Optimized Food Factory Layout: Plant Design, Utilities & Equipment Placement

www.pmg.engineering Vol .02-Issue .03-January 2023 TECH-KNOWLEDGE The Official PMG Engineering Newsletter FOOD & BEVERAGE INDUSTRY ENGINEERING & DESIGN SCIENCE & TECHNOLOGY A PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .03-January 2023 CONTENTS YOUR PARAGRAPH TEXT 1. WHITE PAPER A. Utilities Management B. External Plant building design 2. INDUSTRY BUZZ Latest Food Industry News Updates 3. WEEKS HIGHLIGHT A Look Into The Main Events Of The Week 2-5 6-8 9 4. DID YOU KNOW? Fascinating Food Facts To Expand Knowledge 10-13 PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .03-January 2023 UTILITIES MANAGEMENT Introduction For any food industry, the main challenge it faces during initial stage is the selection and designing of utilities. Utilities of a food industry comprises of environmental air, compressed air, water, and steam. Utilities play major role and are very influential factors for the production and for the quality of product produced. Environmental Air Environmental air is the surrounding air that is present in the vicinity of production plant which can be highly contaminated with physical of microbiological contaminants. Manufacturing plant are segregated into manufacturing area, where the product comes into contact with the environmental conditions and non-manufacturing area, where the non-manufacturing packaging, warehouse, etc. takes place. Manufacturing area or production area need to be maintained at utmost hygiene as product comes in direct contact with environment. certain preventive action are required to maintain the quality of the products. In manufacturing area process like Regular monitoring, trending and review of air quality by appropriate personnel to ensure suitable microbiological quality. Maintaining suitable air pressure differentials between adjacent areas (Non- manufacturing area) to positive, negative, and in relation ambient airflow to prevent contamination Air sourced from outside to be filtered to the level required for the product Air blown on surface of microbiologically sensitive material to be sourced from within processing area Air for controlled or high controlled zones not to be sourced from unprocessed (raw) areas. Air supplied to the filler in an aseptic filling system (for beverages) to be filtered through a HEPA filter (H13) READ MORE.... PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .03-January 2023 Compressed Air PLATE HEAT EXCHANGER Initiate corrective action for out of standard results. the long as care food Compressed air efficiently supports industry as is taken to remove contaminants from the system. Compressed air system is of different type i.e., contact system and non-contact system, depending upon the use and it is food industry requirement that should define how compressed air is to be used in their facility and define a specification for compressed air purity based upon the system. Water in food have industry Water extensive consumption. Depending upon the requirement, water can be used as ingredient or component of ingredient, for cleaning and sanitation or for processing operations. Different form of water is used in industry like soft water, raw water, RO water, process water, as refrigerant or as heating medium. Quality or sanitary level depends on the intended use. Food business should follow good sense practice while considering source and treatment to ensure the quality and safety of the products. Potable water supply system should regulatory meet requirements other requirement as listed below and there national certain local and all is ozone & Test for chlorine chlorinated water and weekly analysis of water being used in product. periodically Steam In food industry, steam can be recognized into two that is plant or process steam (indirect contact or no contact with food) and culinary steam (direct contact with food or food coming in contact surface). Process steam is the steam used indirectly during processing (e.g. steam for jacketed equipment) and the steam to be produced using boiler chemicals or water treatment should be approved under local/ national regulations. Culinary steam or clean steam is suitable for direct product contact and can be directly injected into product. It can be used to sterilize the vessels or parts that comes in contact with food product. Culinary steam should be produced only using approved food grade boiler chemicals. The piping assembly for direct steam should contain an entrainment separator capable of removing particles of 30-micron size and should be delivered through stainless steel pipework to the point of use. Water microbiological quality to be controlled and meet specific requirements and performing periodic microbiological tests. Test all water (reclaim water, hand wash water, water for brine solutions, recirculated cooling water, water as sanitation final rinse) to be tested for TVC (Total Viable Count) and coliform. Recommended limits are TVC< 500 cfu /ml and coliforms <1cfu/100ml. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue 03.January 2023 EXTERNAL - PLANT BUILDING DESIGN Introduction Plant design refers to the overall designing of a manufacturing enterprise/facility. The objectives of designing & constructing a sanitary food handling facility are to eliminate the entrance of pests and other sources of contamination. to minimize harborages and Food Processing plants are quite different from the non-food processing ones, the main difference lies in areas of equipment, selection and sizing, working space design and these differences are due to storage life of foods is relatively limited and temperature, pH, water strongly affected by activity, maturity, prior history, and initial microbial contamination levels. Very high and verifiable levels of product safety and sterility have to be provided as foods are highly susceptible to microbial attack and insect and rodent infestation. Food processing generates wastes with high BOD loads which need treatment before releasing it to environment. special Plant Designing A. Premises and Surrounding Objective for sanitary building are to minimize harborages and infestation, , mold and mildew, and microorganisms for chemical contamination