FEDERAL POLYTECHNIC NEKEDE,

P.M.B 1036 OWERRI,

IMO STATE.

PLANT DESIGN
ON

SOY MILK BEVERAGE

PLANT

BY

NAME: ANEKE CYNTHIA MARYAGNES

REG. NO: 20EH/0031/FT

DEPT: FOOD TECHNOLOGY

LEVEL: HND II (EVENING)

COURSE TITLE: EQUIPMENT & PLANT PROCESS DESIGN

COURSE CODE: FST 412

LECTURER: ENGR. ARINZE & MR. CHIBUIKE NJOKU

DATE: MAY, 2022

1
 CERTIFICATION

This is to certify that this work on the “SOY MILK BEVERAGE PLANT” was

carried out by ANEKE CYNTHIA MARYAGNES with the registration number

20EH/0031/FT and submitted to the Department of Food Technology, School of

Industrial and Applied Sciences, Federal Polytechnic Nekede, Owerri in partial

fulfillment of the requirement for the award of Higher National Diploma.

……………………. …………………

Mr. Chibuike Njoku Date

(Supervisor)

2
 DEDICATION

This work is dedicated to God almighty for his love and mercies towards

me, and for making my dreams come to reality.

3
 ACKNOWLEDGEMENT

I acknowledge the presence of God in my life, for his mercies and blessings. I say

thank you Jesus. I humbly acknowledge my lecturer, Mr. Chibuike Njoku for his

teachings and instructions as regards to engineering principles. I also acknowledge

my parents for their love and care in all round. I will not forget to acknowledge my

brothers, sisters and friends for their love and care towards me not withstanding all

the storms of life. I pray may God continue to shower his blessings on you all

Amen.

4
 ABSTRACT

This study demonstrates the processing of soya beans into soya milk beverage and
extends its use and convenience. Soya were washed, soaked (3 hours up to
overnight), and grind to produce soya milk beverage. The experiment were carried
out which include heat and mass transfer coefficient, piping and instrumentation,
material and energy balance, equipment design specification and costing of the
equipment, economic analysis and plant location and layout, on the soya milk
beverage production and design. The plant will be situated at Niger state with a
total investment capital N38,620,309, rate of return 70% and payback period of 6
year and 4 months. Detailed economic studies showed that the production of soya
beans into soya milk beverage would be economically viable in Nigeria when the
milk is sold at N500 per 100mg provided a minimum scale of 70% beans
used.

5
 TABLE OF CONTENTS

Title page

Certification

Dedication

Acknowledgement

Executive Summary

Table of contents

CHAPTER ONE

1.0 Introduction

1.1 Background of the study

1.2 Aim and objectives

1.3 Production steps of soya milk

1.4 Properties and structure

1.5 Uses

1.6 Process route

1.7 Other process route

1.8 Why the process route was chosen

• 1.9 Scope of the design

1.10 Limitations

6
1.11 Process flow chart (Diagram)

1.12 Process description

CHAPTER TWO

2.0 Literature review

2.1 History of Soy beans

2.2 History of Soya milk

2.3 Potatoes production

2.4 Nutritional factors of soya milk

2.5 Anti-nutritional factor soya milk

2.6 Effects of spoilage in soya milk

CHAPTER THREE

3.0 Material and energy balances

3.1 Material balance

3.1 Conservation of mass

3.1.4 Material balance assumption

3.1.2 Material balance assumption

3.1.3 Material balance assumptions

3.1.4 Material balance around different units

3.2 Energy balance

3.2.1 Energy balance assumption

7
CHAPTER FOUR

4.0 Piping and instrumentation

4.1 General overview

4.3 Instrumentation and control objectives

4.4 Control system and short down schemes

4.5 Basic start up and operational information

4.0 Safety measures

4.7 Product specifications

4.8 Environmental regulation

4.9 Economic reasons

4.10 Valve selection

4.11 Alarm and safety trips

4.1.2 Material devices

4.1.3 Pump and pipe selection

CHAPTER FIVE

5.0 Equipment design and specification

5.1 Major equipment use (design costing)

5.1.1 solar dryer

5.1.2 Hammer mill

6.1.5 Other economic benefits

8
CHAPTER SEVEN

7.0 Plant location and layout

7.1 Plant location

7.2 Plant layout

7.2.1 Objectives of plant layout

7.3 Environmental impact assessment

CHAPTER EIGHT

8.0 Plant safety and loss prevention

8.1 Process control and hazard control

Conclusion

Recommendation

References

Appendix

9
 CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND OF THE STUDY

Soya milk also known as soy milk or soymilk, is a plant-based drink produced by

soaking and grinding soybeans, boiling the mixture, and filtering out remaining

particulates. It is a stable emulsion of oil, water, and protein. Its original form is an

intermediate product of the manufacture of tofu. Originating in China, it became a

common beverage in Europe and North America in the latter half of the 20th

century, especially as production techniques were developed to give it a taste and

consistency more closely resembling that of dairy milk. Soya milk may be used as

a substitute for dairy milk by individuals who are vegan or are lactose intolerant.

Soya milk is also used in making imitation dairy products such as soy yogurt, soy

cream, soy kefir and soy-based cheese analogues. It is also used as an ingredient

for making milkshakes, pancakes, smoothies, bread, mayonnaise, and baked goods.

Soya milk (called soymilk in America) is made from soya beans. Essentially, it is

an aqueous extract that is prepared by grinding soya beans that have been soaked

in water. The process of making soya milk was discovered in China where soya

beans were originally cultivated and consumed. It was mainly used in the process

of making tofu or bean curd. By 1931, calcium-fortified soya milk was being

produced in America by Madison Foods in Tennessee.

10
Soymilk and its related food products are getting popular throughout the world due

to their nutritional and medicinal qualities. Soymilk is high in protein and low in

fat and carbohydrate and contains no cholesterol. Soymilk is an excellent food for

babies, children and the elderly people including pregnant and lactating women as

it contains vegetable protein that is very easy to digest.

Soya Milk is an inexpensive and remarkably versatile high protein food made from

soya beans. It is a white liquid made from the seed. Unlike most other protein

foods, milk is entirely free from cholesterol and low in fat (specially saturated

fats). The quality of protein is as high as that found in chicken. It is also good for

dieters as this contain low calories. It is an excellent food for babies, children,

elderly people and pregnant and lactating women since it contains vegetable

protein which is very nutritious and easy to digest. Soya milk and its derivatives

are the cheapest source of protein, its derivatives tofu (soya paneer) makes testy

dishes like matar paneer, palak paneer etc. and snacks like soya burger, patties,

sand witches, pakoras etc. and also used in desserts.

Process of Manufacture

The initial stage involves the cleaning, sorting of the Soyabean followed by

dehulling and soaking at room temperature in 0.5 – 1% sodium bicarbonate

solution in 1:3 ratio (soya: solution). After soaking the weight of original soyabean

becomes double, the split (dehulled beans) are ground in hot water in1:7 ratio and

11
filtered to get milk. The residue is known as okra. The milk is then cooled to 700 C

and 0.1 molar calcium sulphate/magnesium chloride or 2% citric acid solution is

added with slow stirring. These chemicals precipitate/coagulate the proteins of

soya milk. The muslin cloth containing Soya protein is pressed in paneer making

boxes for 3 to 5 mts. And then cut into pieces of approx. desired size and put in

cold water for another 30 minutes. Vacuum packed tofu should always be kept in

the fridge and after unpacking, immersed in water. The various products which can

be manufactured are mentioned in the Chart below

1.2 AIMS AND OBJECTIVE OF THE DESIGN

The aim of this design is to present on the Paper a replica of Soya milk Plant.

The objectives of this study is to represent on the paper, a replica of a food

processing plant capable of producing soya milk with tones 500,000 per year and

41,666.7Kg/hr by carrying out the financial and economic evaluation of the plant.

12
PROCESS ROUTE

Directions

Step 1

Soak beans overnight in water. Drain, rinse, and discard water. Combine

soaked beans with 2 quarts fresh water. In a food processor or blender,

process beans with water until smooth.

Step 2

Strain into a pot through a double layer of cheesecloth, or a fine sieve. Add

pandan leaf or ginger, and sugar to taste. Boil soy milk for 15 minutes. Stir

frequently to prevent skin from forming. Remove pandan leaf or ginger, then

flavor with vanilla. Stir in sugar to taste. Cool to room temperature, then

refrigerate.

13
 FLOW DIAGRAM OF SOYA MILK BEVERAGE

Clean and Soak Soyabeans

1 kg. Beans 3.3 ltr Water

Airless grind and cook

5.2 litre water and 1.3 kg
steam.

Extract Soya milk Base 7.5

litre Soya milk 1.4 kg Okara

Add coagulant or Add Sweetener Salt Okra Add salts, spices,

AddWater Sweetened
citric and yoghurt culture Flour Vegetables
flavor salt etc.

Homogenize or Mix Incubate Yoghurt

Extract Curd pressing Bake or Fry or add to
well Soya milk optionally and fruits
a forming Box Tofu foods and Cook
(Paneer)

14
1.8 SCOPE OF DESIGN

The design covered market analysis, financial analysis, material balance

assessment of the commercial viability each of the equipment will be designed

strictly based on the requirement of the correspondent process in order to achieve a

maximum production and working at full capacity (100%) at the end of the day.

