The design of a snack production factory with a capacity of 3000 tons per year

ECONOMIC AND TECHNICAL RATIONALES OF THE PROJECT

Economic basis

According to statistics and forecasts on Vietnam's population, up to October 2021, it is 98.42 million people, it is forecasted that by 2050 the population will increase to 109.6 million people In which, it is estimated that the average number of children born every day is more than 4000 children, statistics in 2019 the proportion of children under 15 years old accounts for 33.6% of the total population and the proportion of the age group from 15 to 64 years old is 55% is the age group of adolescents [1] The group of children under 15 years old and the youth age group are the ones with the highest demand for snack consumption today

Figure 1 1 Graph of Vietnam's population over the years (Danso.org)

According to The Sweet and Savory Snacks report on Vietnam's snack segment published by Euromonitor International, the industry's total revenue is estimated at $535 million in

2017, higher than 2016 ($479.5 million) [2] In which, the snack market in 2017 in Vietnam has a total product revenue of about 354 million USD, equivalent to nearly 8.000 billion VND However, in terms of snacks production market size in Vietnam is still quite small compared to the world, only about 1/170 compared to the leading country in snacks production, which is the US Besides, Vietnam is considered as one of the most developed

2 snack markets in the ASEAN region behind Thailand, Indonesia, and the Philippines The average consumption per capita is 0.8 kilograms, equivalent to 130.000 VND/person However, in the snack market by 2020, there has been a decline According to a report by Statista, the total revenue of the industry is estimated to be only about 429 million USD in

2020 Today's life is significantly improved, and the spending trend of young people on snacking is increasing That makes the snacks market in Vietnam very potential But as the current situation of the world makes people's awareness about healthy lifestyle increase, this makes the Snacks market in recent times trend down In the period 2011-2015, the market always maintained a double-digit increase, but by 2018 it was only 5.5% maximum The revenue of the whole market is forecasted to be about 455 million USD by 2021, equivalent to 10.300 billion VND [3].

Selection of factory’s location

1.2.1 Natural features and construction location

Based on references about current industrial parks, we chose the location to build the factory as Amata Industrial Park located on National Highway 1A, Long Binh Ward, Bien Hoa City, Dong Nai Province Amata Industrial Park was created by a joint venture between reputable contractors, Sonadezi Company and Amata Corp.Public Company of Thailand This is a project with modern infrastructure, advanced management level compared to the whole country and the region and was established in 1994, after many expansions, the industrial park has an area of 513 hectares The total investment capital in the industrial park has so far reached 1.9 billion VND, meeting the employment needs of more than 60,000 employees By 2020, the industrial park will be upgraded and expanded by 27 hectares [4]

Amata Industrial Park has many favorable conditions in terms of geographical location, infrastructure, services and investment:

- Geographical location: Because it is located at an important traffic hub of the Southern key economic center, it has many favorable conditions in terms of road, waterway

3 and air About 30km from Ho Chi Minh City center and Saigon station, Dong Nai port with 4km, Tan Cang and Phu My port with 26-40km, Tan Son Nhat International Airport with 32km [4]

- The industrial park is surrounded by land projects designed by Amata in a modern model with full architecture of available utilities such as markets, schools, hospitals, parks, entertainment areas, etc, that meet the necessary needs for workers living and working in factories Amata Industrial Park is designed and built with developed and reliable infrastructure Modern, fully equipped facilities and professional customer support services in all manufacturing industries are here

- The internal traffic axis is safe, clean and beautiful with 4 lanes solidified by reinforced concrete with 2 layers 40cm thick

Currently, electricity is mainly supplied from the Amata power plant with a capacity of up to 20 MVA In addition, the national electricity network through the substation has a capacity of 40MVA on an area of 100,000m 2 The price of electricity is 0.073 USD/1KWh Ensure sufficient production of electricity for factories, leased land for factories and factories in industrial parks, even if there is a problem with the national power grid [4]

Clean water supply system with a capacity of 8.000m 3 /day and night, to ensure sufficient water supply for factories and enterprises in the industrial park to use during the process manufacture The price of water is 4.600 VND/m 3 [4]

The wastewater treatment system has a capacity of 5.000m 3 /day and night, meeting the standards of the Ministry of Natural Resources and Environment To ensure the wastewater treatment in factories is not blocked, causing odor and pollution Waste is treated right at the waste factory in the industrial park The price of wastewater treatment is 0.28 USD/m 3

The warning, prevention and firefighting system is installed in the industrial park according to national regulations to ensure the safety of the entire area quickly and in a timely manner

Use natural gas and liquefied propane because their combustion products are non-toxic In addition, oil is also used as a fuel in some heat exchangers

The industrial park is located in the key area of Dong Nai province and near the center of

Ho Chi Minh City, so the human resource is abundant, along with the available facilities, it is close to the zone activities such as markets, supermarkets, entertainment areas, hospitals, etc With a large number of residents living here, the search for human resources is very convenient

Investors who lease land in Amata Industrial Park will be granted an investment certificate with the operating period of the industrial park for 50 years, and enjoy incentives when renting land, including tax exemption for 2 years and reduction of 50% for the next 4 years according to the Decree 218/2013/NĐ-CP [4]

- Land rental price with infrastructure: 65 USD/ m 2 , minimum rental area 5000 m 2

- Factory rental price: 4 USD/m 2 , minimum rental area 10000 m 2

- Electricity price: rush hours are 0 USD/ KWH, normal hours are 0.073 USD/KWH, off-peak hours are 0 USD/KWH According to electricity prices in Vietnam, Electricity

- Clean water price: According to the State price, 4.6 VND/m 3

- Wastewater fee: 0.28 USD/ m 3 , calculated by 80% clean water The water quality after treatment is grade A according to regulations QCVN40:2011/BTNMT

To ensure the factory operation and long-term product quality, the sources of raw ingredients must be clean, strictly tested to meet the criteria of national standards, and ensure environmental hygiene Moreover, the closer the source of raw ingredients to the factory, the lower the cost of transporting raw ingredients and ensuring the quality of input ingredients The factory will use flour supplied from Tai Ky Food Flour Joint Stock Company in Ho Chi Minh City, auxiliary ingredients and spices will be supplied from hai Giang Son Private Enterprise in Dong Nai

The factory's goal is to produce high-quality products with modern technologies, creating many products with many distinctive shapes and flavors that can be consumed throughout the country, and exported to other countries, neighboring countries in the future The factory is located in Amata Dong Nai industrial park, this is a large industrial zone of Dong Nai province, adjacent to many provinces such as Ho Chi Minh City, Binh Duong province, and near ports and airports, so transportation is convenient for exporting to domestic provinces such as the region West, Central and North and also abroad in the future.

Consumption area

The factory's goal is to produce high-quality products with modern technologies, creating many products with many distinctive shapes and flavors that can be consumed throughout the country, and exported to other countries, neighboring countries in the future The factory is located in Amata Dong Nai industrial park, this is a large industrial zone of Dong Nai province, adjacent to many provinces such as Ho Chi Minh City, Binh Duong province, and near ports and airports, so transportation is convenient for exporting to domestic provinces such as the region West, Central and North and also abroad in the future

OVERVIEW OF PRODUCT AND INGREDIENTS

The development history of the snack industry

Over many years of history, the snack industry has made strong growth steps, so far snack products are widely traded around the world and the production quantity every year increases, bringing a lot of benefits profits for many industrial countries in the world, including Vietnam A little about the history of the birth and development of the snack industry:

- In 1853, George Crum, who created the first "sliced french fries", was working in a fancy restaurant serving traditional french fries, but one customer was not satisfied with the dish because they were too thick, so he tried slicing the potatoes and deep-frying, coincidentally the customer was very pleased with the fries and since then his "sliced fries" became famous and named Saratoga Chips after his local name [5]

- In 1895, Mr William Tappendon of Cleveland, in Ohio, started selling french fries as a snack in his store

- However, until the early 19th century, potato chips were still not popular because they were difficult to transport and store because now only boxes or tins were used for packaging, which made the potatoes easy to go rancid broken in transit Until 1926, Laura Scudder living in California invented the wax paper bag to solve the difficulty of transporting and storing potato chips, from which the potato chips became widespread [6]

- At the same time in 1908, the Leominster Potato Chip Company was founded in Leominster, Massachusetts, United States and claimed to be the first manufacturer of potato chips in the United States [7]

- In 1929, Freeman Mcbeth of J.D Ferry built a device for the continuous production of French fries, and the machine was brought to the Ross Potato Chip Company in Richland Pennsylvania, USA

- In 1932, Herman Lay opened a fast food establishment in Nashville, Tennessee In

1938, he purchased the Atlanta, Georgia-based French Fries manufacturer "Barrett Food

Company" and changed its name to "HW Lay Lingo & Company", from which Lay traveled throughout the southern United States [8]

- In 1933, Dixie Paper Company - Dallas, Texas produced oil-proof wax paper packaging for potato chips

- In 1937 National French Fries association (NPCI) was established

- In 1950, the first snack made from deep-fried pork skin was produced and marketed

- In 1954, the first barbecue flavored fries were produced in the United States [9]

- In 1958, Herr's was the first company to introduce barbecue-flavored fries in Pennsylvania, and the National Potato Chip Institute (NPCI) held an international potato chip conference in London, which was later renamed become Potato Chip Institute International (PCII)

