IV Year B.

Tech Food Technology I - Semester

FOOD PLANT DESIGN AND LAYOUT

UNIT – I
Introduction : Plant design concepts - situations giving rise to plant design problems - general design
considerations - differences in design of food processing and non-food processing plants. Feasibility study :
Steps involved including planning of the study - collection of information - information flow diagrams - market
analysis, technical analysis and preparation of feasibility report. Plant location : Factors affecting plant location,
their interaction with plant location, theory models for evaluation of alternate locations. Plant size : Economic
plant size - factors affecting the plant size - raw materials availability, market demand, competition in the
market - return on investments. Procedures for estimation of economic plant size - break even analysis and
optimization techniques - estimation of volume of production for each product - in case of more than one
product that will maximize profits. Process scheduling

UNIT – II
Plant layout : considerations involved in planning an efficient layout. Types of layouts. Equipment symbols -
flow sheet symbols - electrical symbols - graphic symbols for piping systems including pipe fitting and valves.
Standards for space requirements - distances between critical plant areas and for setting different plant facilities.
Development of the pilot layout : Size and structure of the pilot plant, minimum and maximum size, types and
applications, pilot plant design. Engineering Economy : Definitions : Time value of money, inflation, Interest,
Interest rate, compound interest, rate of return, payment, receipt , cash flow, present value, Equivalence, sunk
costs, opportunity costs, Asset, Life of an asset, depreciation, book value of an asset, salvage value, retirement,
replacement, defender and challenger. Methods of economic evaluation of engineering alternatives
1. Undiscounted cash flow methods -pay back period method
2. Discounted cash flow methods
a) Net present value method
b) Equivalent annual method
c) Rate of return method
Cost- benefit analysis, Social costs, social benefits

UNIT – III
Linear Programming:Introduction, Salient features of Linear programming (Terminology), Formulation of linear
programming model, Advantages, limitations and applications of linear programming, solution of linear
programming problems. Linear Programming:Introduction, Salient features of Linear programming
(Terminology), Formulation of linear programming model, Advantages, limitations and applications of linear
programming, solution of linear programming problems. Queuing theory : Introduction, Elements of queuing
system, 1) Input source, 2) Queue and 3) Service mechanism. Queuing theory : Introduction, Elements of
queuing system, 1) Input source, 2) Queue and 3) Service mechanism. Common problems in plant layout :
Service system layout problem, Manufacturing layout
problem, Warehouse layout problem, Nontraditional Layout problem.

UNIT – IV
Selection of equipment : Process equipment - material handling equipment – service equipment- valves and
fittings - instruments and controls- considerations involved in equipment selection. Estimation of Services and
Utilities : Utilities : Fuel oil cost, Natural gas cost, electricity cost, steam cost, cooling water cost, Refrigeration
cost, waste treatment cost. Estimation of Services such as Cafeteria, locker rooms, water closets, sinks, parking
lots, exercise area. Office Layout. Line Balancing and Line balancing techniques. Materials of construction of
Building / structure and Equipment : Building and Structure :Foundations, supporting structure, walls, Floors,
Slope of Floors, Doors, piping, Electrical, Ventilation, Hand - Cleaning - Stations.

UNIT – V
Materials of construction of Equipment : Characteristics of suitable construction material : Stainless steel,
Aluminum, Nickel and Monel, Plastic Materials. Materials of construction of Equipment : Characteristics of
suitable construction material : Stainless steel, Aluminum, Nickel and Monel, Plastic Materials. Maintenance of
Food Plant Building : Safety Color Code, Roof Inspection, Care of Concrete floors Color Coding : Color - Code
System - Specific Hazards Color codes for buried pipes and cablesColor Scheme for pipes. Illumination and
ventilation. Cleaning & sanitization Painting and colour coding and Fly and insect control.
References
1. M Moor, Mac Millan, Plant Layout & Design. Lames, New York.
2. H.S. Hall & Y.S. Rosen, Milk Plant Layout. FAO Pubs, Rome.
3. F.W. Farrall, Dairy & Food Engineering. John Willy & Sons, New York.
4. Food Plant Design by Antonio López. Gómez,
5. Food plant engineering systems by Theunis C. Robberts, CRC Press, Washington
6. Food plant economics by Zacharias B. Maroulis and George D. Saravacos published by
Taylor and Francis Group, LLC
7. Fundamentals of Production Systems Engineering, G.S.Sekhon and A.S.Sachdev, Published
by Dhanpat Rai and Company Private Limited, Delhi (Chapter NO. 19)
8. Operations Research by Manohar Mahajan, Published by Dhanpat Rai and Company Private
Limited, Delhi
9. Food Process Design by Zacharias B. Maroulis published by Marcel Dekker, Inc , Cimarron
Road, Monticello, New York 12701, U S A