Orange Juice Orange HCMUT

HO CHI MINH UNIVERSITY OF TECHNOLOGY
FACULTY OF CHEMICAL ENGINEERING

DEPARTMENT OF FOOD TECHNOLOGY
---------------o0o---------------
FOOD PLANT DESIGN ESSAY
Student: Le Minh Hieu – 1611012
Ta Thi Thao – 1613225
Class: HC16KTTP
Instructor: Dr. Lai Quoc Dat
Ho Chi Minh City, 05/2019
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CONTENT
CHAPTER 1: CHARACTERISTICS OF JUICE PLANT ..................................................... 1

1.1 Characteristics of raw material .......................................................................................... 1
1.1.1 Fresh orange .................................................................................................................. 1
1.1.2 Orange season ................................................................................................................ 4
1.1.3 Storage ............................................................................................................................ 5
1.2 Characteristic of juice products ......................................................................................... 6
1.2.1 Contaminations of product........................................................................................... 6
1.2.2 Sensitve attribute of products in storage and distribution ........................................ 7
1.2.3 Role of distribution system ........................................................................................... 9
1.2.4 Customer behaviors .................................................................................................... 10
1.2.5 Scale up ability............................................................................................................. 11
CHAPTER 2:SOCIO – ECONOMIC CONTEXT ................................................................... 12
2.1 Situation of market ............................................................................................................ 12
2.1.1 Volume and demands .................................................................................................. 12
2.1.2 Necessity of the related products ............................................................................... 13
2.1.3 Possibility of export ..................................................................................................... 14
2.1.4 Possibility of distribution system ............................................................................... 14
2.2 Possibility of market development in future (Hiếu) ....................................................... 15
2.2.1 Global market .............................................................................................................. 15
2.2.2 Vietnamese market ...................................................................................................... 16
2.3 Strength of price and distribution system ....................................................................... 18
2.3.1 Material cost ................................................................................................................ 18
2.3.2 Labor cost..................................................................................................................... 18
2.3.3 Distribution and saling cost ........................................................................................ 18
2.3.4 Efficiency of process .................................................................................................... 19
2.4 Threats ................................................................................................................................ 19
2.4.1 Competition from import ........................................................................................... 19
2.4.2 Capacity of competitors .............................................................................................. 19
2.4.3 Risks of technologies ................................................................................................... 20
2.4.4 Risks on quality and consumer belief ........................................................................ 20
2.4.5 Capital .......................................................................................................................... 21
2.4.6 In stock ......................................................................................................................... 21
2.6 SWOT analysis ................................................................................................................... 22
2.7 Capacity estimation ........................................................................................................... 23
2.8 Product design .................................................................................................................... 24
2.8.1 Product quality ............................................................................................................ 24
2.8.2 Product appearance .................................................................................................... 26
2.9 Factory location.................................................................................................................. 26
2.9.1 Location criteria .......................................................................................................... 26
2.9.2 Location selection ........................................................................................................ 27
CHAPTER 3: MATERIALS ...................................................................................................... 31
3.1 Orange................................................................................................................................. 31
3.2 HFCS 42% .......................................................................................................................... 31
3.3 Water................................................................................................................................... 32
3.4 Enzyme Pectinase ............................................................................................................... 34
3.5 Potassium sorbate .............................................................................................................. 35
3.6 Beta – carotence ................................................................................................................. 35
3.7 Odor, β-Naphtylmetylxeton .............................................................................................. 36
CHAPTER 4: JUICE PROCESS DESIGN .............................................................................. 37
4.1 Sorting ................................................................................................................................. 37
4.2 Washing .............................................................................................................................. 38
4.3 Extraction ........................................................................................................................... 39
4.4 Enzyme treatment .............................................................................................................. 41
4.5 Filtration ............................................................................................................................. 42
4.6 Mixing ................................................................................................................................. 43
4.7 Concentration ..................................................................................................................... 44
4.8 Pasteurization ..................................................................................................................... 46
4.9 Packaging ............................................................................................................................ 47
4.10 Labeling ............................................................................................................................ 47
CHAPTER 5: MASS BALANCE & ENERGY BALANCE .................................................... 49
5.1 Mass balance ...................................................................................................................... 49
5.1.1 Sorting .......................................................................................................................... 50
5.1.2 Washing ........................................................................................................................ 50
5.1.3 Extracting ..................................................................................................................... 51
5.1.4 Enzyme treatment ....................................................................................................... 52
5.1.5 Filtration ...................................................................................................................... 52
5.1.6 Mixing 1........................................................................................................................ 53
5.1.7 Concentration .............................................................................................................. 54
5.1.8 Mixing 2........................................................................................................................ 55
5.1.9 Pasteurization .............................................................................................................. 56
5.1.10 Packaging ................................................................................................................... 56
5.2 Energy balance ................................................................................................................... 58
5.2.1 Enzyme Treatment ...................................................................................................... 58
5.2.2 Mixing 1........................................................................................................................ 60
5.2.3 Concentration .............................................................................................................. 62
5.2.4 Mixing 2........................................................................................................................ 63
5.2.5 Pasteurization .............................................................................................................. 65
CHAPTER 5: EQUIPMENT SELECTION ............................................................................. 66
5.1 Equipment selection ........................................................................................................... 66
5.2 Gantt chart ......................................................................................................................... 73
5.2.1 Gantt chart by process ................................................................................................ 73
5.2.2 Gantt chart by equipments ......................................................................................... 75
CHAPTER 6: FACILITIES ....................................................................................................... 77
6.1 Electricity ............................................................................................................................ 77
6.1.1 Electrical energy for equipments ............................................................................... 77
6.1.1 Electrical energy for lighting system ......................................................................... 78
6.1.3 Total electrical energy for the plant .......................................................................... 78
6.2 Water................................................................................................................................... 78
6.3 Steam ................................................................................................................................... 81
CHAPTER 7: INDUSTRIAL BUILDING DESIGN ................................................................ 83
7.1 Layout of plant ................................................................................................................... 83
7.2 Layout of equipment .......................................................................................................... 86
CHAPTER 8: PERSONNEL MANAGEMENT....................................................................... 87
8.1 Construction of human organanization structure ......................................................... 87
8.2 Human resource ................................................................................................................. 87
8.2.1 Estimating labor for each department ...................................................................... 87
8.2.2 Insurance businesses ................................................................................................... 88
8.3 Manufacturing plan ........................................................................................................... 89
CHAPTER 9: ECONOMIC CALCULATION ........................................................................ 90
9.1 Fixed cost ............................................................................................................................ 90
9.2 Working cost ...................................................................................................................... 91
9.3 Marketing cost.................................................................................................................... 93
9.4 Back up ............................................................................................................................... 93
9.5 Price of product (P) ............................................................................................................ 94
9.6 Profit ................................................................................................................................... 94
9.7 Payback period ................................................................................................................... 94
CHAPTER 10: WASTE TREATMENT ................................................................................... 95
10.1 Characteristics of Wastewater ........................................................................................ 95
10.2 Waste treatment system .................................................................................................. 95
10.3 Waste trash ....................................................................................................................... 97
CHAPTER 11: SAFETY IN FACTORY .................................................................................. 98
11.1 Food safety regulations .................................................................................................... 98
11.2 Safety equipment and production areas ........................................................................ 99
11.3 Fire prevention and fighting rules ................................................................................ 100
11.4 Electrical safety .............................................................................................................. 100
11.5 Regulations on emergency exit and emergency response ........................................... 101
REFERENCES .......................................................................................................................... 102
TABLES OF CONTENT
Table 1: Chemical composition among 100g of orange .................................................................. 3
Table 2: Price of orange juice of some countries .......................................................................... 19
Table 3: Nutritional information of 100mL orange juice .............................................................. 24
Table 4: Physico – chemical quality of product ............................................................................ 25
Table 5: Biological quality of product ........................................................................................... 25
Table 6: Weight for criterias .......................................................................................................... 27
Table 7: Productivity of citrus fruits in each province (hungred weight/ Ha) ............................... 27
Table 8: Labor resources from each province in 2016 (thousand people) .................................... 28
Table 9: Scoring of each criteria.................................................................................................... 28
Table 10: Industrial production value of Tien Giang province over the years .............................. 29
Table 11: Criteria for HFCS .......................................................................................................... 32
Table 12: Physical quality of water in food manufacturing .......................................................... 33
Table 13: Chemical properties of water in food manufacturing .................................................... 33
Table 14: Biological quality of water in food manufacturing ....................................................... 34
Table 15: Criteria for Pectinase quality ......................................................................................... 34
Table 16: Chemical criteria for sorbates........................................................................................ 35
Table 17: Criteria select β- carotene .............................................................................................. 36
Table 18: Loss of each operation ................................................................................................... 49
Table 19: Summary of mass balance of each operation ................................................................ 57
Table 20: Summary of material quantity for production ............................................................... 58
Table 21: Other equipments used in factory.................................................................................. 72
Table 22: Total power of main equipments in a working day ....................................................... 77
Table 23: Total power of lighting equipments in a working day ................................................. 78
Table 24: Amount of water for cleaning equipment and floor ...................................................... 79
Table 25: Amount of water for CIP ............................................................................................... 80
Table 26: Total consumption of water per day .............................................................................. 80
Table 27: Consumption of steam in 1 day ..................................................................................... 82
Table 28: Area estimation for auxiliary material........................................................................... 85
Table 29: Summary of feature area in plant .................................................................................. 85
Table 30: Number of administrative staffs .................................................................................... 87
Table 31: Number of employees in the factory ............................................................................. 88
Table 32: Number of workers during manufacturing .................................................................... 88
Table 33: Equipment cost .............................................................................................................. 90
Table 34: Total fixed cost and ....................................................................................................... 91
Table 35: Total pepreciation of fixed cost ..................................................................................... 91
Table 36: Water cost per year ........................................................................................................ 91
Table 37: Labor cost ...................................................................................................................... 92
Table 38: Material cost .................................................................................................................. 93
Table 39: Total working cost ......................................................................................................... 93
Table 40: Characteristics of Wastewater from juice plant ............................................................ 95
Table 41: Criteria for Wastewater (QCVN 40:2011/BTMT) ........................................................ 95
FIGURES OF CONTENT
Figure 1: Structure of orange fruit ................................................................................................... 3
Figure 2: Effect of temperature on vitamin C content in orange juice during storage. ................... 8
Figure 3: B2C distribution system ................................................................................................... 9
Figure 4: Juice consumption habit by age ..................................................................................... 10
Figure 5: Juice consumption habit by packages (per point of 5) .................................................. 11
Figure 6: Juice consumption habt by package volume (per point of 5) ........................................ 11
Figure 7: Market share of fruit juice in the United Kingdom in 2016 by flavor ........................... 12
Figure 8: Global Concentrated Fruit Juice Market Size and Forecast 2015- 2024 (US$ Billion) 13
Figure 9: Distribution system for orange juice .............................................................................. 15
Figure 10: Proportion of each fruit used in global juice consumption in 2016 ............................. 16
Figure 11: Non – alcoholic drink consumption in Vietnam from 2015 to 2020 ........................... 17
Figure 12: Market shares in non – alcoholic drink in Vietnam ..................................................... 17
Figure 13: Inventory index of food production and processing 75.2% (08/2017) ........................ 22
Figure 14: Structure of β – naphthyl methyl ketone ...................................................................... 36
Figure 15: Orange juice production line ........................................................................................ 37
Figure 16: Diagram of bubble washing machine with conveyor belt (1-Inlet; 2-Conveyor; 3-
Bubble-blowing device; 4-High pressure water sprinklers) .......................................................... 39
Figure 17: A squeezer-type orange juice extractor ........................................................................ 41
Figure 18: Operation of squeezer-type orange juice extractor ...................................................... 41
Figure 19: Layout of the mixing tank ............................................................................................ 42
Figure 20: Diagram of falling film evaporator .............................................................................. 45
Figure 21: Plate heat exchanger..................................................................................................... 47
Figure 22: Labeling machine ......................................................................................................... 48
Figure 23: Conveyor ...................................................................................................................... 66
Figure 24: Bubble washing machine ............................................................................................. 67
Figure 25: A squeezer-type juice extractor.................................................................................... 68
Figure 26: Mixing tank .................................................................................................................. 68
Figure 27: Filter press .................................................................................................................... 69
Figure 28: Falling film evaporator................................................................................................. 70
Figure 29: Plate – type pasteurizer ................................................................................................ 70
Figure 30: Rotary packing machine .............................................................................................. 71
Figure 31: Labelling machine ........................................................................................................ 71
Figure 32: Tapping machine .......................................................................................................... 72
Figure 33: Gantt chart by process for the first period.................................................................... 73
Figure 34: Gantt chart by process for the second period ............................................................... 74
Figure 35: Gantt chart by equipment for the first period process .................................................. 75
Figure 36: Gantt chart by equipment for the first period process ................................................. 76
Figure 37: Boiler............................................................................................................................ 81
Figure 38: Diagram for steam consumption in 1 day .................................................................... 82
Figure 39: Personnel management diagram .................................................................................. 87
Figure 40: Schematic block diagram of the proposed treatment schemes .................................... 96
Figure 41: Two-stage up-flow anaerobic sponge reactors (UASRs) ............................................. 96
Figure 42: Schematic diagram of the proposed treatment system. ................................................ 97
Chapter 1: Juice Plant Introduction Dr. Lai Quoc Dat
CHAPTER 1: CHARACTERISTICS OF JUICE PLANT
1.1 Characteristics of raw material
Orange juice is a popular drink made from oranges by extracting fresh orange juice
by squeezing or squeezing fresh oranges. For orange juice products that are manufactured
in an industrial fashion, orange juice can be extracted from concentrated orange juice and
saved and added with preservative additives, then bottled for consumption. Orange juice
contains flavonoids that are healthy and a source of antioxidant hesperidin. At the same
time in orange juice contains a lot of vitamin C, has the effect of strengthening resistance,
preventing fatigue. Orange juice often varies between orange and yellow, although some
ruby red or orange colors are orange or even pinkish. In orange juice containing sugar,
organic acids, essential oils including isoamylic, geraniol, teryrineol ... orange juice has
sweet, sour, honey-tasting properties, has the effect of refreshing, new fluids, bile, sputum
and diuretic. As a nutritious beverage, drinking lots of orange juice also helps your hair stay
healthy. Health experts in the UK claim that just one glass of orange juice a day can help
improve skin, hair and nails because oranges are high in vitamin C, potassium and folic
acid. Vitamin C is needed in the production of collagen with super nutrients lutein, which
delay the aging process of the skin. The yellow pigment in oranges is associated with
reduced sun damage caused by sunlight, and improved skin elasticity.
1.1.1 Fresh orange
Oranges are among the world's most popular fruits, any of several species of small
trees or shrubs of the genus Citrus of the family Rutaceae and their nearly round fruits,
which have leathery and oily rinds and edible, juicy inner flesh. A number of species and
varieties of orange are economically important, namely the China orange, also called the
sweet, or common, orange (Citrus ×sinensis); the mandarin orange (C. reticulata), some
varieties of which are called tangerines; and the sour, or Seville, orange (C. ×aurantium),
which is less extensively grown.
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Chapter 1: Charracteristics of Juice Plant Dr. Lai Quoc Dat
The orange is a hybrid between pomelo (Citrus maxima) and mandarin (Citrus
reticulata). The chloroplast genome, and therefore the maternal line, is that of pomelo. The
sweet orange has had its full genome sequenced.
Orange trees are widely grown in tropical and subtropical climates for their sweet
fruit. The fruit of the orange tree can be eaten fresh or processed for its juice or fragrant
peel. As of 2012, sweet oranges accounted for approximately 70% of citrus production.
In Vietnam, being a sub-tropical plant, orange thrives best in the cool climate of
northern Vietnam, especially in the highlands. The cold nights allows the fruit to develop a
deep orange color, on the tree at maturity and a pleasant aroma and an ideal combination
of sweet and sour.The main production areas are in the northern provinces of Ha Giang,
Yen Bai, Lang Son, Phu Tho, Hanoi, Thanh Hoa, Ninh Binh, Nghe An and Ha Tinh. But
oranges are also grown in the South, mainly in Can Tho, Tien Giang, Vinh Long, Ben Tre,
Dong Thap, Tra Vinh, Dong Nai.
Structure
Essentially, an orange is a ball of juice sacs protected by a waxy skin, the peel. The
peel consists of a thin outer layer called the flavedo and a thicker, fibrous inner layer called
the albedo. Orange-coloured substances called carotenoids in the flavedo give the fruit its
characteristic colour. Vesicles (small sacs or cavities) containing peel oil also present in the
flavedo contribute to the fruit’s fresh aroma. The white spongy albedo contains several
substances which influence juice quality, often negatively, if they find their way into
extracted juice. These substances include flavonoids, d-limonene, limonin and pectin.
The edible portion of the fruit is known as the endocarp. It consists of a central fibrous
core, individual segments, segments walls and an outer membrane. The segments contain
juice vesicles, or juice sacs, that are held together by a waxy substance. Seeds may also be
present within the segments.
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Figure 1: Structure of orange fruit

