FEDERAL POLYTECHNIC NEKEDE

P.M.B 1036 OWERRI,

IMO STATE.

PLANT DESIGN
ON

MALT PRODUCTION

PLANT

BY

NAME: NWOSU CYNTHIA CHINYEAKA

REG. NO: 21HWP/0001/FT

DEPT: FOOD TECHNOLOGY

LEVEL: HND II (EVENING)

COURSE TITLE: EQUIPMENT & PLANT PROCESS DESIGN

COURSE CODE: FST 412

LECTURER: ENGR. ARINZE& MR. CHIBUIKENJOKU

DATE: MAY, 2023

1
 CERTIFICATION

This is to certify that this work on the “MALT PRODUCTION PLANT” was
carried out byNWOSU CYNTHIA CHINYEAKA with the registration number
21HWP/0001/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. ChibuikeNjoku 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. ChibuikeNjoku for his

teachings and instructions asregardstoengineering 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
 EXECUTIVE ABSTRACT

Malt is germinated cereal grain that has been made to germinate by

soaking in water and is then halted from germinating further by drying with
hot air, a process known as "malting". This study demonstrates the processing
of Malt and extends itsconvenience use. The experiment was 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 Malt production plant and
design. The plant will be situated at Niger state with a total investment capital
N338,620,3299, rate of return 70% and payback period of 6 year and 4 months.
Detailed economic studies howed that the production ofMalt would be
economically viable in Nigeria when the product is sold at N500 per
100mgprovided a minimum scale of 85% is 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 ofMalt

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 ofthe 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 Malt

2.2 History of Malt

2.3 Malt Productionproduction

2.4 Nutritional factors of Malt

2.5 Anti-nutritional factor of Malt

2.6 Effects of Spoilage in Malt

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 solardryer

5.1.2 Hammer mill

6.1.5 Othereconomic 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

CHAPTER NINE

9.1 Conclusion

9.2 Recommendation

References

Appendix

9
 CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND OF THE STUDY

Malt is germinated cereal grain that has been made to germinate by soaking

in water and is then halted from germinating further by drying with hot air,

a process known as "malting".Malted grain is used to make beer, whisky,

malted milk, malt vinegar, confections such as Maltesers and Whoppers,

flavored drinks such as Horlicks, Ovaltine, and Milo, and some baked

goods, such as malt loaf, bagels, and Rich Tea biscuits. Malted grain that

has been ground into a coarse meal is known as "sweet meal".

1.2 AIM AND OBJECTIVES

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

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

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

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

Because of the under laying reason that cereals are perishable grains, it is

necessary to carry out quality assessment. The proximate and preliminary

processing will help to determine the quality standard.

The heat, energy and mass transfer for the processing plant will be established by

selecting appropriate equipment size and design of plant layout.

10
It is also a guide to share handy tips and resources for the individual that has an

interest in Juice processing in Nigeria or elsewhere, whether as a hobby or as an

investment or business opportunity.

This guide gives all the answers to those seeking and asking the “how to”, “ where

to” and “why to” questions about Juice processing.

1.3 PRODUCTION STEPS OF MALT

Visual inspection: Inspect the apples. No moldy apples allowed!

Washing: Apples are then water-washed for up to 45 minutes. The goal is to

remove pesticide and surface dirt. Physical scrubbing is sometimes included and

can reduce wash time.

Mash: The apple is macerated by a grinder or mill. From the washers, the apples

are chopped up by a grinder, apple mill, or hammer mill and turned into apple

mash. The primary enzymes used in apple juice production are pectinases. A blend

of pectin methylesterase and endo-polygalacturonase can increase juice yield

during the maceration process. The enzymes reduce stickiness and viscosity

without impacting pressability. Some blends including cellulase and hemicellulase

will break down cell walls and improve juice production by at least 5%.

11
Press: The mash moves to a hydraulic press to extract the juice. The typical yield

is 60-70%. As apples age, they produce less juice and become more sticky and

soft. This is the ripening process at work. The pulp residue and water are combined

and pressed again. The goal of this is to increase the sweetness, which is measured

in Brix. Brix is the measurement scale of soluble solids in a liquid and can go from

12 to 12.3 Brix during this process. In apples, the solids are mostly sugar, so this

can be roughly translated as 12 to 12.3% sugar.

Filtration: The apple juice then goes into holding tanks for sedimentation

removal. Sometimes enzymes are added at this stage if they are not added to the

mash. The goal of the enzyme addition may be to prevent filter clogging, increase

filtration, improved clarity, or filtration rate.