- In 1961, the Frito Company, founded by Charles E Doolin, merged with Lay, forming Frito-Lay In 1965, Frito-Lay merged with the Pepsi-Cola Company to form PepsiCo In 1991, the company introduced a new formula for their products to be crisper and stay fresh longer Soon after, the company introduced "Wavy Lay's" products with a nationwide rollout in 1994 [10]

- In 1976, PCII changed its name to the French fries and snack food association

- In 1995, low-fat or fat-free Snacks were produced and marketed during that time

- In 1997, the development of seasoning technology further diversified snack products

Main ingredients

Corn flour is a finely ground powder from corn kernels including ground germ, endosperm and bran, so it contains a lot of nutrients of corn such as protein, fiber, starch, vitamins and

8 bioactive compounds higher education is in corn starch The color of corn flour usually depends on the type of corn used, but in snack production, people often use yellow cornstarch (yellow corn flour or maize flour) Corn flour has 9–10% protein [11], mostly as a series of zein proteins However, Zein protein cannot create gluten [12], so people often mix flour or rice flour in the ingredients to create a gluten network for the product

Corn flour is often used to produce corn snacks, used in everyday cooking to create a thick consistency for soups or sauces Corn flour contains many nutrients such as fiber, carbohydrates, vitamin A, minerals Moreover, corn flour can help keep the heart healthy because corn flour contains a good amount of omega 3 that can remove cholesterol in the body, helps prevent anemia, decreased risk in the development of type 2 diabetes, yellow corn is a rich source of beta-carotene which is essential for the maintenance of good vision and skin

Table 2 1 Composition of Corn Flour per 100 grams [13]

Table 2 2 Quality criteria of corn flour follow by TCVN 11015:2015 [14]

Raw fats ≥ 3.1% dry matter mass

Size ≥ 95% passes through a sieve with a hole size 0.85mm

≥ 45% passes through a sieve with a hole size 0.71mm

≤ 25% passes through a sieve with a hole size 0.21mm

Rice flour is a flour made by removing the husk of rice and finely grinding raw rice, white rice or brown rice is commonly used to make rice flour Rice flour is often used as a substitute for flour and used to thicken dishes such as soups, sauces, etc Which are kept cold or frozen because rice flour prevents liquid separation in food Rice flour is a staple in India, Japan, and Southeast Asia because it's cheap, easy to make, and readily available The common types of rice flour today such as white rice flour, glutinous rice flour, brown rice flour, depending on the purpose of use, grind the rice according to the size needed In addition, rice flour does not contain gluten so people who are often allergic to wheat flour can use them to replace them in dishes, rice flour is also being focused in diet menus

Table 2 3 Composition of Rice Flour per 100 grams by USDA Standard [15]

Extra ingredients

Salt is mineral composed of Natri Clorua, salt in the form of a natural crystalline mineral is known as rock salt or halite Salt is present in vast quantities in seawater The open ocean has about 35 grams (1.2 oz) of solids per liter of sea water, a salinity of 3.5% Salt is a spice that has been used for a long time by the ancients for cooking, is an indispensable spice in life, there are many foods preserved by salting such as fish, meat, etc Many nutrients are necessary for the body, however, if too much salt is consumed, it will cause cardiovascular disease, high blood pressure, if iodine deficiency will cause endemic goitre, growth retardation in children [16]

Table 2 4 Quality criteria of salt by TCVN 3974:2007 [17]

Sugar is a familiar spice in most dishes, it has a sweet taste, is soluble in water, in the form of sugar crystals, white in color Sugar is the generic name for sweet-tasting, soluble carbohydrates Types of sugar commonly: Simple sugars also called monosaccharides, include glucose, fructose, and galactose Compound sugars also called disaccharides or double sugars, examples are sucrose, lactose, and maltose Sugar is found in most plants, is a natural source of abundant sugar, there are many types of plant sugars used such as cane sugar, jaggery, sugar beet Consuming too much sugar has been linked to the onset of obesity, diabetes, cardiovascular disease, dementia and tooth decay In 2015, the World Health Organization recommended that adults and children reduce their free sugar intake to less than 10% and encouraged them to reduce it to less than 5% of their total energy intake [18]

Table 2 5 Quality criteria of refined sugar by TCVN 6958 : 2001 [19]

1 Appearance White crystals, relatively uniform in size, dry, no lumps

2 Flavor, taste Sugar crystals or sugar solution with a sweet taste, no strange taste

3 Color Iridescent white crystals When mixed with distilled water, the solution is clear

7 Mass loss on drying at 105 o C for 3 hours

Water is an indispensable ingredient in the product, it helps the dry ingredients stick together during the kneading stage Water has a great influence on product quality, the water put into the production process must be of high quality, clean water has removed impurities, water hardness < 7-9 mg/l, decomposed minerals in water such as: iron, calcium, magnesium, copper, aluminum appear will cause erratic hydration of the flour

Cooking oil is an indispensable ingredient in most processing and recipes, cooking oil is now derived from plants or animals in liquid form There are many types of vegetable oils currently used such as olive oil, soybean oil, canola oil, sunflower seed oil, palm oil, canola oil, etc According to studies, it is necessary to use saturated fat within the permissible range, because using too much unsaturated fat can increase the amount of LDL cholesterol, which is harmful to the body By following American Heart Association (AHA) recommend using only 20-35% total fat, which equates to 44 -77g of fat in a 2.000 - calorie diet Facilitates the process of spraying seasoning powder easily and evenly into the product [21]

Monosodium Glutamate is an additive that has the effect of enhancing the taste and flavor of the product, also known as super monosodium glutamate It is a colorless, odorless, water-soluble crystals composed of the sodium salt of glutamic acid, one of the non- essential amino acids Additive E621 is widely used and popular in food today, it brings attractive taste to consumers, manufacturers often use it to enhance the flavor of products However, if using too much MSG in a short time will be harmful to health, especially the brain, it is necessary to control and use the appropriate dosage for each product and daily meal Adults are recommended not to use more than 6g / day and children under 18 years old should not use MSG [22]

E320 is an antioxidant, it prevents oxidation in products, commonly used in food and beverage, especially in fatty food products E320 can withstand high temperatures and is also used as a preservative In addition, BHA is also used in some drugs such as: cholecalciferol (Vitamin D3), isotretinoin, lovastatin and simvastatin The U.S National Institutes of Health report that BHA is reasonably anticipated to be a human [23] [24]

Butylated hydroxytoluene (BHT), also known as dibutylhydroxytoluene, is a lipophilic organic compound BHT is also an antioxidant food additive, used to maintains freshness, prevents spoilage, decrease the rate at which the texture, color, or flavor of food changes Cost of BHT is cheaper than BHA but less resistant to high temperatures than BHA Furthermore, BHT to be generally recognized as safe and allow small amounts to be added to foods [25]

EXPLAIN THE TECHNOLOGICAL PROCESS OF PRODUCING

Explain the technological process of producing Snack products

+ Purpose: This stage is an important stage because the input quality of the ingredients must be checked to meet the required quality, in order to ensure the quality of the product

+ Requirement: Main raw ingredients and extra ingredients must be strictly inspected, weighed in the right quantity, prepared for mixing, preserved and stored in accordance with regulations

+ Purpose: Preliminary mixing of ingredients to form a mixture prepared for extruding + Requirement: Mix the ingredients thoroughly to avoid clumping and excess too much

+ Processing: Put the prepared ingredients into the mixer and preliminary mixing until the ingredients are homogeneous

+ Purpose: After the pre-mixing process, the ingredients are put into the extruder for the purpose of mixing and kneading the ingredients into a flexible dough Use heat to cooked the dough and pressure to inflate the product

+ Requirement: The dough going through this stage must be completely homogeneous, cooked, and inflated with the correct volume and size of the product

+ Processing: put the pre-mixed powder mixture into the extruder, adjust the rotation speed of the device, mix the ingredients into a homogeneous mass, and adjust the appropriate temperature to cooked the dough

+ Purpose: Shape the product and prepare it for frying, saving frying time

+ Requirement: cut the correct size and thickness of the pellet

+ Processing: adjust the blade size to suit the product, put the dough prepared in the extrusion process into the cutter and cut into the pellet of the specified size of the product, the unsatisfactory workpieces will be rejected cancel

+ Purpose: Give the product a bright yellow color, crispiness, and killing some microorganisms present in the product

+ Requirement: The sides of the product must be uniform in color, after drying, it will still retain its crispness, sponginess, and not be crushed

+ Processing: Raise the conveyor temperature to the right temperature After that, the pellets from the cutting stage are put into the drying oven by the conveyor system Carry out drying according to the specified procedure for the product After drying, the pellets are conveyed by the conveyor belt to the spice sprayer During the process of moving through the conveyor, the unsatisfactory pellets will be discarded

• Change of product’s characteristics during drying process:

The increase in temperature during drying, the diffusion of fat from the heating medium into the product will cause the ingredients to be changed such as the density decreases, the volume increases

High temperature is the agent that promotes many important chemical reactions such as Maillard reaction and Caramelization, these two reactions affect the sensory value of food, making the product dark, create a unique flavor In addition, there is a reaction of vitamin decomposition, which reduces the nutritional value

The product will have a lower moisture content than the original because during the high temperature drying process, the water inside the product evaporates

The drying process also reduces the microbial density in the food, which increases the shelf life of the food During this process, a protein denaturation reaction occurs

+ Purpose: create a specific flavor for the product, can create more specific colors on the outside of the product, increasing the attractiveness of the product to consumers

+ Requirement: Spray evenly on all sides of the product, impregnate the right amount of seasoning as required

