A diploma project on the introduction of a technological line for the production of feed flour and food fat with the modernization of a hammer crusher at Veal Tenderness LLC.

Contents

Introduction

1. Analysis of production and economic activities of the enterprise

1.1. History of the enterprise

1.2. Energy supply of the enterprise

1.3. Technochemical, microbiological and hygienic

production control

1.4.Marketing assessment of economic activity

enterprises

2. Review of literature on the subject of the diploma project

2.1. Technological Ya8-FOB-M line for production of bone meal

and fat traps

2.2. Requirements for raw materials

3. Process Part

3.1. Process of bone fat and flour production

3.2.Compute and select equipment

4. Design Development

4.1.Base Design Design Selection

4.2. Purpose, arrangement and principle of mechanism operation

hammer crusher

4.3.Compute and select bearings

4.4. Refined calculation of drawn shaft

4.5.Operations and Maintenance Rules

selected main process equipment

4.5.1. Selection of main process equipment

4.5.2. Calculation of annual number of repairs and inspections

of the main process equipment of the enterprise

4.5.3 Calculation of annual labour intensity of repairs and inspections

of the main process equipment of the enterprise

4.5.4. Calculation of required number of repair workers

4.5.5. Preparation of annual schedule of repairs and inspections

of the main process equipment of the enterprise

4.6. Business Case for Design Development

5. Project business case

6. Mechanical Process Design

part machining

7. Safety of life

Conclusions and proposals

List of literature

Introduction

Recently, the processing of agricultural products in small-capacity workshops has become increasingly widespread in our country. The development of small meat processing shops solves a number of important problems, in particular, providing the population with a number of different products. And the construction of these workshops is much cheaper, and they are commissioned faster than the capacity at large meat processing plants.

But on the other hand, the development of small workshops creates new problems, including the rational use of raw materials in processing, compliance with technological, sanitary and hygienic and veterinary standards, as well as regulatory and technical documentation, training personnel, etc. However, these workshops exist and develop as an objective necessity of today.

For the production of grinding devices, machine-building plants produce a wide variety of machines and equipment, and on the line with the creation of new ones there is a continuous change and improvement of existing machines and an overall increase in their output.

The enormous costs associated with grinding processes, at the modern level of production development, cause an urgent need to develop fundamentally new methods of grinding materials, as well as to create new technologies and equipment based on them.

Most workshops are built without standard projects, are located in adapted rooms, are equipped mainly with decommissioned equipment.

It has been established that former carpenters, machine operators, electronics workers, teachers, people of other professions and generally "personnel" without any specialties are sometimes engaged in the manufacture of food products. In this regard, the lightness and carelessness is of great concern. You can understand the desire of these leaders to feed their workers, fellow countrymen. But this must be done in friendship with science, in accordance with veterinary and sanitary legislation, with the requirements of regulatory and technical documentation, otherwise the consequences may be sad .

Crushing and grinding equipment has gone its historical way of development, based on the achievements of modern sciences. This is reflected in grinding principles such as ball, vibratory, self-grinding, percussion, impact centrifugal, jet and others.

I would like to draw attention to the need for strict compliance with veterinary legislation when directing raw materials to the production of animal fat. Checks show that slaughter products are not always examined for trichinellosis, insides are untimely extracted from carcasses of animals cut on farms; veterinary supervision of the work of dumpling shops is carried out sporadically, which is unacceptable. And this is not the fault, but rather the trouble of veterinary doctors, the load of which in livestock farms does not allow daily control over the work of dumpling workshops.

Only the assignment of a veterinary doctor to a specific meat processing plant with the assumption of completeness of personal responsibility for the veterinary and sanitary condition of the workshop can improve the matter.

Managers, as a rule, underestimate the danger to the health of consumers of violations of technological regimes and the role of production and laboratory control in preventing such violations and ensuring the epidemiological reliability of products. Microbiological control in most workshops is not organized at all, which excludes the possibility of an objective assessment of the epidemiological reliability of dumpling products and the level of sanitary culture of production.

