CHAPTER I

INTRODUCTION

I.General Introductory Statement

A doughnut or donut is a type of fried dough confection or dessert food. The

doughnut is popular in many countries and is prepared in various forms as a

sweet snack that can be homemade or purchased in bakeries, supermarkets, food

stalls, and franchised specialty vendors.

Throughout the years the Doughnut Industry is growing in the Asia especially

in South East Asia. In the Philippines many Donut Franchise are established.

The great profitability of American fast food has already won millions of Filipino

plates. Here in the Philippines particularly, eating food that’s easy to eat and

drink, whether in a rush or not are popular.

Today, Donut industry has been increase and this is because Filipinos is

fond of eating specially sweets like donuts. They are also having this tradition

“pasalubong”. This occurs when a worker or parents bring homecoming treats to

their children after their work. Donuts are always in the trend because they are

flexible in terms of flavors and design. They offered a lot of flavors and can easily

adapt when there an occasions. Everyplace in the country we see different stores

who sell donuts, such as Mister Donut, Dunkin Donut, Krispy Kreme, Country

Style donuts, J.Co etc.

The designers came up to design a doughnut manufacturing plant since

popularity of donuts still increases and thousands of it is being sold at roadside

stalls and school canteens all around the country. It is also baked and sold on

premises at small, privately run bakeries, grocery stores, and in franchise

operations that offer a standard product through the use of a pre-packed mix and

carefully-controlled production. Large commercial bakeries make thousands of

dozens of doughnuts each day, packaging them for distribution across vast

regions.

Following the demand and love of Filipinos in donuts, making a

manufacturing plant which includes different processes which will provide a high

quality product will be checked upon. The design considered some of the

existing industrial plant to give some important information relative to the

proposed project. It will be consists of sequential operations that will established

in the factory where components will be assembled to make a finished article or

where materials are will be put through a refining process to produce an end-

product that is suitable for onward consumption

One of the major topics to be investigated in this field is the processes and

equipment that will be used during the design stage. Having all these

considerations and information that provided, the group decided to choose

prospective location which the resources that will be needed such as raw

materials for the product are available and transportation of the finished product

will be easily accessible to public.

As one of the towns adjacent to the province’s capital, San Pascual,

Batangas is a bustling town full of businesses and establishment. It is a location

conducive to the plant needs especially finding employees for the job. Building

the proposed plant in the said area will meet operational needs not just for now

but also in the future.

II. Subject of the Report

In this proposal, basic ideas of the group will be considered to come up with

the design of the proposed doughnut manufacturing plant and reviewing a brief

history of related existing plant that serves as initial reference in determining

design parameters.
 Furthermore, different design processes and procedures will be followed. It

includes the sequence of plant production process, identification of the

equipment involved, process flow diagram, specification of the equipment, plant

layout and capacity. Proper economic analysis will be considered taking into

account the total plant costing, production cost and payback period.

The proposal will be based on the factors that determine the design of the

proposed industrial plant. It will undergo into engineering approach of solving and

calculations, then the processes involved in the doughnut manufacturing will also

be discussed for the better understanding of the study in order to design the

equipment and facilities necessary for carrying out the process.

The equipment that will be included in the study include doughnut mixing and

forming equipment, filling equipment, finishing equipment, deep frying equipment,

gas and electric, cooling tunnels and spirals, weigh scales, hoppers, forming

equipment, cutters, injectors, provers and enrobers.

This part discusses the series of stages in designing the doughnut

manufacturing plant:

A. Inception Stage

During this stage, basic concepts and knowledge helped the designers come

up with the chosen design of the industrial plant. Review of related literature

discussed the essential and reliable information and background that served as

reference in designing, planning and selecting the location of the industrial plant.

The proponents decided to design a doughnut manufacturing plant based on

their knowledge and expertise. Moreover, several parameters were also

considered 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.

B. Research Stage

In research stage, the group come up first with identifying the general study

area in order to formulate plans and methodology for the design of the proposed

doughnut manufacturing plant. Several articles and study materials were re-

viewed in order to establish facts and reach new conclusions regarding the

doughnut production, the manufacturing processes involved and also the

materials and equipment that will be used in the in the production. However,

collection of data relies not only in the related articles and researches,

interviewing experienced workers or experts in the field helped a lot to have the

knowledge in designing the doughnut manufacturing plant. The collected data will

later be analyzed and interpreted to function as a basis in designing the plant.

