Transporting Operations of Food Materials within Food Factories

Front Cover
Transporting Operations of Food Materials within Food Factories: Unit Operations and Processing Equipment in the Food Industry
Copyright
Dedication
Contents
Contributors
Preface
Chapter One: Introduction to food material handling within food factories
1.1. Introduction
1.2. Why material handling is important?
1.3. Handling related food properties
1.3.1. Density
1.3.2. Viscosity
1.3.3. Geometrical properties
1.3.4. Flow properties
1.4. How to select a proper material handling system?
1.5. Material handling principles
1.6. Classification of material handling equipment
1.7. Receiving and storage facilities
1.7.1. Liquid storage
1.7.2. Solid storage
1.8. Liquid food transportation
1.9. Solid material transportation
1.10. Industrial transportation vehicles
1.11. Robotics for material handling
1.12. Conclusions
References
Part One: Receiving and storage facilities
Chapter Two: Storage vats, vessels, and tanks
2.1. Introduction
2.2. Industrial vats, vessels, and tanks: Types and applications
2.2.1. Dairy industry
2.2.2. Edible oil industry
2.2.3. Alcoholic beverages industry
2.2.4. Non-alcoholic beverages industry
2.3. Engineering aspects of tanks and vessels
2.3.1. Clean-in-place (CIP) considerations
2.4. Novel technologies in storage tanks and vessels
2.5. Conclusions
References
Chapter Three: Pallets and bags
3.1. Introduction
3.2. Packaging
3.3. Pallet
3.3.1. Materials
3.3.1.1. Wood pallets
3.3.1.2. Plastic pallets
3.3.1.3. Composite pallets
3.3.1.4. Paper-based pallets
3.3.1.5. Metal pallets
3.3.2. General standards and requirements
3.3.3. Standards for mechanical tests
3.3.4. Cleaning and sanitizing treatments for food safety
3.3.5. Supply chain
3.3.5.1. Green supply chain and environmental sustainability
3.3.5.2. Pallet pool
3.4. Big bags
3.4.1. Paper bags
3.4.2. Plastic bags
References
Chapter Four: Silos and bins
4.1. Introduction
4.2. Storage principles
4.2.1. Moisture content
4.2.2. Temperature
4.3. Different storage structures
4.3.1. Food storage structures
4.3.1.1. Systems for open storage
4.3.1.2. Systems for partly open storage
4.3.1.3. System of closed storage
4.3.1.4. Cribs
4.3.2. Conventional storage structures
4.3.2.1. Storage in bunker
4.3.2.2. Underground storage
4.3.2.3. Storage in bags
4.3.2.4. Storage in bulk
4.3.2.5. Warehouse (shed) storage
4.3.3. Bulk storage structures (silos and bins)
4.3.3.1. Tower silos
4.3.3.2. Tower silos with reduced oxygen levels
4.3.3.3. Bunker storage
4.3.3.4. Bag silo storage
4.3.3.5. Plastic silo
4.3.3.6. Metal silo
4.3.3.7. Concrete silos
4.3.3.8. Storage in silos
4.3.3.9. Storage in bins
Steel bin
Aluminum bin
RCC-bin
Other storage structures
4.3.4. Changes in food products during storage
4.3.4.1. Physical changes
4.3.4.2. Chemical changes
4.3.4.3. Biological changes
4.3.4.4. Physicochemical changes
4.3.5. Types of spoilage during storage
4.3.5.1. Weight loss
4.3.5.2. Reduction in seed germination
4.3.5.3. Spoilage due to respiration heat generation
4.3.5.4. Contamination by insects
4.3.6. Practices used for control of spoilage
4.3.6.1. Curative measures
4.3.6.2. Physical methods
4.3.6.3. Radiation
4.3.6.4. Mechanical methods
4.3.6.5. Biological methods
4.3.6.6. Chemical methods
4.3.6.7. Insecticides
4.3.6.8. Fungicides
4.3.6.9. Disinfestation and detoxification treatments
4.3.6.10. Fumigation
4.3.7. Storage costs in godowns and silos
4.4. Concluding remarks
References
Part Two: Liquid food transportation
Chapter Five: Transportation and metering of fluids
5.1. General elements and equipment of the system
5.2. Pipes and channels
5.2.1. Pipe types and specifications
5.2.2. Selection of a suitable pipe size
5.2.3. Methods used for joining pipes
