APPLE JUICE MAKING PROCESS

INTRODUCTION
Apple is a fruit good for healthy, either red apple or green apple. Specific name for apple is
Malus domestica. Apple juice is a fruit juice made by the maceration and pressing of apples.
The resulting expelled juice may be further treated by enzymatic and centrifugal clarification to
remove the starch and pectin, which holds fine particulate in suspension and then pasteurized for
packaging in glass, metal or aseptic processing system containers, treated by dehydration process
to a concentrate.
Apples were almost eaten close to where they were grown but in the world now, modern
advances in processing technology, packaging and transport have gradually transformed this
scenario into a global market with juice as a prime feature. The use of technical enzymes has
been an essential part of the entire technology of fruit juice production from the beginning. In the
early 1030s, the first step were made to process fruits into juices that could be stored for a longer
time without the danger of alcoholic fermentation or other forms o undesired spoilage.
The purpose of this project is to produce a polymer additive mixture formulated by mixing a
fluid solution and two types of powder. This project has a series of three 10 000-gallon tanks that
will hold raw materials, one for fluid and two for powder. The tank that holds the liquid is
heated with a steam jacket. A mixing tank is mounted on a rail and it moves under each tank to
receive 100 gallons of the liquid ingredient and 200 pounds of each of the dry ingredient that will
be mixed together to form the polymer additive.
Our group will use red apple to making the apple juice. The raw materials that have been used
are fruits, water, sugar, overall flavor, organics acids (primarily citric, malic and tartaric) and etc.
Also, the manufacturing process that have been included is washing(fruit reception), milling,
mixing the (liquid), mash heating, enzymation, clarification, pasteurization, concentration,
cooling, and filling into the bottle.

PROCESS FLOW

Figure1: Process Flow

Apples are brought to the processing building and dumped by the truckload or out of pallet
bins, into a water-filled tank.
Fruit are then spray, washed and sorted. Clean, sorted fruit are stored and inspected again
before juicing or juiced immediately.
Hammer mill or grating mill used to grind the apples.
Mash enzyme treatment is used for accelerating the juicing process in conjunction with
higher yields.
Mash is pumped to rack and cloth press. This mash is pumped on to a hydraulic packing
press where it is squeezed with gentle pressure to thoroughly extract the juice which filters
through press cloth.
The pomace are being process again to take the juice.
The pasteurization process is a heating process which heats the juice to approximately 78
Celsius. This short-term heating process eliminates bacteria without altering the natural
flavor of the apple.
Filtration removes suspended solids and other high molecular solids such as proteins and
starch in a temperature around 82 C to 85 C.
The pre-concentration phase temperature 120 C. Then it will concentrate again for the
second time to make the juice have a smooth flow.

PROCESS PLANT DRAWING (P&ID)

Figure 2: P&ID apple juice making process

Process Control Drawing Description

No.
1

Symbol
LC

Meaning
Level Controller

LR

Level Recorder

LI

Level Indicator

TC

Temperature Controller

TI

Temperature Indicator

TT

Temperature
Transmitter

6
7
8
9
10
11
12

PC
PI
FC

FR

Description
Use at washing, enzymation, water leaching,
buzzer, pasteurization, deceptinization and
concentration process

Use at washing, enzymation, filtration and

concentration process.

Pressure Controller
Use at milling and extraction process.
Pressure Indicator
Flow Controller
Use at mash heating process
Flow Recorder
Gate Valve
Control Valve

Use to control the flow of juice from one

process to another.

1. Fruit reception, milling & mash heating

The mature apples are picked from the tree, cleaning and washing the apples and send into fruit
reception. Make sure the apples are mature requirement to processing. After that, apples will in
milling process and through mash heating process. Equipment use in this process is fruit washing
tank, temperature sensor, level sensor and clean water.
2. Enzymation
There is a hot and a cold method for enzyme treatment. In the hot method, the enzyme is mixed
into juice at 54C and held for 1 to 2 hours. In the cold treatment, the enzyme is mixed into the
juice at room temperature, 20C and held 6 to 8 hours. The enzyme activity can be monitored by
adding five milliliters of juice to 15 ml of HCL-acidified ethyl alcohol, observing the mixture for
5 minutes for gel formation. No gel formation means that the depectinization has been
completed. Equipment use in this process is liquid mix tank, steam jacket, temperature sensor,
level sensor and valve.

