JIMMA UNIVERSITY

INSTITUTE OF TECHNOLOGY
Department of Architecture and Urban Planning

Coordinated Design III

Overall Design Work Report:

Coffee Roasting Industry

Advisor – Ar. Bruk H.

Instructors – Biruk H. Gelila, Dejene B., Tigist Y., Yared & Mikias M.

Student’s name – Kaleab Demissie, RU2345/08

Biniam Neway, RU0400/07

March 12, 2020 G.C.

Jimma Ethiopia
 Abstract
This Feasibility Study Report was prepared for Jimma city industrial development to evaluate
potential growth area of the city and address its physical condition such as background of the
site, available raw materials, human resources, Market study and etc. in order to formulate an
idea of what can be developed on the site with the main site selection and industry selection
criterion.
Table of Contents
Abstract.......................................................................................................................................I

List of Tables...........................................................................................................................IV

List of Figures...........................................................................................................................V

1. Chapter One– Feasibility Study.........................................................................................6

1.1 Introduction.................................................................................................................6

1.1.1 Purpose of the study.............................................................................................6

1.1.2 Project Selection...................................................................................................6

1.1.3 Project Selection Criteria.....................................................................................7

1.1.4 Coffee production.................................................................................................7

1.2 Technical Study...........................................................................................................8

1.2.1 Materials and Inputs.............................................................................................8

1.2.2 Technology and Engineering...............................................................................9

1.2.3 Organization and Manpower................................................................................9

1.3 Market Study.............................................................................................................10

1.3.1 Data analysis (Farmers Selling Per Year)..........................................................10

1.3.2 Calculation for the Products...............................................................................10

1.4 Conclusion.................................................................................................................10

2 Chapter Two – Literature Review Summary...................................................................12

2.1 Summary....................................................................................................................12

2.2 Program.....................................................................................................................12

2.2.1 Delivery, Unloading & Storage..........................................................................12

2.2.2 Production Room...............................................................................................12

2.2.3 Supportive Buidings and spaces.........................................................................12

2.2.4 Packaging...........................................................................................................13

2.2.5 Assisting Spaces.................................................................................................13

3 Chapter Three – Case Study.............................................................................................14

 3.1 INTERNATIONAL CASE STUDY OF INDUSTRIAL BUILDINGS...................14

3.1.1 BC Passive House Factory.................................................................................14

4 Chapter Four – Site Analysis...........................................................................................18

4.1 Location.....................................................................................................................18

4.2 Physical and Natural Feature of the Site...................................................................18

4.3 Bubble Diagram.........................................................................................................18

4.4 Concept Development...............................................................................................19

4.5 Overall Design...........................................................................................................19

4.5.1 Site Plan.............................................................................................................20

4.5.2 Site Sections.......................................................................................................20

4.6 Building Designs.......................................................................................................21

4.6.1 Main Production Room......................................................................................21

4.6.2 Admin Building..................................................................................................22

4.6.3 Laboratory..........................................................................................................22

4.6.4 Ware House........................................................................................................23

4.6.5 Clinic Building...................................................................................................24

4.6.6 Cafeteria Building..............................................................................................25

4.6.7 Toilet Facility.....................................................................................................26

4.6.8 Details................................................................................................................27

5 References........................................................................................................................29
 List of Tables
Table 3-1 Marketing analysis on Farmers & labors cost Expense................................................10
Table 3-2 Product Cost Estimation................................................................................................10