1.4 PROPERTIES AND STRUCTURE

Blackberries contain a high level of vitamin C. One serving of 100 grams (g)

contains 35 percent of an individual’s recommended daily allowance (RDA) of

vitamin C. Humans are unable to synthesize their own vitamin C, so it is essential

to include it as part of a healthy diet. Vitamin C is involved in protein synthesis

and is necessary for the body to produce collagen and certain neurotransmitters.

These processes are vital for many bodily functions, including wound healing.

12
Vitamin C also has antioxidant properties and is involved in immune system

functioning.

Source of fiber: A 100 g serving of blackberries contains 14 percent of the RDA

of fiber. Fiber is a type of carbohydrate that the body cannot break down into

smaller, sugar molecules, as it does with other carbs. Fiber plays an crucial role in

regulating blood sugar levels and sugar consumption. There are two types of fiber

in food, soluble and insoluble.

Soluble fiber dissolves in water, and it is associated with lowering blood sugar

levels and helping a person maintain a healthy level of cholesterol.

Insoluble fiber does not dissolve in water but supports healthy digestion.

Blackberries contain both soluble and insoluble types of fiber.

3. Antioxidants

Blackberries contain high levels of antioxidants, such as anthocyanins.

Antioxidants help people to fight against the adverse impact of free radicals in the

body.

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Free radicals can damage cells and are thought to be closely involved in the aging

process plus other health conditions, such as cancer and heart disease.

The body uses antioxidants to reduce the damage that free radicals can cause. It is

possible that when people eat foods that contain antioxidants, they are supporting

this process, but more research is required to confirm this.

4. Vitamin K

Blackberries are an excellent source of vitamin K. This is a necessary nutrient for

blood clotting, which is essential for proper wound healing.People have also linked

good bone health to vitamin K. However, it is essential that a person discusses

their vitamin K intake with their doctor if they are on any blood thinners.

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Vitamin A: Blackberries also contain vitamin A, which serves several functions in

the body. Vitamin A supports the immune system, which combats infections and

illness. It also supports the growth and maintenance of teeth and bones, as well as

keeping skin healthy. Vitamin A is responsible for producing the pigments in the

retina of the eye and helps to support sight, particularly in dim lighting.

Brain functioning: A study in 2009 found that rats that consumed blackberries

had improved cognitive and motor skills compared to a control group of rats that

did not consume blackberries. The authors of the study suggested that this could be

due to chemicals called polyphenols that are in blackberries.

1.5 USES

15
1.6 PROCESS ROUTE

Malt

16
1.7 OTHER PROCESS ROUTE

Malt

17
1.7 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.

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 CHAPTER TWO

LITERATURE REVIEW

A method of Malt Productionpreservation is presented here which processes

soluble Juice extract into water soluble powder or packaged in tea bags. In this

way, the Malt Productioncan last for years making the drink(having the powder

dissolved in water) easily available for consumption and the extract production

becomes economical because of longer shelf life.

2.1 HISTORY

One of the earliest known instances of blackberry consumption comes from the

remains of the Haraldskær Woman, the naturally preserved bog body of

a Danish woman dating from approximately 2,500 years ago. Forensic evidence

found blackberries in her stomach contents, among other foods. The use of

blackberries to make wines and cordials was documented in the London

Pharmacopoeia in 1696. In the culinary world, blackberries have a long history of

use alongside other fruits to make pies, jellies and jams.

Blackberry plants were used for traditional medicine by Greeks, other European

peoples, and aboriginal Americans. A 1771 document described brewing

blackberry leaves, stem, and bark for stomach ulcers.

Blackberry fruit, leaves, and stems have been used to dye fabrics and hair. Native

Americans have even been known to use the stems to make rope. The shrubs have
19
also been used for barriers around buildings, crops and livestock. The wild plants

have sharp, thick prickles, which offered some protection against enemies and

large animals.[10]

Cultivar development

Modern hybridization and cultivar development took place mostly in the United

States. In 1880, a hybrid blackberry-raspberry named the loganberry was

developed in Santa Cruz, California, by an American judge

and horticulturalist, James Harvey Logan. One of the first thornless varieties was

developed in 1921, but the berries lost much of their flavor. Common thornless

cultivars developed from the 1990s to the early 21st century by the US Department

of Agriculture enabled efficient machine-harvesting, higher yields, larger and

firmer fruit, and improved flavor, including the Triple Crown,[10][11] Black

Diamond, Black Pearl, and Nightfall, a marionberry.

