MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION GRADUATION THESIS MAJOR: FOOD TECHNOLOGY CALCULATION AND DESIGN OF A FACTORY PRODUCING CHOCOLATE WITH A CAPACITY OF 2200KG PER DAY INSTRUCTOR: HOANG VAN CHUYEN STUDENT: LE MINH SANG Ho Chi Minh city, June 2024 HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF INTERNATIONAL EDUCATION -------------------- GRADUATION PROJECT CALCULATION AND DESIGN OF A FACTORY PRODUCING CHOCOLATE WITH A CAPACITY OF 2200KG PER DAY LE MINH SANG Student ID: 17116031 Major: FOOD TECHNOLOGY Supervisor: Hoang Van Chuyen, PhD. Ho Chi Minh City, June 2024 ACKNOWLEDGEMENTS The process of researching and completing the graduation thesis is a very important stage for every student. Graduation thesis is a premise to equip students with necessary and valuable skills before going to work. First of all, I would like to express my deep gratitude to Hoang Van Chuyen, PhD.
wholeheartedly instructed, guided and imparted the experience, professional knowledge as well as necessary skills for me to carry out the experiment effectively and scientifically. I would like to express my gratitude to the faculty members of the Department of Food Chemistry and Technology, Ho Chi Minh City University of Technology and Education in general, and the teachers of the Department of Chemical Technology in particular. The teachers enthusiastically taught and equipped me with the necessary knowledge in the learning process to lay the foundation for me to be able to complete the thesis. Finally, I would like to thank my family, brothers and sisters who have always been by my side to encourage, help, and be a spiritual support for me during the past time.
In the process of implementation, because I myself have many limitations in knowledge and reasoning ability, the thesis cannot avoid shortcomings. I can be more perfect. I appreciate it! 1 DISCLAIMER Except where there is obvious recognition and reference to the work of others, I hereby declare that all content and material presented and involved in this thesis is my work. I also certify that the contents referenced in the thesis have been adequately and accurately cited in accordance with regulations.
Ho Chi Minh City, 20 June 2024 Signature 2 3 4 5 6 7 TABLE CONTENT CHAPTER 1: LITERATURE OVERVIEW. Overview of raw materials. Introduction of cocoa beans:. The chemical composition of cocoa :.
Benefits of Cocoa. Harvesting and preversing cocoa. Introduction of chocolate .4 Status of cocoa and chocolate. 23 CHAPTER 2: FACTORY DESIGN AND PRODUCTION PROCESS SELECTION.
Factory construction site. Source of raw materials and energy. Labor sources and cooperate. Flowchart of the production process of chocolate.
Mixing with ingredients. 44 CHAPTER 3: CALCULATION DESIGN OF CHOCOLATE PRODUCTION SYSTEM. Factory production plan. Material harvesting chart.
59 CHAPTER 4: CALCULATE INVESTMENT COSTS, OPERATING COSTS AND SELECT EQUIPMENT. Equipment and technology. YX Chocolate production line. Chocolate production line uses equipment from China.
Summary of devices. Calculation of steam-water-electricity. Steam for alkalization. Steam for CIP.
Equipment in the production workshop. 77 CHAPTER 5: CALCULATION FOR ORGANIZATION. Design of main production workshop. Factory organization chart.
Function and tasks. Features of the factory construction site. Traffic problems in the factory. Main production workshop.
Guard standing room. Cocoa butter ware house. Warehouse for auxiliary materials and packaging. Power supply area.
Chemical, fuel, oil storage. Wet and dry scrap warehouse. Water supply for production. Wastewater treatment facilities.
Room for date printing, labeling, packaging. Calculating plan for factory constructions. Calculate the utilization factor Ksd .1 Purpose and meaning .1 Investment capital in construction .2 Investment capital for equipment .3 Cost of raw materials.4 Cost of fuel .5 The cost for workers .6 Cost of social insurance.3 Price to product .3 Economic performance of invested capital. 108 CHAPTER 7: PRODUCT QUALITY AND PRODUCTION SAFETY.
Quality control system and food safety assurance. Labor safety and fire prevention. Factory requirements in production. Waste treatment of the production process.
Rules and regulations on fire protection at the factory. Inspection, training and equipment on fire prevention and fighting tasks at the factory. Check the quality of finished products. 113 CONCLUSION AND RECOMMENDATION.
115 List of table Table 1. Characteristics of cocoa groups. Chemical composition of fresh cocoa beans. Sunrise Screening equipment specifications.
Technical specifications of magnetic separator. Technical specifications of aerodynamic classification equipment. Technical specifications of drying equipment. Technical specifications of dehulling equipment.
Technical specifications of Grinding equipment. Technical specifications of Alkalizing equipment. Technical specifications of roasting equipment. Technical specifications of mixing equipment.
Technical specifications of refine grinding equipment. Technical specifications of tempering equipment. Technical specifications of molding equipment. Packaging equipment technology parameters .1: Raw material harvesting chart .2: Loss rate of chocolate products.
Equipment parameters in the Chinese production line. Investment costs in some technology lines. Selected production line parameters. Investment costs for additional equipment.
Equipment summary table. Electricity of equipment.2: Manpower for the production line .4: Summary of construction works of the whole factory. 1 Statistics of investment capital for construction works. 2 Statistics of investment capital for equipment in the factory.
