MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING CAPSTONE PROJECT FOOD TECHNOLOGY THE DESIGN OF A SNACK PRODUCTION FACTORY WITH A CAPACITY OF 3000 TONS PER YEAR LECTURER: PhD. HOANG VAN CHUYEN STUDENT: LE TO QUYEN LE THI THUY NGA SKL 0 0 8 5 0 1 Ho Chi Minh City, January, 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT THE DESIGN OF A SNACK PRODUCTION FACTORY WITH A CAPACITY OF 3000 TONS PER YEAR LE TO QUYEN Student ID: 17116029 LE THI THUY NGA Student ID: 17116021 Major: FOOD TECHNOLOGY Advisor: HOANG VAN CHUYEN, PhD. Ho Chi Minh City, January 2022 THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, December 31st, 2021 GRADUATION PROJECT ASSIGNMENT Student name: Le To Quyen Student ID: 17116029 Student name: Le Thi Thuy Nga Student ID: 17116021 Major: Food Technology Class: 17116CLA Advisor: Hoang Van Chuyen, PhD. Phone number: 0948012849 Date of assignment: October 3rd, 2021 Date of submission: December 31st, 2021 1.
Project title: The design of a snack production factory with a capacity of 3000 tons per year 2. Initial materials provided by the advisor: - Design project of a meat processing plant - Design project of a brewery of 30 million liters per year 3. Content of the project: - Choose the construction location and product consumption area - Choose ingredients and build a snack production process - Calculate the amount of fuel - electricity - water used in the factory - Calculate capital investment and costs in the production process - A1 drawings of the total ground of the factory and the main production workshop section 4. Final product: Snack factory with a capacity of 3000kg/year CHAIR OF THE PROGRAM ADVISOR (Sign with full name) (Sign with full name) ACKNOWLEDGEMENT We would like to thank the teachers in charge of the Department of Food Technology, Faculty of Chemical and Food Technology, and Ho Chi Minh City University and Technology and Education for creating favorable conditions for us to carry out this design project to finish the study program soon.
Therefore, we would like to thank the wonderful knowledge that the lecturers imparted during the study, and their practical experience in factories, it is an important asset for us to use to complete the project. To complete and achieve today’s result, we have confronted and overcome all the strenuousness and challenges involved within and throughout the project. In addition, there is also a great contribution, motivation and support to us, coming from our dear lecturers, classmates and family. We would also like to thank our guide, Dr.
Hoang Van Chuyen, who has always trusted, enthusiastically guided and shared all the knowledge and teaching experience for us to successfully complete this graduation thesis on time. We sincerely thank! i DECLARATION We hereby declare that the content of this project is our own implementation with the guidance of Dr. Hoang Van Chuyen. All texts either quoted directly or paraphrased are indicated in the references in the text.
Ho Chi Minh City, December 31st, 2021 Students ii iii iv v vi vii viii ix x xi TABLE OF CONTENTS ACKNOWLEDGEMENT. ECONOMIC AND TECHNICAL RATIONALES OF THE PROJECT .2 Selection of factory’s location .1 Natural features and construction location .4 Clean water system .5 Wastewater treatment system .6 Fire protection system .3 Raw ingredient supply. OVERVIEW OF PRODUCT AND INGREDIENTS. The development history of the snack industry.
EXPLAIN THE TECHNOLOGICAL PROCESS OF PRODUCING SNACK PRODUCTS .1 Technological process of producing Snack products .2 Explain the technological process of producing Snack products. The plan of main raw ingredients. The plan of production. Material balance for the product.
CALCULATE AND SELECT EQUIPMENT. Seasoning spray equipment. Bucket Elevator Conveyor. Hand pallet truck .1 Design of the main production workshop.
Management organization chart. Function and tasks. Raw ingredients warehouse. Packaging materials warehouse.
Canteen and kitchen. Auxiliary works area. Energy supply zone in the factory. CALCULATION FOR STEAM – ELECTRICITY – WATER 73 7.
Calculate the amount of steam and fuel. Calculate the amount of steam used for production equipment. Calculate the amount of vapor used for the ripening stage……………………. Calculate the amount of steam used for the drying stage…………….2 Total amount of steam used in daily life .3 Steam cost of steam boiler .4 Total amount of vapor due to loss .5 Selection of steam boiler.2 Calculate the amount of fuel .2 Electricity for lighting load .1 Calculate the amount of water used in the factory .2 Calculate the water tank .1 Purpose and meaning .1 Investment capital in construction .2 Investment capital for equipment .3 Cost of raw ingredients .4 Cost of fuel.5 The cost for workers .6 Cost of social insurance .3 Price to product .4 Economic performance of invested capital.