C. Design Stage

In this stage, the plans or specification for the construction and

implementation of the design of the proposed doughnut manufacturing plant will

be discussed by sharing ideas within the group in order to connect and improve

ideas that will be used to come up with the optimum design of the proposed

doughnut manufacturing plant. The graphical representation of the complete

process that details the sequencing of processes required to create output will

also be included at this stage. During the equipment selection, the specification

of materials and equipment that will be used in each process will be determined.

D. Economic Analysis Stage

In economic analysis stage, it includes the analysis that aims to determine

how effectively the economy within it is operating and to find out what the

optimum use of resources is. The estimation for the capital cost of the proposed

doughnut manufacturing plant will be made. This includes the expenses incurred

in the purchase of land, building, and also the cost for the equipment and

materials that will be used in the process. Also, this stage involves comparing at
least two alternatives in achieving a certain goal under specific constraints and

assumptions that will also be used for the analysis of the operation and

maintenance cost of the doughnut manufacturing plant.

III.Review of Related Literature

A.History of Doughnuts

The doughnut supposedly came to us from the eighteenth century Dutch of

New Amsterdam and was referred to as olykoeks, meaning oily cakes. In the

nineteenth century, Elizabeth Gregory fried flavored dough with walnuts for her

son Hanson Gregory, hence the name doughnut. By the late nineteenth century,

the doughnut had a hole.

Doughnuts were a great favorite at lumbering camps of the Midwest and

Northwest as they were easy to make and full of calories needed to provide quick

energy for arduous logging jobs. "Doughboys" of World War I ate thousands of

doughnuts served up by the Salvation Army on the French front. Soldiers

reminisced that the doughnut was far more than a hot snack.

Soon after the doughboys returned, dough-nut shops flourished. A

Russian immigrant named Levitt invented a doughnut machine in 1920 that

automatically pushed dough into shaped rings. By 1925, the invention earned

him $25 million a year and it was a fixture in bakeries across the country. The

machine-made doughnut was a hit of the 1934 World's Fair. Other machinery

quickly developed for everything from mixing to frying. Franchises soon followed.

By 1937, Krispy Kreme was founded on a "secret recipe" for yeast-raised

doughnuts and Dunkin' Donuts (currently the franchise that sells the most

doughnuts worldwide) was founded in Massachusetts. Presently, Krispy Kreme

totals 147 stores in 26 states, while Dunkin' Donuts has 5,000 franchises in the

United States and is present in 37 countries.

B.Raw Materials

a.Flour

The main function of flour in baking is to build structure. When the proteins

found in wheat flour are hydrated, they interact with each other forming what is

known as gluten. As dough or batter containing wheat flour is worked, an elastic

network is developed. This gluten network stretches to contain the leavening

gasses in the baked good. Wheat flour and the production of gluten are essential

for the structure of traditional baked goods. 

Figure 1. Pastry Flour

(Source: Cheat Sheet, 2018)

b. Eggs

Whole eggs, as well as egg yolks, are required in most doughnut recipes.

Whole eggs make light, puffy doughnuts, while additional egg yolks contribute

extra richness. Eggs are used as both a dough strengther (the white) and a

tenderizer (the yolk).

Eggs are binders which help hold all the ingredients together. Eggs

contribute liquid to a recipe and thus serve as a toughener, especially the egg

white portion. Egg whites, as mentioned, are often used to produce a light, airy

texture, and yolks contribute to the color, flavor, and texture of baked products.

But, too many egg whites, such as in a reduced-fat cake recipe make it dry.

Including at least one whole egg helps to tenderize. Eggs can also act as

leaveners especially when egg whites are beaten separately. The yolk functions

to emulsify fat and liquids due to its lecithin content.

