FEDERAL POLYTECHNIC NEKEDE

P.M.B 1036 OWERRI,

IMO STATE.

PLANT DESIGN
ON

FRANKFURTER PLANT

BY

NAME: UKASOANYA CHINWENDU MIRIAM

REG. NO: 22BH/0159/FT

DEPT: FOOD TECHNOLOGY

LEVEL: HND II (EVENING)

COURSE TITLE: EQUIPMENT & PLANT PROCESS DESIGN

COURSE CODE: FST 412

LECTURER: ENGR. ARINZE & MR. CHIBUIKE NJOKU

DATE: APRIL, 2024

1
 DEDICATION

This research work is dedicated to the almighty God for his divine grace and mercy

upon my life in my academic pursuit.

2
 ACKNOWLEDGEMENT

I acknowledge the presence of God in my life, for his mercies and blessings. I say

thank you Jesus. I humbly acknowledge my lecturer, Mr. Chibuike Njoku for his

teachings and instructions as regards to engineering principles. I also acknowledge

my parents for their love and care in all rounds. I will not forget to acknowledge my

brothers, sisters and friends for their love and care towards me not withstanding all

the storms of life. I pray may God continue to shower his blessings on you all

Amen.

3
 EXECUTIVE ABSTRACT

Frankfurter is a parboiled sausage that is either made with pork or wrapped in a

casing. This study demonstrates the processing of frankfurter and extends its
convenience use. The experiment was carried out which include heat and mass
transfer coefficient, piping and instrumentation, material and energy balance,
equipment design specification and costing of the equipment, economic analysis
and plant location and layout, on the frankfurter production plant and design. The
plant will be situated at Imo state with a total investment capital N438,620, 3299,
rate of return 80% and payback period of 5year. Detailed economic studies showed
that the production of Frankfurter would be economically viable in Nigeria when
the product is sold at N1500 per 100mg provided a minimum scale of 85% is used.

4
TABLE OF CONTENTS

Title page

Certification

Dedication

Acknowledgement

Executive Summary

Table of contents

CHAPTER ONE

1.0 Introduction

1.1 Background of the study

1.2 Aim and objectives

1.3 Production steps of frankfurter plant

1.4 Properties and structure

1.5 Uses

1.6 Process route

1.7 Other process route

1.8 Why the process route was chosen

1.9 Scope of the design

1.10 Limitations

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1.11 Process flow chart (Diagram)

1.12 Process description

CHAPTER TWO

2.0 Literature review

2.2 History of frankfurter

2.3 production

2.4 Nutritional factors of frankfurter

CHAPTER THREE

3.0 Material and energy balances

3.1 Material balance

3.1 Conservation of mass

3.1.4 Material balance assumption

3.1.2 Material balance assumption

3.1.3 Material balance assumptions

3.1.4 Material balance around different units

3.2 Energy balance

3.2.1 Energy balance assumption

CHAPTER FOUR

4.0 Piping and instrumentation

4.1 General overview

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4.3 Instrumentation and control objectives

4.4 Control system and short down schemes

4.5 Basic start up and operational information

4.0 Safety measures

4.7 Product specifications

4.8 Environmental regulation

4.9 Economic reasons

4.10 Valve selection

4.11 Alarm and safety trips

4.1.2 Material devices

4.1.3 Pump and pipe selection

CHAPTER FIVE

5.0 Equipment design and specification

5.1 Major equipment use (design costing)

5.1.1 solar dryer

5.1.2 Hammer mill

6.1.5 Other economic benefits

CHAPTER SEVEN

7.0 Plant location and layout

7.1 Plant location

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7.2 Plant layout

7.2.1 Objectives of plant layout

7.3 Environmental impact assessment

CHAPTER EIGHT

8.0 Plant safety and loss prevention

8.1 Process control and hazard control

CHAPTER NINE

9.1 Conclusion

9.2 Recommendation

References

Appendix

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 CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND OF THE STUDY

Plant design refers to the overall design of a manufacturing enterprise /facility. It

moves through several stages before it is completed. The stages involved are

identification and selection of the product to be manufactured, feasibility analysis

and appraisal, design, economic evaluation, design report preparation, procurement

of materials including plant and machinery construction, installation and

commissioning. The design must consider the technical and economic factors,

various unit operations involved, existing and potential market conditions etc.

Frankfurter is a parboiled sausage that is either made with pork or wrapped in a

casing. Americans call them Vienna or wiener sausages. Sometimes they are also

referred to as hot dogs. The meat is usually seasoned with salt, garlic, sugar, pepper,

nutmeg, and mustard. Frankfurters are cured and smoked. They are usually cooked

by heating them in hot water for a few minutes before serving. Sometimes they are

also cooked on grills or lightly smoked for that delicious smoky taste! Traditionally,

frankfurters are served with mustard, bread, and horseradish.

1.2 AIM AND OBJECTIVES

The aim of this design is to manufacture food products of consistent quality and

nutritional value at affordable cost which will be essential to the success of the food

9
industry today. The efficient use of resources is, therefore, growing concern for all

involved in handling of raw materials and energy for processing, production,

distribution and retailing of food. The unique features of the raw materials of the

food processing industries such as seasonality, perishability and variability in

conjunction with sophistication required for processing to maintain high quality

standards, necessitates special attention towards skilled technical manpower,

effective technologies, efficient machinery in the food plant.

The objectives of this study is to represent on the paper, a replica of a food

processing plant capable of producing frankfurter with tones 500,000 per year and

41,666.7Kg/hr by carrying out the financial and economic evaluation of the plant.

Because of the under laying reason that pork meat can easily deteriorate due to

microbial activity, it is necessary to carry out a design to ascertain the techonoly

best for these food product in a large scale. The heat, energy and mass transfer for

the processing plant will be established by selecting appropriate equipment size and

design of plant layout.

It is also a guide to share handy tips and resources for the individual that has an

interest in frankfurter processing in Nigeria or elsewhere, whether as a hobby or as

an investment or business opportunity.

This guide gives all the answers to those seeking and asking the “how to”, “where

to” and “why to” questions about

10
1.3 SCOPE OF DESIGN

The design covered market analysis, financial analysis, material balance assessment

of the commercial viability each of the equipment will be designed strictly based on

the requirement of the correspondent process in order to achieve a maximum

production and working at full capacity (100%) at the end of the day.

The design work will also show the plant location and layout, piping and

instrumentation, plant safety and loss prevention, environmental impact assessment

and finally the cost estimation of the project.

1.4 SIGNIFICANCE OF THE STUDY

It is hoped that the market analysis, financial analysis, material balance assessment

of the commercial viability of the equipment properly designed will result in the

production of frankfurter that are less expensive, acceptable and highly nutritive

than those produced from in the market all ready.

1.3 LIMITATIONS OF THE DESIGN

The primary limitations were time, finance and scope of the project again

combining resources to achieve set objective.

The design of the required proprietary equipment (extractor press etc) is beyond the

scope of this work.

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They were only specified here after carrying out a simple calculation which showed

forth the basis of the specification. On the long run, the basis of the design might be

modified to suit prevailing conditions.

1.4 PROCESS DESCRIPTION

MEAT: A mixture of lean and fatty meat is used (40% pork and 60% beef). If the

meat is too lean, fat can be added.

FAT: When additional fat is required, lard can be added provided that it is not older

than 3 days and contains no skin.

ICE AND WATER: Ice or water is included into the formula to control the

temperature during mincing. The quality of the water used both as an ingredient in

any meat product, as well as a cooling agent, is of major importance. Potable water

is defined as water free from suspended matter and from substances that could be

harmful to the products or to human health, must be used. In addition, the water

should be treated (by flocculation, filtration, chlorination or other acceptable

processes) to ensure compliance with the following microbiological requirements:

Total count shall not exceed 100 per ml;

Coliform organisms shall not exceed five organisms per 100 ml, and Faecal

coliform shall not be detectable in 100 ml of the water.

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Edible offal (where permitted) such as heart, liver, tongue and kidney must be

limited to 5% by mass of the product and must be declared in the ingredient list on

the label when used.

