APPLE JUICE MAKING PROCESS

INTRODUCTION

Apple is a fruit good for healthy, either red apple or green apple. Specific name for apple is “Malus domestica”. Apple juice is a fruit juice made by the maceration and pressing of apples. The resulting expelled juice may be further treated by enzymatic and centrifugal clarification to remove the starch and pectin, which holds fine particulate in suspension and then pasteurized for packaging in glass, metal or aseptic processing system containers, treated by dehydration process to a concentrate.

Apples were almost eaten close to where they were grown but in the world now, modern advances in processing technology, packaging and transport have gradually transformed this scenario into a global market with juice as a prime feature. The use of technical enzymes has been an essential part of the entire technology of fruit juice production from the beginning. In the early 1030s, the first step were made to process fruits into juices that could be stored for a longer time without the danger of alcoholic fermentation or other forms o undesired spoilage.

The purpose of this project is to produce a polymer additive mixture formulated by mixing a fluid solution and two types of powder. This project has a series of three 10 000-gallon tanks that will hold raw materials, one for fluid and two for powder. The tank that holds the liquid is heated with a steam jacket. A mixing tank is mounted on a rail and it moves under each tank to receive 100 gallons of the liquid ingredient and 200 pounds of each of the dry ingredient that will be mixed together to form the polymer additive.

Our group will use red apple to making the apple juice. The raw materials that have been used are fruits, water, sugar, overall flavor, organics acids (primarily citric, malic and tartaric) and etc. Also, the manufacturing process that have been included is washing(fruit reception), milling, mixing the (liquid), mash heating, enzymation, clarification, pasteurization, concentration, cooling, and filling into the bottle.

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PROCESS FLOW

Figure1: Process Flow

Apples are brought to the processing building and dumped by the truckload or out of pallet bins, into a water-filled tank.

Fruit are then spray, washed and sorted. Clean, sorted fruit are stored and inspected again before juicing or juiced immediately.

Hammer mill or grating mill used to grind the apples. Mash enzyme treatment is used for accelerating the juicing process in conjunction with

higher yields. Mash is pumped to rack and cloth press. This mash is pumped on to a hydraulic packing

press where it is squeezed with gentle pressure to thoroughly extract the juice which filters through press cloth.

The pomace are being process again to take the juice. The pasteurization process is a heating process which heats the juice to approximately 78°

Celsius. This short-term heating process eliminates bacteria without altering the natural flavor of the apple.

Filtration removes suspended solids and other high molecular solids such as proteins and starch in a temperature around 82 °C to 85 °C.

The pre-concentration phase temperature 120 ºC. Then it will concentrate again for the second time to make the juice have a smooth flow.

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PROCESS PLANT DRAWING (P&ID)

Figure 2: P&ID apple juice making process

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Process Control Drawing Description

No.

Symbol Meaning Description

1 LC Level ControllerUse at washing, enzymation, water leaching, buzzer, pasteurization, deceptinization and concentration process

2 LR Level Recorder

3 LI Level Indicator

4 TC Temperature Controller

Use at washing, enzymation, filtration and concentration process.

5 TI Temperature Indicator

6 TT Temperature Transmitter

7 PC Pressure ControllerUse at milling and extraction process.

8 PI Pressure Indicator

9 FC Flow ControllerUse at mash heating process

10 FR Flow Recorder

11 Gate Valve Use to control the flow of juice from one process to another.12 Control Valve

1. Fruit reception, milling & mash heating

The mature apples are picked from the tree, cleaning and washing the apples and send into fruit reception. Make sure the apples are mature requirement to processing. After that, apples will in milling process and through mash heating process. Equipment use in this process is fruit washing tank, temperature sensor, level sensor and clean water.

2. Enzymation

There is a hot and a cold method for enzyme treatment. In the hot method, the enzyme is mixed into juice at 54°C and held for 1 to 2 hours. In the cold treatment, the enzyme is mixed into the juice at room temperature, 20°C and held 6 to 8 hours. The enzyme activity can be monitored by adding five milliliters of juice to 15 ml of HCL-acidified ethyl alcohol, observing the mixture for 5 minutes for gel formation. No gel formation means that the depectinization has been completed. Equipment use in this process is liquid mix tank, steam jacket, temperature sensor, level sensor and valve.