3. Extraction
Continuous plate or belt press is a press in which a layer of apple pulp is squeezed between
moving vertical plates. Apple pulp with press aid added is spread on a horizontal nylon belt
having a weave similar to that in press cloths used in the hydraulic press. After extraction, the
water leaching (apple juice) will send into buffer and the next step process. Equipment use in this
process is pressure sensor, hydraulic press and liquid mix tank and valve.
4. Clarification & Pasteurization(cloudy apple juice)
The juice passes to clarification and pasteurization for configure to remove any trub that may
settle and determine the level of solid in the juice. No depectinization or filtration is required.
This process will used a steam jacket to pasteurization the apple juice and mixing the liquid
(sugar,acid, etc). Equipment use in this process is pasteurizer tank, level sensor, temperature
sensor, pressure sensor, pump, and valve.
5. Depectinization
This process will do with by treatment that removes pectin and starch. The depectinized juice
then undergoes clarification in filtration system, followed by concentration. This is done at low
temperatures and with minimal residence times, to ensure juice of the best quality. The aroma
recovery system is used to capture all aromas while cooling the tank of juice apple. Equipment
use in this process is liquid mix tank, pump, valve and level sensor.
6. Filtration
To obtain a brilliantly clear apple juice polish filtration is necessary. Filtering freshly pressed
juice is a difficult operation due to the pertinacious nature of apple juice and the potential for
post filtration haze formation. Untreated juice can be rough filtered in large capacity filters with
large filter areas that can be easily cleaned. The juice from this method has superior flavour and
excellent body. Equipment use in this process is liquid mix tank, pressure sensor, temperature
sensor and valve.
7. Concentration
In order for natural fruit juice to get converted into concentrated juice, the diluted liquid must
receive a heat treatment that evaporates nearly all of the water from the naturally squeezed
mixture. Once the water gets depleted from the liquid, only the flavorful contents remain behind.
This concentrate juice then becomes more powerful through reverse osmosis. The contents get
packaged, froze and stored or shipped. Equipment use in this process is liquid mix tank, steam
jacket, temperature sensor, level sensor, pump and valve.

8. Packing(filling in bottle)
To ensure sterility, the pasteurized juice should be filled while still hot. Where possible metal or
glass bottles and cans be preheated. Instead of heat, hydrogen or another approved sterilizing
agent may be used prior to filling. The filling head meters the precise amount of product into the
container and depending on the design of the package, it may immediately invert to sterilize the
lid. After filling, the containers are cooled as fast as possible.

CONTROLLER
PLC (programmable logic controller)
Omron CS1GH/H Rack PLC
Our group will be use PLC (programmable logic controller) included supervisory control and
data acquisition (SCADA) system as a controller for apple juice process plan. Programmable
Controller is a digital computer used for automation of electromechanical processes, such as
control of machinery on factory assembly lines, amusement rides, or light fixtures and critical
infrastructures.
Earlier automation systems had to use thousands of individual relays, timers and sequencers,
which had to be replaced or rewired whenever the automated process needed to change. In many
cases, a programmable logic controller allows all of the relays and timers within a factory system
to be replaced by a single controller. Modern PLCs deliver a wide range of functionality,
including basic relay control, motion control, process control and complex networking. They
also can be used in a distributed control system (DCS).

Figure 3: PLC

Figure 4: Omron CS1GH/H Rack PLC

Omron Rack PLC Series are backwards compatible with the C200H series. Offering the widest
selection of I/O and special function units, high resolution, high speed, analogue data acquisition
makes the Omron CS1 a universal PLC for a wide range of demanding applications.
The Omron CS1G/H rack based PLC with over 200 types of I/O units CS1 is Omron's most
extensive PLC family.
(Maximum capacity of 5120 local digital I/Os) Up to 7 expansion racks can be connected to a
single CPU rack, brining the maximum number of I/O units to 80. Combinations made from over
200 models of digital me /Os, analogue I /Os, control units and communication units can be
mounted in any order on the Omron CS1G/H. The huge instruction set of the Omron CS1G/H
and function block library allow users to write very compact programs, using any mix of IEC
61131-3 Structured Text and ladder language.
Main Features:

Fast CPUs with large program capacity

Extensive choice of special function units for motion- and temperature control, and
special communication processing
IEC 61131-3 Structured Text programming, extensive function block libraries
Compact Flash memory card slot for data storage and program exchange
Easy migration from C200H systems, re-use your existing I/Os