+ Processing: adding spices to the seasoning sprayer, the fried pellets are led through the seasoning spray system Carry out seasoning according to the specified specifications for the product The pellets after seasoning will move by conveyor to the packing machine, unsatisfactory pellets are discarded

+ Purpose: packaging products before putting on the market, preserving products from direct sunlight, preventing moisture, water, odors, toxins, and dirt from the environment Product packaging will help increase visual appeal to consumers and help consumers easily recognize some of the product's properties through the information on the package

+ Requirement: joints are not open, not wrinkled, and the swelling is satisfactory The product information, instructions for use, production date and expiry date are clearly printed, in the right position

MATERIAL BALANCE

The plan of main raw ingredients

The factory produces continuously for 12 months out of a year, so raw ingredients will be imported monthly to ensure sufficient capacity, the plan is shown in Table 4.1

Table 4 1 The diagram of main ingredients input

The plan of production

- The factory will work 2 shifts/day (16 hours):

- Equipment will be maintained once every 3 months

- Sundays, public holidays and New Year are off according to the regulations of the state

Table 4 2 Shows the number of days and shifts per month ( in 2021)

- The initial data: Factory with a capacity of 3000 tons/year

- According to the data of the table above:

+ The number of production days in a year is 300 days

+ The number of production hours in a year is 4800 hours

 Productivity in a day of the factory is: Qday = 3000

 Productivity in a hour of the factory is: Qhour = 10

4.3 Ingredient balance for the product

- The composition of product and mixing ratio

Table 4 3 The composition of product and mixing ratio [26]

Components Contents (%) Mass (kg) / 700 kg of product

- Loss of main ingredients through each stage

Assuming that through each stage, the amount of ingredients will be lost depending on different machines, shown in Table 4.4

Table 4 4 Loss of main ingredients through each stage [27]

- Moisture content of semi-finished dough through stages

Table 4 5 Moisture content of semi-finished dough through stages [26]

- Loss of extra ingredients through each stage

Table 4 6 Loss of extra ingredients through each stage [27]

• Calculating the standard of using ingredients

- Raw ingredients will be lost after each production stage, so the mass of dough at each stage is different

- Ingredients loss at each stage is calculated according to the amount of material input stage:

T is the amount of ingredient at each stage, (kg)

S is the final amount of ingredient in a unit of finished product, (kg)

N is the number of stages

X1, X2,… Xn is the % of ingredient l loss at each stage compared to the time when the ingredient is put into that stage (%)

- The composition of dough (corn and rice flour) in the product is 900kg per 1 ton of product

+ The mass of semi-finished product in the packaging stage:

(100−0.2) = 631.3 (kg) + The mass of semi-finished product in the seasoning spray stage:

(100−0.2) = 632.5 (kg) + The mass of dough in the drying stage:

100−18 = 750 (kg) The mass of water lost during drying:

G water 1 = G3 – G2 = 750 – 632.5 = 117.2 (kg) + The mass of dough in the cutting stage:

(100−1) = 757.6 (kg) + The mass of dough in the extruding stage:

100−24= 821.5 (kg) The mass of water lost during extrusion:

G water 2 = G5-G4 = 821.5 – 757.6= 63.9 (kg) + The mass of powder to be used in ripening stage:

100−13 = 717.6 (kg) The mass of water added during this period:

G water 3 = G5-G6 = 821.5 – 717.6 = 103.9 (kg) + The mass of powder to be used in mixing stage:

+ Mass of corn flour and rice flour in the mixture needed for the preliminary mixing stage (ratio 9:1)

Mass of corn flour: Gcorn = G7 × 90% = 719.76 × 90% = 647.8 (kg)

Mass of rice flour: Grice = G7 × 10% = 719.76 × 10% = 71.98 (kg)

 The total mass of semi-finished products after each stage of main ingredient is shown in the table 4.7:

Table 4 7 The mass of semi-finished products after each stage of main ingredients

Stages Input ingredients (kg/h) Input ingredients (tons

 The mass of semi-finished products after each stage of extra ingredients is shown in table 4.8

Table 4 8 The mass of semi-finished products after each stage of extra ingredients

Stages Input ingredients (kg/h) Input ingredients (tons /year)

Sugar Salt Oil Additives Sugar Salt Oil Additives

CALCULATE AND SELECT EQUIPMENT

Mixing machine

- Purpose: to mix ingredients evenly

- The mass of powder needed for this stage in 1 hour: 719.76 kg/h

* Select device: Horizontal ribbon mixer WLDH-1500, China [28]

+ All elements in contact with the product have a smooth surface or are made of stainless steel, resistant to corrosion

+ Easy to use and easy to adjust

Extrusion machine

- Purpose: to ripen the ingredients and give the product a satisfactory structure

- The mass of powder needed for this stage in 1 hour: 821.5 kg/h

* Select equipment: TSE90 –Twin Screw Extruder of Jinan Datong Machinery Company, China [29]

* Main features of Twin Screw Food Extruders:

+ High stability and high capacity

+ Individual and centralized controlling panel

+ Material extrusion screws with long lifetime

+ All motors with frequency converters speed control system

Figure 5 2 Twin Screw Food Extruders

Cutter

- The purpose: to cut the dough into the desired shape and length

- The mass of powder needed for this stage in 1 hour: 757.6 kg/h

* Select device: Nimki Corn Snack Making Machine Namakpara Cutter Machine, China[30]

Drying equipment

* The size of the conveyor

- The volume of material contained in the conveyor, V (m 3 ) [31]

𝜌 is the density of the dough (kg/m 3 ), 𝜌= 641 (kg/m 3 )

B is the width of the conveyor belt (m), choose B=2m h is the thickness of the steel layer on the conveyor belt (m)

Lb is total length of conveyor (m)

𝜏 is the drying time, 𝜏 = 1 hour

 From equation 5.2 , the total length of the conveyor belt required is:

- Assume the number of conveyors in the dryer is i = 3

 The length of each conveyor should be: Lb = 14.6

So the drying equipment consists of 3 conveyors Each conveyor has a length of Lb = 4.9m and a width of B = 2m

- The mass of dough needed for this stage in 1 hour: 750 kg/h

* Select device: Automatic three-layer food drying oven of Shandong, China [32]

+ The uttermost temperature can be 300°C

+ Fuel can be electric, gas diesel

Seasoning spray equipment

- Purpose: to create a unique flavor for the product

- The mass of powder needed for this stage in 1 hour: 632.5 kg/h

* Select device: SR-FM - Flavoring Machine of Tianjin, China [33]

+ This is consist of hoister, flavoring drum, oil spaying tank, spraying gun

Oil spaying tank is equipped with a heating pipe to heat the flavors and help them mix more evenly

+ This is an automatic device and continuous seasoning spray and low noise

+ The rotary speed and capacity of the product can be adjusted during production

+ Eight-angle type is designed inside the seasoning drum so that the product can be fully stirred to ensure the uniformity of the seasoning powder in a short time

Packaging machine

- Purpose: to pack products into small bags to help preserve products and bring them to market

- The mass of semi-product for this stage in 1 hour: 631,3 kg/h

* Select device: APVT-160 - horizontal packing machine of Anh Minh Trade and Technology Solutions Co., Ltd [34]

+ With touch screen, independent temperature PID controller, easy to operate

+ With dual inverter controller, PLC system, automatic fault diagnosis, dual encoder

+ Wrapping film width: max.340mm

+ Diameter of film roll: max.380mm

- The amount of product that needs to be packed in an hour: 631.3 kg/h

Assuming, every minute the device can make 150 packages, then 9000 packages can be made per hour For each pack of 80g, the productivity of the device in one hour is:

Ancillary equipment

- Inclined screw conveyor is a kind of continuous conveying equipment, it is used to convey materials from mixer to extruder

* Select device: LS219 Type Inclined screw conveyor of Xinxiang, Henan, China [35]

 Number of devices needed: choose 2 equipment for 1 production line

* Select device: Automatic Bucket Elevator Conveyor, China [36]

 Number of devices needed: choose 2 equipment for 1 production line

- Purpose: Transport finished products to product storage

* Select device: HPT30S Hand Pallet Truck Meditek, China [37]

- Based on the production line choose the number of 2 cars

=> Summary of equipment in the production line is shown in Table 5.1

7 Dryer Three-layer drying oven

CONSTRUCTION CALCULATION

Design of the main production workshop

After designing and installing equipment in accordance with the continuous production technology line and the design standards of the factory, the main production workshop has the following dimensions

Figure 6 1 The diagram of production process

Corn flour and rice flour are processed and taken out from the raw material room, then mixed by a screw-drive automatic continuous mixer with the structure: outside is a mixing tank, inside is a horizontal stirring shaft operated by a motor [28] Raw ingredients are fed into the equipment at the inlet hopper, the powder is mixed by the agitator shaft and continuously removed at the discharge port

The ingredients then goes to the extruder to perform the next task through the screw conveyer Here, the product of the mixing stage is stored in the hopper and inlet and delivered to the outlet by the action of the spiral blade

Extrusion is the name for the process that uses pressure to push dough through small holes for the purpose of shaping and ripening products or semi-finished products When the material is input into the machine, along the length of the machine can go through three stages: mixing stage, kneading stage and cooking stage Through each of these stages, there will be different transformations of the raw ingredients [29]

+ Mixing stage: The pressure and temperature are not high, so the structure of the raw ingredients does not change significantly