The design work will also show the plant location and layout, piping and

instrumentation, plant safety and loss prevention, environmental impact assessment

and finally the cost estimation of the project.

1.9 LIMITATIONS OF THE DESIGN

The primary limitations were time, finance and scope of the project again

combining resources to achieve set objective.

The design of the required proprietary equipment (extractor press etc) is beyond

the scope of this work.

They were only specified here after carrying out a simple calculation which

showed forth the basis of the specification. On the long run, the basis of the design

might be modified to suit prevailing conditions.

15
1.7 QUANTITATIVE FLOW DIAGRAM
Process
Raw Material

Process

1. Unit operation

2. Unit process

Events

1. Inspiration

2. Transportation

3. Storage

Finished product

16
 Pipe -----------------------------------

C Cooled or heated pipe

Motor Drive Dryer

Belt

Pump ---
---
---
Wer or motor drive

Conveyor

Wer or motor drive

Conveyor Tray or solar dryer

Diagram Valve

Rotor Motor Wheel

17
 Course

Hopper
Fine Screen Filler (sieve)

Drum or Tank Drain Size Reduction Equipment

Weighing Scale

Agitator

CHAPTER TWO

LITERATURE REVIEW

18
2.1 HISTORY OF SOY BEANS

Soybeans originated in Southeast Asia and were first domesticated by Chinese

farmers around 1100 BC.  By the first century AD, soybeans were grown in Japan

and many other countries.

Soybean seed from China was planted by a colonist in the British colony of

Georgia in 1765. Benjamin Franklin sent some soybean seeds to a friend to plant in

his garden in 1770. Soy sauce had been popular in Europe and the British colonies

in America before soybean seeds arrived. It wasn’t until 1851 that soybean seeds

were distributed to farmers in Illinois and the corn belt states. This seed was a gift

from a crew member rescued from a Japanese fishing boat in the Pacific Ocean in

1850. In the 1870s soybeans increased in popularity with farmers who began to

plant them as forage for their livestock. The plants flourished in the hot, humid

summer weather characteristic of North Carolina. By the turn of the century, the

United States Department of Agriculture was conducting tests on soybeans and

encouraging farmers to plant them as animal feed. In 1904, the famous American

chemist, George Washington Carver (pictured left) discovered that soybeans are a

valuable source of protein and oil. He also realized the benefits of soybeans for

preserving good quality soil. Mr. Carver encouraged cotton farmers to “rotate”

their crops in a three-year plan so that peanuts, soybeans, sweet potatoes or other

plants would replenish the soil with nitrogen and minerals for two seasons, and

19
then the third year farmers planted cotton. To the surprise of many farmers, this

produced a far better cotton crop than they had seen for many years!

In 1919 William Morse co-founded the American Soybean Association and

became its first president. At the time farmers used only 20 proven varieties of

soybeans. Morse recognized that there was much potential to be discovered in the

soybean plant.  In 1929, Morse spent two years gathering soybeans in China. He

brought back more than 10,000 soybean varieties for agricultural scientists to

study. Morse understood that new, improved varieties meant better production for

farmers.

Henry Ford is known for producing automobiles but did you know that he once

made a car with plastic bodywork made from soybeans? Ford owned a large

research facility. He came to the lab one day with a bag of soybeans. He dumped

them out on the floor and told the scientists, “You guys are supposed to be smart.

You ought to be able to do something with them.” In time, the scientists in Ford’s

lab made a strong enough plastic for the gearshift knobs, horn buttons, window

frames, accelerator pedals, light-switch assemblies and ignition-coil casings. They

also fashioned the exterior of an automobile from “soybean plastic.” By 1935 Ford

was using one bushel of soybeans for every car he manufactured. It wasn’t until the

1940’s that soybean farming really took off in America. Soybean production in

China, the major supplier at that time, was halted by World War II and internal

20
revolution. When the United States entered the war, the steep increase in demand

for oils, lubricants, plastics and other products greatly increased the demand for

soybeans. United States farmers produced the needed soybeans.

Following the Second World War, the United States experienced a period of

increasing prosperity. Demand for meat consumption increased as people’s diets

improved. Livestock producers found that soybean meal was the preferred source

of protein at an affordable cost. Chickens, turkeys, cattle and hogs were fed diets

containing tens of millions of tons of soybean meal each year. This increase in the

use of soybean meal for livestock feed began in the 1950’s and soybean meal has

been the preferred choice ever since. One of the great scientific advances in

agriculture was the improvement of the soybean in the 1990s to withstand

herbicides. This meant that farmers could control weeds without killing the

soybean plant. They wouldn’t have to cultivate the fields with steel implements,

which meant less soil erosion, less fuel expended, and more yield per plant. This

development resulted in new production practices that are gaining acceptance

around the world. Farmers in food deficit regions of Africa and Asia are realizing

that this technology will feed many more people on the same amount of land. The

technology has allowed U.S. farmers to become suppliers to the world at a time

when global demand for food is reaching unprecedented levels. Thirty-one U.S.

states have a soybean production industry. The top producers are the states of

21
Iowa, Illinois, Indiana and Minnesota. These midwestern states have deep, rich

soils and relatively cool summer nights. North Carolina in comparison produces

about one-tenth of the volume of soybeans produced in Iowa. But North Carolina

produces many other crops besides soybean. A typical North Carolina soybean

farmer might also grow corn, wheat, cotton, tobacco, sweet potatoes or

peanuts. North Carolina has one of the largest pork and poultry industries in the

world. As a net importer of soybeans and soybean meal, North Carolina ranks has

high as many entire countries!

2.2HISTORY OF SOYA MILK

The oldest evidence of soy milk production is a Chinese mural incised on a stone

slab. It shows a kitchen scene that proves that soy milk and tofu were being made

in China during the period A.D. 25-220. The oldest written reference to soy milk

appeared in also in China at about A.D. 1500, in a poem "Ode to Tofu" by Su Ping.

The earliest European reference to soy milk was in 1665 by Domingo Fernandez

de Navarrete and in 1790 by Juan de Loureiro, a Portuguese missionary who lived

in Vietnam. All these early references to soy milk only mentioned soy milk as part

of the process for making tofu. Only 1866, Frenchman Paul Champion, who had

traveled in China, mentioned that the Chinese drank hot soy milk for breakfast.

Soy milk was first referred to in the United States by Henry Trimble in 1896 in the

22
American Journal of Pharmacy. In 1910, Li Yu-ying, a Chinese living in Paris

founded the world's first soymilk factory. In 1917, the first commercial soymilk in

the US was produced J.A. Chard Soy Products in New York.

The first calcium fortified soy milk was produced in 1931 by Madison Foods,

Tennessee. This Madison Foods company was run by the faculty of the Madison

College. In 1939 Miller started to produce canned liquid soy milk, which was

called Soya La, because the dairy industries prevented Miller from calling the

product "soy milk".

Agriculture along with animal husbandry has been and will continue to be the

lifeline of Indian economy. India is the largest and one of the most economical

milk producers in the world (estimated production of 105 MT).It is the most

important sector of the Indian economy particularly in poverty alleviation and

employment generation. This sector contributes close to one-fourth of India’s

National income and total work force engaged in agriculture is about 60 per cent.

At global level, milk has been identified as an integral part of food for centuries.

The success of White Revolution in India has largely been written by millions of

small holders. About 70 million dairy farmers produce more than 50 per cent of the

milk in the country. Milk and milk products are one of the important components

of the Indian food industry. Consumption of milk and milk products is deeply

23
rooted in our tradition and it is an essential item during rituals, festivals and other

auspicious events.

Dairy is currently the top-ranking commodity in India, with the value of output in

2004 at 1.179 billion rupees (US$39 million), which is almost equal to the

combined output value of rice and wheat. Despite the importance of the dairy

sector in overall GDP, it receives less government budgeting than the agriculture

sector. Further, there has been no concentrated investment in the development of

value-added or innovative products, nor any serious effort to support and

modernize the informal sector.

In light of the increasing demand driven by the growing population, higher

incomes and more health consciousness, the slowdown in dairy industry growth is

severely worrisome. Based on estimates by the National Dairy Development Board

(NDDB), the demand for milk is likely to reach 180 million tonnes by 2022. To

supply the market, an average incremental increase of 5 million tonnes per annum

over the next 15 years is required – a doubling of the average incremental rate

achieved over the past 15 years. In the absence of sufficient increased production,

India will need to rely on the world market for imports. And because of the huge

volume required, it will affect global milk prices. Thus, focusing on areas for local

dairy development is critical. According to the chairperson of National Dairy

Development Board (NDDB). India is set to face milk shortage soon due to rising

24
consumption in both rural and urban areas while productivity remains low despite

the country being the world’s largest producer “We will without doubt start facing

milk shortage as demand is increasing at a much faster rate than production due to

rising consumption in village households and demographic dividend in urban

areas,”.

Quality Control and Standards

Product should conform to the PFA (Prevention of Food Adulteration), Act, 1955

Soybeans are stored and transported under various humidity and temperature

conditions. Soymilk and tofu are two of the most important foods made from

whole soybeans. The objective of this study was to investigate the influence of

storage conditions on soybean quality as related to soymilk and tofu-making

properties. Soybeans of 3 different genotypes (Proto, IA2032, and Vinton 81) were

stored in varying conditions: temperature ranging from 4 to 50 degrees C, relative

humidity from 55% to 80%, initial moisture content from 6% to 14%, and storage

time up to 15 mo depending upon storage conditions. The effects of different

storage conditions on soybean color, solids and protein extractability, soymilk pH,

tofu yield, tofu solids and protein contents, tofu color, and texture were

investigated. While no significant changes occurred for the soybeans stored at 4

degrees C, the soybeans stored at high temperatures (30 to 50 degrees C) exhibited

significant quality loss (P < 0.05).