Apart from the juice itself, droplets of juice oil and lipid are also present in the juice vesicles.
The juice contains sugars, acids, vitamins, minerals, pectins and coloured compounds, along with
many other components.
Chemical composition
Table 1: Chemical composition among 100g of orange
Component Amount (g)

Water 86,6
Protein 0,7 - 1,3
Oil 0,1 - 0,3
Fiber 0,5
Ash 0,5 - 0,7
Calcium 0,04 - 0,043
Phosphorus 0,017 - 0,022
Iron 0,0002 – 0,0008
Carotene 200 IU. (Vitamin A)
Thiamine 0,00010
Riboflavin 0,00004
Orange's carbohydrate content varies are between 15% to 10%. Carbohydrates in
orange; as sugars and polysaccharides can be analyzed in two main sections. Sugars in
orange, respectively sucrose (3.46%), fructose (2.45%), glucose (2.27%). Orange's glisemic
index is 62. Moreover, sorbitol as a derivative of sugar in some fruits are not definitely
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available in orange. The main polysaccharides found in fruits are cellulose and
hemicelluloses which the basis of cell wall substances. Also, they are found in large
amounts in orange shell, core zone membrane. Cellulose and hemicelluloses are separated
and discarded in waste at process of orange juice. However, a portion goes to pulp. The
dominant fiber is pectin in orange. Orange includes pectin which has 70% with 65% of the
total fiber.
Benefit
Today, they are grown in most warm regions of the world and consumed either fresh
or as juice. Oranges offer many health benefits: They may boost your immune system, give
you better skin, and even help improve your health heart and cholesterol levels. In addition,
some evidence suggests that eating oranges may help reduce the risk of respiratory diseases,
certain cancers, rheumatoid arthritis, ulcers and kidney stones.
Most citrus fruits have a good deal of vitamin C, and oranges have high levels even
compared to their tangy brethren. Vitamin C, a potent antioxidant, protects cells by
scavenging and neutralizing harmful free radicals. In addition to vitamin C, oranges contain
fiber, potassium and choline, all of which are good for your heart. Potassium, an electrolyte
mineral, is vital for the healthy functioning of the nervous system, and a lack of potassium
can lead to arrhythmia (an irregular heartbeat), increased blood pressure and a depletion of
calcium in bones. The fiber in oranges may help lower blood sugar levels in people with
type 1 diabetes and improve blood sugar, lipids and insulin levels in people with type 2
diabetes.
1.1.2 Orange season
Being a sub-tropical plant, orange thrives best in the cool climate of northern Vietnam,
especially in the highlands. The cold nights allows the fruit to develop a deep orange color,
on the tree at maturity and a pleasant aroma and an ideal combination of sweet and sour.The
main production areas are in the northern provinces of Ha Giang, Yen Bai, Lang Son, Phu
Tho, Hanoi, Thanh Hoa, Ninh Binh, Nghe An and Ha Tinh. But oranges are also grown in
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the South, mainly in Can Tho, Tien Giang, Vinh Long, Ben Tre, Dong Thap, Tra Vinh,
Dong Nai.
The time to start their crops is also extremely diverse, but on average, the orange crop
starts from September to March next year. Thus, there will be months when the factory
does not have raw materials to meet the production needs of the factory. So, the crop
problem of orange greatly affects the operation of the plant during the year. The factory
must focus on this issue and propose appropriate solutions to ensure the continuous
operation of the factory.
1.1.3 Storage
Plastic crates or boxes are used for storing fruit. Sweet oranges should be stored with
three or four layers per box. Too many layers in one box may cause bruising of the fruit.
Boxes should be stacked inside the cool storage room with temperature from -2oC to
15oC in a way that maintains good ventilation. For the first few weeks of storage, ventilation
windows should be left open. Throughout the storage period, the windows should be left
open at night or in cold weather, in order to cool the fruit.
When temperatures are high in the day time, the ventilation windows should be closed.
Sunlight should not be able to penetrate inside the storage room. Any rotting fruit that are
found should be removed.
Storage rooms should be constructed in places where cold air can flow into the room
at night. The storage room should have a high roof, to allow better circulation of cold air at
night. Ventilation windows should be small but there should be a large number of them, to
allow better air circulation. It is recommended to that some ventilation pipes should be
buried under ground, to bring in cool air through the floor of the room.
The roof and walls should have good heat insulation, to keep temperatures as cool as
possible. The storage room should be insect-proof and rat-proof. A good storage room is
the key for extending the shelf life while maintaining fruit quality. The room should be kept
clean, and all rotting fruits should be removed. Before storage, the room should be sanitized
by washing the walls and floor with 5% formalin.
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1.2 Characteristic of juice products
1.2.1 Contaminations of product
The contamination of juice can be divided into three groups including physical,
chemical, and biological contaminants.
Physical contaminants are foreigned impurities mixed into the material during
cultivation, harvesting, storage or transportation. They can be sand, dust particles that are
stricked on the fruit surface, metal pieces, stones or insect carcasses, theses impurities when
entering the human body can cause some physical effects such as teeth broken, throat
damage, stomach,.. However, this hazards can be easily eliminated by sorting and washing
carefully the input materials. Most of impurities containing in final product are mainly
originated from poor QA/ QC of manufacturer.
Chemical compounds contaminated into materials can come from a variety of sources
such as natural elements available in the soil or toxic compounds that are discharged
directly to environment during the industrial activities of humans (lead, mercury, cadmium,
polychlorinated biphenyls, ..). These toxic compounds can also be the metabolites produced
by contaminated microoganisms during their metabolism activities or chemicals
compounds that human intentionally use in agriculture in oder to increase the crop yield
(pesticides). This source of contaminants can cause serious affect to customers health if
they are not strictly controlled.
Biological infects in food analysis consist of three main aspects: microoganisms,
viruses, and insects. Besides toxic chemical compounds, this type of contaminant is
considered as the main reason for food poisoning, especially to pathogenic bacteria
infection.
However, orange juice products have some properties that can limit the contaminated
microoganism from growing, for example, juice contains low pH value, normally varies
from 4 to 4.5, this property can inhibit partially the microoganism, when combine with the
pasteurized operation, almoslt they are killed by both low pH and hight temperature
conditions.
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1.2.2 Sensitve attribute of products in storage and distribution
Orange juice is well – known for its vitamins content, however, these vitamins are
relatively senstive and can be loss during processing or storage at ambient condition,
especially for vitamin C. Typical concentrations of vitamin C in freshly extracted juice
range from 450 to 600 mg per liter, but the values for orange juice when consumed range
from 200 to 300 mg vitamin C per liter. Therefore, some appropriate conditions should be
considered in oder to maintain the vitamin content of final products as high as possible until
they are in hand of customers.
Oxygen content
Oxygen plays a major role in the loss of quality in orange juice during storage, mainly
for its responsibility of vitamin degradation and colour changes (become browning).
Vitamin C is the most oxygen-sensitive compound in orange juice. Its loss is thus closely
related to oxygen content in packages.
Generally, vitamin C is lost through two different chemical pathways – anaerobic and
aerobic degradation. As its name implies, the anaerobic pathway is independent of oxygen
and dependent mainly on storage temperature. Losses caused by anaerobic degradation
cannot be prevented by packaging and are the same in all types of package. The only
possible method is to reduce storage temperature. The aerobic pathway needs oxygen and
is therefore strictly related to the presence of headspace oxygen and oxygen dissolved in
the juice, as well as the oxygen-barrier properties of the package. In aerobic vitamin C
degradation, the presence of 1 mg oxygen corresponds theoretically to a loss of 11 mg
vitamin C. This calculation is based on the reaction in which vitamin C oxidizes to
dehydroascorbic acid. Both anaerobic and aerobic degradation take place simultaneously
in orange juice. Which one dominates depends on storage temperature and oxygen
availability.
For packages with good oxygen-barrier properties, for example glass bottles,
anaerobic degradation plays the major role regarding total vitamin C loss. In cases where
oxygen permeation into the package is considerable, headspace oxygen is present or oxygen
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is dissolved in the product, the contribution of anaerobic degradation to total vitamin C loss
is small compared to aerobic degradation.
Temperature
Storage temperature is also the important reason for vitamin C degradation. As a
result, the loss of vitamin C is much more at high temperature conpared to that in chilled
condition. Figure shows the change in vitamin C content in orange juice during storage for
30 weeks at 4°C and 23°C respectively in the same package type (Tetra Brik Aseptic, TBA,
250 ml). The calculated vitamin C loss due to anaerobic degradation is indicated in the
graph. The difference in vitamin C retention between storage at 4°C and 23°C is obvious.
During 30 weeks storage, an increase in temperature from 4°C to 23°C results in increased
losses of vitamin C of 28 mg/l due to anaerobic degradation, and 42 mg/l due to aerobic
degradation.
As mentioned, the rate of oxidative degradation of vitamin C is slowed dramatically
under chilled storage. Consequently, packages for chilled distribution do not need as high
oxygen-barrier properties as packages stored at ambient temperature.
Figure 2: Effect of temperature on vitamin C content in orange juice during storage.
Light: Light is known to accelerate the aerobic (but not an-aerobic) degradation of
vitamin C. Therefore, light has an effect only when the oxygen is present. Consequently,
for packages with low oxygen permeation rate sush as glass and high barrier PET bottles,
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the impacts of light is not significant. However, for which packages that have low oxygen
barrier properties, the limited contact of light to the products is very necessary.
1.2.3 Role of distribution system
In juice processing, the company can implement both B2C (Business to Consumers)
and B2B (Business to Business) or one of them depending on the characteristic of each
factory.
B2C means that the company will supply the packaged juice to cunsumers under its
own brand name. For this type of producers, there are many requirements on the distribution
system and also the marketing skills. Products will be distributed through different levels
such as retailers, supermarkets,.. before being sold to customers. Therefore, it is necessary
to perfect the distribution system in oder to optimize the profits of manufacture.
Figure 3: B2C distribution system
In the other hand, B2B companies mainly sell their products in bulk forms
(concentrated juice) to other manufactures, which carry out the downstream operation to
produce the final products. Besides, during the processing, there are some secondary –
products that can be sold as the input materials for other industries, such as peel oil which
is sold to flavour manufacturers for the production of various flavour compounds used in
the beverage, cosmetics and chemical industries; dry wastes (containing peel, rag, seed,
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pulp) left over from juice processing is used for animal feeding; peel for the manufacturers
producing pectin,..
1.2.4 Customer behaviors
Customer behaviors depend on many different factors, such as:

Gender: Normally, juice products is consumed by mostly women, while other
beverages such as alcoholic drink (beer, rượu,..), tea, coffee,.. are much more attracted to
men.
Age: According to a research of Vinaresearch in 2013, the highest frequency of juice
consumption (1 time/day) belongs to the 16 – 29 years old group, while for the age group
of 30 – 35 years old, almost 36.1% people uses juice for 2 to 3 times per day.
Figure 4: Juice consumption habit by age
Income: High – income people will use this product more frequently.
Brand: Consumers prefer to purchase products orginated from well – known
manufacturers as Vinamilk, Coca Cola, Tan Hiep Phat,..
Package: This is not only important in preserving the products from outside conditions
but also contributing to the consumers attraction. The popular packages using in orang juice
are tetra pak, carton pack, plastic bottles, glass bottles.
Volume: Almost consumers prefer using juice bottles that have capacity from 100–
500 ml.
Others: Addition of nutrients, against hunger, want to try, habit,...
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Figure 5: Juice consumption habit by packages (per point of 5)
Figure 6: Juice consumption habt by package volume (per point of 5)
1.2.5 Scale up ability.
Overall, the ability to scale up of juice processing is relatively easy to perform due to
some reasons:
― The large amount of orange material cultivating in dosmestic
― The diversity of material.
― The technolical process is relatively simple compared to other food industries.
― Many production method.
― The production can be converted into automation.
― Low labor cost.
― Can standardize the final product easily.
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Chapter 2: Socio – Economic Cont Dr. Lai Quoc Dat
CHAPTER 2:SOCIO – ECONOMIC CONTEXT
2.1 Situation of market
2.1.1 Volume and demands
Recent market research shows that the trend of using juice, fruit juice and fruit juice
is increasingly popular. The reason, promoting growth in this industry is because consumers
are increasingly interested in healthy drinks. This is a good signal for manufacturers of
natural fruit juices. The Ministry of Industry and Trade forecasts that the market for fruit
and vegetable juices will reach 6 billion liters in 2017, as consumers are increasingly
interested in natural fruit juice products. The juice product group will continue to grow at
an average rate of 17.5% per year over the next 5 years.
Figure 7: Market share of fruit juice in the United Kingdom in 2016 by flavor
According to the research result about market share of fruit juice in the United
Kingdom in 2016 by flavor, orange juice accounts for the largest market share, 64%
compared to the market share of fruit juice. In Vietnam, the volume of soft drink market
increase from 800 million litters to over 3,5 billion litters during 2010 – 2015.
About demand: Nowaday, because of health needs, consumers tend to like to use
nutritious products that contribute to improvement. Fruit juice is also one of those options.
By bringing many health benefits, especially skin beauty and fruit juice has been replacing
Page | 12
gas drinks in the market. The average soft drink consumption is more than 23 liters / person
/ year. Inside, Vfresh orange juice gets highest selection (69.3%).
2.1.2 Necessity of the related products
As mentioned above, because of the problem of not enough raw materials for factories
to produce continuously for a year, the production of more related products in the factory
is a useful solution. The first concentrated fruit juice that we mentioned, the factory carried
out the production of concentrated fruit juice in the first time, when the material was not
enough to maintain the plant's operation, her juice The concentrate will be brought to
reconstitution to produce the juice as usual. Similar to fruit juices, concentrated juice also
occupies a large market share globally.According to research result about Global
Concentrated Fruit Juice Market Size and Forecast, during 2015 to 2024 the market size
continue to increase rapidly.
Figure 8: Global Concentrated Fruit Juice Market Size and Forecast 2015- 2024 (US$ Billion)
Besides concentrated fruit juice, another product that can be produced in the factory
is bottled water. With a fruit juice production line including a water treatment system, the
production of additional bottled water is a viable, easily feasible solution. However, the
launch of bottled water products to the market will certainly encounter many risks because
currently bottled water products are very diverse with very famous brands, such as
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Aquafina, Vinh Hao, Lavie, …So the market segment for this product will have to be
narrowed to ensure it is not competing by famous brands.
2.1.3 Possibility of export
The export market for beverages is growing, especially due to health needs, so fruit
juice is exported in large quantities. Market demand assessments in Vietnam as well as in
the world show that demand for fruit juice products increases. Thus, its export potential is
huge. In particular, foreign markets, particularly European countries with cold climates or
Asian countries with a tropical climate, prefer tropical fruit juice products. Therefore, the
export of fruit juice has the opportunity to implement and highly competitive in the market.
Since 2013, Europe's fruit juice exports have increased by an annual average of 2%
in both volume and value, reaching € 6 billion, equivalent to 5.7 million tons in 2017.
European countries The highest export growth rate in the last 5 years is Romania (25%
annual growth; especially for non-concentrated orange juice), Cyprus (22%; especially
citrus juice). ) and the UK (16%; especially with a mixture of fruit juices).
Fruit products with the largest export share are concentrated and non-concentrated
orange juice (accounting for 31%), most of which are re-exporting orange juice imported
from Brazil.
In the our country, there have been many enterprises focusing on production with
modern technology investment and high quality products to export to foreign markets.
Viet Nam exports juice to countries like America, Korea, Japan, …Vietnamese drinks
exported to the Korean market have soared 7 times in the last 4 years because many Koreans
like tropical fruit drinks.
2.1.4 Possibility of distribution system
The fruit juice market is growing for several years, and will be continuing to expand,
mainly because these products are aligned with general trends regarding food and beverage
consumption. So, distribution system must have some change to adapt that thing. Juice
distribution from the juice packer to the retailer is becoming increasingly complex. Given
that consumers expect to find their favourite drink when and where they need it, retailers
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have expanded their channels to market. Physical stores come in many formats – forecourt
sales outlets like petrol stations, convenience stores, supermarkets, hypermarkets and
discounters. Every major retailer operates many formats. Digitalization and automation
help to track and trace products to ensure they are available for consumers when and where
they want them.
Figure 9: Distribution system for orange juice
2.2 Possibility of market development in future (Hiếu)
2.2.1 Global market
Global fruit juice market is predicted to continue growing due to the rising in health
awareness among consumers and also the introduction of new products. The global fruit
juice market valued USD 82.4 billion in 2016 and is expected to expand at a compound
annual growth rate (CAGR) of 3.4% over the forecast period 2016 – 2024. Global fruit
juice market is projected to reach USD 110.2 billion by the end of 2024. The US, Germany
and Japan are the top juice consuming countries, consuming a combined 9.9 billion litres
of juice in 2015. In the US, consumers drank more than 6.7 billion litres of 100 percent
juice, just under a third of the worldwide total. Per capita this amounted to 20.9 litres per
person per year, the fourth highest per capita consumption globally after Canada (30.1 litres
per person per year), Norway (25.4 litres) and Germany (21.7 litres).
Among fruits, orange is still the most popular flavour globally accounting for 46% of
total juice sales, followed by apple with 17%, but both are seeing a decline, while the health-
Page | 15
conscious option of mixed vegetable and mixed fruits is seeing a rise in demand. Cranberry
and mango have also seen significant growth, but from a much smaller base. But
outstripping them all in growth is coconut water, which has exploded from a niche to a
fashionable mainstream product in just a few years. In the last year, Americans drank nearly
94 million litres of packaged coconut water, increased by 15% conpared to the previous 12
months.
Figure 10: Proportion of each fruit used in global juice consumption in 2016
2.2.2 Vietnamese market
Vietnam beverage industry is now entering the potential period for developing the
drink consumption due to the rise of economic in general and consumers living – standards
in particular. In 2016, the total drink consumption was over 7.0 billion liters and is expected
to rise to the value of 9.1 billion liters in 2020. Similiar to non – alcoholic drinks industry,
the consumption is predicted to increase from 3.5 to approximately 4.9 billion liters, which
is equivalent to USD 7.3 billion, in 2020 with the very impressing CAGR value of about
6%.
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Figure 11: Non – alcoholic drink consumption in Vietnam from 2015 to 2020
5%
11%
5% 37%
2014
18%
24%
RTD Tea Carbonated Drink Energy Drink Bottled Water Juice Others
Figure 12: Market shares in non – alcoholic drink in Vietnam
The market shares for non – alcoholic drink in Vietnam in two period 2014 and 2017
are shown in Figure 8, overall, there was an increase in proportion of juice as well as botted
water, while that of carbonated and energy drinks were significantly decline during the 3
years period. For more detail, in 2014, the percentage of juice in Vietnam account for
Page | 17
approximately 11%, but this rosed up to 15% in 2017, that means more and more people
interest in using drinks which bring many health benefits to their body.
2.3 Strength of price and distribution system
2.3.1 Material cost
Constructing plant near material place is an big advantage, that decrease transport
charge, decrease manufacturing charge, increasing competitive opportunities in market.
The price of orange when buying at the garden is only 5,000-7,000 VND / kg while the
price of commercial orange is 30,000 - 50,000 VND/ kg, 10 fold higher than when buying
directly. Thus, it can be seen that the construction of factories near raw materials has a huge
price advantage. Great savings in production costs.
The reason was that the fruit, which is the major raw materials for the production for
the juice is not readily available all year making it difficult to source at certain times of the
year. Also the need to test the market acceptance and quantity of the juice products the
market can take is another factor.
2.3.2 Labor cost
Nowaday, due to the strong development of science and technology, many production
facilities have gradually shifted to automate and modernize production facilities so the
number of workers in the juice production industry has also decreased. Salary for ordinary
workers is about 4 million VND / person / month. When the number of employees decrease,
the labor cost in the factory will be reduced, saving part of production costs and the more
chance of competition in the market
2.3.3 Distribution and saling cost
In any business, investing in costs for distribution and sales is a very important job.
Usually, this cost is quite high among indirect costs that businesses need to invest. When
this cost is reduced, improve the competitiveness of businesses in the market. It depends on
the location of the factory, infrastructure and capacity of the plant.
+ Traffic and infrastructure are not developed → Increasing distribution cost
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+ The factory operates with too high capacity → The amounts of products created is
too much, exceeding the market demand → Must make efforts to sell to avoid inventory
→Costs for marketing and saling increase.
2.3.4 Efficiency of process
Traditional methods are still employed in the extraction of juice from fruit. These
involved macerating fruit with hand or peeling, slicing, blending and pressing the fruit.
These methods are not only energy sapping and time consuming, but also yield low quantity
juice and are unhygienic. Thus, traditional method of juice extraction cannot be employed
for small to medium scale production to meet local commercial need. Therefore, in oder
to meet this demand, we need to develop a small to medium size mechanical device that is
capable of extracting juice from a number of tropical fruit crops.
2.4 Threats
2.4.1 Competition from import
Nowadays, there are many kinds of imported fruit juices from different countries in
the world: Europe, Thailand, Korea, Japan, ... with a highly competitive price with the
domestic market.
Table 2: Price of orange juice of some countries
Country Average price for 330ml (VN dong)

