Design of spring roll factory with a yield of 1500 tons per year

MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING CAPSTONE PROJECT FOOD TECHNOLOGY DESIGN OF SPRING ROLL FACTORY WITH A YIELD OF 1500 TONS PER YEAR LECTURER: PhD HOANG VAN CHUYEN STUDENT: BUI NGOC XUAN LINH PHAM MAI PHUONG SKL 0 4 Ho Chi Minh City, December, 2021 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING DEPARTMENT OF FOOD TECHNOLOGY GRADUATION THESIS ID: 2021-17116017 DESIGN OF SPRING ROLL FACTORY WITH A YIELD OF 1500 TONS PER YEAR Advisor: HOANG VAN CHUYEN, PhD Student: BUI NGOC XUAN LINH – 17116017 PHAM MAI PHUONG – 17116028 HO CHI MINH CITY – DECEMBER 2021 ii HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING DEPARTMENT OF FOOD TECHNOLOGY MISSION OF THESIS Name of students: Bui Ngoc Xuan Linh Student ID: 17116017 Pham Mai Phuong Student ID: 17116028 Major: Food Technology Thesis title: Design of spring roll factory with a yield of 1500 tons per year Thesis’s ID: 2021 – 17116017 Mission of thesis: - Choosee the construction location and product comsumption - Choose ingredients and builds a production process - Calculate the fuel, electricity, wastes in the factory - Calculate the fee, capital investment in the production process - Drawing A1 of the main production - Drawing A1 of the total factory Date of assessment: 16/09/2021 Date of completion: 31/12/2021 Name of advisor: Hoang Van Chuyen, PhD Instruction section: The whole thesis The content and requirements of the graduation thesis have been approved by Head of Department of Food Technology Ho Chi Minh City, , _, 2021 Chair of the program Advisor iii iv v vi vii viii ix x Industrial buildings: 1.5 × 106 (VND/ 𝑚2 ) Cold storage: 1.35 × 106 (VND/ 𝑚2 ) → X1 = 1.5 × 106 × 1512 + 1.35 × 106 × 340 = 2727 × 106 (VND) ❖ House indirectly serves production: take 25% X1 X2 = 0.25 × X1 = 0.25 × 2727 × 106 = 681.75 × 106 (VND) ❖ Other construction work: take 30% X1 X3 = 0.3 × X1 = 0.3 × 2727 × 106 = 818.10 × 106 (VND) Total construction investment capital: X = X1 + X2 + X3 = (2727 + 681.75 + 818.10) × 106 = 4226.85 × 106 (VND) Average annual depreciation on construction: AXD = a × X = 0.1 × 4226.85 × 106 = 422.69 × 106 (VND) With a = 0.1: Average annual depreciation factor 9.2.2 Capital investment in machinery ❖ Main machine: Spring roll rolling machine: × 912.80 × 106 = 5476.8 × 106 (VND) IQF freezer: × 294 × 106 = 293 × 106 (VND) So the cost of buying the main machine is: T1 = (5476.8 + 293) × 106 = 5769.8 × 106 (VND) ❖ Ancillary machine: take 5% T1 T2 = 5% × T1 = 5% × 5769.8 × 106 = 288.49 × 106 (VND) ❖ Other expenses (inspection, maintenance, repair…): take 1% T1 T3 = 1% × T1 = 1% × 5769.8 × 106 = 57.70 × 106 (VND) Total investment capital in machinery: 88 T = T1 + T2 + T3 = (5769.8 + 288.49 + 57.70) × 106 = 6115.99 × 106 (VND) Average annual depreciation: ATB = B × T = 0.2 × 6115.99 × 106 = 1223.20 × 106 (VND) With B = 20% annual depreciation factor Total investment capital of fixed assets: V = X + T = (4226.85 + 6115.99) × 106 = 10342.84 × 106 (VND) Annual depreciation: ACD = AXD + ATB = (422.69 + 1223.20) × 106 = 1645.89 × 106 (VND) 9.3 Direct costs 9.3.1 Cost of raw ingredients Table Ingredient cost Ingredients Amount Unit price Price (kg/day) (VND/kg) (VND) Flour 231.04 30,000 6,931,200 Shrimp 1148.96 130,000 149,364,800 Pork 1428.96 56,000 80,021,760 Jicama 1093.12 1,500 1,639,680 Taro 707.36 3,000 2,122,080 Carrot 578.72 4,000 2,314,880 Onion 141.44 10,000 1,414,400 Garlic 115.76 15,000 1,736,400 Wood-Ear Mushrooms 514.4 70,000 36,008,000 Salt 16.96 2,000 33,920 Sugar 56.64 2,000 113,280 MSG 11.36 30,000 340,800 Oil 16.96 20,000 339,200 11.36 Total 50,000 568,000 282,948,400 Pepper 89 So the total cost of raw ingredients is: B1 = 282.95 × 106 (VND/ day) = 80357.35 × 106 (VND/ year) 9.3.2 Packaging cost Average packaging cost 15 × 103 (VND/ 10kg product) Packaging cost for each product in a day: B2 =15 × 103 × 10 × 5300 = 795 × 106 (VND/ day) = 225780 × 106 (VND/ year) 9.3.3 Energy cost ❖ Electricity: Price: 2,500 (VND/ kWh) The total cost of electricity