25
 The degradation of soybean lightness (Hunter L), color difference (Delta E), and

solid extractability exhibited a linear relationship with time. Soak weight decreased

at high temperature and relative humidity, but increased at mild storage conditions.

Several combinations of storage conditions at temperatures exceeding 30 degrees

C produced a drastic loss in tofu yield. Storage also affected the tofu making

process by reducing optimum mixing time to produce the highest tofu yield.

Varietal difference in soybean storability was observed. The results provided

useful information for the soybean processing industry to store soybeans using the

optimal storage conditions and to estimate soybean quality after storage.

2.3 NUTRITIONAL FACTORS OF SOYA MILK

There are so many types of soy milk on the market, and the number of calories and

added sugar will differ depending on what you buy. Always check the nutrient

facts label on your brand of choice. The following is the nutrition facts for one cup

of a popular organic unsweetened soy milk:

 Calories: 80

 Fat: 4 grams (g)

 Saturated fat: 0.5 g

 Carbohydrates: 3 g

26
 Fiber: 2 g

 Sugars: 1 g (0 g added sugars)

 Protein: 7 g

2.4 ANTI NUTRITIONAL FACTORS SOYA MILK BEVERAGE

Soy milk was prepared from 'PK 416' and 'PK 472' varieties of soybean. The seeds

were evaluated for anti-nutrients content in terms of phytic phosphorus, trypsin

inhibitor activity, oligosaccharides (raffinose and stachyose) and saponins at

various stages of soy milk preparation. All the anti-nutrients showed a significant

(p≤.05) decrease at every step of the soy milk production. Blanching of seeds in

0.5% NaHCO3 solution for 30 min followed by washing of the seeds caused

maximum reduction in the anti-nutrients, whereas subsequent washings showed

lesser extent of reduction in the anti-nutrients. The soy milk prepared by using

Pantnagar process contains very low amounts of anti-nutrients. 'PK 472' possesses

less anti-nutrients as compared to 'PK 416' and is more suitable for soy milk

preparation.

2.5 SPOILAGE IN SOYA MILK BEVERAGE

Locally produced soymilk was subjected to microbiological analysis(under two

storage conditionsambient and refrigeration) to ascertain their hygienic standard of

production and the and the shelf life.Standard microbiological techniques,pour

27
plate method were used in the enumeration of potential spoilage organism in

soymilk sample. Result of microbial analysis showed that activities of

microorganism were more pronounced in the sample kept at ambient

temperature(270C) with bacterial count of 2×103 on the first day after production

but later increased to 2.9×104 after six days of storage. There was outstanding

difference in the bacterial count of the refrigerated sample as none was observed in

the first day after production but later increased to 1.5×104 after the sixth

day.Result obtained showed that soymilk can be kept for up to three(3) days at

refrigeration temperature(40C).Seven bacterial isolates, Bacillus spp, Enterobacter

spp and Escheria coli and three fungal isolates.Aspergillus spp,Rhizopus spp,and

Penicillum spp were detected in the soymilk stored at both ambient and

refrigeration conditions.The microbial population detected in terms of number and

types of microorganism reflected poor hygienic standard of production,constituting

a public health hazard among the consumers. The result of statistical analysis

carried out revealed that there was significant treatment effect on the growth of

microorganism. The implication of this study is that the quality of locally produced

soymilk needs to be critically monitored to avoid transmission of infection to

consumers. It is also very necessary that local producers should be enlightened

about good manufacturing practices and the effect of proper storage as this will

ensure products free of pathogenic microorganisms.

28
The diets of people in many developing countries comprise mainly starchy roots,

cereals, and few legumes. Unfortunately, animal sources of protein, which are used

to complement the starchy diets, are expensive and times, out of reach for low

income families (Kolapo and Oladimeji, 2008). In recent years, different edible

varieties of legumes have been identified to have high plant protein, and therefore

could help to address a number of diet related problems globally. Grain legumes

serve as a cheap source of proteins to a large proportion of the population in poor

countries of the tropics. Several legume based milk and milk products have been

developed in attempts to extend the supply of milk-like products especially in areas

where milk is in short supply. Since legumes are important sources of relatively

inexpensive protein, introduction of imitation milk products from legumes will

contribute to the alleviation of protein malnutrition (Gesinde et al, 2008).

Development of milk substitutes extracted from legume serves as an alternative

way of producing an acceptable nutrious food. Soybean (Glycine max) is

rcognized as one of such legume crops with huge potential the world over. This

plant has been exploited for the manufacture of food products with soymilk

identified as one of the promising products (Osundahunsi and Awor, 2005, Kolapo

and Sanni, 2-005). Soymilk is a fine, off-white or creamy emulsion, which

resembles cow milk in both appearance and consistency (Soya Be, 2006). The

increasing popularity of soymilk as a beverage worldwide (Dashiell et al, 1990) is

29
credited to it health benefits. For example, low cholesterol and lactose levels, its

ability to reduce bone loss and menopausal symptoms, prevention and reduction of

heart disease and certain cancers (Soya Be. 2006). The attendant increase in the

rate of soymilk consumption has encouraged low-scale production of the milk

under house-hold conditions with little or no regard to quality control measures.

Consumers are increasingly aware of the effect of good diet on their well being and

health soymilk is not only consumed for refreshment, but also to increase well

being and to help in preventing health related disorders. An increasing number of

consumers prefer minimally processed products from natural raw materials for

reducing the intake of chemical additive from food and for obtaining products with

improved nutritive and sensory characteristics (Iwe. 1991). The greatest problem

associated with soymilk remains its beany flavor and very short shelf life due to

microbial activity. The nutritious nature of soymilk however, makes it prone to

microbial attach if not properly processed and stored as the nutrients it contains are

also required for the growth of most spoilage organisms. A large number of

microorganisms such as mesophilic aerobic bacteria, coliforms and fungi are

known to be responsible for the spoilage of soymil, producing undesirable changes

in milk (Momoh et al., 2011). It is therefore of paramount importance to subject

soymilk production to a reasonable degree of hygiene. This coupled with the effect

of refrigeration could help in extending the shelf-life. The presence of coliform

30
bacteria in soymilk generally provides an index of the hygienic standard of

soymilk and its keeping quality (adeleka et al. 2000). Control of microbial growth

and spoilage of product is achieved by restricting and controlling microorganisms

from contaminating the product through good manufacture and handling practice

(Ofoefule, 2002).

Shelf-Life Studies

The soymilk derived from the soybean seeds were divided into two clean bottles

having screw corks.The bottles were tightlyscrewed and stored under two different

conditions for shelf life studies. One of the bottles was stored at room temperature

(27+2°C) and the other at refrigeration temperature (4°C) to monitor the

occurrence of various bacterial isolates and the vable bacterial counts during

decomposition. Shelf-life studies were carried out immediately after production (0

hour) and after every 24 hours thereafter, until each of the bottles were determined

spoilt. Bad odour. Bad taste and separation of the milk into two distinct portions

(curdling), were indicative of spoilage in each of the bottles.

Methodology for total viable count (Serial Dilution)

1ml of the soymilk sample was picked with the aid of a sterile pipette after

vigorous shaking. A plastic rack was arranged with sterile test tubes containing 9

ml of sterile distilled water. A ten fold serial dilution (Dhawale and LaMaster,
31
2003), was carried out by dropping 1ml of the sample into the first test tube labeled

10-1. This was mixed properly. 1ml was again taken from the 10-1 dilution tube

and transferred into the next test tube labeled 10-2. The dilutions continued to

dilution 10-5. Each test tube was vigorously shaken before each transfer.

Inoculation

The pour Plate method (Dhawale and LaMaster, 2003) was used in plating all the

samples. 1ml from dilution 10-3 was dropped into sterile petri dish with the aid of

a sterile pipette. A molten Nutrient agar, mannitiol salt agar, macConkey agar,

deMan Rogosa and Sharpe agra and Potato Dextrose agar were poured into the

several Petri dishes containing 1ml of diluted sample. The plates were rotated

clockwise for easy mix up of the sample and the media. All plates were allowed to

solidify on the bench. All plate samples were duplicated. All media were prepared

by weighing appropriate amount of the powder according to manufacturer’s

specification Incubation The potato dextrose agar plates were transferred into an

incubator at 25°C for 3-5 days while the other plates for bacteria isolation were

transferred into another incubator at 37oC for 18 – 24 hours.