5.2.3.1. Connection of pipes
5.2.3.2. Expansion allowances and pipe supports
5.2.3.3. Fittings
5.3. Control of flow rate
5.3.1. Adjustment of flow
5.3.2. Measurement of flow rate
5.3.2.1. Full-section flowmeters
5.3.2.2. Insertion (point)-type meters
5.3.2.3. Different types of measurement devices
5.4. Flow-inducing machinery, pumps, blowers, and compressors
5.4.1. General relations
5.4.2. Fluid moving machinery
5.4.2.1. Liquid moving machinery: Pumps
5.4.2.1.1. The positive displacement pumps
5.4.2.1.2. The centrifugal pump
5.4.2.2. Gas moving machinery: Fans, ventilators, blowers, and compressors
References
Suggested books
Chapter Six: Centrifugal pumps
6.1. Introduction
6.2. Classification and application of centrifugal pumps
6.2.1. Centrifugal pumps
6.2.2. Types of centrifugal pumps
6.2.3. Applications of centrifugal pumps
6.2.4. Centrifugal pumps sizing
6.3. Centrifugal pump standards
6.3.1. ANSI/HI standards
6.3.2. API 610 standard
6.3.3. API 685 standard
6.3.4. ANSI/ASME B 73.1/73.1 M standard
6.3.5. ANSI/ASME B 73.2/73.2 M standard
6.3.6. ANSI/ASME B 73.3/73.3 M standard
6.3.7. NFPA 20 standard
6.3.8. ISO 5199 standard
6.3.9. Other standards
6.4. Main parts of centrifugal pumps
6.4.1. Impeller
6.4.1.1. Closed impellers
6.4.1.2. Semi-open impellers
6.4.1.3. Open impellers
6.4.2. Pump casing
6.4.2.1. Vaneless guide ring
6.4.2.2. Concentric casing
6.4.2.3. Volute casing
6.4.2.4. Vaned diffuser ring
6.4.3. Shaft
6.4.4. Sealing systems
6.4.4.1. Stuffing box
6.4.4.2. Mechanical seals
6.4.5. Type of bearing
6.4.6. Sealing of bearing chambers
6.4.7. Lubrication of bearings
6.4.8. Pump wear rings
6.4.9. Axial force balancers
6.5. Centrifugal pump accessories
6.5.1. Coupling
6.5.1.1. Gear coupling
6.5.1.2. Grid coupling
6.5.1.3. Disc coupling
6.5.1.4. Elastomeric compression type coupling
6.5.1.5. Elastomeric shear-type coupling
6.5.2. Base plates
6.5.3. Drivers
6.5.4. Cooling water systems
6.5.5. Forced lubrication system of hydrodynamic bearings
6.5.6. Cooling systems and lubrication of mechanical seals
6.5.7. Piping of centrifugal pumps and accessories
6.5.7.1. Discharge piping
6.5.7.2. Check valve
6.5.7.3. Suction piping
6.5.7.4. Strainers
6.5.8. Foundation
6.5.9. Coupling guard
6.6. Centrifugal pumps selections
6.6.1. Common errors in pump selection
6.6.1.1. Hydraulic failures
Cavitation
Pressure pulsations
Suction and discharge recirculation
Air in the suction pipe
6.6.1.2. Mechanical failure
Impeller contact with casing/backplate
Bearing failure in motor
Seal failure
6.6.2. Pump specification
6.6.3. Type and size selection
6.6.3.1. Pump type
6.6.3.2. Pump size
6.6.4. Technical and qualitative criteria in the selection of centrifugal pumps
6.6.5. Production quality of centrifugal pumps
6.6.6. High-energy pumps
References
Chapter Seven: Positive displacement pumps
7.1. Positive displacement pumps
7.2. Types of positive displacement pumps
7.2.1. Reciprocating positive displacement pumps
7.2.1.1. Types of reciprocating positive displacement pumps
Piston or plunger-type reciprocating pumps
Diaphragm-type reciprocating pumps
7.2.1.2. Capacity of reciprocating pumps
7.2.1.3. Efficiency and power of reciprocating pumps
7.2.2. Rotary positive displacement pumps
7.2.2.1. Types of rotary positive displacement pumps
Eccentric rotor
Sliding vane
Flexible vane
Gear pumps
External gear
Internal gear
Lobe
Screw pumps
Single screw
Two-screw
Three-screw
7.2.2.2. Capacity of rotary pumps
7.2.2.3. Efficiency of reciprocating pumps
7.2.3. Peristaltic positive displacement pumps
7.3. Positive displacement pump characteristic curve
7.4. Benefits and limitations of positive displacement pumps
7.4.1. Benefits
7.4.2. Limitations