All these facts show that the time has come when numerous meat processing plants should have one owner who would provide effective assistance to farms in the design, construction, equipment and installation of equipment, its adjustment and development, training and retraining of specialists, the supply of laboratory equipment, the development of regulatory and technical documentation and its delivery to each contractor.

Of course, assistance to farm managers is necessary, but much depends on themselves. What management assistance is needed to ensure that the raw material receipt, recipe journals, processing journals, and heat treatment are properly recorded first? It is extremely surprising that almost every farm has its own standards for meat output when cutting carcasses into sausages, as well as the output of finished products, which creates loopholes for abuse.

Based on the world experience, it is planned to bring the industry to a qualitatively new level, ensuring the restoration of the volumes of produced products, improving its quality, and significantly increasing the assortment and depth of raw materials processing.

To solve these problems, it is necessary to re-equip large meat processing plants and urban dairy plants, as well as significantly increase the technological level of equipment produced for small and medium-sized processing enterprises.

Almost all grinding methods are ineffective in many respects at the modern level of technology development. Therefore, in order to increase productivity, reduce metal consumption and material consumption, reduce capital costs, it is necessary to look for new ways to improve equipment for grinding materials.

1 Analysis of production and economic activity of the enterprise

1.1 History of the enterprise

In the late 1990s Karpinsky and Volkov bought the sausage shop of the first meat processing plant and set up the production of sausages and boiled sausages. December 1999 - the company was purchased by Alcion LLC and renamed the state of emergency Feoktistov A.L. "Calf tendencies." Reconstruction was carried out and new modern equipment was purchased, all electrical equipment was replaced. Summer 2000 - the company passed certification. On September 1 of the same year, the first products were released.

Currently, the company produces: sausages, boiled sausages, ham, delicacies, raw smoked and raw sausages. Products are made from beef and pork, it is planned to produce products from poultry meat.

Market: large hypermarkets and wholesale bases of the cities of Nizhny Novgorod, Cheboksary, Saransk, Penza, Arzamas, Sarov, Diveev, Pavlov, Vyksa, Navashino, etc .

For this period, the equipment of the enterprise has been completely replaced by imported ones, such as: Mauting (Slovakia), Schaller (Germany, Ukraine), Luteciya (France), Henkelman (Italy).

Meat supplies are produced by: Brazil and Denmark, but there are also supplies of Russian-made raw materials. The purchase price of meat is unstable.

2. Review of literature on the subject of the diploma project

Food animal fats are consumed mainly for culinary purposes, the preparation of fat mixtures (margarine, prefabricated fat) and as raw materials in canning, sausage, confectionery industries.

Currently, meat processing plants produce beef, pork, lamb, bone, bird fats, as well as prefabricated mixtures of various fat raw materials (beef, pork and lamb).

Bone fat is a mixture of fats extracted from various bones (tubular, spongy) of slaughter animals. Oleic acid predominates in bone fat (59%); the content of polyunsaturated fatty acids is slightly higher than in other animal fats, and is 510%. Bone fat contains about 0.2% phospholipids, vitamin A and carotene. The color of high-grade fat - from white to yellow, first grade grayish and greenish tint is allowed, the consistency is liquid, ointment-like or dense, used as culinary fat.

Bone flour is a product of processing pet bones, used as phosphorus fertilizer (contains 2934% P2O5).

It is used for cadet crops (citrus fruits, laurels) and open ground plants. It is considered a slow-acting fertilizer.

Bone flour consists of organic (fat and glue - 26-30%) and mineral (mainly Ca3 (PO4) 2-58-62%) substances. Defatted bone flour contains up to 21% phosphoric acid and up to 4% nitrogen, de-glued bone flour (waste from glue plants) contains about 30% phosphoric acid and up to 1.5% nitrogen.

In potted cadet culture, bone flour is added at the rate of 1 part of flour per 100 parts of the earth. Fertilizer watering is prepared at the rate: 1 kg of flour per 20 liters of hot water. The solution is stirred 2-3 times a day. After a week, the liquid was filtered, diluted with 380 L of water and used for irrigation.