Counting of the Colonies After incubation of all the plates, counts of the number of

colonies in each plates was done with a hand tally counter (Dhawale and LaMaster,

2003). A mean of the count was obtained and multiplied with the appropriate

32
diluting factor. The mean count was calculated as shown below. Mean = total

Viable Count Number of plates The estimation of viable number of

microorganisms (total viable counts) in each samples was made in colony forming

units (cfu) TVC = 1 Weight of sample *N*D Where N = average number of

colonies D = dilution factor Isolation of Microorganisms from soymilk Sample The

soymilk samples (ambient and refrigeration) were diluted in a ten-fold serial

dilution as stated above. The pour plate method of incubation was used in plating

all the samples. 1ml from the 10-3 dilution tube was dispensed into several sterile

Petri dishes with the aid of a sterile pipette. Molten Nutrient agars, MacConkey

agar, deman Rogosa and Sharpe agar, mannitol salt agar and potato dextrose agra

were poured into the plates. The plates were rotated for easy mix up of the sample

and the media. All plates were allowed to solidify on the bench. Each plated sami;e

was duplicated. All the potato dextrose agar plates were transferred into an

incubator at 25oC for 3 – 5 days while the other nutrient plates sample was

duplicated. All the potato dextrose agar plates were transferred into an incubator at

25oC for 3 – 5 days while the other nutrient plates were transferred into another

incubator at 37oC for 18 – 24 hours. All the incubated plates were examined daily

for mycelia and colony growth. Sub- Culture and purification After incubation

period, discrete colonies from bacteria plates were picked with a flamed wire loop

and sub-cultured onto a newly prepared nutrient agar plates. Also, a flamed knife

33
was used to sub-culture different colour of mycelia growth from potato dextrose

agar plates onto a newly PDA plates. All plates were incubated appropriately. All

nutrient plates were transferred into an incubator at 37oC for 18 -48 hours while all

the PDA plates were incubated at 25oC for 3 – 5 days. Purified colonies and

mycelia were transferred into slants and stored properly for further

characterization. Characterization of purified cultures *Fungi) Macroscopic

examination was done by physical characteristics of the mycelia for colour and

structure. Microscopic characteristics were also done through the morphological

structure according to bernette and Hunter (1987). A wet mount method (Dhawale

and LaMaster, 2003) was done before viewing the isolates under X40 objective of

the microscope. The morphological structures include septate, non- septate,

presence of sporangiophores, fruiting bodies and special organism like rhizoids etc.

each morphological structure of each isolate was matched with a mycology atlas

(Bernette and Hunter, 1987) for identification. Characterization of purified Culture

(Bacteria) Each purified bqcteria was examined macroscopically for colony

morphology, microscopically and then gram stained to determine the gram status.

Characterization of the bacterial isolates was done through some standard

biochemical tests. Sugar fermentation test were also carried out and recorded. The

results were matched with a bacteriology atlas (Buchanan and gibbons, 1975). The

biochemical tests analyzed were as follows. Catalase, Indole, methyl red, voges-

34
Proskauer, Urease, H, S. Methylene blue test (Methodology) This test was used to

check the contamination of bacteria in the sample of soymilk. It tells us about the

vable count of bacteria that may be present in the milk. It is equally used to know

the quality of the milk and in which quantity bacteria invaded the milk. Principle:

This test is based on the principle that if viable bacteria are present in the milk,

they will reduce the methylene blue dye and decolourize the sample if kept for

sometime. The methylene blue is reduced due to depletion of oxygen in the milk as

it is consumed by bacteria. The bacteria in milk ferment lactose to lactic acid.

During this process, electrons are released, which are taken up by methylene blue

and results in its reduction andultimately decolouration so, more bacteria will

produce more electrons, in turn it would result in faster reduction and rapid

decolouration.

Procedure

The samples (ambient and refrigerated soymilk) to be analyzed were well mixed

and 10ml of each was poured into a clean and sterilized test tube. With the aid of a

sterile pipette, 1ml of methylene blue dye was added into the soymilk samples

Gently. The test tubes were then closed with a rubber stopper and turned slowly so

that all the contents (soymilk and methylene tue) mixed together. the test tubes

were placed in a water bath at 37oC for half an hour making sure that water level

35
was at a sufficient height of the testtubes. The soymilk was examined after 30

minutes for decolouration of the mixture. A control tube was also set up in which

no methylene blue dye was added. Itcontained only the milk sample.

Interpretation

If viable bacteria decorlorize the milk within 30 minutes, then the test is positive

and the milk is of unsatisfactory quality. If the milk is not decolorized within 30

minutes, then the test is negative and the milk is of good quality.

Gram Staining method

Gram stain was carried out to help to identify bacteria isolate from the microscope.

A heat fixed smear of the isolated organism was made on a clean grease free slide

and flooded with crystal violet solution for one minute. This was rinsed under slow

running tap water, and then flooded with Lugols iodine solution for one minute.

The slide was rinsed under slow running tap water and then decolourized drop-

wise with acetone for two minutes. After which the slide was rinsed under slow

running tap water and then counter stained with Safranin for 30 seconds. The slide

was rinsed, air dried and viewd with a magnification of X100 using oil

immersion

36
III. Biochemical Tests Catalase test : the catalase test was done using a glass slide

with a wireloop, cells were transferred from the centre of a well isolated colony. 1-

2 drops of 3% hydrogen peroxide was added to the slide. a positive result is

indicated by the rapid appearance of sustained gass bubbles. No bubble production

shows negative result. Hydrogen Sulfide Test. Tubes of sterile peptone medium

were inoculated separately with the test organisms

using some uninoculated medium tubes as control.. in each tube, a strip of lead

acetate paper was inserted to hang well above the medium and held at the neck of

the tubes with stoppwer. They were incubated at 37oC for up to one week being

examined daily for the presence of blackening at the cover end of the acctate paper

indicating a positive result.

Indole test (Using Kovac’s reagent) Tryton water was added to the test organism in

a test tube and incubated at 37oC for 48 hour 0.5 ml of Kovac’s reagent was added

and shaken properly, then examined after one (1) minute. A red colour ring in the

tube indicated the presence of indole (positive reaction). No red colour indicated

negative result. Urease test the test organism was inoculated into urea agar slope

using a sterile wire loop. This incubated at37oc for 18 – 24 hours. A reddish –pink

medium indicated a positive result (urease production). No red pink colour

indicates negative result.

37
Methyl Red test: two drops of methl red solution was added to the test organism,

shaken and examined for colour change Red colour indicated a positive reaction

Voges Proskauer test. Samples from methyl red test were tested further in the

voges proskauer test. 0.6ml Dnaphtol solution and 0.2ml of aqueous 40% KOH

were added and shken. The test tubes were kept in slanting position and examined

after 15 minutes. A strong red colour indicated a positive result.

Sugar Fermentation Test: the test was carried out using these sugars: sucrose,

glucose, lactose, mannitol, and xylems. The test identifies organisms capable of

utilizing the sugar concerned. The medium was prepared using 1% sugar peptone

and two drop of indicator solution. After mixing thoroughly it was dispensed into

test tubes and Durham tubes were dropped into the test rtubes in inverted position.

The test tubes were corked and sterilized in autoclave at 121oC for 156 minutes.

After cooling the test organism were inoculated into different tubes and incubated

at 37oC for 48 hours. Gas production in the Durham tube and colour change from

yellow to pink indicated a positive gas and acid production respectively

38
 CHAPTER THREE

3.0 MATERIAL AND ENERGY BALANCES

3.1 MATERIAL BALANCE

Material balance also known as material balance is an application of law

conservation of mass analysis on physical system. Here materials supplied are

accounted for in natural units; it is based on total mass, mass of dry solids, or mass

of particular components. Since matter cannot be created nor destroyed rather it is

converted from one phase to other.

3.2 CONSERVATION MASS

The all-round conservation of mass equation for any given system can be

expressed as: material input=material output.

3.2.1 MATERIAL BALANCE ASSUMPTION

Necessary assumptions were made during the material balance calculations. The

system is operating at a steady state, there was no accumulation.

39
It is intended to produce soy milk by drying peeled soy beans at 60% moisture

content to 8% moisture. If the soy bean peels constitutes 12% by weight, therefore

the amount of soy bean required for producing I metric tones of soy milk will be.

3.3 MASS BALANCE FLOW DIAGRAM

Soya beans Soya beans Sorting Soaking

41666.7

Washing
Soya milk Cooking Wet milling
Beverage
Waste water

28666.7kg/hr Accumulation Vapour 0kg/hr

Check input = output

Input (raw groundnut) = 41 666.7kg/hr

Output

Peels = 13.00kg/hr

Soy milk = 28,666.7kg/hr

Vapour = 0kg/hr

Raw agricultural material = peel + vapour + material out = material in +

40
generation.

41666.7kg/hr = 13,000kg kg/hr +28,666.7-041666.7kg/hr

3.3.1 MATERIAL BALANCE ASSUMPTIONS

Necessary assumptions were made during the material balance calculations.

MATERIAL BALANCE FOR PEEL

P=V+W

41666.7= 13,000kg + W

Making W subject of the formula

W = 41666.kg/hr—13,000kg/hr = 28,666.7kg/hr

3.3.2 MATERIAL BALANCE AROUND DIFFERENT UNITS

Balance around the slicer, dryer and mill

MATERIAL BALANCE AROUND SYSTEM

Soy beans Soy milk

System

Input Output

Soy bean 41666.7kg/hr

Soy bean 41 .666.7kg/hr

MATERIAL BALANCE AROUND DRYER

Vapour

41
Dryer
Wahed soy bean Dried soy bean

Input Output

Washed soy bean = 41666.7kg/hr

Vapour = 13,000kg/hr

Soy milk = 28666.7kg/hr

Input =41666.7kg/hr output =41666.7kg/hr

Miller

MATERIAL BALANCE AROUND MILLER

Dried soy bean Miller soy milk

Accumulation

Input Output

Dried soy bean 41666.7kg/hr

Accumulation 500kg/hr

Soy milk 41166.7kg/hr

Input = 4l666.7kg/hr Output = 41666.7kg/hr

3.2 ENERGY BALANCE

Energy balance may refer to the first law of thermodynamics. It is a calculation

used in designing industrial processes in which all energy flows and

42
transportations, such as changes in temperature, heat of reaction, use of steam or

other source of heat are accounted for.

