Report- Çok Iyi- Eti

8/11/2019 Report- Çok Iyi- Eti

http://slidepdf.com/reader/full/report-cok-iyi-eti 1/30

1

Middle East Technical University

Chemical Engineering Department

ChE 400 - Summer Practice Report

Submitted By: Can ATASEVER

Submitted To: Prof. Dr. Göknur BAYRAM

Practice Place: ETİ Food Industries Biscuit Production Facility, Eskişehir



2

ABSTRACT

After my first summer practice in Türk Henkel Chemical Industries INC in 2011 for ChE 300

course, I have done my second summer practice in ETİ Food Industries INC in Eskişehir. Themain purposes of this practice was getting familiar to the business life, taking responsibilities

in any production process, learning from the experiences of employees and applying the

knowledge acquired from the university courses.

During the summer practice, I had been employed different units like Chocolate Facility

Quality Control Laboratory, Chocolate Facility Semi-Finished Product Unit, Biscuit Facility

Semi-Finished Product Unit and Biscuit Facility Packaging Unit.

This report contains information about ETİ Food Industries, general organizational structure

of ETİ Food Production Facilities, general information about the preparation and production

of biscuit products and detailed process flowcharts and detailed information about some of the

products. Also, through the end of this report, material and energy balance equations have

been applied together with using literature values and some unknowns have been determined.

It was a great pleasure and experience for me to do my summer practice in ETİ Food

Industries, one of the biggest food firms in Turkey. I hope, one day, I can be a part of this

"Civilization of Taste".



3

TABLE OF CONTENTS

1 - GENERAL INFORMATION ABOUT ETİ FOOD INDUSTRY ....................................... 1

1.1 - History of ETİ and Its Logo .................................................................................. 1

1.2 - Locations of ETİ Food Industry Facilities ............................................................ 2

1.3 - Brief Information About The Facilities ............................................................... 2

1.4 - Number of Shifts and Production Technique ........................................................ 3

1.5 - Main Raw Materials ............................................................................................. 3

1.6 - General Organization Scheme for ETİ Food Industries ....................................... 3

1.7 - Number of Employees and Functions of Engineers ............................................. 4

2. DESCRIPTION OF PRODUCTION IN PLANT ............................................................... 5

3. PLANT AUXILLARIES ..................................................................................................... 8

4. WORK DONE IN PLANT .................................................................................................. 9

4.1 - Approval of Raw Materials .................................................................................. 9

4.2 - Brix Measurement ................................................................................................ 9

4.3 - Viscosity Measurement ...................................................................................... 10

4.4 - Content Percentage Measurement ....................................................................... 10

4.5 - Microbiological Culture Analysis ...................................................................... 12

4.6 - Fault Determination and Statistical Analysis for Packaging

Machines on Different Production Lines ............................................................ 13

4.7 - Routine Brix Value Measurement for Cin, Puf and Benim'o Syrups ................. 14

4.8 - SAP Software ...................................................................................................... 14

4.9 - Details and Flowcharts of Observed Processes .................................................. 14

4.10 - Material and Energy Balances .......................................................................... 19

5. APPENDIX ......................................................................................................................... 25

6. REFERENCES .................................................................................................................... 27



4

1 - GENERAL INFORMATION ABOUT ETİ FOOD INDUSTRY

1.1 - History of ETİ and Its Logo

ETİ Food Industry has been established on 20th of January in 1962 (more than 50 years ago)

by Mr. Firuz KANATLI with his own design drawings and only 20 employees in Eskişehir.

Petit Beurre, Kremalı, Marie, Sable and Bademli were the first products of ETİ.

1963 - Second facility was founded by Turkish engineers to increase capacity

1965 - The first automation improvement was implemented - Automatic tunnel oven

1967 - First automatic cookie production plant was established.

1972 - The ETİ Cookie Plant is renamed as ETİ Food Industries. The well-known riddle

jingle "Bir bilmecem var çocuklar" which is created, composed and written by Oktay TEM

was used as commercial jingle.

1974 - First export was made to Cyprus.

1976 - Bozüyük Plant was founded.

... Different new products were introduced to the market

2003 - TPM was implemented over all the ETİ Food Industries Plants. Chocolate plant was

founded.

2005 - Cake Plant was founded. Braille alphabet was used on Browni Packages so that

visually impaired consumers can recognize the product.