List of Figure
Figure 1-1 W140A Coffee Roaster (latest Roasting Technology).............................................9
Figure 2-1 Supply Chain in Coffee Roasting\..........................................................................12
Figure 3-1Passive House Factory.............................................................................................14
Figure 3-2The program includes the factory floor, mezzanine office and a showroom..........14
Figure 3-3The showroom and office areas are constructed to the Passive House Standard....15
Figure 3-4The super-insulated walls are of vapor-open construction & Interior of factory....15
Figure 3-5Abundant daylight and exposed wood finishes give the interior a warm and
inviting quality & the central line of columns reduces the depth and cost of the roof structure
..................................................................................................................................................16
Figure 3-6the roof panels sit on ledgers attached to the glulam beam.....................................16
Figure 3-7Partial building section: the CLT wall panels span two structural bays, and are
staggered to improve diaphragm action...................................................................................17
Figure 3-8clerestory windows on all sides offer panoramic views of the mountains..............17
Figure 3-9Prefabricated wall panel with fir and larch slats.....................................................17
Figure 4-1 Site Location...........................................................................................................18
Figure 4-2Physical & Natural features of the site....................................................................18
Figure 4-3 Concept Development............................................................................................19
Figure 4-4 Overall Site Render................................................................................................19
Figure 4-5 Site Plan..................................................................................................................20
Figure 4-6 Sections..................................................................................................................20
Figure 4-7 Floor Plan, Elevation & Section of Main Production Building.............................21
Figure 4-8 Admin Building......................................................................................................22
Figure 4-9 Laboratory Building...............................................................................................22
Figure 4-10 Workshop Building Renders................................................................................23
Figure 4-11 Cafeteria Building Floor Plans.............................................................................24
Figure 4-12 Elevations of Cafeteria Building..........................................................................24
Figure 4-13 Clinic Building Render.........................................................................................24
Figure 4-14Cafeteria Building Render.....................................................................................25
Figure 4-15Toilet Floor Plan....................................................................................................26
Figure 4-16 Toilet Building Render.........................................................................................26
Figure 4-17 Connectors and Connection..................................................................................27
Figure 4-18 Truss Details.........................................................................................................28
 1. Chapter One– Feasibility Study
1.1 Introduction
1.1.1 Purpose of the study
This feasibility study provides data about the city to select a preferred an industrial
development alternative which will be described in a Proposed Plan in order to select the
appropriate industrial sector which is beneficial for the city and improve the social and
economic growth of the district.

1.1.2 Project Selection

Jimma is one of the biggest and most important towns in Ethiopia and served as a significant
market center in the area of South-West Ethiopia from the 19th century, most notably in the
Gibe Valley.

In the market of Jimma there are sections for handicrafts, agricultural goods, and livestock
products. The most common items in the local market are grains and flour, coffee, honey,
livestock and livestock products, handicraft products such as baskets, chairs, etc. Which
could be transformed in to a large-scale production. Currently most of the commercial
operators in Jimma engaged in industry are (31.7%), trade (26.8%), and services (22%). This
showed that the city economic activity mainly depends on and occupied by industries and
trades. The rest were engaged in construction (12.2%) and urban agriculture (7.3).

Under industry building design there are well known factories in our country, which are
Textile, Leather, Plastic, Paper, Coffee etc... Since Ethiopia is the birthplace of coffee and
there is a huge resource supply in Jimma, it has an opportunity of a higher demand &
Consumption for Coffee Processing Industry. More than 1,000 years ago, it is vital to the
cultural and socio-economic life of Ethiopians and contributes 25%-30% of the country's
foreign exchange, half of the GDP, 90% of exports, 85% of total employments in the country
and part of the culture; about 50 % of the produced coffee is consumed domestically.
[CITATION Deme \l 1033 ] Because of these reasons, We have selected coffee processing
factory.

Coffee production in Ethiopia is a longstanding tradition, which dates back to dozens of

centuries. Ethiopia is where Coffee arabica, the coffee plant, originates. The plant is now
grown in various parts of the world; Ethiopia itself accounts for around 3% of the global
coffee market. Coffee is important to the economy of Ethiopia; around 60% of foreign
income comes from coffee, with an estimated 15 million of the population relying on some
aspect of coffee production for their livelihood. In 2006, coffee exports brought in $350
million, equivalent to 34% of that year's total exports.

1.1.3 Project Selection Criteria

- Coffee is loved by the peoples in the world which is a Higher Demand
- Profitable fund for the supply and demand in industries.
- Availability of coffee plant and production.
- Coffee production is a major source of income
- Farmers and countries can increase the revenue from coffee.
- Job provision for unemployment and labors.
- Setup the Association of coffee bean suppliers.
- Opportunities and motivation for broader Coffee Farm.
- Enough distribution to any environment.

