Project of yogurt production line with development of packing plant and its maintenance organizations - exchange rate

Contents

Introduction

1. Development of cover closure machine

1.1. Overview of closure machines and trends

1.2. Construction Description

1.3. Initial data

1.4. Process calculation

1.5. Kinematic calculation

1.6. Calculation of the drive

1.7. Calculation of bevel gear train

2. Slug hopper with separator and orientator

2.1. Study of the principle of operation and trends in the development of silos for the supply of raw materials

2.2. Construction Description

2.3. Initial data

2.4. Process calculation

2.5. Calculation of the drive

3. Business case from introduction of new silo with separator and orientator for supply of plugs

3.1. Definition of investments

3.2. Comparative analysis of designed equipment with

Analog

3.3. Calculation of electricity consumption

4. Operation and maintenance

4.1. Planned Process Maintenance and Equipment Repair System

4.2. Purpose of equipment, description of operating principles

4.2.1. Purpose of equipment

4.2.2. Description of equipment arrangement and operating principle

4.3. Process Flow Diagram and Assembly Map - Disassembly

4.4. FTP Schedule

4.5. Safety Requirements for Installation and Operation of Process Equipment

4.5.1. Safety requirements for the main components of the equipment and its controls

4.5.2. Equipment hazardous area fencing facilities

4.5.3. Rules of equipment placement in the production room

4.5.4. Safe equipment operation conditions

5. Safety of life

5.1. State of occupational safety in the industry

5.1.1. Basic requirements

5.1.2. Requirements for safe organization of works to production (technological) processes

5.1.3. Requirements for production equipment, its placement and organization of workplaces

5.1.4. Requirements for raw materials and finished products

5.2. Sanitary and hygienic conditions at the enterprise, washing and disinfection of equipment

5.2.1. Main tasks of sanitary treatment

5.2.2. Disassembly-free washing

5.2.3. Methods of sanitary treatment of equipment at the final stage

5.3. Safety Requirements for Process Equipment

5.4. Calculation of general ventilation

Conclusion

List of literature

Introduction.

Russia's national security depends heavily on the production of agricultural products. Until recently, milk was a strategic raw material that ensured the production of drinking normalized milk, yoghurts, as well as sour milk crops in the necessary volumes and ruled out the emergence of "dairy riots" for the consumption of dairy products [14].

Currently, various types of yogurt are produced in Russia. Depending on the technology determining the characteristics of the finished product, yoghurts prepared by the thermostat method, with undisturbed clot and dense consistency, yoghurts produced by the reservoir method, with impaired clot and drinking [512] are distinguished.

Abroad, the technology of drinking yogurt is characterized in that the product after fermentation is mixed, homogenized, cooled to a storage temperature (5 ° C) and poured. In our country, when producing drinking-type yogurt, the product, after fermentation and mixing, is partially cooled in a tank or in a stream to a storage temperature (4 ± 2 ° C) and poured. In this case, the milk-protein clot undergoes destruction during the cooling process and poorly restores the structure, so the recovery ability and water-retaining ability of the system take on particular importance. There are several ways to improve these indicators [512].

One of them is the choice of starters. It is known that microorganisms that are part of yoghurt starters form milk-protein clots with different types of consistency during milk fermentation. For drinking yoghurt, starters of viscous consistency with various degrees of traction are used. The structural properties of yogurt are also affected by the culture temperature of starters. A decrease in the fermentation temperature causes the production of a product characterized by more pronounced consistency stability, but also excessive tightness.

Another way to obtain a uniform, non-alloying viscous consistency of yogurt is to use various additives. The use in certain concentrations of additives containing protein (milk powder, milk-protein concentrates, soy protein, etc.) leads to an increase in the content of dry substances and an increase in density, elm-bone. Stabilizers [50] can also be used in the production of yogurt.

Recent research shows that the most promising is the use of multicomponent stabilization systems with both gelling agents and thickeners. They create structures in yoghurt exhibiting good resistance to destruction and greater recovery ability compared to single-component stabilizers [512].

Thus, the best organoleptic, structural-mechanical characteristics and water-retaining ability of drinking yoghurt over a long shelf life provided multicomponent stabilizing additives with pronounced thickening properties [50].

Drinking yogurt is becoming an increasingly popular product. Its unique food properties with a wide variety of flavors, practical and attractive packaging, lower cost compared to other types contribute to the real success of the consumer.

There are many areas of development and improvement in the dairy industry. This is due to the fact that milk, both in itself and all its derivatives, is still a perishable product. In this regard, one of the main directions of development is the way of improvement of containers and methods of its sealing [512.50].