2.2 NUTRITIONAL FACTORS OF Malt Production

NUTRITIONAL VALUE PER 100g (3.5 OZ)

Energy 205 kJ (49 kcal)

Carbohydrates 11.31 g

Fat 0.64 g

Protein 0.96 g

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Vitamins Quantity %DV†

Vitamin A equiv. 14 μg 2%

Thiamine (B1) 0.011 mg 1%

Riboflavin (B2) 0.028 mg 2%

Niacin (B3) 0.31 mg 2%

Vitamin C 12 mg 14%

Minerals Quantity %DV†

Calcium 215 mg 22%

Iron 1.48 mg 11%

Magnesium 51 mg 14%

Phosphorus 37 mg 5%

Potassium 208 mg 4%

Sodium 6 mg 0%

Link to USDA Database entry

Units

μg = micrograms • mg = milligrams

IU = International units

†Percentages are roughly approximated using US recommendations for adults.

Source: USDA FoodData Central

21
2.1 Malt ProductionPRODUCTION PROCESSING INTO WATER

SOLUBLE EXTRACT

The following process for conversion of Juice into water soluble powder will be

Discussed;

 Pre-washing

 Size Reduction(cutting of Juice to pieces).

 Leaching and Washing

 Extract concentration

 Filtration

2.1.1 PRE-WASHING

The Juice harvested from the farm or purchased from a vendor is first washed after

the quality of the supplied calyx has been determined. The pre-washer removes

sand, debris and other foreign from the Juice.

2.1.2 SIZE REDUCTION

The Juice is cut into pieces after pre-washing to expose more surface area. Particle

size influences the extraction rate in a number of ways. The smaller the size, the

greater is the interfacial area between the solid and liquid, and therefore the higher

is the rate of transfer of material and the smaller is the distance the solute must

diffuse within the solid as already indicated. It is generally desirable that the range

22
of particle size should be small so that each particle requires approximately the

same time for extraction(Coulson and Richardson Vol 2,(2002)).

2.1.3 LEACHING AND WASHING

Leaching which will involve the extraction of needed minerals from Juice by

dissolving it in water through an industrial process. Leaching is the process by

which inorganic-, organic contaminants or radionuclides are released from the

solid phase into water phase under the influence of minerals dissolution,

desorption, complexation, processes as affected by pH, redox, dissolved organic

matter, and (micro)biological activity. The process itself is universal, as any

material exposed to contact with water will leach components from its surface or

its interior depending on the porosity of the material

considered(en.wikipedia.org/wiki/leaching_(chemical)).

Three distinct processes are usually involved in leaching operations:

a. Dissolving the soluble constituent.

b. Separating the solution, so formed, from the insoluble solid residue.

c. Washing the solid residue in order to free it of unwanted soluble matter or to

obtain as much of the soluble material as possible as the product.

Leaching has in the past been carried out mainly as a batch process although many

continuous plants have also been developed. The type of equipment employed

23
depends on the nature of the solid—whether it is granular or cellular and whether it

is coarse or fine. The normal distinction between coarse and fine solids is that the

former have sufficiently large settling velocities for them to be readily separable

from the liquid, whereas the latter can be maintained in suspension with the aid of

only a small amount of agitation.

Generally, the solvent is allowed to percolate through beds of coarse materials,

whereas fine solids offer too high a resistance. As already pointed out, the rate of

extraction will, in general, be a function of the relative velocity between the liquid

and the solid. In some plants the solid is stationary and the liquid flows through the

bed of particles, whilst in some continuous plants the solid and liquid move

counter-currently (Coulson and Richardson Vol 2,(2002)).

2.1.4 EXTRACT CONCENTRATION

Evaporation, a widely used method for the concentration of aqueous solutions,

involves the removal of water from a solution(Juice extract absorbed in water) by

boiling the liquor in a suitable vessel, an evaporator, and withdrawing the vapour.

If the solution contains dissolved solids, the resulting strong liquor becomes

saturated which will be dried into powder. Liquors which are to be evaporated may

be classified as follows:

(a) Those which can be heated to high temperatures without decomposition, and

those that can be heated only to a temperature of about 330 K.

24
 (b) Those which yield solids on concentration, in which case crystal size and

shape may be important, and those which do not.

(c) Those which, at a given pressure, boil at about the same temperature as

water, and those which have a much higher boiling point(Coulson and

Richardson Vol 2,(2002)).