The slogan of the company is "Lezzet Uygarlığı" and its logo consists of the company name

and a Hittite Sun as seen in Figure 1.1 below:

Figure 1.1 - Logo of ETİ Food Industry[3]



5

1.2 - Locations of ETİ Food Industry Facilities

Except the Bozüyük Facility, all the facilities of ETİ Food Industry are located in Eskişehir

Organized Industry Zone. The one that this report will be focused on is Biscuit Facility which

is located on 11th Street of Industrial Zone, Eskişehir .

1.3 - Brief Information About The Facilities[3]

1.3.1 - Chocolate Facility: This facility has been established in 2003. There

are two main product lines: Bar and tablet. All the chocolate products are produced in tablet

production line and all of the products with chocolate around it are produced in bar line.

Products like Petito, Karam, Canga, Maximus, Sticks etc. are produced here. In this facility,

Hoşbeş Wafer is also produced with different aroma options. The facility has HACCP, GMP,

ISO 9001:2008 and ISO 22000 certificates. As a management method, Total Productive

Management (TPM) is applied.

1.3.2 - Cake Facility: Cake products like Topkek, Paykek, Browni, Popkek

etc. are all produced in this facility with different flavors like mixed fruit, grape, caramel,

banana, strawberry, cacao, orange etc. since 2005. The cake facility has ISO 9001:2008 and

ISO 22000 certificates. Again, Total Productive Management (TPM) method is applied as a

management method,.

1.3.3 - BTIF Facility: Its Turkish name is "Bütünleşik Tahıl İşleme Fabrikası"

and in this facility, healthy-light products like Form, Gong, Form Biscuit, Yulaf Ezmesi etc.

are produced. This facility is also used for the other facilities' grain related processes.

1.3.4 - Biscuit Facility: This is the main facility focused on this report. In this

facility, production amount is almost 40 % of the total production amount of ETİ. Productslike Benim'o, Petite Beurre, Tutku, Cin, İkram, Kremalı, Yulaflı, Burçak etc. are the products

of this facility. This facility is the first one in which TPM method has been applied (2005).

ISO 9001:2008 and ISO 22000 management and food safety certificates are also held by this

facility.

1.3.5 - Cracker Facility: This facility has been established in 1980 and there

have been expansions and renovations until now. All the crack er products like Tadında, Crax,

Çubuk Kraker, Balık Kraker, Pizza Kraker, Can Kraker, Katmer Kraker are produced in this



6

facility. TPM is used as main management method and the plant has ISO 9001:2008 and ISO

22000 certificates.

1.3.6 - Bozüyük Facility: This second oldest facility that belongs to ETİ Food

Industry is founded in 1978 with 15 tons/day capacity. Etimek, Topkek, Popkek, Browni,

Turti, Etimek, Lifalif are the products produced in this facility. TPM has been applied in 2007

and the plant has ISO 9001:2008 and ISO 22000 certificates also.

1.3.7 - Semi-finished Production Facilities: There are also two semi-finished

production plants located inside the chocolate and biscuit production facilities. These semi-

finished production plants are used to produce flavored syrups, creams, chocolate sauce

placed on, in or around any product and granules used on the surface of some products like

Cin, Puf, Benim'o. Each of the two semi-finished plants are specialized according to which

semi-products are required in which facility.

1.4 - Number of Shifts and Production Technique

All of the ETİ Food Industry Facilities have 7/24 production. There are 3 shifts as 07:00 -

15:00, 15:00-23:00 and 23:00-07:00. Production is continuous except the semi-finished

product plants in which batch operation is used.

1.5 - Main Raw Materials

With the overall look, the main raw materials used in ETİ Food Industry Facilities are water,

flour, milk, fat, sugar, egg, flavors and baking powder. These raw materials are all obtained

from domestic market.

1.6 - General Organization Scheme for ETİ Food Industries

All of the ETİ Food Industries Facilities have different organization schemes; but a general

one can be found in Figure 1.2. All the facilities use this scheme and may make additions

according to the requirements.



7

Figure 1.2 - General organization scheme for ETİ Food Industries facilities

1.7 - Number of Employees and Functions of Engineers

In ETİ Food Industries, around 4900 people is working (September 2013) of which around

250 of them are engineers. There are 45 engineers graduated from Middle East Technical

University and 3 of them are METU Chemical Engineering Department graduates. Majority

of the engineers are industrial engineering program graduates.