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3. Extraction

Continuous plate or belt press is a press in which a layer of apple pulp is squeezed between moving vertical plates. Apple pulp with press aid added is spread on a horizontal nylon belt having a weave similar to that in press cloths used in the hydraulic press. After extraction, the water leaching (apple juice) will send into buffer and the next step process. Equipment use in this process is pressure sensor, hydraulic press and liquid mix tank and valve.

4. Clarification & Pasteurization(cloudy apple juice)

The juice passes to clarification and pasteurization for configure to remove any trub that may settle and determine the level of solid in the juice. No depectinization or filtration is required. This process will used a steam jacket to pasteurization the apple juice and mixing the liquid (sugar,acid, etc). Equipment use in this process is pasteurizer tank, level sensor, temperature sensor, pressure sensor, pump, and valve.

5. Depectinization

This process will do with by treatment that removes pectin and starch. The depectinized juice then undergoes clarification in filtration system, followed by concentration. This is done at low temperatures and with minimal residence times, to ensure juice of the best quality. The aroma recovery system is used to capture all aromas while cooling the tank of juice apple. Equipment use in this process is liquid mix tank, pump, valve and level sensor.

6. Filtration

To obtain a brilliantly clear apple juice polish filtration is necessary. Filtering freshly pressed juice is a difficult operation due to the pertinacious nature of apple juice and the potential for post filtration haze formation. Untreated juice can be rough filtered in large capacity filters with large filter areas that can be easily cleaned. The juice from this method has superior flavour and excellent body. Equipment use in this process is liquid mix tank, pressure sensor, temperature sensor and valve.

7. Concentration

In order for natural fruit juice to get converted into concentrated juice, the diluted liquid must receive a heat treatment that evaporates nearly all of the water from the naturally squeezed mixture. Once the water gets depleted from the liquid, only the flavorful contents remain behind.

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This concentrate juice then becomes more powerful through reverse osmosis. The contents get packaged, froze and stored or shipped. Equipment use in this process is liquid mix tank, steam jacket, temperature sensor, level sensor, pump and valve.

8. Packing(filling in bottle)

To ensure sterility, the pasteurized juice should be filled while still hot. Where possible metal or glass bottles and cans be preheated. Instead of heat, hydrogen or another approved sterilizing agent may be used prior to filling. The filling head meters the precise amount of product into the container and depending on the design of the package, it may immediately invert to sterilize the lid. After filling, the containers are cooled as fast as possible.

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CONTROLLER

PLC (programmable logic controller)

Omron CS1GH/H Rack PLC

Our group will be use PLC (programmable logic controller) included supervisory control and data acquisition (SCADA) system as a controller for apple juice process plan. Programmable Controller is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or light fixtures and critical infrastructures.

Earlier automation systems had to use thousands of individual relays, timers and sequencers, which had to be replaced or rewired whenever the automated process needed to change. In many cases, a programmable logic controller allows all of the relays and timers within a factory system to be replaced by a single controller. Modern PLCs deliver a wide range of functionality, including basic relay control, motion control, process control and complex networking. They also can be used in a distributed control system (DCS).

Figure 3: PLC Figure 4: Omron CS1GH/H Rack PLC

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Omron Rack PLC Series are backwards compatible with the C200H series. Offering the widest selection of I/O and special function units, high resolution, high speed, analogue data acquisition makes the Omron CS1 a universal PLC for a wide range of demanding applications.

The Omron CS1G/H rack based PLC with over 200 types of I/O units CS1 is Omron's most extensive PLC family.(Maximum capacity of 5120 local digital I/Os) Up to 7 expansion racks can be connected to a single CPU rack, brining the maximum number of I/O units to 80. Combinations made from over 200 models of digital me /Os, analogue I /Os, control units and communication units can be mounted in any order on the Omron CS1G/H. The huge instruction set of the Omron CS1G/H and function block library allow users to write very compact programs, using any mix of IEC 61131-3 Structured Text and ladder language.