Evaporation is achieved by adding heat to the solution to vaporise the solvent. The

heat is supplied principally to provide the latent heat of vaporisation, and, by

adopting methods for recovery of heat from the vapour, it has been possible to

achieve great economy in heat utilisation. Whilst the normal heating medium is

generally low pressure exhaust steam from turbines, special heat transfer fluids or

flue gases are also used. The design of an evaporation unit requires the practical

application of data on heat transfer to boiling liquids, together with a realisation of

what happens to the liquid during concentration. In addition to the three main

features outlined above, liquors which have an inverse solubility curve and which

are therefore likely to deposit scale on the heating surface merit special attention.

After which the concentrated Malt Productionextract can be mixed with addictives.

Heat Transfer In Evaporators

The rate equation for heat transfer takes the form(Coulson and Richardson Vol 2,

(2002)):

Q = UA∆T

25
where: Q is the heat transferred per unit time,

U is the overall coefficient of heat transfer,

A is the heat transfer surface, and

∆T is the temperature difference between the two streams.

2.1.5 SPRAY DRYING GRANULATOR

Spray drying is a method of producing a dry powder from a liquid or slurry(e.g.

concentrated Juice extract) by rapidly drying with a hot gas. This is the preferred

method of drying of many thermally-sensitive materials such as foods

and pharmaceuticals. A consistent particle size distribution is a reason for spray

drying some industrial products such as catalysts. Air is the heated drying media;

26
however, if the liquid is a flammable solvent such as ethanol or the product is

oxygen-sensitive then nitrogen is used.

All spray dryers use some type of atomizer or spray nozzle to disperse the liquid or

slurry into a controlled drop size spray. The most common of these are rotary

nozzles and single-fluid pressure swirl nozzles. Alternatively, for some

applications two-fluid or ultrasonic nozzles are used. Depending on the process

needs drop sizes from 10 to 500 micrometres can be achieved with the appropriate

choices. The most common applications are in the 100 to 200 micrometre diameter

range. The dry powder is often free-flowing.

The hot drying gas can be passed as a co-current or counter-current flow to the

atomiser direction. The co-current flow enables the particles to have a lower

residence time within the system and the particle separator (typically a cyclone

device) operates more efficiently. The counter-current flow method enables a

greater residence time of the particles in the chamber and usually is paired with a

fluidised bed system.

Alternatives to spray dryers are:

1. Freeze dryer: a more-expensive batch process for products that degrade in

spray drying. Dry product is not free-flowing.

27
 2. Drum dryer: a less-expensive continuous process for low-value products;

creates flakes instead of free-flowing powder.

3. Pulse combustion dryer: A less-expensive continuous process that can

handle higher viscosities and solids loading than a spray dryer, and that

sometimes gives a freeze-dry quality powder that is free-flowing.

Spray Drier

A spray dryer is a device used in spray drying. It takes a liquid stream and

separates the solute or suspension as a solid and the solvent into a vapor. The solid

is usually collected in a drum or cyclone. The liquid input stream is sprayed

through a nozzle into a hot vapor stream and vaporised. Solids form as moisture

quickly leaves the droplets. A nozzle is usually used to make the droplets as small

as possible, maximising heat transfer and the rate of water vaporisation. Droplet

sizes can range from 20 to 180μm depending on the nozzle.

Spray dryers can dry a product very quickly compared to other methods of drying.

They also turn a solution, or slurry into a dried powder in a single step, which can

be advantageous for profit maximization and process simplification.

28
Micro encapsulation

Spray drying often is used as an encapsulation technique by the food and other

industries. A substance to be encapsulated (the load) and an amphipathiccarrier

(usually some sort of modified starch) are homogenized as a suspension in water

(the slurry). The slurry is then fed into a spray drier, usually a tower heated to

temperatures well over the boiling point of water.

29
As the slurry enters the tower, it is atomized. Partly because of the high surface

tension of water and partly because of the hydrophobic/hydrophilicinteractions

between the amphipathic carrier, the water, and the load, the atomized slurry

forms micelles. The small size of the drops (averaging 100micrometers in

diameter) results in a relatively large surface area which dries quickly. As the

water dries, the carrier forms a hardened shell around the load.