 Figure 2. Eggs
(Source: https://www.eggs.ca/nutrition/view/1/egg-nutrition)

c.Dairy Products and Water

Water and milk enhance the development of gluten and/or gelatinization of

starch in the flour or the setting of the structure (baking) and thus serve as a

toughener. Dairy products are used for flavoring, and sugars to sweeten and to

aid fermentation. Dairy products also contain proteins which act as a structural

enhancer. But, too much liquid will cause a baked good to collapse or the batter

to become too thin, with the final baked good too heavy. The perfect balance of

liquid offers both structural support and moistness which is perceived as

tenderness.

Figure 3. Dairy Products

(Source: Retail.com, 2019)

Water and milk enhance the development of gluten and/or gelatinization of

starch in the flour or the setting of the structure (baking) and thus serve as a

toughener. Dairy products are used for flavoring, and sugars to sweeten and to

aid fermentation. Dairy products also contain proteins which act as a structural
enhancer. But, too much liquid will cause a baked good to collapse or the batter

to become too thin, with the final baked good too heavy. The perfect balance of

liquid offers both structural support and moistness which is perceived as

tenderness.

d. Sugar

Figure 4. Sugar
(Source: Healthline, 2017)

Sugar keeps baked goods soft and moist, and it does a lot more than just

satisfy our craving. The bond between sugar and water allows sugar to lock in

moisture so that items such as cakes, muffins, brownies, and frostings don't dry

out too quickly. It creates tenderness, deepens colour and flavour, and adds

crunch

Sugar is an important contributor to flavour by interacting with other

ingredients. Depending on the food application, sugar has the unique ability to

heighten flavour or depress the perception of other flavours.

Fermentation, an extremely important process in the baking industry, is

fuelled by sugars. Sugars are used to activate yeast for fermentation. The type

and amount of sugar added can increase the dough yield and softness of bread

by altering the rate of fermentation. Sugars remaining after fermentation

contribute to the overall flavour, colour, and texture of the final product.

e. Yeast
 Figure 5. Yeast

(Source: https://www.thespruceeats.com/yeast-varieties-1328651)

Yeast commonly used in baking bread and bakery products, serving as

a leavening agent which causes the bread to rise by converting

the fermentable sugars present in the dough into carbon dioxide and ethanol.

In baked products, yeast increases the volume and improves the flavor,

texture, grain, color, and eating quality. When yeast, water, and flour are mixed

together under the right conditions, all the food required for fermentation is

present as there is enough soluble protein to build new cells and enough sugar to

feed them.

f. Salt

Figure 6. Salt
(Source: Bake Info)

Salt has several functions in baked goods. It modifies flavour, increases crust

colour and controls the rate of yeast fermentation and enzyme activity.

Salt also strengthens gluten, making it more cohesiveness and less sticky.

With salt present, gluten holds more water and carbon dioxide, allowing the

dough to expand without tearing. This means that salt prevents excessive tearing
when gluten stretches so bread is easier to handle and has a better volume and

a finer crumb. Because salt noticeably strengthens gluten, bread bakers

sometimes delay the addition of salt to dough made from strong flour, adding it

late in the mixing process. The dough mixes faster and cooler as there is less

resistance and frictional heat generated during mixing. Once salt is added, the

dough tightens and is more difficult to stretch, but it will stretch further without

tearing.

C.Equipments

There are many facets to running a doughnut shop, but first and foremost,

this specific type of bakery requires the correct doughnut equipment to run

smoothly. It is important to start with the correct bakery equipment necessary for

making doughnut in order that they not only come out looking great but are also

produced as efficiently as possible.

a. Bakery Mixers

Any type of bakery, including doughnut centered ones, will require an

industrial-sized, bakery mixer. To begin with a start-up doughnut shop should do

well with a 40 quart mixer. If production is expected to be larger, a bakery mixer

that holds 140 quarts or more will be necessary.

Figure 7. Mixer
(Source: https://rvoshare.files.wordpress.com/)

b.Doughnut Fryers
 A doughnut fryer, not an oven, is the key bakery equipment to running

doughnut shop. A fryer can be either gas or electric and should be able to make

between 80 dozen to 150 dozen doughnuts per hour.

Figure 8. Doughnut Fryers

(Source: https://www.moline.com)

c. Doughnut Proofer

A doughnut proofer is necessary in order to make yeast-raised doughnuts.