3.2.1 ENERGY BALANCE ASSUMPTION

Just like material (mass) balance necessary assumption that is a needed during the

course of energy balance calculations are made which may include:

- Equipment assumed to be in a steady state of conditions

- Effect of pressure, heat lost etc

- Since material balance and energy balance makes up of the general equation

which is energy out-energy in general consumption=accumulation

ENERGY BALANCE ASSUMPTION FOR DRYER

Soy bean Dryer Flour

() = Mcp TΔ = Mcp T + MvΔ

Raw Soy bean = 41666.7kg/hr

43
 CHAPTER FOUR

4.0 PIPING AND INSTRUMENTATION

Piping is a system of pipes (hollow, cylindrical tubes) fittings, vale used to convey

fluids (solid, liquid, gas) from one location to another. The pipe can be made with

aluminum, steel or rubber, instrumentation is an art and science of measurement

and control process variables within a production.

Before the milk get to the plant another. This transportation is done in piping

system.

The pipes are regularly checked for scaling condensation, leakages, liquid

hamming as well as corrosion in order to ensure free flow of the Soy milk, thus

enhancing efficiency.

4.1 GENERAL OVERVIEW

Piping and instrumentation is an arrangement that shows the interconnection of

process used in controlling the process and it plays significant role in the

maintenance and modification of that process, the diagram which is described in

details which provides basis for the development of system control schemes,

44
allowing for further safety and operational investigation, such as a hazard and

operability study (Hazop).

4.1 INSTRUMENTATION AND CONTROL OBJECTIVES

Different specified tool has been set up, in order to assist installation, long

run of plant and product specification, to achieve a rundown rate. This is

done to reduce several disturbance and influences to environment.

4.3 CONTROL SYSTEM AND SHORT DOWN SCHEMES

A control system is a device, or set of devices that managers, commands,

direct or regulates the behavior of other devices or systems in production

industry.

A switch is a control system which controls the inflow and outflow of power

in the soy milk production company.

4.4 SAFETY AND REGULATORY REQUIREMENT

It is a guide that provides an overview of a safety management.

A safety meter or boxes placed on an equipment, shows working temperature,

therefore, when an equipment in working at a particular temperature, ones the

temperature exceed there is a warning alarm.

4.5 BASIC START UP AND OPERATIONAL INFORMATION

45
In a plant (dryer, miller and slices) there is a step by step operation on how to

control the system.

46
There is an operational manual on how to switch on the plant, and a temperature

will be given so as to allow the equipment boost before putting

in your feed.

4.6 SAFETY MEASURES

This is a measure taken in order to protect people against accidents, damages or

harm, so as to enable continued contributor to the economic development.

4.7 PRODUCT SPECIFICATIONS

The plant is intended to produce 2.61 tones per hour so as to meet up with the need

of producing the units needed in a day, so that condition necessary for processing

can be kept. The milk is rich in iron, fat and oil, protein etc and can be used as food

(swallow) when cooked with that water for people that are washing weight and for

diabetic patient and for people want to control their sugar level.

4.8 ENVIRONMENTAL REGULATION

The conversion of raw agricultural commodities into finished food can be

determined to the environment of precautions are not taken. Food processing

47
can have adverse environmental effects on air and water quality as well as

producing toxic side product.

4.9 ECONOMIC REASONS

Operations of the plant must conform to market conditions, and effective control

system must be adopted, so as to safety the customer or consumer to avoid sub-

standard production which might lead to losses.

4.10 VALVE SELECTION

Valve is an instrument of in or out of a fluid. It controls the flow in a production.

Apart from diagram valve, an emergency valve must be installed

this enables all system to shut down during emergencies and can be used to

control the plant both automatically and manually.

TYPES OF VALVE

1. Diagram valve

2. Control valve (fail safe closed)

3. Control valve (fail safe open)

48
4.11 ALARM AND SAFETY TRIPS

There are built alarm in the plant to warn in case of foreseen danger or hazard and

this helps prevent overall harm to the people, as well as the environment. It is

placed in such away that when the danger is foreseen, the alarm and safety trips

become activated.

In a plant, the operator in the main control room should be familiar and

conversant with these alarms to enable, him handle each alarm that comes up

effectively.

4.12 MATERIAL DEVICES

Is a small device fixed into equipment controller, which include: flow rate,

temperature etc.

Electric metering device is used to measure the quantity of raw material used in the

beginning of production in order to be able to account for the loss, and get the

material balance at the end of the production process.

4.13 PUMP AND PIPE SELECTION

49
Pump and pipes are selected based on their power requirement in a plant.

E.g. since production of potatoes flour (fluidize fluid) involves unit

process/unit operation of raw milk, there is a pump to transfer the materials from

one form to another.

TYPES OF PUMPS SELECTED INCLUDE:

1. Stainless steel pipe non corrosive

2. Aluminum pipe-non corrosive, non ferras

3. Metals

4. Alloy pipe

When determining pipe size (diameter) during design calculation factors are

considered and they include: initial steam pressure, flow rate, steam velocity etc

while pump cost decreases with increases with diameter.

W=g

50
 CHAPTER FIVE

5.0 EQUIPMENT DESIGN AND SPECIFICATION

There are many equipment involve in processing and production of soya milk.

Equipment designs and specification include the design and specification of the

physical equipment in a processing plant.

Also an estimated costing of the equipment are made for alternative design and
project evaluation.

5.1 MAJOR EQUIPMENT USE (DESIGN COSTING)

5.1.1 SOLAR DRYER

A PHOTO VOLATIC BOND SOLAR DRYER

1. Capacity of the dryer: 20kg

Type of material used: aluminum and stainless

Type of joint: bolts and nuts (easily assemble and disassemble)

Number of tray: 3 to 4

Design temperature: 90°c

Length: 100cm

Tray dimension: 98Ommx48mm

51
Breath: 50mm

Ce — purchase cost: 2022

C = constant from table 6.2

S = characteristic size parameter in the units given (6.2)

n = index for the type of equipment

Cost in 2021 x cost index in 2015

Cost index in 2022

Cost for solar dryer = 32328.7 =N9,698,610

5.1.2 HAMMER MILL

Material of construction: stainless steel

Cutting device stainless steel rotating knives

Dryer power

Length: 40m

Belt size: 0.6m wide

Shat diameter: 70mm

Model: 1320

Housing: 12mm

Rotor Diameter 610mm

52
Bearing: 60mm

Shaft speed: 3600rpm

Screen area: 475 inches

Type: pulverisers

Ce = purchase cost: 2022

C- constant from table 6.2

S= characteristic size parameter in the units given (6.2)

n =index for the type of equipment

Cost in 2022 x cost index in 2015

Cost index in 2022

Cost for hammer mill = £31,663.957=N9,499.18

5.1 ELECTRIC SLICER

Material of construction: aluminum and stainless steel

Motor speed: 75rev/min

Volt: 24 volts

Shaft speed: 450rpm

Shaft diameter: 40mm

Weight diameter: 40mm

Weight of wheel: 4.55 5kg

53
 Conveyor, type

Belt size: 0.5m

Length: 160mm

Driver power: 2kw

Capacity: 7,932kg/hr

Ce=purchase cost: 2022

C = constant from table 6.2

S= characteristic size parameter in the units given (6.2)

n = index for the type of equipment

cost in 2022 x cost index in 2015

cost index in 2022

Cost for electric slicer = £36308.68 =N10,892,604

5.1.4 FOR SORTER

Material of construction: stainless steel

Model: TT-1200

Capacity: 60,000pcs/hr

Detection system: image capture (OCP)

Length: 135mm

Width: 85mm

54
Thickness: 0.15mm

Weight: 2-100kg

Type conveyor belt (0.lm wide)

Ce = purchase cost: 2022

C = constant from table 6.2

S characteristic size parameter in the units given (6. .2)

n index for the type of equipment

cost in 2022 x cost index in 2015

cost index in 2022

Cost, for sorter = £12630.1=N33,3789,030

5.1.5 FOR BLANCHER

Material of construction stainless steel

Model: BM1O

Weight: 3,500 (16) filled with water

Length: 369mm

Diameter: 60

In feed: 17,000

Weight: 2-100kg

Discharger 20, 125, type: process tank

55
Ce = purchase cost: 2022

C = constant table 6.2

56
S=characteristic size parameter in the units given (6.2)

n = index for the type of equipment

cost in 2022 x cost index in 2015

cost index in 2022

Cost for blancher = £16,498.54 =N4,949,562

5.1.6 FOR PEELER

Voltage: 22v

Power: 0.37-1.5kw

Weight: 8-15kg

Capacity: 68-140kg

Material of construction: spray paint and stainless steel

Height: 220m

Length: 120m

Type: conveyor belt

Ce= purchase cost: 2022

C= constant from table 6.2

S = characteristic size parameter in the unit given (6.2)

n = index for the type of equipment

57
cost in 2022 x cost index in 2015

cost index in 2022

Cost for peeler = £26518.88 = N7,955,664

Equipment Quantity Cost in 2022 Cost in 2015 Cost in 2015

(£) (£) (₦)

Solar dryer 1 4000 32328.7 9,698,610

Hammer mill 1 1750 31,663.95 9,499,185.3

Electric slicer 1 1000 36,308.68 10,892,604

Sorter 1 2500 112,630.1 33,789,030

Blancher 1 1250 16,498.54 14,949,562

Peeler 1 2800 26518.88 7,955,664

Total 13,500 255,948,85 76,784,655.3

CHAPTER SIX
58
6.0 ECONOMIC ANALYSIS

This company will be effective on market segmentation through the identification

of several riche markets and strategies implementation. The company intends to

advertise, implement, direct marketing merchandisers, team workers and

advertising will rotate around and to be able to penetrate the market within and

outside the production, site. Therefore, our key to a successful business will

include the following factors.