Load loss is usually a function of molecular weight. That is, lighter molecules tend

to boil off in larger quantities at the processing temperatures. Loss is minimized

industrially by spraying into taller towers. A larger volume of air has a lower

average humidity as the process proceeds. By the osmosis principle, water will be

encouraged by its difference in fugacities in the vapor and liquid phases to leave

the micelles and enter the air. Therefore, the same percentage of water can be dried

out of the particles at lower temperatures if larger towers are used. Alternatively,

the slurry can be sprayed into a partial vacuum. Since the boiling point of a solvent

is the temperature at which the vapor pressure of the solvent is equal to the ambient

pressure, reducing pressure in the tower has the effect of lowering the boiling point

of the solvent.

The application of the spray drying encapsulation technique is to prepare

"dehydrated" powders of substances which do not have any water to dehydrate. For

example, instant drink mixes are spray dries of the various chemicals which make

30
up the beverage. The technique was once used to remove water from food

products; for instance, in the preparation of dehydrated milk. Because the milk was

not being encapsulated and because spray drying causes thermal degradation, milk

dehydration and similar processes have been replaced by other dehydration

techniques. Skim milk powders are still widely produced using spray drying

technology around the world, typically at high solids concentration for maximum

drying efficiency. Thermal degradation of products can be overcome by using

lower operating temperatures and larger chamber sizes for increased residence

times.

Recent research is now suggesting that the use of spray-drying techniques may be

an alternative method for crystallization of amorphous powders during the drying

process since the temperature effects on the amorphous powders may be significant

depending on drying residence times.

Nano spray dryer

The nano spray dryer offers new possibilities in the field of spray drying. It allows

to produce particles in the range of 300 nm to 5μm with a narrow size distribution.

High yields are produced up to 90% and the minimal sample amount is 1mL.

2.2 TEA BAG PRODUCTION

31
The Juice is first pre-washed to remove debris, cut into pieces for adequate surface

exposure, flavoured with addictives and finally packed in water permeable

material.

CHAPTER THREE

3.0 MATERIAL AND ENERGY BALANCE

3.1 MATERIAL BALANCE

This is an application of conservation of mass to the analysis of physical systems.

By accounting for materials entering and leaving a system, mass flows can be

identified which might have been unknown or difficult to measure without the
32
techniques. The exact conservation law used in the analysis of the system, depends

on the context of the problem, but all revolves around the mass conservation i.e

that matter can neither be created nor destroyed, (en.rn.Wikipedia.

Org/Wiki/massbalance).

The basis of these mass or material balance is the conservation of mass stating that

mass can be neither created nor destroyed” thus all mass (i.e Weight) of the

individual components entering the process must be accounted for in the final

products, by-products, wastes etc.

General materials balance equation =input +generation-Output-

Consumption= accumulation Input: Enters through system boundaries

generation: is produced within the system

Output: existed through system boundaries.

Consumption: Is used up within the system.

Accumulation: Is built up within system.

3.1.1 CONSERVATION OF MASS

This general conservation equation for any process system can be within as

material out = material in + generation consumption – Accumulation. Input +

generation =output + accumulation + conservation (generation term is zero).In the

absence of chemical reaction, the amount of any chemical species flowing in and

33
out will be the same, this gives rise to an equation for each specie present in the

system Material in =material out.

3.1.2 MATERIAL BALANCE ASSUMPTIONS

- This system is operating at steady state i.e there is no accumulation of any sort in

the system.

- Non reactive system

- The following assumptions were made, this is based on the fact the

total material in = total

- Output + Accumulation (Total material under steady condition therefore the

rate of input – rate of output +rate of Accumulation A-B+C

3.1.3 MATERIAL BALANCE AROUND DIFFERENT UNIT

DATA:

Expect plant attainment on installation = 100%

No of days to energy in production = 347x100

Production days/annum = 347x24=8328hrs/annum

Expected plant capacity = 21000 bags/annum

= 21000 8328 hrs/annum = 2,521613833kg/hrs

Quantity of raw material needed per hour 5602.5kg/hr

34
Input- output

3.1.4 MASS BALANCE FLOW DIAGRAM

Input Product

5602.5kg/hr System 5602.5kg/hr

3.1.5 ENERGY BALANCE

An energy balance states that the amount of heat or mechanical energy entering a

process = the total energy leaving with the product and wastes + stored energy +

energy lost to the surroundings. If heat losses are minimized, energy losses to the

surrounding maybe ignored for approximate solutions for calculations, for example

the quality of system hot air or refrigerant required. Energy out- Energy in +

generation consumption = Accumulation.

3.1.6 ENERGY BALANCE ASSUMPTION

- Steady state condition is assumed in all process equipment.

