Design of a small scale factory for yam bean snack (sengkuang calit)

Johari, Nurulnadiah (2019) Design of a small scale factory for yam bean snack (sengkuang calit). [Project Paper] (Submitted)

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Abstract

Food factory is a manufacturing system that transforms raw ingredients into food product that can be consumed or easily prepared by the consumers using physical, mechanical chemical and thermal changes. In Malaysia, the food and beverage manufacturing are dominated by more than 95% of small and medium enterprises (SMEs). However, most SMEs have problems related to low productivity and hygiene. Previous studies showed that the problems can be sourced back to the poor design of the food factory that overlook aspects related to production efficiency and hygienic design. Thus, this project was performed to solve the productivity and hygiene requirement through the design of the new factory owned by Company X, a Malaysian SME that ventures in yam bean snack business in which the product consists of slice yam bean, sauces and roasted nuts. The new factory was designed using nine design stages that integrates the Good Manufacturing Practice (GMP) aspects and considers the productivity requirement. The new factory has a Production Program of 42560 kg/year, reserve capacity of 20%, Modified Atmosphere Packaging (MAP) processes, optimizes machines’ capacity as well as has efficient spine layout, adequate number of facilities and utilities supplies. Simulation analysis with FlexSim software showed that the productivity of the new factory was increased by 2 times for all products, while the production lead time was reduced by 17% for slice yam bean, 90% for sauces and 67% for roasted nuts. The improvement was due the designed continuous line, tangible Production Program, optimized machines capacity and layout arrangement. Meanwhile, the analysis with Hygienic Checklist Tool shows that the new design complied with majorities of hygiene requirement (96%) thus, ready for implementing GMP once the operation is run. This include separation of low and high risk area, onward material and personnel flow, hygienic airflow, adequate spatial design and building structures specification. In conclusion, an efficient and hygienic food factory system can be achieved when the productivity and GMP requirement were addressed as early as at the design process.

Item Type:	Project Paper
Faculty:	Faculty of Engineering
Depositing User:	Ms. AZLINA ZAINAL ABIDIN
Date Deposited:	18 Oct 2023 04:25
Last Modified:	18 Oct 2023 04:25
URI:	http://psaspb.upm.edu.my/id/eprint/1565

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