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17 views6 pages

FPLD PBL

Uploaded by

Anas Khan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Department of Food Engineering

NED University of Engineering and Technology

Food Plant Layout and Design (FD-411)


Problem Based Learning
Group Number: 9 Batch: 2020
Group Members Name: Seat Numbers:
Muhammad Anas Khan FD-06
Muhammad Bilal Ali FD-07
Mufaddal Mandviwala FD-08
Muhammad Yahya FD-35
Submitted To: MISS SADIA
PROBLEM BASED LEARNING
COURSE TITLE: Food Plant Layout and Design COURSE CODE: FD-411
Title: Develop a Process Flow Diagram for the given food processing unit. Evaluate its Location
Selection Decision and design a unit operation for this processing plant.
Objectives: The purpose of this exercise is to guide the students to work out in the design and
development of a food plant, to analyze the behavior of the food process and to answer the
questions mentioned below regarding its design, development and location selection.
Project Details: The potatoes are used since ancient times for food. The production of potato chips
is carried out from sorting the potato at low temperature to final packaging. To convert the raw
material potatoes into chips it has to pass from different stages.
This project, of potato making, is divided into three tasks.
Task 1: To develop a Process Flow Diagram (PFD) by using MS Visio.
Task 2: Evaluate and discuss the strategic importance of plant location.
Task 3: To design a unit operation and compare its result by using ASPEN PLUS.
Complex Problem Attributes and Knowledge Attributes:
The following attributes qualify this issue as a complex engineering problem:
1) Require in-depth fundamental and specialized engineering knowledge.
2) High level problems including component parts and sub-problems.
3) Solutions are not obvious, require originality or analysis, based on fundamentals.
4) Require judgement in decision making in uncertain context.

Project Deliverables:

Following are the deliverables of the projects:


1) A complete process Flow sheet development for the given food processing plant.
2) Strategic Importance of Location decision and its evaluation.
3) Designing of the process equipment by the development of mathematical model of a unit
operation mentioned in the process.
4) Comparison of the results by using software.

Instructions:
1) The project report can be submitted in group form. Each group should not contain more
than 3 members.
2) Copied content from any group will be marked as zero.
3) Submission deadline is last day of 13th week of the semester. 4) Attach rubrics after each
part of the project report.
Marks Distribution with linkage to CLOs:
Marks Marks in each
Questions Total Marks
Obtained CLOs
CLO 3 a. 02 CLO 1 05
TASK 1
CLO 4 b. 03 CLO 2 04
a. 03 CLO 3 02
TASK 2 CLO 1
b. 02 CLO 4 09
CLO 2 a. 04 Total 20
TASK 3
CLO 4 b. 06
20
Task 1:
Problem statement:
The potatoes are first washed and peeled. For making chips only medium sized potatoes are used.
Hence, care must be taken while procuring, to minimize waste. The washed potatoes are cut into
thin slices using the wafer making machine. The cut slices are then fried in oil. Salt and other
seasonings and additives are added to get the required flavors.

a. Develop the objectives and constraints for the production of potato chips.
b. Develop a Process Flow Diagram (PFD) of potato chips using MS Visio.

Process flow chart for potato chips making is given below:

Raw Material

Washing and Sorting

Peeling

Slicing/Cutting

Frying

Seasoning

Packaging

Storing/Loading/Supply
Task 2:
Problem Statement:
According to the FAO data (updated in late December 2023, includes potato production statistics
up to 2022), a total of 375 million of potatoes were produces worldwide, with China (95.5 million
tons) and India (56 million tons) being the top producers. Potato production in Pakistan in 2022
reached 7.93 million tons.
A country is planning to develop a new factory for the production of potato chips in one of the
three Asian countries mentioned in the table. As a manager of a company, you have been charged
with making the decision to evaluate the potential countries on the basis of five key success factor.
Using a rating system of 1 (least desirable) to 5 (most desirable).

Key success Weightage score


Weightage China India Pakistan
factor
China India Pakistan
Soil condition 0.6
Climate
0.4
condition
Availability of
0.7
Raw material
Skilled labor
availability and 0.3
attitude
Land cost 0.3
Total

a) Giving a rating to each country based on key success factor and find out which country is
selected for the new factory?
b) If the land cost in Pakistan is increases, which lowers the score to 50%. Does your
conclusion changes? Discuss
Task 3:
Problem Statement:
Consider a Dryer used in potato chips making factory. 1800 kg/hr of potato chips entering into the
dryer with initial moisture content of 0.66(wet basis) and (remaining component are potassium,
calcium, and phosphorus, consider them as in equal amount other than water) and the rest of the
component (carbohydrates, protein and vitamin C) can be neglected. The inlet temperature of
potato chips is 35ᴼC dried in a co-current dryer. The dryer length is 7m, and the solid residence
time in the dryer is 4 hr. The air initial temperature is 120ᴼC, its mass flowrate is 8000 kg/hr and
mass fraction of water in inlet and outlet air is 0.002 and 0.014 kg H2O/ kg dry air. Consider the
following data for convective mass transfer coefficient, drying curve (Table 1), and assume the
size of the potato slices are almost equal. Convective mass transfer coefficient of 6.5 * 10-4 m/sec,
equilibrium moisture content of solid phase of 0.05 dry basis, and critical moisture content of 0.1
dry basis.
a) Calculate the final moisture content on wet basis and dry basis both at the dryer outlet.
b) Compare the result by simulating the dryer using ASPEN PLUS and find out the
remaining unknown properties of this dryer.

Table 1: Drying curve data


Normalized solid moisture 0 0.1 0.2 0.35 0.65 0.85 1.0
Normalized drying rate 0 0.1 0.5 0.8 0.9 0.95 1.0

Table 2: Particle size distribution

Size (mm) 4-5 5-6 6-8 8-10


% 20 20 40 20

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