Baby Food Production

BABY FOOD PRODUCTION
Welcome to our presentation
BABY FOOD PRODUCTION
SUPERVİSOR: ASSOC.PROF.DR.K.BÜLENT BELİBAĞLI

•INTRODUCTION:GÖKÇEN TÜRKER
•PROCESS:BETÜL AKALIN-MÜGE UZUNOĞLU
•COST ANALYSİS:FATİH DEMİRCİ
•QUALİTY CONTROL:SEDA AYHAN
INTRODUCTION
•WHAT İS BABY FOOD?
•Baby food is any food, other than breastmilk that is made specifically for infants,between the ages of four months to two years.
COMPARASION FOR BABIES
between;
HİSTORY OF BABY FOOD
The first commercial baby food was invented by Leibig in 1869. It was a powdered formula made from potassium bicarbonate, wheat flour, and malt flour. This was then added to warmed cow’s milk. The product was widely sold in Europe
Henri Nestlé created his own formula treating malnourished babies. Nestle’s formula was mixed with water and did not need the addition of any Cow’s milk. This made it the first complete formula.
Improved commercial formulas had a comeback in the 1960’s, almost completely replaced evaporated milk in the 1980’s.
Raw material availability
The cheapest land (FREE)
Private zone stimulated by government
So KONYA-EREĞLİ is the best one
Consumption of baby food in some Countries
OUR PRODUCTS
Infant formula for babies up to 6 months.
Follow-up formula for babies 6months and older.
RAW MATERİALS and INGREDIENTS
•Skim milk powder
•Cereals
•Vitamins
•Minerals
•Vegatable oils
•Lecitin
•Whey powder
•Starch
•Corn syrup
SKIM MİLK POWDER
Powdered milk is a dairy product produced from cow milk.
Milk powder is prepared by skimming the milk whereby a considerable but proportional cream substance is extracted before it is powdered.
Cereals
mostly used;
rice
wheat
barley
MINERALS
Sodium
Potassium
Calcium
Phosphorus
Magnesium
Iron
Zinc
Copper
Iodine
VITAMINS
Vitamin A
Vitamin D
Tiamin
Riboflavin
Niacin
Pantothenic asid
Vitamin B6
Folik asit
Vitamin B12
Vitamin C
Vitamin K
Vitamin E
VEGETABLE OİLS
Palm oil
•Palm oil is composed of fatty acids esterified with glycerol just like any ordinary fat. It is high in saturated fatty acids.
Sunflower oil
•Sun flower oil contains predominantly linoleic acid in triglyceride form.
•Palmitic acid : 4 – 9%,
•Stearic acid : 1 – 7%,
•Oleic acid : 14 – 10%,
•Linoleic acid : 48 – 74%.
Canola
canola is one of two cultivars of rapeseed or Brassica campestris Their seeds are used to produce edible oil that is fit for human consumption because it has lower levels of erucic acid than traditional rapeseed oils and to produce livestock feed because it has reduced levels of the toxic glucosinolates.
STARCH
Modified food starches were developed as a stabilizer, suspending the food particles and providing a desirable consistency, texture, and storage ability. They are used primarily in strained and junior foods and to a minor extent in infant formulas
LECITHIN
•it is sometimes used as an emulsifier and to prevent sticking.
•composed of phosphoric acid, choline, fatty acids, glycerol, glycolipids, triglycerides, and phospholipids.
CORN SYRUP
•Corn syrup is a food syrup, which is made from the starch of maize and composed mainly of glucose. Corn syrup is used in foods to soften texture, add volume, prevent crystallization of sugar, and enhance flavor.
ORGANISATION CHART
PLANT LAY-OUT
THANKS FOR LISTENING TO ME
SKIM MILK POWDER AND CREAM
E.BETÜL AKALIN
Milk powder manufacture is a simple process now carried out on a large scale.
It involves removal of water under hygiene conditions , retaining all the desirable natural properties colour, flavour, solubility, nutritional value.
Milk powders contain 33- 35% protein,0.25-1%fat,max 4% moisture ,52-55% lactose, calcium 1.3%, potassium 1.8%and other ingredients.
Whole (full cream) milk contains about 87% water
Skim milk contains about 91% water.
13 kg of whole milk powder (WMP) or 9 kg of skim milk powder (SMP) can be made from 100 L of whole milk.
Milk powders may vary in their gross composition (milkfat, protein,lactose), the heat treatment they receive during manufacture, powder particle size and packaging.
Milk powders of various types are used in a wide range of products such as
baked goods,
snacks and soups,
chocolates and confectionary (e.g. milk chocolate),
ice cream, infant formula
FLOWCHART OF CREAM AND SKİM MİLK POWDER
bulk storage seperator pasteurizer buffer silo pre-heater evaporator

