Food plant design

Contents Chapter 1 Economic and Technical Context of Food Plant Design.................................................. 1 1.1 Food Science, Technology, and Engineering............................. 1 1.1.1 Historical Evolution ..................................................... 1 1.1.2 The Design Engineer in Food Engineering ................ 9 1.2 Socioeconomic and Technical Context.................................... 10 1.2.1 Agro-Industrial System and the Food Chain ........... 10 1.2.2 Food Processing Systems, Auxiliary Systems, and Food Plants.......................................................... 14 References......................................................................................... 28 Chapter 2 Mathematical Modeling of Food Processing Systems and Food Plant Simulation ...................... 31 2.1 Transfer Phenomena and Property Balance ......................... 31 2.1.1 Transfer Phenomena .................................................. 31 2.1.2 Macroscopic Balances and Physical Properties ....... 36 2.1.2.1 Mass Balance................................................ 36 2.1.2.2 Energy Balance............................................. 37 2.1.2.3 Momentum Balance ..................................... 42 2.1.2.4 Physical Properties....................................... 47 2.1.3 Microscopic Balances and Transfer Phenomena...... 48 2.1.3.1 Microscopic Mass Balance: Fick’s Laws...... 49 2.1.3.2 Momentum Balance: Newton’s Law............ 53 2.1.3.3 Energy Balance: Fourier’s Law ................... 59 2.2 Transfer Properties: Viscosity, Conductivity, and Diffusivity................................................................................. 65 2.2.1 Viscosity ...................................................................... 65 2.2.2 Thermal Conductivity ................................................ 68 2.2.3 Diffusivity.................................................................... 69 © 2005 by Taylor & Francis Group, LLC xviii Contents 2.3 Heat Transfer in Fluids .......................................................... 71 2.3.1 Individual Coefficients of Heat Transfer by Convection................................................................... 71 2.3.2 Heat Transfer Coefficients in Newtonian Fluids ..... 72 2.3.3 Heat Transfer Coefficients in Non-Newtonian Fluids........................................................................... 75 2.4 Mathematical Model of a Unit Operation: Hot Air Drying......................................................................... 77 2.4.1 Equations for General Model .................................... 84 2.4.2 Equations from This Model ....................................... 85 2.4.3 Results of Experiment................................................ 89 2.4.4 Nomenclature.............................................................. 92 2.5 Mathematical Modeling of Refrigeration and Thermal Storage Systems ...................................................................... 93 2.5.1 Modeling the Components of a Refrigeration System ......................................................................... 95 2.5.1.1 Compressor ................................................... 97 2.5.1.2 Condenser.................................................... 103 2.5.1.3 Evaporator .................................................. 106 2.5.1.4 Expansion Valve ......................................... 112 2.5.2 Trends in Refrigeration Systems Modeling............ 116 2.5.3 A Case Study ............................................................ 117 2.5.3.1 Model Formulation ..................................... 117 2.5.3.2 Heat Transfer Coefficients Analysis ......... 120 2.5.3.3 Experiment Validation ............................... 121 2.6 Food Plant Simulation .......................................................... 127 2.6.1 Malting Plant............................................................ 127 2.6.1.1 Knowledge-Based System Development ............................................... 128 2.6.1.2 Simulation Results ..................................... 131 2.6.2 Winery ....................................................................... 131 2.6.2.1 Refrigeration Requirements Profile for Wineries................................................. 133 2.6.2.2 Thermal Behavior of the Fermentation Process......................................................... 134 2.6.2.3 The Use of Thermal Storage Systems ...... 135 2.6.2.4 The Use of Advanced Control Systems in Fermentation.......................................... 136 2.6.3 Frozen Vegetables Plant .......................................... 139 References....................................................................................... 141 © 2005 by Taylor & Francis Group, LLC Contents xix Chapter 3 Documentation of Food Plant Design ................... 153 3.1 Introduction ........................................................................... 153 3.2 Preliminary Studies of Food Products and Raw Materials ................................................................................ 154 3.3 Literature Review and Laboratory Studies on Food Processing Technology and Engineering.............................. 155 3.4 Pilot Plant Studies ................................................................ 156 3.5 Food Processing Systems and Food Plant Preliminary and Final Projects ................................................................. 157 3.5.1 The Food Processing Plant Preliminary Project........................................................................ 157 3.5.2 The Food Processing Plant Final Project ............... 162 3.5.2.1 Food Processing System Final Project...... 163 3.5.2.2 Auxiliary System Final Project ................. 166 3.5.2.3 Buildings and Services Final Project........ 168 3.6 Information Handling in Flowchart Form........................... 171 3.6.1 Basic Modules General Flowchart .......................... 171 3.6.2 Flowcharts................................................................. 172 3.6.3 Mass Balance in the Process ................................... 176 3.6.4 Energy Balance in a Food Processing System ....... 187 3.6.4.1 Energy Accounting in Food Processing Plants .......................................................... 187 3.6.4.2 Measuring Energy Flow Rates.................. 189 References....................................................................................... 194 Chapter 4 Processing System Alternatives: Process Synthesis ................................................... 213 4.1 Introduction ........................................................................... 213 4.2 Synthesis Methods ................................................................ 215 4.2.1 Evolutionary Methods .............................................. 