Also, bone flour is used as mineral feed for s.-x. animals. It is added to the diet of cattle 40100 g per day, small animals - 8-20 g. Bone flour includes up to 1% of the weight of the feed.

2.1 Process line Ya8PHOBM for bone flour production and fat removal

Ya8PHOBM line has horizontal vibration extractor 5 for bone degreasing. Bone is supplied to receiving table 1, from where after inspection it is loaded into power grinder 2. Crushed bone is fed by scraper elevator 3 into loading neck of vibration extractor 5. Fat release occurs in hot water with a temperature of 85... 87 "C when acute steam is supplied. The mixture of fat, water and bone obtained in the apparatus is supplied to the washing separator 15, from where the water-fat emulsion with protein phase residues is supplied by the pump 14 to the settling horizontal screw centrifuge 16, and the silo after additional grinding by the screw elevator 6 is charged to the six-hull screw conductive dryer 7. Dry squash is milled and sieved on crushing-sieving vibration unit 8.

The fat is cleaned in two sequentially installed separators 12, cooled and packed. Water separated in separators (so-called process water) is collected in collecting tank 11 and pumped by pump 10 through pipeline 9 to preheating tank 4, where steam is heated to 85 ° C. This water is then re-fed into the vibration extractor and the washing separator. Reuse of process water reduces hot water consumption to 0.1 m3 per 1 t of treated bone. Capacity of Ya8FBM line up to 1000 kg/h of raw bone at electricity consumption of 100 kWh and steam mass flow rate of 300 kg/h.

2.2 Requirements for raw materials

Quality is determined by organoleptic indices (color and consistency at temperature 1520 ° C, smell and taste, transparency in molten state) and physicochemical indices (weight fraction of moisture, acid number). Melted fats in molten form should be transparent; high-grade fat of all types should have a taste without extraneous flavors, in the first class a pleasant toasted taste is allowed. The weight fraction of moisture in beef and lamb fat of prime grade is not more than 0.20%, in pork and bone - 0.25%; first grade - 0.30% (in fat of all types). The acid number of beef and pork fat of extra grade is not more than 1.1; in lamb and bone - 1.2 mg KOH; in all types of fat of class I - not more than 2.2 mg KOH.

3. Process Part

3.1 Process of bone fat and flour production

The process begins with the preparation of raw materials. The main raw materials in the production of food animals of melted fats include adipose tissue, skeletal bones. According to the type of raw materials from which adipose tissue is obtained, raw fat is divided into beef, lamb, pork. Taking into account peculiarities of processing, fatty acid composition and location in animal carcass raw fat is divided into 1st and 2nd groups. Raw fat with pathological changes, unsatisfactory organoleptic indicators, as well as mezzanine fat from cartilage skins are not allowed for processing for food purposes.

An important source of raw material for the production of melted fats is the bones of slaughter animals, the yield of which is 945% of the weight of the animal's carcass. The raw bone of the skeleton belongs to the 1st category, and the defatted bone belongs to the 2nd. Bone of the 1st category is used for production of food melted fat.

Extracting fat from bone. Food bone processing is given great attention in all countries. A large number of bone processing lines used both in Russia and abroad are known. They are proposed for production of not only food fat, but also bone flour, extraction cake, concentrated broth. These are Spomasz (Poland), Lildal (Denmark), Berlin Consalt (Germany), Wartex (Belgium), FMC (USA), Centrifuglow (Sweden), etc.

Substance of fat extraction from bone by wet method consists in the following. The raw material is contacted with water into which steam is bubbled, vibration oscillations are simultaneously applied, constant mixing occurs, as a result, fat is released from the bone and bone residue.

Domestic line Ya8FOB consists of bone grinder, elevator, vibration extractor, centrifugal separator, settling centrifuge and separator.