CASINGS: Both natural and synthetic casings can be used. Natural casings are

produced from the cleaned intestines of sheep, pigs and cattle. Sheep intestines are

generally used for thin sausage while pig intestines are more suitable for thick

sausages. Pig and sheep intestines are sold in bundles of about 100m, packaged in

dry salt. These intestines are stored at 4°C and rinsed in cold water prior to use. The

casings are allowed to soak for 45 minutes at room temperature. Natural casings are

delicate and easily broken during stuffing or linking and could therefore be

substituted by edible collagen casings. Natural casings are permeable to moisture

and smoke, and thus shrink during processing, thereby remaining in close contact

with the surface of the sausage. Other manufactured (synthetic) casings can also be

used and include the following:

CELLULOSE - close to natural casings, but must be removed before consumption

Inedible collagen very strong Plastic casings are not suitable since they are

impermeable to smoke

MINCING OF MEAT FOR FRANKFURTERS:

The lean meat (containing a maximum of 20% fat) and the rest of the fat is

separated before mincing. The lean meat is passed through a 3mm die (aperture size

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of final sieve plate in mincer). The temperature of the meat should be kept below

5°C for mincing to ensure a clean, neat cut without smearing. The meat should be

free from bone chips; gristle, cartilage and excessive amounts of connective tissue

since these would damage and block the sieve plate. The rest of the fat is minced

separately and also passed through a 3mm die

CHOPPING OF INGREDIENTS FOR FRANKFURTERS:

The finely minced meat is transferred to a bowl cutter for the next processing step.

The fat is not added at this stage. Half of the ice water together with the salt is

added and chopping commences. The water dissolves the salt to form a brine with a

concentration of 7 - 8%. The salt soluble proteins are extracted the mixture is while

chopped at high speed. Chopping is halted as soon as the mixture reaches a

temperature of 8.5°C. At this point the mixture should be a uniform, sticky mass.

Temperature, rather than time, is used as a guide for chopping. Ice water is

necessary to keep the temperature down for protein extraction since chopping

creates mechanical energy that is converted into heat. High temperatures would

prevent protein extraction and even cause protein coagulation and emulsion

destabilisation.

EMULSIFICATION OF FRANKFURTER

Mixture Emulsification involves stabilising a mixture of two liquids by adding an

emulsifying agent that reduces the interfacial tension and creates a barrier to droplet

14
coalescence. An emulsion is created when the minced fat is added to the lean meat

mixture in the bowl cutter and chopped until a homogenous mixture is formed

(around 12 - 16°C). It is particularly important that the meat extenders and starches

should be added after protein extraction has taken place, since they are hygroscopic

and will absorb a lot of moisture, making it less suitable for the solubility of

proteins.

STUFFING AND SHAPING OF FRANKFURTERS: The meat emulsion is

transferred from the bowl chopper or vacuum mixer to the sausage filler. The

selected casings are placed over the sausage filler funnel. Collagen casings are

stuffed dry, while natural casings are rinsed in water and stripped of all the excess

moisture prior to stuffing. As the casings fill with meat, they are supported and

allowed to slide off the stuffing horn at a pace that ensures maximum filling while

eliminating air pockets. The ends of the casings are knotted to retain the meat. A

great variety of sausage fillers are available, varying considerably in capacity.

Hand-driven models generally offer from 5 to 15 liter capacities, while fully

automated hydraulic stuffers can accommodate from 50 to 500 liters. Continuous

fillers are also available and although very expensive, the best option for large-scale

operations because of their versatility. Continuous fillers can be equipped with

additional equipment such as portioners, link twisters or casing clipping units.

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SMOKING OF FRANKFURTERS: Smoking enhances the flavour of the

sausages but does not cook the meat. Traditionally, meat was smoked in barrels

over burning wood. Today, smoking is a much more controlled process that

requires a smoking cabinet where smoke can be generated by controlled combustion

of moist sawdust or a rapidly moving steel plate against a log. The smoke is then

carried into the smoking chamber by fans. The sausages are hung over bars and

placed in the smoking chamber. The temperature can be kept at 54 - 60°C for 10 -

20 minutes to attain surface drying of the sausages. Smoke is then introduced and

the temperature is slowly raised to 72 - 75°C and kept there until the internal

temperature of the product reaches 60 - 73°C. The recent interest in alternative

methods of smoke application arose from consumer demand for non carcinogenic

containing food products. The penetration of surface applied liquid smoke is greatly

enhanced at temperatures around 37°C. Although liquid smoke has its advantages,

it is left to the processor to decide which method is preferred, and the product must

be labelled correctly to ensure that the consumer is correctly informed regarding the

origin of the smoke.

COOKING OF FRANKFURTER: Cooking is necessary to coagulate the

proteins and to fixate the desired shape and colour of the product. The Frankfurters

are usually cooked in a steam cabinet or in hot water. The simplest procedure is to

set the temperature of the steam cabinet at 72 - 75°C and then to cook the product to

16
an internal temperature of 68°C. This takes only a few minutes. Cooking time

depends on the weight and dimension of the product. Humidity is once again a

crucial factor in the quality of the cooked product.

COOLING OF FRANKFURTERS: The cooked Frankfurters should be cooled

immediately after being removed from the cookers to prevent overcooking and

bursting. The product is cooled with cold, potable running water until the internal

temperature is reduced to 30°C. The Frankfurters are then placed in cold room

storage for further cooling. The product should be handled carefully during and

after cooling to prevent damage.

PACKAGING OF FRANKFURTERS: Frankfurters are usually vacuum packed

in thick plastic films for retailing. This preserves the product by reducing the

chance of fat oxidation. If products are sold in bulk, no special packaging is

required for Frankfurters.

LABELING OF MEAT PRODUCTS: The casings are labelled/printed with the

necessary information. Labelling in South Africa is controlled by legislation.

Anyone who wants to use the information provided in this document must

familiarise him/herself with all the laws that apply to the producing, processing,

manufacturing and storage of the products referred to in this document.

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1.5 PROPERTIES AND USES

Frankfurters is increasingly becoming a popular choice among health-

conscious individuals due to its numerous health benefits. This type of

sausage is typically made from ground chicken, which is much leaner than its

pork or beef counterparts. This results in a lower fat content, making it an

excellent choice for those looking to reduce their fat intake.

One of the primary health benefits of chicken sausage is its high protein

content. Protein is essential for building and repairing tissues, making

chicken sausage an ideal food for muscle growth and maintenance. It’s

particularly beneficial for athletes or anyone engaged in regular physical

activity.

Moreover, chicken is a good source of essential vitamins and minerals. It

contains B vitamins, particularly niacin and B6, which are crucial for energy

production and maintaining healthy blood cells. It’s also a source of

phosphorus, which is important for healthy bones and teeth.

For those concerned about cholesterol and heart health, chicken frankfurters

is a better option than red meat sausages. Its lower saturated fat content

helps in maintaining healthy cholesterol levels, thereby reducing the risk of

heart disease.

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Furthermore, chicken is often available in various flavors and seasonings,

providing versatility in cooking without adding excessive calories. It can be

grilled, baked, or added to soups and salads, making it a convenient and

tasty addition to a balanced diet.

In conclusion, chicken frankfurters are a nutritious and delicious alternative

to traditional sausages. Its high protein content, essential nutrients, and

lower fat levels make it a healthy choice for anyone looking to maintain a

balanced diet while enjoying flavorful meals.

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1.6 PRODUCTION ROUTE

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 1.7 PROCESS FLOW CHART

1.8 CHOICE OF PROCESS ROUTE

Reasons for Choosing Orange over other Citrus Fruits

- They last longer than much other food when they are stored.

- They are easily transported.

- They are commonly available source of vitamin and minerals.

- The equipment chosen amongst other types of equipment is because of their flexibility and
ease of operation. They have a minimal loss of product and is comparatively cheaper to the
other types. There is an increase in time between the juice and the steam and therefore
increase efficiency. The tray-type de-aerator has a spray nozzle that sprays the juice into
droplets increasing the surface area of contact between the juice and the steam. These types
of equipments are therefore the most suitable for this project.

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1.10 QUANTITATIVE FLOW DIAGRAM

Process
Raw Material

Process

1. Unit operation

2. Unit process

Events

1 Inspiration

2 Transportation

3 Storage

Finished product

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 Pipe -----------------------------------

C Cooled or heated pipe

Motor Drive Dryer

Belt

---
Pump ---
---

Wer or motor drive

Conveyor

Wer or motor drive

Conveyor Tray or solar dryer

Diagram Valve

rotor motor wheel

23
 Course

Hopper
Fine Screen Filler (sieve)

Drum or Tank Drain Size Reduction Equipment

Weighing Scale

Agitator

24
25
26
27
 CHAPTER TWO

LITERATURE REVIEW

From the earliest times up to the beginning of recorded history, man has probably

prepared some type of meat product comparable to sausage. In all instances the

evaluations made of the residues in caves, mounds or tombs are opinions. Some

evidence is based on the practices of primitive tribes or on travelers and explorers

comments of foods and food preparation of the aborigines or primitive groups. The

food economy and preservation methods have always been a big factor for survival

of man and undoubtably the use of offal and the drying of meat in some form was

practiced by early man. Samples of meat, including a mtton joint were uncovered in

a tomb in ancient Jericho. about chopped meat in a goat's stomach Clay tablets from

Babylon give some fragmentary information (possibly a type of Haggis). At about

1000 B.C., "an approximation since Homer's birth date is uncertain, dates ranging

from 830 to 1159 B.C. are given by various early writer's." slaughter of beef, goats

and sheep. He gives in detail the slaughter of a heifer as part of a religious

ceremony. The collection of the blood from the animal and the manner of slicing

and roasting the meat reflects the importance the Greeks placed on animal products

as food. The prize of a sausage was awarded Odysseus when he defeated the sturdy

beggar =os in a boxing match. The sausage was described as a type of black

pudding, stuffed with blood and fat and sizzled on the hearth. Homer mentions

28
often in the Odyssey details of the in the tomb of Rameses. A painting depicts the

manner in which the Egyptians prepared their food. detail and is not too different.