3 Cost of raw materials to produce 2,55 tons of chocolate/day in 1 year. 5 Cost of fuel and water used in the plant. 106 11 List of figures Figure 2. Sunrise Screening equipment.
Magnetic separator equipment. Aerodynamic classification equipment. Working principle of Dehulling equipment. Operating principle of grinding equipment.
Operating princible of roasting equipment. Refine grinding equipment. Operating principle of grinding equipment. Operating principle of Conching equipment.
Operating principle of Tempering equipment. Working principle of Tempering device. Working principle of Molding device. Molding, cooling and separate molding system in chocolate production.
Working principle of Molding system. Working principle of cooling equipment. Working principle of packaging equipment. YX Chocolate production line.
Equipment diagram of chocolate production process according to YX production line. Chocolate samples are created from the YX production line. Chocolate production equipment line. Chocolate products from the above production line.
Line diagram of Chengdu Chocolate Company LST Science and Technology. Product lines produced from Chengdu LST Science and Technology line. 1 The diagram of production process. Factory organization chart.
Factory layout design drawing. Workshop layout design drawing. 101 12 ABSTRACK Nowadays, chocolate products are very popular and widely developed all over the world, along with new flavors and special shapes that attract a lot of consumers, especially children and teenagers. The development in chocolate production also brings high profits to the economies of countries around the world.
The first products produced were black chocolate, which were extremely popular in the Americas and Europe, bringing a lot of profit to the countries. When modern technology is developing more and more, specialized machines for chocolate production are put into production lines, at this time, the chocolate manufacturing industry has made very clear developments. The products are no longer limited as before, but more and more types available, many flavors, many shapes are produced, serving the needs of today's consumers. Thanks to advanced technologies, the chocolate production economy is growing rapidly around the world.
13 CHAPTER 1: LITERATURE OVERVIEW 1. Overview of raw materials 1. Introduction of cocoa beans: Cocoa belongs to the family sterculiaceae, genus Theobroma, species Cocoa. Cocoa originate from the tropical forests of Central and South America, which is about wild in origin.
Extensive cultivation of the cocoa tree originated in Central America and Mexico, was discovered and then expanded by the indigenous Aztecs and Mayans. In Vietnam, cocoa was introduced very early, following Western missionaries many years ago. Currently, cocoa is widely grown in many regions, notably the Central Highlands, which is still considered to have the most ideal conditions for growing cocoa. Here, according to statistical research, the trees flower and bear fruit all year round, with an average yield of 3 kg of dry seeds per 5-year-old tree.
In the previous period, cocoa trees were not heavily invested in because of difficulties in harvesting, preserving and distributing, but now when technology is advanced, human demand for products made from cocoa has increased. Cocoa trees are increasingly being invested in by people. Flowers are small, about 15mm in diameter, yellow, red, white or purple depending on the species. Flowers grow directly from the stem and branches, are bisexual and pollinated mainly by insects.5% of blooming flowers produce fruit, of which 90% of young fruits will dry and fall.
General shape of cocoa fruit: • Cocoa fruit can reach a length of 15 - 20cm, with a weight of about 200g or more depending on the variety. Depending on the species, the fruit shape is different (long, round or oval). Fruit colors are quite diverse: red, green or yellow. • Cocoa fruit contain between 25 and 80 beans.
Cocoa beans are egg-shaped, slightly flattened and usually pale reddish-lilac in color. The seed coat consists of a thin, fragile outer shell also called the hard shell and a very thin, fatty white silk shell that covers the seed core and eats into the seed core, dividing the seed core into angular cells. • Cocoa beans have not kernel, fat, 2 - 3cm long, surrounded by a white mucus layer with a sweet, slightly sour taste. • The color of the two endosperms can vary from the white of Criollo to the deep purple of Forastero through to the intermediate colors of Trinitario hybrids occupying the entire volume of the seed.
The embryo has many wrinkles and consists of many overlapping lobes, surrounded by a thin, clear, shiny membrane. They are connected at the base by a 6-7 mm long rootlet and a rudimentary sprout in the middle surrounded by lobe to form the sprout of the cocoa bean. 14 There are two species of cocoa, Crillo and Forastero, but scientists have researched and created a hybrid species of cocoa from the above two species called Trinitario and is now widely grown all over the world because it combines the advantages of 2 original cocoa tree species. Characteristic Criollo Forastero Trinitario long, tapered, Fruit shape Round, oval Long pointed tip Spine of cocoa Pointed, deep Sleek, no deep Deep grooves are not fruit grooves grooves clear Fruit peel thin, soft, little Hard, thick, rich Mostly hard texture wood tissue in wood Yellow-red with Color small brown Green yellow Not certain spots flower Pale pink pistil Purple pistil Green and red Bean 20 – 40 beans 30 – 60 beans More than 40 beans Table 1.
Characteristics of cocoa groups The embryo emulsion has a fairly high cocoa butter content, a little seed shell and no mucilage. Cocoa butter accounts for about 31.3% of the embryo's mass. Cocoa butter mainly contains triglycerides of glycerol and unsaturated fatty acids. Cocoa butter melts at a temperature of 16 – 37oC, depending on the crystalline form of the fat formed during crystallization.
Cocoa butter extracted from cocoa beans is in the form of small white crystals and has a characteristic aroma. Cocoa butter contributes to the flavor of cocoa. The chemical composition of cocoa : Table 1.