Equip Process

1
Equip Process
16
either
you must find everything yourself
or you must use what is available
look ahead!
2
Get Equipment
flow diagram
structure!
operations?
read, listen, try
orient
what available?
in one vessel?
combine?
now, later
cost?
list of equipment
borrow, lease or buy
3
Operations
list is by no means complete
4
Wokkels
a light snack
containing air?
natural ingredients
5
Recipe (1)
1
mix starch and water
recipe
2
cook under pressure
process
3
foam by pressure relief
equip
4
shape and cut foam
5
toast surface of foam
scale-up
6
dry the snacks
7
cool the snacks
6
Get Equipment (1)
pre-cook in batch mixer
toast
dry
pump
heat
cut
foam
pack
product
this works, we build a cost model and...
7
Need New Analysis
marketing tells us that this is
recipe
Too Expensive!
we have to go back
process
need a better recipe and process
equip
marketing influences decisions
8
Dissolving Starch
H2O
1
add water for swelling
2
heat to release amylose
3
shear to release amylopectin
linear poly-glucan
branched poly-glucan
9
High or Low Temperature?
heat uptake
75
44
35
27
we can choose
high water, low T
20
low water, high T
50
100
150
10
Foaming by Expansion
liquid 20 water
die opening
150 oC
void fraction in foam
0.4 water evaporation
foam must solidify quickly
bubbles
vapour pressure at 150 oC 100 kPa
11
Get Equipment (2)
residence time, s
browning
slurry reactor
cooking extruder
corn cooker
sterilising
temperature, oC
12
Recipe, Equipment (2)
1
mix starch and water
2
cook under pressure
3
foam by pressure relief
starch
water
die
cooking
mixing
foaming
13
New Idea Wokkling
concepts
the die(extrusion opening)
select
protect
recipe
process
small flow in middle
large flow at the edge
equip
spiral shape
14
Extruder Design
W
Dp
D
u
L
V
outlet temperature 150 oC
feed V 1000 kg h-1
residence time 20 s
D?
d?
W?
u?
L?
Dp?
15
Extruder Design (2)
screw geometry
from model and advice of manufacturer, experiment
starch water salt, milk powder, fat, spices
recipe
moisture content
natural 11 - 14 , 10 added
temp profile
20 0C
150 0C
pressure profile
0.1 MPa
20 MPa
residence time
20 s
feed
1000 kg hr-1
die head
shape of product, enough resistance
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Plant Design (1)
starch silos
metal separator
cut
dry
toast
cool
vacuum
water
equip
scale-up
aromas,additives
make
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Plant Design (2)
equip
scale-up
pre-conditioner
make
water
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New!! 3rd Generation Snacks
density of Wokkels in package 20 kg m-3
substantial transport and storage costs
New Idea
preparation by manufacturer
foaming at home
19
Ideal and Real
plan
plan
cooking extruder
concept
concept
wokkling
extruder changes
develop
develop
pre-conditioner
make
make
foaming at home
product
product
20
Summary
flow diagram
operations?
orient
what available?
combine?
cost?
list of equipment