Main Features:

Fast CPUs with large program capacity Extensive choice of special function units for motion- and temperature control, and

special communication processing IEC 61131-3 Structured Text programming, extensive function block libraries Compact Flash memory card slot for data storage and program exchange Easy migration from C200H systems, re-use your existing I/Os

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SENSORS AND SIGNAL CONDITIONING

Sensor

1. Capacitance Level (Level sensor)

Figure 5: Liquicap M FM151

Capacitance level sensor is detecting the level of substances that flow, including liquids, slurries, granular materials and powder. Fluids and fluidized solids flow to become essentially level in their containers (or other physical boundaries) because of gravity whereas most bulk solids pile at an angle of repose to a peak. This product will measure for continuous measurement in liquid.

Advantages:-

No calibration necessary for media with a conductivity of 100 μS/cm and higher. The probes are calibrated to the ordered probe length on leaving the factory (0 % to 100 %). This makes easy and fast commissioning possible.

Menu-guided local configuration via plain text display (optional) Universal application thanks to wide range of certificates and approvals Use also in safety systems requiring functional safety to SIL2 in accordance with IEC 61508 Material in contact with the process made of corrosion-resistant material and FDA-listed

materials for wetted parts

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Two-stage overvoltage protection against discharge from the container (gas discharger + protective diodes)

Electronics can be switched for media forming buildup

Reason:-

No need for recalibration after replacing electronics Automatic monitoring of electronics

2. Resistance temperature detectors (Temperature sensor)

Figure 6: Omnigrad M TR47

Resistance temperature detectors are RTD temperature sensor with weld in connection. Its sensors used to measure temperature by correlating the resistance of the RTD element with temperature. Most RTD elements consist of a length of fine coiled wire wrapped around a ceramic or glass core. The element is usually quite fragile, so it is often placed inside a sheathed probe to protect it. The RTD element is made from a pure material whose resistance at various temperatures has been documented. The material has a predictable change in resistance as the temperature changes; it is this predictable change that is used to determine temperature.

Characteristic:-

Fast response time High pressure resistance Surface finishing down to Ra < 0.4 µm, with or without electro-polishing Stainless steel, aluminum or plastic housing, all of them easily cleanable and IP65 at minimum

(IP68 available) Replaceable mineral insulated insert; it, installed inside the thermowell, avoids plant shut

down during the substitution or the verification of the instrument PCP (4...20 mA, with enhanced accuracy), HART® and Profibus-PA® 2-wire transmitters Pt 100 sensing element with class A accuracy (DIN EN 60751)

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Double Pt 100, for redundancy or validation purposes ATEX 1 GD EEx ia certification Material certification (3.1.B, ...) EA calibration certificate Ferrite content determination Sensor matching calibration Supplied with or without thermowell

3. Digital pH sensor

Figure 7: Orbisint CPS11D

This product is a digital pH electrode with Memosens technology for standard applications in process and environment technology. It is designed with a dirt-repellent PTFE diaphragm and a built-in temperature sensor. With ATEX, FM and CSA approval it is made for application in hazardous areas.

Advantages:-

Robust electrode requiring low maintenance due to large PTFE ring diaphragm Certified biocompatibility Application under pressures of up to 16 bar / 232 psi Long service life due to double junction system of metal lead and thus long electrode poison

diffusion path Sterilizable Process glass for highly alkaline applications available Built-in temperature sensor for effective temperature compensation Poison-resistant reference with ion trap available

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4. Conductivity sensors

Figure 8: Indumax H CLS54

Indumax H CLS54 is an inductive conductivity sensor with hygienic design specifically for applications in the food, beverage and pharmaceutical industries as well as in biotechnology. Thanks to its food-grade virgin PEEK body, its jointless and creviceless design and its hygienic certificates, it meets the extremely exacting demands of these industries.

Advantages:-

Unique hygienic design, thus no risk of recontamination With all hygienic certificates required in hygienic applications With all process connections commonly used in hygienic applications Durable thanks to encapsulated, jointless design Fast measurement with temperature response time t90 under 26 s enables safe and efficient

phase separations Insensitive to electrode soiling and polarisation thanks to electrodeless, inductive measuring

principle Suitable for application in hazardous areas

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5. Ultrasonic continuous sensor (level sensor)

Figure 9: Prosonic 8 FMU90

Ultrasonic’s sensor work on a principle similar to radar or sonar which evaluate attributes of a target by interpreting the echoes from radio or sound waves respectively. Ultrasonic sensors generate high frequency sound waves and evaluate the echo which is received back by the sensor. Sensors calculate the time interval between sending the signal and receiving the echo to determine the distance to an object.