Engineers are generally working as the manager of a production line by getting feedbacks

from team leaders, observing the routine data, inserting the production and consumption data

to the stock system (SAP) and deciding/making improvements on the line. There are also

engineers working in R&D and Quality Control departments.

Board ofDirectors

FacilityManager

R&D Manager

R&D Engineers

ProductionManager

ProcessAdministrators

Work andWorker Safety

Specialist

ProcessEngineers

Quality ControlManager

MaintenanceManager

HR Manager





9

has the least water ingredient. Fat percentage is higher in rotary dough and most of the

products, (Negro, Cin, Sultani, Yulaflı, Burçak, Kombo) in biscuit facility includes this type.

The third type is extruder dough which is to the consistency of cream. It has higher fat

percentage than rotary dough, so it is the softest dough type. It is used when the feeling of

disintegration in mouth is desired and important. Tutku and Çay Keyfi biscuits are made from

extruder dough.

2.3 - Dough Forming

Before the baking process, dough is formed according to the shape of the desired product.

Different forming type machines have been implemented and automated. First type of dough

forming is hard forming in which dough is fed to the prefiner cylinders with a thickness of 18-

20 mm and after passing through four cylinders, it is made sheet and as thin as 0.8 mm. After

the thinning, the sheeted dough passes under a forming cylinder, male molds cut the dough

and unused part of the dough is sent back to the prefiner. Second type of dough forming is

rotary forming. Process is the same with the hard forming until the forming cylinder, where

female molds are used instead of male molds so that there is no unused dough like the hard

forming. Last type is extruder forming in which the dough behaves like a Bingham plastic.

Due to its high fat content, extruder dough is soft and viscous enough and can be pressed

through the former head with the help of a nozzle. The former cuts the dough and cutted

dough falls onto the moving band.

2.4 - Baking

3 different types of ovens are used: Direct, indirect, hybrid. Dough is facing the flame in

direct ovens whereas a baking cell without the direct contact with the flame is used in indirect

ovens. Hybrid oven is the one in which indirect and direct ovens are used together in order to

meet the product's characteristic requirements.



10

2.5 - Flavor Addition

Granules, syrups, chocolate sauce and coconut are added in this stage. All of the flavors,

sauces and granules are produced in the semi-finished product plant placed in the main

facility.

2.6 - Cooling

First part of this stage may take place before the flavor addition for some products, like Puf, in

order to prevent the melting of the marshmallow on the hot biscuit. All the products must be

cooled down to the room temperature before packaging in order to keep the product healthy.

Cooling tunnels and long cooling bands (if natural cooling is desired) are used for this

purpose.

2.7 - Packaging

There are 5 types of packaging types used in the biscuit facility as envelope (Petite Beurre),

flow pack (Tutku, Benim'o, Yulaflı, Burçak), bag pack (Çay Keyfi), pay pack (Cin 6lı, Tutku

İkramlık) and sitting pack (Cin Mini). Most of the lines have packaging machines and robots

that do the packaging job. Improvements and projects are still in progress to make automation

systems available for all the production lines. After packaging, the packed product is sent to

the storehouse by automated lines.



11

3. PLANT AUXILLARIES

Tap water is used after refinement for the production. Because of the hot environment due to

the baking processes, there are coolers and air-conditioners all around the plant. The pipelines

and electricity are easy to find because the plant is in an industrial zone. In case of an electric

outage, 4 big generators are held ready and production can continue with them. There are also

dehumidifiers around the cooling tunnels to take the humidity in the coolant air away.

All of the measurement and control of the process parameters are done by digital systems and

computers around the company. Team leaders and operators continuously check the measured

process data and take any required action.

In the biscuit plant, main management system is Total Productive Management (TPM). TPM

has three main purpose: Zero stopping, zero work accident, zero faulty production. It also

includes autonomous maintenance in order to obtain the main purposes. The plant has 3rd

Degree (out of 5) in TPM Evaluations and it is aimed to complete all the 5 evaluation steps by

2016. The plant has also TS EN ISO 9001:2008 Quality Management System and it is used

together with TPM to increase efficiency. Quality control laboratory is placed near the

production facility and all the routine controls of products, raw materials, packaging

cardboards and routine biological observations and controls are made in this lab.



