Smart Design for Food Manufacturing: Aligning Plant Construction with Process Needs

www.pmg.engineering Vol .02-Issue .04-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 .04-January 2023 CONTENTS YOUR PARAGRAPH TEXT 1. WHITE PAPER A. Plant Designing: Internal Building B. Equipment 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 9-10 4. DID YOU KNOW? Fascinating Food Facts To Expand Knowledge 11-14 PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .04-January 2023 PLANT DESIGNING: INTERNAL BUILDING Introduction Outdated and classic ways is still used by many food manufacturers safety, to however, the it is well known that hygienic design of food process, equipment and factories can contribute significantly to enhance food safety. control food of The sanitary objectives for interior building design to minimize potential and construction are harborages and microorganisms, pests maximize cleanability and maximize the protection of the food products from contamination. Ideally, a facility should be designed to provide a flow pattern for food products (as well as personnel and equipment) to prevent potential contact of the finished product with raw materials. Flow should be in one direction and follow a logical sequence from raw material handling to finished product storage. Junctures between walls and ceilings, and between walls and floors should be rounded (or coved) with a radius of one inch or greater. Coving minimizes a right angle crevice, which is difficult to clean and maintain. Ceilings the potential Improperly installed ceilings, ceilings that promote condensation, or poorly maintained ceilings (e.g., flaking paint) can for increase overhead contamination of food products. The most recommended installation is the concrete slab with exposed double tee beam construction, which avoids I-Beam construction. Concrete ceilings should be ground smooth, appropriately finished, and caulked at the joints. Dropped ceilings are acceptable only if properly installed. False ceilings, which create a crawl space above the ceiling for utilities and services, should be avoided. ledges associated with Interior Walls Floors A cleanable, sanitary wall is one that is hard, flat, and smooth which is free of any type of pits, cracks, checks, and crevices. Walls should be covered with a light colored paint and caulked, joints and sealed or grouted appropriately at junctions. Floors should be smooth, impervious, non- absorbent, corrosion resistant, cleanable and in good repair. READ MORE.... PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .04-January 2023 PLATE HEAT EXCHANGER For safety considerations, floors should not be so smooth that they cause employees to slip and fall. Floor should be installed to provide adequate slope for drainage to prevent pooled water. The most recommended are sealed concrete, epoxy sealed concrete, quarry tile. Unsealed concrete floors should be avoided as they are highly porous and break down with continued exposure to chemicals. tile, and glazed be should constructed, Systems designed, installed, cleaned, and maintained so that they are not a source of contamination. For example, the air supply should be located to not draw air from nearby sources of contamination (e.g., chemicals, bird droppings); adequate filters should be installed and duct work should be located outside of the processing areas. Drains Floor drains should be of adequate number and size with appropriately located in reference to installation should requirement. Designing and focus on cleanability and scheduled maintained should be followed for good repair. Circular, catch basket drains are most often recommended provided that they are appropriately sealed and grouted to the floor, and are maintained in good repair. A trench drain should be constructed and installed to provide adequate slope or grade ensuring there is no standing water in the trench. Interior Lighting Light fixtures should be of the type approved for food facilities, and should be equipped with break lenses or shatterproof shielding. The resistant fixtures should be designed to be moisture resistant and cleanable. Electrical boxes and related equipment should be water proof and of acceptable sanitary design HVAC Systems Heating, ventilation, and air conditioning (HVAC) systems function to maintain the temperature and humidity of a facility. Employee Facilities& Restrooms Employee facilities should not open directly into processing or other critical areas. Most food regulations require a two-door separation between locker rooms or restrooms and food processing areas or food handling areas. Lockers should be sealed to the wall and should have sloped, rather than flat, tops to prevent accumulation of dust and debris. Physical Separation As much as is practicable, there should be a physical separation between raw and finished products and minimal entry into critical areas. Such physical separation should be accomplished by installation of walls and doorways with anti- features, and by adjusting air back handling systems to provide positive pressure in finished product rooms. tracking As the best physical separation can be undermined by human error or improper personnel flow, there should be an operational and philosophic separation between raw and finished product. This can be accomplished by barring employees working with raw materials from entering finished includes maintenance and product rooms, this janitorial staff. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue 04.January 2023 EQUIPMENT DESIGN Introduction For sanitary construction and design of food equipment, it is important to know the general aspects. Designing of processing equipment is not to just focus on the containment of the material, the strength of the components, the efficiency of the operation, and the transfer of energy. It should also comply with strict standards and regulations, which are necessary for securing the quality and safety of the food products then it can be of importance. The surfaces of food equipment are subdivided into two categories i.e., food product contact surfaces, where direct contact of food residue or chances that it can drip, drain, diffuse or be drawn. And non-product contact surfaces are those part of equipment that do not come in direct contact with food like legs, supports etc Food Product Contact Surfaces In terms of sanitary design, all food contact surfaces should be smooth, impervious, free of cracks and crevices, nonporous, nonabsorbent, corrosion non-contaminating, resistant, durable and maintenance free. If any modification or process is used in fabrication (e.g., welded, bonded, or soldered) it should be done using appropriate materials and in a manner that ensures the final surface meets the sanitary design criteria. nonreactive, 1. Materials: A variety of materials are used in the construction different applications in food equipment. These materials vary in their properties with regard to workability, compatibility, and sanitary design features. fabrication and for Metals: Stainless steel is the preferred metal for food contact surfaces because of its corrosion resistance and durability in most food applications. Titanium has excellent durability and corrosion resistance (especially in an acidic environment), however, its use is limited by high cost. Titanium is used in stainless steel alloys for food equipment used in the processing of food products with high acid and/or salt content (e.g., citrus juice, tomato products). Copper is primarily used for equipment used in the brewing industry, with some use for cheese vats in Swiss cheese manufacture, due to tradition but should be avoided from acid processing as chances of copper leaching into product is there. Aluminum is used in certain parts and components where lighter weight is desired. However, aluminum has poor corrosion resistance and can become pitted and cracked with continued use. Carbonized metal and cast iron are only used for frying and cooking surfaces, and similar applications in food service. Galvanized iron should be avoided as a food contact surface because it is highly reactive with acids. READ MORE.... PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue04.January 2023 Non-Metals: Plastics, rubber, and rubber-like materials that should be food grade if they are in contact of food. Ceramics are used coming primarily in membrane filtration systems. Glass may be used as a food contact surface but it needs to be assured that it is durable, break resistant or heat resistant glass. 2. Surface Texture and/or Finish: If any surface is grinded, polished, or textured in any way, it must be checked for final surface to be smooth, durable, free of cracks and crevices. The surface texture or finish of a material is decided by Ra Value (Roughness Value) which is determined using a sensitive instrument (termed a profilometer) which employs a diamond tipped stylus to measure peaks and valleys in a relatively smooth surface. Shafts, bearings, agitators, and other attachments or ancillary components should be attached to in such a way that the food food equipment contact zone is sealed from contamination caused by leakage of lubricants or other contaminants into the product zone. Such components should be for cleaning. Any accessible and opening or cover should be designed, and constructed in such a manner as to adequately protect food products from contamination and to divert potential contamination away from the food product zone. removable Non-food contact surfaces (e.g., continuous substantially 3. Construction and Fabrication: Food equipment should be designed and fabricated in such a way that all food contact surfaces are free of sharp corners and crevices. All mating surfaces must also be flush). Construction of all food handling or processing equipment should allow for easy disassembly for cleaning and inspection. Where appropriate (e.g., vessels, chambers, tanks), equipment should be self-draining and pitched to a drainable port with no potential hold up of food materials or solutions. Piping routine disassembly must be sloped to drain. designed systems not for Internal angles should be coved or