Handbook of Food Factory Design PDF
Preview Handbook of Food Factory Design
Christopher G.J. Baker Editor Handbook of Food Factory Design Handbook of Food Factory Design Christopher G.J. Baker Editor Handbook of Food Factory Design Editor ChristopherG.J.Baker ChemicalEngineeringDepartment CollegeofEngineeringandPetroleum KuwaitUniversity Kuwait ISBN978-1-4614-7449-4 ISBN978-1-4614-7450-0(eBook) DOI10.1007/978-1-4614-7450-0 SpringerNewYorkHeidelbergDordrechtLondon LibraryofCongressControlNumber:2013944214 ©SpringerScience+BusinessMediaNewYork2013 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned,specificallytherightsoftranslation,reprinting,reuseofillustrations,recitation,broadcasting,reproductionon microfilmsorinanyotherphysicalway,andtransmissionorinformationstorageandretrieval,electronicadaptation,computer software,orbysimilarordissimilarmethodologynowknownorhereafterdeveloped.Exemptedfromthislegalreservationare briefexcerpts in connection withreviews orscholarlyanalysisor materialsuppliedspecifically for the purposeofbeing enteredandexecutedonacomputersystem,forexclusiveusebythepurchaserofthework.Duplicationofthispublicationor partsthereofispermittedonlyundertheprovisionsoftheCopyrightLawofthePublisher’slocation,initscurrentversion,and permissionforusemustalwaysbeobtainedfromSpringer.PermissionsforusemaybeobtainedthroughRightsLinkatthe CopyrightClearanceCenter.ViolationsareliabletoprosecutionundertherespectiveCopyrightLaw. Theuseofgeneraldescriptivenames,registerednames,trademarks,servicemarks,etc.inthispublicationdoesnotimply, evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfromtherelevantprotectivelawsandregulationsand thereforefreeforgeneraluse. Whiletheadviceandinformationinthisbookarebelievedtobetrueandaccurateatthedateofpublication,neithertheauthors nor the editors nor the publisher can accept any legal responsibility for any errors or omissions that may be made. The publishermakesnowarranty,expressorimplied,withrespecttothematerialcontainedherein. Printedonacid-freepaper SpringerispartofSpringerScience+BusinessMedia(www.springer.com) Preface Food manufacturing has evolved over the centuries from a kitchen industry to a modern and sophisticated operation involving a wide range of different disciplines. Thus, the design of food factories requires a holistic approach based on a knowledge of the natural and biological sciences, most engineering disciplines, relevant legislation, operations management, and economic evalua- tion.Atypicalfactoryincludesthefood-processingandpackaginglines,thebuildingsandexterior landscaping,andtheutility-supplyandwastetreatmentfacilities.Designoftheproductionline,the heart of the factory, is in itself interdisciplinary in nature and can involve food scientists; microbiologists; and chemical, mechanical, and control engineers as well as other specialists. The specification and design of the buildings is naturally a civil engineering responsibility but inputs fromothermembersofthedesignteamareessential.Finally,provisionoftheutilities(e.g.,water, steam,electricity,HVAC,andcompressedair)andwastetreatmentfacilitiesrequiresotherspecialist engineeringinput.Theprojectmanagerhasavitalroletoplayincoordinatingallrequiredactivities both in the design and construction phases. It is his responsibility to ensure that all tasks are completedontimeandwithinbudget. This Handbook attempts to compress comprehensive, up-to-date coverage of the areas listed aboveintoasinglevolume.Naturally,compromiseshavetobemade,particularlywhenattempting tobalancebreadthversusdepth.Thus,manyofthetopicscoveredasachapterhereincouldand,in somecaseshave,beenthesubjectofcompletebooks.Referencestothesemorecomprehensivetexts are given in the chapters concerned. Another difficulty is that every country has its own body of legislationcoveringallaspectsoffoodmanufacture.Inthiswork,referencehas beenmadealmost exclusively to US, EU, and UK legislation. Information pertaining to other countries is widely availableontheInternet,whichalsoenablesthereadertokeepupwithlegislativechanges.Useof theInternet,however,shouldnotbeusedasasubstituteforsoundprofessionaladviceinthisarea. ItishopedthattheHandbookofFoodFactoryDesignwillprovetobeofvalueacrossthefood- manufacturingcommunity.Itwillundoubtedlybeofinteresttoprofessionalsinvolvedinconstruc- tion projects. The multidisciplinary nature of the subject matter should facilitate more informed communicationbetweenindividualspecialistsontheteam.Itshouldalsoprovideusefulbackground informationonfoodfactorydesignforawiderrangeofprofessionalswithamoreperipheralinterest in the subject: for example, process plant suppliers, contractors, HSE specialists, retailers, consultants, and financial institutions. Finally, it is hoped that it will also prove to be a valuable reference for students and instructors in the areas of food technology, chemical engineering, and mechanicalengineering,inparticular. v vi Preface Iwouldliketoexpressmygratitudetoeachoftheauthorswhohasprovidedchaptersforthisbook. Their knowledge, patience, and professionalism cannot be acknowledged too highly. Special thanks arealsoduetoCampdenBRI,LeatherheadFoodResearch,andtheUKHealthandSafetyExecutive whograntedpermissionfortheirworktobefreelyquotedandadaptedforuseinthisHandbook. Al-Khaldiya,Kuwait ChristopherG.J.Baker Contents 1 Introduction................................................................ 