In appearance from the methods used in the 1920's in the U.S. In another tomb a

model of a shop in which the shop worker is carrying dried meat indicates that

preservation by drying was a common practice of that time in Egypt. The

butchering of a cow is given in the classic Greek meals have been depicted on vase

paintings and other works of art. Athenaeus in the Deipnosophistae gives accounts

of feasts and foods and cites my experts on foods. Unfortunately, the cook books

and reports he cites have not been uncovered to date, however his works are

available In the Bohn's Classical Library. He indicates that Charides of Athens was

a specialist on seasonings and Aphthonetus a specialist in sausage. were highly

diversified in food prewrat ions that included sausage and other meat products.

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2.2 Nutritional Factors of Pork Frankfurter Production
Nutritional Value Per 100g (3.5 Oz)

Vitamins

Nutrient Amount DV

Vitamin A, RAE 0.00 mcg 0%

Carotene, alpha 0.00 mcg

Carotene, beta 0.00 mcg

Cryptoxanthin, beta 0.00 mcg

Lutein + zeaxanthin 0.00 mcg

Lycopene 0.00 mcg

Retinol 0.00 mcg

Thiamin [Vitamin B1] 0.048 mg 4%

Riboflavin [Vitamin B2] 0.218 mg 17 %

Niacin [Vitamin B3] 3.984 mg 25 %

Pantothenic acid [Vitamin B5] 0.901 mg 18 %

Vitamin B6 0.275 mg 16 %

Vitamin B12 [Cobalamin] 0.46 mcg 19 %

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 Vitamin B12, added 0.00 mcg

Folate, DFE [Vitamin B9] 7.65 mcg 2%

Folate, food 3.40 mcg

Folic acid 2.55 mcg

Vitamin C [Ascorbic acid] 0.0 mg 0%

Vitamin D 0.42 mcg 2%

Vitamin E (alpha-tocopherol) 0.19 mg 1%

Vitamin E, added 0.00 mg

Tocopherol, alpha 0.19 mg

Vitamin K 21.3 mcg 18 %

Vitamin K1 [Phylloquinone] 0.0 mcg

Vitamin K2 [Menaquinone] 21.3 mcg

Dihydrophylloquinone 0.0 mcg

Betaine 4.9 mg

Choline 42.9 mg 8%

Minerals

31
 Nutrient Amount DV

Calcium 62.90 mg 5%

Copper 0.07 mg 8%

Iron 0.99 mg 6%

Magnesium 17.00 mg 4%

Manganese 0.050 mg 2%

Phosphorus 137.70 mg 11 %

Potassium 171.70 mg 4%

Selenium 19.55 mcg 36 %

Sodium 872.95 mg 38 %

Zinc 0.94 mg 9%

32
NUTRITIONAL CONTENT OF PORK MEAT

Protein

Pork, like other meat, is mainly made of protein. Lean pork has a protein level of

roughly 26% by wet weight. When dried, lean pork has a protein level of up to

89%, making this a protein-dense food. Pork provides all nine essential amino acids

required for the growth and maintenance of your body. Red meat is, in fact, among

the complete protein sources available. As a result, pork is particularly beneficial

for bodybuilders, recovering athletes, people recovering from surgery, and others

who need to strengthen their bodies.

Pork Fat

Pork has a varying range of fat content. These Pork fats content typically ranges

between 10-16%, but it can be much higher depending on trimming and other

factors. Lard is clarified pig fat that serves as a cooking fat. Like different varieties

of red meat, pork mainly consists of saturated and unsaturated fats in roughly equal

amounts. However, pork meat differs slightly from that of ruminant animals like

beef and lamb in terms of fatty acid composition. It has a lower conjugated linoleic

acid (CLA) and a higher content of unsaturated fats.

Minerals and Vitamins

Pork is high in a variety of minerals and vitamins, including:

33
 Thiamine: Pork, unlike other red meats, including beef and lamb, is

exceptionally high in thiamine, a B vitamin that is important for a variety of

body activities.

 Selenium: Selenium is abundant in pork. Animal-derived foods, such as

meats, seafood, poultry, and dairy products, are the most significant sources

of this essential nutrient.

 Zinc: Zinc is a vital mineral abundant in pork and induces a healthy immune

system activation.

 Vitamin B12: It is a water-soluble vitamin. Vitamin B12 is necessary for

blood production and brain function and is almost entirely present in animal-

based foods. Anaemia and neuronal damage can result from this vitamin

deficiency.

 Niacin: Niacin, often known as vitamin B3, is a B vitamin that plays a range

of functions in the body, including growth and metabolism.

 Phosphorus: Phosphorus is abundant and ubiquitous in all cuts of pork, so

it’s usually a big part of most people’s diets. It’s necessary for physical

development and maintenance.

34
  Iron: Pork has lower iron content than lamb or beef. However, it is still a

great source of iron because the digestive tract can absorb iron efficiently

from pork meat.

Other Types of Meat Compounds in Pork

Pork, like plants, includes a variety of bioactive compounds that may have health

implications. Some of the red meat-based compounds present in pork are:

 The amino acid creatine, which is abundant in pork, provides energy to your

muscles. It’s a popular bodybuilding supplement to help with muscular

growth and maintenance.

 Taurine is an oxidative amino acid that your body produces and can be

present in pork. Taurine can be advantageous to heart or muscle function if

consumed sufficiently.

 Glutathione is an inhibitor found in high red meat concentrations, but your

body also produces it. So despite its importance as an antioxidant,

glutathione’s significance as a vitamin is unknown.

 Cholesterol content varies depending on the type of pork. For example,

centre-cut pork chops have 70 mg of cholesterol per 100 grams. On the other

hand, the same serving size of pork bacon has more than 80 mg of

cholesterol.

35
HEALTH BENEFITS OF PORK

Muscle Mass Preservation

Like most animal products, pork is an excellent source of protein. Maintaining

muscle mass as you become older is vital for your health. Muscle mass naturally

degrades as you age if you don’t exercise and eat a healthy diet.

Muscle wasting can progress to sarcopenia, a condition characterised by low muscle

mass and a poor quality of life. Sarcopenia is particularly common in senior

citizens.

Studies show that inadequate high-quality protein consumption can hasten age-

related muscle loss and put you at risk for sarcopenia. Pork—or other protein-rich

foods—is an excellent way to get enough high-quality protein in your diet, which

can help you maintain muscle mass.

Improves Muscle Function

Consumption of pork is not only good for mass muscle maintenance but can also

help with muscle function and athletic performance. It is because pork provides a

range of valuable nutrients to your muscles. Taurine, creatine, or beta-alanine are

among them. Beta-alanine is an amino acid required by your body to produce

carnosine, a substance necessary for muscle function.

36
In the past research, high carnosine levels in muscle tissues led to less fatigue and

improved athletic performance. Following a low-beta-alanine veggie or vegan diet

diminishes the quantity of carnosine in your muscles over time.

On the other hand, pork intake raises muscle carnosine levels. As a result, people

looking to improve their physical performance may benefit from eating pork or

other foods high in beta-alanine.

Prevents Vitamin B Deficiency

All the thiamin, niacin, riboflavin, and vitamins B12 and B6 are abundant in pork.

These B vitamins aid in the conversion of food into energy. They aid in the

production of DNA, hormones, or red blood cells in the central nervous system.

Tension, anxiety, and other mental diseases arise due to B-vitamin deficiency.

Vitamin B12, in particular, has been discovered to have the ability to aid in the

prevention of depression.

Pork Improves Thyroid Function

Pork is high in selenium and essential for thyroid function. Studies show that pork

is a rich source of selenium. For example, 100 g of pork contains 30.8 µg of

selenium.

37
The thyroid gland is an essential hormone that plays a vital part in the human

body’s metabolism, growth, and development. Therefore, consuming selenium-rich

foods is necessary for avoiding thyroid disorders and maintaining general health.