with pollutants. environmental potential and is in place IIt is imperative that an adequate pest control food management program processing and handling facilities. And proper records and documentation of a pest control program is important to the success of an overall sanitation program. Focus area’s being location of plant, site condition, preparation & maintenance, exterior lighting, driveways & receiving areas. for e.g., from located away chemical plant, 1.Location: Ideally, the food processing facility sources of should be contamination sewage treatment facility, salvage yard, livestock housing, cow pasture, or body of water). In case source of contamination are found to be located near the plant, special precaution should be taken to avoid odors & contaminants from entering the yard or the facility. should be toxic materials and graded 2. Site condition, preparation & maintenance: When preparing a new site for construction the cleaned of any site thoroughly potentially for appropriate drainage and prevention of standing or pooled water. Storm sewers should be designed and located to allow for adequate runoff and paving should be used to minimize dust. Prompt and accurate documentation of work provides official information or serves as a record helping in compliance and traceability. In case of error, these records can serve as the basis of investigation. E.g. Equipment user manual, GMP Manual READ MORE.... PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue03.January 2023 importance for preventing 3. Exterior Lighting: Exterior lighting attracts insects and hence location of these fixtures is of insects from critical entering the facility. The location of fixtures, especially when positioned over doorways, needs special attention. Lighting should be mounted on least 30 feet from poles or standards, be at buildings, and the light directed towards doorways and entrances. Lighting fixtures should be shielded with a non-breakable, transparent material. are last areas designed line of defense 4. Driveways and receiving areas: Receiving area is the in protecting the building, care should be taken to make sure that such to minimize contamination and intrusion from pests. Asphalt driveways should be avoided, as this material may leading to receiving attract rodents. Driveways areas and should be constructed for adequate drainage. Drains should be designed with catch baskets for debris, and hose stations should be provided to facilitate cleaning and maintenance. appropriately paved B. Exterior Building Building materials used for exterior walls vary in their need for preventative maintenance with regard to re-caulking of joints. For example, a poured concrete wall, needs less maintenance than other materials because it does not have seams. Low-density concrete block (e.g., cinder block), commonly used in domestic building, should be avoided unless an adequate sealer is used to avoid moisture intrusion and penetration of mold and mildew. Concrete block walls should be sealed at the base and capped at the top. Corrugated metal siding least desirable material for wall construction in a food handling facility. If used, it is imperative that it be adequately caulked along the base and at the seams. is the Loading Docks, Platforms, and Receiving Rooms: Receiving areas and rooms should be enclosed as much as is practicable as an improperly designed and constructed receiving room will provide an attractive harborage rodents, and insects. Loading docks should be at least 3 feet above ground with the underside lined with a smooth, galvanized metal or similar material with a 12-inch over-hang from climbing into the building to prevent for birds, rodents Exterior Walls: Building materials used for exterior walls vary in their need for preventative maintenance with regard to re-caulking of joints. For example, a poured concrete wall, needs less maintenance than other materials because it does not have seams. Low-density concrete block (e.g., cinder block), commonly used in domestic building, should be avoided unless an adequate sealer is used to avoid moisture intrusion and penetration of mold and mildew Plant design specifies the equipment to be used, performance requirements for the equipment, interconnections and raw material flows in terms of flow charts and plant layouts, the placement of equipment, storage spaces, shop facilities, office spaces, delivery and shipping facilities, access ways, site plans and elevation drawings, required instrumentation and process monitoring and control interconnections, utility and waste treatment requirements, connections and facilities, the rationale for site selection, the basis for selecting and sizing critical pieces of equipment, ways the design was in which optimized and the engineering basis for such optimization. controls, and PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter FOOD INDUSTRY INDUSTRY BUZZ The FSSAI publishes detailed regulatory guidelines for basmati rice Radico Khaitan plans to introduce four "luxury" brands in Assam. For the first time, the Food Safety and Guidelines Authority of India, or FSSAI, has announced extensive regulatory standards for basmati rice. These requirements will be followed starting on August 1st of this year. According to these specifications, basmati rice must not contain any chemical colouring, polishing agents, or scents and must have the typical natural aroma of basmati rice. As well as defining several identification and quality criteria for basmati rice, these guidelines also set maximum moisture, uric acid, and damaged grain restrictions. Two-thirds of the world's supply of basmati rice, a popular kind of rice both locally and internationally, comes from India. Radico Khaitan, one of the biggest IMFL companies in India, has announced the launch of four of its premium brands in Assam. Radico Khaitan will introduce these premium brands in Assam on January 11, 2023, following a resounding reception to its four premium brands—Royal Ranthambore Heritage Collection Whisky, Jaisalmer Indian Craft Gin, Morpheus XO Brandy, and Magic Moments Dazzle Vodka— from all over the nation and abroad. It will establish a larger position in the Northeastern market with this introduction by introducing customers to the "premium" taste. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION India will stop importing duty-free soy oil on April 1 Pepsi improves Recipe for Pepsi Zero Sugar India, the world's largest importer of vegetable oils, will stop duty-free imports of crude soyoil beginning on April 1, the government announced on Wednesday. This move is part of an effort to promote regional oilseed producers. In May 2022, New Delhi approved the duty-free import of 2 million tonnes of soy oil for the years 2022–2023; an additional 2 million tonnes were initially anticipated for the years 2023–2024. According to the ministry, 2 million tonnes of crude sunflower oil would continue to be imported duty- free by the government in the current and following fiscal years until March 2024. 2022 REVENUE GROWTH FOR CARGILL OF 23% TO $165 BILLION AA new and better Pepsi Zero Sugar has been introduced by PepsiCo, a company in Purchase, New York. Additionally, the business is allowing customers to redeem up to 10 million free Pepsi Zero Sugar drinks starting during the NFL Playoffs and continuing until the Super Bowl. located According to the company, the new Pepsi Zero Sugar recipe employs a new sweetener technology to deliver a more energizing and robust flavour profile than the original Pepsi Zero Sugar variety. The plant-based market in India is expected to be valued Rs 81,000 crore Plant-based products including plant-based meat, plant-based dairy, and plant- based nutraceuticals are in high demand in India right now. Items made from ingredients originating from plants, such as fruits, vegetables, whole grains, nuts, seeds, and legumes, are known as plant-based food products. In order to live better and healthier lifestyles, a rising segment of the population is choosing plant-based food products, particularly plant-based "meat." A 2020 study found that while 48.7% of Indians would still opt to eat meat from conventional sources, 62.8% of Indians are very inclined to purchase plant-based products. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Packaging accessibility: Coca-Cola includes on-pack help for visually impaired customers Vegetable oil imports increased by 28% to 15.66 lakh tonnes in December as exports of palm oil increase For the first time, the cardboard casing of Coca- Cola Europacific Partners (CCEP) GB's Christmas can multipacks will use NaviLens codes, allowing consumers who are partially sighted and have trouble using conventional signage to find their desired products. Shoppers who are partially sighted may now scan barcodes with their smartphone's camera, and the NaviLens software contextualises the information once it has been scanned. They don't need to be aware of the exact location of the codes because they can be seen from a wide angle, up to four metres away, and when not concentrated. Vegetable oil imports into India, which include both edible and non-edible oils, increased by 28% to 15.66 lakh tonnes in December due to increased shipments of both refined palmolein and crude palm oil. According to a statement from the Solvent Extractors' Association of India (SEA), there were 15,66,129 tonnes of vegetable oils imported in December 2022 as opposed to 12,26,686 tonnes the previous year. According to the data, shipments of non-edible oils jumped to 10,349 tonnes from 9,832 tonnes, while imports of edible or cooking oils increased to 15,55,780 tonnes from 12,16,863 tonnes. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION WEEKS HIGHLIGHT 15-18 JANUARY PONGAL Pongal is a four-day-long festival celebrated in Tamil Nadu when the crops like rice, sugarcane are harvested. As celebrations begin, the festival is celebrated with a lot of enthusiasm and there are traditional dishes that are prepared on this occasion. N O N - T E C H N I C A L C O N T E N T 15 JANUARY WIKIPEDIA DAY Wikipedia Day on January 15 is an occasion that celebrates the birth and formation of the site. Almost every single person in the world knows what Wikipedia is. When we search for something, a Wikipedia link is the first thing that pops up on our search engines. It is also a popular site since it provides presents everything in a user-friendly way. So without further ado, let’s dedicate this day to the information provider that has been feeding us with knowledge since day one. information in-depth and DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Y R A U N A J PMG DID YOU KNOW? T E C H N I C A L C O N T E N T Y R A U N A J PMG Fact 1 Alcohol enters the bloodstream via the stomach lining. It then spreads throughout the body's tissues. Alcohol enters the brain in five minutes and begins to affect the brain in ten minutes. DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter T E C H N I C A L C O N T E N T 1/3 2/3 Fact 3 A 750 mL bottle of wine typically contains 600-800 individual grapes, or 10 wine grape clusters. This figure, however, can change depending on the: Grape varieties used to make the wine. 3/3 Y R A U N A J PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter T E C H N I C A L C O N T E N T 1/51/5 2/5 4/5 Fact 4 Serotonin has been linked to certain foods, and its role in human physiology is a prevalent topic of scientific research for improving mental health and happiness. Serotonin is a mood-enhancing chemical found in the brain that influences mood, feelings of well-being, and appetite regulation. 3/5 5/5 DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter Y R A U N A J PMG T E C H N I C A L C O N T E N T 2/3 Fact 5 Institute. This information most likely came from a 2013 programme run by the National Human Genome Research genome, approximately 60% of our genes have a recognisable counterpart. "When compared, the amino acid sequence of the human protein to its equivalent in the banana, the proteins encoded by them are roughly 40% identical. the banana In 1/3 3/3 Y R A U N A J PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter Vol .02-Issue .03-January 2022 PMG ENGINEERING About PMG About PMG Delivering End-to-End Engineering Design & Construction Management in Food & Beverage Industry MAKING CUSTOMERS THE INDUSTRY LEADERS ENGINEERING MUST CREATE BUSINESS VALUE MEET THE EXPECTATIONS OF ALL STAKEHOLDERS OPTIMAL ENGINEERING Website Link Click Here Follow Us on