This will allow the dough to set on racks at room temperature and be able to rise.

A good idea is to have a mobile proofer that can hold multiple sheet pans at the

same time and be transported to different areas of the doughnut shop. It would

definitely be a good choice to look into a proofer designed specifically for

doughtnuts.

Figure 9. Doughnut Proofers

(Source: https://www.moline.com)

d. Doughnut Icers, Glazers, and Sugar Coaters

This bakery equipment can either be several pieces or combined into one. An

icer station is definitely needed if you own a doughnut shop. What kind of
doughnut does not have glaze? A glazer can be attached to the icer to make

sure the doughnuts are given their nice, shiny coat. Additionally, a sugar tumbler

can be added so the doughnuts are all evenly coated in sugar.

Figure 10. Doughnut Finalizing Equipment

(Source: https://www.moline.com)
 
e. Doughnut Cutters and Depositors

There are various other pieces of bakery equipment that would serve any

doughnut shop owner very well. These are all gadgets that will make running

your shop as easy and seamless as possible. A cutter, for one, is necessary to

make bar shapes and other raised doughnuts from dough. These can be built

into a dough sheeter or hand-held. Another piece of equipment is a depositor.

These put the dough into the doughnut shape before dropping it into the fryer.

Figure 11. Doughnut Depositors

(Source: https://www.moline.com)

f. Bakery Oven

Like most bakeries, a doughnut shop will probably have a few extra pastries

to serve their guests. If this is the case, an oven will most likely be necessary. If
you will not require many extra desserts, it might be a good idea to look for a

smaller oven – like a proofer/ oven combination.

Figure 12. Oven

(Source: https://www.berndorfband-group.com/)

D. Manufacturing Processes

1. Acquiring and Measuring of Ingredients

The productions of variety of doughnuts undergo the process of acquiring the

ingredients that have approved quality. These raw materials are use in order to

attain the target quantity of products to be merchandise in the market. In

maximizing the minimum required matter in the manufacturing process, having

the required materials in detailed while bulk buying is important.

For instance, many bakeries and franchises that produce hundreds of dozen

doughnuts per day develop mixes often in large bags that can contain up to 50lb

(22.7kg). The company warehouses within the region shipped the ingredients to

different manufacturing chains and this were stored on the premises and used as

needed. Additionally, bakeries shop for large quantities of perishable ingredients

like eggs and milk and keep the stored in refrigerator.

2. Mixing and Kneading

Kneading attains the mixing of the ingredients as the dough for the bread

comes to be in stable status or with strength. The strength of the bread expands

when the glutenin and gliadin proteins is present after the kneading process was
performed. These two strands converts the dough from loosed mix into a texture

of hard and elastic as it allows a springy motion in the molecular structure of the

dough. This will hold carbon dioxide as the gas enters the yeast through the tiny

pockets made from the kneading process as it collapses in a thicker loaf.

The effective kneading comprises of putting the dough of ball form into a flat

surface as the machine squeezes and stretches the dough in repetitive process.

This will develop the gluten molecules that will tighten the dough in order to have

the tiny holes. Kneading process should take a while for like 8 to 10 minutes for it

will be so dense if it does take lesser time for kneading and too grit in taking

longer time.

This process is available by doing on hand as the word kneading actually

refers to but the process needed is obtained by the machine as the dough is

introduced to hook attachment on a stand mixer or in a food processor.

The ingredients are put onto the large bowl as being mixed giving the space

confined with equivalent amount of liquid ingredients as it occupies the mixer with

appropriate amount depending on the weight of the batch and the type of

doughnut being produced.

The machine starts to knead as the large amount of dough is being pulled

and stretched normalizes to attain gluten in elongated fibers as per doughnut’s

priority structure. The separated yeast is then added along the automatic timer

allows the mixer to associate it into the kneaded dough for about 13 minutes.

Types of Industrial Kneader

a. Agitators

Agitator mixers imply on stagnant on its center axis as the substance inside of

the container having removable agitating rods placed for the substance for the
proper mixing of the ingredients. Most likely, agitators are not effective to use in

viscous materials instead appropriate to more liquefied.