INDUSTRIAL SAFETY AND HYGIENE .1 Purpose of production inspection.2 Steps in production inspection .1 Check input ingredients.2 Checking the production stages .3 Check the quality of finished products. 121 xvii LIST OF COMMON ACRONYMS Abbreviations Original words DO oil Diesel Oil FO oil Fuel Oil QC Quality control PE bag Polyethylene bag W Watt m Meter TCVN Tiêu chuẩn Việt Nam QCVN Quy chuẩn kỹ thuật quốc gia CFU Colony forming unit l Litter xviii LIST OF FIGURES Figure 1. 1 Graph of Vietnam's population over the years (Danso. 1 Processing of product.
2 Twin Screw Food Extruders. 5 Seasoning spray equipment. 8 Bucket Elevator Conveyor. 9 Hand pallet truck.
1 The diagram of production process. 2 Management organization chart. 3 The drawing of design the factory. 69 xix LIST OF TABLES Table 2.
1 Composition of Corn Flour per 100 grams [13]. 2 Quality criteria of corn flour follow by TCVN 11015:2015 [14]. 3 Composition of Rice Flour per 100 grams by USDA Standard [15]. 4 Quality criteria of salt by TCVN 3974:2007 [17].
5 Quality criteria of refined sugar by TCVN 6958 : 2001 [19]. 1 The diagram of main ingredient input. 2 Shows the number of days and shifts per month ( in 2021). 3 The composition of product and mixing ratio [26].
4 Loss of main ingredients through each stage [27]. 5 Moisture content of semi-finished dough through stages [26]. 6 Loss of extra ingredients through each stage [27]. 7 The mass of semi-finished products after each stage of main ingredients 29 Table 4.
8 The mass of semi-finished products after each stage of extra ingredients30 Table 5. 1 Equipment statistics table. 1 Number of employees working in administrative work. 2 Distribution of direct workers in 1 shift.
3 Number of indirect workers. 4 Construction works in administrative buildings. 5 Statistics of the buildings. 1 Statistics of equipment using electricity in the main workshop.
2 Statistics of areas using electricity in sub-workshops. 3 Statistics on the number of lights in the production buildings. 4 Statistics on the number of lights in the administrative building. 5 Summary of lamp power for buildings.
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 3000 tons of snack/year. 4 Cost of fuel used in the plant.
1 Checklist of materials used for production [52]. 2 Checklist of production stages [53]. 117 xxi ABSTRACT Nowadays, snack 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 snack production also brings high profits to the economies of countries around the world.
The first products produced were potato chips, 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 snack production are put into production lines, at this time, the snack manufacturing industry has made very clear developments. At the same time, the raw materials put into production are no longer just potatoes, but instead are many other ingredients such as corn, sweet potatoes, etc. 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 snack production economy is growing rapidly around the world. ECONOMIC AND TECHNICAL RATIONALES OF THE PROJECT 1.1 Economic basis According to statistics and forecasts on Vietnam's population, up to October 2021, it is 98.42 million people, it is forecasted that by 2050 the population will increase to 109. In which, it is estimated that the average number of children born every day is more than 4000 children, statistics in 2019 the proportion of children under 15 years old accounts for 33.6% of the total population and the proportion of the age group from 15 to 64 years old is 55% is the age group of adolescents [1]. The group of children under 15 years old and the youth age group are the ones with the highest demand for snack consumption today.
1 Graph of Vietnam's population over the years (Danso.org) According to The Sweet and Savory Snacks report on Vietnam's snack segment published by Euromonitor International, the industry's total revenue is estimated at $535 million in 2017, higher than 2016 ($479. In which, the snack market in 2017 in Vietnam has a total product revenue of about 354 million USD, equivalent to nearly 8. However, in terms of snacks production market size in Vietnam is still quite small compared to the world, only about 1/170 compared to the leading country in snacks production, which is the US. Besides, Vietnam is considered as one of the most developed 1 snack markets in the ASEAN region behind Thailand, Indonesia, and the Philippines.
The average consumption per capita is 0.8 kilograms, equivalent to 130. However, in the snack market by 2020, there has been a decline. According to a report by Statista, the total revenue of the industry is estimated to be only about 429 million USD in 2020. Today's life is significantly improved, and the spending trend of young people on snacking is increasing.
That makes the snacks market in Vietnam very potential. But as the current situation of the world makes people's awareness about healthy lifestyle increase, this makes the Snacks market in recent times trend down. In the period 2011-2015, the market always maintained a double-digit increase, but by 2018 it was only 5. The revenue of the whole market is forecasted to be about 455 million USD by 2021, equivalent to 10.2 Selection of factory’s location 1.1 Natural features and construction location Based on references about current industrial parks, we chose the location to build the factory as Amata Industrial Park located on National Highway 1A, Long Binh Ward, Bien Hoa City, Dong Nai Province.
Amata Industrial Park was created by a joint venture between reputable contractors, Sonadezi Company and Amata Corp.Public Company of Thailand. This is a project with modern infrastructure, advanced management level compared to the whole country and the region and was established in 1994, after many expansions, the industrial park has an area of 513 hectares. The total investment capital in the industrial park has so far reached 1.9 billion VND, meeting the employment needs of more than 60,000 employees. By 2020, the industrial park will be upgraded and expanded by 27 hectares [4].