After determining the production capacity, the team developed the manufacturing process for the

product. The first thing that the team did is to collect the information for the manufacturing process,
then make an adjustment regarding the raw material and the assembling activity. In the production
of viscoelastic surfactant, there are some sequences of the process in order to get a good quality
product.

Block Flow Diagram

Process selection requires a broad and extensive knowledge of various manufacturing process. We
need to consider many alternatives that can be used in manufacturing. Process selection is the very
first step selection of a manufacturing process, which is in combination with a geometric design
and material. Actually, the process of making photocatalytic roof tile is about mixing the raw
materials in the right composition, forming, and coating the roof with photocatalytic materials.
Figure 5.2 shows block flow diagram of the manufacture process of photocatalytic roof tiles.

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In designing the manufacturing process, before we design a plant, we should start from the simplest
design. Plant design starts from Block Flow Diagram (BFD), the simple flow of process made
from blocks. The BFD of manufacturing process of photo paper product explain the process to
make photo paper in plant scale. The BFD explain the big preview of process principle to give
easier understanding of manufacturing process and give a brief evaluation of economical design.
The BFD of photo paper on plant is presented below:

5.3.1 Material Preparation (Unloading Raw Materials)

Material preparation is included in procurement of the raw materials. There are water, aluminum
oxide silicate, quartz, magnesium oxide, sodium monoxide, TiO2, PEG 600 and iron oxide.
Aluminum oxide silicate, quartz, magnesium oxide and sodium monoxide will be stored in a
storage room separated by walls with numbering system to mark each material. Iron oxide, TiO2
and PEG 600 will be stored in a storage tank due to its sensitivity. In this section, the unloading
process will be from trucks, especially for ingredients which is imported or brought from another
city to be placed in the storage room and storage tanks.
5.3.2 Mixing
There are three mixing process in this plant. First, mixing process of raw materials for the roof tile
itself. The raw materials for roof tile from storage room is transported to pug mill by conveyor
with different speed that will variate the composition of the raw materials according to composition
that stated before.
The second mixing is for the coloring materials, which is iron oxide with water by composition
2.5% iron oxide in the water. This process is held in a mixing tank. The last mixing process is for
making sol of TiO2. The components that is involved in this process are TiO2 itself, PEG 600 as
a binder and also water as a solvent.

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The very first step of this manufacturing process is mixing. Mixing is the process of thoroughly
combining different materials to produce a homogenous product. The mixture is generally a
combination of dissimilar materials. In this manufacturing process, mixing intend to make coating
ingredient for paper. Encapsulated fragrance, Glycidol, PVOH and silica gel will be mixed until
the mixture become homogeneous. PVOH and silica gel enter the mixing tank in solid phase. Since
we need liquid phase of coating ingredient, we adding the water into mixing tank, so it must be
turned into liquid.
The mixing tank should have strong agitator which can handle routine viscosities. Because of that,
the mixing tank can assure the complete and uniform blending of the product. Since our product
is sensitive to product’s composition, the amount of materials that is fed into the mixer must be
controlled to the exact value. The flow of materials into the mixer will be controlled by Process
Logic Controller (PLC), which enables the workers to set the target weight, open all the correct
valves and pump the materials into mixer. This mixing tank operates at temperature 90oC to
accelerate the mixing process.

Packaging
Our product will be packaged and labelled. After that, the roof tile products will be stored in the
warehouse before being distributed by trucks to our target market. Warehouse is needed in case
that there will be decreasing or increasing demand of the product, we can store our product in
warehouse.

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Packaging is the last process in this manufacturing. This process is done by the machine that
automatically packs the photo paper into package. The machine is set to pack 50 photo papers in
1 package. After packed the photo paper into packages, then photo paper is ready to be distributed.