SENSORS AND SIGNAL CONDITIONING

Sensor
1. Capacitance Level (Level sensor)

Figure 5: Liquicap M FM151

Capacitance level sensor is detecting the level of substances that flow, including liquids, slurries,
granular materials and powder. Fluids and fluidized solids flow to become essentially level in
their containers (or other physical boundaries) because of gravity whereas most bulk solids pile
at an angle of repose to a peak. This product will measure for continuous measurement in liquid.
Advantages:

No calibration necessary for media with a conductivity of 100 S/cm and higher. The probes
are calibrated to the ordered probe length on leaving the factory (0 % to 100 %). This makes
easy and fast commissioning possible.
Menu-guided local configuration via plain text display (optional)
Universal application thanks to wide range of certificates and approvals
Use also in safety systems requiring functional safety to SIL2 in accordance with IEC 61508
Material in contact with the process made of corrosion-resistant material and FDA-listed
materials for wetted parts
Two-stage overvoltage protection against discharge from the container (gas discharger +
protective diodes)
Electronics can be switched for media forming buildup
Reason:-

No need for recalibration after replacing electronics

Automatic monitoring of electronics
9

2. Resistance temperature detectors (Temperature sensor)

Figure 6: Omnigrad M TR47

Resistance temperature detectors are RTD temperature sensor with weld in connection. Its
sensors used to measure temperature by correlating the resistance of the RTD element with
temperature. Most RTD elements consist of a length of fine coiled wire wrapped around a
ceramic or glass core. The element is usually quite fragile, so it is often placed inside a sheathed
probe to protect it. The RTD element is made from a pure material whose resistance at various
temperatures has been documented. The material has a predictable change in resistance as the
temperature changes; it is this predictable change that is used to determine temperature.
Characteristic:

Fast response time

High pressure resistance
Surface finishing down to Ra < 0.4 m, with or without electro-polishing
Stainless steel, aluminum or plastic housing, all of them easily cleanable and IP65 at minimum
(IP68 available)
Replaceable mineral insulated insert; it, installed inside the thermowell, avoids plant shut
down during the substitution or the verification of the instrument
PCP (4...20 mA, with enhanced accuracy), HART and Profibus-PA 2-wire transmitters
Pt 100 sensing element with class A accuracy (DIN EN 60751)
Double Pt 100, for redundancy or validation purposes
ATEX 1 GD EEx ia certification
Material certification (3.1.B, ...)
EA calibration certificate
Ferrite content determination
Sensor matching calibration
Supplied with or without thermowell

10

3. Digital pH sensor

Figure 7: Orbisint CPS11D

This product is a digital pH electrode with Memosens technology for standard applications in
process and environment technology. It is designed with a dirt-repellent PTFE diaphragm and a
built-in temperature sensor. With ATEX, FM and CSA approval it is made for application in
hazardous areas.
Advantages:

Robust electrode requiring low maintenance due to large PTFE ring diaphragm
Certified biocompatibility
Application under pressures of up to 16 bar / 232 psi
Long service life due to double junction system of metal lead and thus long electrode poison
diffusion path
Sterilizable
Process glass for highly alkaline applications available
Built-in temperature sensor for effective temperature compensation
Poison-resistant reference with ion trap available

11

4. Conductivity sensors

Figure 8: Indumax H CLS54

Indumax H CLS54 is an inductive conductivity sensor with hygienic design specifically for
applications in the food, beverage and pharmaceutical industries as well as in biotechnology.
Thanks to its food-grade virgin PEEK body, its jointless and creviceless design and its hygienic
certificates, it meets the extremely exacting demands of these industries.
Advantages:

Unique hygienic design, thus no risk of recontamination

With all hygienic certificates required in hygienic applications
With all process connections commonly used in hygienic applications
Durable thanks to encapsulated, jointless design
Fast measurement with temperature response time t90 under 26 s enables safe and efficient
phase separations
Insensitive to electrode soiling and polarisation thanks to electrodeless, inductive measuring
principle
Suitable for application in hazardous areas

12

5. Ultrasonic continuous sensor (level sensor)

Figure 9: Prosonic 8 FMU90

Ultrasonics sensor work on a principle similar to radar or sonar which evaluate attributes of a
target by interpreting the echoes from radio or sound waves respectively. Ultrasonic sensors
generate high frequency sound waves and evaluate the echo which is received back by the
sensor. Sensors calculate the time interval between sending the signal and receiving the echo to
determine the distance to an object.
Advantages:

Simple, menu-guided operation with 6-line plain text display; 15 languages selectable
Envelope curves on the display for quick and simple diagnosis
Easy operation, diagnosis and measuring point documentation with the supplied "FieldCare"
operating program.
Option: four digital inputs (e.g. for pump feedback) and one external temperature input
Time-of-flight correction via integrated or external temperature sensors
Linearisation (up to 32 points, freely configurable)
Linearisation tables for the most common flumes and weirs pre-programmed and selectable
Online calculation of the flume-/weir-flows via integrated flow curves
Pre-programmed pump control routines
System integration via HART or PROFIBUS DP
Automatic detection of the sensors FDU9x
The sensors of the series FDU8x can be connected

13

6. Absolute measurement with metal sensor

Figure 10: Cerabar S PMP75

Its is Pressure transmitter with metal sensor and Overload-resistant and function-monitored;
Communication via HART, PROFIBUS PA or FOUNDATION Fieldbus
Advantages:

Very good reproducibility and long-term stability

High reference accuracy: up to 0.075%, as PLATINUM version: 0.05%
Turn down 100:1, higher on request
Used for process pressure monitoring up to SIL3, certified according to IEC 61508 by TV
SD
HistoROM/M-DAT memory module
Function-monitored from the measuring cell to the electronics
Continuous modularity for differential pressure, hydrostatic and pressure (Deltabar S,
Deltapilot S, Cerabar S), e.g.
- replaceable display
- universal electronic
Quick commissioning thanks to quick setup menu
Menu-guided operation
Extensive diagnostic functions
Device versions in conformity with ASME-BPE

14

Sensor Characteristics
Thermocouple
Thermoelectric

Semiconductor
Semiconductor
junction

-100 to +325C

Platinum RTD
Platinum wirewound or metal
film
-200 to +650C

-200 to +1750C

-70 to 150C

0.05 to 1.5 C

0.1 to 1.0C

0.5 to 5.0C

0.5 to 5.0C

0.2C/year (epoxy)
0.02C/year
(glass)
NTC Resistance
-4.4%/C typical
Exponential

0.05C/year (film)
0.002C/year
(wire)
PTC resistance
0.00385//C
Fairly linear

>1C/year

Constant voltage
or current
Generally slow
1 to 50 seconds

Cost

Low to moderate

Fast
0.10 to 10
seconds
Susceptible/Cold
junction
compensation
None over short
runs. TC
extension cables
required.
Low

Slow
5 to 50 seconds

Lead Resistance
Effects

Constant voltage
or current
Fast
0.12 to 10
seconds
Rarely susceptible
High resistance
only
Low resistance
parts only

Variable, some
types very prone
to aging
Thermovoltage
10V to 40V/C
Most types nonlinear
Self-powered

Sensor

Temperature
Range (typical)
Accuracy
(typical)
Long-term
Stability @ 100C
Output
Linearity
Power Required
Response Time

Susceptibility to
Electrical Noise

NTC Thermistor
Ceramic (metaloxide spinel)

Rarely susceptible

Very susceptible.
3 or 4-wire
configurations
required
Wire-wound
High
Film - Low

Table 1: Sensor Characteristic

15

Digital, various
outputs
Linear
4 to 30 VDC

Board layout
dependent
N/A

Moderate

Sensor Advantages and Disadvantages

Sensor

Advantages

Disadvantages

NTC Thermistor
Ceramic (metaloxide spinel)

Sensitivity
Accuracy
Cost
Rugged
Flexible
Packages
Hermetic Seal
Surface Mount
Non-linearity
Self-heating
Moisture failures
(non-glass only)

Platinum RTD
Platinum wirewound or metal
film
Accuracy
Stability
Linearity

Thermocouple
Thermoelectric

Semiconductor
Semiconductor
junction

Temperature

Lead resistance

Cold-junction

error
Response time
Vibration
resistance
Size
Package
limitations

compensation
Accuracy
Stability
TC extension
leads

Range
Self-Powered
No Self-heat
Rugged

Table 2: Sensor advantages & disadvantages

16

Ease of Use
Board Mounting
Rugged
Overall Cost

Accuracy
Limited

applications
Stability
Response time

TANK/VALVE/PIPE SIZING
Valves
1. Jacketed Ball Valves

Figure 11: Jacketed Ball Valve (Full Jacketed Ball Valve)