Provides Energy

It would help if you had adequate iron to boost your energy levels. Iron attaches to

red blood cells and helps carry oxygen in the body. Low energy and weariness are

common iron insufficiency symptoms.

Pork is a good source of iron. In addition, pork is an excellent source of B vitamins

such as thiamine and niacin. Furthermore, they aid in converting carbohydrates into

energy.

Pork Enhances Immunity

Zinc, a crucial element for a healthy brain and immune system, is abundant in pork.

The body’s immune system must function effectively, as well as cell division, cell

development, wound healing, and carbohydrate breakdown. Zinc is also necessary

to boost the central nervous system’s growth and improve mental performance.

2.1.5 SPRAY DRYING GRANULATOR

38
Spray drying is a method of producing a dry powder from a liquid or slurry(e.g.

concentrated malted barley extract) by rapidly drying with a hot gas. This is the

preferred method of drying of many thermally-sensitive materials such as foods

and pharmaceuticals. A consistent particle size distribution is a reason for spray

drying some industrial products such as catalysts. Air is the heated drying media;

however, if the liquid is a flammable solvent such as ethanol or the product is

oxygen-sensitive then nitrogen is used.

All spray dryers use some type of atomizer or spray nozzle to disperse the liquid or

slurry into a controlled drop size spray. The most common of these are rotary

nozzles and single-fluid pressure swirl nozzles. Alternatively, for some applications

two-fluid or ultrasonic nozzles are used. Depending on the process needs drop sizes

from 10 to 500 micrometres can be achieved with the appropriate choices. The most

common applications are in the 100 to 200 micrometre diameter range. The dry

powder is often free-flowing.

The hot drying gas can be passed as a co-current or counter-current flow to the

atomiser direction. The co-current flow enables the particles to have a lower

residence time within the system and the particle separator (typically a cyclone

device) operates more efficiently. The counter-current flow method enables a

greater residence time of the particles in the chamber and usually is paired with a

fluidised bed system.

39
Alternatives to spray dryers are:

1. Freeze dryer: a more-expensive batch process for products that degrade in

spray drying. Dry product is not free-flowing.

2. Drum dryer: a less-expensive continuous process for low-value products;

creates flakes instead of free-flowing powder.

3. Pulse combustion dryer: A less-expensive continuous process that can handle

higher viscosities and solids loading than a spray dryer, and that sometimes

gives a freeze-dry quality powder that is free-flowing.

Spray Drier

A spray dryer is a device used in spray drying. It takes a liquid stream and separates

the solute or suspension as a solid and the solvent into a vapor. The solid is usually

collected in a drum or cyclone. The liquid input stream is sprayed through a nozzle

into a hot vapor stream and vaporised. Solids form as moisture quickly leaves the

droplets. A nozzle is usually used to make the droplets as small as possible,

maximising heat transfer and the rate of water vaporisation. Droplet sizes can range

from 20 to 180μm depending on the nozzle.

40
 CHAPTER THREE

3.0 MATERIAL AND ENERGY BALANCE

3.1 MATERIAL BALANCE

This is an application of conservation of mass to the analysis of physical systems.

By accounting for materials entering and leaving a system, mass flows can be

identified which might have been unknown or difficult to measure without the

techniques. The exact conservation law used in the analysis of the system, depends

on the context of the problem, but all revolves around the mass conservation i.e that

matter can neither be created nor destroyed, (en.rn.Wikipedia.

Org/Wiki/massbalance).

The basis of these mass or material balance is the conservation of mass stating that

mass can be neither created nor destroyed” thus all mass (i.e Weight) of the

individual components entering the process must be accounted for in the final

products, by-products, wastes etc.

General materials balance equation =input +generation-Output-

Consumption= accumulation Input: Enters through system boundaries

generation: is produced within the system

Output: existed through system boundaries.

Consumption: Is used up within the system.

Accumulation: Is built up within system.

41
3.1.1 CONSERVATION OF MASS

This general conservation equation for any process system can be within as material

out = material in + generation consumption – Accumulation. Input + generation

=output + accumulation + conservation (generation term is zero).In the absence of

chemical reaction, the amount of any chemical species flowing in and out will be

the same, this gives rise to an equation for each specie present in the system

Material in =material out.

3.1.2 MATERIAL BALANCE ASSUMPTIONS

- This system is operating at steady state i.e there is no accumulation of any sort in

the system.

- Non reactive system

- The following assumptions were made, this is based on the fact the

total material in = total

- Output + Accumulation (Total material under steady condition therefore the rate

of input – rate of output +rate of Accumulation A-B+C

3.1.3 MATERIAL BALANCE AROUND DIFFERENT UNIT

DATA:

Expect plant attainment on installation = 100%

No of days to energy in production = 347x100

42
Production days/annum = 347x24=8328hrs/annum

Expected plant capacity = 21000 bags/annum

= 21000 8328 hrs/annum = 2,521613833kg/hrs

Quantity of raw material needed per hour 5602.5kg/hr

Input- output

3.1.4 MASS BALANCE FLOW DIAGRAM

Input Product

5602.5kg/hr System 5602.5kg/hr

3.1.5 ENERGY BALANCE

An energy balance states that the amount of heat or mechanical energy entering a

process = the total energy leaving with the product and wastes + stored energy +

energy lost to the surroundings. If heat losses are minimized, energy losses to the

surrounding maybe ignored for approximate solutions for calculations, for example

the quality of system hot air or refrigerant required. Energy out- Energy in +

generation consumption = Accumulation.

3.1.6 ENERGY BALANCE ASSUMPTION

- Steady state condition is assumed in all process equipment.

43
- Heat loss from ail process equipment is negligible.

- Pressure drop along the pipeline is negligible.

- Effect of pressure on enthalpy is ignored.

- Potential and kinetic energy contribution are negligible.

3.1.7 ENERGY BALANCE AROUND THE SYSTEM

Mass flow rate of the plant

= 14193.85kg/hr

Inlet temp = 30◦C

Output temp of 85◦C

Heat capacity = 3.18kj/kg/k

Mass flow rate of stream = 14000kg/hr

Heat capacity rate of = 4.18kgII KI I

Inlet temp of stream = 105◦C

Outlet temp of stream = x◦C

Given that Q- MCP T mixture = MCPD T stream for Mixture, heat gain.

Q – 14193.85 X 3.18X (85-30)

Therefore outlet temp of stream Tin- Tout =

MCP T mixture

MCP T stream

= 105- Tout= 42.42146898

44
Tout – 62.6◦C,,

ENERGY FLOW DIAGRAM AROUND THE SYSTEM

input Output
System
14193.8kg/hr 14193.kg/hr

80◦c

30oc

Steam

Steam out

14000k/hr

14000kg/hr 105oc

Dressing Separator

Mass flow rate = 14193.85kg/hr

Heat Capacity of mixture = 3.18kj/kg kII I

Inlet temp = 80◦C

Outlet temp = 900◦C

Latent heat of stream at 105◦C = 2356 kjkII I

Latent heat of vapour at 90◦C = 2024kjkII I

Heat capacity of water = 4.18kj/kgkII I

45
Heat gained by mixture = MCPDT

14193.85 X 3.18 (90-80) = 451364.43kj

Heat to evaporate water = Q = M x LHY

= 451364.43kj

Heat to evaporate water = Q = M x LHY

-14193.85 x 2358 – 33469, 698,30kj

Total heat input

= heat gained by mixture + heat evaporated H2O

= 451364,43 +33469098.30kj

= 339020,462.73kg = 33920.46273kj

Mass flow rate of stream = heat input/LHE of stream at 90oC

= 31920,46273

2024= 16783.99937kg/hr

46
 CHAPTER FOUR

4.0 PIPING AND INSTRUMENTATION

Piping is a system of pipes (hollow, cylindrical tubes) fittings, valve used to convey

fluids (solid, liquid, gas) from one location to another. The pipe can be made with

aluminum, steel or rubber, instrumentation is an art and science of measurement

and control process variables within a production. Before the Malt Productionget to

the plant another. This transportation is done in piping system. The pipes are

regularly checked for scaling condensation, leakages, liquid hamming as well as

corrosion in order to ensure free flow of the Malt, thus enhancing efficiency.

4.1 GENERAL OVERVIEW

Piping and instrumentation is an arrangement that shows the interconnection of

process used in controlling the process and it plays significant role in the

maintenance and modification of that process, the diagram which is described in

details which provides basis for the development of system control schemes,

allowing for further safety and operational investigation, such as a hazard and

operability study (Hazop).