+ Kneading stage: in here the temperature and pressure gradually increase The components such as water have been mixed well, diffused into the structure of the material, forming hydrogen bonds between water and molecules containing hydrophilic groups such as proteins, pentosane, starch As the dough swells, some soluble molecules will diffuse out into the liquid medium The dough becomes denser

+ Cooking stage: Under high pressure, the mechanical forces acting on the ingredients in opposite directions have the effect of breaking the starch granule structure or tearing the protein fiber bundle During this stage, the ingredients change like in normal food heating, so it is also known as the cooking stage At the end of the cooking phase, the ingredients are in the form of a flexible or liquid mass and are subject to very high pressure This flow of viscous liquid will flow through the mold hole and shape the flow according to the shape of the mold

The ingredients then continue to flow through the screw conveyor to the cutting and shaping machine In this machine, the dough is simply shaped into rolls and rolled into a die, cutting the dough into certain shapes [30]

Then the ingredients will pass through Automatic Bucket Elevator Conveyor, transported to the conveyor dryer The purpose of the machine is to remove water, reduce the moisture content of corn snacks to the required moisture content (about 3%), increase the shelf life of snacks The ingredients will be fed into the equipment at one end of the machine, and the product will be discharged at the other end Inside the drying chamber, there are three drying layers to help prolong the contact time between ingredients and heat The temperature at all points in the drying room is the same The ingredient is loaded by the conveyor in the 3rd layer The conveyor belt moves in turn through the drying chambers, down to each conveyor layer, in the opposite direction Once out of the drying chamber, the semi-finished products are cooled by the fan unit [31], and then transported by the Automatic Bucket Elevator Conveyor to the seasoning spray equipment

The seasoning sprayer completes the product by creating a unique flavor and sensory value for corn snacks The seasoning is taken from the seasoning room to feed into the feed hopper and agitated by the stirrer to be transported horizontally to the seasoning sprayer Semi-finished products, which have just been dried at the drying stage, will be transported by conveyor to the impregnating tank Oil will be sprayed before the seasoning to help the seasoning stick to the product easily Through rotary motion, the product is mixed, evenly permeated with seasoning and oil [32] The product at the bottom of the tank will be transported to the packaging machine by the Automatic Bucket Elevator Conveyor

On the packaging machine consists of a roll of pre-labelled packaging, stretched and folded into a rectangular shape, an automatic dosing system The product is placed on the surface of the conveyor belt, then the plastic film for packaging is cut off and the product is placed into a complete bag and welded, double-sealed [33]

Finally, the product is put into the packaging room to be sorted into large bags and transported to the finished product warehouse.

Organizational structure

- The number of production days in a year is 300 days

- The factory will work 2 shifts/day (16 hours):

- The number of production hours in a year is 4800 hours

- Equipment will be maintained once every 3 months

- Sundays, public holidays and New Year are off according to the regulations of the state

- Director: is the head in the factory, responsible for operating and controlling the activities in the factory The director will supervise the production activities of the enterprise, develop production schedule plans, approve the books related to costs, the company's budget and other documents submitted by other departments At the same time, establish

47 methods for improving the production process, equipping machines, equipment, ingredients and arranging factory premises The director also plays the role of inspecting and urging employees and workers to work on schedule, ensuring product quality and increasing labor productivity

+ Technical vice director: is the person responsible for managing activities related to engineering, design, and assembly of production machinery As the person who directly directs the technique, proposes measures to arrange and assemble machines in the production line Check, supervise, assign tasks to employees of the technical department, supervise the activities of machines in production to offer solutions when encountering problems At the same time, manage and check the quality of output products, evaluate and adjust plans as well as build reasonable production processes

+ Vice Sales Director: is the person who directly directs, manages, builds the company's business plan, manages the company's finances and the rest of the departments in the factory As the manager, assigning work to the departments of the business department As the person who directly manages the company's business and cooperation projects, supervises and checks marketing plans, evaluates and recommends sales policies

- KCS room: This is a very important room for factories, KCS stands for Product Quality Control The KCS department staff plays the role of checking the quality of input and output materials of the product, to ensure that the product meets quality standards and complies with the regulations of the Ministry of Health Regularly check quality throughout the production process, inspect labor safety during production, have the right to make records, and impose penalties for violations of regulations in production that affect quality Check, monitor and resolve quality-related problems of all raw materials and products throughout the production process

- Technical Department: is the department that plays the role of building and maintaining structures, machines, equipment, systems and operating programs of machines and equipment in factories This department directly manages the technical, technological and

48 machinery related activities of the enterprise to ensure that the technical and technology related activities take place smoothly, efficiently, quickly, and repair fix technical errors

+ Main production workshop: is an indispensable part in production factories This department is responsible for the management of the factory's produc t manufacturing operations The production room is the room that stores and maintains equipment and machinery, performs the production process, preserves, transports, and delivers goods for business needs, controls all aspects of operations manufacture As a place to store the main production line, it should be protected from outside agents and located in the center of the factory

+ Electromechanical workshop: for optimal operation of the production facility, the electromechanical workshop is responsible for managing and maintaining, ensuring smooth, continuous and efficient operation of machines and equipment Mainly inspect, maintain and repair in time machinery and equipment that are damaged during the production process

+ Auxiliary workshop: is a workshop consisting of parts that do not have a direct role in functional activities in production, but this part is necessary for direct departments, providing services, serving departments other part

- Planning and Sales Department: advising the Director on the strategy and business development plan of the factory Employees in the planning and sales department are responsible for planning long-term business development strategies and plans, managing and implementing the balance of capital and capital use for the plant Propose measures to prevent and handle risks in the factory's business, develop customer strategies and classify customers

- Accounting Department: is the department for making estimates, making budget settlements, managing revenues and expenditures, strictly complying with regulations on economic and financial management Employees in the accounting department must carry out accounting checks, summarization and settlement reports to superiors Overall management of enrollment plans, labor wages and other funding sources Manage revenues and expenditures such as: production

49 labor fund, bonus and welfare fund, product sales, equ ipment fines, canteen income and expenditure, parking and other services

- Administration Department: is the department responsible for completing archival, administrative and asset management tasks for the agency The staff in the administrative department must perform tasks such as protecting internal politics, in charge of emulation, reward and discipline work, and carry out inspection, examination, supervision, and legal work according to regulations current regulations Manage, update and supplement records, resumes and social insurance books of officials and employees and labor contracts Manage human resources, arrange, arrange, receive and mobilize officials and employees in accordance with the functions, tasks and development scale of each department

- Marketing Department: is the department that manages all sales activities of the company, is the bridge between the company and the external market, between products and consumers, planning, pricing, promoting and distributing products, services, ideas to meet the needs of the market The marketing department also plays the role of building the company's brand image, planning transmission to consumers, building and managing a customer care system, designing after-sales programs and product warranties for customers enterprise

- Health and security department: is the department responsible for and manages the factory's security and medical staff This is an indirect part of the factory, but plays a very important role, the medical staff is responsible for treating and taking care of the workers when they have health problems during their work Security guards are responsible for maintaining order, ensuring that no strangers enter the factory, harass or damage factory operations, and also play the role of monitoring cameras in the factory, if there is an incident If something goes wrong or if something strange is discovered, report it immediately to that department for inspection

Table 6 1 Number of employees working in administrative work

Head of Planning and sales department

Total number of employees working in administrative work: 36 people Number of direct workers

Table 6 2 Distribution of direct workers in 1 shift

1 Handling and transporting raw ingredients 2

9 Transfer products to temporary storage 2

10 Transfer products to finished product warehouse

15 Garbage and wastewater treatment staff 2

Total number of workers working in 1 shift: 32 people

Table 6 3 Number of indirect workers

Total number of indirect workers: 20 people

- Number of workers working in 1 day:

(Number of direct workers in 1 shift x 2 ) + number of indirect workers = (33 x 2) + 20 84 people

- Total number of employees working in the factory

Construction design

The input ingredients are corn flour, rice flour and spices, so the storage needs to be dry, cool, avoid moisture, away from sources of pollution, toxic chemicals, inflammable and explosive areas Raw ingredients warehouse needs to meet some structural requirements such as:

- The warehouse must be solid to prevent the direct impact of weather factors (rain, sun, heat) on all raw ingredients The structure of the warehouse must be suitable for the import and export of materials and products by motor vehicles

- Warehouse substructure: made of concrete must ensure firmness, not subsidence and must be built at least 30 cm higher than the standard reinforcement

- Warehouse foundation: made of concrete, resistant to the maximum pressure of the product mass; good moisture insulation; prevent underground water circuit; must be higher than the ground outside the warehouse to ensure avoiding the effects of weather and the surrounding environment

- Warehouse walls: solid construction, waterproof, moisture-proof, good insulation, sealed to avoid the penetration of insects and harmful animals to raw ingredients

- Warehouse roof: flat slanted or arched roof, impermeable, leak-proof, with ventilation doors and natural lighting installed

- Warehouse door system: solid construction, tight door lock, preventing insects and harmful animals from entering, and convenient for natural ventilation, suitable size for import and export motor vehicles incoming ingredients

Choose an ingredient warehouse that is a mechanized warehouse and has the ability to store ingredients for 10 days of production

- Mass of rice flour used in 10 days of production: 71,22 x 16 x 10 = 11396 kg

- Mass of corn flour used in 10 days of production: 640,9 x 16 x 10 = 102544 kg

- Mass of sugar used in 10 days of production: 35 x 16 x 10 = 5600 kg

- Mass of salt used in 10 days of production: 7 x 16 x 10 = 1120 kg

 The total mass of ingredients needed for 10 days of production is:

Ingredients will be stored in sacks – 50kg (B1 ), size (L x W x H) = 1,1 x 0,6 x 0,3 m so the area occupied by one bag is: Sbag1 = 1,1 x 0,6 = 0,66 m 2 and are stacked into 7 layers - Mbag1

Mass of ingredient per 1 m 2 : M1 = B 1 × M bag

In addition, it is necessary to arrange a room to store additives and cooking oil, we choose a room with an area 25m 2

So, the total occupied area of the ingredient excluding the walkway is:

The occupied area of the passageway, accounting for 30% of the occupied area of the ingredients So, the passageway area is:

 So, the area of the ingredients including the passageway is:

- The warehouse needs an area to store enough products for 7 days of production

- The product comes in a bag with size: L x W x H = 0.2 x 0.1 x 0.2 m so the area occupied by one bag is: Sbag2 = 0.2 x 0.1 = 0.02 m 2 Each bag contains 100g – B2 of product and is stacked in 30 layers, Mbag2 = 30

 Mass of ingredient per 1 m 2 : M2 = B 2 ×M bag2

- Mass of products produced in one hour: 700kg/hour

 Total mass of product in 7 days of production is:

- The occupied area of the passageway, accounting for 30% of the occupied area of the ingredient => The passageway area is: S5 = 0.3 x 448 = 135 m 2 [page 52, (38)]

So, the occupied area of the material including the passageway is:

S6 = S4 + S5 = 448 + 135 = 583 m 2 Warehouse size: (length x width x height) : 28 x 21 x 9 (m)

- The capacity of the workshop is enough to supply 10 days of production

- The factory's largest capacity in 1 day: Qsb= 0.7 x 16 = 11.2 (tons/ day)

- Weight in each bag is: 80 (g) = 0.08 (kg)

 The number of PE bags used to hold 1 ton of product is: n1 = 1000

So, the PE bag used to pack in 1 day is: n2 2 × 12500 = 140000 bags

- Suppose the weight of 1 bag without snack is 2g, then the weight of snack bag needs used in 1 day is:

- Amount of packaging in reserve: mreserve1 = 25 kg

So, the amount of packaging needed in 1 day

- The number of snacks in the big bag is: n3 = 100 bags

- The quantity of big PE bags needed in 1 day is: n4 = 140000

- Suppose the weight of 1 big PE bag without snack is 10g

- Amount of packaging in reserve: mreserve2 0 kg

So, the weight of a big PE bag to store products that need to be used in 1 day is:

Mbb = (1400 × 0.01) + 30 = 44 (kg/day) = 0.044 (tons/day)

• Area required to store packaging material

Fb: Area required to store packaging material, (m 2 )

C: Cost of materials to be packed in 1 day, G = (tons/day) fb: Standard area, choose f0 = 1 m 2 /ton n: Reserve days, choose n = 20 days

So, the required area for packaging is:

Fb= Fb1 + Fb2 = 6.1 + 0.88 = 6.98 (m 2 ) Packaging material warehouse area: F = Fb× K

Fb: Area required to store materials, (m 2 )

K: Coefficient including the way, choose k = 1.3

Table 6 4 Construction works in administrative buildings

 Total area of administrative building and lobby: 254 + 14.4 = 268.4 m 2

Based on the total area of the rooms in the administrative building, we build 2 floors with the size of each floor is:

+ Dimensions of the 1st floor (L x W x H): 13 x 11 x 5 (m)

+ Dimensions of the 2 nd floor (L x W x H): 13 x 11 x 5 (m)

Total number of employees in the most staff shift: administrative staff, direct workers of 1 shift, indirect workers

Canteen area is calculated for 2

3 of the number of employees in the most staff shift [page

Standard area for 1 worker: 2,25 m 2 / people:

3 x 88 x 2.25 = 132 m 2 Design the area of the dining room 1 floor (L x W x H): 15 x 9 x 5 (m)

The garage is used to store bicycles and motorbikes of employees in the factory Build a long house near the security gate

+ Calculated for 70% of people working in the largest shift [page 54, (37)]

+ Number of workers in the factory: 80 people

+ Design for 1 day of production, with standard area: 1 m 2 /motorbike (TCVN 4601:2021) [38]

+ According to regulations, the minimum parking area for motorbikes is from 2.5 to 3m²/ motorbike

Car garage to store: 3 cars for the board of directors, vice - directors and passenger cars + Parking area for a car is 25 m 2 (TCVN 4601:2021) [39]

+ The length of the common car parking space ranges from 4.75 - 5.5 m

+ The width for one-way car aisles ranges from 6 to 9.15m

The bus garage includes 1 shuttle bus for workers and passenger cars

+ The length of a parking space is 12m (TCVN 4601:2021) [39]

+ The width of a bus parking lot size is 3.5m

+ The truck garage includes: 2 cargo trucks and a raw material import truck

+ Parking area for a truck is 30 m 2 (TCVN 4601:2021) [39]

+ The area calculated for a vehicle is 6 m 2 , in addition, about 10 m 2 is added as a battery charging room [page 55, (38)]

+ Placed in the corner of the factory, next to the traffic road and near the most consuming place [page 55, (38)]

+ Number of bathrooms: Calculated for 60% of workers in the largest shift, standard 7 people/ 1 shower

Area of each bathroom: 0.9 x 0.9 = 0.81 (m 2 ) [page 55, (38)] n5 = 89 ×60

 Construction area of the bathroom: Sbath = 0.81 x 8 = 6.48 m 2

The number of toilets is equal to 1/4 of the number of bathrooms

 Construction area of the toilet: St = 1.08 x 32= 2.16 m 2

+ Changing room: according to standard is 0,2 (m 2 /person )

Calculated by the number of workers in the largest shift:

Construction area of the changing room: Sc = 89 x 0.2 = 17.8 m 2

 Total area to build changing room and toilet:

S = Sbath + St + Sc = 6.48 + 2.16 + 17.8 = 26.44 m 2 Construction Dimensions (L x W x H), (m): 6 x 5 x 3.5

+ Wastewater treatment works with an area of 250 m 2

+ Waste treatment works with an area of 250 m 2

6.3.10 Energy supply zone in the factory

+ The water supply project has an area of: 120 m 2

This is the workshop to repair damaged mechanical parts in the factory

Table 6 5 List of the buildings/constructions

6.3.11 Explain the drawing of the factory construction site

+ Land area of the whole factory:

(Choose a construction factor for the factory: Kxd = 0,35)

To evaluate the economic and technical criteria of the total factory site, we determine the construction coefficient: Fsd, Ksd

- The area of roads and sewers accounts for 20%; Trees account for 15% of the total area of the land

+ Total area of roads and sewers: 20

+ Total area of green trees: 15

 Usable area of the land: Fsd = 3745.5 + 442+ 2392.8 + 1794.6 = 8374.9 (m 2 )

Usage factor for the whole factory:

Figure 6 3 The drawing of design the factory

The figure 6.3 shown the drawing of design the factory, the total factory construction has an area of 11970 m 2 with a length of 140m and a width of 85.5m The factory is located in Amata Industrial Park, Bien Hoa city, Dong Nai province, a modern industrial park with many factories and utilities for workers working at the factory The factory is located at a location with two roads in the south and east, wide and clear roads for trucks and buses to move in and out of the factory The construction factory includes 2 main gates with 2-way street road to come in and out, 1 gate for trucks and 1 gate for vehicles such as motorbikes, cars, buses, construction The 2 entrance gates are to avoid traffic jams during rush hour and to limit collisions accidents when trucks go in and out to import and export goods The main area of the factory, which is an area with a large land area, is in away from the wind and the sun This area is arranged in the middle of the factory in order to easily contact other areas in the factory, convenient for repair, maintenance, material supply, energy supply When entering from the gate for the trucks, the trucks that import raw ingredients will move into the garage for trucks, the garage is located in front of the raw ingredients warehouse gate, easy to put raw ingredients into the warehouse, the garage is built simply with high corrugated iron roof and wall columns After the raw ingredients are put into the warehouse, the workers in the warehouse will put the ingredients into the main production workshop, the remaining ingredients will be neatly arranged in the appropriate positions in the warehouse, the warehouse is built with reinforced concrete walls to protect against external factors affecting the quality of raw ingredients The main production workshop is located near the raw ingredients warehouse and energy supply area of the plant, far from the wastewater treatment area When the ingredients are brought to the main production workshop, the staff will check the quality of the raw ingredients and then put them on the production line, the main production workshop is built with reinforced concrete walls to preserve and resist heat factors affecting the product In addition, outside the workshop, arrange more lawns and trees to ventilate the air and reduce the temperature around the workshop After the production line is completed, the Snack products will be put into the product warehouse for preservation and export The product warehouse is located near the garage for trucks so that trucks can easily come and bring the Snack products to distribute to retailers

- Area of auxiliary works of the factory: including construction such as waste and wastewater treatment areas, toilets are built at the end of the factory to against polluted The factory and these ancillary works, when operating, often generate dust, noise, emissions, and the risk of explosion and fire should be located far away from the main production area and at the end of the dominant wind direction to avoid contaminating the main factory The wind direction of the factory is Southeast, so the area of waste and wastewater is placed at the end of the wind in the Northwest direction, avoiding the situation of polluted odors blowing into the main workshop affecting the hygiene quality of the factory products, this area is responsible for treating waste and wastewater of the whole factory after production and use by employees in the factory At the same time, workers' toilets are located next to these works, so that workers working in workshops and surrounding areas can easily move to here