Containers for drinking milk, yoghurt and sour milk crops are very diverse, which means that the problems associated with its production, bottling of the finished product into it and its subsequent sealing are also diverse [13-18, 50].

The designed packing plant is designed for production in PET bottles. Which is a promising way to solve the problems associated with the packaging, since the PET bottle has a number of great advantages over other packaging materials:

1. aseptic bottling is possible;

2. the shelf life of the product in this container fully meets all available GOST;

3. easy application of the brand label;

4. the configuration of the stopper and bottle may be different;

5. the bottle, as well as the cork are easy to manufacture, and it is also possible to completely process them, without significant air pollution, as in the case of TETRAPAK packaging;

6. A 0.5L PET bottle is the most ergonomic package for drinking dairy products of all existing:

- it is stable;

- conveniently lying in his hand;

- it is easy to open;

- it is possible to close, without using the product to the end, in order to further transport it, while manually tightening the lid is enough for reliable healing of containers from spilling the product even when turning the bottle.

In the food industry, depreciation costs, equipment maintenance costs and power supply costs dominate the self-cost of products and amount to about 80%. By reducing these costs, we will significantly reduce the cost of production and will be able to sell it at a more attractive price than competitors. From this, it follows that in order to ensure profitability of production, it is necessary to use the most efficient, reliable, energy-saving equipment, but producing products that meet all quality standards [33, 36, 40].

The designed equipment, in addition to significantly increasing the level of automation and safety, has many design solutions that provide significant energy savings. What makes them competitive in the food processing equipment market [1820].

Many energy-saving solutions are used in the developed closure machine, for example:

• More efficient main and adjustment drive;

• Lightweight pusher closures;

• Considerably lightweight and technological (as a result, much cheaper) closure heads;

• Lightweight screw.

The hopper for supplying plugs is minimal material-intensive, has the most efficient motor - reduction gear, belt transmission was excluded from the drive. All this together resulted in a 25% reduction in energy consumption, which, together with an increase of more than 15% in production, resulted in significant savings in unit costs [18, 19, 36].

Description of device and principle of equipment operation.

The designed silo with separator and orientator for plugs supply is shown in Figure 7.2.1.

Plugs are filled with solid mass into hopper 10. They can be supplied by a scraper conveyor, supplied from a bunker storage from the upper floor by gravity, and also manually filled. The level of plugs entering the plug channel consisting of the rims 11 and 12 is controlled by the level regulator 9. In the separator they enter the gap between the movable disc 4 and the fixed disc 6. On the rotating disc 4 there are trapezoidal protrusions which prevent the plugs oriented by the wall towards these protrusions from falling down. Properly oriented plugs fall into the formed gap and engage the projections. Rising on the rotating disk upwards, the plugs are removed from the ledges and fall into the sample line 5. Through this sample line, already correctly oriented plugs move further along the production line.

Description of purpose, design and operating principles:

The designed silo with separator and orientator for plugs supply is shown in Figure 5.2.1.

This silo with separator and orientator for supply of plugs has narrow technological application. The object of this equipment is to convert the chaotic mass of plugs in the plug storage into a stream of properly oriented plugs and deliver them through the plug conduit to a device that dresses the plugs on bottles and presses them to a state that ensures that the plug cannot be overturned from the bottle, for transporting drinking yogurt through the process in a PET bottle in order to seal the container.

Plugs are filled with solid mass into hopper 10. They can be supplied by a scraper conveyor, supplied from a bunker storage from the top floor by gravity, and also be filled manually. The level of plugs in the plug channel consisting of the rims 11 and 12 is controlled by the level regulator 9. In the separator they enter the gap between the movable disc 4 and the fixed disc 6. On the rotating disc 4 there are trapezoidal protrusions which prevent the plugs oriented by the wall towards these protrusions from falling down. Properly oriented plugs fall into the formed gap and engage with you-stups. Rising on the rotating disk upwards, the plugs are removed from the ledges and fall into the sample line 5. Through this sample line, already correctly oriented plugs move further along the production line.

Conclusion.

As a result of the thesis, a closure machine was designed to seal a PET bottle filled with drinking yogurt with a capacity of 12,000 booths/hour. Technological calculations of the machine were made, all transmissions of closure devices and devices for automatic delivery of bottles to the closure carousel were kinematically calculated, and the necessary drive devices were selected.

All process calculations of the silo with a separator and orientator for the supply of plugs with a capacity of 12,000 samples/hour were carried out, as well as the calculation and selection of the drive for the separation device .

Maintenance of the closure was organized, a business case was made from the introduction of a new silo for the supply of plugs, general exchange ventilation for the packing workshop was calculated.

Payback period is 6 months.

The required air flow rate is 200 m3/h.