Fat is extracted from crushed bone in vibration extractor with water temperature 7585 ° C (ratio of water and bone mass 1:1) with gradual increase to 9095 ° C, at pressure 0.10.3 mPa, with oscillation frequency 25 Hz during 2 min. Fat mass is supplied from vibration extractor to washing separator, from which two fractions come out: bone and fat emulsion. The latter enters the centrifuge for separation of bone residue, water and fat. The method of digestion significantly affects the formation of the quality of the finished product. So, when fat is drained from crude fat of the 1st group at atmospheric pressure by a wet and dry method, high-grade fat is obtained; under excessive pressure and under vacuum - fat of the 1st grade and prefabricated. From a fleece obtained by deluge of fats of the highest grade, fat of the 1st grade; from a fleece obtained by digging fats of the 1st grade - prefabricated fat.

Refining of melted fats. Raw melted fats, as well as vegetable oils, contain a variety of impurities in a suspended, emulsified or dissolved state.

Mechanical impurities include skvara particles, water, and mineral salts. In the dissolved state are free fatty acids, pigments, phosphatides, vitamins, sterols, enzymes.

The main operations of refining melted fats are settling, including peeling, filtration, separation, neutralization, bleaching and deodorization. Refining melted fats has the same purpose as refining vegetable oils. After refining, the fat is sent for cooling.

Cooling the fat. This process has two objectives: preventing the development of oxidative processes and forming the necessary structural and plastic properties.

Glycerides, being polymorphic substances, form small crystals with rapid cooling, and fat acquires a uniform consistency and plastic properties. At a low rate of heat removal, large crystals are formed, which leads to the stratification of the crystallizing solid and the remaining liquid fraction. Depending on the type of fat, its purpose and the type of packaging, animal fats are subjected to one- or two-stage cooling. When packed into large containers (barrels), the fats undergo one cooling stage, when using consumer containers, the fats are cooled in two stages, the second stage being called supercooling.

For cooling fats, continuous coolers are used in which the fat does not have contact with air (D5FOP, "Titanium") and is cooled to an average of 38 ° C. For supercooling fat, the cooler "Astra" (Germany), "Votator" (England), ice generators are used. The fats have a lower temperature than after cooling to an average of 27 ° C.

After cooling and supercooling, the fat is sent for packing and packaging.

Packing and labeling of fat. To pack fat into packs, an APM machine designed for butter and AP1M for meat mince are used. To pack supercooled fat into cups of polyvinyl chloride weighing 250 and 400 g - M6ORV machine. Imported subcooling lines include packing machines. The most common packing of pork fat, new packaged form also produce beef and bone fats.

Food fats intended for sale in consumer containers are packed in parchment, aluminum capped foil weighing 250 g net, polyvinyl chloride film cups, metal and glass cans weighing 400, 450 g. The following mass deviations (in g) are allowed: 200 ± 3; 250 ±3; 300 ±3,5; 400 +4; 450 ±4,5; 2500 ±5; 7000 ±5.

Food animals melted fats are also packed in wooden filling barrels with a capacity of 25, 50, 100 and 120 dm3, in plywood stamped barrels or cardboard drums, plywood, cardboard boxes - no more than 25 kg.

Before filling with fat into barrels, boxes, drums, bags-inserts made of polymer film materials are placed; packagings may also be lined with parchment. The following deviations of net fat mass in barrels with a capacity of: 50 dm3 - 40 ± 0.5 kg are allowed; 100 dm3 - 80 ± 0.5 kg; 120 dm3 - 98 ± 0.5 kg.

Storage of food melted fats. Fats are stored at temperature not higher than 25 0C. The most suitable temperature is - 5 to - 8 ° C. At the same time, beef, lamb, pork, horse and bone fats in boxes or barrels are stored 6 months, metal cans - 24 months; prefabricated in barrels - 4 months, in consumer containers - 2 months. Fats with antioxidants in boxes and barrels store 24 months, in consumer containers - 3 months. The technological process for the production of frozen dumplings should be carried out in accordance with sanitary rules and with instructions on washing and preventive disinfection for meat industry enterprises.