1 C.G.J.Baker PartI ProcessConsiderations 2 ProcessSpecification........................................................ 13 D.L.Pyle 3 Food-ProcessingEquipment................................................. 51 C.Skjo¨ldebrand 4 HygienicDesignofFood-ProcessingEquipment............................... 79 C.G.J.Baker 5 MovementofMaterials...................................................... 119 R.C.Kill 6 ProductivityIssues:IndustrialEngineeringandOperationsManagement...... 147 A.A.AlyandC.G.J.Baker 7 SafetyandHealth........................................................... 171 C.G.J.Baker 8 ProtectingtheEnvironment.................................................. 199 C.G.J.BakerandH.M.S.Lababidi 9 ControlandMonitoringofFood-ManufacturingProcesses.................... 229 I.McFarlane 10 UseofComputersintheDesignofFood-ManufacturingFacilities.............. 257 D.Hartono,G.Joglekar,andM.Okos PartII FactoryInfrastructure 11 SiteConsiderations.......................................................... 283 K.P.Sutton 12 DesignPrinciples............................................................ 297 P.J.Wallin vii viii Contents 13 Construction:TechniquesandFinishes....................................... 325 K.P.Sutton PartIII UtilitiesandServices 14 SteamSystems.............................................................. 357 N.Riches 15 RefrigerationSystems....................................................... 385 S.J.James 16 Heating,Ventilation,andAirConditioning................................... 403 G.L.Quarini 17 UtilitiesandTheirConservation............................................. 427 A.A.AlyandC.G.J.Baker 18 EffluentTreatment.......................................................... 443 W.E.Whitman PartIV ProjectEngineeringandManagement 19 RoleoftheProjectEngineerintheDesignStage.............................. 465 G.M.Kirt 20 RoleoftheProjectEngineerintheConstructionStage........................ 477 G.M.Kirt Index........................................................................... 487 Chapter 1 Introduction C.G.J.Baker 1.1 Introduction Food and drink are essential to human life. Although basic foodstuffs have remained largely unchanged over the centuries, the availability and choice of different products have increased enormously. This can be attributed largely to the introduction of industrial production techniques. This is clearly illustrated in Lynn Olver’s Web site http://www.foodtimeline.org in which she compiledawell-researchedanddocumentedhistoryoffoodfrombefore10,000BCtothepresent. In many cases, today’s commonly enjoyed mass-produced foods have evolved from the kitchen to thefactory. It is not absolutely certain which product holds the distinction of being the first to be manufacturedina“modern”foodfactory.Whatiscertainisthatthefacilitywouldhavebeenvery different from those inoperationtoday. One of the earliest examples listed by Olver indicatesthat chocolate“bricks”weremanufacturedonanindustrialscaleasearlyas1764byaJamesBakeranda JohnHannoninDorchester, MA.However,incommonwithmanyotherindustrysectors,automa- tion and growth of the food industry did not start to take off until the middle of the nineteenth century.Thereafter,thenumberofexampleshascontinuedtomushroomuntilthepresentday. The present handbook focuses on the design of food factories. This is a multifaceted exercise, whichinvolvesanumberofdisciplinesandtechno-economicareasasdiscussedbelow.Itdoesnot describespecificfood-manufacturingprocessesindetailasthesehavebeendiscussedelsewhere.For example, the 24th edition of Food Industries Manual (Ranken et al. 1997) devotes individual chapterstothefollowingsectorsofthefoodindustry:meatandmeatproducts,fishandfishproducts, dairyproducts,fruitandvegetableproducts,cerealsandcerealproducts,fruitjuicesandsoftdrinks, alcoholic beverages, fats and fatty foods, salt, acid and sugar preserves, hot beverages, sugar and chocolateconfectionery,snackfoodsandbreakfastcereals,and,finally,compositefoodsandready meals.Eachofthesechaptersislogicallystructuredsoastogivethereaderanin-depthoverviewof therawingredients,processingsteps,finishedproducts,andqualityissues.FoodIndustriesManual alsoincludesadditionalchapterscoveringavarietyoftopicsofgeneralinteresttothefoodindustry. Bartholmai(1987)containsaseriesofchaptersthatdescribeinsomedetail41processdesignsspread acrossmanysubsectorsofthefoodindustry.Theseincludeequipmentlists.Theprincipalresultsare summarizedintheAppendixtothischapter.Althoughthecostsaredated,theinformationpresented C.G.J.Baker(*) ChemicalEngineeringDepartment,CollegeofEngineeringandPetroleum, KuwaitUniversity,P.O.Box5969Safat,13060Kuwait e-mail:[email protected] C.G.J.Baker(ed.),HandbookofFoodFactoryDesign,DOI10.1007/978-1-4614-7450-0_1, 1 #SpringerScience+BusinessMediaNewYork2013
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