7.5. Applications of positive displacement pumps in the food and beverage industry
7.6. Considerations for maintenance and operations
7.6.1. Liquid end inspection and maintenance
7.6.2. Crankcase inspections and maintenance
7.6.3. Troubleshooting
7.7. Summary
References
Part Three: Solid and semi-solid transportation
Chapter Eight: Fundamentals of conveyors
8.1. Introduction
8.2. Scope and importance of solid and semi-solid material handling systems
8.3. Classification of materials
8.4. Engineering properties of food materials related to conveying systems
8.4.1. Angles of materials
8.4.2. Density
8.4.3. Flowing properties
8.4.4. Moisture content
8.5. Principles of material handling for selection of conveyors
8.5.1. Planning
8.5.2. Systems
8.5.3. Material flow
8.5.4. Simplification
8.5.5. Gravity
8.5.6. Space utilization
8.5.7. Unit size
8.5.8. Safety
8.5.9. Mechanization/automation
8.5.10. Equipment
8.5.11. Standardization
8.5.12. Flexibility
8.5.13. Deadweight
8.5.14. Motion
8.5.15. Idle time
8.5.16. Maintenance
8.5.17. Obsolescence
8.5.18. Control
8.5.19. Capacity
8.5.20. Performance
8.6. Classification of solid and semi-solid material handling systems and conveyors
8.6.1. Conveyors
8.6.2. Hoisting equipment
8.6.3. Robotic handling equipment
8.6.4. Containers
8.6.5. Auxiliary equipment
8.7. Type of conveyors
8.7.1. Belt conveyors
8.7.1.1. Belt conveyor elements
8.7.1.2. Design consideration
8.7.1.3. The capacity of belt conveyor
8.7.2. Bucket elevators
8.7.2.1. Types of bucket elevators
8.7.2.2. Buckets
8.7.2.3. Theoretical power requirement
8.7.3. Screw conveyors
8.7.3.1. Types of screw conveyors
8.7.3.2. Types of screws
8.7.3.3. Aspects of screw conveyor design
8.7.4. Numerical problem
8.7.5. Power requirement
8.7.6. Numerical problem
8.7.7. Roller conveyors
8.7.8. Chain conveyors
8.8. Pneumatic conveyors
8.8.1. Positive pressure pneumatic conveying systems
8.8.2. Negative pressure pneumatic conveying systems
References
Chapter Nine: Different mechanical conveyors in food processing
9.1. Introduction
9.2. Basic design rules
9.3. Materials of construction
9.4. Design for manufacturing and assembly (DFMA) of conveyors
9.4.1. Modular conveyor belts
9.4.2. Round and V-profile belts
9.4.3. Open mesh wire belts
9.4.4. Food-grade conveyor belts
9.4.5. Fabric-reinforced/ply belts
9.4.6. Homogeneous flat belts
9.4.7. Positive-drive homogeneous belts (tooth-driven, light conveyor belts without woven fabric mesh)
9.5. Food conveying systems and their hygiene
9.5.1. Cleanability
9.6. Conclusions
References
Chapter Ten: Pneumatic conveyors
10.1. Introduction
10.2. Advantages of pneumatic conveying
10.2.1. Dust-free transportation
10.2.2. System flexibility
10.2.3. Lower operational cost
10.2.4. Higher safety
10.2.5. Easier automation
10.3. Disadvantages of pneumatic conveying
10.3.1. Limited conveying speed of fragile material
10.3.2. Higher energy consumption
10.3.3. Inadequacy for transportation of some materials
10.4. Applications of pneumatic conveying in the food industry
10.5. System components
10.5.1. Air supply
10.5.2. Feeding devices
10.5.2.1. Low pressure feeding devices
Rotary valves (rotary air lock)
Venturi feeders
10.5.2.2. High pressure feeding devices
10.5.3. Conveying ducts and bends
10.5.3.1. Ducts
10.5.3.2. Bends
Common-radius bends
Common fittings
Special bends
10.5.4. Gas-solid separation devices
10.6. System types
10.6.1. Classification by the flow pattern
10.6.1.1. Dilute phase
10.6.1.2. Dense phase
Types of dense phase regime
10.6.1.3. Criteria for recognizing the flow pattern
Velocity of air
Saltation velocity
Solids loading ratio (SLR)
Predictive charts
Phase diagram (Zenz plot)
10.6.2. Classification by working pressure of the system
10.6.2.1. Negative pressure system