12

4. WORK DONE IN PLANT

During my internship, I have worked in different departments of both chocolate and biscuit

facilities like quality control, semi-finished production, main production and packaging. There

is no HR department in my main working area, biscuit production facility, therefore I couldn't

work in that department.

4.1 - Approval of Raw Materials

Raw materials are transported from other plants and brought to facility with tankers. There are

some standards that are required to be controlled for all raw material due to TS EN ISO

22000, HACCP Food Safety, TPM and ETİ itself. All the raw materials coming to any facility

is checked by taking samples from each transportation vehicle according to these standards by

that facility's quality control department. Without the approval of QC, the related raw material

is not used in production or it is not put into the silo and tanks in order not to contaminate the

whole tank content. During my QC work, I had assisted to the QC expert to take samples and

analyze them.

4.2 - Brix Measurement

Brix measurement is one of the first raw material controls that is taken into account. It is done

in order to determine the sugar content in a solution (in other words, undissolved content in

the solution) by using refractive index values of the solution in 20˚C. A simple device called

refractometer is used for this purpose.

Coming raw materials must have some ingredient levels in them such that all the ingredients

is between the acceptable range in amount. Sugar content is very crucial in food industry and

this is why brix measurement is important.

During the work in quality control department for four days, collected brix data for fructose

syrup can be found in Table 4.1 on the next page.



13

Table 4.1 - Daily brix measurements for fructose syrup

Day Temperature (˚C) Brix Value

1 23.8 79.1

2 24.2 79.2

3 24.1 79.1

4 23.9 79.1

The accepted range is 79.0 - 79.4 and during my routine measurements, no problem occurred

about the fructose syrup, one of the most important raw materials.

4.3 - Viscosity Measurement

Viscosity is again crucial in food industry because there are lots of pumps, nozzles, pipes etc.

that may affect the production when the viscosity is not normal. Also, chocolate viscosity

affects the baked dough plating processes. I have also measured viscosities of the coming raw

materials in a daily routine during the quality control internship, however, quality control

manager didn't let me use the outputs of the viscosity measurement as it is digital, includes

graphics and technical specifications.

4.4 - Content Percentage Measurement

Some products like chocolate with pistachio or nut are guaranteed to have a minimum content

percentage in them. This is the necessity by law in Turkey. To check the content percentage

within a product, routine daily measurements are done in quality control laboratory.

Additionally, some trial products not existing in market are again tested for their content

percentage and an average is found. According to the position of the average value with

respect to the desired value, some changes in recipe or machinery are done by the engineers.

To apply this test, product is melted in a glass beaker (placed in a water bath) with hot water

by dividing the product into parts, putting them into the beaker and stirring the content

continuously for complete melting. After some time, the solution (water + melted product) is

filtered and the content of which percentage is wanted to be determined is stays unfiltered

above the filter paper. The remaining content is washed with distilled water for better



14

measurement and put into drying oven (100 ˚C) for 24 hours. The purpose of drying is to

remove the humidity and find the exact amount of the content of which percentage is being

tested.

Figure 4.1 - Flowchart for content percentage measurement

For Çikolata Keyfi (Long Bar) product (that includes pistachio in it), the data obtained is

tabulated in Table 4.2:

Table 4.2 - Pistachio Content Percentage in Çikolata Keyfi (Long Bar)

Sample Number Pistachio Percentage Sample Number Pistachio Percentage

1 13.1 11 16.3

2 14.4 12 13.5

3 13.7 13 14.6

4 15.2 14 14.7

5 14.2 15 12.2

6 15.0 16 13.9

7 13.6 17 15.7

8 12.9 18 14.8

9 13.5 19 14.4

10 13.9 20 14.6

The average content percentage is found as 14.21 % (w/w) and it is in the desired range.

Weighing thewhole product

Dividing the product into

small parts

Melting thedivided partsin hot water

Continuous stirringfor good melting, no

chocolate desiredaround the content

Filtering thesolution to isolate

desired content

Washing the remaining part with distilled water

for better result

Drying the contentin a drying oven toremove its humidity

Weighing thedryed content

Calculating thecontent percentage



15

4.5 - Microbiological Culture Analysis

A microbiological analysis is a method of creating appropriate environment for the micro-

biologic organisms to replicate themselves and making observations on a sample whether it is

micro-biologically contaminated or not. If micro-biological colonies are formed, than the

analyzed sample is contaminated and intervention to find the source of and remove the

contamination is a must, as soon as possible. An example of micro-biological growth on a

Petri dish can be found in Figure 4.2 below.