1.1.4 Coffee production

Coffee production is the industrial process of converting the raw beans of the coffee plant
into the finished coffee or coffee powder. Coffee production is a major source of income,
especially for developing countries where coffee is grown. By adding value, processing the
coffee locally, coffee farmers and countries can increase the revenue from it. The main
services of a coffee industry can be:

- Roasting

- Grinding

- Packaging &

- Distributing

Roasting is the most essential part in coffee processing; the desired aroma and flavors of
coffee are developed in the process. During this process, the beans undergo a series of
reactions leading to the changes in physical properties and chemical composition. It is
important to control the roasting process, and stop the process when the aromas have fully
developed and the color of the coffee is homogeneous throughout the whole bean. Therefore,
a method to evaluate the coffee roasting doneness in real-time is necessary. Many studies
have been done to evaluate the quality of roasted coffee experimentally using different
parameters such as aroma, flavor, color, bean temperature, pH, and chemical composition.
However, these techniques could not be implemented in real-time and have their own
limitations.

The main products will be:

- Roasted Coffee beans

- Flavored Coffee Product
- Grinded & Packed Coffee

Work process in the Factory will be

1. buying coffee beans from farmers 7. Stored in bags

2. Sorting 8. Roasting
3. Milling 9. Grinding
4. Drying 10. Instant coffee
5. Parchment removal 11. Distribution
6. Grading

1.2 Technical Study

1.2.1 Materials and Inputs
The main raw material for coffee processing plant is pre-cleaned green coffee. The major
producing regions are Oromia and SNNP Region of the country. The plant receives
precleaned green coffee from cooperatives of primary producers. The pre-cleaned coffee is
processed in to value added products to be exported and consumed locally. The annual plant
green coffee consumption is 28,439.57 tons of un-cleaned coffee. The unite price of
uncleaned coffee is Birr 103,125.00 (One hundred three thousand one hundred twenty-five
Birr) and the total annual raw material cost of the coffee processing plant is Birr
2,932,830,446.60 (Two billion nine hundred thirty-two thousand four hundred forty-six Birr
and sixty cents). The auxiliary materials required by the plant are chemicals used for coffee
decaffeination process and packaging materials. The other inputs of the plant are electricity,
water and lubricant oils. The annual packaging material is Birr 16,139,000. The utilities used
by the envisaged plant is electricity, cost of utility is Birr 71,097,478.00 (Seventy-one
thousand ninety seventy thousand four hundred seventy eighty), out of which USD 29,661.58
(Twenty-nine thousand six hundred sixty-one USD and fifty-eight cents). [CITATION Min15
\l 1033 ]
1.2.2 Technology and Engineering
The major process of value-added coffee processing plants is: coffee cleaning, roasting,
grinding, coffee extract and instant coffee processing. Accordingly, the major technology and
machinery required for the envisaged plant is coffee pre-cleaning and storage, coffee roasting
and grinding, coffee extraction and instant coffee plant and utility equipment. The latest
available machine for coffee roasting Process is “W140A Coffee roaster” with a capacity of
140kg per Batch & can roast up to 560 kg/hr.

Figure 1- 1 W140A Coffee Roaster (latest Roasting Technology)

The total cost of process plant machinery and equipment including utility equipment,
mechanical and electrical workshops, vehicles, and lab equipment is Birr 674,744,259.65,
9,450,000.00, 13,500,000.00 & 269,897.70, respectively. The total cost of building and civil
work and office furniture and equipment is Birr 90,768,925.00 and Birr 2,109,830,
respectively.[ CITATION Min15 \l 1033 ]

1.2.3 Organization and Manpower

The organizational structure of the envisaged plant is constructed considering the extent of
the industry. The plant structure follows the functional organizational structure approach to
achieve operational efficiencies within a group. The plant has four functional departments
and two services. The functional departments are namely: production and technique
departments, commercial department, finance department and human resource and
administration departments. The two services are Planning and IT services and Internal Audit
service. The project will have 122 employees with annual cost of salary at full capacity
operation is estimated to be Birr 17,135,348.00, including training expenses of Birr
1,173,654.00.[ CITATION Min15 \l 1033 ]

1.3 Market Study

1.3.1 Data analysis (Farmers Selling Per Year)
Table 1-1 Marketing analysis on Farmers & labors cost Expense

Minimum Maximum
let for 1 day = l ton, Let for l day = 2ton,
1 year = 12month x 30days(1ton) = 360ton 1 year = 12month x 30days(2ton) = 720ton
so, for one year 360-ton coffee beans so, for one year = 720-ton coffee beans

General market system of green coffee in birr of l kg = 70 birr

Coffee beans directly from Farmers of 1kg = 30 birr
l quintals = 100kg so,
1qun=3000birr, 1ton=30,000birr
Minimum coffee bought Maximum coffee bought
360 ton = 10,800,000birr 720 ton = 21,600,000birr

