Transporting Operations of Food Materials Within Food Factories : Unit Operations and Processing Equipment in the Food Industry

Transporting Operations of Food Materials within Food Factories, a volume in the Unit Operations and Processing Equipment in the Food Industry series, explains the processing operations and equipment necessary for storage and transportation of food materials within food production factories. Divided into four sections, Receiving and storage facilities, Liquid food transportation, Solid and semi- solid transportation and General material handling machines in food plants, all sections emphasize basic content relating to experimental, theoretical, computational and/or applications of food engineering principles and relevant processing equipment. Written by experts in the field of food engineering in a simple and dynamic way, the book targets all who are engaged in worldwide food processing operations, giving readers comprehensive knowledge and an understanding of different transporting facilities and equipments. Thoroughly explores alternatives in food processing through innovative transporting operations Brings novel applications of pumping and conveying operations in food industries Covers how to improve the quality and safety of food products with good transporting operations 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 Back Cover