Figure 4.2 - An example for micro-biological growth in a petri dish[4]

A sample was taken from one of the raw materials with special care by the laboratory expert

and it is placed in a Petri dish (that is prepared before) under the UV-Lighted environment to

prevent external bacterial contamination. Then, the closed Petri dish was placed into an

appropriate environment of which temperature is controlled and the Petri dish had been kept

inside that environment for a suitable amount of time to wait the bacterial colony forms. Next

day, there were no bacterial growth on the Petri dish and the raw material passed the

microbiological analysis test.



16

4.6 - Fault Determination and Statistical Analysis for Packaging Machines on

Different Production Lines

The production manager of the biscuit facility requested the interns to make a determination

analysis for packaging machines on different production lines and create statistics about the

determination. For a week, me and two more intern students made observations on the

packages leaving the packaging machines and record data for different fault types (like

wrong-oriented package, deformation on package, disordered product in the package, false

taping, un-aligned taping, non-standard package etc.) for all the production lines. There were

hundreds of packages (maybe a few thousand) analyzed, so it is not possible to supply all the

analysis information. As an example of the work, for Benim'o 16x88g product, the most

fr equent faul t was false taping (89 % for 300 packages) and the least fr equent fault was

found as non-standard package (0 % for 300 packages).

4.6.1 - False Taping: The taping machine is not successful for the ends of the

tape where the tape is cut, it was always wrinkled. This is undesired because the tape may

stick to anything during transportation and the package may open or be torn. This problem is

called as false taping.

4.6.2 - Non-Standard Package: All the packages must meet some

requirements, in other words, standards. There were no non-standard package fault

determined for the Benim'o 16x88g packaging machine. The engineers said that ETİ used to

have serious packaging problems but after a new agreement with another package firm, there

is no package standardization problem recently.

Statistical analysis like above were made for all the packaging machines for different

production lines and the result is submitted to a authorized engineer. I don't know whether the production manager got the results or not, but I am sure this work has been a good study for

TPM as it aims zero fault throughout the whole production.



17

4.7 - Routine Brix Value Measurement for Cin, Puf and Benim'o Syrups

For two weeks, me and two other intern students whom we work together through the

internship have measured the brix values of Cin, Puf and Benim'o syrups from the storage

tanks and production lines twice in a day and reported the data to the process administrator.

The measurement data for these products is long and therefore it is given in appendix part of

this report in Tables 5.1, 5.2 and 5.3. Later, the process administrator stated that all that data

would be used to detect if any water content loss exists during the transaction between stock

tank and production line or not.

4.8 - SAP Software

SAP is a business management software firm and their Enterprise Resource Planning (SAP

ERP) is used in ETİ Food Industry Facilities to record and have a control over the inventory.

During the internship, I did not use the SAP ERP software so much, because it is very

complicated and I, as an intern, wasn't allowed to use the software. Instead, I have tried the

learn the back-end and front-end of the software by watching an authorized employee while

the software was being used. It was very complex but in the same time, all the business

management solutions could be found within the software.

4.9 - Details and Flowcharts of Observed Processes

A general production flowchart has been shared in Figure 2.1, and now specific-to-product

flowcharts will be shared in this section for Petite Beurre, Benim'o and Puf.

4.9.1 - Petite Beurre Production

For the Petite Beurre, production flowchart can be seen in Figure 4.3 below:

Figure 4.3 - Production Flowchart of Petite Beurre

DoughPreparation

Dough ThinnerCylinders

Dough Formingwith male mold

Baking with directtype oven

Cooling withcooling tunnels

PackingSending toInventory



18

There are some specifications for this production:

1. Dough is prepared with low fat and high water content in order to obtain crispy state

of the biscuit.

2. The purpose of using direct type oven is the same, to obtain crispy state. Additionally,

it is appropriate to use it because the dough is thin so that inside of the dough can also be

cooked easily. If the dough was not thin enough, it would be required to use indirect or hybrid

type of oven. Otherwise, the surface may be over cooked or the inside of the product remains

uncooked.

3. Because of the fact that male mold is used, there is also some unused part of the

dough. That unused part is fed back to the dough that comes to the thinner.

4. In cooling tunnels, cold air is used and the humidity of the air is removed by using

dehumidifiers to prevent undesired effect on product.