In 1 year =10,800,000birr up to 21,600,000birr

For buying coffee from farmers
Min Labor Salary Max Labor Salary
20 Labors a day 40 labors a day
1 labor = 50 birr/day 1 labor = 100 birr/day
Therefore 50x20 Therefore 100x40
= 1000 birr/day for labor = 4000 birr/day for labor
2 labors/quintal 2 labors/quintals
Payment = 1000 up to 4000 birr per day for labors

1.3.2 Calculation for the Products

Table 1-2 Product Cost Estimation

Let say for the Roasted Product

1kg pack of Roasted beans = 130br only
From l ton = pure 9quintals after processing
900 pack of roasted coffee beans x = 117,000 birrs
130birr
1.4 Conclusion
The project will create direct employment opportunities for about 134 persons. Furthermore,
it creates a conducive environment for the rapid growth of service and trade sectors around
the project site of Jimma which in turn create employment opportunity for a substantial
number of persons. Moreover, the project will also create backward linkages with the
agricultural sector.
 2 Chapter Two – Literature Review Summary
2.1 Summary
In this section a study is made related to Standards to follow for Industrial (Site Layout,
Structural planning grids, Ventilation and Heating, Natural lighting, Noise control, Waste
Removal, Planning for Fire Control, Site planning, …) & Detail Knowledge about coffee
roasting in Industrial Scale.

Figure 2-2 Supply Chain in Coffee Roasting\

2.2 Program * Digital Monitoring Desk

* Manual Weigh & Input Machine
2.2.1 Delivery, Unloading &
* Manual Storage Can
Storage
* Conveyors
- Truck Parking & Rotating Space - 810
- Grinding Space - 150 m2
m2
* Pallet Racks
- Unloading Space - 100 m2
* Weighing Machine
- Screening Storage (Static) - 120 m2
* Screening Hopper
- Record Room - 28 m2
* Conveyor Machine
- Green Storage - 150 m2
* Silo
2.2.2 Production Room * Vacuum loader motor
- Roasting Space - 150 m2
* Hopper & Rotation Drum
* Conveyors
2.2.3 Supportive Buidings and - Extension - 5000 m2

spaces - Circulation (30%) - 3000 m2

2.2.4 Packaging
- Administration - 473m2 - Packaging Room - 225 m2
- Cafeteria - 220 m2 * Packaging Machine
- Training Centre - 55 m2 * Consignment Machine
- Power Station - 107 m2 * Belt Conveyors
- Toilet Facility - 50 m2 * Fork Lift Truck
- Emergency Clinic - 84 m2 - Packed Product Storage - 145 m2
- Waste Disposal & Recycling Plant - 130
2.2.5 Assisting Spaces
m2
- Laboratory - 250 m2
- Security House - 20 m2
- Utility Room - 15 m2
- Garage - 375 m2
- Security Monitoring Room - 22 m2
- Plaza - 2580 m2
- Changing Room - 30 m2
- Parking for the office - 225 m2
- Supervision Office - 15m2
- Experimentation Farm - 2500 m2

Total Area
No Space type
with Circulation

1 Indoor 2400 m2

2 Outdoor 14600 m2

3 Gross 17,000 m2

2.2.6
 3 Chapter Three – Case Study
3.1 INTERNATIONAL CASE STUDY OF INDUSTRIAL BUILDINGS
3.1.1 BC Passive House Factory

Figure 3-3Passive House Factory

 Client: BC Passive House

 architect: Hems worth Architecture
 structural engineer: Equilibrium Consulting
 Engineered Wood supplier: Structural Mass Timber Corp.

The design of this factory in BC’s spectacular Pemberton Valley reflects the quality of the
components it produces: prefabricated wood roof, wall and floor panels for high performance
buildings.

The structure, parts of which meet the Passive House standard for energy conservation, was
constructed at a cost comparable to that of a traditional tilt-up concrete building.

Figure 3- 4The program includes the factory floor, mezzanine office and a showroom.

Located in Pemberton, BC, this 15,000-square-foot manufacturing facility was completed in

2014. It comprises a large high-bay workshop, a mezzanine office area and a small showroom
all contained within a single rectangular volume. BC Passive House (BCPH) grew out of co-
owner Mateo Duffield’s previous construction company that built Canada’s first Passive
House structure, known as Austria House, for the 2010 Winter Olympic Games in
Whistler.

