Frozen French Fries and Potato Chips Factory

BEYNELMILEL FOOD CORPORATION FROZEN FRENCH FRIES ANDPOTATO CHIPS FACTORY DESIGN PROJECT
PRESENTATION ORDER
INTRODUCTION
RECEPTION – DESTONING & WASHING – PEELING
POTATO CHIPS LINE
FRENCH FRIES LINE

SLICING & SLICE WASHING – BLANCHING – FRYING

PRECOOLING – FREEZING – COLD STORAGE
CLEANING AND WASTE TREATMENT
INTRODUCTION
GENERAL INFORMATION
NAME OF COMPANY : Beynelmilel Food Industrial Corporation
DATE OF ESTABLISH : 01.01.2008
ADDRESS : BOLU Organization Zone / BOLU
PHONE NUMBER : +90 374 215 98 74
WEB : www.beynelmilel.com
TYPE OF PROCESS : Continuous
SERVICE LIFE : 15 years
ENERGY SUPPLY : Electricity and fuel oil (no:4)
CAPACITY : 7200 tons french fries/year
14400 tons potato chips/year
OPERATING TIME : 26 days/month
300 days/year
•MISSION AND VISIONOUR PRODUCTS
Our products are mainly potato chips and frozen french fries. Also, we have starch and peel as by-products.
Starch is sold to related industries. Potato peel is sold as animal feed.
QUALITY POLICY
MARKETING AND TRANSPORTATION
PROCESS FLOW DIAGRAM
PLANT LAYOUT
PROCESS LAYOUT
MACHINE LOCATION (Side View)
GENERAL MASS BALANCES
TOTAL MASS BALANCE FOR FRENCH FRIES
GENERAL MASS BALANCES
TOTAL MASS BALANCE FOR POTATO CHIPS
WASTE TREATMENTS
Peel is sold as animal feed.
Starch solution from slicing, slice washing and blanching is fed to rotary vacuum drum filter.
Starch obtained as cake and is sold to related industries.
Wastewater from washing is treated in water treatment unit and reused after specific controls.
The waste oil is sold to biodiesel producers.
REVISIONS
We have some revisions due to the advises we are given at Food Engineering Design (1st Semester) course.
The blanching unit is removed from potato chips line
The water tank design is rearranged.
The used salt amount is changed
The waste oil is sold to biodiesel producers
The membrane filtration is changed with rotary vacuum drum filter.
REVISIONS ON COST ESTIMATION
The revisions on purchased equipments (addition and removal of equipments) were analyzed if there an identical change exists or not.
REVISIONS ON COST ESTIMATION
As a result of these changes the Cumulative Cash Position and Break-Even Point Calculations were repeated.
As one can observe from the results above it was concluded that the Cumulative Cash Position and Break-Even Point were not effected very much from these changes.
PROCESS MODELLING AND SIMULATION
Potato Chips Line
PROCESS MODELLING AND SIMULATION
French Fries Line
PROCESS MODELLING AND SIMULATION
The graphical representation of potato chips production
PROCESS MODELLING AND SIMULATION
The graphical representation of french fries production
RECEPTION
RECEIVING
DESTONING AND WASHING
Tee Connection Loss: Contraction loss from 3” diameter to 1.5” diameter:
V : 0.48 m/s h: 0.55*(1-A2/A1)*(V2/2*α*g)
h : (K*V2)/(2*g) K : 1 α: 1.0
h : 0.12 j/kg h: 0.53 j/kg

900 elbow loss: Other straight pipes;
Q = V * A 2 m length, 3” diameter: 2.51 j/kg
(0.00136 m3/ s) = V * (π * (0.039)2 /4) 3 m length, 1.5” diameter: 3.78 j/kg
h : (K*V2)/(2*g) K : 0.75
h : 0.53 j/kg
Expansion loss from 1.5” diameter pipe to equipment:
h: (1-A1/A2)2*(V2/2*α*g)
h: 0.65 j/kg
WATER TANK THICKNESS OF WATER TANK:

Dtank: 10 m rtank: 5 m
h tank: 6 m
V tank: 471 m3 (cylindrical)

Vwater= 375 m3 (for 2 days need)
: 7808 kg/hr * 48 hr
: 375000 kg

Vwater: Π*r2*h
: Π*(5m) 2* h water
h water: 5.09 m

P water: ρ * g * h
: 0.493 atm
Theoritical thickness: So
So : D*P / [2*(σs/n)*V*100] : 10000 mm* 0.439 atm /
[200*(2.5/2)*0.9] : 21,917 mm

S : So+C
: 21,917 +1.5
: 23,417 mm

WATER TANK
Volume of steel: V inside+tank thickness – V inside
: 4.422 m3
Mass of steel: V* ρ
: 4.422 m3*8000kg/ m3
: 35377.671 kg
Total mass in tank: msteel+mwater
: 35377.671 + 375000
: 410377.671 kg

Number of legs: 4 (because of radius higher than 1.5 m)

Force on each leg: 410377.671 kg/4 leg
: 102600 kg
WATER TANK
PEELING
SLICING
SLICE WASHING
DEWATERING
Water on 1325 kg sliced wet potato is removed on porous conveyor belt to the frier.
5 kg water is removed from this amount of potato.
Power required for this conveyor is 0.04498 kW.
FRYING
OIL TANK
THICKNESS OF OIL TANK:

Dtank: 4.37 m rtank: 2.185 m
h tank: 4 m
V tank: 60 m3 (cylindrical)

Voil: 48 m3 (for 2 days need)
: 825 kg/hr * 48 hr
: 42000 kg

Voil: Π*r2*h
: Π*(2.185m) 2* h oil
h oil: 3.20 m

P oil: ρ * g * h
: 0.272 atm

Theoritical thickness: So

So : D*P / [2*(σs/n)*V*100] : 4370 mm* 0.272 atm / [200*(2.5/2)*0.9] : 5.28 mm

S: So+C
: 5.28+1.5
: 6.78 mm

Volume of steel: 13.72*4 m*0.00678mm
: 0.372 m3

OIL TANK
Mass of steel: V* ρ
: 0.372 m3*8000kg
: 2978 kg

Total mass in tank : msteel+moil
: 2978+42000
: 44978 kg
Number of legs: 4 (because of radius higher than 1.5 m)
Force on each leg: 45000 kg/ 4 leg
: 11250 kg/leg
PIPING OF OIL TO FRYING
For common oil pipe of diameter 3 in;
1. straight pipe loss (14 m)

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