4.9.2 - Benim'o Production

Benim'o production is a little more complex than Petite Beurre production. A representative

production flowchart for Benim'o can be found in Figure 4.4:

Figure 4.4 - Production flowchart for Benim'o

DoughPreparation

Dough ThinnerCylinders

Baking in HybridType Oven

First CoolingStage

MarshmallowAddition

CappingSecond Cooling

StageChocolate Sauce

Addition

Coconut AdditionThird Cooling

StagePackaging



19

Specifications for Benim'o product are:

1. For Benim'o, rotator dough is used. Water content is low and fat content is higher to

obtain the disintegration feeling in mouth.

2. The dough after thinner cylinders is thicker with respect to Petite Beurre, therefore

hybrid type oven is used here.

3. The purpose of first cooling stage is to prevent marshmallow melting on the hot baked

biscuit. The cooling is obtained by spraying water-preservative solution. The used

preservative chemical is 10% of the legal maximum value.

4. Marshmallow is prepared in a machine that blows compressed cold air into the

Benim'o syrup that comes from semi-finished product plant inside the biscuit facility.

5. The first cooling stage is very important just before the marshmallow addition, if there

is a problem about that cooling stage, the product and the marshmallow becomes unusable

and it is a loss.

6. Capping is the term used to define putting a second biscuit over the first one and

flavor. In Benim'o production, an empty biscuit is followed by a biscuit with marshmallow on

it, a robot takes the empty biscuit with vacuum and then put it on the other biscuit with

marshmallow. In that way, we have two layered product - biscuit and marshmallow.

7. Chocolate sauce which comes from the semi-finished product production facility is

added here after capping to cover the product. The viscosity and density of the sauce is very

important at this part. If the viscosity is high, the covering becomes thicker on the top part;

and if the viscosity is low, very thin (below the minimum desired value) covering on the top is

obtained so that coconut flavor cannot be added properly.



20

4.9.3 - Puf Production

For the very-liked Eti Puf product, a representative flowchart is given in Figure 4.5 below:

Figure 4.5 - Production Flowchart of Puf

Production specifications for Puf product are listed below:

1. Rotary dough is used in Puf production so that the disintegration feeling of the biscuit

in mouth is obtained.

2.

Cooking is done with direct ovens here; because dough is thin and fat content is high.3. Purpose of the first cooling is the same, to prevent melting of the marshmallow.

4. Purpose of second cooling is, as the same for all products, obtaining an appropriate

temperature for the product just before the packaging so that health of the product can be kept

under control after the packaging.

5. In packaging of Eti Puf, automated systems and location-aware robots are used.

DoughPreparation

Dough Forming Baking First cooling

MarshmallowAddition

GranuleAddition

Second Cooling Packaging



21

4.9.4 - Chocolate Conching

Conching is, with the simplest definition, the process to turn mixed and thinned ingredients to

liquid chocolate. A schema for chocolate conching process is given in Figure 4.6 below:

Figure 4.6 - Conching Process

Without this step, the chocolate product becomes gritty and non-smooth. The more conching

process takes time, the more delicious the chocolate becomes. The main purposes of this

process are decreasing the humidity of chocolate, removing any unwanted odor, removing

volatile acids, obtaining the desired aroma, preventing clumping, covering the particles with

cacao fat and adjusting the viscosity of the final chocolate sauce.

There are three stages of conching as dry, plastic and liquid conching . In dry conching, small

amount of lecithin and fat is added at 65-70˚C and the process continues for around 200

minutes. The main purpose is making more circular particles, removing the undesired odor,

removing the volatile acids and removing the humidity. Later, during plastic conching, more

fat and lecithin is added to the system at 60-65 ˚C and this second part of conching goes on

for 90-360 min depending on the product type. The purpose here is to push the fat content

through the particle center to delay fat bloom taking place (the white layer onto the chocolate

surface, due to crystallization of the cacao fat). For the last stage of conching, which is liquid

conching, all the lecithin and fat that is defined in the recipe is fed into the system. This last

stage takes around 120-270 minutes and the temperature should be 45-55 ˚C. The main aims

in this last stage are to complete sending fat content through the particle center and adjust the

viscosity of chocolate sauce.