47
4.1 INSTRUMENTATION AND CONTROL OBJECTIVES

Different specified tool has been set up, in order to assist installation, long

run of plant and product specification, to achieve a rundown rate. This is

done to reduce several disturbance and influences to environment.

4.3 CONTROL SYSTEM AND SHORT DOWN SCHEMES

A control system is a device, or set of devices that managers, commands,

direct or regulates the behavior of other devices or systems in production

industry. A switch is a control system which controls the inflow and outflow of

power in the Malt Production company.

4.4 SAFETY AND REGULATORY REQUIREMENT

It is a guide that provides an overview of a safety management.

A safety meter or boxes placed on an equipment, shows working temperature,

therefore, when an equipment in working at a particular temperature, ones the

temperature exceed there is a warning alarm.

4.5 BASIC START UP AND OPERATIONAL INFORMATION

In a plant (dryer, miller and slices) there is a step by step operation on how to

control the system. There is an operational manual on how to switch on the plant,
48
and a temperature will be given so as to allow the equipment boost before putting

in your feed.

4.6 SAFETY MEASURES

This is a measure taken in order to protect people against accidents, damages or

harm, so as to enable continued contributor to the economic development.

4.7 PRODUCT SPECIFICATIONS

The plant is intended to produce 2.61 tones per hour so as to meet up with the need

of producing the units needed in a day, so that condition necessary for processing

can be kept. The Malt Production is rich in minerals, vitamins etc and when cooked

with that water for people that are washing weight.

4.8 ENVIRONMENTAL REGULATION

The conversion of raw agricultural commodities into finished food can be

determined to the environment of precautions are not taken. Food processingcan

have adverse environmental effects on air and water quality as well as producing

toxic side product.

In frankfurter Production, the environmental problem are caused by having a lot of

water around the processing unit, which can easily enter the dried Juice plant and

49
make it to be hard while entering the Malt Production (i.e the final product) thereby

reducing the quality and texture.

4.9 ECONOMIC REASONS

Operations of the plant must conform to market conditions, and effective control

system must be adopted, so as to safety the customer or consumer to avoid sub-

standard production which might lead to losses.

4.10 VALVE SELECTION

Valve is an instrument of in or out of a fluid. It controls the flow in a production.

Apart from diagram valve, an emergency valve must be installed

this enables all system to shut down during emergencies and can be used to

control the plant both automatically and manually.

TYPES OF VALVE

1. Diagram valve

2. Control valve (fail safe closed)

3. Control valve (fail safe open)

50
4.11 ALARM AND SAFETY TRIPS

There are built alarm in the plant to warn in case of foreseen danger or hazard and

this helps prevent overall harm to the people, as well as the environment. It is

placed in such away that when the danger is foreseen, the alarm andsafety trips

become activated.

In a plant, the operator in the main control room should be familiar and

conversant with these alarms to enable, him handle each alarm that comes up

effectively.

4.12 MATERIAL DEVICES

Is a small device fixed into equipment controller, which include: flow rate,

temperature etc. Electric metering device is used to measure the quantity of raw

material used in the beginning of production in order to be able to account for the

loss, and get the material balance at the end of the production process.

4.13 PUMP ANDPIPE SELECTION

Pump and pipes are selected based on their power requirement in a plant.

E.g. since production frankfurter plant involves unit process/unit operation of

plant ,there is a pump to transfer the materials from one form to another.
51
TYPES OF PUMPS SELECTED INCLUDE:

1. Stainless steel pipe non corrosive

2. Aluminum pipe-non corrosive, non ferras

3. Metals

4. Alloy pipe

When determining pipe size (diameter) during design calculation factors are

considered and they include: initial steam pressure, flow rate, steam velocity etc

while pump cost decreases with increases with diameter.

W=g

52
 CHAPTER FIVE

5.0 EQUIPMENT DESIGN AND SPECIFICATION

There are many equipment involve in processing and production of Malt.

Equipment designs and specification include the design and specification of the

physical equipment in a processing plant.

Also an estimated costing of the equipment are made for alternative design and

project evaluation.

5.1 MAJOR EQUIPMENT USE (DESIGN COSTING)

5.1.1 SOLAR DRYER

A PHOTO VOLATIC BOND SOLAR DRYER

1. Capacity of the dryer: 20kg

Type of material used: aluminum and stainless

Type of joint: bolts and nuts (easily assemble and disassemble)

Number of tray: 3 to 4

Design temperature: 90°c

53
Length: 100cm

Tray dimension: 98Ommx48mm

Breath: 50mm

Ce — purchase cost: 2023

C = constant from table 6.2

S = characteristic size parameter in the units given (6.2)

n = index for the type of equipment

Cost in 2023 x cost index in 2015

Cost index in 2023

Cost for solar dryer = 32328.7 =N9,698,610

5.1.2 FRANKFURTER STUFFERS

Material of construction: stainless steel

Cutting device stainless steel rotating knives

Length: 40m

54
Shat diameter: 70mm

Model: 1320

Housing: 12mm

Screen area: 475 inches

Type: pulverisers

Ce = purchase cost: 2024

C- constant from table 6.2

S= characteristic size parameter in the units given (6.2)

n =index for the type of equipment

Cost in 2024 x cost index in 2016

Cost index in 2024

Cost for frankfurter stuffers = £31,663.957=N9,499.18

55
 5.1 VACUUM SEALERS

Material of construction: aluminum and plastic

Motor speed: 75rev/min

Volt: 250 volts

Weight diameter: 40mm

Conveyor, type

Belt size: 0.5m

Length: 160mm

Driver power: 2kw

Capacity: 7,932kg/hr

Ce=purchase cost: 2024

C = constant from table 6.2

S= characteristic size parameter in the units given (6.2)

n = index for the type of equipment

cost in 2024 x cost index in 2015

cost index in 2024

Cost for vacuum sealer = £36308.68 =N10,892,604

56
5.1.4 FOR SPICE BLENDS

Material of construction: stainless steel

Model: TT-1200

Capacity: 80 to 100 Kg/Batch

Detection system: image capture (OCP)

Length: 135mm

Width: 85mm

Thickness: 0.15mm

Weight: 2-100kg

Type conveyor belt (0.lm wide)

Ce = purchase cost: 2024

C = constant from table 6.2

S characteristic size parameter in the units given (6. .2)

n index for the type of equipment

cost in 2024 x cost index in 2015

cost index in 2023

Cost, for sorter = £12630.1=N33,3789,030

57
5.1.5 MEAT AND BONE SAWS.

Material of construction stainless steel

Model: BM1O

Weight: 2-5kg

Length: 369mm

Diameter: 60

Ce = purchase cost: 2024

C = constant table 6.2

S=characteristic size parameter in the units given (6.2)

n = index for the type of equipment

cost in 2024 x cost index in 2015

cost index in 2023

Cost for blancher = £16,498.54 =N4,949,562

5.1.6 INDOOR SMOKEHOUSES.

Material of construction: ruffling sheet, bricks, paint.

Height: 220m

Length: 120m

Ce= building cost : 2024

58
C= constant from table 6.2

S= characteristic size parameter in the unit given (6.2)

n = index for the type of equipment

cost in 2023 x cost index in 2015

cost index in 2023

Cost for peeler = £26518.88 = N7,955,664

Equipment Quantity Cost in 2024 Cost in 2016 Cost in 2016

(£) (£) (₦)

Frankfurter Stuffers 1 5000 32328.7 9,698,610

Frankfurter Casing 1 3750 31,663.95 9,499,185.3

Vacuum Sealers 1 2000 36,308.68 10,892,604

Meat and Bone Saws1 2700 112,630.1 33,789,030

Indoor Smokehouses.1 7650 16,498.54 14,949,562

Spice blender 1 28000 26518.88 7,955,664

Total 50,500 255,948,85 76,784,655.3

59
 CHAPTER SIX

6.0 ECONOMIC ANALYSIS

This company will be effective on market segmentation through the identification

of several riche markets and strategies implementation. The company intends to

advertise, implement, direct marketing merchandisers, team workers and

advertising will rotate around and to be able to penetrate the market within and

outside the production, site. Therefore, our key to a successful business will include

the following factors.

1.Marketing know-how: In an increasingly competitive market, there is need to

market out product effectively so as to be at the top of our honourable, prospective

and current clients mind continuously, even if it will warrant that the whole

workers/departments will take part in the marketing of the product or by, breaking

the bulk.

2. Dedication and loyalty: The loyalty and dedication of our employees, no matter

your rank in the company, qualification, age etc shall be necessary to the property

of the business, will recognize that corporate commitment to success should lead to

the survival and long lasting or long run of the products, and the organization as a

whole.

60
3. Excellent in fulfilling promise: We intend to produce and provide products of

uncompromised quality to our customers. In so doing we are meeting up with the

needs and standards of our honourable customers by providing them with a high

quality and nutritive frankfurter Production.