Advantages:-

Simple, menu-guided operation with 6-line plain text display; 15 languages selectable Envelope curves on the display for quick and simple diagnosis Easy operation, diagnosis and measuring point documentation with the supplied "FieldCare"

operating program. Option: four digital inputs (e.g. for pump feedback) and one external temperature input Time-of-flight correction via integrated or external temperature sensors Linearisation (up to 32 points, freely configurable) Linearisation tables for the most common flumes and weirs pre-programmed and selectable Online calculation of the flume-/weir-flows via integrated flow curves Pre-programmed pump control routines System integration via HART or PROFIBUS DP Automatic detection of the sensors FDU9x The sensors of the series FDU8x can be connected

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6. Absolute measurement with metal sensor

Figure 10: Cerabar S PMP75

Its is Pressure transmitter with metal sensor and Overload-resistant and function-monitored; Communication via HART, PROFIBUS PA or FOUNDATION Fieldbus Advantages:-

Very good reproducibility and long-term stability High reference accuracy: up to ±0.075%, as PLATINUM version: ±0.05% Turn down 100:1, higher on request Used for process pressure monitoring up to SIL3, certified according to IEC 61508 by TÜV

SÜD HistoROM®/M-DAT memory module Function-monitored from the measuring cell to the electronics Continuous modularity for differential pressure, hydrostatic and pressure (Deltabar S,

Deltapilot S, Cerabar S), e.g.- replaceable display- universal electronic

Quick commissioning thanks to quick setup menu Menu-guided operation Extensive diagnostic functions Device versions in conformity with ASME-BPE

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Sensor Characteristics

NTC Thermistor Platinum RTD Thermocouple SemiconductorSensor Ceramic (metal-

oxide spinel)Platinum wire- wound or metal film

Thermoelectric Semiconductor junction

TemperatureRange (typical)

-100 to +325˚C -200 to +650˚C -200 to +1750˚C -70 to 150˚C

Accuracy(typical)

0.05 to 1.5 ˚C 0.1 to 1.0˚C 0.5 to 5.0˚C 0.5 to 5.0˚C

Long-termStability @ 100˚C

0.2˚C/year (epoxy)0.02˚C/year(glass)

0.05˚C/year (film)0.002˚C/year(wire)

Variable, some types very prone to aging

>1˚C/year

Output NTC Resistance-4.4%/˚C typical

PTC resistance0.00385Ω/Ω/°C

Thermovoltage10µV to 40µV/°C

Digital, various outputs

Linearity Exponential Fairly linear Most types non- linear

Linear

Power Required Constant voltage or current

Constant voltage or current

Self-powered 4 to 30 VDC

Response Time Fast0.12 to 10 seconds

Generally slow1 to 50 seconds

Fast0.10 to 10 seconds

Slow5 to 50 seconds

Susceptibility toElectrical Noise

Rarely susceptible High resistance only

Rarely susceptible Susceptible/Cold junction compensation

Board layout dependent

Lead ResistanceEffects

Low resistance parts only

Very susceptible.3 or 4-wire configurations required

None over short runs. TC extension cables required.

N/A

Cost Low to moderate Wire-wound – HighFilm - Low

Low Moderate

Table 1: Sensor Characteristic

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Sensor Advantages and Disadvantages

NTC Thermistor Platinum RTD Thermocouple SemiconductorSensor Ceramic (metal-

oxide spinel)Platinum wire- wound or metal film

Thermoelectric Semiconductor junction

Advantages • Sensitivity• Accuracy• Cost• Rugged• FlexiblePackages• Hermetic Seal• Surface Mount

• Accuracy• Stability• Linearity

• TemperatureRange• Self-Powered• No Self-heat• Rugged

• Ease of Use• Board Mounting• Rugged• Overall Cost

Disadvantages • Non-linearity• Self-heating• Moisture failures

(non-glass only)

• Lead resistance error• Response time• Vibration resistance• Size• Package limitations

• Cold-junction compensation

• Accuracy• Stability• TC extension leads

• Accuracy• Limited applications• Stability• Response time

Table 2: Sensor advantages & disadvantages

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TANK/VALVE/PIPE SIZING

Valves

1. Jacketed Ball Valves

Figure 11: Jacketed Ball Valve (Full Jacketed Ball Valve)

Jacketed ball valves for handling highly viscous materials or materials that solidify at ambient temperatures are available from Metso Automation for use with steam or other heat transfer media. These valves ensure free flow through the valve and prevent clogging when the valve is closed.