is: BD = (Pdl + Pcs) × 2,500 = (426.02 + 36.96) × 2,500= 1,157,450 (VND/ day) ❖ Water: Price: 8,800 (VND/m3) The total cost of water is: BN = 150.24 × 8,800 = 1,322,112 (VND/ day) → Total cost of energy: B3 = BD + BN = 1,157,450 + 1,322,112 (VND/ day) = 2,479,562 (VND/ day) = 2.48 × 106 (VND/ day) = 704.32 × 106 (VND/ year) So direct costs: B = B1 + B2 + B3 = (80357.35+ 225780 + 704.32) × 106 = 306841.67 × 106 (VND/ year) 9.4 Salary ❖ The salary paid to main and auxiliary workers in month is: × 106 (VND/ month) There are 70 workers in all So the salary paid to main and auxiliary workers in year is: C1 = 70 × × 106 × 12 = 5880 × 106 (VND/ year) 90 ❖ The salary paid to the director in month is: 20 × 106 (VND/ month) There is director So the salary paid to the director in year is: C2 = × 20 × 106 × 12 = 240 × 106 (VND/ year) ❖ Salary paid to deputy director in month is: 10 × 106 (VND/ month) There are deputy directors So the salary paid to the deputy director in year is: C3 = × 10 × 106 × 12 = 360 × 106 (VND/ year) ❖ Salary paid to employees of administrative departments Administrative departments: 7× 106 (VND/ month) There are 10 employees in all So the salary paid to employees of departments and divisions in one year is: C4 = 10 × × 106 × 12 = 840 × 106 (VND/ year) ❖ Salary paid to workshop manager in month is: + Quality Assurance (QA): × 106 (VND/ month) + Quality Control (QC): × 106 (VND/ month) There are QA and QC So the salary paid to the factory manager in year is: C5 = (1 × × 106 × 12) + (3 × × 106 × 12) = 396 × 106 (VND/ year) ❖ The salary paid to medical, sanitation team and guard in mouth is :6 x106 There are 15 workers in all So the salary paid to workers in year is: C6 = 15 × × 106 × 12 = 1080 × 106 (VND/ year) ❖ The total salary for all factory workers in year is: C = C1 + C2 +C3 + C4 + C5 + C6 = (5880 + 240 + 360 + 840 + 396 + 1080) × 106 = 8796 × 106 (VND/ year) 9.5 Social insurance cost Social insurance cost is calculated at 3.5% of total factory salary: D = 3.5% × C = 0.035 × 5616 × 106 = 196.56 × 106 (VND/ year) 91 9.6 Indirect costs Depreciation of fixed assets: A1= AXD + ATB = (422.69 + 1223.20) × 106 = 1645.89 × 106 (VND/ year) Non-manufacturing costs: Costs within the scope of circulation of commodities, transportation and external advertising taken as 10% of direct costs A2 = 10% × B = 0.1 × 306841.67 × 106 = 30684.16 × 106 (VND/ year) Bank loan interest: The factory borrows capital at an interest rate of 12% per year to pay for construction, equipment purchases, and direct costs: A3 = 12% × (V + B) = 12% × (10342.84 + 306841.67) × 106 = 38062.14 × 106 (VND/ year) So the total indirect costs are: AGT = A1 + A2 + A3 = (1645.89 + 30684.16 + 38062.14) × 106 = 70392.19 × 106 (VND/year) 9.7 Product cost ❖ Total cost calculation: Total cost = Direct cost + Salary cost + Social insurance cost + Indirect cost: GT = B + C + D + AGT GT = (306841.67 + 8796 + 196.56 + 70392.19) × 106 = 386226.42 × 106 (VND/year) ❖ Product cost: Z1 = GT/a = (386226.42 × 106 ) 3.01 × 106 = 128,314 (VND) a: Productivity: 5300 (kg/day) or 3.01× 106 (pack/year); 500(g/pack) ❖ Selling price: Selling price plus 5% product cost: 𝐙′ = 128,314 + 0.05 ×128,314 = 134,730 (VND) 9.8 Economic performance of invested capital ❖ Calculate profit 92 L = ∑ni=1 × (Z ′ - Z1) =3.01× 106 × (134,730 – 128,314) = 19311.32 × 106 (VND/year) : Number of packages produced in year Z ′ : Selling price for product package Z1: Product cost for product package ❖ Profit after tax: profit tax 40% of profit 𝐋′ = 0.6 × 19311.32 × 106 = 11586.79 × 106 (VND/year) ❖ Payback period: V 10342.84 × 106 Y= L′ = 11586.79 × 106 = 0.89 (year) So the factory payback period after 10 months 20 days with the condition that the productivity reaches 100% and the revenue also reaches 100% 93 CHAPTER 10: WORK SAFETY AND HYGIENE 10.1 Introduction to occupational safety Occupational health and safety applications create good conditions for workers to perform important tasks Today, science and technology are constantly evolving, and scientific inventions aim to