4. Technology assembly: We will ensure a consistent quality of our product, that is

when it is essential to make use of the latest technology

but to utilize it and know in which unit operation each particular technology in

needed and also the department that needs the latest technology is most (i.e. can

utilize them to facilitate production).

5.Effective distribution network: We intend to establish an excellent distribution

network, that is by setting up/creating roots for each

marketers, communities etc and meet their targets, this will enable us to rapidly

respond to our customers order, and be available in remote areas that our

competitors has never get exploit

6. Adherence to stringent values and principles: There is need to always

acknowledge the fact that the financial and strategic management of the business

will ultimately determine its success and prosperity. This is why we need to adhere

to stringent values and principles that will enable such to be achieved.

61
6.1 ECONOMIC EVALUATION

6.2 PREPARING A PROCESS FLOW DIAGRAM

A process flow diagram has initially been prepared on the chapter one of this

project

6.3 CALCULATION MASS ENERGY AND ENERGY FLOW

Mass flow rate and energy flow has been calculated on chapter 3 (refer back

to chapter 3 and appendix).

6.4 SIZE OF MAJOR EQUIPMENT

Equipment Size (unit) Size range Index Type

Frankfurter Stuffers Area(m²) 2-10 0.35 Pan

Casing area (m²) 20-200 0.35 pan

Vacuum sealer Length(m) 20-40(30) 0.75 Conveyor belt

Meat and Bone Saws. Length(m) 20-40(36) 0.75 pan

Indoor smoke house Length (m) 3-50 0.60 bricks

Spice blends Length(m) 20-40(50) 0.75 steel

62
6.5 ESTIMATION OF FIXED CAPITAL COST, REF TABLE 6.1

solid processing plant

Major equipment Total purchase cost: ₦

Fl - equipment erection 0.45

F2 - Piping 0.45

F3 -instrumentation 0.15 2.15

F4 -electrical 0.10

F5 -building process 0.10

F6 -utilities 0.45

F7 -storage 0.20

F8 -site development 0.05

F9 -auxiliary building 0.20

F10 -design and engineering 0.30

F11 -contractors fee (non) 0.70 0.40

F12 -contingency 0.10

6.6 WORKING CAPITAL

This is the money required to operate a plant from the period of one month to

a period of one year.

63
6.7 BREAK-EVEN POINT

The break-even point is the point at which total cost and total revenue are equal,

meaning there is no loss or gain for your small business.

To calculate the break-even point in units use the formula: Break-Even point (units)

= Fixed Costs ÷ (Sales price per unit – Variable costs per unit) or in sales dollars

using the formula: Break-Even point (sales dollars) = Fixed Costs ÷ Contribution

Margin.

6.8 PAYBACK PERIOD

It is the time frame for a business or project to fully amortize the initial investment

fund from income generated. It is useful criterion for judging projects that have a

short life. It does not consider the performance of the business after the payback

period.

6.9 CAPITAL COST

Is a financial outlay, that is required for the physical erection of the plant is well as

erecting the plant for the period of the month, it include land cost, cost of plant

erection and working capital.

6.10 FIXED COST

This consists of two broad components namely:

Direct and indirect fixed cost

64
Direct fixed cost: Includes cost of those items that can be seen at the plant site

which include:

i. Cost of process equipment

ii. Cost of equipment installation

iii. Cost of piping

iv. Cost of foundation structure, plant building, road bridges etc

Indirect fixed cost: Include cost of engineering and design contractor over

held and contractor fee as well as. construction contingences.

6.11 PROFIT/ANNUM

It is an annual profit after various taxes are paid.

NPV = annual turnover — annual cost of production

Annual turnover = quantity of sales X selling price

6.12 RATE OF RETURN (ROR)

It is the percentage of profit after tax but before depreciation to the total

invested fund.

ROR = profit (per year) x 100

Total investment 1

65
6.13 HOW TO RAISE THE CAPITAL

In order to raise capital for the proposed project both the owners savings and

fund any reliable financial institution. Although institutions usually have

their terms and conditions that their clients have to sign before services are

rendered.

These terms and conditions include:

1. The debenture loan sough must be secured on the project fixed assets is

inadequate; collateral security may be added.

2. The institution should not provide more than 70% of the total project cost.

Therefore, the balance of 30% should come from the owners equity

shares.

According to terms and conditions, I have suggested for the proposed projects, with

the following capital structure which, I believe will be acceptable to the financial

institutions.

Equity shares 40% of TIC = N142,220,538.6

Bank overdraft 10% of TIC = 35,555,134.64

Debenture loan 50% of TIC = N177,775,673.2

66
6.14 SUMMARY OF ECONOMIC ANALYSIS

COST ESTIMATION COST (N)

Purchased equipment 76,784,655.3

Total capital investment 355,551,346.4

Annual raw profit 1.041,000. 833

Total production 85,645,388.4

Annual net profit 2.5x10’’

Break-even point(unit) 14.093,598.33

Break-even point (Naira) 7,046,799,164

Payback period 1.4(1 year and 4 months)

6.15 OTHER ECONOMIC BENEFITS

Apart from commercial viability reasons, this proposed project will also take care of

socio economic benefits which include: job creation, increase in

government revenue, establishment of industrial linkage, provision of socio-

amenities and diversification of the economy.

67
 CHAPTER SEVEN

7.0 PLANT LOCATION AND LAYOUT

7.1 PLANT LOCATION

The place or area the plant is situated has the profitability of the project and the

scope for future expansion. Therefore, many factors are considered when selecting a

suitable site for the frankfurter Production plant. They include:

Availability of raw material or feedstock: The main raw material needed in

frankfurter Production plant in large quantity in Nigeria, is in (Imo, Akwa Ibom

Ebonyi etc). The plan site should be located near where the frankfurter Production

plant raw material is available in order to reduce transportation cost, also the

purchase price, availability and reliability of the supply should also be put into

consideration. Hence, the proposed plant site will be at industrial clusters, in Niger

state, due to the nearness of Malt Production plant from the Northern parts of

Nigeria.

Availability of energy: The plant will run production and will require continually

with constant supply of energy, but due to the inconsistent

character of energy supply in the country, it will depend on beer energy source.

Therefore, an alternative means of energy will be provided (Generator power).

68
Transportation: The frankfurter Production plant will be provided with adequate

transport facilities for case in the distribution of goods at various destinations. The

transportation modes will includes trucks, buses etc. This production plant will be

located close to a good access and for easy

distribution of the finished good to the customers.

Market assessment: The marketing problem will be tackled by carrying out pre-

marketing research to find but how the consumer assessed to before producing to

large quantity.

Also, when this is known, the product will be located near a primary market

where a buyer can comfortably purchase the finished product; also cost of the

product will be relatively low.

Site characteristics: Test boring information will be made available for the entire

plant site, there will be adequate drainage system to avoid stagnant water, since

industrial cluster Nekede, Owerri in a leveled ground there will be no sloppy or

construction cost on the plant site.

Community factors: The development of this project will include representatives

from the community it is sited, also worked will include indigenes of the

community, so that it will stand as a job generator not only for outsiders but also for

indigenes of the community.

69
Also if the community officials and the company representative develop a method

of interacting together, it will determine the extent to which the community will

boost and support the project from hoodlums and theirs.

Labour supply: Labour needed for the construction and operation of this Malt

Production plant will include both skilled (brought from outside) and will paid to

pay scales of every individual or group of workers. Also there should be training

(workshop) to enlighten the unskilled ones.

Waste disposal: There will be proper treatment of waste in the industry by

adopting the ISO (international Standard Organization) which is set aside for

guiding the interest of the nation. In order for the company not to pollute the

environmental there will be large waste management until for treatment of waste in

the plant before disposal.

Taxation and legal restriction: The plant will run for two years as stipulated by

the legal regulation of Imo state. This is to build a strong grand for industrial. plant

which is located at No. 3, industrial Cluster, Nekede, Owerri in Imo State, is an area

mapped out for industries.

The area is for only industry, because individual buildings are restricted from the

area, to avoid the industrial equipment causing nuisance.

70
7.2 PLANT LAYOUT

This involves where the plant will be suited, which is at No No. 3, industrial

Cluster, Nekede, Owerri in Imo State . It also involves the space requirement, to

ensure continuous and steady movement for the production take place.

These include:

Personal, operating equipment, storage space, material shading equipment and all

other supporting devices along with the design of the best structure to accommodate

the named facilities.

7.2.1 OBJECTIVES OF PLANT LAYOUT

• Providing comport and catering to workers

• Providing good and improved working conditions

• Minimizing delays in production and making efficient use of the space that

is available

• Having a better control over the production cycle and other activities within

the plant premises.

