Chocolate Covered Cookies

Bell Ringer When handling food at your house, what are some safety precautions you always take? How do you handle the food while preparing it? (Example: Always wash your hands before touching food) When you receive a box that is labeled, “some assembly required,” what will you look for when you open the box?

What is Chemical Engineering? The branch of engineering that deals with the application of chemistry, biology, physics, and mathematics, to the process of transforming raw materials or chemicals into more useful or valuable forms (i.e. soaps, detergents, shampoo, skin lotion, cosmetics, etc...) One of the areas within ChE is Process Design and trying to figure out how to make large quantities (batches) of a product. Why would someone want to make large batches? Key words: Transforms chemicals into more valuable products in large quantities.

Good Manufacturing Practices In many processes, companies are required to use Good Manufacturing Practices (GMPs), which provide guidance for manufacturing, testing, and quality assurance in order to ensure that a product is safe for use.

Good Manufacturing Processes

GMPs and Key Performance Indicators

GMP Examples These are a few examples of common GMP guidelines: Must maintain a clean and hygienic manufacturing area Controlled environment to prevent cross contamination of food All critical processes must be validated, or checked, to ensure consistency Instructions and procedures are written in clear language Operators are trained to carry out and document procedures Manufacturing records are made to enable the complete history of a batch to be traced Complaints about products are examined, causes of quality defects are investigated, and appropriate measures are taken For each of these GMP guidelines, ask your students why they are important, and what could be the ramification if they aren’t implemented properly.

Process Flow Diagram A process flow diagram shows all of the steps of a process in sequential order including all of the inputs and outputs.

Unit Operations Each step of the Process Flow can be linked to a UNIT OPERATION. A unit operation is a basic step in a process. Unit operations involve a physical change or a chemical transformation. Example: In Milk processing, homogenization, pasteurization, chilling, and packaging are unit operations that make up the Process Flow Diagram. In chemical engineering and related fields, a unit operation is a basic step in a process. Unit operations involve a physical change or chemical transformation such as separation, crystallization, evaporation, filtration, polymerization, isomerization, and other reactions. For example, in milk processing, homogenization, pasteurization, chilling, and packaging are each unit operations which are connected to create the overall process. A process may require many unit operations to obtain the desired product from the starting materials, or feedstocks. from wikipedia.

Unit Operations of the Process Flow Diagram for Milk

Process Flow Diagram

Process Flow Diagram It doesn’t have to be that complex!

Process Flow Diagram If you understand the simple ones, it will help you understand the more complicated ones! You put Toluene (C7H8) and Hydrogen (H2) in a reactor. After those have combined according to a specific procedure, the resulting product goes into a gas separator. The gas separator will then use some method (likely heat or water/air cooling methods) to separate the input to form C6H6 as an output and send the liquid portion into a still. The liquid portion then goes through the still (which is another method of separating) with the output being Benzene (CH4). Ask the class: So what are the two inputs? Toluene (C7H8) and Hydrogen (h2) What are the two final outputs? Mixed gases (C6H6) and Benzene (CH4) How many unit operations happened to get the final output? Three...reactor, gas separator, and distillation (ie still, ie another form of separation)

Chocolate! The process of taking cocoa beans and making chocolate is likely more complicated than you thought. With a partner, take two minutes and discuss the steps below. What does each step do, and what kind of machinery is needed for each?

Chocolate! Chemical Engineers are tasked with taking small-scale operations and upscaling them. For example, here is a video on how chocolate is made from scratch in bulk.