- Area of energy works: where workshop and energy supply works are located, including boiler, water supply works, electromechanical workshop, backup generator room, fuel warehouse It is located in a separate area but still ensures sufficient power supply for the production plant The water supply area is the place that will provide water for all activities in the factory, the water supply area is built with brick walls Backup generator room and fuel warehouse are located next to each other to easily provide fuel and power for the plant to operate throughout the production process, these two houses are built of brick walls The electromechanical workshop is a workshop for repairing and maintaining electrical equipment in the factory, ensuring the smooth operation of electrical equipment The workshop is built with a brick wall with a large area for the repair easier The steam supply furnace is located in the corner of the factory to ensure safety for other areas in the event of an accident, the boiler is the place to provide steam for production activities in the factory, the steam house is built by brick wall The mechanical workshop is located in the right area of the factory, the mechanical workshop is the place to repair and maintain the machines operating in the factory, to ensure the smooth and limited operation of the equipment damage control, the workshop is built of brick walls

- The area on the right side of the factory is where vehicles parks are located, including electric vehicles parks, bus parks, car parks, and motorbikes The garage for electric vehicles is built with the size to accommodate 2 electric vehicles and a charging house

The garage for bus is for the staff shuttle car employees and bus of visitors to the factory, the garage for cars is built to accommodate the cars of the leaders and business partners when they come to the factory, and finally the garage for motorbikes for workers and administrative staff, garages are designed to be spacious and airy for the movement of vehicles in and out and are simply built with high sun-proof corrugated iron roofs and wall columns

- Finally, the area in front of the factory is arranged with construction such as canteen, administrative building, security room, voltage converter, landing area for future This area has beautiful and foreign affairs, so it is located in a place convenient for accessing road traffic outside the factory, easy to see and is the face of the factory This zone is located at the head of the dominant wind direction The administrative building is located near the entrance gate, which is the place to handle administrative issues of the factory, and at the same time, the place to receive guests and introduce products to business partners, the administrative building is built on 2 floors to saving space and convenient for the arrangement of departments inside the administrative building The kitchen and canteen are located near the administrative building, which is responsible for meals for the workers and employees working in the factory, the canteen is located far from the auxiliary area to avoid pollution and in a convenient place for employees to move to, around the kitchen and canteen to plant more trees to make the air cooler The security room consists of 2 rooms located at the 2 main gates of the factory, the security room has the function of protecting and checking people when going in and out of the factory, ensuring that no strangers entering the factory affect operation of the factory The voltage converter is located next to the protection room, the substation has the function of ensuring voltage to match the amount of electricity used by the plant Finally, the land used for the future is where new production workshop and necessary areas will be built for future construction plans if the factory improves production capacity

- Around the factory, a solid fence is erected and green trees are planted, green areas around the factory are planted to help fresher and greener air The lawns and trees are arranged throughout the workshop, around the high heat areas and the area near the main gate of the factory, the grass helps the atmosphere in the workshop cooler and creates a good sensory for investors and business cooperation companies when come visit to the factory

CALCULATION FOR STEAM – ELECTRICITY – WATER 73 7.1 Calculate the amount of steam and fuel

Calculate the amount of steam used for production equipment

7.1.1.1 Calculate the amount of vapor used for the ripening stage

* Calculate the amount of heat required to cook the dough, Q (kJ/h) [40]

Q1 = QW + QD + QM + QE (7.1) With:

QW: The heat required to heat the water in the device

QD: The heat required to heat the device

QM: The heat required to heat the material fed into the device

QE: The heat lost to the environment

V1: The amount of water that needed to be heated in one hour (liters)

CW: Specific heat capacity of water, CW = 4.186 kJ/(kg 0 C) t1: The initial temperature of the water, t1 = 25 0 C t2: The final temperature of the water, t2 = 90 0 C [40]

GD: The mass of the device, GD = 800 (kg)

CT: Specific heat capacity of steel, CT = 0.46 kJ/(kg 0 C) [41] t3: The initial temperature of the device, t3 = 25 0 C t4: The final temperature of the water, t4 = 90 0 C

G6: The mass of material, G6 = 717.6 (kg) (in table 4.7)

CM: Specific heat capacity of material, J/(kg 0 C)

Ck = 1.6 kJ/(kg o C): Specific heat capacity of dry matter

(For food materials,Ck = 1.2 –1.7 kJ/kg 0 C ) [42] φ: The moisture content of material, φ = 13% t5: The initial temperature of material, t5 = 25 0 C

75 t6: The final temperature of material, t6 = 90 0 C

So the total amount of heat needed is:

* Calculate the amount of vapor needed for this process

The amount of vapor is calculated by the formula:

𝑟 𝑛 (7.2) With rn is he heat of vaporization of water at a pressure of 2.5 at rn = 2184 kJ/kg [41]

So the amount of vapor consumed in an hour: 68.52 (kg/h)

7.1.1.2 Calculate the amount of steam used for the drying stage

* Calculate the amount of heat required in the drying stage, Q2 (kJ/h)

The total amount of heat entering the device is equal to the total heat leaving the device, so we have the heat balance equation: [41]

Qs + Qb = L(I2 – I0) + G2.CVL.(θ2 – θ1) + GVC CVC.( TC + TD) + QMT – W θ1.C (7.3) Set:

+ The heat required to heat the material:

QVL = G2.CVL.(θ2 – θ1) (7.3.1) + The heat required to heat the conveying unit:

QVC = GVC CVC.( TC + TD) (7.3.2)

 The heat balance equation becomes:

Q2 = Qs = L(I2 – I0) + QVL + QVC + QMT – W θ1.C (7.3.3) With:

+ Qs - The heat expended in the main calorifer, W

+ Qb - The heat expended in the additional calorifer, W

(Because there is no additional calorifer part, Qb = 0)

+ I0, I1, I2 - The enthalpy of the air before entering the calorifer, entering the dryer and after leaving the drying device, kJ/kg dry air

+ θ1, θ2 – The temperature of ingredients before entering the drying device and after leaving the drying device, 0 C

+ CVL, CVC, CW – Specific heat capacity of the material, the conveying unit and the water, kJ/kg o C

+ G2, GVC – The mass of material after drying and conveying unit, kg/h

+ TC, TD – The pre-drying and post-drying temperature of the conveying unit, 0 C

+ QMT – Heat loss and specific heat loss to ambient, W and J/kg.humid

• Calculate the theoretical drying process

- Calculate the parameters of the drying agent before entering the drying chamber

+ The average humidity of outdoor air in Vietnam is between 80-90% Select the outdoor air state with temperature t0 = 25 0 C ( this is the lowest temperature of the year in HCMC) and humidity φ0 = 85%

+ Saturated vapor pressure: 𝜌bh0 = 0.0323 at [43]

760 − 0.85 × 0.0323 = 0.0179 (kg humid/kg dry air) + The enthalpy of humid air is calculated for 1 kg of dry air by the formula: [44]

Ckk - Specific heat capacity of dry air, Ckk = 1.004 kJ/kg o C

Cph - Specific heat capacity of steam at 0 o C, Cph = 1.842 kJ/kg o C r0 - The latent heat of vaporization of water at 0 0 C : r0 = 2500 kJ/kg [41]

- Calculate the parameters of the drying agent entering the drying chamber

Air is introduced into the drying device to perform the drying process

+ Select the drying temperature as t1 = 90 o C, 𝜌bh1 = 0.715 at [43]

+ Moisture content: d1= d0 = 0.0179 (kg humid/kg dry air)

+ Enthalpy: I1 = 1.004× 90 + 0.0179×(2500 + 1.842 × 90) = 138.1 (kJ/kg dry air)

- Calculate the parameters of the drying agent coming out of the drying chamber

+ To minimize the heat loss due to the drying agent and avoid condensation and moisture return of the material, choose t2 = 40 0 C

+ Saturated vapor pressure: 𝜌bh2 = 0.0752 at [43]

2500+1.842 ×40 = 0.04 (kg humid/kg dry air) + Relative humidity: From the formula 7.6 => φ2 = 80%

So this humidity value is suitable economically – technically and no dew-point occurs [43] + The theoretical amount of dry air required is: L0 [43]

0.04−0.0179 = 5303.2 (kg dry air/h) With W is the amount of moisture needed to evaporate in one hour, W = 117.2 (kg/h)

- Heat loss carried by the drying material, QVL

(The output product of the drying device has a temperature lower than the temperature of the drying agent about 5 – 10 0 C) [44]

(φ 1 is the moisture content of the dough when entering the drying device, φ 1 = 18%)

- Heat loss due to conveying unit, QVC

QVC = nGVC × CT ×( TC + TD)

+ n is the number of conveyors, n = 3

+ GVC = 60 kg- the mass of each conveyor

+ CT: Specific heat capacity of steel, CT = 0.46 kJ/(kg 0 C)

+ TC = 25 0 C - The initial temperature of conveyor

+ TD = 90 0 C - The final temperature of conveyor

- Heat loss due to escape to the environment, QMT

Heat loss to the environment is about 5%, calculated by the following formula:

- From equation 7.3.3, set ∆ = 𝑊 × 𝜃 1 × 𝐶 𝑤 – QVL - QVC - QMT

• Calculate the actual drying process

+ 𝑖 2 is the enthalpy of 1kg of vapor

2571+ 117.2 2785 = 0.038 kg humid/kg dry air

• Calculate the actual amount of dry air required, L

So, the amount of heat required in the drying stage:

* The amount of steam required in the drying stage:

2184 = 180.58 kg/h (r is the heat of vaporization of water at a pressure of 2.5 at)

 Total steam consumption in continuous working equipment

- Amount of steam to sterilize equipment: take 20% of total steam consumption

So, total steam consumption in continuous working equipment:

Total amount of steam used in daily life

The total number of workers in the factory is 120 people/day and the average amount of steam used by each person is 0.5 (kg/h)

 The amount of steam used in daily life

 Total amount of overall steam consumed:

Steam cost of steam boiler

Db = Dc x 10% = 349.848 x 0.1 = 34.9848 (kg/h) The steam boiler's own consumption is calculated as 10% of the overall steam consumption

Total amount of vapor due to loss

Assume steam loss is 8% of total steam consumption

 The amount of vapor due to loss is:

 So the total amount of steam needed in one hour

Selection of steam boiler

* Choose Ainet LD3/10TPH device of Fansipan Vina Co., Ltd [45]

Calculate the amount of fuel

• FO oil used for the steam boiler

The required amount of oil used in the steam boiler in 1 hour is calculated by the formula:

Q p ×n 100 (kg/h) (7.14) With: ih – Enthalpy of steam at working pressure, ih = 661.9 (kcal/kg) [page 312,43] in – Enthalpy of the water fed into the boiler at a temperature of 25 0 C, in = 25 (kcal/kg) [page 312,43]

Qp – The heat emitted when burning 1 kg of fuel oil, Qp = 9800 Kcal/kg

 The mass of fuel oil consumed in 1 year:

• DO oil used for generator

Assuming the norm is 10 kg/day, the amount of fuel oil needed for 1 year is:

Assuming the norm is 10 liters/ car/ day, the amount of gasoline needed for 1 year is:

Calculate electricity

Electricity used in the plant is taken from the city grid Includes electrodynamics and electricity for lighting

The equipment in the factory uses electricity to run the motors Table 7.1 lists the equipment using electricity in the main workshop

Table 7 1 Statistics of equipment using electricity in the main workshop

• Electrodynamics for sub-production workshops

Table 7 2 Statistics of areas using electricity in sub-workshops

- The total power used in the plant is

- Actual consumption load of electrodynamics [47]

Ptt1 = Pdl x Ktt1 = 295.1 x 0.6 = 177.06 (KW) (7.15) With:

+ Ktt1- is the utilization factor; (Ktt1 = 0.5 – 0.6)

+ Pdl – The power of the electrodynamic, (kW)

Adl = Kc x Pdl x T, (KWh) (7.16) With

+ T- t is the maximum usage time, T = 16 x 300 = 4800 (h)

+ Kc = 0.6 – 0.7 - is the utilization factor

+ Type of lights used: LED lighting made from aluminum alloy of Aplico, with a power consumption of 60W and 120W

+ The luminous efficiency: 105 lumen/watts

+ Made of aluminum alloy material, so it has good heat dissipation and high durability

+ Good power saving and long life Ensure good lighting and evenly distributed light

- Choose the height of the lamp hanging: Lighting design must ensure the requirements are:

+ No glare due to reflection

+ The illuminance must be uniform

+ H is the height of the lamp hanging, (m)

+ Hmin is the minimum height to hang the light, (m)

Because the factory uses lamps with a power of < 200W, Hmin = 3.5m

With a lamp power of 120W, the hanging height is selected as H = 5m

- The distance between lights, L (m): Choose L = 5 (m)

+ ho is the height from the floor to the working surface (m);

+ hc is the height from the work surface to the lamp (m) hc = H – ho = 5 – 1.2 = 3.8 (m)

For uniform lighting, the ratio L h c = 1.2 ÷ 1.5 is the most beneficial

- For the best lighting, the lights must be evenly arranged throughout the room to create squares or near squares

- Select the distance from the lamp to the wall

The distance from the outermost row of lights to the wall is: l = (0.3 ÷ 0.5) x L

• The number of lights required:

The number of lights in a room is calculated by the formula:

N1: is the number of light bulbs calculated by the length of the room

N2: is the number of light bulbs calculated by the width of the room

L + 1 (7.17.2) With: A is the length of the room, (m)

B is the width of the room, (m)

Table 7 3 Statistics on the number of lights in the production buildings

Table 7 4 Statistics on the number of lights in the administrative building

8 Reception room and product introduction

Total number of lights used in the buildings:

• Calculate the power consumption of LED lights

Depending on the workshop, use the specific wattage method to calculate the lighting power of each area

Pcs =Pđ × N (kW) (7.18) With Pcs: is the lighting power on the whole house, (kW)

Pđ: is the specific power of the luminaire, (kW)

Use luminaires with a power consumption of 60W and 120W depending on the workshops N: is the number of lights

Table 7 5 Summary of lamp power for buildings

- Actual consumption load of lighting

Ptt2 = 22.86 x 0.9 = 20.574 (KW) With : Ktt2- is the asynchrony factor between the lights; Ktt2 = 0.9

Pcs - is the lighting power, [kW]

Acs = Pcs x Ktt2 x T; (KWh) (7.20) With: T- The maximum lighting time in 1 year, (h)

T = 16 x 300 = 4800 (h) The average lighting time in a day is 16 (h)

- The calculated load of the whole factory:

 Total lighting power and dynamic load in 1 year:

- Calculate the reactive power, Q tt

Calculate for electrodynamics and ignore lighting electricty The reactive power is calculated by the formula:

Qtt = Ptt1 x tan φ1 ,(KVA) (7.23) With: cos φ1 is the angle of the power factor

Assuming initial power factor is cos φ1 = 0.65 then tan φ1 = 1.169

Determine the dimension of the capacitor bank to improve the power factor of the plant Let cos φ2 be the improved power factor

The offset capacity is calculated by the formula

Qb = Ptt1 (tan φ1 - tan φ2) Choose cos φ2 = 0.9 => tan φ2 = 0.484

- Determine the number of capacitors

Select the type of capacitor ELCO with the following parameters [48]

+ The actual capacity of the capacitor

+ The power factor after compensation is calculated: cos φtt = P tt1

+ The transformer capacity is calculated according to the formula:

+ Select transformer 250KVA 22/0.4kV Ddyn11 of Hanoi power transformer manufacturing joint stock company [49]

Calculate water

7.4.1 Calculate the amount of water used in the factory

Water is taken from the pipes of the city water supply system

- Water used for the main production workshop

+ Amount of water used in the cooking stage: 103.9 (kg/h)

+ Amount of water used to clean the machine: 3000kg/production line/day

 The amount of water used for 1 day for the main production workshop:

- Water used for the steam boiler

+ The amount of steam used for the boiler is 412.83 (kg/h) = 412.83 (liters/h)

+ Assuming 1 kg of water will give 1 kg of steam and the loss of water is 10%, the amount of water used for the steam boiler is: 412.83 + 0.1 x 412.83 = 454.1 (liters/h)

 The amount of water used in 1 day for the boiler: 454.1 x 16 = 7265.808 (liters/day)

- Water used for bathing and cleaning

+ According to QCVN 02:2009/Ministry of Health, the amount of water used for bathing and cleaning is 60 liters/person/day, calculated for 60% of workers in a day

 The amount of water used in a day for bathing and cleaning:

- Water used for kitchen and canteen

+ According to the standard of consumption is 30 liters/person/day

+ Calculated for 2/3 workers in the factory

 Amount of water used in a day for the kitchen and canteen: 30 x 120 x 2

- Water used to irrigate trees and roads

+ The standard is 2 liters /m 2 /day

 The amount of water used in one day to irrigate trees and roads:

- Water used for fire fighting

+ The norm is 1 column 2.5 (liter/s) Assume fire fighting time is 3 hours

 Amount of water needed in 3 hours: 2.5 x 3600 x 3 = 27000 ( liters/day)

So the total amount of water needed for 1 day of production:

 Amount of water used in one year:

The factory has a water tank for production and fire fighting in 1 day

Assuming the water tank holds twice the amount of water needed in one day, the water reserve is: 54.02 x 2 = 108.04 (m 3 )

ECONOMIC CALCULATION

Purpose and meaning

For an enterprise and production business, the calculation of economic costs is the most important thing This is also the basis to prove that this project is feasible and practicable The closer the economic costs are calculated to reality, the higher the feasibility and production efficiency of the plant

It is necessary to ensure the accuracy of the calculation in each period and ensure the reasonableness in each economic time.