rounded with radii. Equipment standards generally defined joints on stainless steel require that welded joints and surfaces be continuous, butt-type ground smooth. Care should be taken when connecting pipes, gauges, thermometers, probes, or other equipment to food contact surfaces. It is necessary to ensure the connection does not create a dead end or an area where food product can accumulate and is not accessible to cleaning solutions. Non-product contact surfaces of food equipment are a source for environmental contamination of a food facility with pathogens. These areas can also be harborage areas insects and rodents. for Therefore, care should be used in evaluating these surfaces of equipment with regard to sanitary construction and design. Non-product surfaces of equipment should be constructed with appropriate materials and fabricated in such a manner as to be reasonably cleanable, corrosion-resistant, and maintenance equipment framework should be entirely sealed and not penetrated (e.g., bolts, studs), to avoid creating niches for microorganisms. Whenever practicable, attachments should be welded to the surface of the tubing and not attached via drilled and tapped holes. free.Tubular steel improvement With Continuous in equipment design, there is evident improvement with the sanitation, cleaning and food safety programs. Equipment designing should always incorporate the inputs and should consider the requirement of processor for coming up with design that can provide required output. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter FOOD INDUSTRY INDUSTRY BUZZ Reducing Carbon emission in Agri,Dairy could save USD1.7 trillion by 2070 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. NIC Ice Cream introduces Waffle Cones The fastest-growing ice cream brand in India, NIC Honestly Crafted Ice Creams, has released its newest product, NIC Waffle Cones. These crispy, crunchy cones go perfectly with NIC's wonderful ice cream. cones are vacuum-packed to The waffle guarantee they arrive in great shape at the consumer's home. The vacuum packing also keeps the cones crisp and crunchy for the ideal ice cream experience in the comfort of your own home. This packing approach is not only hygienic, but it also helps to reduce damage during handling and shipping, ensuring that the product reaches the end customer in the best possible shape. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Arkeon, a pioneer in sustainable protein components, has received an investment from ICL Nestlé invests $43 million in the development of its Wisconsin facility. ICL, a leading worldwide speciality minerals firm, has announced an investment of €2.75 million in Arkeon, GmbH through its agrifood innovation and investment platform, ICL Planet Startup Hub. gas innovative and sustainable one-step Arkeon's fermentation bioprocess, which creates completely customisable protein ingredients by capturing the greenhouse and converting it into the 20 proteinogenic amino acids required for human nutrition, will be supported by the investment. The resulting carbon negative and clean-label functional compounds are alternative proteins. carbon dioxide (CO2) 2022 REVENUE GROWTH FOR CARGILL OF 23% TO $165 BILLION Nestlé Health Science will invest $43 million in a manufacturing expansion in Eau Claire, Wisconsin. The company stated that it will add two production lines to accommodate increased demand for its Boost and Carnation Breakfast Essentials ready-to- drink products. The investment will result in the creation of 60 new positions at the plant. The CPG behemoth stressed that sustainability is a crucial component of the new plant. In addition to achieving 0% waste-to- landfill, the plant will produce its beverages in recyclable TetraPak cartons. Cheddar cheese: a value-added dairy product ingredient earns market worth Milk and milk products provide a valuable niche for value addition, particularly cheese, which has huge market potential. The Indian cheese market will reach $135.4 billion by 2024, increasing at a CAGR of roughly 26% between 2019 and 2024. Cheddar cheese, which originated in the English village of Cheddar in Somerset, is a moderately hard, off-white cheese that is popular due to its strong flavor and use as a component in a variety of culinary preparations. Cheddar cheese has a high protein content, notably casein, which comprises varied amounts of all necessary amino acids, fat, trace amounts of vitamins A, B2, B6, B12, and calcium, all of which play a significant role in providing a balanced diet. Cheddar cheese, which is one of the varieties produced on a commercial scale in India, requires a lengthy ripening period of 4-12 months for flavour development, which increases the cost of the cheddar cheese. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Monster increases sales via a price increase and relies on innovation to regain units in 2023 Sunflower oil imports hit a new high as Russia and Ukraine compete for market dominance Following a long-delayed and category-leading price rise that went into effect this fall, Monster Beverage Corporation officials believe that sales growth across its energy drink portfolio will pick up and continue to surpass overall category growth in the coming months. The company maintained 36.4% of the total energy drink market dollar share in the last 13 weeks of 2022 across all measured channels barely edging out its largest competitor red bull, which saw its dollar share dip 0.8% to 35.1% in the period, according to Nielsen data. It also saw dollar sales climb 11 % to $1,73 bn in their period. industry officials, India's January According to sunflower oil imports are expected to reach a record 473,000 tonnes, virtually tripling the typical monthly imports, as leading producers Russia and Ukraine strive to reduce stocks.Record purchases by India, the world's largest vegetable oil importer, come as the price differential between sunoil and rival soyoil increased to the widest in nine months. The increase in imports will assist key Black Sea producing countries reduce their stocks, but it may depress India's palm oil imports and weigh on Malaysian palm oil prices. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION N O N - T E C H N I C A L C O N T E N T WEEKS HIGHLIGHT 23 JANUARY PARAKRAM DIWAS Freedom is not given, it is taken"Famous saying of Netaji Subhas Chandra bose " Tum mujhe khoon do, mai tumhe azaadi dunga"Bose, fondly remembered as ‘Netaji’, was an Indian freedom fighter. India will always remain grateful to Netaji Subhas Chandra Bose for his bravery and indelible contribution to resisting colonialism. 24 JANUARY NATIONAL GIRL CHILD DAY National Girl Child Day is celebrated every year in India on 24 January. The day is celebrated to raise awareness about the rights of a girl child and to promote the importance of their education, health, and nutrition. 24 JANUARY INTERNATIONAL DAY OF EDUCATION The International Day of Education is annually celebrated on January 24. This year marks the fourth year of celebration, with the theme 'Changing Course, Transforming Education'. 25 JANUARY NATIONAL TOURISM DAY Traveling makes the relations better; this world tourism day take your loved ones outside and explore the beauty of our country! Traveling gives you a lifetime experience which leaves you amazed and gets your minds open with getting so much of knowledge. DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Y R A U N A J PMG N O N - T E C H N I C A L C O N T E N T 25 JANUARY NATIONAL VOTERS DAY National Voters Day is celebrated to aware people of their voting rights and make more people contribute to the electoral political process in the country, mostly the newly eligible generation. However, the main objective of the day is to educate and encourage young voters to vote during elections. 26 JANUARY REPUBLIC DAY Be proud to be an Indian. Have a great Republic Day! We salute our India on Republic Day with freedom in the mind, strength in the words, purity in the blood, pride in our souls, and zeal in our hearts. 26 JANUARY VASANT PANCHAMI Vasant Panchami is a Hindu festival that celebrates the arrival of spring. Sarasvati is the Vasant Panchami festival's Hindu goddess. The colour yellow has special significance for this celebration because it represents the brilliance of nature and the vibrancy of life. During the festival, the entire area is covered in yellow. 27 JANUARY INTERNATIONAL HOLOCAUST REMEMBERANCE DAY The International Day in memory of the victims of the Holocaust is thus a day on which we must reassert our commitment to human rights.We must also go beyond remembrance, and make sure that new generations know this history. We must apply the lessons of the Holocaust to today's world DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Y R A U N A J PMG DID YOU KNOW? Fact 1 The more than 7,000 apple cultivars known today are the result of a long and complex history wherein multiple wild species were crossed into fruit's lineage as it travelled all along Silk Road from China to Europe. And approximately 20 of them are grown in India. T E C H N I C A L C O N T E N T Y R A U N A J PMG 1/6 2/6 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 3/6 4/6 5/6 6/6 Fact 2 Heat transfer is defined as "the movement of heat across the system's border due to a temperature difference between the system and its surroundings." In the food industry, this is a common occurrence. There are three types of heat transfer in food: conduction, convection, and radiation. 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 1/3 2/3 Fact 3 Enzymes produced and secreted by the pancreas which aid in the proteolysis of proteins in the digestive tract 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 1/4 2/4 3/4 4/4 Fact 4 Trace amounts of naturally occurring radionuclides can be found in some foods. The most well-known foods containing radioactivity are bananas and Brazil nuts. These foods do not pose a radiation risk because the amount of radiation is so small. DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter Y R A U N A J PMG Vol .02-Issue .04-January 2023 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