1. Marketing know-how: In an increasingly competitive market, there is need to

market out product effectively so as to be at the top of our

honourable, prospective and current clients mind continuously, even if it will

warrant that the whole workers/departments will take part in the marketing of the

product or by, breaking the bulk

2. Dedication and loyalty: The loyalty and dedication of our employees, no matter

your rank in the company, qualification, age etc shall be necessary to the property

of the business, will recognize that corporate commitment to success should lead to

the survival and long lasting or long run of the products, and the organization as a

whole.

59
3. Excellent in fulfilling promise: We intend to produce and provide products of

uncompromised quality to our customers. In so doing we are meeting up with the

needs and standards of our honourable customers by providing them with a high

quality and nutritive soya milk.

4. Technology assembly: We will ensure a consistent quality of our product, that

is when it is essential to make use of the latest technology

but to utilize it and know in which unit operation each particular technology in

needed and also the department that needs the latest technology is most (i.e. can

utilize them to facilitate production).

5. Effective distribution network: We intend to establish an excellent distribution

network, that is by setting up/creating roots for each

marketers, communities etc and meet their targets, this will enable us to rapidly

respond to our customers order, and be available in remote areas that our

competitors has never get exploit

6. Adherence to stringent values and principles: There is need to always

acknowledge the fact that the financial and strategic management of the business

will ultimately determine its success and prosperity.

This is why we need to adhere to stringent values and principles that will enable

such to be achieved.

60
6.1 ECONOMIC EVALUATION

6.2 PREPARING A PROCESS FLOW DIAGRAM

A process flow diagram has initially been prepared on the chapter one of this

project

6.3 CALCULATION MASS ENERGY AND ENERGY FLOW

Mass flow rate and energy flow has been calculated on chapter 3 (refer back

to chapter 3 and appendix).

6.4 SIZE OF MAJOR EQUIPMENT

Equipment Size (unit) Size range Index Type

Solar dryer Area(m²) 2-10 0.35 Pan

Hammer mill Kg/hr 20-200 0.35 Pulveisers

Sorter Length(m) 20-40(30) 0.75 Conveyorbelt

Electric slicer Length(m) 20-40(30) 0.75 Conveyor belt

Blancher Capacity(m) 3-50 0.60 Process tank

Peeler Length(m) 20-40(50) 0.75 Conveyor belt

61
6.5 ESTIMATION OF FIXED CAPITAL COST, REF TABLE 6.1

Fluids-solid processing plant

Major equipment Total purchase cost: ₦

Fl - equipment erection 0.45

F2 - Piping 0.45

F3 -instrumentation 0.15 2.15

F4 -electrical 0.10

F5 -building process 0.10

F6 -utilities 0.45

F7 -storage 0.20

F8 -site development 0.05

F9 -auxiliary building 0.20

F10 -design and engineering 0.30

F11 -contractors fee (non) 0.70 0.40

F12 -contingency 0.10

6.6 WORKING CAPITAL

This is the money required to operate a plant from the period of one month to

a period of one year.

62
6.7 BREAK-EVEN POINT

This occurs when the total annual product cost equals the total annual sales.

We have break-even point in unit and in naira.

Break-even point in until

Fixed cost

Contribution

Contribution = sales cost (selling price) — variable cost

Break-even point in Naira +

Fixed cost

1-variables

Sales cost

6.8 PAYBACK PERIOD

It is the time frame for a business or project to fully amortize the initial investment

fund from income generated. It is useful criterion for judging projects that have a

short life. It does not consider the performance of the business after the payback

period.

6.9 CAPITAL COST

Is a financial outlay, that is required for the physical erection of the plant is well as

erecting the plant for the period of the month, it include land cost, cost of plant

63
erection and working capital.

6.10 FIXED COST

This consists of two broad components namely:

Direct and indirect fixed cost

Direct fixed cost: Includes cost of those items that can be seen at the plant site

which include:

i. Cost of process equipment

ii. Cost of equipment installation

iii. Cost of piping

iv. Cost of foundation structure, plant building, road bridges etc

Indirect fixed cost: Include cost of engineering and design contractor over

held and contractor fee as well as. construction contingences.

6.11 PROFIT/ANNUM

It is an annual profit after various taxes are paid.

NPV = annual turnover — annual cost of production

Annual turnover = quantity of sales X selling price

6.12 RATE OF RETURN (ROR)

It is the percentage of profit after tax but before depreciation to the total

invested fund.

64
ROR = profit(per year) x 100
Total investment 1

6.13 HOW TO RAISE THE CAPITAL

In order to raise capital for the proposed project both the owners savings and

fund any reliable financial institution. Although institutions usually have

their terms and conditions that their clients have to sign before services are

rendered.

These terms and conditions include:

1. The debenture loan sough must be secured on the project fixed assets is

inadequate; collateral security may be added.

2. The institution should not provide more than 70% of the total project cost.

Therefore, the balance of 30% should come from the owners equity

shares.

According to terms and conditions, I have suggested for the proposed projects,

with the following capital structure which, I believe will be acceptable to the

financial institutions.

Equity shares 40% of TIC = N142,220,538.6

Bank overdraft 10% of TIC = 35,555,134.64

65
Debenture loan 50% of TIC = N177,775,673.2

6.14 SUMMARY OF ECONOMIC ANALYSIS

COST ESTIMATION COST(N)

Purchased equipment 76,784,655.3

Total capital investment 355,551,346.4

Annual raw profit 1.041,000.833

Total production 85,645,388.4

Annual net profit 2.5x10’’

Break-even point(unit) 14.093,598.33

Break-even point (Naira) 7,046,799,164

Payback period 1.4(1 year and 4 months)

6.15 OTHER ECONOMIC BENEFITS

Apart from commercial viability reasons, this proposed project will also take care

of socio economic benefits which include: job creation, increase in

government revenue, establishment of industrial linkage, provision of socio-

amenities and diversification of the economy.

66
 CHAPTER SEVEN

7.0 PLANT LOCATION AND LAYOUT

7.1 PLANT LOCATION

The place or area the plant is situated has the profitability of the project and the

scope for future expansion. Therefore, many factors are considered when selecting

a suitable site for the soya milk beverage production plant.

They include:

Availability of raw material or feedstock: The main raw material needed is

sourced in large quantity in Nigeria, Niger, Ondo, Lagos etc). The plan site should

be located near where the raw material is sourced in order to reduce transportation

cost, also the purchase price, availability and

reliability of the supply should also be put into consideration.

Hence, the proposed plant site will be at industrial clusters, in Niger state, due to

the nearness of soya beans from the Northern parts of Nigeria.

Availability of energy: The plant will run production and will require continually

with constant supply of energy, but due to the inconsistent

character of energy supply in the country, it will depend on beer energy source.

67
Therefore, an alternative means of energy will be provided (Generator power).

Transportation: The soya milk beverage production plant will be provided with

adequate transport facilities for case in the distribution of goods at various

destinations. The transportation modes will includes trucks, buses etc. This

production plant will be located close to a good access and for easy

distribution of the finished good to the customers.

Market assessment: The marketing problem will be tackled by carrying out pre-

marketing research to find but how the consumer assessed to before producing to

large quantity.

Also, when this is known, the product will be located near a primary market

where a buyer can comfortably purchase the finished product; also cost of the

product will be relatively low.

Site characteristics: Test boring information will be made available for the entire

plant site, there will be adequate drainage system to avoid stagnant water, since

industrial cluster Nekede, Owerri in a leveled ground there will be no sloppy or

construction cost on the plant site.

Community factors: The development of this project will include representatives

from the community it is sited, also worked will include indigenes of the

68
community, so that it will stand as a job generator not only for outsiders but also

for indigenes of the community.

Also if the community officials and the company representative develop a method

of interacting together, it will determine the extent to which the community will

boost and support the project from hoodlums and theirs.

Labour supply: Labour needed for the construction and operation of this soya

milk plant will include both skilled (brought from outside) and will paid to pay

scales of every individual or group of workers.

Also there should be training (workshop) to enlighten the unskilled ones.

Waste disposal: There will be proper treatment of waste in the industry by

adopting the ISO (international Standard Organization) which is set aside for

guiding the interest of the nation. In order for the company not to pollute the

environmental there will be large waste management until for treatment of waste in

the plant before disposal.

Taxation and legal restriction: The plant will run for two years as stipulated by

the legal regulation of Imo state. This is to build a strong grand for industrial. Meat

plant which is located at No. 1, industrial Cluster, Nekede, Owerri in Imo State, is

an area mapped out for industries.