Figure 13. Agitator

(Source: Process Equipment, 2014)

b. Ribbon Blenders

For this type of mixer, it is more appropriate for dry mixing with huge amount

of solid ingredients unlike the agitators. This is enclosed in a semi-cylinder

having ribbon blenders or paddles that rotate in its central axis. It enables to

shred and shear materials in other to mix and blend well. Ingredients like flour

and other solids are combined through this blender.

Figure 14. Ribbon Blender

(Source: Process Equipment, 2014)

c. Paddle Mixers
 The orientation of paddle mixers has same to do with the ribbon blenders as it

has only paddle-shaped blades instead of shearing ribbons. It is well to use in dry

substances and for wet mixtures like slurry mixing and with high viscosity.

Figure 15. Paddle Mixers

(Source: Process Equipment, 2014)

d. Static Mixers

Instead of having central axis, this mixer instates an inline motion. Stationary

parts are installed in this kind of mixer. It is also installed with ribbon-like

obstructions where the flow of liquid penetrates to it blending in to mix with other

ingredients as the tubes are attached to increase the homogeneity without the

use of the parts.

Figure 16. Static Mixers

(Source: Process
Equipment, 2014)

e. Emulsifiers

Emulsifiers vary from

either inline, static or separate machines as these types are used to blend the

liquids like immiscible liquids; oil and water or cream and milk. It actually presses

to force the liquid mixture to the tiny filters to break up into bits of molecule size.

Through the aid of emulsifying agents, it helps the components to break dying

into smaller sizes as centrifugal motion is indulged into the process.

 Figure 17. Emulsifiers
(Source: Process Equipment, 2014)

f. Homogenizer

Homogenizers mean with the construction of vertical axis shearing blades as

like as the emulsifier does. This relies to the force and pressure that are used in

the breakdown of molecule of the materials used in the making of the dough.

Blended in closed containers, homogenizers run at very high speeds.

Figure 18. Homogenizers

(Source: Process Equipment, 2014)

3. Resting the Yeast

 Resting the yeast entails to associate the quality of the dough to be served in

the market. The dough must be transferred through conveyors that will sit each in

every container to preserve the sponginess and softness and it is for about 10

minutes for ideal resting.

Due to this, the fermentation absolutely uses the resting of the dough to

absorb the developing gas in the yeast converting it into carbon dioxide as it rises

instead of flattens.

4. Shaping Doughnuts

Doughnut extrusion is a process of forming the big chunks of dough into the

desired size single pieces that are being baked and fried for finishing touches.

The dough extrusion forces the dough by the pressure applied as it passes by an

orifice and cut into single piece of product.

The dough is being pressurized into the tubes as it extrudes pre-shaped

dough forming to be ring-shaped doughnuts or just a simple doughnut for

Bavarian or cream-filled doughnuts. Process follows 15-minute duration for rate

out of 30 dozen doughnuts. The extruders run at low speeds for it will not be

destructed to its form providing balanced and undistorted products.

5. Proofing

Proofing is one way of the industrial process that will take in the development

of the products as it undergoes to leave the dough in the machine for about 30 to

50 minutes keeping it in steady temperature of 27°C. With this given time, the

yeast cells initiate to expound and produces alcohol and carbon dioxide. This

gives sensation of elastic to the dough and the expansion of its size until it

becomes double of its original shape.

6. Frying
 In this process, doughnuts that undergo on the proofing will fall into the fryer

one row at one time. The temperature must not be lowered for that the frying time

takes longer. Oil is one of the most expensive ingredients so it is not approved to

soak the doughnuts for much time since it reduces the profit margin for each

batch. After frying is done, doughnuts are now brought by the mechanical flipper

to be forced into the glazer after two minutes.

7. Glazing and Drying

Glazing area for the process is installed with a bridge having holes as for the

glaze is forced through this on the top of the fried doughnuts. They obtain

showering the doughnuts as they are coated from top, sides and bottom part.

After this, they transport the glazed doughnuts through conveyoring out into the

production area to lower the high temperature and cool.