Salient Features:

High Performance Ball Valve Longer Life Positive Shut off Quick in Action No Lubrication

Compact Design Low Pressure Drop Simplicity Heating / Cooling Jackets Wide selection of Different Jacket Material

Design & Testing International Standard:

Valve Design : BS 5351 / ANSI B 16.34 / API 6D

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Pressure Testing : BS 6755 Part II / API 598 / API 6D

Face To Face : As Per ANSI B 16.10

Flange Drilling : ANSI B 16.5 / BS 10 Table / DIN / IS 6392

Size Range : ½" x 1" To 8" x 10"2. Butterfly Valves

Figure 12: Butterfly Valves

A butterfly valve is a valve which can be used for isolating or regulating flow. The closing mechanism takes the form of a disk. Operation is similar to that of a ball valve, which allows for quick shut off. Butterfly valves are generally favored because they are lower in cost to other valve designs as well as being lighter in weight, meaning less support is required

Salient Features :

Concentric, Slim-Seal Design Greater Sealing Capacity Soft Seat Design Lower Torque with any fluid Permanently tight closure Bi-Directional Valve Optimum operation under Vacuum

Condition Suitable for On-off as well as Throttling

Service Materials for almost all media Short Face To Face Dimension Wafer Design Body Long Service Life Smooth, Easy Operation Maintenance Free Version

Special Options :

Off Set Disc Design Butterfly Valve for high pressure & temperature service.

Moulded / Replaceable Seat option Gear / Pneumatic Rotary Actuator

Operated P.T.F.E. (PFA/FEP) Lined Butterfly

Valve Flanged End, Butterfly Valve Damper Type Butterfly Valve for

High Temperature Air Service Off Set Disc Design Butterfly Valve

for high pressure & temperature service

Tailor Made Valve

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Less Weight, Easy To Install

3. Safety valve

Figure 13: Safety valve

4. Glove valve

Figure 14: Glove valve

5. Gate valve

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Figure 15: Gate Valve

Tank

1. Pasteuriser Tank

Figure 16: Pasteurizer Tank

We made an extensive variety of meticulousness engineered Pasteurizers which are designed

using latest mechanisms and highly developed technology. These pasteurizers have

acknowledged incredible appreciation in the market for their robustness, performance and robust

construction.

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Technical Specifications

Rectangular tank with inclined bottom made up completely of stainless steel (SS • 304).

Function by gas burner unit

Engineered with four-leg retrenchment for impeccable balancing.

The inner liner outer shell is made up of stainless steel with 2” glass wool insulation.

Feature include high speed stirrer for the perfect blending of dry ingredients.

Incorporated emulsifier with 2-speed motor.

Regulate high temperature pasteurization at +85 oC and the low temperature

pasteurization at +65oC.

Temperature is indicated by digital temperature meter & heating medium by water.

2. SS Liquid Mixing Tank

Figure 17: SS Liquid Mixing Tan

Other details of the product:

Inner and outer mirror smooth For the stirrer shaft entry a lid with ¾ opening hinge and slot window is provided Silicon gasket ring is also provided. Handle and legs are made out of S.S. 304 pipe Caster wheel with brake system S.S. 316 ball valve provided for liquid out at bottom/ side of the vessel

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The advanced build SS Liquid Mixing Tank is accurately developed by our highly knowledgeable and well-organized engineers. These finest quality SS Liquid Mixing Tanks are made in comply with the national as well as international existing standards and norms. Our clients can avail from us this SS Liquid Mixing Tank at reasonable price to gain full client satisfaction.