Viet Nam 10 000 – 20 000
Korea 20 000 – 30 000
Thailand 15 000 – 30 000
Consumers tend to choose imported products because (Australia, Thailand) tastes
more fragrant and real, the price is only 15-20% higher. Because Vietnamese fruit juices
do not taste good, the natural and often sweet taste loss is difficult to drink
2.4.2 Capacity of competitors
Nowadays, when the market for fruit juices is growing, the fruit drinks are gradually
replacing the kinds of soft drinks with gas, more and more businesses turn to produce these
items, contributing Part of making a diversified market for fruit juice in the country. Besides
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the fruit juice brands of Vietnamese companies such as Vinamilk, Tan Hiep Phat, which
are trusted by many people, the products of international beverage companies like Coca-
Cola and Pepsico also have a large market share. In addition, there are many products of
other domestic brands, though not as well known as the above brands, but their products
also contribute to increase the market share of fruit juices.
Not only do ordinary fruit juices produce, nowadays businesses also produce many
other types of products related to attracting consumers such as: milk juice, fruit juice and
vegetables, ...
Thus, the construction of our factory will face huge competition. We must strive to
work out solutions, improve processes and product quality to stand firm in the market in
the future
2.4.3 Risks of technologies
Fruit processing industry in our country has great potential but processing technology
is limited, not meeting domestic and international demand. The market for fruit juice
products is competed by imported products with modern production technology so the
product quality is higher, attracting consumers' attention.
2.4.4 Risks on quality and consumer belief
Recently, consumers across the country have always nurtured the worries before the
situation that manufactured goods do not guarantee quality, food is dirty in the market.
More than ever, the problem of dirty food and goods of unknown origin, the production
process does not guarantee food safety and hygiene has been emerging many urgent issues.
refreshments, harmful information to the brand always takes place like meals. Even so, if
handled improperly, the consequences will be extremely disastrous.
Tan Hiep Phat is typical of that harm. At the end of 2014, because a fly in a water
bottle, this brand had lost 2,000 billion VND (according to what Tan Hiep Phat
representative announced).
Not only property damage, but also consumer confidence about the product gradually
decreases. This will greatly affect the business situation of any business. –
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–Water is currently obtained from boreholes on the farm. A threat exists that the
quality might not be up to standard for the required use for juice making→ Wastewater
needs to be handled before discharging into the environment
–Raw material constraints. Seasonality of raw material is the main supply constraints
→ Not uniformed product → Quality of produce not being up to standard as required by
buyers → Appearance of rumor→ Loss of consumer belief.
Therefore, in order to minimize to the extent of unnecessary rumors, businesses must
always ensure safe production, ensure HACCP or ISO 22000 and strictly control of
production process.
2.4.5 Capital
In order to conduct a business production cycle, capital is needed. The capital

expenditure refers to the estimated expenditure or costs incurred during the acquisition of
assets needed to establish a juice processing plant, such as cost of renting premises,
repairing premises; equipment and tools, advertising and sales costs, …These assets will
be vital to the operation of the juice processing plant. Therefore, the enterprises need to
have the management and use of capital effectively to preserve and develop capital, to
ensure that businesses are increasingly develop and need calculating carefully, ensure
enough capital to manufacturing.
When the capital source is not enough to produce, production is interrupted leading
to many consequences: no money to pay workers, electricity and water costs and other
services.
2.4.6 In stock
According to the report of the General Department of Statistics, Inventory index of

processing and manufacturing industry as of November 1, 2017 increased by 9.3%
compared to the same period last year (same period in 2016 increased by 8 , 8%) food
processing up 3.9%
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Figure 13: Inventory index of food production and processing 75.2% (08/2017)
The number of inventories is too large while the market demand is not high, leading
to an increase in storage costs, in the long run will lead to a shortage of capital for
production, production disruption, more serious is possible closed factory. There are many
reasons for the juice to be in stock:
⎯ Enterprises do not know the market, production exceeds the demand of consumers
⎯ The distribution and sales are not good
⎯ Do not optimize the required storage level
⎯ The warehouse system has not been well managed.
Summarize, in production and business, the factory needs to minimize inventory in
order to avoid shortage of capital for production, maintain a stable production line.
2.6 SWOT analysis
Strengths
– Abundant material sources in country (approximately 976 thousand tonnes).
– Low labor cost.
– Diversity of retail system.
– Product is rich in nutritional value.
– The product price is more affordable compared to other drinks.
– Large and potential market.
Weaknesses
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– Limitations on capital, science and technology.

– High competition with foreigned company such as Coca Cola, Pepsico,..
– Poor in food safety management
Opportunities
– Vietnam has a young population structure with 62% of population belongs to the
age group of 15 – 45 years old, this group has the greatest demand on soft drink
consumption.
– Vietnam is located in a tropical climate zone, the temperature is predicted to increase
by 1 – 2% in the next 10 years, thus, promote the demand of drinking of people.
– The development of fast food trends also contributes to increased demand in soft
drink industry.
– Growing demand for fresh juices: People become more and more focused on health
fruit juices are growing in popularity.
– Vietnam enters international organizations like WTO, APEC, this will benefit to
Vietnamese exporters, with the gradual removal of market barriers and trade restrictions set
to increase.
– In line with consumer’s rising income, there are opportunities for
premium-branded products.
Threats
– The increase in competitors from foreigned country. –
– Not stable material sources, depend on cultivation.
– The increase in material cost, production fee, tax,..
2.7 Capacity estimation
The juice product is mainly served for consumers at Southern Vietnam including Ho
Chi Minh city, Mekong Delta region..., thus the capacity of factory is designed based on
their consumption demand of product, which is approximately 1.7 – 1.8 million liters per
day. Besides, when estimating the productivity, we also consider to the ability to supply
materials of enterprise. Because the orange material is mainly supplied by local provinces
Page | 23
as we do not import this from foreign supplier, thus the stability or availibity or orange
during season is extremely important for factory.
Another note is that orange is a seasonal fruit which have the harvesting season
normally last from September to March of the next year, so that the production plant must
be carefully calculated to stabilize the output product.
After analyzing 3 factors above, the factory capacity is estimated to produce
approximately 15000 liters of juice, equivalent to 4 500 000 liters per year.
2.8 Product design
2.8.1 Product quality
The product is designed as a nutrious drink for people of all age with high content of
vitamin, mineral, antioxidant compounds and other basic nutrients for body. Most of the
calories in orange juice come from carbohydrate. There is almost no fiber or starch in
orange juice so most of the carbs in juice are provided in the form of sugar. The fat and
protein content in orange is minor, which account for less than 0.1% and 1%, respectively.
Ingredient: Fresh orange juice, water, HFCS (12%), β – carotene (E161), orange odor
(E150), potassium sorbate (E202)
Nutrient value:
Table 3: Nutritional information of 100mL orange juice
Nutrient Value per 100mL Unit

Calories 48 kcal
Total Fat 0.1 g
Trans Fat 0 g
Total Carbohydrates 12 g
Dietary Fiber 0.5 g
Sugars 11.2 g
Protein 0.9 g
Minerals
Calcium, Ca 40 mg
Iron, Fe 0.1 mg
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Magnesium, Mg 10 mg
Phosphorus, P 14 mg
Potassium, K 181 mg
Sodium, Na 1 mg
Vitamins
Vit. A 11 µg
Vit. C 53.2 mg
Vit. E 0.18 mg
Physico – chemical quality of product

Table 4: Physico – chemical quality of product
Criteria Requirement
Dry matter content 12%
pH 5 – 6%
Heavy metal content not larger than
Sn 200 ppm
Pb 0.3 ppm
Zn 5 ppm
Cu 5 ppm
Asen 0.2 ppm
Fe 15 ppm
Total Cu, Fe, Zn content 20 ppm
SO2 10 ppm
Biological quality of product
Table 5: Biological quality of product
Maximum limit
Criteria
(cfu/ 1ml of product)
Total aerobic microorganisms 100
Coliforms 10
Escherichia coli 0
Staphylococcus aureus 0
Streptococci 0
Pseudomonas aeruginosa 0
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Clostridium perfringens 0
Total yeast – mold 10
2.8.2 Product appearance
Package: PET bottles.

Volume: 350mL
Key properties of PET plastic:
― It has higher strength and stiffness than PBT
― It is very strong and lightweight & hence easy and efficient to transport
― It is known for its good gas (oxygen, carbon dioxide) and moisture barrier properties
― It exhibits excellent electrical insulating properties
― PET has broad range of use temperature, from -60 to 130°C
― It has low gas permeability, in particularly with carbon dioxide
― PET is suitable for transparent applications, when quenching during processing
― PET doesn’t not break or fracture. It is practically shatter-resistant and hence, a
suitable glass-replacement in some applications
― It is recyclable and transparent to microwave radiation
― PET is approved as safe for contact with foods and beverages by the FDA, Health
Canada, EFSA & other health agencies
Bottle dimension: Diameter x Height is 75mm x 200mm.
2.9 Factory location
2.9.1 Location criteria
Availability of materials
The factory must be placed close to the raw material supllier in oder to reduce the
transportation cost, especially for sensitive materials like vegetable and fruit. This criteria
is very necessary to ensure the quality and quantity of input orange.
Near to the markets
The fatory is near the maket not only to reduce the transportation costs but also for a
quick product suppliment to the customers. If the plant is located far away from the markets
Page | 26
then the chances of spoiling and breakage become high during transport. If the industry is
nearer to the market then it can grasp the market share by offering quick services.
Availability of labor
Another most important factor which influences the plant location decisions is the
availability of labor. The combination of the adequate number of labor with suitable skills
and reasonable labor wages can highly benefit the factory.
Infrastructure, transportation facilities
The plant location must have high infrastucture and transportation facilities for more
convenients in importing and exporting the materials and products.
Availability of power and water: To ensure the stability in production of plant.
Suitability of climate: Climate is really an influencing factor for the labor efficiency
and productivity of plant. For juice factory, the humid and dry conditions are not
appropriate for plant location.
Government policies: While selecting a location for the plant, it is very important to
know the local existed Government policies such as licensing policies, institutional finance,
Government subsidies, Government benefits associated with establishing a unit in the urban
areas or rural areas.
Table 6: Weight for criterias
Criteria Weight
Material ara 0.4
Near market 0.2
Labor resources 0.2
Transportation 0.1
Water sources 0.1
2.9.2 Location selection
Selection of plant location is identified using scoring methods. The proposed

provinces belong to the Mekong Delta region due to their availability of raw materials.
Table 7: Productivity of citrus fruits in each province (hungred weight/ Ha)
Year 2008 2009 2010
Page | 27
Province
Dong Thap 180 188.3 192
Tien Giang 164 167.8 169.7
Tra Vinh 112.4 90.3 151
Can Tho 111.1 108.8 126.2
Hay Giang 110.4 115 114
Vinh Long 103.0 106.8 160.8
Ben Tre 96.7 95.1 96.2
Soc Trang 95.2 95.4 95.2
Data is collected from Ministry of Agriculture and Rural Development (2010)
Table 8: Labor resources from each province in 2016 (thousand people)
Year
2016
Province
Dong Thap 1112.1
Tien Giang 1101.8
Tra Vinh 615.5
Can Tho 712.9
Hay Giang 471.7
Vinh Long 630.4
Ben Tre 807.3
Soc Trang 712.1
Table 9: Scoring of each criteria
Đồng Tháp Tiền Giang Trà Vinh

Criteria Weight
Point Ex – Point Point Ex – Point Point Ex – Point
Material area 0.4 10 4.0 9 3.6 8 3.2
Near market 0.2 7 1.4 9 1.8 6 1.2
Labor 0.2 9 1.8 9 1.8 6 1.2
Transportation 0.1 7 0.7 8 0.8 7 0.7
Water source 0.1 7 0.7 8 0.8 9 0.9
Total 8.6 8.8 7.2
Tien Giang province information
From the analysis table above, Tien Giang province is chosen as the location to build
the factory. Tien Giang usually places as a top province in the whole country in terms of
Page | 28
fruit cultivation are and fruit yield with the value of over 68 251 ha and 815 360 tons of
fruti per year, respectively. This makes Tien Giang a very potential location for food,
espectially fruit industry. In addition, industry sector also develops at a high and stable rate.
During the period of 2001 – 2006, the average growth rate was 20.66% per year. In 2007,
it was over 45.6% in camparison with 2006, contributing to raising the proportion of
industry and construction sector in the economic structure up to 25%.
Table 10: Industrial production value of Tien Giang province over the years
Industrial production value