71
PLANT LAYOUT

Security office
Vehicle park Weigh bridge

General Manager’s
Reception office Office

Filling Station
Loading and
Chemical Office uploading

Storage room for raw

material
Administrative block

Processing House

Finished Product
Store for Packaging

Waste treatment
plant and disposal Utilities Storage room for
office finished goods
Room for expansions
Administration building: Located far away from potential hazardous plant area,

72
• Central control room (CCR): Located adjacent to processing unit, but with

potential hazardous processes

• Field auxiliary room (FAR): Located right inside the plant area. It is a mini

control room

• Tank farm: Located close to the plant for supply of raw materials and also

close to loading and exist point for easy movement of trucks

• Maintenance workshop: Located far from the administrative officers and

close to the plant for easy maintenance and repairs of equipment. There is a

good network for easy transportation of machineries to and from the building

• Laboratory: Located far from potential hazardous area, but not too far from

plant. It is where samples of batches are tested for standard

• Emergency block: Located close to potential hazardous area, it consists of

fire station, fire pumps. Fire pumps are situated at each of the layout in case

of emergency

• Plant area: A place where production takes place

• Car park: Located very far from plant

73
• Canteen: Located not far from administrative building, so that workers will
not spend which time going to where they can refresh thereby abiding their
work.

• Clinic: Located very close to plant, to ensure urgent attention to any injured
worker

• Residential area: Located very far from plant it is where company staffs
reside, for the safety of the workers.

• Mustard point: Located close to different structures in the industrial area, to

enhance easy convergence of staff during emergency.

7.3 ENVIRONMENTAL IMPACT ASSESSMENT

Environmental impact analysis was carried out on the early stage of this design, to
investigate the likely environmental challenge that will be posed by the proposed
plant on the environment. The environmental challenges which is likely to be
caused by waste (by products of Malt production and waste water). That is why the
waste water will be treated before disposal and by products sold to people or
company that will need them for production. All these are done to presence the
earth and protect its habitant.

74
 CHAPTER EIGHT

8.0 PLANT SAFETY AND LOSS PREVENTION

Safety is a state of being staff freedom from the occurrence or risk of injury,

danger or loss.

Therefore, for a potential organization to run safe and efficient plant

operation there should be legal and moral obligation to safe guard the welfare of

employees and public at large. In the sense that all unit operation and unit processes

should be carried out under appropriate condition. While loss prevention is all the

effective measures put in place to contain potential

financial loss posed by accidents in the overall plant preview. These losses can lead

to the shutdown of the company or plant.

8.1 PROCESS CONTROL AND HAZARD CONTROL

PROCESS CONTROL

This is a system established in the Malt Production industry which involves the

effective use of instrumentation to yield high efficiency with less harm on the

people and less hazard in the plant during operation. This system generally

improves production and maintains the output within the desired range. The

processes system can be set up in a different room where every

75
individual equipment or connection in the factory and other section of plant is

connected to in order to rapidly put to a halt any occurring hazard.

HAZARD CONTROL

Is a system used in industry to minimize or eliminate exposure to hazards.

System used to prevent and control hazard includes engineering control, safe work

practices, and administrative controls, personnel protective equipment, systems to

track hazard correction, preventive maintenance system and

medical.

To ensure that hazard occurrences are minimized in the Malt Production industry,

regularly and thoroughly maintain equipment, ensure the hazard

correction procedure are in place, ensure that everyone know how to use and

maintain personal protective equipment (PPE), make sure that everyone

understands and follow safe work procedures and ensure that when needed there is

medical program tailed to the facility to help prevent work place hazard and

explosion.

8.2 IDENTIFICATION OF POSSIBLE HAZARDS

Hazards are unpredicted, unplanted occurrence that is harmful to personnel,

machineries and materials, and it can cause complete breakdown of a running plant.

76
Possible hazards of Malt production plant include:

The effect of water, carbohydrate and dietary fiber on the pumps and piping

materials of construction. When water is retained in a washing tank for a long time,

it will rust, also when allow, are exposed to moisture in air it corrodes.

PREVENTION MEASURES

There should be containment during the design of equipment and piping, and water

after washing the raw production should be discarded in order to avoid rust, there

should be ventilation.

REACTIVITY: CHO reacts with oxygen in the following vedox equation.

C6H12O6+6O2------------------------6CO2+6H2O

The carbon dioxide and water is a waste product and reaction is exothermic, and

when it is not accounted for can lead to breakdown of equipment.

VENTILATION

Fans will be installed to reduce odour and lower humidity; there will be windows

and doors all around the plant area, to ensure adequate ventilation.

CORROSION

Moisture enhances corrosion on material of consumption like Alloy,

77
therefore water should always be transferred to waste tanks to avoid corrosion.

OPERATION AND HUMAN ERROR

Since human errors are inevitable, impite training, education and exposure, safety

measures will be adopted in order to minimize and prevent the various human

errors.

They include:

 Adequate training of staff in safe start-up and shut down of equipment,

overall operation and maintenance.

 Adequate dressing kit for specified operation.

 Adherence of safety rules and regulations.

 Keeping away from moving parts of machines and devices while

handling properly etc.

78
 CHAPTER NINE

CONCLUSION AND RECOMMENDATION

9.1 CONCLUSION

Based on the economic analysis of this project, it can be seen that it is worth

investing on so that the implementation of what is contained in this work could be

achieved.

Since the total investment is N355, 551, 346.4 net profit N2.5x 1011, this

shows that the company can repay borrowed capital within a short period of time

and this profit will bring open doors to the economy of the state and Nigeria at

large.

9.2 RECOMMENDATION

WENDY FRANKFURTER PLANT will employ a new and unique processing

technology. This has already made it to stand a ground of competing and heating

other competitors in the market. Since this plant is aimed at production, the product

will not reluctantly shut down, rather it has been programmed to produce in order to

meet the increasing demand of customers. Its administration will not frustrate

employees and will not let the firm down.

79
 REFERENCES
Brothwell, D. and P. Brothwell. Food in Antiquity. Thomes and Hudson, London.
1969. Homer. The Odyssey. Rouse trans. Mentor, New York. 1937.

Iabarge, M. W. A Baronial Huusehold of the Thirteenth Century. Barnes and Noble,

Inc. New York. 1965. “he Nat bnal Provisioner The Significant Sixty .”
Chicago, January 1952.

Johann, E. Das Jahr des bktzgers. Kalle & Co., Weisbaden. 1957.

Horsford, E. N . “he Army Ration of 1864. Library Bullet in #1. Quartermaster

Research and Engineering Command. U .S . Army. Chicago. 1961.

Clair, C . Kitchen and Table. Abelord and Schuman Ltd New York. 1964.

80
APPENDIX

Plant attachment 95% =95/100 = 0.95

Number of days to be engaged in production

= 0.95x365—346.75=347 days

34/days/year

347x24 = 8328 hours/year

Plant capacity on installation = 500,000 tones/year

1 tonne = 1000kg

500,000 tones =?

= 500,000 tones xl000kg= 500,000,000kg/year

1tonne

Mass of meat= 500,000.000

8328 =60038kg/hr

Quantity of plant in required per hour = ?

To change days to kilogram

That is 347000,000 =1000,000kg

347 24

= 41666.7kg/hr

81
ENERGY BALANCE ASSUMPTION FOR DRYER

Q=MCpΔT

Washed meat = 41666.7kg/hr

MCpT =MCp T ΔMv

41666 .7kg/hrX3.91kgX(60°-0) =28666 .7kj/kg(90°60°)+Mv

41 666.7kg/hrX3.91kj/kgx60° =28666kg3.9kj/kg(30°)+Mv

=9775007.82kg/hr = 3,362,603.91+Mv

Making Mv subject

MV = 9775,0007.82-3362,603.91

Mass vapour = 6412,40191kg/hr

COSTING OF THE EQUIPMENT

Cost for sealer assumption

Purchase cost in 2024 = £4,000

Costindexin 1990 = 60

Cost index in 2024 = 80

From 1990 to 2024 = 3 yrs

(80-60) 20 index

82
3 years = 20 (from 1990—2023)

22 years ?

=20 x 22

31

= 146.6

Cost index for solar dryer in 2015

146.6+80=226.6

C = 4000

n = 0.35

S = 10m²

Ce = CXSⁿ

£4000 x 10m2(0.35)

£4000 x 10m2(0.35)

£11,413.5(2023)

Update cost

2024 x 2015

2024

11,413.5x 226.6

83
= 11,413.5 x 2.8325

= £323287

CONVERT TO NAIRA

Exchange rate = £1 = N500

Therefore £32328.7 =?