3. Steam Jacket

Figure 18: GPE Steam Jacket

G.P.E. Equipment offers a complete line of stainless alloy, batch process and transfer tanks for the Food / Dairy / Beverage, Pharmaceutical, Cosmetic, and Chemical Industries. Vessel specifications can include multi-zone jacketing, vacuum pressure options, single-motion, double-motion or twin action agitators, portability, standard or special Ra and electropolish surface finishes as well as digital readouts and controls for motors and temperature. Our custom designed tanks are quality crafted to your specifications.

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4. Fruit washing tank

Figure19: Jwala Fruit Washing

Suitable for various fruits like mango, guava, apple and vegetables like potato, carrot, cucumber, beetroot, peas etc.

Complete stainless steel body and supports. Products are subject to

o Soakingo Agitationo Fresh water rinsing

Specially designed takeoff conveyor to transfer the product from the washing tank to the discharge end.

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Sturdy construction; streamlined appearance. Sanitary design and ease in cleaning. Compact unit with a wide range of capacity.

Pipe Sizing

1. Stainless Steel Seamless Pipe

Figure 20: Stainless Steel Seamless Pipe

These pipes are used in: Heat-exchangers Condenser Boiler Economizers Super-heater Pre-heater Oil coolers

SizesProducts Size / RangeHeat Exchanger Tubes 10.00 mm to 50.80 mm OD

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Instrumentation Tubes 6.00 mm to 25.40 mm ODPipes 1/8" to 6" NB

2. Stainless Steel pipe

Figure 21: Stainless Steel SUS 439 pipe

Beside these, TSA also supplies other SUS 439 products such as:-

SUS 439 Coil and SUS 439 Plate : Thickness : 0.4mm - 3.0mm (2B, 4B, HL,BA, Mirror) Thickness : 3.0mm - 6.0mm (1B)

SUS 439 Angle, Flat Bar and Rod

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Actuators1. VCB, 2 Port Solenoid Valve for Warm Water, Single Unit

Figure 22: Solenoid Valves

Series VC is a multipurpose, direct operated, 2 port solenoid valves for air. Special construction

reduces operating resistance and moving parts for improved longevity and wear resistance. A

built-in rectifier eliminates AC coil burning and buzzing. The VC enclosure is IP65 equivalent.

Fluid: heated water (99°C or less) Max. operating pressure (MPa): 3.0 Effective area (Cv): 0.16 to 2.1 Coil rated voltage: 100, 110, 200, 220, 230VAC (50/60Hz) Ambient temp: -20° to 100°C Fluid temp: 99°C or less

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2. LVM09/090, 2/3 Port Solenoid Valve for Chemicals

Figure 23: Solenoid Valve for Chemical

Series LVM is a compact, direct acting, 2/3 port solenoid valve for chemicals. The unique

construction reduces residual liquid to a minimum. Superior resistance to chemicals requires less

maintenance. Service life (based on SMC test conditions) is 10 million cycles or more.

Orifice diameter: 1.1mm Available with power-saving circuit 2 port N.C. or N.O. types; 3 port Universal type Diaphragm choice of EPDM, FKM or Kalrez® Wetted part material: PEEK (body/plate)

3. NVM800, 800 Series, 3 Port Mechanical Valve

Figure 24: Solenoid Mechanical valve

The VM series is a mechanical, poppet valve. Their compact size requires little mounting space.

The VM series offers a wide variety of actuator styles and flow capacity up to 1.0 Cv.

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Fluid: air Operating pressure: -100kPa to 1.0MPa Effective area (Cv): 6mm 2 (0.33) Ambient and fluid temperature: -5° to 60°C (no freezing) Port size (nominal size): 1/8 (6A) North American threads (NPT)

Pumps

1. Lobe Pump

Figure 25: Pumps for fruits

These pumps offer a variety of lobe options including single, bi-wing, tri-lobe (shown), and multi-lobe. Rotary lobe pumps are non-contacting and have large pumping chambers, allowing them to handle solids such as cherries or olives without damage. They are also used to handle slurries, pastes, and a wide variety of other liquids. If wetted, they offer self-priming performance. A gentle pumping action minimizes product degradation. They also offer reversible flows and can operate dry for long periods of time. Flow is relatively independent of changes in process pressure, so output is constant and continuous.