- Heat loss from ail process equipment is negligible.

- Pressure drop along the pipeline is negligible.

- Effect of pressure on enthalpy is ignored.

35
- Potential and kinetic energy contribution are negligible.

3.1.7 ENERGY BALANCE AROUND THE SYSTEM

Malt Productionextractor and smout peeler polisher

System

Mass flow rate of mixture

= 14193.85kg/hr

Inlet temp = 30◦C

Output temp of 85◦C

Heat capacity = 3.18kj/kg/k

Mass flow rate of stream = 14000kg/hr

Heat capacity rate of = 4.18kgII KI I

Inlet temp of stream = 105◦C

Outlet temp of stream = x◦C

Given that Q- MCP T mixture = MCPD T stream for Mixture, heat gain.

Q – 14193.85 X 3.18X (85-30)

Therefore outlet temp of stream Tin- Tout =

MCP T mixture

MCP T stream

= 105- Tout= 42.42146898

36
Tout – 62.6◦C,,

ENERGY FLOW DIAGRAM AROUND THE SYSTEM

input Output
System
14193.8kg/hr 14193.kg/hr

80◦c

30oc

Steam

Steam out

14000k/hr

14000kg/hr 105oc

Dressing Separator

Mass flow rate = 14193.85kg/hr

Heat Capacity of mixture = 3.18kj/kg kII I

Inlet temp = 80◦C

Outlet temp = 900◦C

Latent heat of stream at 105◦C = 2356 kjkII I

Latent heat of vapour at 90◦C = 2024kjkII I

Heat capacity of water = 4.18kj/kgkII I

37
Heat gained by mixture = MCPDT

14193.85 X 3.18 (90-80)

= 451364.43kj

Heat to evaporate water = Q=MxLHY

451364.43kj

Heat to evaporate water = Q = M x LHY

-14193.85 x 2358 – 33469, 698,30kj

Total heat input

= heat gained by mixture + heat evaporated H2O

= 451364,43 +33469098.30kj

= 339020,462.73kg = 33920.46273mj

Mass flow rate of stream = heat input/LHE of stream at 90oC

= 31920,46273

2023 = 16783.99937kg/hr

38
 CHAPTERFOUR

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 Malt Productionget

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 Malt, thus enhancing efficiency.

4.1 GENERALOVERVIEW

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,

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
39
run of plant and product specification, to achieve a rundown rate. This is

done to reduce several disturbance and influences to environment.

4.3CONTROL 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

inthe Malt Productionproduction 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 ANDOPERATIONAL INFORMATION

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

control the system. There is an operational manual on how to switch on the plant,

40
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 Malt Productionis rich in minerals, vitamins etc and when cooked

with that water for people that are washing weight.

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 processingcan

have adverse environmental effects on air and water quality as well as producing

toxic side product.

In Malt Productionproduction, the environmental problem are caused by having a

lot of water around the processing unit, which can easily enter the dried Juice plant

41
and make it to be hard while entering the Malt Production(i.e the final product)

thereby reducing the quality and texture.

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)

42
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 andsafety 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 ANDPIPE SELECTION

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

E.g. since production of Malt Production(fluidize fluid) involves unit process/unit

43
operation of raw Juiceplant ,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

CHAPTER FIVE
44
5.0 EQUIPMENT DESIGN AND SPECIFICATION

There are many equipment involve in processing and production of Malt.

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 ofjoint: bolts and nuts (easily assemble and disassemble)

Number of tray: 3 to 4

Design temperature: 90°c

Length: 100cm

45
Tray dimension: 98Ommx48mm

Breath: 50mm

Ce — purchase cost: 2023

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 2023 x cost index in 2015

Cost index in 2023

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

46
Belt size: 0.6m wide

Shat diameter: 70mm

Model: 1320

Housing: 12mm

Rotor Diameter 610mm

Bearing: 60mm

Shaft speed: 3600rpm

Screen area: 475 inches

Type: pulverisers

Ce = purchase cost: 2023

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 2023 x cost index in 2015

47
 Cost index in 2023

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

Conveyor, type

Belt size: 0.5m

48
Length: 160mm

Driver power: 2kw

Capacity: 7,932kg/hr

Ce=purchase cost: 2023

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 2023 x cost index in 2015

cost index in 2023

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

Thickness: 0.15mm

Weight: 2-100kg

49
Type conveyor belt (0.lm wide)

Ce = purchase cost: 2023

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 2023 x cost index in 2015

cost index in 2023

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

Ce = purchase cost: 2023

C = constant table 6.2

50
S=characteristic size parameter in the units given (6.2)

n = index for the type of equipment

cost in 2023 x cost index in 2015

cost index in 2023

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: 2023

C= constant from table 6.2

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

n = index for the type of equipment

cost in 2023 x cost index in 2015

51
cost index in 2023

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

Equipment Quantity Cost in 2023Cost 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

52
 CHAPTER SIX

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.