Investment costs

Table 8 1 Statistics of investment capital for construction works [

Unit price for a unit m 2 (10 6 VND)

The amount for investment in building the factory is: T1 = 8510 x 10 6 (VND)

• Investment capital for construction of auxiliary works (walls, roads, sewers ) is 30% of T1

• Exploration and design costs are: 10% T1

• The average annual depreciation on construction:

Hb = k x Tb = 0,1 x 11914 x 10 6 = 1191.4 x 10 6 (VND) With k = 0,1: the average annual depreciation coefficient on construction

Table 8 2 Statistics of investment capital for equipment in the factory

So the cost of buying the main equipment is: X1 = 5437.8 x 10 6 (VND)

• Investment capital to purchase auxiliary equipment: 20% T1

• Investment capital to purchase inspection and control equipment: 10% T1

• Investment capital to buy industrial cleaning equipment: 5% T1

• Investment capital for equipment assembly: 10% T1

• Other costs (exploration costs, design work costs, transportation costs, equipment loading and unloading costs): 15% T1

Hd = b x X = 0,2 x 8700.48 x 10 6 = 1740.096 x 10 6 (VND) With b = 20%: annual depreciation factor

• Total investment capital of fixed assets:

Table 8 3 Cost of raw ingredients to produce 3000 tons of snack/year

Numbers Ingredients Mass (kg) / year

Cost of raw ingredients to produce 3000 tons of snack/year: T1 = 139948.8733 x 10 6 (VND)

In addition, in a year of production, we have to spend about 2.5 billion VND for packaging, packing cartons: T2 = 2.5 x 10 6 (VND)

 The total cost of raw ingredients to produce 3000 tons of snack/year is:

Table 8 4 Cost of fuel and water used in the plant

Numbers Fuels Unit Amount used in the year

So the total cost of energy and water is: Tf = 11943.2814 x 10 6 (VND)

• The salary paid to main and auxiliary workers in 1 month: 8 x 10 6 (VND)

There are 73 workers in all So the salary paid to main and auxiliary workers in 1 year is:

• The salary paid to director in 1 month:: 22 x 10 6 (VND)

There is 1 director So the salary paid to the director in 1 year is:

• The salary paid to the vice - director in 1 month is: 19 x 10 6 (VND)

There are 2 vice - directors So the salary paid to the vice - director in 1 year is:

• The salary paid to employees of departments, divisions and sales in 1 month is: 13 x 10 6 (đ)

There are a total of 36 employees So the salary paid to employees in departments, divisions and sales in 1 year is:

• Salary paid to security guards and cafeteria staff for 1 month: 7 x 10 6 (VND) There are 7 people in all So the salary for security guards and canteen staff in 1 year is:

• Salary paid to janitors in 1 month is: 7 x 10 6 (VND)

The factory has 4 janitors So, the salary paid to the janitors in 1 year is:

So the salary paid to all employees of the factory in 1 year is:

Social insurance is calculated at 10% of the total factory salary:

That is the cost covered by the circulation of goods, transportation and advertising outside the factory, taken as 10% of the direct costs

The factory borrows capital at an interest rate of 10% per year to pay for construction, equipment purchases, and direct costs:

So the total indirect costs are:

Price to product

Total cost = direct cost + salary cost + social insurance cost + indirect cost

37.5×10 6 = 9566.4 (VND) With: a is the number of bags produced in 1 year

Selling price plus 5% of product cost:

Economic performance of invested capital

With: a: Number of bags of snacks produced in 1 year

Z’: selling price for 1 bag of products

Z1: the price of 1 bag of products

So the payback period of the factory is 1 year 1 months 5 days

INDUSTRIAL SAFETY AND HYGIENE

Industrial hygiene

- For equipment and machine: The enterprise always ensures labor safety, machine and equipment are always covered in places where there is a possibility of problems of occupational accidents and always clean after use Machines and equipment are made of stainless steel, easy to clean after each shift

- For personal hygiene: People directly producing in the factory are fully equipped with labor protection according to regulations: gloves, hats, masks, protective clothing, boots Before working, workers must wash their hands with antiseptic water, absolutely do not eat, drink, smoke during the production process

- For factory cleaning: Regularly perform cleaning before and after production with disinfectant water The entrances and exits must have membranes to prevent insects from entering the factory The floor is made of a material that is waterproof; has no cracks, protrusions or dents; is non-slip; and is easy to clean and disinfect.

Working safety

- In the processing workshop of the enterprise, it is always fully equipped with light, equipment and a well-ventilated working environment Chemicals are carefully preserved

- The circuit breakers and switches are carefully covered The electrical wiring system is checked periodically and staff are regularly monitored in order to promptly detect damaged incidents so that they can be remedied and repaired

- Means used for fire prevention are fire hydrants, CO2 cylinders and other rudimentary tools Steam boilers must be placed away from crowded areas to ensure safety in case of fire

Wastewater treatment

Wastewater contains many organic impurities, so microorganisms easily grow and pollute the living environment of humans Therefore, before being discharged to the outside, the wastewater is treated in the wastewater treatment area of the factory

PRODUCTION INSPECTION

Purpose of production inspection

- Product quality is the top concern of all industries in general and the food industry in particular because it directly affects consumers' health Therefore, when products are exported to the market, it is necessary to ensure hygienic quality Raw materials must be tested before entering production and finished products before leaving the factory

- Production inspection also aims to detect and prevent deficiencies in the production process for timely correction The inspection process is carried out systematically from raw ingredients, production technology, machine and equipment, workers' manipulations to finished products.

Steps in production inspection

- The inspection of production and product quality is carried out according to the following steps:

Table 10 1 Checklist of ingredients used for production [53]

Numbers Ingredients Test criteria Level of requirements

1 Rice flour and corn flour

+ Humidity + Protein content + Microorganisms + Weight

+ Packaging and expiry date the warehouse and before putting into production

- When there is a request to check

2 Salt + Sense of color, odor, state, impurities

+ White, odorless, no lumps, no impurities + ≤ 5

+ White crystals, relatively uniform in size, dry, no lumps

+ Sugar crystals with a sweet taste, no strange taste + Meet technical requirements

Table 10 2 Checklist of production stages [54]

Numbers Stages Test criteria Level of requirements

1 Quantitative Weight of each batch

Exactly according to production yield

3 Extruding Evaluate the structure of the dough

4 Cutting Evaluate the shape and structure of snack

5 Drying Drying mode: drying temperature, allowable humidity of finished products, drying time

The level of uniformity and adhesion of the seasoning to the product

7 Packaging + Tightness of product packaging + Packaging quality

10.2.3 Check the quality of finished products

- The criteria for finished product quality to be checked are:

+ Check the outer packaging shape

+ Determination of sensory criteria of finished products

+ Determination of physicochemical parameters of finished products

+ Determination of microbiological criteria of finished products

- Check products when leaving factory:

+ The container must be sealed, the packaging state must not be defective or peeled off the text on the label

+ Sensory indicators: The characteristic aroma and yellow color of corn ingredients, crispy when eaten

+ Physicochemical indicators: puffiness, porosity, crispiness and moisture content of snack

Snack is a popular food product for people of all ages and countries, so designing and building a new factory is essential in the future And hopefully, the project can develop and expand into reality in the future

With the enthusiastic guidance of Mr Hoang Van Chuyen, along with the knowledge learned in the process of studying and searching in books, the internet, etc, we were able to complete the project on time with the topic: “The design of a snack production factory with a capacity of 3000 tons per year ”

However, due to the large production capacity, complicated equipment and the possibility of uneven production from month to month, this map still has errors Hope to receive suggestions and help from teachers and friends And in the process of implementing this project, we have accumulated a lot of useful knowledge and have a better understanding of the basic principles to build a food processing factory

Finally, we would like to thank the teachers, and everyone who helped us complete this project

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[2] https://tranminhdung.vn/thi-truong-banh-snack-viet-nam/

[3] Phương Đông, Người Việt chi gần 8.000 tỷ đồng ăn snack trong năm 2017, 30/12/2017

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[14] TIÊU CHUẨN QUỐC GIA TCVN 11015:2015

[15] USDA Standard reference, Cereal Grains and Pasta, nutritionvalue.org/Rice flour, unenriched, white

[17] TIÊU CHUẨN QUỐC GIA TCVN 3974:2007

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[21] wiseGeek “What is the Healthiest Oil to Use for Cooking?”

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123 https://kegelmachines.pl/en/mills-mixers-tanks/145803-horizontal-ribbon-mixer-wldh- 1500.html

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[30] Henan Gelgoog Machinery Co., Ltd https://gelgooginc.en.alibaba.com/product/60610220058-

806861349/Commercial_Nimki_Corn_Snack_Making_Machine_Namakpara_Cutter_Ma chine.html

[31] Nguyễn Bin Các quá trình thiết bị trong công nghệ hóa chất và thực phẩm, tập 4 Nhà xuất bản khoa học kỹ thuật, 2005, 396 pages

[32] Global Movement Co., Ltd https://bangtai-vn.vn/he-thong-bang-tai/say-thuc-pham/

[33] Tianjin Sure International Trading Co., Ltd https://www.alibaba.com/product-detail/Automatic-rotary-drum-mix-flavoring- machine_60787235991.html

[34] Anh Minh Trade and Technology Solutions Co., Ltd https://maytudong.com.vn/product/may-dong-goi-bao-bi-thuc-pham-vt-series/

[35] Xinxiang Sanyuantang Machinery Co., Ltd https://m.made-in-china.com/product/Inclined-Feed-Spiral-Conveyor-Cement-Flexible- Screw-Conveyor-740215442.html

[36] http://www.bigpac.com.au/product/granule-bucket-elevator-conveyor/

[37] Nhat Nam Industrial Service and Trading Co., Ltd http://xenangnhatnam.com/xe-nang-tay-meditek-hpt30s-848760.html

[38] Trần Thế Truyền Cơ sở thiết kế nhà máy, Danang University of Technology, 1999

[39] TCVN 4601:2021 https://vanbanphapluat.co/tcvn-4601-2012-cong-so-co-quan-hanh-chinh-nha-nuoc-yeu- cau-thiet-ke

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[51] canhogiatotsaigon.com/don-gia-xay-dung-1m2-nha-xuong/

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[54] Báo cáo thực tập công ty liên doanh Phạm- Asset

HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION

LAYOUT OF THE MAIN WORKSHOP

24 Packaging materials warehouse PART LIST

HCMC University of Technology and Education

The design of a snack production factory with a capacity of 3000 tons per year