Year Average growth rate/year Job creation for
(billon VND)
2010 8 670 19% 68 000 workers
2015 18 209 16% 100 000 workers
2020 36 704 15.05% 127 000 workers
Road: road networks in Tien Giang link with national highways and freeways, which
is very convenient for traveling and transporting goods from Tien Giang to the other
provinces of Mekong Delta and Ho Chi Minh City.
Waterway: the waterway system with a length of over 1,679 km is very convenient.
Large rivers such as Tien River, Vam Co Tay River, Soai Rap River, Cho Gao Canal,
Nguyen Van Tiep Canal, etc. connect provinces of Mekong Delta with Ho Chi Minh City
and are the gateway to East Sea for provinces along Tien River. Particularly, Tien River is
an international connecting route to Cambodia, so Tien Giang has advantages to become a
marine transport center of Mekong Delta to connect it with other localities in the country
and other countries in the region.
Electricity: electricity network has covered the entire province with over 2,405 km of
medium voltage cable and 1906 km of low voltage cable obtaining electricity from the
national electricity network through intermediate transformer stations of 110/22KV and
220/22KV whose total transforming capacity is 552.8 MVA, providing electricity stably
and continuously for the province.
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Water: at the present, there are 8 water supply factories whose total supplying capacity
is 107,200 m3/day. Water is obtained from 13 surface-water treatment stations and 31
underground-water treatment stations.
My Tho industrial park information
Among the industrial parks in Tien Giang province, My Tho is the most appropriate
one for plant location.
– My Tho Industrial Park was established under decision No. 782 / TTG dated
September 20, 1997 of the Prime Minister with an area of 79.14 hectares. My Tho Industrial
Park was built in two communes including Trung An commune (My Tho City) and Binh
Duc commune (Chau Thanh district).
– Investor: Tien Giang Industrial Park Infrastructure Development Company
– Address: Road 4, Trung An industrial cluster, Trung An commune, My Tho city
– Total investment capital: 176 058 billion VND
– Area: 79.14 ha
– Geographical location: located along Tien River and provincial roads 864, with a
length of about 2.4 km, 3 km far from the center of My Tho city to the west, 72 km from
Ho Chi Minh City to the southwest, 4km from the National Highway 1A to the south.
– Number of operating enterprises: 28, including 8 foreign-invested enterprises,
attracting more than 8,000 employees.
– Main fields of production activity: Processing animal feed, processing aquatic and
sea products for export, manufacturing PP packaging, agricultural processing, cold storage
service, manufacturing and trading garment products, producing rice paper, soft drinks,
producing commercial concrete, close the waterway vehicles.
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Chapter 3: Materials Dr. Lai Quoc Dat
CHAPTER 3: MATERIALS
3.1 Orange
Criteria for quality

⎯ The oranges must have reached an appropriate degree of development and ripeness
account being taken of the characteristics of the variety, the time of picking and the
area in which they are grown.
⎯ Fruits with a light green color are allowed, provided it does not exceed one-fifth of
the total surface area of the fruit.
⎯ Average fruit size with a diameter of about 50-70 mm, weight is about 150-200g /
fruit.
⎯ Orange fruit must be intact, no scratches, no worms, no infection on the peel, not
crushed, no stench.
⎯ The ratio of fruits has not met the requirements of color, the size of not more than 5%
of the total volume of raw materials, fruits are crushed, and the depth is not more than
2% of the total volume of raw materials.
⎯ Impurities not exceeding 3% of the total volume of raw materials.
3.2 HFCS 42%
Function
High fructose corn syrup (HFCS) is a liquid alternative sweetener to sucrose that is
made from corn, the “king of crops” using enzymes (α-amylase and glucoamylase) to
hydrolyze corn starch to corn syrup containing mostly glucose and a third enzyme (glucose
isomerase) to isomerize glucose in corn syrup to fructose to yield HFCS products. It is
added into juice to improve taste of product.
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Table 11: Criteria for HFCS
Criteria Value
Physical:
Solids, % 71.0
Moisture, % 29.0
pH 3.5
Ash, Sulfated, % 0.05
Sulfur Dioxide, ppm, max 3
Color, RBU, max 25
Weight/ Volume Factors:
Lbs./Gallon 11.16
Dry Subtances Lbs./Gallon 7.93
Carbohydrate composition (dry basis)
Fructose, % min 42
Monosaccharides, % min 94
Dextrose, % 52
Higher Saccharides, % 6
Biology: microbiological (cfu/10 grams)
Total Plate Count < 200
Yeast < 10
Mold < 10
Salmonella Absent
Listeria Absent
3.3 Water
Function
Water acts as a solvent in the process of washing, boiling raw materials, dissolving
the additives, mixing. Water affect directly to the quality of product.
Water is indispensable in production. Water is used in a wide range of steps (water to
treat material, add to juice, clean the tool and equipment…).
✓ Physical
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Table 12: Physical quality of water in food manufacturing
Criteria Requirement
pH 6.5 - 7
Full hardness Below 15°
Permanent hardness 7°
✓ Chemical
Table 13: Chemical properties of water in food manufacturing
Criteria Content
CaO 50-100mg/l
MgO 50mg/l
Fe2O3 0,3mg/l
MnO 0,2mg/l
2-
SO4 0,5mg/l
BO43- 1,2-2,5mg/l
Amoniac (NH3) Below 5,0 mg/l
Nitrit (-NO2) 0,0
Natri clorua (NaCl) 70,0 – 100,0 mg/l
Lead (Pb) Below 0,1 mg/l
Copper (Cu) 3,0 mg/l
Zinc (Zn) 5,0 mg/l
Iron (Fe) 0,3 – 0,5 mg/l
Asen (As) Below 0,05 mg/l
Flo (F) 0,7 mg/l
Iot (I) 5,0 – 7,0 ɣ/l
Crom 0.05mg/l
Mercury <0.001mg/l
Cyanogens < 0.05mg/l
Clo < 10mg/l
Organic compound 0,5 – 2,0 mg/l
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✓ Biological
Table 14: Biological quality of water in food manufacturing
Microorganisms Number
Aerobic microorganism in 1 ml of water Below 100 cfu
E. Coli in 1 liter of water Below 2 cfu
Bacteria that cause dysentery or typhoid 0
Eggs of helminths 0 (egg)
3.4 Enzyme Pectinase
Function
Pectinase is an enzyme that breaks down pectin, a polysaccharide found in plant cell
walls. Commonly referred to as pectic enzymes, they include pectolyase, pectozyme, and
polygalacturonase, one of the most studied and widely used (citation needed) commercial
pectinases. It is useful because pectin is the jelly-like matrix which helps cement plant cells
together and in which other cell wall components, such as cellulose fibrils, are embedded.
Therefore, pectinase enzymes are commonly used in processes involving the
degradation of plant materials, such as speeding up the extraction of fruit juice from fruit.
Table 15: Criteria for Pectinase quality
Criteria Level
Concentration pectinase 0.1% to 0.5%
Concentration cellulase in pectinase 0.5% to 1.5%
Optimal Temperature incubated enzyme 30°C to 45°C
Optimal Time incubated enzyme 1-6 hours
Optimal pH 4-5
Enzyme activity 10,291 PGU/ml
Solubility Good
Page | 34
3.5 Potassium sorbate
Potassium sorbate is the potassium salt of sorbic acid, chemical formula

CH3CH=CH−CH=CH−CO2K. It is a white salt that is very soluble in water.
It is primarily used as a food preservative due to its inhibition to yeast, mold and some
aerobic bacteria. The antimicrobial activity of potassium sorbate is related to pH. This
compound is more active at low pH values of foods but essentially ineffective at neutral
values.
Potassium sorbate is permissible in foods at levels not to exceed 0.2%. The respective
acceptable daily intakes (ADI) is: 25 mg/ kg by weight per day. The acute toxicity of sorbate
is rare, however, in some cases, it is reported as a reason for urticaria and contact dermatitis.
Table 16: Chemical criteria for sorbates
Potassium sorbate (INS 202)

Water content ≤ 1%
Sulfate ash -
Alderhyde (calculated according to formaldehyde) ≤ 0.1%
Florid -
Lead (Pb) ≤ 2mg/kg
Content in anhydrous product ≥ 98%
3.6 Beta – carotence
Function
Color is one of the most important elements of food quality. Colors are often added
to create color specific products, improve sensory quality of product as color compounds
are lost during processing at high temperature.
Standard of selection
Based on TCVN 9957:2013
Apparently: Crystalline or crystalline red to reddish brown, sensitive to oxygen and light.
Solubility: Insoluble in water, practically insoluble in ethanol, soluble in vegetable oils.
Page | 35
Table 17: Criteria select β- carotene
Physico-chemical criteria Required value

Total carotenoid color content, % mass, not less 96
The secondary color content of the carotenoid except-carotene, % mass of the 3
total color substance, not greater than
Content of ash sulfate, % mass, not greater 0.1
Lead content, mg / kg, is not greater 2
3.7 Odor, β-Naphtylmetylxeton
Function
During processing, because we perform high temperature, so some volatile
compounds include flavor compounds can be lost, quality of product will be reduced.
Therefore, we add it into the juice to improve flavor of product.
Figure 14: Structure of β – naphthyl methyl ketone
Page | 36
Chapter 4: Juice process design Dr. Lai Quoc Dat
CHAPTER 4: JUICE PROCESS DESIGN
Figure 15: Orange juice production line
4.1 Sorting
Technological purpose: Preparation for washing sector.

This step is operated to ensure the quality of raw materials by removing the damaged
fruit or cutting/trimming parts of the fruit which are partially damaged. Avoiding
substances that are produced from the damage that occurs in the worms affect other fruits
and affect sensory quality of the product.
Transformation of material
Page | 37
Physical: Size: Standardize raw materials, ensuring the material to achieve size
uniformity. Mechanical damage can occur on the surface of fruit when traveling on a
conveyor but not significantly.
Equipment: In this step, manual method with the support of conveyor is selected.
Description: The conveyor belts are made of plastic modules, assembled in an
interlocking pattern. Combined with full-length hinge rods, this creates an inherently strong
design.
Principle of operation: The fruit are put on conveyors. Workers stand along the
conveyor to remove unripe or damaged fruit. The speed of conveyor belt movement is slow
enough for workers to trim the fruit directly. The width is about 0.6 to 0.8 m for the workers
to reach the central position of conveyor.
Technological parameters:
― Speed of conveyor: 0.02 m/s.
― Conveyor width: 0.8m.
4.2 Washing
Technological purpose: Preparation for the extraction operation.

This step is operated to remove sandy soils, dirt, microorganisms from the peel.
Remove some toxic chemicals used in agricultural techniques, such as pesticides or plant
protection drugs residue, toxic compounds from the metabolism of microorganisms.
Physical: It may cause some mechanical damage to the fruit surface during washing.
However, the damage is not really serious.
Chemical: Loss of some water-soluble vitamins during washing.
Biological: The material is cleaned and the quantity of microorganisms on the surface
are
reduced.
Equipment: Bubble washing machine with conveyor belt is selected.
Page | 38
Description: The machine consists of a stainless steel conveyor and a large volume
washing tank. The conveyor is divided into three sections, the horizontal part submerged in
water, the sloping section with strong water sprinklers and a horizontal section on the high
side. Underneath the conveyor belt, the inlet portion is equipped with bubble device,
improve soaking and washing effect.
Principle of operation: The washing step includes two periods: soaking and washing.
During the soaking period, the material on the horizontal section is submerged in water, the
dirt on the peel of the fruit is softened and move away. The effect of immersion process is
enhanced by blown air, thus increasing the contact area of the fruit and water, so that the
immersion time is shortened. The conveyor belt will carry fruit to the sloping section. High
pressure water from the sprinklers system will completely remove all the dirt. At the end of
the washing process, the fruit is transfer to the upper part. Depending on the dirt, it is
possible to adjust the conveyor belt speed. If the material is too dirty, the conveyor belt will
slow down, increasing the washing time. If the dirt is less, the conveyor belt may go faster
to increase the productivity.
― Conveyor belt speed: 0.14 - 0.15 m/s.
― Water pressure of sprinklers: 2 - 3 atm.
― The amount of water needed to wash: 0.7 to 1 liter/ kg of material.
― Water temperature: 25 °C.
Figure 16: Diagram of bubble washing machine with conveyor belt (1-Inlet; 2-Conveyor; 3-
Bubble-blowing device; 4-High pressure water sprinklers)
4.3 Extraction
Technological purpose
Page | 39
Preparation: Reduce the size of material for better enzyme treatment efficiency.
Exploitation: Eliminate almost the pulp and seed out of material, only collect the juice.
Physical: Size is reduced to about 0.03 – 0.05 mm. The temperature of materials may
increase slightly due to friction. A slight drop in mass of material can be observed due to
some
parts that are traped inside equipment.
Equipment: The The Squeezer-Type Extractor is selected.
Description: Figure 12 shows a squeezer-type extractor. This equipment is placed
after the washsing machine and can ben equiped with up to five heads, which are available
in different sizes so that they can handle the type and quality of fruit availabe. Typical sizes
are 2, 3, 4, and even 5 inches. The head size for each extractor in a line is chosen to optimize
the handling of sized fruit. The extractor separates the fruit into four parts – pulpy juice,
peel, core (rag, seeds and pulp) and oil emulsion.
The head of an extractor comprises an upper and a lower cup (see Figure 13). The
cups have metal fingers that mesh together as the upper cup is lowered onto the lower cup.
A cutter comes up through the centre of the lower cup to cut a hole through the skin in order
to allow the inner parts of the orange to flow out.
Principle of operation: Once the strainer tube has cut into the fruit, the upper cup
squeezes down on the lower cup. This pressure initially forces the juice to burst out of
the juice vesicles and pass through the perforations of the strainer tube. Remnants of the
ruptured juice sacs will pass through with the juice as pulp. The upper cup continues to
squeeze down on the lower cup to extract as much juice as possible.
Eventually, the downward pressure causes the peel to break up, disintegrate and pass
up through the fingers of each cup. Juice flows through the strainer tube into the juice
manifold. The core material is discharged from the bottom of the strainer tube through the
orifice tube.
― Pressure: 1.3 atm.
Page | 40
― Mesh size of filter screen: 0.5 mm.
Figure 17: A squeezer-type orange juice extractor
Figure 18: Operation of squeezer-type orange juice extractor
4.4 Enzyme treatment
Page | 41
Improvement: The enzyme pectinase will break down the pectin structure, therefore,
prevent the jelly – like matrix formation of pectin in the juice during the heating operation.
As a result, the transparency of final product will be improved.
Biochemical: Pectin degradation due to the catalysis of pectinase.
c) Equipment: The mixing tank is selected.
Description: The tank is made of stainless steel. It composes of pot body and foot.
The pot body is a double-layer structure formed by the inner and outer spheres, and the
space between 2 layers is fill with heating agent (hot water). The stirrer axis is connected
to engine system and another end is connected with ball bearings to avoid shaking due to
high velocity. The products are collected through the ouput at the bottom of quipment.
Principle of operation: Firstly, the juice is pumped into the equipment to certain level.
Hot water is supplied into the jacket and start to heat the juice to 40 – 45oC. During heating,
pectinase is added until achieve the required dosage. To improve the efficiency of the
enzyme catalysis, the mixer is stired during the operation.
― Temperature: 40 – 45oC.
― Time: 60 minutes.
― The amount of enzyme added: 0.1% of juice volume
Figure 19: Layout of the mixing tank
4.5 Filtration
Page | 42
Improvement: Remove the remaining pulp that still contain in the juice, thus, improve
the transparency of product.
Transformation of material: There is no significant change, only impurities are
trapped on the filter surface.
c) Equipment: The plate and frame filter press is selected.
Description: The equipment consists of two main parts: frame and plate. The frame
keeps the residue and this also is the place where suspension is pumped into. The plate has
the trench to guide the material and it creates a filtration surface.
Principle of operation: When pressing frames and plates together, the holes of the
four corners form the path for suspension come in and the liquid outlet. Suspension is
pumped in the equipment and distributed into frames. Solid phase is kept in frames by the
partition. Liquid phase go through the frames and go along the trench of the plate to the
outlet.
― Material flow rate: 2400kg/h
― Filter area: 20m2
― Number of plates: 15
― Filtration pressure: 0.6 MPa
4.6 Mixing
Processing: Mixing the ingredients together to get the final product which has the
required chemical composition, flavor and color. Besides, mixing is a way to make the
mixture become uniform.
Transformation of material:
Chemical: Loss of vitamin C due to high temperature.
Physico – chemical: Disolve of all components into water, thus, increase the dry
content of product as well as viscosity.
Page | 43
Equipment: The mixing tank is selected.