53
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 Malt Productionjuice.

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. Adherenceto 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.

54
6.1 ECONOMIC EVALUATION

6.2 PREPARING A PROCESS FLOW DIAGRAM

Aprocess 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) 0.75Conveyorbelt

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

55
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.

56
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 CAPITALCOST

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

57
erecting the plant for the period of the month, it include land cost, cost of plant

erection and working capital.

6.10 FIXEDCOST

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

58
6.12 RATE OF RETURN(ROR)

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

invested fund.

ROR = profit(per year) x 100

Total investment 1

6.13 HOW TO RAISETHE 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
59
financial institutions.

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

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

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

60
government revenue, establishment of industrial linkage, provision of socio-

amenities and diversification of the economy.

61
 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 Malt Productionproduction plant. They include:

Availability of raw material or feedstock: The main raw material needed in Malt

Productionwhich is grown in large quantity in Nigeria, Niger, Ondo, Lagos etc).

The plan site should be located near where the Malt Productionplant is grown 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 Malt Productionplant 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.

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

62
Transportation: The Malt Productionproduction 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

63
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 Malt

Productionplant 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. plant

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

area mapped out for industries.

64
The area is for only industry, because individual buildings are restricted from the

area, to avoid the industrial equipment causing nuisance.

7.2PLANT 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

65
• Having a better control over the production cycle and other activities within

the plant premises.

66
 PLANT LAYOUT

Security office

Vehicle park Weigh bridge

General Manage’s
Office

Reception office

Filling Station Loading and

Chemical Office uploading

Storage room for raw

material
Administrative block
Processing House

Finished Product
Store for Packaging

Utilities Storage room for

Waste treatment finished goods
plant and disposal
office
Room for expansions

67
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

68
• 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.

69
The environmental challenges which is likely to be caused by waste (by products

of Malt Productionproduction and waste water). That is why the waste water will

be 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.

70
 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 Malt Productionindustry 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

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

71
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 Malt ProductionI 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 HAZARDS

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

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

plant.

72
Possible hazards of Malt Productionproduction 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: CHOreacts 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.

73
 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.

74
 CHAPTER NINE

CONCLUSION AND RECOMMENDATION

9.1 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 profitN2.5x 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.

9.2 RECOMMENDATION

Queen Malt ProductionCompany 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

75
of customers. Its administration will not frustrate employees and will not let the

firm down.

9.3 CONTRIBUTION TO KNOWLEDGE

The Juiceare used for medicinal purposes for longer time period. Greeks consume

this fruits regularly for preventing mouth diseases and aching joints. Leaves of

blackberry plant are boiled to make tea and used to cure upset stomachs and

thinning of hair. Blackberries are rich in antioxidants that help to counteract free

radicals with significant health benefits. 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.

76
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the calyces of Juice (Hibiscus sabdariffa L.). J. Food Technol. Afr., 6: 133-134.

Bernie, R., 1991. Drugs Facts and Comparism. J.B. Lippincott, USA

Duke, J.A., 1985. Hand Book of Medical Herbs. 5th Edn., CRS Press Inc.,

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Holden, J.M., A.L. Eldridge, G.R. Beecher, I.M. Buzzard and S. Bhagwat et al.,

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78
 Rao, P.U., 1996. Nutrient composition and biological evaluation of mesta

(Hibiscus sabdriffa) seeds. Plant Food Hum.Nutr., 49: 27-34.

Wong, P.K., S. Yusof, H.M. Ghazali and Y.B.Che Man, 2002. Physico-chemical

characteristics of Juice (Hibiscus sabdariffa L.).Nutr. Food Sci., 32: 68-73.

Kolawole, J.A. and S.O.Okeniyi, 2007. Quantitative mineral ion content of A

Nigerian local refreshing drink (water extract of hibiscus sardriffa calyx). Res. J.

Pharmacol., 1: 23-26.