Advantages

Pass medium solids No metal-to-metal

contact Superior CIP/SIP

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capabilities Long term dry run

(with lubrication to seals)

Non-pulsating discharge

Disadvantages

Requires timing gears Requires two seals Reduced lift with thin

liquids

2. Helios Hygienic Pump

Figure 26: Hygienic pump

Polished stainless steel is used for all metal parts in contact with the product and reliable operation and reduced downtime is further enhanced by the inclusion of a sealed pin joint.

Capacity Pressure Temperature

m³/hUp to 180

bar Up to 24 °C -10 up to 100

gpm Up 660 psi Up to 347 °F 14 up to 212

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ESTIMATION COST

In view of size of the market and the ensure economic viability of the project, rated production capacity of 150 tons per year with 2 shift working and 300 working days in advisable.

Item Qty Price(RM)

Fruit Washing Tank 2 10 000Juice Extractors 2 85 000Steam Jacket Kettles 2 40 000Stirrer 1 15 000Boiler 1 60 000Bottle Washing and Filling Machine 1 75 000Testing Equipment 2 30 000Jacketed Ball Valves 5 15 000Stainless Steel Seamless Pipes 1 3 000SS Liquid Mixing Tank 1 6 000Pasteuriser Tank 1 7 000Butterfly Valves 3 2 000LVM09/090, 2/3 Port Solenoid Valve for Chemicals 3 1 200VCB, 2 Port Solenoid Valve for Warm Water, Single Unit 3 1 150

Absolute measurement with metal sensor 3 2 000

Ultrasonic continuous sensor (level sensor) 4 4 500

Conductivity sensors 1 1 000

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Digital pH sensor 2

Resistance temperature detectors (Temperature sensor) 3 2 500

Capacitance Level (Level sensor) 5 3 000

NVM800, 800 Series, 3 Port Mechanical Valve 1 1 700Lobe pumps 4 4 000Safety valves 1 2 000Globe Valves 1 1 300Gate Valves 2 1 400Stainless Steel pipe 1 7 010Helios Hygienic Pump 4 5 400

TOTAL RM 384,160.00

CONSTRAINT

A constraint is anything that prevents the system from achieving more of its goal. There are a few constraints in this plant. The internal constraints are:

Equipment use is overestimates (more cost required) Equipment use is underestimates (lack of efficiency) Insufficient technical knowledge for the high technology equipment, Insight from real plant engineer Process instruction limited the availability of idea Not enough engineering software to support the project

The chance to do this assignment is very useful for us to get to know the real plant process. This is because we use the actual equipment that is used there in the plant.

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CONCLUSION

Conclusion from this plan is we know how to build a plan process using a technical process like

electrical, mechanical and electronic part. To build a plan processing needs to know the

characteristic of the equipment like sensors and etc. Process of cloudy apple juice need to do

twice process and enzymation because it does can be effective. Also using a steam jacket it’s can

be save time and The temperature in the jacket can be controlled much more accurately with hot

water than with steam.

From the sensor selection we had learned a lot of type of sensor that are available in the market

and how to select the correct sensor based on the application. Furthermore, we also learned how

to use the sensor and how to calibrate it.

From the software selection, we can say that we had managed to learn a lot of latest software

such as CX-Programmer for PLC, P&ID software, and others. Based on that software we were

managed to develop the smart and efficient soap production process plant as we desired. Besides,

this software helps us to run our project smoothly and the duration of our project become lesser

as we don’t have to worry about the time chase anymore.

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REFERENCES

http://www.engineersgarage.com/articles/what-is-level-sensor?page=4

http://www.engineeringtoolbox.com/valves-types-d_218.html

http://www.alfalaval.com/industries/food-dairy-beverages/Documents/Juicy%20apples.pdf

http://www.fao.org/docrep/005/y2515e/y2515e15.htm

http://www.elibrary.dep.state.pa.us/dsweb/GetRendition/Document-48902/html

http://www.westfalia-separator.com/applications/beverage-technology/fruit-and-vegetable-juices/citrus-juices.html

http://www.tepsmarttech.com/turnkey-projects/fruit-juice-plant.html

http://www.dylanwelsh.org/food-processing-plants.html

http://www.endress.com/eh/home.nsf/#page/id/1B0C22334F927D3AC12577C900686598

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