Principle of operation: Firstly, the juice is pumped into the equipment to certain level.
Hot water is supplied into the jacket and start to heat the juice to 60 – 70oC. During heating,
syrup and other additives are inturn added to the tank. To improve the efficiency of mixing,
the mixer is stired during the operation.
― Velocity of stirrer: 30 – 50 rpm.
― Temperature: 60 – 70oC.
― Time: 30 minutes.
4.7 Concentration
Preservation: high sugar content increases the osmotic pressure effecting on
microoganism
cell wall, thus, reduce the spoilage ability of products caused by microoganisms.
Physical: reduces weight due to water evaporation.
Chemical: Maillard reaction may occur lead to the transformation in the product color
(darker). In addition some coloured and flavored compounds can be decomposed.
Biological: Microorganisms are inhibited by heat and high levels of dry matter.
Bio – chemical: Biochemical reactions are completely suspended.
Equipment: The falling film evaporator is selected.
Description: In juice processing, falling film evaporator is a widely applicable in
concentrated operation. Continuous low-temp evaporation under vacuum to ensure saves
energy and time with low loss and convenient to keep product color, taste and nutrition.
Principle of operation: The liquid to be concentrated is supplied to the top of the
heating tubes and distributed in such a way as to flow down the inside of the tube walls as
a thin film. Heating agent (steam) is add from above. Steam condenses on the outside of
the tubes supplying the required energy to the inside of the tubes. The liquid film starts to
Page | 44
boil due to the external heating and is partially evaporated as a result so that the product
become more and more concentrated. The evaporators are designed such that a given flow
of material can be concentrated to needed solids concentration by the time the stream exits
the evaporator.
The ouput include the concentrated product and the two-phase product (liquid +
vapor). This stream is usually run through a vapor-liquid separator after exiting the
evaporator. This separator allows the vapors to be drawn off the top and the concentrated
liquid to exit the bottom. The second steam is going to reused as a heating agent for the
next equipments for saving energy Most falling film evaporators are run under vacuum
conditions on the process side.
― Temperature: 80oC.
― Pressure: 0.4 atm
Figure 20: Diagram of falling film evaporator

A = Product, B = Concentrate, C = Condensate, D = Heating steam, E = vapor, 1 = Head,
2 = Calandria, 3 = Separator, 4 = Separator duct, 5 = Calandria base
Page | 45
4.8 Pasteurization
Preservation: The pasteurization will inactivate the enzymes and inhibit almost
pathogenic or spoilage microoganisms that still remain in the product due to the high
temperature, therefore, the juice shelf life can be gradually extened.
Physical: Increase in temperature of the products.
Chemical: Maillard reaction may occur lead to the transformation in colour of the
product. In addition, some colouring and flavouring compounds can be degraded due to
high temperature.
Biological: Almost microoganisms are inhibited.
Bio – chemical: Enzymes are inactivated/
Equipment: Plate heat exchanger is selected.
Description: The equipment include series of thin plates that are press-formed with a
corrugated pattern on the surface and sealed with synthetic rubber gaskets. These gaskets
help to seals the flow channel and directs the fluid into alternate channels.
Principle: The steam or vapour enters through one of the upper connections and the
condensate leaves through the connection underneath. The liquid enters through one of the
lower connections and leaves through the connection above. As the fluids pass through the
heat exchanger, heat is transferred from the steam to the media. Specially designed sealing
gaskets located between the plates direct the fluids so that the hot and cold fluids pass
counter-currently in alternating channels. When the fluid enters between the plates, it passes
over the distribution area. This area ensures an even flow of fluid over the entire plate and
maximize the heat transfer efficiency. After heating, liquid-vapor mixture is discharged at
the exit and then enters the cylindrical vessel, it is separated in the vessel to obtain
concentrated liquid and secondary steam. The secondary steam is the recycle to the system
for energy saving.
― Temperature parameters: 95oC
Page | 46
Figure 21: Plate heat exchanger
4.9 Packaging
Preservation: Avoiding microbial infection by high temperature, creating a vacuum
environment in the package, reducing the amount of air remaining in the space of the
package.
Improvement: Increasing the commercial value of the product.
Transformation of material: There is no significant change
Equipment
Principle of operation: Containers moving on conveyor, feed below the filling nozzles
through a settable twin pneumatically operated valve system. The twin pneumatically
operated stopper system and can precisely match for centering of container below nozzles,
to avoid spillage of juice on container. The filling machine is further attached to a capping
machine which is to be operated by an operator who would carry the bottle from the filling
section
4.10 Labeling
Page | 47
Improvement: Increasing the commercial value of the product.
Transformation of material: There is no significant change during the drying.
Equipment: Bottle labeling machine is selected.
Figure 22: Labeling machine
Page | 48
Chapter 5: Mass Balance & Energy Balance Dr. Lai Quoc Dat
CHAPTER 5: MASS BALANCE & ENERGY BALANCE
5.1 Mass balance
The orange fruit harvest season in Vietnam starts form September to Match of the
next year, therefore, to ensure the stabilize the quantity of output products throught out the
year, the factory need to produce both juice (not from concentrate – NFC) and concentrated
juice. The juice that is not from concentrate will be supplied to the market by distribution
system while the other will be stored in warehouse due to its high resistance to microbes
contamination. The storage time can last from 6 to 12 months, even several years it is
preserved in the ideal conditions (frozen temperature). When the input material (orange) is
not enough for the production, the concentrate is rehydrated and mixed with appropriate
amount of additives, syrup and performed the pasteurization and packaging as in NFC juice
production line.
The estimated productivity of factory is about 48 tons of main material per day. Half
of it is used for NFC juice production, the other goes into the concentration operation.
Calculated for 1000kg of orange fruits.
A whole fruit consists of skin, pulp, seed, juice with the proportion of each is about
25 : 5 : 4 : 66, respectively. Theoreically, 1000 kg of material will produce 660 kg of pure
juice, however, loss in quantity of material can be observed for each operation which results
in the reduction of expected amount of juice. The estimated loss of each operation is shown
in the Table below:
Table 18: Loss of each operation
Operation Loss based on material (w/w)

Classification 4%
Washing 0.1%
Extracting 1.0%
Enzyme Treament 0.05%
Filtration 1.0%
Mixing 1 0.1%
Concentration 0.5%
Page | 49
Mixing 2 0.5%
Pasteurization 0.5%
Packaging 0.5%
Labelling 0%
5.1.1 Sorting
Gloss1 = 4% Gin1
Raw Orange Standard Orange

SORTING
Gin1 = 1000kg Gout1 = ? kg
Mass balance for classification operation:

mraw orange = mstandard orange + mloss1
 Gin1 = Gout1 + Gloss1
 Gout1 = Gin1 – 4%Gin1
 Gout1 = 1000 – 4% x 1000
 Gout1 = 960 kg
5.1.2 Washing
Gloss2 = 0.1% Gin2
Orange Clean Orange

WASHING
Gin2 = 960 kg Gout2 = ? kg
Mass balance for washing operation:
morange = mclean orange + mloss2
 Gout2 = Gin2 – 0.1%Gin2
 Gout2 = 960 – 0.1% x 960
 Gout2 = 959.04 kg
Page | 50
5.1.3 Extracting
As mentioned above, the proportion of peel, pulp and seed in orange is about 25%,
5% and 4% by weight, respectively.
Calculating the mass of pulp and seed:
After washing mpulp = 5%Gout2 = 5% x 959.04 = 47.95 kg.
mpeel = 25%Gout2 = 25% x 959.04 = 239.76 kg
mseed = 4%Gout2 = 4% x 959.04 = 38.36 kg.
Total solid content in the input material of this operation:
mpulp +mpeel +mseed 47.95+239.76+38.36
%solid = = × 100% = 34%
Gin3 959.04
Residue: Gresidue =?
%solid = 80% Gresidue
Gloss4 = 1% Gin4
Cleaned Orange Juice
EXTRACTING
Gin3 = 959.04 kg Gout3 = ? kg
%solid = 34% Gin3 %solid = 0.5% Gout3
Mass balance for extracting operation:
mcleaned orange = m juice + mresidue + mloss3
 Gin3 = Gout3 + Gresidue + Gloss3
 Gout3 + Gresidue = Gin3 – 1%Gin3
 Gout3 + Gresidue = 959.04 – 1% x 959.04
 Gout3+ Gresidue = 949.45 kg.
Mass balance for solid content in extracting operation:
msolid input = msolid output + msolid residue + msolid losss
 34%Gin3 = 0.5%Gout3 + 80%Gresidue + Gsolid loss
 0.5%Gout3 + 80%Gresidue = 34%Gin3 – 1% x 34%Gin3
 0.5%Gout3 +80%Gresidue = 34% x (959.04 – 1% x 959.04)
 0.5%Gout3 + 80%Gresidue = 322.81kg.
Solve two equations above, we have:
Page | 51
Gout3 = 549.37 kg
Gresidue = 457.58 kg
5.1.4 Enzyme treatment
Gloss4 = 0.05% (Gin4+ Genzyme)
Juice Enzyme Treated Juice

ENZYME TREATMENT
Gin4 = 549.37 kg Gout4 = ? kg
Enzyme Pectinase
Genzyme = 0.1%Gin4
Mass balance for enzyme treatment operation:
msuspended juice + menzyme= menzyme treated juice + mloss4
 Gin4 +Genzyme = Gout4 + Gloss4
 Gout4 = Gin4+ 0.1%Gin4 – 0.05%(Gin4 + 0.1%Gin4)
 Gout4 = 549.37 + 0.1% x 549.37 – 0.05% x (549.37 + 0.1% x 549.37)
 Gout4 = 549.64 kg
5.1.5 Filtration
The total solid content of juice after treating with enzyme:

0.5%Gout3 0.5% ×501.04
%solid = = = 0.5%
Gout4 501.31
Residue: Gresidue = ?kg

%solid = 90% Gresidue
Gloss5 = 1% Gin5
Juice Clear Juice
Gin5 = 549.64 kg FILTRATION Gout5 = ? kg

%solid = 0.5% Gin5 %solid = 0.05% Gout5
Page | 52
Mass balance for filtration operation:

mjuice = mclear juice + mresidue + mloss5
 Gin5 = Gout5 + Gresidue + Gloss5
 Gout5 + Gresidue = Gin5 – 1%Gin5
 Gout5 + Gresidue = 549.64 – 1% x 549.64
 Gout6 + Gresidue = 544.14 kg.
Mass balance for solid content in filtration operation:
msolid input = msolid output + msolid residue + msolid losss
 0.5%Gin5 = 0.05%Gout5 + 90%Gresidue + Gsolidloss
 0.05%Gout5 + 90%Gresidue = 0.5%Gin5 – 1% x 0.5%Gin5
 0.1%Gout5 + 90%Gresidue = 0.5% x (549.64– 1% x 549.64)
 0.1%Gout5 + 90%Gresidue = 2.72 kg.
Solve two equations above, we have:
Gout5 = 541.72kg
Gresidue = 2.42 kg
5.1.6 Mixing 1
Gloss7 = 0.1% (Gin7 + GHFCS + GvitaminC + Gpotassium

sorbate + Gβ – carotene + Godor)
Clear Juice Mixture
Gout6 = ? kg
Gin6 = 270.86 kg Mixing 1
Soluble dry matter
Soluble dry matter
= 12% w/w
= 8% w/w
GHFCS 42% = ? kg
Gvitamin C = 0.2%Gout7
Gpotassium sorbate = 0.1%Gout7
Gβ – carotene = Godor = 0.01%Gout7
Mass balance for whole mixing 1 operation:
mclear juice + mvitamin C + mpotassium sorbate + mHFCS + mβ – carotene + Godor= mmixture + mloss
 Gin6 + Gvitamin C + Gpotassium sorbate + GHFCS + Gβ – carotene + Godor = Gout6 + Gloss6
Page | 53
 Gout6 – GHFCS – Gvitamin C – Gpotassium sorbate – G β – carotene - Godor = Gin6 – Gloss6

 Gout6 – GHFCS – Gvitamin C – Gpotassium sorbate – G β – carotene - Godor = Gin6 – 0.1% (Gin6 + GHFCS
+ GvitaminC + Gpotassium sorbate + Gβ – carotene+ Godor)
 99.68%Gout6 – 99.9%GHFCS = 270.59
Mass balance for soluble dry matter content of mixing 1 operation:
8%mclear juice + 42%mHFCS = 12%mmixture + mloss
 8%Gin6 + 42%GHFCS = 12%Gout6 + 0.1%(8%Gin7 + 42%GHFCS)
 12% Gout6 – 41.79%GHFCS = 8%Gin6 – 0.1% x 8%Gin6
 12% Gout6 – 41.79%GHFCS = 21.65
Solving a system of equations above
99.68%Gout6 − 99.9%GHFCS = 270.59
{
12%Gout6 − 41.79%GHFCS = 21.65
Gout7 = 308.25 kg
⇒{
GHFCS = 36.71 kg
5.1.7 Concentration
Vapor: G vapor=? kg
Gloss7 = 0.5% Gin7
Condensate
Clear Juice Concentrated Juice
Gin7 = 270.86 kg CONCENTRATION Gout7 = ? kg

Soluble dry matter = 8% w/w Soluble dry matter = 55% w/w
Steam
Mass balance for soluble dry matter content of concentration operation:
8%mclear juice = 55%mconcentrated juice + mloss
 8%Gin7 = 55%Gout7 + 0.5% x 8%Gin7
 55%Gout7 = (8%Gin7 – 0.5% x 8%Gin7)
Page | 54
 Gout7 =39.2 kg
Mass balance for whole concentration operation:
mclear juice = mconcentrated juice + mvapor + mloss
 Gin7 = Gout7 + Gvapor+ Gloss7
 Gvapor = Gin7 – Gloss8 – Gout7
 Gvapor = Gin7 – 0.5%Gin7 – Gout7
 Gvapor = 230.31 kg
5.1.8 Mixing 2
Gloss8 = 0.5% (Gin9 + GHFCS + GvitaminC + Gpotassium

sorbate + Godor+ Gβ – carotene + Gwater)
Concentrated Juice Mixture
Gin8 = 39.2 kg Mixing 2 Gout8 = 308.25 kg

Soluble dry matter = Soluble dry matter
55% w/w = 12% w/w
GHFCS 42% = ? kg
Gvitamin C = 0.2%Gout8
Gpotassium sorbate = 0.1%Gout8
Gβ – carotene = Godor= 0.01%Gout8
Gwater =? kg
Mass balance for soluble dry matter content of mixing 1 operation:
55%mclear juice + 42%mHFCS = 12%mmixture + mloss
 55%Gin8 + 42%GHFCS = 12%Gout8 + 0.5%(55%Gin8 + 42%GHFCS)
 41.79% GHFCS = 15.53
 GHFCS = 37.18 kg
We have
Gvitamin C = 0.2%Gout8 =0.2% x 308.25 = 0.62kg
Gpotassium sorbate = 0.1%Gout8 =0.1% x 308.25 = 0.31 kg
Gβ – carotene = Godor =0.01%Gout8 =0.01% x 308.25= 0.031 kg
Page | 55
Gloss8 = 0.5% (Gin8 + GHFCS + GvitaminC + Gpotassium sorbate + Gβ – carotene + Godor +Gwater)
= 0.5%GHFCS + 0.5%Gwater + 0.5% x ( 37.18 + 0.62 + 0.31 + 0.031x2)
= 0.5%GHFCS + 0.5%Gwater + 0.19
Mass balance for whole mixing 2 operation:
mconcentrated juice + mvitamin C + mpotassium sorbate + mHFCS + mβ – carotene + modor +mwater = mmixture + mloss
 Gin8 + Gvitamin C + Gpotassium sorbate + GHFCS + Gβ – carotene + Godor + Gwater = Gout8 + Gloss8
 Gwater = Gout8 + Gloss8 – Gin8 – GvitaminC – Gpotassium sorbate – Gβ – carotene – Godor - GHFCS
 Gwater = 308.25 +0.5% x 37.18 + 0.5%Gwater + 0.19– 37.18– 0.62 – 0.31 – 0.031x2
 Gwater = 271.81 kg
5.1.9 Pasteurization
Gloss9 = 0.5% Gin9
Juice Pasteurized Juice

PASTEURIZATION
Gin9 = 308.25kg Gout9 = ? kg
Steam
Mass balance for pasteurization operation:
mjuice = mpasteurized juice + mloss
 Gout9 = Gin9 – 0.5%Gin9
 Gout9 = 308.25 – 0.5% x 308.25
 Gout9 = 306.71 kg
5.1.10 Packaging
Gloss10 = 0.5% Gin11
Pasteurized Juice Bottled Juice

PACKAGING
Gin10 = 306.71 kg Gout10 = ? kg
Mass balance for pasteurization operation:

mpasteurized juice = mbottled juice + mloss
Page | 56
 Gout10 = Gin10 – 0.5%Gin10

 Gout10 = 306.71 – 0.5% x 306.71
 Gout10 = 305.18 kg.
Density of orange juice after mixing with syrup and other additives: ρorange= 1.08 kg/L
m 305.18
The volume of juice: V = = = 282.57 L
ρorange 1.08
Table 19: Summary of mass balance of each operation
Operation Unit Input Output

Classification Kg 1000 960
Washing Kg 960 959.04
Extracting Kg 959.04 549.37
Enzyme Treament Kg 549.37 549.64
Filtration Kg 549.64 541.72
Mixing 1 Kg 270.86 308.25
Concentration Kg 270.86 39.2
Mixing 2 Kg 39.2 308.25
Pasteurization Kg 308.25 306.71
Packaging Kg 306.71 305.18
― Capacity of plant: tons of orange fruit / hour from September to Match of the next
year. The other months of the year, we produce orange juice orginated from
concentrated juice.
― The workers work for 16 hours a day, 6 days per week.
― For each month, we spend 1 day – off for equipment maintenance => The working
day of factory is about 300 days per year.
― Volume of bottle: 350 mL
282.57 ×103 ×3×16
→ A amount of bottle needed for 1 day is: 350
= 38752,46 ≈ 𝟑𝟖𝟕𝟓𝟑 𝐛𝐨𝐭𝐭𝐥𝐞𝐬
Page | 57
Table 20: Summary of material quantity for production
Materials Unit Day Week Month Year

