Food Plant Design and Pilot Demonstration University of Agriculture, Abeokuta Department of Food Science and Technology Course guide on Food Plant Design and Pilot Demonstration (FST 409)

Synopsis Concept of a food plant Plant design concepts Definitions Process design Optimal design principles Sanitary design General appreciation of the food industry and various plant facility need Design principles Feasibility study Site selection Plant economics and profitability

Concept of a Food Plant Food plant as physical entity Conversion processes in a food plant Energy consumption and cost Waste generation Human expertise need Life cycle of a plant

Plant design concepts Design as an idea generation exercise Fitness to a purpose Enormity of task depends on the intended scale of operation of the plant Food Plant design as a multidisciplinary project Coordinated by a Food Engineer/Food Technologist Team may involve all or some of the following: Civil, Engineer, Mechanical Engineer, Electrical Engineer, Accountants, Architects, Quantity Surveyor, Economists, etc.

Definitions Food process Process simulation Process optimization Process instrumentation and control Food plant sanitation

Stages in plant design Inception Preliminary evaluation of economics and market Development of data necessary for final design Final economic evaluation Detailed engineering design Procurement Erection Startup and trial runs Production

The Food Industry The producers The processors The marketers The consumers

Plant Design Principles Material Flow Sanitary Design Site Location Design for People

Feasibility studies Types, definitions and goals: Technical Economic Viability of a project

Issues in Technical Feasibility Study Raw material requirement Labor requirement Equipment and facility requirement Technology Process flow Facility construction and material suitability Land suitability Climatic consideration Energy and utilities Transportation

Issues in economic feasibility Projected expenditures on the design project Capital Recurrent Projected incomes Sales Services Projected profits Time value of money

Plant economics Asset values Initial value Salvage value Scrap value Present value: book value market value replacement value

Plant economics contd. Types of depreciation: Physical Functional Depletion Purpose of depreciation cost Methods of calculating depreciation: Straight line Declining balance Sum-of-the-year-digit Sinking fund Present worth

Plant economics contd. Profitability defined Profitability evaluation methods: Rate of return Discounted cash flow Net present worth Capitalized costs Payout period