10.6.2.2. Positive pressure system
10.6.2.3. Combination of negative and positive pressure systems
10.6.3. Classification by loop configuration
10.7. Pressure drop in a pneumatic conveying system
10.8. Conclusions
References
Chapter Eleven: Hydraulic conveyors, bucket conveyors, and monorails
11.1. Hydraulic conveyors
11.1.1. Principle
11.1.2. Components of a hydraulic conveying system
11.1.2.1. Pumps
11.1.2.2. Dewatering equipment
11.1.2.3. The pipeline
11.1.2.4. Slurry preparation plant
11.1.3. Other design considerations
11.1.4. Applications in food industries
11.1.5. Advances
11.2. Bucket elevators
11.2.1. Types
11.2.1.1. Centrifugal discharge elevator
11.2.1.2. Continuous discharge elevator
11.2.1.3. Positive discharge elevator
11.2.2. Components
11.2.3. Design considerations
11.2.4. Applications
11.2.5. Advantages and disadvantages
11.3. Monorail
11.3.1. Principle
11.3.2. Heights of monorails
11.3.3. Monorails in the meat industry
11.3.3.1. Static monorail scale
11.3.4. Monorail conveyor for beverage industry
11.3.5. Monorail in the tea factory
11.3.6. Monorail in the bakery industry
References
Part Four: General material handling machines in food plants
Chapter Twelve: Transporting vehicles/trucks used in food plants
12.1. Introduction
12.2. Hand trucks
12.2.1. Hand lift trucks
12.2.2. Hydraulic hand lift trucks
12.2.2.1. Hand low-lift pallet trucks
12.2.2.2. Hand low-lift platform trucks
12.2.3. Mechanical hand lift trucks
12.2.3.1. Multiple-stroke truck
12.2.4. Two-wheel hand trucks
12.2.4.1. Barrel trucks
12.2.4.2. Bag trucks
12.2.4.3. Beverage trucks
12.2.4.4. Utility trucks
12.2.4.5. Grain trucks
12.2.4.6. Pry trucks
12.2.5. Multiple-wheel hand trucks
12.2.5.1. Dollies
12.2.5.2. Platform trucks
Tilt or balance type
Non-tilt type
12.2.5.3. Wagon-type trucks
12.2.5.4. Superstructures trucks
12.2.5.5. Semi-live skid platforms
12.3. Powered trucks
12.3.1. Walkie trucks
12.3.1.1. Low-lift pallet trucks
12.3.1.2. Low-lift platform trucks
12.3.1.3. High-lift pallet trucks
12.3.1.4. High-lift platform trucks
12.3.1.5. Fixed platform powered trucks
12.3.1.6. Walkie tractors
12.3.2. Rider trucks
12.3.2.1. Conventional or standard aisle
Counterbalance trucks
12.3.2.2. Narrow aisle
Straddle trucks
Swing-mast trucks
Reach trucks
Double reach trucks
12.3.2.3. Very narrow aisle
Typical fork-lift trucks
Turret trucks
Hybrid trucks
12.3.2.4. Special vehicle
12.3.3. Robot trucks
12.4. Conclusions
References
Chapter Thirteen: Robotics for general material handling machines in food plants
13.1. Introduction
13.2. Robotics
13.2.1. Classification of end-effectors
13.2.1.1. Sensors
13.2.1.2. Grippers
13.3. Design consideration of robots and machine learning
13.3.1. Design considerations based on food properties
13.3.1.1. Defining food types, surface properties, and processing conditions
13.3.1.2. Hygiene and safety during handling
13.3.1.3. Environmental conditions during handling
13.3.2. Machine learning for robotic motion and control
13.3.2.1. Machine vision for sensing the object
13.3.2.2. Mathematical models for robotic manipulation
13.4. Application of robotics in food industries
13.4.1. Fruit and vegetable processing industry
13.4.1.1. Pick and place
13.4.1.2. Primary processing
13.4.1.3. Classification
13.4.1.4. Grading
13.4.2. Cereal grain and nut processing industries
13.4.2.1. Cereal grains
13.4.2.2. Nuts
13.4.3. Dairy processing industries
13.4.4. Egg, meat, and seafood processing industries
13.4.4.1. Egg processing industries
13.4.4.2. Meat processing industry
13.4.4.3. Seafood processing industries
13.4.5. Food packaging
13.5. Limitations in industries and future scope
References
Index
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