Orange Kg 48 000 288 000 1 152 000 14 400 000
Enzyme Pectinase Kg 26.37 158.22 632.88 7 911
HFCS Kg 1 762.08 10 572.48 42 289.92 528 624
Vitamin C Kg 29.76 178.56 714.24 8 928
Potassium Sorbate Kg 14.88 89.28 357 120 4 464
β- carotene Kg 1.488 8.928 35 712 446.4
Odor Kg 1.488 8.928 35 712 446.4
Water Kg 13 046.88 78 281.28 313 125.12 1 957 032
Plastic Bottle Bottle 38 753 232 518 930 072 11 25 900
― A amount of concentrated orange juice produced per day: 39.2 × 3 × 16 = 1881.6 kg

― The total amount of storage concentrated juice for 6 months is:
1881.6 × 6 × 4 × 6 = 270 950.4 kg
5.2 Energy balance
Calculated for 1 hour

∆H’F: Enthalpy of feed, kJ/kg
∆H’P: Enthalpy of concentrated juice, kJ/kg
∆H’S: Enthalpy of saturated steam at temperature Ts, kJ/kg
∆H’V: Enthalpy of vapour at temperature T1, kJ/kg
∆H’C: Enthalpy of condensate, kJ/kg
5.2.1 Enzyme Treatment
a) Heating juice
Condensate TC = 120oC
∆H’c = 504.1 kJ/kg
Clear Juice Warm juice

Heating juice
Gin = 1648.11 kg T= 40oC Gout=1648.11 kg
Tin = 25oC Tout= 40oC
Steam TS = 120oC
∆H’s = 2711 kJ/kg.
G steam =?
Page | 58
The compositions of input and output juice are 92% water and 8% soluble compounds.
Specific heat capacity: Cp = 3349 x 0.92 + 837.36 = 3.918 kJ/Kg.K.
Assume loss by heat in this operation is 1 %
Energy balance for heating juice
Qin = Qout + Qloss
 Qin = Qout + 1%Qin
 99%Qin = Qout
 99% G steam. (∆H’s – ∆H’c) = Gin . Cp. (Tout - Tin)
 99% x G steam × (2711 – 504.1) = 1648.11 × 3.918 × (40 – 25))
 S = 44.3 kg.
b) Enzyme
Condensate Tc = 120oC
∆H’c = 504.1 kJ/kg
Juice Enzyme treated juice

ENZYME TREATMENT
Gin = 549.37 x 3=1648.11kg T= 40oC Gout = 1648.92 kg
Tin= 40oC Tout= 40oC
Steam Ts = 120oC
∆H’s = 2711 kJ/kg
G steam =? Kg
Enzyme Pectinase = 1.648 kg
Assume that the energy for heating the mixture after adding enzyme added to 40 oC
equals to 10% of total energy for heating juice.
Energy balance for heating additives
Qmixing = 10% Qheating juice
 Gsteam mixing . (∆H’S – ∆H’c) = 10% (Gsteam heating juice) . (∆H’S – ∆H’c)
 Gsteam mixing = 10% x (44.3)
 Gsteam mixing = 4.433kg.
Assume that loss of this operation is 1% based on the amount of steam.
 Gsteam mixing = 4.433 x 1.01 = 4.48 kg.
Page | 59
5.2.2 Mixing 1
a) Heating juice
∆H’c = 504.1 kJ/kg
Clear Juice Hot juice

Heating juice
Gin = 812.58 kg T= 60oC Gout=812.58 kg
Steam TS = 120oC
∆H’s = 2711 kJ/kg.
G steam =?
The compositions of input and output juice are 92% water and 8% soluble compounds.
Specific heat capacity: Cp = 3349 x 0.92 + 837.36 = 3.918 kJ/Kg.K.
Energy balance for heating juice
Qin = Qout + Qloss
 99%Qin = Qout
 99% G steam. (∆H’s – ∆H’c) = Gin . Cp. (Tout - Tin)
 99% x G steam × (2711 – 504.1) = 812.58 × 3.918 × (60 – 25))
 S = 51 kg.
b) Heating HFCS
∆H’c = 504.1 kJ/kg
HFCS 42% Hot juice

Heating HFCS
Gin = 36.71 x 3 = 110.13 kg T= 60oC Gout=110.13 kg
Steam TS = 120oC
∆H’s = 2711 kJ/kg.
G steam =?
Specific heat capacity of HFCS 42%
― At 25oC: Cpin = 3.21 kJ/Kg.K.
Page | 60
― At 60oC: Cpout = 3.32 kJ/Kg.K.

Energy balance for heating HFCS
Qin = Qout + Qloss
 99%Qin = Qout
 99% (Gin . Cpin . (Tin – 0) + S.∆H’S) = Gout . Cpout . (Tout – 0) + Gsteam . ∆H’c
 99% x (110.3 x 3.21 x 25 + S x 2711) = 110.13 x 3.32 x 60 + S x 504.1
 S = 6.044 kg.
c) Mixing 1
∆H’c = 504.1 kJ/kg
Clear Juice Mixture

Mixing 1
Gin = 812.58 kg T= 60oC Gout = 924.75 kg
Steam TS = 120oC
∆H’s = 2711 kJ/kg.
G steam =?
GHFCS 42% = 110.13 kg
T in= 60oC
G vitamin C = 1.86kg
Gpotassium sorbate = 0.93kg
Gβ – carotene = 0.093 kg
Godor = 0.093 kg
Assume that the energy for heating the mixture after adding additives to 60oC equals
to 10% of total energy for heating juice and HFCS.
Qmixing = 10% (Qheating juice + Q heating HFCS)
 Gsteam mixing . (∆H’S – ∆H’c) = 10% (Gsteam heating juice + Gsteam heating HFCS) . (∆H’S – ∆H’c)
 Gsteam mixing = 10% x (51 + 6.044)
 Gsteam mixing = 5.7044 kg.
Page | 61

5.2.3 Concentration
Vapor: G vapor = 690.93 kg
Condensate: Gcondensate = Gsteam;
TC= 120oC
Clear Juice Concentrated Juice
Gin = 812.58 kg CONCENTRATION Gout = 117.6 kg

T= 40oC T = 80oC T = 80oC
Soluble dry matter = 8% Soluble dry matter = 55%
w/w w/w
Steam, TS = 120oC; Gsteam = ? kg
Assume that the concentration takes place at 80oC (T1 = 80oC) under vacuum in the
evaporator.
― Loss in this operation: 1% based on feed
Look up the table of physical properties of saturated steam, we have
― Enthalpy of steam: ∆H’s = 2696 kJ/kg
― Enthalpy of condensate: ∆H’C = 461.3 kJ/kg
― Enthalpy of vapor: ∆H’V = 2644 kJ/kg
― Specific heat capacity of juice: Cpin = 3349 x 0.92 + 837.36 = 3.918 kJ/Kg.K.
― Specific heat capacity of concentrate: Cp concentrate = 3349 x 0.45 + 837.36 = 2.344
kJ/Kg.K.
Energy balance for concentration operation
Qin = Qout + Qloss
 99%Qin = Qout
 99% (Gin . Cpin . (Tin – 0) + S.∆H’S) = Gconcentrate . Cp concentrate . (Tout – 0) + Gsteam . ∆H’c +
Gvapor . ∆H’V
 99% x (812.58 x 3.918 x 40 + S x 2711) = 117.6 x 2.344 x 80 + 690.93 x 2644 + S x 504.1
 S = 790.35 kg/h
Page | 62
5.2.4 Mixing 2
a) Heating concentrated juice

∆H’c = 504.1 kJ/kg.
Concentrated Juice Juice

Heating concentrated juice
Gin = 117.6 kg T= 60oC Gout = 117.6kg
Steam Ts = 120oC
∆H’S = 2711 kJ/kg.
G steam =?
Specific heat capacity of concentrate: Cp = 3349 x 0.45 + 837.36 = 2.344 kJ/Kg.K.
Energy balance for this operation
Qin = Qout + Qloss
 99%Qin = Qout
 99% (Gin . Cp . (Tin – 0) + S.∆H’S) = Gout . Cp . (Tout – 0) + S. ∆H’C
 99% x (117.6 x 2.344 x 25 + S x 2711) = 117.6 x 2.344 x 60 + S x 504.1
 S = 4.45 kg
b) Heating water
∆H’c = 504.1 kJ/kg.
Water Warm water

Heating water
Gin = 815.43 kg T= 60oC Gout = 815.43 kg
Steam Ts = 120oC
∆H’S = 2711 kJ/kg.
G steam =?
Specific heat capacity of water: Cp = 4.18 kJ/Kg.K.
Energy balance for this operation
Page | 63
Qin = Qout + Qloss

 99%Qin = Qout
 99% (Gin . Cp . (Tin – 0) + S.∆H’S) = Gout . Cp . (Tout – 0) + S. ∆H’C
 99% x (815.43 x 4.18 x 25 + S x 2711) = 815.43 x 4.18 x 60 + S x 504.1
 S = 55.12 kg/h
c) Mixing 2
∆H’c = 504.1 kJ/kg
Consentrated Juice Mixture
Gin = 117.6 kg Mixing 2 Gout = 924.75 kg

Tin = 60oC T= 60oC Tout= 60oC
Soluble dry matter = Soluble dry matter =
55%w/w 12%w/w
Steam TS = 120oC
∆H’s = 2711 kJ/kg.
G steam =?
GHFCS 42% = 111.54 kg; Tsyrup= 60oC
Gwater = 815.43 kg; Twater = 60oC
G vitamin C = 1.86kg
Gpotassium sorbate = 0.93kg
Gβ – carotene = 0.093 kg
Godor = 0.093 kg
Assume that the energy for heating the additives added from 25oC to 60oC equals to
10% of total energy for heating concentrated juice, HFCS, and water.
Qmixing = 10% (Qheating juice + Qheating HFCS + Qheating water)
 Gsteam mixing . (∆H’S – ∆H’c) = 10% (Gsteam heating concentrated juice + Gsteam heating HFCS + Gheating
water) . (∆H’S – ∆H’c)
 Gsteam mixing = 10% x (4.45 + 6.044 + 55.12)
 Gsteam mixing = 6.56 kg.
Page | 64

5.2.5 Pasteurization
Condensate: Gcondensate = Gsteam

TC= 120oC; ∆H’C = 504.1 kJ/kg
Juice Pasteurized Juice

PASTEURIZATION
Gin = 924.75 kg T = 80oC Gout = 920.13 kg;
T in = 60oC T out = 95oC
Steam; TS = 120oC
∆H’s = 2711kJ/kg.
Gsteam = ? kg
Assume that the compositions of input and output juice remain unchanged during
pasteurization, so the heat capacity of both are constant. The water content in juice is 12%
w/w.
Specific heat capacity of juice: Cp = 3349 x 0.88 + 837.36 = 3.784 kJ/Kg.K.
Assue that loss in this operation is 1% based on feed
Energy balance for pasteurization:
Qin = Qout + Qloss
 99%Qin = Qout
 99% (Gin . Cp . (Tin – 0) + S.∆H’S) = Gout . Cp . (Tout – 0) + Gsteam . ∆H’c
 99% x (924.75 x 3.784 x 60 + S x 2711) = 920.13 x 3.784 x 95 + S x 504.1
 S = 56.39 kg
Page | 65
Chapter 5: Equipment Dr. Lai Quoc Dat
CHAPTER 5: EQUIPMENT SELECTION
5.1 Equipment selection
Table 5.1: Summary of mass balance of each operation for 1 hour

Operation Unit Input Output
Classification Kg 3000 2880
Washing Kg 2880 2877.12
Extracting Kg 2877.12 1648.11
Enzyme Treament Kg 1648.11 1648.92
Filtration Kg 1648.92 1625.16
Mixing 1 Kg 812.58 924.75
Concentration Kg 812.58 117.6
Mixing 2 Kg 117.6 924.75
Pasteurization Kg 924.75 920.13
Packaging Kg 920.13 915.54
a) Sorting
Equipment parameters:
Power: 2kW
Dimension (L x W x H), mm: 1000 x 800 x 1000
Number of equipment: 2
Number of worker: 10
Brand: Plastlink
Price: 20 000 0000 VND / set
Figure 23: Conveyor
Page | 66
b) Washing machine
Equipment parameters:
Capacity: 2000 kg/hour
Power: 5kW
Brand: Gelgoog
Price: 150 000 000 VND / set
Figure 24: Bubble washing machine
c) Extractor
Equipment parametes:
Capacity: 2000 kg/hour
Power: 7.5kW
Brand: Triowin
Price: 250 000 000 VND / set
Page | 67
Figure 25: A squeezer-type juice extractor

d) Mixing tank
Total tank volume: 3500L
Working volume 3000L
Power: 2.2kW
Dimension (D x H), mm: 1750 x 2000
Total height, mm 3150
Brand: Conson
Price: 60 000 000 VND / set
Figure 26: Mixing tank
Page | 68
e) Filter
Capacity: 2000L/h
Power: 2.2 + 0.75kW
Plate size, mm 800 x 800
Brand: ACRO
Price: 300 000 000 VND / set
Figure 27: Filter press
f) Evaporator
Capacity: 2000L/h
Power: 12kW
Brand: ACE
Price: 400 000 000 VND / set
Page | 69
Figure 28: Falling film evaporator
h) Pasteurization
Capacity: 2000 L/h
Power: 3.7kW
Brand: Goldcheer
Price: 300 000 000 VND / set
Figure 29: Plate – type pasteurizer
i) Packaging machine
Capacity: 7200 bottles/h
Power: 7kW
Page | 70

Brand: Keyuan
Price: 200 000 000 VND / set
Figure 30: Rotary packing machine
i) Labelling machine
Capacity: 7200 bottles/h
Power: 1.5kW
Brand: Keyuan
Price: 100 000 000 VND / set
Figure 31: Labelling machine
Page | 71
j) Carton tapping machine

Power: 0.24kW
Brand: Youna
Price: 40 000 000 VND / set
Figure 32: Tapping machine
k) Others
Table 21: Other equipments used in factory
Power, Dimension Price, VND

Equipment Quantity
kW (L x W x H), mm Per set Total
Intermediate tank 6 0 D = 1800, H = 3150 50 000 000 300 000 000
Storage tank 5 0 D = 3500, H = 7200 200 000 000 1 000 000 000
Bottle molding machine 1 40 2000 x 1300 x 2000 2 300 000 000 2 300 000 000
Pump 14 0.75 305 x 175 x 210 1 500 000 21 000 000
Plate heat exchanger 2 2 1500 x 750 x 2200 40 000 000 80 000 000
Conveyor 4 2 3000 x 1000 x 1200 20 000 000 80 000 000
CIP system 1 2.2 3000 x 1400 x 2000 150 000 000 150 000 000
Page | 72
5.2 Gantt chart
5.2.1 Gantt chart by process
The factory operates 2 shifts per day, each shift lasts for 8 hours. The first one starts
from 6.am to 2.pm, another from 2.pm to 10.pm. The workers will take a 1 – hour break for
each shift, however, the break will take place alternately so that it does not affect so much
to the production schedule.
The production plan is devided into 2 periods, the first period which last for 6 months
(from Septemper to March of the next year), the factory wil produce juice directly from
orange fruit, while the other period, the juice will be rehydrated from concentrate.
For the first period, 48 tons of orange fruit is carried out for each day.
Figure 33: Gantt chart by process for the first period
Page | 73
For the second period, 1881.6kg of concentrated juice is produced for each day.
Figure 34: Gantt chart by process for the second period
Page | 74
5.2.2 Gantt chart by equipments
First period
Figure 35: Gantt chart by equipment for the first period process
Page | 75
Second period
Figure 36: Gantt chart by equipment for the first period process
Page | 76
Chapter 6: Facilities Dr. Lai Quoc Dat
CHAPTER 6: FACILITIES
6.1 Electricity
6.1.1 Electrical energy for equipments
Main equipment electrical energy

Table 22: Total power of main equipments in a working day
First period Second period