215 4.2.1.1 Basic Modules Method ............................... 215 4.2.1.2 Evolutionary Design Method..................... 218 4.2.2 Methods Based on Problem Solving........................ 220 4.2.3 Heuristic Design Methods ....................................... 223 4.2.4 Algorithmic or Mathematical Programming Methods..................................................................... 224 Nomenclature ................................................................................. 227 References....................................................................................... 228 © 2005 by Taylor & Francis Group, LLC xx Contents Chapter 5 Food Processing System Alternatives Analysis.... 231 5.1 Outlining the Problem .......................................................... 231 5.2 Selecting Design Variables ................................................... 232 5.2.1 Process Subsystems.................................................. 233 5.2.1.1 Degrees of Freedom and Information Flow Diagram ............................................. 233 5.2.1.2 Inversion of Information Flow................... 237 5.2.1.3 Algorithms for Selecting Design Variables...................................................... 240 5.2.2 Process Systems........................................................ 243 5.2.2.1 Information Flow through Subsystems .... 243 5.2.2.2 Inversion of Information Flow................... 249 5.2.2.3 Algorithm for Selecting Design Variables...................................................... 251 5.3 Alternative Analysis by Means of Simulation .................... 256 5.4 Design Economic Criteria ..................................................... 257 5.4.1 Static Criteria ........................................................... 257 5.4.2 Dynamic Criteria...................................................... 259 5.4.2.1 Net Present Worth...................................... 260 5.4.2.2 Net Present Worth/Initial Investment Ratio ............................................................ 261 5.4.2.3 Payback Period ........................................... 261 5.4.2.4 Internal Rent Share ................................... 262 5.5 Cost Estimation ..................................................................... 263 5.5.1 Initial or Capital Investment Estimation............... 263 5.5.1.1 Cost Estimation of Food Processing Equipment................................................... 263 5.5.1.2 Auxiliary System Cost Estimation............ 269 5.5.2 Operating Cost Estimation...................................... 269 References....................................................................................... 282 Chapter 6 Experimentation in Pilot Plant............................. 285 6.1 Introduction ........................................................................... 285 6.2 Size and Structure of the Pilot Plant .................................. 286 6.2.1 Basic Principles of Scaling....................................... 286 6.2.2 Minimum and Maximum Size................................. 287 6.3 Types and Applications ......................................................... 288 6.4 Pilot Plant Design ................................................................. 292 6.5 Experimentation Strategies.................................................. 293 6.6 Capital Investment and Operation Cost ............................. 296 References....................................................................................... 297 © 2005 by Taylor & Francis Group, LLC Contents xxi Chapter 7 Materials for Construction of Food Equipment ... 299 7.1 Characteristics of Suitable Construction Material............. 299 7.2 Types of Materials and Applications ................................... 301 7.2.1 Stainless Steel .......................................................... 301 7.2.1.1 Surface Finish............................................. 303 7.2.1.2 Corrosion ..................................................... 309 7.2.2 Aluminum ................................................................. 311 7.2.3 Nickel and Monel...................................................... 311 7.2.4 Plastic Materials....................................................... 312 References....................................................................................... 314 Chapter 8 Hygienic Design of Processing Systems and Auxiliary Systems........................................... 315 8.1 Basic Principles for Hygienic Design of Food Equipment .... 315 8.2 Hygienic Design of Auxiliary Systems in Contact with Foods.............................................................................. 318 8.2.1 Tanks ......................................................................... 318 8.2.2 Pumps........................................................................ 322 8.2.3 Valves ........................................................................ 325 8.2.4 Pipes .......................................................................... 328 8.3 External Design of Processing Equipment and Auxiliary Systems ................................................................. 333 8.4 CIP (Clean-in-Place) System Design ................................... 335 8.4.1 Single-Use or Single-Tank Systems........................ 337 8.4.2 Multiple-Use or Multitank Systems ....................... 340 8.4.3 Compact Systems and Foam-Cleaning Systems .... 341 8.4.4 CIP System Design Details ..................................... 345 8.4.4.1 Spray Distribution Devices........................ 346 8.4.4.2 Pumps, Heat Exchangers, and Valves....... 349 References....................................................................................... 350 Chapter 9 Food Processing Plant Design Considerations..... 351 9.1 Designing the Food Plant ..................................................... 351 9.1.1 Legal Aspects ............................................................ 352 9.1.2 Functional Aspects ................................................... 354 9.1.3 Plant Layout ............................................................. 357 9.2 Selecting Food Plant Site...................................................... 360 9.2.1 Land Conditions and Location ................................ 360 9.2.2 Distribution of Zones at the Site............................. 361 © 2005 by Taylor & Francis Group, LLC xxii Contents 9.3 Hygienic Design of the Food Processing Plant ................... 362 9.3.1 Resistant Structure .................................................. 362 9.3.2 Building Enclosure and Interior Divisions............. 362 9.3.3 Floors......................................................................... 366 References....................................................................................... 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