Feeding the rawmaterial forchocolate

Mixing Dry ConchingPlastic

Conching

LiquidConching

Stocking in theTank



22

4.10 - Material and Energy Balances

For the production of Product A (it is not allowed to share the name of the product), all the

measured and given data are tabulated below in Table 4.3. Time basis for the following data is

1 hour, hour-second corrections will be made during the energy balance calculations (4.10.2).

Table 4.3 - Data for Product A

ContentWeight

(kg/h)Dry material (%)

Dry weigh

(kg/h)

Percentage in

Product

Flour 150 87 130.5 66.1

Sugar 36 99.2 35.7 18

Oil 18 100 18 9.3

Fructose Syrup 13 80 10.4 4.7

Lecithin 0.09 100 0.09 0.04

Milk powder 20 97 19.4 0.9

NH4(HCO)3 1.7 - - -

NaHCO3 0.57 50 0.29 0.2

Salt 1 99 0.99 0.7

Water 4 - - -

TOTAL 244.36 - 215.37 ≈100



23

4.10.1 - Material Balance

For Product A, a simple representation of the production process can be found in Figure 4.7

below:

Figure 4.7 - Process of the production for Product A

Moisture contents of the materials found in Figure 4.7 are tabulated below in Table 4.4:

Table 4.4 - Moisture content of the materials used during the production of Product A.

Dough 1 (D1) Dough 2 (D2) Final Product (P)

Moisture Content % 21.0 15.5 11.9

If we apply material balance on the direct oven, following equations can be obtained:

Water Balance : 22111

%% D DV D D moisturemmmoisturem

21.036.244 155.021

DV mm

Total mass balance: 211 DV D mmm

We know1 D

m and we can write1V

m as a function of2 D

m by using total mass balance. That

means we can solve the above equations for unknowns. After that simple calculation,1V

m has

been found as 15.9 kg and2 D

m has been found as 228.1 kg. This values are the amounts per

hour.



24

If we apply one more material balance on the indirect oven, following equations can be

obtained:

Water balance : P P V D D moisturemmmoisturem %%222

119.0155.01.228 2 P V mm

Total Mass Balance: P V D mmm 22

Again, we have two unknowns and two equations; that means the unknowns can be

determined by solving the equations simultaneously. After the calculation, P

m has been

calculated as 219 kg and2V

m has been determined as 9.1 kg. These values are also amounts

per hour.

4.10.2 - Energy Balance

An energy balance is applied on a hypothetical oven (Figure 4.8 below) by thinking the direct

and indirect ovens that are shown in Figure 4.7 as one single oven. LPG is used as

combustible and effect of air inside the oven is simply neglected as it is impossible to measure

its content and temperature.

Figure 4.8 - Hypothetical representation of direct and indirect ovens together as one single oven and the

components for the production of Product A

LPG, TLPG=30 ˚C

mLPG = 50 kg/h

Product, TP=100˚C

mP=219 kg/h

Vapor, Tv= 200˚C, mv=25 kg/h

Dough, TD: 30˚C

mD = 244.36 kg/hOven, Toven = 200˚C



25

In order to apply an energy balance, we need to know the C p values of all the product

components listed in Table 4.3; however, only the following heat capacity values (Table 4.5)

could be obtained due to technical limitations and lack of information:

Table 4.5 - Component heat capacity values that could be obtained

Flour Sugar Fructose Syrup Oil

Cp (kj/kg) 1.8 1.3 1.3 2.1

Since the data in Table 4.5 does not contain all components and heat capacity values of some

components could not be obtained, only those four C p values will be considered. This

assumption seems valid as those four components together represent 98.1% of the product

(Table 4.3).

In order to make calculation easier, a hypothetical C p value for the whole materials can be

determined by using their percentages and C p values.

oil poil fructose p fructose sugar p sugar flour p flour material p C C C C C ,,,,, %%%%

After the calculation, C p,material was found approximately as 1.68 K kg kj .