Power
Operation Equipment Quantity Working time Total Working time Total
(kW)
per day (hour) (kWh) per day (hour) (kWh)
Sorting Conveyor 2 2 15 60 0 0
Washing Washing machine 5 2 15 150 0 0
Extraction Squeeze extractor 7.5 1 15 112.5 0 0
Enzyme Mixing tank 2.2 1 9 19.8 0 0
treatment
Filtration Filter press 3 1 15 45 0 0
Mixing Mixing 2.2 2 3 13.2 3 13.2
Concentration Falling film evaporator 12 1 7.5 90 0 0
Pasteurization Plate – type pasteurizer 3.7 1 7 25.9 7 25.9
Molding machine Bottle molding machine 40 1 7 280 7 280
Packaging Packaging machine 7 1 7 49 7 49
Labeling Labeling machine 1.5 1 7 10.5 7 10.5
Carton tapping Carton tapping machine 0.24 1 7 1.68 7 1.68
Total 95.54 857.58 380.28
So that we have total electrical energy for equipment operation in this factory per year is:
E = 857.58 x 25 x 6 + 380.28 x 25 x 6 = 185679 kWh.
Auxiliary equipment electrical energy
Assume that electrical energy for auxiliary pump, transportation conveyor, CIP
system,.. equal 10% of total energy for main equipments:
E’ = 10% x E = 10% x 185679 = 18567.9 kWh
Page | 77
6.1.1 Electrical energy for lighting system
Table 23: Total power of lighting equipments in a working day
Luminous
Illuminance Area Power
Sector efficacy Quantity Time Total
(lm/m2) (m2) (W)
(lm/W) (h/day) (kWh)
Material warehouse 100 600 80 40 20 16 12.8
Product warehouse 100 1000 80 40 32 16 21.0
Production area 500 840 80 40 132 16 84.5
Package chamber 300 80 80 40 8 16 5.0
Office 500 375 80 40 60 8 19.2
Security room (x2) 200 12 80 20 2 14 1.12
WC (x3) 200 32 80 20 4 6 1.44
Canteen 300 80 80 20 15 5 1.5
Total 10.5 146.56
So that we have total electrical energy for lighting in this factory per year is:
E = 146.56 x 300 = 43968 kWh.
6.1.3 Total electrical energy for the plant
Assume that other electrical energy equal 10% of total energy from quipments and
lighting system.
Total electrical energy consumption per year
Total electricity = Electricity for equipments + Electricity for lighting + Other electricity
= (185679 + 18567.9) + 43968 + 10%(185679 + 18567.9 + 43968)
= 273036 kWh.
Total power of equipments and lighting: 95.54 + 10.5 = 106.04
Chose the substation: 200 kVA, 3 phases.
6.2 Water
Technical water
Water for orange washing
Consumption water per 1 washing machine: 1 L/ kg materials/h
Page | 78
We have 2 washing machine and 1.5 tons orange/h, so

→Amount of water for orange washing: 1 x 1500 x 2 x 15 = 45 000 L
Water for 2th mixing operation
We need 246.31 kg water for 1 hour mixing in 1 tones orange
Amount of water for mixing: 271.81 x 3 x 3= 2446.29 L
Non-technical water
Water for staff activities in factory
Standard: Amount of water permitted to use: 60L/ person/day
Amount of water for staff activities: 60 x 77= 4 620 L
Water for irrigating of greenery area
Standard: Amount of water permitted to use: 2.5 L/ m2/day
Area of greenery area: 4250 m2
Amount of water for irrigating of greenery area: 2.5 x 4250= 10 625 L
Water for firing distinguish
Standard: Amount of water permitted to use for volume that is lower than 25 000 m3:
2.5 L/s/column of firing
Area of manufacturing volume: < 25 000 m3
We design 1 columns of firing in manufacturing section and assume that, the fire
occurs in 3 hours
Amount of water for firing distinguish: 2.5 x 3x 3600 =27 000 L
Water for cleaning equipment and floor
Table 24: Amount of water for cleaning equipment and floor
Equipment Quantity Amount of water/machine/day (L) Total (L)

Washing machine 2 1000 2000
Sorting conveyor 2 600 1200
Filtrating machine 1 800 800
Total 4000
Page | 79
Table 25: Amount of water for CIP
CIP Quantity Amount of water /machine/day (L) Total (L)

Tank 14 3 500 4900
Plate heat exchanger 2 700 1400
Pasteurization 1 700 700
Enzyme treatment tank 1 3 500 3500
Filling machine 1 700 700
Extractor 1 1 000 1000
Evaporator 1 1 500 1500
Total 57 800
― Amount of water for cleaning floor of manufacturing section: 2.5 x 920 = 2 300 L/day
― Water for boiler
Amount of steam used in plant per day (for first 6 months): 6 440.6 kg
We recycle amount of condensate from plate heat exchanger, pasteurization and
evaporator for boiler. Assume that, recovery performance is 80% → Amount of recycled
condensate: 6 413.7 x 0.8= 5130.96 kg
Amount of water supply for boiler: 7 257.51 – 5 130.96 = 1 288.12 kg ≈1. 3 m3/ day
Table 26: Total consumption of water per day
Estimate amount of Wastewater

Purpose Amount of water (L/day)
(L/day)
Technical water
Orange washing 45 000 44 100
2nd mixing 2 446.29 0
Non- technical water
Staff activities 4 620 3000
Greenery area 10 625 0
Fire distinguish 27 000 0
Cleaning equipment 4 000 3 500
Cleaning floor 2 300 2 300
CIP 57 800 56 640
Boiler 1 300 0
Page | 80
Total 155 079.04 96 971.6

≈ 𝟏𝟓𝟓 m3 ≈ 97 m3
6.3 Steam
Parameters of steam:
― Temperature: 120oC
― Pressure: 2.025 kg/cm2
Selection of boiler
Figure 37: Boiler

― Size of boiler: 2650x1200x2500 (mm)
― Working pressure: 10 kg/cm3
― Capacity of boiler: 750 kg steam /h
― Using steam is non- directly
𝑚𝑠𝑡 960
― Number of boilers: 𝑛 = [ ]+1=[ ]+1=2
𝑃𝑠𝑡 750
― Efficiency of boiler: h= 80%

Fuel for boiler
― Type of fuel used for boiler is coal
― Estimate of amount of fuel
𝑄 ℎ𝑔 × 𝑚𝑠𝑡 2711 × 6413.7 𝑘𝑔
𝑚𝑓𝑢𝑒𝑙 = = = = 1 370.8( )
𝐸×ℎ 𝐸×ℎ 80% × 3800 × 4.19 𝑑𝑎𝑦
Where:
E: Calorific value of coal (kcal/kg)
h: Efficiency of the boiler (%)
Page | 81
hg: Enthalpy of saturated steam (kJ/kg)

mst: Amount of steam need for boiler (kg/h)
Estimate the consumption of steam
Table 27: Consumption of steam in 1 day
Working time Amount of consumption Total consumption of

Operation
(hour) steam (kg/h) steam (kg)
Heating syrup 1/3 6.044 2.01
Enzyme treatment 9 4.48 40.32
Mixing 3 5.76 17.28
Heating juice for enzyme
1/3 44.3 14.77
treatment
Heating juice for mixing 1/3 51 17.00
Pasteurization 7 56.39 394.73
Concentration 7.5 790.35 5927.63
Total (in day) 6 440.6
Diagram for steam

900
800
700
600
m st (kg/h)
500
400
300
200
100
0
6:20:00 SA 8:44:00 SA 11:08:00 SA 1:32:00 CH 3:56:00 CH 6:20:00 CH 8:44:00 CH
Time(h)
Figure 38: Diagram for steam consumption in 1 day
Page | 82
Chapter 7: Industrial Building Design Dr. Lai Quoc Dat
CHAPTER 7: INDUSTRIAL BUILDING DESIGN
7.1 Layout of plant
Feature of layout
Product warehouse
― Amount of product box in day: 1 696 (boxes)
― Size of each carton box: 50 x 35 x 20 (cm)
― Product boxes will be put in pallet that its size is 110 x 110 x 20 (cm), so we will
arrange 6 boxes/ pallet, each pallet has 7 layers and 42 boxes.
― Height of each pallet: 1.6 m
― Pallets will be arranged in shelfs that its area (L x W = 1100 x 110 = 121 000 (cm2)
= 12.1 m2. Each shelf has 5 floors, each floor has 10 pallets.
― The number of pallets in each shelf: 50 pallets. Two shelves are arranged in a pair,
the other racks are 4 m apart, 1.5 m from the wall
― The amount of shelf we need in a day: 1 shelf
― Estimate product will be stored in 16 days, so we need 21 shelfs or 10 pair of
shelves
― Area of product warehouse to store enough product in 2 weeks:
F0 = (22x2+ 1.5x2+4) x (1.1x4 + 4x3 + 1.5 x2) = 989.4(m2) ≈ 1000 (m2)
→Choose size of warehouse: L x W = 35 x 30 (m)
Fuel warehouse
The area of the warehouses is calculated by the following formula:
F0 = G× f0× N× k, m2
= 1.54 x 1.2 x 5 x 1.3 = 12.01m2
Where:
F0: Area of warehouse, m2.
G: Amount of materials to contain, tons / day.
f0: Standard area for 1 ton of raw materials, m2/ton
N: Number of days reserved.
Page | 83
k: Coefficient including the path, choose k = 1.3

→Choose size of warehouse: L x W = 12 x 10 (m)
Orange and auxiliary warehouse
Orange warehouse
⎯ Material storage warehouse is used to store raw materials for 6 days of production
of the factory.
⎯ Box to contain 1 ton of orange are sized: L x W x H = 1 x 1 x1 (m)
⎯ Amount of oranges needed to be produced in 1 day: 48 ton, → For 9 days, box
amount: 48 x 9= 432 (boxes)
⎯ Choose shelf:
✓ Boxes are stacked on shelves. Two shelves are arranged in a pair, the other racks
are 4 m apart, 1.5 m from the wall. Each shelf has 2 floors, 6 boxes each.
✓ The number of shelves to use is 72. Shelves are arranged into 3 of floors, each
floor has 2 pair of shelves.
✓ Choose a shelf with dimensions L x W x H = 3.5 x 2.5 x 2.2 (m)
⎯ With 36 pairs of shelves, orange warehouse area: (1.5 x 2 + 3.5 x 2 x 2 +4) x (2.5x3
+ 1.5 x2 +4x2) = 388.5 (m2)
Auxiliary warehouse
Because the transportation and supply of raw materials for the factory cannot be done
every day, the factory will build material warehouses to meet the production line
continuously.
The area of the warehouses is calculated by the following formula:
F0 = G× f0× N× k, m2
Where:
F0: Area of warehouse, m2.
G: Amount of materials to contain, tons / day.
f0: Standard area for 1 ton of raw materials, m2/ton
N: Number of days reserved.
k: Coefficient including the path, choose k = 1.3
Page | 84
Table 28: Area estimation for auxiliary material
Material G (ton/day) N (day) f0 (m2/ton) F0 (m2)

Potassium sorbate 0.1488 30 1.2 5.36
Enzyme pectinase 0.02637 30 1.2 0.95
Odor 0.001488 30 1.2 0.05
β – carotene 0.001488 30 1.2 0.05
HFCS 1.762 30 1.3 68.72
Embryos bottle 0.732438 30 1.9 41.75
Carton 0.5088 30 2 30.53
Label 0.1017275 30 2.5 7.63
Total 155.38
➔ Total orange and auxiliary warehouse area: 388.5 + 155.38 = 543.88 (m2)
➔ Choose orange and auxiliary warehouse has L x W = 30 x 20(m)
Table 29: Summary of feature area in plant
Construction Quantity Size (Length × Width) (m) Area (m2)

Manufacturing section 1 40 x 23 920
Warehouse
Material warehouse 1 30 x 20 600
Fuel warehouse 1 12 x 10 120
Product warehouse 1 35 x 30 1000
Auxiliary construction
Canteen 1 10 x8 80
Boiler section 1 5x4 20
WC 3 8x4 32
Office 1 25 x 15 375
Security room 2 3x3 9
Garage for employees 1 15 x 5 75
Wastewater treatment area 1 8x5 40
Garbage treatment 1 5x5 25
Waste gas treatment section 1 7x5 35
Car parking lot 1 10 x 6 60
Page | 85
Product moving section 1 15 x 10 150

Substation 1 3x3 9
Fuel warehouse 1 5x3 15
Greenery area 4250
Traffic sytems
Total 17 000
Design principles
― There must be enough space to build an existing building
― Has a reasonable area to expand later
― Planting area of trees (25 - 30% S) to filter noise, air, prevent fire, increase oxygen.
― Reasonable transportation system.
― Ensuring regulations on FPF, having works for fire protection.
― Public works must always be located near the entrance, transformer station located
near the main traffic road.
― Ensure proper distance between two branches to take advantage of natural light,
natural ventilation, and fire - fighting.
― Select the direction of the house so that it can be ventilated and illuminated smoothly,
facing the main road.
― Post-treatment of water supply, Wastewater, boiler, fountain, ...
Drawing: ATTACHED FILE (CAD)
7.2 Layout of equipment
Drawing: ATTACHED FILE (CAD)
Page | 86
Chapter 8: Personnel Management Dr. Lai Quoc Dat
CHAPTER 8: PERSONNEL MANAGEMENT
8.1 Construction of human organanization structure
Figure 39: Personnel management diagram
8.2 Human resource
8.2.1 Estimating labor for each department
Table 30: Number of administrative staffs
Position Quantity
Director 1
Vice director 2
Financial accountant 2
Business department 4
Financial manager 1
HR department 4
Security guards 6
Kitchen staff 4
Serviceagent 2
Page | 87
Medical staff 2
Total 28
Table 31: Number of employees in the factory

Quantity Quantity Total
Position
(person/ shift) (shift/ day) (person/day)
Factory manager 1 2 2
Production leader 1
Storekeeper 1 2 2
Technical department 2 2 4
Mechanical and electrical team 2 2 4
Lab employees 4 2 8
Boiler team 4 2 8
Wastewater treatment team 1 2 2
Total 31
Table 32: Number of workers during manufacturing

Quantity Quantity Total
Operation
(person/ shift) (shift/day) (person/day)
Sorting 8 1 8
Mixing 1 2 2
Enzyme treatment 1 2 2
Carton packaging 1 1 1
Moving bottles 2 1 2
Label packaging 1 1 1
Carton tapping 1 1 1
Product moving to warehouse 1 1 1
Total 18
➔ Total labors of factory in a day: 31 + 28 + 18 = 77
8.2.2 Insurance businesses
― Social insurance: 10% salary

― Health insurance: 3% salary
Page | 88
― Accident insurance: 1% salary

→Total insurance premiums paid by enterprises to employees 14%salary
8.3 Manufacturing plan
― Working mode of the factory: do 2 shifts per day, 8 hours per shift, 300 working
days per year.
― Financial staff working hours:
Morning from 7:30 - 11:30 pm, afternoon from 13:00 - 17:00
― Employees work in shifts
Shift 1: 6h - 14h
Shift 2: 14h - 22h
Page | 89
Chapter 9: Economic Calculation Dr. Lai Quoc Dat
CHAPTER 9: ECONOMIC CALCULATION
9.1 Fixed cost

Equipment cost
Table 33: Equipment cost
Equipment Quantity Price per unit Total cost

Conveyor 6 20 000 000 120 000 000
Washing machine 2 150 000 000 300 000 000
Extractor 2 250 000 000 500 000 000
Mixing tank 3 60 000 000 180 000 000
Filter press 1 300 000 000 300 000 000
Evaporator 1 400 000 000 400 000 000
Pasteurizer 1 300 000 000 230 000 000
Molding machine 1 2 300 000 000 2 300 000 000
Packing machine 1 200 000 000 200 000 000
Labeling machine 1 100 000 000 100 000 000
Tapping 1 40 000000 40 000 000
Intermediate tank 6 50 000 000 300 000 000
Storage tank 6 200 000 000 1 200 000 000
Pump 14 1 500 000 21 000 000
Plate heat exchanger 2 40 000 000 80 000 000
CIP system 1 150 000 000 150 000 000
Total 6 491 000 000
Renting cost
― Ground renting price per month: 20 000 000 (VND)
― Ground renting price per year: 240 000 000 (VND)
― Maintaining facilities cost per year: 10 000 000 (VND)
→ Total renting price and maintaining facilities cost per year: 250 000 000 (VND)
Construction cost
― Constructing and auxiliary works cost: A= 1 500 000 VND/m2
― Total of factory area: S = 17 000 m2
― Total of constructing and auxiliary works cost: B = 1 500 000 x 17 000
= 25 500 000 000 VND
Page | 90
― Depreciation of constructing and auxiliary works cost: 5%B=1 275 000 000 VND
Table 34: Total fixed cost and
Fixed cost Cost (VND)

Equipment cost 6 491 000 000
Renting cost 250 000 000
Construction cost 25 500 000 000
Total 32 241 000 000
Table 35: Total pepreciation of fixed cost
Depreciation of fixed cost Cost (VND)

Equipment 324 550 000
Construction 1 275 000 000
Total 1 599 550 000
9.2 Working cost
Water cost
Table 36: Water cost per year
Price
Amount of consumption water (m3/year) Cost (VND)
(VND per m3)
Manufacturing water 33 160.3 10 000 331 603 239.8
Activity water 5 263.5 4000 21 054 000
Wastewater treatment 29 091.48 20 000 584 829 600
Total 934 486 839.8
Fuel cost
− Amount of used coal: 1 370.8 kg/day ≈ 1.4 tons
− Price of coal: 1 500 000 VND/ton
→Total fuel cost for year: 1.4 × 1 500 000 × 300= 630 000 000 VND.
Electric cost
− Total electric in year: 273036 kWh
− Price of electric: 1 570 VND/ kWh
− Total electric cost in year: 273036 x 1 570 = 428 666 520 VND
Page | 91
Labor cost
Table 37: Labor cost
Quantity Salary Insurance Total salary