serve human life and constantly improve the health of workers Therefore, industrial hygiene and workplace safety have become important requirements of our country with an interest in investment, research and application Food factories are increasingly equipped with modern technology, and workers need to comply with more stringent occupational safety regulations This ensures safety in production Causes of injury in the food industry include: • The device has no guards • Unsuitable loading and unloading of goods • Unskilled workers are not allowed to attend occupational safety classes • Fabrication and assembly of unfinished equipment Therefore, to ensure safety, workers must follow these principles after: • Regularly review accident cases, propose measures guard • In each workplace and workstation of workers, there must be a set of rules work • Inform workers some memorable things, need to pay attention in production • Set up models, organize clubs and exhibitions to introduce safety all labor In addition to the safety of workers when working, it is also necessary to pay attention to the conditions other for workers such as: • Climate safety for workers • Safe from dust and toxic gas • Safety about noise and vibration • Lighting safety • Safe use of equipment 10.2 Climate safety for workers 94 The physical properties of air during production have a (physiological) effect on the human body in terms of work processes and productivity Climatic conditions include indoor temperature, pressure, humidity, air movement, and heat radiation from devices operating indoors Pressure P=760mmHg is suitable for humans because it needs to cope with the pressure of capillaries and tissues in normal temperature air If the outside temperature or pressure deviates from normal conditions, you will feel uncomfortable Climate safety issues require special attention for cold workers such as refrigerated warehouses Cold room temperatures are often close to 0°C, so every time a worker enters the workspace, the worker loses a lot of heat to exchange heat with the environment To reduce the effects of the climate on the human body, workers entering cold rooms must wear cotton shirts, boots and masks to prevent the cold Sudden heat and cold are very detrimental to health, so workers must pass through a buffer chamber to gradually adjust their body to a lower temperature before entering the refrigerator Workers who work in cold rooms not work continuously for long periods of time 10.3 Safe against dust and toxic gas In food factories, the air in many production areas is often polluted and easily polluted with dust from the production process Dust is harmful to the respiratory tract, nose, ears and teeth Dust is also unsanitary during production because it contains many microorganisms Good dust management in food preservation is an important contribution to limiting the entry of microorganisms into food destruction Avoiding toxic gases is just as important in food factories Poisonous gas not only poisons people, it also poisons food Toxic substances often dissolve in water and body fluids and penetrate the blood, causing cells to elicit physicochemical reactions that lead to poisoning 10.4 Safety against noise and vibration Countermeasures against noise and vibration are very important Vibrating movements affect the nervous system, causing headaches, malaise, weakness in the body, desensitizing the brain, and impairing memory Vibrational motion generally reduces work capacity and can cause occupational accidents 10.5 Lighting safety Proper use of lighting is an important prerequisite for creating hygienic working conditions and order on the production floor Well-organized work positions for workers are aimed at 95 improving work efficiency Insufficient lighting can have a serious impact on the visual organs, causing immediate dizziness on workers, affecting labor productivity and product quality In the storage room, the lamp cover must be tightly closed to prevent snow from adhering to the bulb and diminishing its luminosity 10.6 