When the oven shown in Figure 4.8 is chosen as the system on which the energy balance will

be applied, the following overall energy equation can be obtained if the conservation of

energy law is considered:

QLPG = Qmaterial + Qvapor + Qloss

After the application of energy balance with above equation, it is desired to determine Qloss,

heat loss to the environment from oven. In order to find QLPG, it is required to know

combustion reactions of butane and propane as LPG contains both of these components as a

mixture. Combustion reactions for butane and propane are given below:

C4H10(g) + 6.5 O2(g) 4CO2 + 5H2O(g) - Δ H c,butane = 49509.6 kJ/kg

C3H8(g) +5 O2(g) 3CO2 + 4 H2O(g) - Δ H c, propane = 49931.97 kJ/kg



26

For the combustion of LPG, assumptions of full combustion and negligible effect of 5% air

content have been made and they both seem acceptable. Besides 5% air content of LPG,

butane weight fraction is 0.6 and propane weight fraction is 0.35. These values were given by

the ETİ engineers. With these assumptions and given data, QLPG can be calculated by

considering fractions, mass flow rate, time basis of operation (1 hour, correction for second

was done below) and heat of combustions together:

propanew propaneC ebuwebuC LPG

LPG X H X H m

Q,,tan,tan,

3600

kjQ LPG 183.39397.4993135.06.495096.03600

30

With the same approach, Qmaterial can be found easily:

kJ T C m

Q material material p

p

material 154.73010068.13600

219

3600 ,

Literature values for C p,water , C p.vapor and latent heat of vaporization for water, at the given

temperatures and atmospheric pressure, are 4.18 K kg kJ [5], 2.79 K kg kJ [2], 2256.9

kg kJ [2], respectively.

Qvapor can be found by focusing on the water content as follows (dividing by 3600 is to obtain

values as per second):

vapor vapor p

vapor

latent

vapor

water water pwater

vapor T C m

H m

T C m

Q,,

360036003600

kJ Qvapor 97.1910020079.2

3600

259.2256

3600

253010018.4

3600

99.28



27

After we substitute the values into the overall energy balance, we can determine the energy

loss from the oven walls to the environment, Qloss.

lossvapor material LPG QQQQ

kJ QQQQ vapor material LPGloss 06.36697.1915.718.393



28

5. APPENDIX

Brix measurement data for ETİ Cin is given in Table 5.1 below. For the products Puf and

Benim'o, brix measurement data can be found in Table 5.2 and Table 5.3, respectively, within

this appendix section. Stock tank is where syrup of the product is kept after its production and

measurement tank is placed after the stock tank and before the production line.

Table 5.1 - Brix measurement data for Cin product.

Date Hour Place Temperature Brix

04.09.2013 15:00 Stock Tank 90.0 74.5

04.09.2013 15:00 Measurement Tank 83.1 76.0

04.09.2013 17:00 Stock Tank 90.1 75.5


09.09.2013 13:15 Stock Tank 90.3 76.4


11.09.2013 13:30 Stock Tank 89.9 75.5


11.09.2013 15:30 Stock Tank 90.1 75.1


Table 5.2 - Brix measurement data for Puf product.


04.09.2013 15:00 Stock Tank 45.1 75.2


04.09.2013 17:00 Stock Tank 47.0 75.1


09.09.2013 13:30 Stock Tank 47.8 76.5


11.09.2013 13:30 Stock Tank 48.0 75.2


11.09.2013 15:30 Stock Tank 46.7 74.8




29

Table 5.3 - Brix measurement data for Benim'o product.


04.09.2013 15:00 Stock Tank 46.0 73.9


04.09.2013 17:00 Stock Tank 46.3 72.704.09.2013 17:00 Measurement Tank 44.5 73.9

09.09.2013 13:20 Stock Tank 46.5 73.8


11.09.2013 13:30 Stock Tank 46.2 72.5


11.09.2013 15:30 Stock Tank 46.0 72.7




6. REFERENCES

[1] Sandler, Stanley I. Chemical and Engineering Thermodynamics. 3rd Edition. New York:

Wiley, Print.

[2] Incropera, Frank P., David P. Dewitt, et al. Fundamentals of Heat and Mass Transfer . 6thEdition. New York: Wiley, Print.

[3] Eti gıda sanayi ve ticaret a.ş.. (2009, September 5). Retrieved from:

http://www.etietieti.com/kurumsal_sirketler.aspx?mainId=229

[4] Hunter, A. (Photographer). (2009, January 31). Four 3-day old Aspergillus colonies on a

Petri dish [Web Photo]. Retrieved from:

http://commons.wikimedia.org/wiki/File:Four_3-

day_old_Aspergillus_colonies_on_a_Petri_dish.png

[5] McCabe, W. L., Smith, J. C., & Harriott, P. (2001). Unit operations of chemical

engineering . (6th ed., p. 1085). Singapore: McGraw-Hill Higher Education.

Documents

Report- Çok Iyi- Eti