scrape surface heater buffer tank

homogenizer
cyclones atomizer
drier

fluid bed

PROCESS OF SKİMMİLK POWDER
1. SEPARATION / STANDARDIZATION:
separating it into skim milk and cream using a centrifugal cream separator.
Pasteurization and packaging and sale for cream.
The cream is rich in
nutritions,vitamin,
mineral(calcium).
2. PREHEATING
temperatures between 75 and 120°C few second
It is for;
controlled denaturation of the whey proteins,
destroys bacteria,
inactivates enzymes,
generates natural antioxidants,
imparts heat stability.
The via heat exchanger is used.
3.EVAPORATION
from around 9.0% total solids content to 45-52% total solids.
by boiling the milk at 72°C in a falling film on the inside of vertical tubes, and removing the water as vapour.
This vapour is mechanically or thermally compressed,and used to heat to milk in next effect of evaporator.
More than 85% of the water in the milk may be removed in the evaporator.
4.HOMOGENİZATİON
to decrease the free fat content.
to convert free fat into fat globules.
Two stage homogenization is preferable to ensure minimal re-coalescing of globules take place
5.SPRAY DRYING
atomising the milk concentrate from the evaporator into fine droplets.
inside a large drying chamber in flow of hot air with disk atomiser.
hot air (up to 200°C)
particle size typically of < 0.1 mm diameter.
“secondary” drying takes place in a fluid bed.
product with a moisture content of 2-4%.
6.PACKAGING AND STORAGE
For skimmilk powder;
multi-kraft paper bags of 25kg net each with poly liner inside.
The nitrogen gase is used to replace air,not CO2.
It consist of several layer.
stored under cool dry conditions (25C, 75%Rh)
store it in a dark place.
1 year from manufacturing date.
For cream;
Cream cups are used for packaging.
shelf-life is 10-12 days.
7.METAL DEDECTOR
examine product in all forms.
detect every particle of metal passing.

MATERİAL BALANCE
The mass balance around seperator:
F:18511kg/h D :2591.5kg/h

C:15919.5kg/h
F:Raw milk, C:Cream, D:Skimmilk
Total Material Balance:
F=C+D=2591.5+15919.5=18511kg/h
The mass balance around evaporator:
w:925.51

D:2591.5kg/h P:1666kg/h

D:Skimmilk, W:Water, P:Skimmilk powder
Total Material Balance:
D=W+P=1666+925.51=2591.5 kg/h

THE USED EQUIPMENT AND MACHINERY FOR MILK POWDER
1.Milk pump:
This is centrifugal pump
stainless steel protection
Temperature is 80℃~90℃
2.Milk dual filter:
for getting rid of all kinds of impurity which can’t be seen by eyes.
work continuously.
3. Plate heat exchanger:
high efficiencyo f heat
transfer,
small heat loss,
compact structure,
small occupation,
convenient install and
washing
4.Double-effect falling film evaporator
suitable for low temperature vacuum concentration of heat sensitive substances.
small influence on the products’ color,flavor and nutritions content
5.Pressure spray drying system
heated in short time and
evaporated quickly
temperature is lower
has little impact on solubility,
color,flavor and
nutrition of the product.
6.Metal dedector
examine product in all forms.
detect every particle of metal passing.
THANKS FOR LISTENING TO ME
PROCESSING OF BABY FOOD
MÜGE UZUNOĞLU
1-STORAGE TANK FOR SKIM POWDER MİLK
2-MIXER TANK
3-PASTEURISATION
4-STORAGE-MIXER
5-COOLER
6-MIXER TANK
7-DRY MATERIAL DOSING
8-HEATER
9-SPRAY DRYER
10-STORAGE TANK FOR BABY FOOD
11-PACKAGING
Infant formula baby food production
Follow-up formula baby food production
The process consist of 8 steps;
1.Mixing
2.Pasteurisation
3.Homogenisation
4.Cooling
5.Storage-mixing
6.Heating
7.Spray drying
8.Packaging
MIXING
The first stage of baby food production is the addition of water, starch, vegetable oil, lecithin,whey powder, corn syrup, ingredients (inositol, L-carnitin, taurin, colin), and minerals to milk powder.