The glaze unused in the process is being pumped in a glazing waterfall

reservoir. Another pump is allowed to put the glaze from the reservoir to the top

of the water fall as the doughnuts fall down on the conveyor belt.

8. Further Finishing and Packaging

Doughnuts are placed in the finishing station wherein they are being sprinkled

with the candies or nuts or just by frosting. Some doughnuts like Bavarian

variants are being injected with fillings. Doughnuts after the process are moved

into containers as they are packed and boxed into desired number of pieces per

box or target of customer’s desire.

E. Existing Plant

Krispy Kreme Doughnuts, Inc. is an American doughnut company

and coffeehouse chain owned by JAB Holding Company. Krispy Kreme Dough-

nuts used to be made by hand before machines took over in 1963

 For the manufacturing process, first it starts with mixing the ingredients

and extruding them into the doughnut shape. They get water, Krispy Kreme

doughnut mix, and yeast to make the dough. Next they pour the dough into a

hopper. The hopper then feeds the dough into an extruder, which is the device

that forms the dough rings that eventually become doughnuts. (laura-andler.com)

Second, it goes to the proof box, where it surrounds the doughnut with

heat and humidity. The proof box is a tall glass case that has a doughnut

conveyer belt. This conveyer belt carries doughnut trays slowly up and down in a

zigzag motion all the way through the proof box. This machine is what makes the

doughnut shape (lauracandler.com)

Third, it goes to frying. The doughnuts float in vegetable oil around 355

degrees to 360 degrees Fahrenheit. They are on a conveyor belt. They fry one

side of the doughnut at a time then when one side is done the machine flips them

over so it can fry the other side. They fry them for a certain amount of time to

make sure they get the right taste and texture (www.lauracandler.com)

Lastly, it goes to the glazing and cooling. The doughnuts are still on the

conveyor belt. Once the bakers are done making the glaze, they have a pump

that draws the glaze out into a glazing waterfall reservoir. Another pump draws

glaze up from the reservoir to the top of the waterfall, where it falls down over the

doughnuts on the conveyer belt. As each doughnut rack passes through the

waterfall, it’s completely coated in glaze (lauracandler.com).

Figure 19. Krispy Kreme Manufacturing Plant

(Source: http://science.howstuffworks.com/innovation/edible-
innovations/krispy-kreme4.htm /)
Quality Control

Ingredients that are obtained in packaged vessel are most likely dry mix and it is

a must to be checked along bringing into the processing plant. Other perishable

product must be in fresh conditions and even the yeast to be used must be in

process within 12 hours. The duty of the employees is to make sure that the time

of interval for the kneading, resting, proofing and drying are being monitored to

avoid product defect.

The temperature set for the frying, baking and cooling must be also monitored

alongside with the ingredients being kept in the silos or storages to be used in

other terms. The yeast is one of the most sensitive ingredients in the process as

it is to be formed with the adding of right tempered water so that the yeast is not

killed or inhibited. Proofer is set for warm temperature in order to maintain the

doughnuts rising. The low temperature of fryer must be balanced so that the

doughnuts could not absorb much oil and not to become greasy. Water treatment

must be settled and inspected by the employees as well as the ambient room

temperature is being monitored. Room temperature affects the rising of the yeast

and may re-calibrate by the defect of the yeast due to the temperature.

IV. Location of the Plant Site

San Pascual is a coastal municipality in the province of Batangas. The

municipality has a land area of 50.70 square kilometers or 19.58 square miles

which constitutes 1.63% of Batangas's total area. Its population as determined by

the 2015 Census was 65,424. This represented 2.43% of the total population of

Batangas province, or 0.45% of the overall population of the CALABARZON re-

gion. Based on these figures, the population density is computed at

1,290 inhabitants per square kilometer or 3,341 inhabitants per square mile.

 Fi
gure 20. Location
(Source: Google map)

This site is selected in the consideration of the following factors:

1. Raw material procurement.

2. Proximity of market.

3. Availability of labour, their training and compensation.

4. Availability of power.

5. Availability of finance.

6. Miscellaneous considerations like donations, subsidies, taxes and non-

interference by government or local bodies, war and political effects and other

facilities or bottle necks.