Design of a small scale factory for pomegranate juice

Azmy, Nur Syahida Laila (2019) Design of a small scale factory for pomegranate juice. [Project Paper] (Submitted)

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Abstract

Food factory system is a manufacturing system that transforms raw ingredients into food product that can be consumed or easily prepare by the consumers using physical, mechanical chemical and thermal process. In Malaysia, the food and beverage manufacturing are dominated by more than 97% of small and medium enterprises (SMEs). Most SMEs have problem related to low productivity and hygiene. Previous reports 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. 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 pomegranate juice business. The new factory was designed using 9 designed stage that integrates the Good Manufacturing Practice (GMP) aspects and considers the productivity requirement. The new factory has Production Program of 145,000 bottles per year, reserve capacity of 22.4% utilizes reconstitution and aseptic filling 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 six times, while the lead time was reduced by 65%. The improvement was due the designated continuous line, tangible Production Program, optimized machines capacity and layout arrangement. Meanwhile, the analysis with Hygienic Checklist Toll shows that the new design complied with majorities of hygiene requirement which is 97% of score percentage. Thus, the factory is ready for implementing GMP once the operation is run. This include separation of low and high risk area, material and personnel flow, airflow, 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:	20 Oct 2023 07:50
Last Modified:	20 Oct 2023 07:50
URI:	http://psaspb.upm.edu.my/id/eprint/1568

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