Figure 3-5The showroom and office areas are constructed to the Passive House Standard

Figure 3-6The super-insulated walls are of vapor-open construction & Interior of factory
Figure 3-7Abundant daylight and exposed wood finishes give the interior a warm and inviting quality & the central line of
columns reduces the depth and cost of the roof structure

o The roof assembly consists of on-site prefabricated panels

framed with 2x10-inch solid sawn members and sheathed
with plywood.
o Dimensionally consistent and easy to secure, the roof
panels kept the structure square and stable during the
erection process, eliminating the need for additional
bracing.
o The exterior walls are made from solid spruce/pine/fir
(SPF) cross-laminated timber (CLT) panels laid
horizontally. The 20-foot column spacing was chosen to
optimize the use of CLT, which is manufactured to a Figure 3-8the roof panels sit on
ledgers attached to the glulam beam
maximum length of 40 feet.
o The CLT panels are exposed on the interior of the building, creating a warm,
comfortable, and inspiring workspace. Above the CLT, a continuous clerestory wraps
 around all four sides of the building. This provides an unprecedented level of
natural light that changes in character as the day progresses. It also means that the
workers have views to the mountains in all directions.
o The roof assembly consists of on-site prefabricated panels framed with 2x10-inch solid
sawn members and sheathed with plywood. Dimensionally consistent and easy to
secure, the roof panels kept the structure square and stable during the erection
process, eliminating the need for additional

Figure 3-9Partial building section: the CLT wall panels span two structural bays, and are staggered to improve diaphragm
action

Figure 3-10clerestory windows on all sides offer panoramic views of the mountains

o The building exterior is finished in horizontal 2x4- inch fir

and larch boards, chamfered on two edges and pre-
assembled into panels. The boards were laid up in a
jig, enabling then spacing between boards to be varied in a
controlled manner. Vertical backing members were then
attached to facilitate installation of the panels. Figure 3-11Prefabricated wall panel
with fir and larch slats
 4 Chapter Four – Site Analysis
4.1 Location

Figure 4-12 Site Location

4.2 Physical and Natural Feature of the Site

Figure 4-13Physical & Natural features of the site

4.3 Bubble Diagram

4.4 Concept Development
The concept is based on the Phrase “Cultural Hierarchy” it represents a system of which
things are placed in a series of levels with different importance or status. It is directly
implemented by the size and placement of buildings from course to grain that exemplifies the
process of coffee ceremony in Ethiopian culture and It is applied on site with the aim of
creating a conjoined and dynamic industrial design. It is a design that initiates people to work
together through highly productive and changing work environment.

Details
To design a community which simplifies lives by sharing resources and minimizing impact
upon the environment. This design will promote sense of place and community by providing
many opportunities to interact with each other

Figure 4-14 Concept Development

4.5 Overall Design

Figure 4- 15 Overall Site Render

4.5.1 Site Plan

Figure 4-16 Site Plan

4.5.2 Site Sections

Figure 4- 17 Sections
4.6 Building Designs
4.6.1 Main Production Room

Figure 4-18 Floor Plan, Elevation & Section of Main Production Building
4.6.2 Admin Building

Figure 4-19 Admin Building

4.6.3 Laboratory

Figure 4-20 Laboratory Building

4.6.4 Ware House

Figure 4-21 Workshop Building Renders

4.6.5 Clinic Building

Figure 4-22 Cafeteria Building Floor Plans

Figure 4-23 Elevations of Cafeteria Building

Figure 4-24 Clinic Building Render

4.6.6 Cafeteria Building

Figure 4- 25Cafeteria Building Render

4.6.7 Toilet Facility

Figure 4-26Toilet Floor Plan

Figure 4-27 Toilet Building Render

4.6.8 Details

Figure 4-28 Connectors and Connection

Figure 4- 29 Truss Details
 5 References
Ministry of Industry,. (1/2/2015). Summary Feasibility Studies for Selected Sub sectors.
ADDIS ABABA: MOI.

Demelash Teferi (Plant Pathologist), Kalifa Nasiro (Coffee Breeder), Melaku Addis
(Breeder). (2019 GC). COFFEE & TEA RESEARCH. Retrieved from Jimma
Agriculture Research center: http://www.eiar.gov.et/jarc/index.php/jarc-
research/coffee-and-tea-research