece of land away from living places where all the waste from a town is deposited. Proper landfill management involves sorting out all the waste (waste separation), and sending only the waste that cannot be recycled and composted to the site. Proper waste disposal is of great importance to both rural and urban areas. Not doing this may bring us to danger in many ways and surely everybody knows this. All of us should be aware of the proper waste disposal. Labor Requirements It is important for any company to have the most efficient and effective workers. Since manpower or labor is the most valuable organizational asset, it is necessary to choose employees that are capable of performing their respective duties. In the part of the company, those employees shall be given considerable benefits and adequate monetary compensation for them to be more productive.

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Employee Administrative Labor: General Manager Finance Manager Secretary Security Guard Janitor Total Sales Labor Marketing Manager Sales Representative Driver

Quantity

Monthly Salary

1 1 1 2 2 _________ 7 1 3 3 _________ 7

P 27,000 P 21,000 P 10,500 P 15,700 P 15,500 _________ P 89,700.00 23,000 33,000 24,000 _________ P 80,000.00 17,000 8,000 __________ P 25,000.00 P 55,500 __________ P 55,500.00

Total Indirect Labor Production Supervisor 1 Utility Man 1 _________ Total 2 Direct Labor Laborer/Worker 7 _________ Total 7

3.2 Basis of the Design Project Cost Calculation In the formulation of the financial projection, assumptions play a major role as the foundation for estimating the future expenditures and revenues of the project. The companys assumptions are as follows: 1. Salaries and wages, and legal benefits are expected to increase by 5% every year. 2. A 5% increase in delivery expense, utilities, and miscellaneous expenses is assumed every year. 3. Supplies and repair and maintenance are expected to appreciate for 3% every year. 4. Interest on capital will have an annual increase of 15% during the period.

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5. Advertisement and promotions are assumed to increase every year by an estimated 3%. 6. Contingencies, permits and licenses are assumed to increase 2% every year. 7. Cash dividend of 8% from net income. 8. Utility expense, miscellaneous expense and repair and maintenance expense is divided into three: 60% in production department, 20% in administrative department and 20% in sales department. 9. Depreciation in building is divided into three: 50% in Production Department, 30% in Administrative department and 20% in the Sales Department. 10. Office Supplies expenses is divided into 50% in Administrative Department and 50% in Sales Department. 11. Depreciation in Furniture and Fixture and in office equipment is divided into two: 50% in Administrative Department and 50% in Sales Department.

3.3 Calculation of the Total Plant Costing The total project cost is composed of the Fixed Capital Investment and the Initial Working Capital. Land Building and Improvement Machineries and Equipment Delivery Trucks Furniture and Fixture Office Equipment P 4,800,000.00 5,445,020.00 2,840,100.00 1,300,000.00 156,500.00 280,100.00 __________________ Sub-total P 11,551,720.00

Add: Initial Working Capital

17,628,812.00 __________________

Total

P 29,180,532.00
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3.4 Conclusion/Recommendation A primary aim for all business organizations is to add value and in the private sector these involves making a profit and contribute to the economic growth of its country.

Findings Based on the research, the following findings are drawn:

1. The researchers found out that a Dried Gulaman manufacturing company has a very large potential in capturing a large market although the industry is in introductory stage only. This is due to the low introductory price. 2. The proponents also found out that adapting the high production rate of the company is an important advantage for a dried gulaman manufacturer.

Conclusion The proponent of the study concludes that: 1. The project is financially viable or feasible. 2. The company is beneficial to socio-economic situations. 3. Batangas Gulaman Manufacturing Indstry is a potential income generating company. 4. The introduction of excellent business within the area of Batangas requires a good marketing plan.

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Recommendations Based on the foregoing research, the designer recommends the following: 1. That the company should register on different Seaweeds Organizations in the country \to have some assistance in marketing the product and have a positive image with regards to the company. 2. That the company should continue to explore the potential market outside the initial target market.

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