69
The area is for only industry, because individual buildings are restricted from the

area, to avoid the industrial equipment causing nuisance.

7.2 PLANT LAYOUT

This involves where the plant will be suited, which is at No 1, industrial cluster,

Niger state.

It also involves the space requirement, to ensure continuous and steady movement

for the production take place.

These include:

Personal, operating equipment, storage space, material shading equipment and all

other supporting devices along with the design of the best structure to

accommodate the named facilities.

7.2.1 OBJECTIVES OF PLANT LAYOUT

• Providing comport and catering to workers

• Providing good and improved working conditions

• Minimizing delays in production and making efficient use of the space that

is available

70
• Having a better control over the production cycle and other activities within

the plant premises.

71
PLANT LAYOUT

72
Administration building: Located far away from potential hazardous plant area,

for the safety of the people working in administrative.

• Central control room (CCR): Located adjacent to processing unit, but with

potential hazardous processes

• Field auxiliary room (FAR): Located right inside the plant area. It is a mini

control room

• Tank farm: Located close to the plant for supply of raw materials and also

close to loading and exist point for easy movement of trucks

• Maintenance workshop: Located far from the administrative officers and

close to the plant for easy maintenance and repairs of equipment. There is a

good network for easy transportation of machineries to and from the

building

• Laboratory: Located far from potential hazardous area, but not too far from

plant. It is where samples of batches are tested for standard

• Emergency block: Located close to potential hazardous area, it consists of

fire station, fire pumps. Fire pumps are situated at each of the layout in case

of emergency

73
• Plant area: A place where production takes place

• Car park: Located very far from plant

• Canteen: Located not far from administrative building, so that workers will

not spend which time going to where they can refresh thereby abiding their

work.

• Clinic: Located very close to plant, to ensure urgent attention to any injured

worker

• Residential area: Located very far from plant it is where company staffs

reside, for the safety of the workers.

• Mustard point: Located close to different structures in the industrial area,

to enhance easy convergence of staff during emergency.

7.3 ENVIRONMENTAL IMPACT ASSESSMENT

Environmental impact analysis was carried out on the early stage of this design, to

investigate the likely environmental challenge that will be posed by the proposed

plant on the environment.

The environmental challenges which is likely to be caused by waste (by products

of potatoes flour production and waste water). That is why the waste water will be
74
treated before disposal and by products sold to people or company that will need

them for production. All these are done to presence the earth and protect its

habitant.

75
 CHAPTER EIGHT

8.0 PLANT SAFETY AND LOSS PREVENTION

Safety is a state of being staff freedom from the occurrence or risk of injury,

danger or loss.

Therefore, for a potential organization to run safe and efficient plant

operation, there should be legal and moral obligation to safe guard the welfare of

employees and public at large. In the sense that all unit operation and unit

processes should be carried out under appropriate condition. While loss prevention

is all the effective measures put in place to contain potential

financial loss posed by accidents in the overall plant preview. These losses can

lead to the shutdown of the company or plant.

8.1 PROCESS CONTROL AND HAZARD CONTROL

PROCESS CONTROL

This is a system established in the Soya milk industry which involves the effective

use of instrumentation to yield high efficiency with less harm on the people and

less hazard in the plant during operation. This system generally

improves production and maintains the output within the desired range. The

76
processes system can be set up in a different room where every

individual equipment or connection in the factory and other section of plant is

connected to in order to rapidly put to a halt any occurring hazard.

HAZARD CONTROL

Is a system used in industry to minimize or eliminate exposure to hazards.

System used to prevent and control hazard includes engineering control, safe work

practices, and administrative controls, personnel protective equipment, systems to

track hazard correction, preventive maintenance system and

medical.

To ensure that hazard occurrences are minimized in the soya milk I industry,

regularly and thoroughly maintain equipment, ensure the hazard

correction procedure are in place, ensure that everyone know how to use and

maintain personal protective equipment (PPE), make sure that everyone

understands and follow safe work procedures and ensure that when needed there is

medical program tailed to the facility to help prevent work place hazard and

explosion.

8.2 IDENTIFICATION OF POSSIBLE HAZARIS

Hazards are unpredicted, unplanted occurrence that is harmful to personnel,

machineries and materials, and it can cause complete breakdown of a running

77
plant.

Possible hazards of soya milk production plant include:

The effect of water, carbohydrate and dietary fiber on the pumps and piping

materials of construction.

When water is retained in a washing tank for a long time, it will rust, also when

allow, are exposed to moisture in air it corrodes.

PREVENTION MEASURES

There should be containment during the design of equipment and piping, and water

after washing the raw production should be discarded in order to avoid rust, there

should be ventilation.

REACTIVITY: CHO reacts with oxygen in the following vedox equation.

C6H12O6+6O2------------------------6CO2+6H2O

The carbon dioxide and water is a waste product and reaction is exothermic, and

when it is not accounted for can lead to breakdown of equipment.

VENTILATION

Fans will be installed to reduce odour and lower humidity; there will be windows

and doors all around the plant area, to ensure adequate ventilation.

78
 CORROSION

Moisture enhances corrosion on material of consumption like Alloy,

therefore water should always be transferred to waste tanks to avoid corrosion.

OPERATION AND HUMAN ERROR

Since human errors are inevitable, impite training, education and exposure, safety

measures will be adopted in order to minimize and prevent the various human

errors.

They include:

 Adequate training of staff in safe start-up and shut down of equipment,

overall operation and maintenance.

 Adequate dressing kit for specified operation.

 Adherence of safety rules and regulations.

 Keeping away from moving parts of machines and devices while

handling properly etc.

79
CONCLUSION AND RECOMMENDATION

CONCLUSION

Based on the economic analysis of this project, it can be seen that it is worth

investing on so that the implementation of what is contained in this work could be

achieved.

Since the total investment is N355, 551, 346.4 net profit N2.5 x 1011, this

shows that the company can repay borrowed capital within a short period of time

and this profit will bring open doors to the economy of the state and Nigeria at

large.

RECOMMENDATION

Mary Soy milk Company is believed to stand a beer chance for profit

earning from sales, it will employ a new and unique processing technology.

This has already made it to stand a ground of competing and heating other

competitors in the market.

Since this plant is aimed at production, the product will not reluctantly shut down,

rather it has been programmed to produce in order to meet the increasing demand

80
of customers. Its administration will not frustrate employees and will not let the

firm down.

Soy milk beverage is very good and rich and good for people washing weight,

reducing of sugar level and for diabetic patient because it is a good source of iron.

81
 REFERENCES

Akinyemi, S.O Aiylaagbe, and Akyeamong E. (2006): Department of

Horticulture, University of Agriculture Abeokuta.

Aruja 0. (1998): Planning, review, review natural products, facts and

comparisons. Arogbepublisher Ibadan-Nigeria.

Awan, J.A. (2006): Some aspect of nutrient changes in stored potatoes

fruits ITTA. Ibadan, Nigeria.

Brower, Tin (1999): Selecting and Purchasing food processing equipment.

OSU Food Technology Facts, FAPC. Okhlahoma.

FAQ (1990,2006): The world vegetable center, sub-regional for west and central

Africa. Journal for Agriculture. .Bamako. Mali

FIIRO (2013): Federal Institute of Industrial Research on Potatoes. Oshodi, Lagos.

Henderson, S. Perry R.L. (1997): Principles of Agricultural Engineers. St. Joseph

Publishing. M.J. http :J/www.thepaleomoi .com//thescience journal.com Internet

sourced article from a print-J Journal of Food Science and Technology (Electric

version). Drying and Dehydration

of Foods. Nigerian Food Journal (2007) Vol. 25(1) Pp 171-17, Pp

52-95.

82
Swenenn R. (1990). Personal Communication, international

Institutional Institute of Tropical Agriculture, Onne. www.clirnatetech.

wiki/Hammer mill

Uchegwu, A.C. (1994). Commercial Potatoes Production is profitable,Technical

Bulletins of fruits Division, National, Horticultural Research Institute, Ibadan.

Nigeria.

83
 APPENDIX

Plant attachment 95% = 95/100 = 0.95

Number of days to be engaged in production

= 0.95x365—346.75=347 days

34/days/year

347x24 = 8328 hours/year

Plant capacity on installation = 500,000 tones/year

1 tonne = 1000kg

500,000 tones =?

= 500,000 tones xl000kg = 500,000,000kg/year

1tonne

Mass of soy milk = 500,000.000

8328 = 60038kg/hr

Quantity of plant in required per hour = ?

To change days to kilogram

That is 347000,000 = 1000,000kg

347 24

= 41666.7kg/hr

84
ENERGY BALANCE ASSUMPTION FOR DRYER

Q=MCp ΔT

Soy milk = 41666.7kg/hr

MCpT =MCp T ΔMv

41666 .7kg/hrX3.91kgX(60°-0) =28666 .7kj/kg(90°60°)+Mv

41 666.7kg/hrX3.91kj/kgx60° =28666kg3.9kj/kg(30°)+Mv

=9775007.82kg/hr = 3,362,603.91+Mv

Making Mv subject

MV = 9775,0007.82-3362,603.91

Mass vapour = 6412,40191kg/hr

COSTING OF THE EQUIPMENT

Cost for solar dryer assumption

Purchase cost in 2022 = £4,000

Cost index in 1990 = 60

Cost index in 2022 = 80

From 1990 to 2022 = 3 yrs

(80-60) 20 index

85
3 years = 20 (from 1990—2022)

22 years ?