79
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 Juice leaf= 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

80
ENERGY BALANCE ASSUMPTION FOR DRYER

Q=MCpΔT

Washed Juice leaf = 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 2023 = £4,000

Costindexin 1990 = 60

Cost index in 2023 = 80

From 1990 to 2023 = 3 yrs

(80-60) 20 index

81
3 years = 20 (from 1990—2023)

22 years ?

=20 x 22

31

= 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(2023)

Update cost

2023 x 2015

2023

11,413.5x 226.6

82
= 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 2023 = £1750

Costindexin 1990 = 60

Cost index in 2023 = 3 yrs

(80-60) = 20 index

3 years = 20 (from 1990 -2023)

22years =? (from2023 —2015)

= 20 x 22

83
 3 1

= 146.6

Cost index for hammer mill in 2015

145.6+80=226.6

C=1750

n =200kg/h

S = 200kg/h

Ce =CXSⁿ

£1750x(200)°35

£11,178.8

Update cost

2023x 2015

2023

11,178.8 x 226.6

80

11,178.8x2.8325

=£31,663.951

84
Convert to Naira

Exchange rate = £1 = ₦500

Therefore £4000 x 10m² (£3163.951)= ?

£31663.951x=₦500

£1

=9,499.185.3

FOR ELECTRIC SECTOR

Purchase cost in 2023 = £1000

Cost index in 1990 = 60

Cost index in 1990 = 80

From1990to2023 = 3 years

(80-60) = 20 index

(If 3 years = 20 (from 1990— 2023)

22years=?

20 x 22

31

=146.6
85
=146.6

Cost index for electric slicer in 2015

146.6+80=226.6

C=1000

n = 0.75

S 30m

Ce = CXSⁿ

£1000 x (00)°.75

£12,818.6

Update cost

2023 x 2015

2023

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

86
Purchase cost in 2023 = £2,500

Cost index in 1990 = 60

Cost index in 2023 = 80

From 1990 to 2023= 3 yrs

(80-60) = 20 index

If 3 years =20 (from 1990—2023)

22 years= ? (From 2023 - 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

87
2023 x 2015

2023

39,763.5 x 226.6

80

= 39.763.5z2.8325

= £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 2023 = £1,250

Cost index in 1990 = 60

Costindexin2023 =80

From 1990to2023 =3yrs

(80-60) = 20 index

If 3 years = 20 (from 1990 — 2023)

88
22years = ?

=20x22

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

2023 x 2015

2023

5824.73x226.6

80

= 5824.73x 2.8325

=16.498.54

89
Convert to Naira

Exchange rate = £1 = 500

Therefore £31663.951 =?

£16.498.54.lx₦500

£1

FOR PEELER

Purchase cost in 2023 = £2800

Cost index in 1990 = 60

Cost index in 2023 = 80

From 1990 to 2023= 3 years

(80-60) = 20 index

If 3 years =? (from2023-2015)

=20 x 22

3 1

90
= 146.6

Cost Index for Peeler in 2015

146.6+80 = 226.6

C = 2800

n = 0.75

S = 5m

Ce = CXSⁿ

£2800 x(5)0.75

£9,362.36

Update Cost

2023 x 2015

2023

9,362.36 x 2.8325

= £26,518.88

Convert to Naira

Exchange rate = £1= N500

Therefore £31663.951 =?

91
£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

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)

92
= N241871664.2x1 .4

WORKING CAPITAL (5% OF FIXED CAPITAL)

Allow 5% 5/100 = 0.05

= 0.05 x ₦338,620.329.9

= ₦16,931,016.49

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

VARIABLECOST

Electric power 700mj/d

ESTIMATED RAW MATERIAL

1. Raw Malt Productionflower = 500,000,000kg/yr

41,667kg/hr:347x24X3

1000

93
==₦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

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

94
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

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

95
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

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

500,000,000x₦500

=2.5x100000000000

NPV=2.5 x 100000000000 - 685,645,3884

96
=2.49 x100000000000

ANNUAL COST OF PRODUCTION (NPR)

Annual profit x100

Annual sales 1

2.49 x 100

500,000,000kg/hr

= 49,800%

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

355,551,346.41

= 70,032.079% = 70%

BREAK-EVENPOINT IN UNITS

= Fixed cost

Contribution

97
Contribution= sales cost - variable cost

= ₦6,853,716,867

₦486.3

= 14,093,598.33units

BREAK-EVEN POINT IN NAIRA

= Fixed cost

1-variable

Sales cost = 6853,716,867

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

98
2.5x1011

1.422205386x 10

= 6 year and 4 months

99