£32383 x N 500

£1

= N9,698,610

FOR CASING

Purchase cost in 2024 = £1750

Cost index in 1990 = 60

Cost index in 2024= 3 yrs

(80-60) = 20 index

3 years = 20 (from 1990 -2024)

22years =? (from 2024 —2015)

= 20 x 22

84
 3 1

= 146.6

Cost index for casing in 2015

145.6+80=226.6

C=1750

n =200kg/h

S = 200kg/h

Ce =CXSⁿ

£1750x(200)°35

£11,178.8

Update cost

2023x 2015

2023

11,178.8 x 226.6

80

11,178.8x2.8325

=£31,663.951

85
Convert to Naira

Exchange rate = £1 = ₦500

Therefore £4000 x 10m² (£3163.951)= ?

£31663.951x=₦500

£1

=9,499.185.3

FOR STUFFERS.

Purchase cost in 2024 = £1000

Cost index in 1990 = 60

Cost index in 1990 = 80

From1990 to 2024 = 3 years

(80-60) = 20 index

(If 3 years = 20 (from 1990— 2024)

22years=?

20 x 22

31

=146.6

86
=146.6

Cost index for electric slicer in 2015

146.6+80=226.6

C=1000

n = 0.75

S 30m

Ce = CXSⁿ

£1000 x (00)°.75

£12,818.6

Update cost

2024 x 2015

2023

12818.6 x 2.8325

=£36,308.68

Convert to Naira

Exchange rate = £1 = N500

Therefore £31663.951 =?

£36,308.68 x N500

87
MEAT AND BONE SAWS

= ₦10,892,604

Purchase cost in 2024 = £2,500

Cost index in 1990 = 60

Cost index in 2024= 80

From 1990 to 2024= 3 yrs

(80-60) = 20 index

If 3 years =20 (from 1990—2024)

22 years= ? (From 2024 - 2024)

20 x 22

3 1

= 146.6

Cost index for server in 2015

146.6+80 = 226.6

C = 2500

n = 0.75

S =40M

Ce = CXSⁿ

88
£2500x(40)0.75

£39,763.5

Update Cost

2024 x 2015

2023

39,763.5 x 226.6

80

= 39.763.5z2.8325

= £112,630.1

CONVERT TO NAIRA

Exchange rate = £1 = ₦500

Therefore

£31663 951 = ?

£112,630.1X₦500

£1

=N33,789,030

FOR SPICE BLEND

Purchase cost in 2023 = £1,250

Cost index in 1990 = 60

Costindexin2024 =80

89
From 1990 to 2024=3yrs

(80-60) = 20 index

If 3 years = 20 (from 1990 — 2023)

22years = ?

=20x22

3 1

= 146.6

Cost index for blancher

146.6+80=226.6

C = 1250

n = 0.60

S =12m

Ce= CXSⁿ

£1250x(13)0.60

£5824.73

Update Cost

2024 x 2015

2024

5824.73x226.6

80

90
= 5824.73x 2.8325

=16.498.54

Convert to Naira

Exchange rate = £1 = 500

Therefore £31663.951 =?

£16.498.54.lx₦500

£1

FOR INDOOR SMOKEHOUSES.

Purchase cost in 2024 = £2800

Cost index in 1990 = 60

Cost index in 2024 = 80

From 1990 to 2024= 3 years

(80-60) = 20 index

If 3 years =? (from 2024-2015)

=20 x 22
91
 3 1

= 146.6

Cost Index for Peeler in 2015

146.6+80 = 226.6

C = 2800

n = 0.75

S = 5m

Ce = CXSⁿ

£2800 x(5)0.75

£9,362.36

Update Cost

2024 x 2015

2023

9,362.36 x 2.8325

= £26,518.88

Convert to Naira

92
Exchange rate = £1= N500

Therefore £31663.951 =?

£26,518.88₦500

£1

ECONOMIC CAPITAL

TOTAL PURCHASE COST OF MAJOR EQUIPMENT (PCE)

Vacuum Sealer = N94991 85.3

Casing = N969810

Electric blender = N10892604

Spice blend = N33789030

stuffer = 795 5664

Blancher = N4949562

Total purchase cost of major equipment =

PCE = £255948.85 =N76,784655.3

ESTIMATION OF FIXED CAPITAL COST, REF TABLE 6.1

Total physical plant cost (PPC)

= ₦76,784655.3(i+2.15)

= ₦76,784655.3x3.1 5

= ₦241,87,664.2

93
Fixed capital = ₦24 1, 871664.2(1+0.4)

= 241 871664.2

Fixed capital 241,871664.2(1+0.4)

= N241871664.2x1 .4

WORKING CAPITAL (5% OF FIXED CAPITAL)

Allow 5% 5/100 = 0.05

= 0.05 x ₦338,620.329.9

= ₦16,931,016.49

TOTAL INVESTMENT CAPITAL (TIC)

TIC = Fixed capital + working capital

= ₦338,620,329.9 ± ₦16,931,016.49

= ₦335,551,346.4

ANNUAL OPERATING COST (REF TO TAB 6.6)

Operating time 34 days /annum

34days x 24 = 8328 hrs/year

VARIABLECOST

Electric power 700mj/d

ESTIMATED RAW MATERIAL

1. Raw meat = 500,000,000kg/yr

94
41,667kg/hr:347x24X3

1000

==₦1,041,000.833

PLANT ATTAINMENT 95%

2.Miscellaneous material (10% of working capital)

= 0.1 x ₦16,93,0l6.49

= ₦1,693,101.64

3. Utilities (Cost from table 6.5)

Power at 1 .2p/mj = 1.2 x 709 x 347

100

=2,914.8

4. Shipping and packaging = negligible

Variable cost: ₦1,041,000.833 + ₦1693101.64+ ₦2,914.8

=₦2,737,017.273

5. Maintenance (5% of fixed capital)

= 0.05 xN338,620,329.9

= ₦16,931,016.5

6. Operating cost for labour: (assumed £20,000/annum) it also allow for overheads.

= £20,000 = ₦6,000,000

7. Supervision: no additional supervision needed

95
8. Plant over heads (50% of operating labour)

= 0.50 x N6,000,000 = N3,000,000

9. Laboratory (20% of operating labour)

= 0.20 x ₦6000,000

10. Capital charges (15% of the fixed capital)

= 0.15 x ₦338,620,329.9

11. Insurance (1 % of fixed capital)

0.01 x ₦338,620,329.9

12. Local taxes (2% of fixed capital)

= 0.02 x ₦338620,329.9

= ₦6,772,406,598

13. Royalties: not applicable

Fixed cost (₦16931,016.5+ ₦6,000,000+ ₦5000,000

+ 1,200,000+50,793,094.49 + ₦3,386,299 + ₦6772,406,598)

= ₦6,853,716,867

Direct production cost

DPC = variable cost + fixed cost

= ₦2,737,017,273 = ₦6,853,7l6,867

= ₦6,856,453,884

14. Sales expense 10% of direct production

96
15. General overheads cost

16. Research and development 0.10 x ₦6,856,453,884

Annual production cost = 685,645,3 88.4

Unit production cost = Annual production cost

Annual production rate

= ₦685,645,384.4x 100

500,000,000

= ₦13.7

Selling price = ₦500

COMMERCIAL VIABILITY

This can be assessed by the relationship between the operating cost and

revenues both in absolute amount and in relative terms.

NET PROFIT/ANNUM:

It is an annual profit after various taxes are paid.

PV = Annual turnover — Annual cost of production

Annual turn-over = Quantity of sales X Selling rate

500,000,000x₦500

=2.5x100000000000

97
NPV=2.5 x 100000000000 - 685,645,3884

=2.49 x100000000000

ANNUAL COST OF PRODUCTION (NPR)

Annual profit x100

Annual sales 1

2.49 x 100

500,000,000kg/hr

= 49,800%

RATE OF RETURN (ROR)

It is the percentage of profit after tax but before depreciation to the total

invested fund.

= Profit (per year) x 100

Total investment capital 1

=2.49 x 1011 x 100

355,551,346.41

= 70,032.079% = 70%

BREAK-EVENPOINT IN UNITS

= Fixed cost

Contribution

98
Contribution= sales cost - variable cost

= ₦6,853,716,867

₦486.3

= 14,093,598.33units

BREAK-EVEN POINT IN NAIRA

= Fixed cost

1-variable

Sales cost = 6853,716,867

1-13.7

500

= 6,853,716.867

1-0.0274

6,853.716,867

0.9726

= 7,046,799,164

PAY-BACK PERIOD

Total investment

Return

355,551,346.4

99
2.5x1011

1.422205386 x 10

= 6 years

100