PASTEURISATION
This is a process that protects against spoilage by eliminating bacteria, yeasts and molds.
Pasteurisation is applied at around 100°C for approximately 23 seconds which is necessary to adequately reduce micro-organisms.
HOMOGENISATION
The mixture is homogenised to ensure a stable emulsion, avoiding separation of oil and water phases.
COOLING
In this section, a heat exchanger is used.Cooling is applied for addition of the vitamins.
STORAGE
Mixture is stored in storage tank and mixing, during addition of the vitamins.
HEATING
Scraped surface heat exchanger is used to increase the temperature of homogeneous mixture.
SPRAY DRYING
Spray drying process is applied to obtain 3% moisture content for baby food at 120-125 ºC.
FLUIDIZER BED
Fluidizer bed can be operated as a drying or cooling unit. A layer of fluid-like powder in which the particles are kept apart by an air flow.
PACKAGING
Horizontal filling is applied.
Nitrogen gas is used to prevent contamination.
METAL DETECTOR
Metal detector is used to increase the safety of our quality control efforts.
THANKS FOR LISTENING TO ME
COST ANALYSIS
FATİH DEMİRCİ
WHAT ABOUT ?
TOTAL CAPITAL INVESTMENT
MANUFACTURING COST
TOTAL PRODUCT COST
CUMULATIVE CASH POSITION
BREAK -EVEN POINT
TOTAL CAPITAL INVESTMENT
TOTAL PRODUCT COST
•TOTAL PRODUCT COST
•Raw material
•Operating labor
•Direct supervisory and clerical labor
•Operating supplies DIRECT PRODUCT COST
•Utilities
•Maintenance and repairs
•Laboratory caharges
•Depreciation FIXED CHARGE COST
•Insurance
•Local taxes
• MANUFACTURING
Medical COST
•Safety and protection
•General plant overhead TOTAL PRODUCT COST
•Payroll overhead
•Packaging
•Restaurant PLANT OVERHEAD COST
•Recreation
•Salvage
•Control laboratories
•Plant superintendence
•Storage facilities
Administrative expense
•Distrubition and marketing cost GENERAL EXPENSES
•Research and development cost
MANUFACTURING COST
DIRECT PRODUCT COST:
OPERATING LABOR:
PACKAGING MATERIAL: All of the packets are made from carton
FIXED CHARGE:
DEPRECIATION: (V – VS) / n
V : Purchased equipment cost, ( 2,786,330 $ )
VS : Salvage value ( taken as zero )
n : Service life of equipments ( 10 years )
•INSURANCE : equals to the 0.8 % of the fixed capital investment
• INSURANCE = 90,000 $
•LOCAL TAXES : 1 % of the fixed capital investment
• LOCAL TAXES : 1,130,000
•MANUFACTURING COST :
•Direct Production Cost + Fıxed Charges + Plant Overhead Cost
•That is; M.COST: 15,884,300 + 1,500,000 + 800,000
GENERAL EXPENSES:
•TOTAL PRODUCT COST :
• Manufacturing cost + General Expenses
•That is ; T.P.C :17,184,300 + 4,550,000
TOTAL INCOME
•TOTAL INCOME :
–SELLING PRICE OF OUR PRODUCT
BREAK-EVEN POINT (B.E.P)
BREAK-EVEN POINT ANALYSIS :
•6,363 X = 3,295 + 1,500,000 (X: ton /year )
•SO ; X : 488.9 ton/year
Break-even Point is ; 488.9 / 6600 * 100 = 7.4 % of Total Product Cost
•If we work 488.9 ton/year capasity , we reach the B.E.P
CUMULATIVE CASH POSITION
CUMULATIVE CASH POSITION ANALYSIS ( C.C.P )
•C.C.P = ( Net Profit + Depreciation ) * X – Total Capital Investment = 0
•Total Capital Investment = 19,500,000 $
•Gross earning = Total Income – Total Production Cost
• = 42,000,000 – 21,750,000
•Gross earning = 20,250,000 $
•Taxes : 20% of the Gross Earning = 4,050,000 $
•Net Profit = Gross Earning – Taxes
• = 20,250,000 – 4,050,000
•Net profit =16,200,000 $
•Depreciation = 280,000 $
•SO ; C.C.P = (16,200,000+280,000)* X – 19,500,000
• X = 1.27 years
CUMULATIVE CASH POSITION
OUR PROJECT IS FEASIBLE OR NOT ?
As the invesment, if we invest the our Money to the HALKBANK, HALKBANK gives the 7% interest ratio for our Money.
Our investment is 19,500,000 $
As the simple interest for 5 years;
Capital * [ 1 + ( interest ratio * #of period )] = interest
19,500,000 $ * [1 + (0.07 * 5 )] =26,325,000 $
As the compound interest for 5 years :
Capital * (1 + interest ratio )ⁿ n: # of period
So , obtained 27,350,000 $
So We say that our Project is FEASIBLE.
THANKS FOR LISTENING TO ME

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