(person) (VND/ person/ month) 14%salary (VND)
Mechanical and
4 5 000 000 2 800 000 17 200 000
electrical team
Boiler team 8 5 000 000 5 600 000 34 400 000
Wastewater treatment
2 5 000 000 1 400 000 8 600 000
team
Lab employees 8 6 000 000 6 720 000 41 280 000
Storekeeper 2 5 000 000 1 400 000 8 600 000
Worker 18 5 000 000 12 600 000 77 400 000
Security guards 6 4 000 000 3 360 000 20 640 000
Kitchen staff 4 4 000 000 2 240 000 13 760 000
Medical staff 2 4 000 000 1 120 000 6 880 000
Service agent 2 4 000 000 1 120 000 6 880 000
Financial accountant 2 6 500 000 1 820 000 11 180 000
Business department 4 6 500 000 3 640 000 22 360 000
Financial manager 1 6 500 000 910 000 5 590 000
HR department 4 6 500 000 3 640 000 22 360 000
Factory manager 2 10 000 000 2 800 000 17 200 000
Production leader 1 8 000 000 1 120 000 6 880 000
Technical department 4 9 000 000 5 040 000 30 096 000
Director 1 40 000 000 5 600 000 34 400 000
Vice director 2 30 000 000 8 400 000 51 600 000
Total 375 902 000
Total per year (12 months) 4 510 824 000
Page | 92
Material cost
Table 38: Material cost
Weight Price Total cost

Material Quantity (/year)
(kg per year) (VND per unit) (VND/year)
Orange 6 912 000 8 000 55 296 000 000
HFCS 7 911 3 000 23 733 000
Vitamin C 8 928 3 500 31 248 000
Potassium sorbate 4 464 2 500 11 160 000
Odor 446.4 2 000 892 800
𝛃 - carotene 446.4 2 500 1 116 000
PET cap 11 625 900 100 1 162 590 000
PET embryos bottles 11 625 900 250 2 906 475 000
Carton 484 413 700 339 089 100
Total 59 772 303 900
Table 39: Total working cost
Working cost Cost (VND)

Material cost 59 772 303 900
Fuel cost 630 000 000
Water cost 934 486 839.8
Electric cost 428 666 520
Labor cost 45 108 224000
Total 66 276 281 260
9.3 Marketing cost
Estimate, Marketing cost = 1% x (Fixed cost + Working cost + Depreciation for fixed cost)
= 1% x (66 276 281 260 + 32 241 000 000 + 1 599 550 000) = 1 001 168 313 (VND)
9.4 Back up
Estimate, back up = 10% (Fixed cost + Working cost)

= 10% x (32 241 000 000 + 66 276 281 260) = 9 851 728 126
Page | 93
9.5 Price of product (P)
P = (Working cost per year + Depreciation for fixed cost + Marketing cost)/ Capacity
66 276 281 260+32 241 000 000+1 001 168 313
=
1 696 × 24 ×300
= 5 640.1 (VND/ bottle)

Price for selling P’= 14 000 VND/bottle
9.6 Profit
⎯ Revenue in year: P’ x (1 696 x 24 x 300) = 14 000 x 1 696 x 24 x 300

= 170 956 800 000 (VND)
⎯ Net profit: Revenue – Cost of goods solid – Tax = 48 % x Revenue
= 82 059 254 000
𝑵𝒆𝒕 𝒑𝒓𝒐𝒇𝒊𝒕 82 059 254 000
⎯ Profit margin: = = 0.48
𝑹𝒆𝒗𝒆𝒏𝒖𝒆 170 956 800 000
9.7 Payback period

𝑇𝑜𝑡𝑎𝑙 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝐹𝑖𝑥𝑒𝑑 𝑐𝑜𝑠𝑡+𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑐𝑜𝑠𝑡+𝑀𝑎𝑟𝑘𝑒𝑡𝑖𝑛𝑔 𝑐𝑜𝑠𝑡+ 𝐵𝑎𝑐𝑘 𝑢𝑝
PP = =
𝑁𝑒𝑡 𝑝𝑟𝑜𝑓𝑖𝑡 𝑁𝑒𝑡 𝑝𝑟𝑜𝑓𝑖𝑡
66 276 281 260+32 241 000 000+1001 168 313+9 851 728 126
= = 1 (years)
82 059 254 000
Page | 94
Chapter 10: Waste Treatment Dr. Lai Quoc Dat
CHAPTER 10: WASTE TREATMENT
10.1 Characteristics of Wastewater
Because in the production process need to use a large amount of water to wash
equipment, Wastewater from the equipment, factory hygiene,... The Wastewater contains
organic substances, even some toxic elements,.. thus handel it is very important for
surrounding residents safety and environment preservation.
Table 40: Characteristics of Wastewater from juice plant
Parameters Unit Value

pH - 5.4 - 8
COD mg/L 1900 - 2875
Color Pt-Co 290
Alkalinity mg CaCO3/L 46
Total nitrogen mg/L 10.06
Total solids mg/L 2976
Conductivity µS/cm 817
Volatile suspended solids mg/L 14 - 580
Volatile solids mg/L 1666.60
Total suspended solids mg/L 118 – 1534.0
Volatile suspended solids mg/L 452.0
Wastewater from the factory after treated must follow some criteria:
Table 41: Criteria for Wastewater (QCVN 40:2011/BTMT)
Parameters Unit Column B
pH - 5.5 - 9
COD mg/L 150
Color Pt-Co 150
Total solids mg/L -
Total nitrogen mg/L 40
Total suspended solids mg/L 100
10.2 Waste treatment system
Proposing Wastewater treatment in juice plant: Treatment of high strength

wastewater from fruit juice industry using integrated anaerobic/aerobic system. Three
Page | 95
treatment schemes have been designed and manufactured. The first scheme is an activated
sludge (AS) system. The second scheme is a two-stage up-flow anaerobic sponge reactor
(UASR). While, the third one is a two-stage UASR followed by an AS system. The three
schemes are located out-door and were operated at a temperature of 25 °C. A schematic
block diagram of the experimental layout is shown in below:
Figure 40: Schematic block diagram of the proposed treatment schemes
Figure 41: Two-stage up-flow anaerobic sponge reactors (UASRs)
The first treatment scheme:The temporal variation of COD in the batch scale operate
with fruit juice wastewater at initial substrate to microorganism ratio of 1.11 mg COD/mg
Page | 96
VSS. COD removal í accomplished within 30 h, and no further reduction in COD is

observed after that, with the steady state COD stabilizing at 30–50 mg/L. Furthermore, the
results of this test clearly show that COD removal efficiencies ranged from 10 to 99.5%
with about 1% of the initial COD is non-biodegradable even after 30 h of treatment. This
is to be excepted since any organic loading above the maximum microbial uptake will be
untreated.
The second treatment scheme: The two-stage UASRs are operated at a total constant
HRT of 13 h, throughout the study. OLR's varied from 5.49 to 15.5 kg COD/ m3 with an
average value of 8.7 kg COD/m3 due to a change in the influent composition
The third treatment scheme: The effluent quality of the anaerobic step does not meet
the standards set regulating the reuse of treated wastewater in agricultural purposes.
Therefore, the activated sludge system has been investigated as a posttreatment for the
UASRs effluent. The AS system was operated at three different HRTs namely, 10, 12 and
14 h.
Figure 42: Schematic diagram of the proposed treatment system.
10.3 Waste trash
― Industry region has arranged a concentrated waste dump to collect waste daily and
combined with functional waste treatment units to transport and treat garbage.
― Garbage is sorted at the source: separate organic and inorganic garbage. After that, trash
truck will move it to the landfills.
Page | 97
Chapter 11: Safety in Factory Dr. Lai Quoc Dat
CHAPTER 11: SAFETY IN FACTORY
11.1 Food safety regulations

–Employees are equipped with labor protection and tools provided during working
hours. –Employees must use the right purpose and all the equipment provided.
–During the working time, public officials and employees are not allowed to travel
outside of their scope.
–When there is an incident or suspicion that the device may have a problem, the
officer and employee must immediately inform the Team Leader to handle
–If not assigned, the officials and employees are not allowed to use and repair the
equipment on their own.
–Without training on safety rules and equipment operation, equipment shall not be
used and operated.
–Products, goods, supplies, finished products, 0.5 m away from the wall, away from
emergency exit doors, circuit breakers, fire fighting equipment, emergency medicine
chests.
–When repairing the machine, turn off the electrical switch and have the new sign
repaired.
–When preparing to operate the machine or after repairing it, check the tool again,
whether the device is on the machine or not and there is no one standing in the danger zone
for the machine to operate.
–Do not let grease, grease and oil spill on the floor, workshop, workplace.
–In the warehouse, it is necessary to arrange neatly, neatly, do not leave tools, wires,
supplies and equipment obstructing travel.
–When a labor accident incident occurs, the persons present at the scene must:
+ Turn off the electrical switch for stopping the machine.
+ Urgently give first aid to the victim, immediately report to the plant's safety and health
officer.
+ Participate in protecting the scene so that the person responsible for handling.
Page | 98
–Employees are obliged to report to the safety and health representative of the labor
accident incident, regarding the violation of labor safety principles at the factory.
–When you see the risk of an accident at your workplace, the employee immediately
leaves the hazardous area and immediately informs the safety officer to handle it.
–Do not dismantle or effectively reduce the safety equipment in the factory.
–Employees must follow the instructions of the prohibition table, the manufacturer's
safety sheet.
11.2 Safety equipment and production areas
–Workshops, warehouses, places to do works, machinery and equipment belong to

the scope of management organizations, the team leaders must assign people to be direct,
arrange, remind, maintain and neat.
–Strictly abide by the regulations on technology, techniques and labor safety in
production and work. Do not use and control the device without training in safety
instructions.
–Strictly prohibit fire cooking, electric stoves, and resistors outside the specified
places of the factory.
–Do not throw away garbage paper, cigarette butts, scraps and labor protection
equipment.
–Absolutely do not smoke in warehouses and places where there is a risk of fire and
explosion.
–Do not take fire protection means to do other jobs.
–Make full and reasonable use of all labor protection equipment provided.
–Arrange cleaners, clean and tidy work places, maintain general hygiene, and
maintain good facilities provided by the factory.
–Do not leave the working position before the end of the working period, when you
have to eat, you must appoint a person to work and do not go to places where your duties
are not.
–The supervisors, leaders, employees in the factory ... must strictly abide by the above.
Page | 99
11.3 Fire prevention and fighting rules
In order to protect the state's property, people's lives and property, and protect the
general production and order. Now the fire prevention and fighting regulations are as
follows:
–Fire prevention and fighting is the duty of every citizen.
–Every citizen must actively prevent fire from happening, and prepare to be ready for
force and means to be in time for effective and timely fire fighting.
–Be careful in using fire, heat sources, chemicals and flammable, explosive, toxic,
radioactive substances. Thoroughly follow the fire protection regulations.
–Prohibited questions, arbitrary electricity use, after hours must check the electrical
consumption devices. Notice the lights, fans, electric cookers before leaving. Do not leave
goods and supplies against the side of the lights and wires. Strictly comply with regulations
on safety techniques in electricity use
–Supplies and goods must be neatly arranged to ensure a safe distance for fire
prevention and fighting to create favorable conditions for protection, inspection and
treatment when necessary. Do not use a lock to open a gas drum and flammable solvents in
steel.
–When delivery, the vehicle must not explode in a warehouse, where there are many
flammable substances and when parked, turn the vehicle out.
–On the walkways, especially the exit routes, do not leave obstacles
–Units or individuals with fire protection achievements will be rewarded, those who
violate the above provisions are subject to the light duty that is dealt with from enforcing
administrative law to prosecution under law. current
11.4 Electrical safety
–Only officials and employees who have received technical and technical training on
electrical safety can repair, install and open electric equipment.
–When working and repairing, tools and equipment must be used properly.
–Do not cut off the power at the circuit breaker, arrange the power without permission.
Page | 100
–Do not use materials with other technical parameters designed to replace the repair.
–When repairing electricity, it is necessary to disconnect the power at the total circuit
breaker, there must be a sign (holding electric hook, repairing) or a person directly at the
circuit breaker.
–Electrical engineering inspects electrical system safety on a weekly basis on
Saturday. Checks must be made in writing.
11.5 Regulations on emergency exit and emergency response
–Possible problems include: fire and explosion incidents, incidents of food poisoning,
unexpected incidents such as wall pouring, factory dumping, factory roofing, etc.
–When an incident occurs, the Fire Prevention Team, Head of the Department
instructs the nearest emergency exit and the safest and closest escape guide and instructs
calm employees to follow the exit route. That is dangerous.
–Exiting rules: Every officer and employee must be calm to find the escape route and
follow the nearest and safest escape instructions, not to run and run to the traffic jams.
Page | 101
REFERENCES
1 Yiu H. Hui, Handbook of Food Science, Technology, and Engineering, Publishing by
CRC Press, 2006.
2 Walstra P, Physical chemistry of foods, Marcel Dekker Inc, New York, 2003.
3 Zacharias B. Maroulis and George D. Saravacos, Food Plant Economics, CRC Press,
2008.
4 Jasim Ahmed and Mohammad Shafiur Rahman, Handbook of Food Process Design,
Wiley – Blackwell, 2012.
5 G. D. Saravacos and A. E. Kostaropoulos, Handbook of Food Processing Equipment,
Kluwer Academic/Plenum Publishers, 2002.
6 D.R. Heldman and D.B Lund, Handbook of Food Engineering, CRC Press, 2007.
7 Perry, R.H. and Green, D.W., Perry’s chemical engineers’ handbook, 7th ed, New
York McGraw-Hill
8 Hala El-Kamah , Ahmed Tawfik, Mohamed Mahmoud, Hisham Abdel-Halim,
Treatment of high strength wastewater from fruit juice industry using integrated
anaerobic/aerobic system, Desalination, 2010.
9 Website: https://apfoodonline.com/industry/juice-a-market-with-great-potential/
10 Website:https://www.goldsteinresearch.com/pressrelease/global-fruit-juice-market-
healthy-market-across-the-globe
11 Website: http://en.tiengiang.gov.vn/development-potentialities
12 Website: http://bqlkcn.tiengiang.gov.vn/khu-cong-nghiep-my-tho
Page | 102

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HO CHI MINH UNIVERSITY OF TECHNOLOGY

FACULTY OF CHEMICAL ENGINEERING

FOOD PLANT DESIGN ESSAY

Student: Le Minh Hieu – 1611012

Ta Thi Thao – 1613225

Instructor: Dr. Lai Quoc Dat

Ho Chi Minh City, 05/2019

CHAPTER 1: CHARACTERISTICS OF JUICE PLANT ..................................................... 1

CHAPTER 1: CHARACTERISTICS OF JUICE PLANT

1.1 Characteristics of raw material

1.1.1 Fresh orange

Figure 1: Structure of orange fruit

Component Amount (g)

1.1.2 Orange season

1.2 Characteristic of juice products

1.2.1 Contaminations of product

1.2.2 Sensitve attribute of products in storage and distribution

Figure 2: Effect of temperature on vitamin C content in orange juice during storage.

1.2.3 Role of distribution system

Figure 3: B2C distribution system

1.2.4 Customer behaviors

Customer behaviors depend on many different factors, such as:

Figure 4: Juice consumption habit by age

Others: Addition of nutrients, against hunger, want to try, habit,...

Figure 5: Juice consumption habit by packages (per point of 5)

Figure 6: Juice consumption habt by package volume (per point of 5)

1.2.5 Scale up ability.

CHAPTER 2:SOCIO – ECONOMIC CONTEXT

2.1 Situation of market

2.1.1 Volume and demands

2.1.2 Necessity of the related products

2.1.3 Possibility of export

2.1.4 Possibility of distribution system

Figure 9: Distribution system for orange juice

2.2 Possibility of market development in future (Hiếu)

2.2.1 Global market

2.2.2 Vietnamese market

Figure 12: Market shares in non – alcoholic drink in Vietnam

2.3 Strength of price and distribution system

2.3.1 Material cost

2.3.2 Labor cost

2.3.3 Distribution and saling cost

2.4.1 Competition from import

Country Average price for 330ml (VN dong)

2.4.2 Capacity of competitors

2.4.3 Risks of technologies

2.4.4 Risks on quality and consumer belief

In order to conduct a business production cycle, capital is needed. The capital

According to the report of the General Department of Statistics, Inventory index of

– Limitations on capital, science and technology.

2.7 Capacity estimation

2.8 Product design

2.8.1 Product quality

Nutrient Value per 100mL Unit

Physico – chemical quality of product

2.8.2 Product appearance

Package: PET bottles.

2.9 Factory location

2.9.1 Location criteria

2.9.2 Location selection

Selection of plant location is identified using scoring methods. The proposed

Year 2008 2009 2010