=20 x 22

3 1

= 146.6

Cost index for solar dryer in 2015

146.6+80=226.6

C = 4000

n = 0.35

S = 10m²

Ce = CXSⁿ

£4000 x 10m2(0.35)

£4000 x 10m2 (0.35)

£11,413.5(2022)

Update cost

2022 x 2015

2022

11,413.5x 226.6

86
= 11,413.5 x 2.8325

= £323287

CONVERT TO NAIRA

Exchange rate = £1 = N500

Therefore £32328.7 =?

£32383 x N 500

£1

= N9,698,610

FOR HAMMER MILL

Purchase cost in 2022 = £1750

Cost index in 1990 = 60

Cost index in 2022 = 3 yrs

(80-60) = 20 index

3 years = 20 (from 1990 -2022)

22years = ? (from 2022 —2015)

= 20 x 22

3 1

87
= 146.6

Cost index for hammer mill in 2015

145.6+80=226.6

C=1750

n =200kg/h

S = 200kg/h

Ce = CXSⁿ

£1750 x (200)°35

£11,178.8

Update cost

2022x 2015

2022

11,178.8 x 226.6

80

11,178.8x2.8325

=£31,663.951

Convert to Naira

Exchange rate = £1 = ₦500

Therefore £4000 x 10m² (£3163.951) = ?

88
£31663.951x=₦500

£1

= 9,499.185.3

FOR ELECTRIC SECTOR

Purchase cost in 2022 = £1000

Cost index in 1990 = 60

Cost index in 1990 = 80

From 1990 to 2022 = 3 years

(80-60) = 20 index

(If 3 years = 20 (from 1990— 2022)

22years=?

20 x 22

3 1

=146.6

=146.6

Cost index for electric slicer in 2015

146.6+80=226.6

C=1000

n = 0.75

89
S 30m

Ce = CXSⁿ

£1000 x (00)°.75

£12,818.6

Update cost

2022 x 2015

2022

12818.6 x 2.8325

=£36,308.68

Convert to Naira

Exchange rate = £1 = N500

Therefore £31663.951 =?

£36,308.68 x N500

FOR SERVER

= ₦10,892,604

Purchase cost in 2022 = £2,500

Cost index in 1990 = 60

Cost index in 2022 = 80

90
From 1990 to 2022 = 3 yrs

(80-60) = 20 index

If 3 years =20 (from 1990—2022)

22 years = ? (From 2022 - 2015)

20 x 22

3 1

= 146.6

Cost index for server in 2015

146.6+80 = 226.6

C = 2500

n = 0.75

S =40M

Ce = CXSⁿ

£2500x(40)0.75

£39,763.5

Update Cost

2021 x 2015

2022

39,763.5 x 226.6

91
 80

= 39.763.5 z 2.8325

= £112,630.1

CONVERT TO NAIRA

Exchange rate = £1 = ₦500

Therefore

£31663 951 = ?

£112,630.1X₦500

£1

=N33,789,030

FOR BLANCHER

Purchase cost in 2022 = £1,250

Cost index in 1990 = 60

Cost index in 2022 =80

From 1990 to 2022 = 3yrs

(80-60) = 20 index

If 3 years = 20 (from 1990 — 2022)

22years = ?

=20 x22

92
 3 1

= 146.6

Cost index for blancher

146.6+80=226.6

C = 1250

n = 0.60

S =12m

Ce = CXSⁿ

£1250x(13)0.60

£5824.73

Update Cost

2022 x 2015

2022

5824.73x226.6

80

= 5824.73x 2.8325

=16.498.54

Convert to Naira

Exchange rate = £1 = 500

93
Therefore £31663.951 = ?

£16.498.54.lx ₦500

£1

FOR PEELER

Purchase cost in 2022 = £2800

Cost index in 1990 = 60

Cost index in 2022 = 80

From 1990 to 2022 = 3 years

(80-60) = 20 index

If 3 years = ? (from 2022-2015)

=20 x 22

3 1

= 146.6

Cost Index for Peeler in 2015

146.6+80 = 226.6
94
C = 2800

n = 0.75

95
S = 5m

Ce = CXSⁿ

£2800 x (5)0.75

£9,362.36

Update Cost

2022 x 2015

2022

9,362.36 x 2.8325

= £26,518.88

Convert to Naira

Exchange rate = £1= N500

Therefore £31663.951 = ?

£26,518.88 ₦500

£1

ECONOMIC CAPITAL

TOTAL PURCHASE COST OF MAJOR EQUIPMENT (PCE)

Hammer mill = N94991 85.3

Solar dryer = N969810

Electric slicer = N10892604

96
Sorter = N33789030

Peeler = 795 5664

Blancher = N4949562

Total purchase cost of major equipment =

PCE = £255948.85 =N76,784655.3

ESTIMATION OF FIXED CAPITAL COST, REF TABLE 6.1

Total physical plant cost (PPC)

= ₦76,784655.3(i+2.15)

= ₦76,784655.3x3.1 5

= ₦241,87,664.2

Fixed capital = ₦24 1, 871664.2(1+0.4)

= 241 871664.2

Fixed capital 241,871664.2(1+0.4)

= N241 871664.2x1 .4

WORKING CAPITAL (5% OF FIXED CAPITAL)

Allow 5% 5/100 = 0.05

= 0.05 x ₦338,620.329.9

= ₦16,931,016.49

97
TOTAL INVESTMENT CAPITAL (TIC)

TIC = Fixed capital + working capital

= ₦338,620,329.9 ± ₦16,931,016.49

= ₦335,551,346.4

ANNUAL OPERATING COST (REF TO TAB 6.6)

Operating time 34 days /annum

34days x 24 = 8328 hrs/year

VARIABLE COST

Electric power 700mj/d

ESTIMATED RAW MATERIAL

1. Raw soy bean = 500,000,000kg/yr

41,667kg/hr:347x24X3

1000

==₦1,041,000.833

PLANT ATTAINMENT 95%

2. Miscellaneous material (10% of working capital)

= 0.1 x ₦16,93,0l6.49

= ₦1,693,101.64

3. Utilities (Cost from table 6.5)

Power at 1 .2p/mj = 1.2 x 709 x 347

98
 100

=2,914.8

4. Shipping and packaging = negligible

Variable cost: ₦1,041,000.833 + ₦1693101.64 + ₦2,914.8

=₦2,737,017.273

5. Maintenance (5% of fixed capital)

= 0.05 xN338,620,329.9

= ₦16,931,016.5

6. Operating cost for labour: (assumed £20,000/annum) it also allow for overheads.

= £20,000 = ₦6,000,000

7. Supervision: no additional supervision needed

8. Plant over heads (50% of operating labour)

= 0.50 x N6,000,000 = N3,000,000

9. Laboratory (20% of operating labour)

= 0.20 x ₦6000,000

10. Capital charges (15% of the fixed capital)

= 0.15 x ₦338,620,329.9

11. Insurance (1 % of fixed capital)

0.01 x ₦338,620,329.9

99
12. Local taxes (2% of fixed capital)

= 0.02 x ₦338620,329.9

= ₦6,772,406,598

13. Royalties: not applicable

Fixed cost (₦16931,016.5 + ₦6,000,000+ ₦5000,000

+ 1,200,000+50,793,094.49 + ₦3,386,299 + ₦6772,406,598)

= ₦6,853,716,867

Direct production cost

DPC = variable cost + fixed cost

= ₦2,737,017,273 = ₦6,853,7l6,867

= ₦6,856,453,884

14. Sales expense 10% of direct production

15. General overheads cost

16. Research and development 0.10 x ₦6,856,453,884

Annual production cost = 685,645,3 88.4

Unit production cost = Annual production cost

Annual production rate

= ₦685,645,384.4x 100

500,000,000

= ₦13.7

100
Selling price = ₦500

COMMERCIAL VIABILITY

This can be assessed by the relationship between the operating cost and

revenues both in absolute amount and in relative terms.

NET PROFIT/ANNUM:

It is an annual profit after various taxes are paid.

PV = Annual turnover — Annual cost of production

Annual turn-over = Quantity of sales X Selling rate

500,000,000 x ₦500

=2.5 x 100000000000

NPV = 2.5 x 100000000000 - 685,645,3884

=2.49 x 100000000000

ANNUAL COST OF PRODUCTION (NPR)

Annual profit x 100

Annual sales 1

2.49 x 100

500,000,000kg/hr

= 49,800%

101
RATE OF RETURN (ROR)

It is the percentage of profit after tax but before depreciation to the total

invested fund.

= Profit (per year) x 100

Total investment capital 1

=2.49 x 1011 x 100

355,551,346.4 1

= 70,032.079% = 70%

BREAK-EVENPOINT IN UNITS

= Fixed cost

Contribution

Contribution = sales cost - variable cost

= ₦6,853,716,867

₦486.3

= 14,093,598.33 units

BREAK-EVEN POINT IN NAIRA

= Fixed cost

1- variable

Sales cost = 6853,716,867

102
1-13.7

500

= 6,853,716.867

1-0.0274

6,853.716,867

0.9726

= 7,046,799,164

PAY-BACK PERIOD

Total investment

Return

355,551,346.4

2.5x 1011

1.422205386x 10

= 6 year and 4months

103