Safe to use the device Since the factory uses small water supply and freezing systems, it is necessary to strictly adhere to the usage rules To ensure safety, always check the water supply safety valve and the frozen storage intake, discharge and discharge lines 10.7 Fire prevention Arrange the refrigeration plant away from the living room Workers working in the boiler area and the area where the air compressor is located must not carry flammable objects, not smoke while working When designing the road, it is necessary to ensure good fire fighting ability in the event of a fire Machine rooms and equipment prone to fire and explosion must be arranged with wide doors and good ventilation Factories need to reach lightning rods, especially tall buildings In the production workshop, it is necessary to arrange appropriate fire extinguishers and sprinkler systems Workers in the factory need to be trained more knowledge about fire prevention 10.8 Factory cleaning The factory uses a lot of water for production and living The water used meets the sanitary requirements and meets the prescribed standards on water used for city activities Water supply must be adequate and regular Water used in processing must be disinfected with chloramine B Wastewater of the factory must ensure drainage conditions, especially liquid waste a lot Therefore, before discharging into the city's wastewater system, wastewater and waste must be treated Storage rooms and processing workshops must be kept clean, production areas must be dry and easily drained Workers standing in the production workshop must be healthy, free of infectious diseases and have regular health checks The factory needs to have a health promotion regime for workers, create conditions for health care and sanitary facilities for workers 96 CHAPTER 11: CONCLUSION Spring rolls from traditional dishes of families are rolled by hand, now using modern technology Applying equipment to the processing stage, reducing manual steps such as shaping, filling, pressing packaging to improve productivity, accuracy and also reduce the risk of contamination affecting product quality The basic calculation data to build the factory are also detailed in the project The project has predicted the feasibility and reasonableness of building a production workshop and hopes to expand it into reality in the near future With the enthusiastic guidance of Hoang Van Chuyen PhD, so far our graduation project has been completed on time with the topic: "Design a spring roll factory with a yeild of 1500 tons per year" However, due to limited knowledge, personal experience and limited time, this project cannot avoid mistakes So, we look forward to receiving our lecturers’ guidance and suggestions to improve our knowledge and gain more experience 97 REFERENCES [1] Trần Thế Truyền (1999), Cơ sở thiết kế nhà máy, Trường ĐH Kỹ thuật Đà Nẵng [2] Phan Thị Thanh Quế (2005), Công nghệ chế biến thủy hải sản [3] Vietnamese standard TCVN 5289:2006 on frozen seafood - Sanitary requirements promulgated by the Ministry of Science and Technology [4] Vietnamese standard TCVN 12614:2019 Frozen black tiger shrimp and white leg shrimp [5] Ahmad, Rabia Shabir, Ali Imran, and Muhammad Bilal Hussain "Nutritional composition of meat." Meat science and nutrition 61.10.5772 (2018) [6] Vietnamese standard TCVN 7046:2009 on fresh meat [7] Vietnamese standard TCVN 7047:2009 on frozen meat [8] Table of nutritional composition of Vietnamese food in 2000 by Medicine Publishing House [9] Vietnamese standard TCVN 1459:1996 (Volume 2, JOINT FAO (JECFA)) on MSG issued by the Ministry of Science, Technology and Environment [10] Vietnamese standard TCVN 6958:2001 on refined sugar promulgated by the Ministry of Science, Technology and Environment [11] Vietnamese standard TCVN 7036:2002 on black pepper - technical regulations promulgated by the Ministry of Science and Technology [12] Vietnamese standard TCVN 5647:1992 on iodized salt promulgated by the Science and State Committee [13] Internal documents of Cholimex Seafood Processing and Exporting Food Enterprise [14] Lê Bạch Tuyết and partner (1996), Các q trình cơng nghệ sản xuất thực phẩm, Nhà xuất Giáo Dục [15] Ngô Hồng Quang – Vũ Văn Tẩm (2005), Thiết kế cấp điện, Nhà xuất Khoa học Kỹ Thuật, Hà Nội [16] Nguyễn, Đức Lợi (2007) Hướng dẫn thiết kế hệ thống lạnh Khoa học kỹ thuật [17] www.cholimexfood.com.vn [18] www.dpi.hochiminhcity.gov.vn [19] http://www.khucongnghiep.com.vn/top-10-khu-cong-nghiep-o-tphcm/ 98 [20] https://moveland.vn/khu-cong-nghiep-vinh-loc/ [21] https://www.alibaba.com/product-detail/Industrial-Machine-DefrostMachine_60196869937.html [22] http://mcbrother.net/san-pham/may-cat-rau-cu-qua-da-nang-sh112n.html [23] https://cokhiviendong.com/may-xay-jx-42/ [24] https://cokhiviendong.com/may-tron-rjb-380/ [25] https://lrocrevn.com/may-quay-ly-tam-tach-nuoc/ [26] http://www.namdung.vn/en-US/flat-belt-iqf-individual-quick-freezer [27] https://cqdetector88.en.made-in-china.com/product/LdNaGARYmmpT/China-Cq818-Metal-Detector.html [28] https://congnghemienbac.com/may-hut-chan-khong-cong-nghiep-dzq-600-2s [29] https://www.gelgoog.com/product/noodles/spring-roll-production-line.html 99 N 100000 6500 6000 6000 15000 6000 12000 6500 12000 5000 W 17500 12 10 20000 11 S 23500 Order 1500 6000 61000 120000 9500 10000 13 2000 15 19 6000 1500 Main production workshop 42 x 36 x 1512 Frozen storage 20 x 10 x 4.8 200 Agricultural storage 10 x 10 x 4.8 100 Electromechanical workshop 15 x 10 x 4.8 150 Solid waste treatment 12 x x 72 Administrative building 22 x 10 x 220, floors Canteen, hall 20 x 10 x 4.8 200 Medical room 10 x x 4.8 40 Voltage converter x x 4.2 16 10 Waste water treatment system 12 x x 4.2 72 11 Fuel depot x x 4.2 36 12 Scrap warehouse 12 x x 4.2 72 13 Two-wheeler garage 10 x 10 x 3.6 100 14 Cars garage 25 x x 3.6 150 15 Garage for trucks 30 x 10 x 4.8 300 16 Water supplying 20 x x 120 17 Fountain R=5 32 18 Fire protection and prevention x x 4.8 36 19 Security room (2 rooms) x x 3.6 18 20 Laboratory x x 3.6 81 21 Laundry room x x 4.8 24 22 Expansion area 355 10000 17 30000 14 7000 10500 25500 6000 1500 6000 1500 L x W x HOUSE Area (m2) 19 3000 6000 6000 21 10000 25000 22 18 3000 120000 6000 Dimensions (m) Name number 20 E 1500 16 1500 6000 3000 6000 1500 6000 3000 6000 5000 20000 5000 5000 HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION PROJECT: MAJOR: FOOD TECHNOLOGY DESIGN OF SPRING ROLL FACTORY WITH A YIED OF 1500 TONS PER YEAR STUDENT Pham Mai Phuong 17116028 RATIO 1/150 STUDENT Bui Ngoc Xuan Linh 17116017 DRAWING NUMBER 1/2 ADVISOR Ph.D Hoang Van Chuyen DATE 8/1/2022 A B C D E G F H I 2000 6000 2000 4000 6000 2000 10000 4200 18 6642 4000 2442 36000 6000 28 17 6000 6000 6000 6000 6000 6000 6000 6000 42000 16 2 6 12 20 19 22 6000 21 15 6000 23 19 42000 11 26 26 6000 15 27 13 6000 14 10 FACTORY CONSTRUCTION Number Name Area Dimension (m2) order 6000 24 FRONT ELEVATION Number Name Area order Dimension (mm) (m2) Flour room 24 4m x 6m 19 Defrost machine 1500*800*980 Argicultural room 36 6m x 6m 20 Centrifuge 2550*1950*1400 Meat room 36 6m x 6m 21 Mixer 880*610*870 Seafood room 36 6m x 6m 22 Cutting machine 1070*1100*530 Spices room 40 4m x 10m 23 Grinder 5300*1200*950 Production tool room 60 6m x 10m 24 Automatic spring roll machine 9000*1500*2400 Mixing room 120 12m x 10m 25 Flat belt IQF 16000*3300*3200 Shaping room 216 18m x 12m 26 Vacuum packaging machine Checking room 144 18m x 8m 27 Metal detector 10 Freezing room 180 18m x 10m 28 Hand wash trough 11 Packaging room 100 10m x 10m 12 Products storage 140 14m x 10m 13 Toilet for men 24 6m x 4m 14 Changing room for men 24 6m x 4m 15 Toilet for women 24 6m x 4m 16 Changing room for women 24 6m x 4m 17 Workshop management office 12 3m x 4m 18 Boots dipping place 1.9 2.4m x 0.8m HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION PROJECT: 1450*590*970 1400*820*900 1083*301 MAJOR: FOOD TECHNOLOGY DESIGN OF SPRING ROLL FACTORY WITH A YIED OF 1500 TONS PER YEAR STUDENT Pham Mai Phuong 17116028 RATIO 1/150 STUDENT Bui Ngoc Xuan Linh 17116017 DRAWING NUMBER 2/2 ADVISOR Ph.D Hoang Van Chuyen DATE 8/1/2022 S K L 0