Jacketed ball valves for handling highly viscous materials or materials that solidify at ambient
temperatures are available from Metso Automation for use with steam or other heat transfer
media. These valves ensure free flow through the valve and prevent clogging when the valve is
closed.
Salient Features:

High Performance Ball Valve

Longer Life
Positive Shut off
Quick in Action
No Lubrication

Compact Design
Low Pressure Drop
Simplicity
Heating / Cooling Jackets
Wide selection of Different Jacket Material

Design & Testing International Standard:

Valve Design

: BS 5351 / ANSI B 16.34 / API 6D

Pressure Testing

: BS 6755 Part II / API 598 / API 6D

Face To Face

: As Per ANSI B 16.10

Flange Drilling

: ANSI B 16.5 / BS 10 Table / DIN / IS 6392

Size Range

: " x 1" To 8" x 10"

17

2. Butterfly Valves

Figure 12: Butterfly Valves

A butterfly valve is a valve which can be used for isolating or regulating flow. The closing
mechanism takes the form of a disk. Operation is similar to that of a ball valve, which allows for
quick shut off. Butterfly valves are generally favored because they are lower in cost to other
valve designs as well as being lighter in weight, meaning less support is required
Salient Features :

Special Options :

Concentric, Slim-Seal Design

Greater Sealing Capacity
Soft Seat Design
Lower Torque with any fluid
Permanently tight closure
Bi-Directional Valve
Optimum operation under Vacuum
Condition
Suitable for On-off as well as Throttling
Service
Materials for almost all media
Short Face To Face Dimension
Wafer Design Body
Long Service Life
Smooth, Easy Operation
Maintenance Free Version
Less Weight, Easy To Install

18

Off Set Disc Design Butterfly Valve

for high pressure & temperature
service.
Moulded / Replaceable Seat option
Gear / Pneumatic Rotary Actuator
Operated
P.T.F.E. (PFA/FEP) Lined Butterfly
Valve
Flanged End, Butterfly Valve
Damper Type Butterfly Valve for
High Temperature Air Service
Off Set Disc Design Butterfly Valve
for high pressure & temperature
service
Tailor Made Valve

3. Safety valve

Figure 13: Safety valve

4. Glove valve

Figure 14: Glove valve

5. Gate valve

Figure 15: Gate Valve

19

Tank
1. Pasteuriser Tank

Figure 16: Pasteurizer Tank

We made an extensive variety of meticulousness engineered Pasteurizers which are designed
using latest mechanisms and highly developed technology. These pasteurizers have
acknowledged incredible appreciation in the market for their robustness, performance and robust
construction.
Technical Specifications

Rectangular tank with inclined bottom made up completely of stainless steel (SS 304).

Function by gas burner unit

Engineered with four-leg retrenchment for impeccable balancing.
The inner liner outer shell is made up of stainless steel with 2 glass wool insulation.
Feature include high speed stirrer for the perfect blending of dry ingredients.
Incorporated emulsifier with 2-speed motor.
Regulate high temperature pasteurization at +85 oC and the low temperature
pasteurization at +65oC.
Temperature is indicated by digital temperature meter & heating medium by water.

20

2. SS Liquid Mixing Tank

Figure 17: SS Liquid Mixing Tan

Other details of the product:

Inner and outer mirror smooth

For the stirrer shaft entry a lid with opening hinge and slot window is provided
Silicon gasket ring is also provided. Handle and legs are made out of S.S. 304 pipe
Caster wheel with brake system
S.S. 316 ball valve provided for liquid out at bottom/ side of the vessel

The advanced build SS Liquid Mixing Tank is accurately developed by our highly
knowledgeable and well-organized engineers. These finest quality SS Liquid Mixing Tanks are
made in comply with the national as well as international existing standards and norms. Our
clients can avail from us this SS Liquid Mixing Tank at reasonable price to gain full client
satisfaction.

21

3. Steam Jacket

Figure 18: GPE Steam Jacket

G.P.E. Equipment offers a complete line of stainless alloy, batch process and transfer tanks for
the Food / Dairy / Beverage, Pharmaceutical, Cosmetic, and Chemical Industries. Vessel
specifications can include multi-zone jacketing, vacuum pressure options, single-motion, doublemotion or twin action agitators, portability, standard or special Ra and electropolish surface
finishes as well as digital readouts and controls for motors and temperature. Our custom
designed tanks are quality crafted to your specifications.

22

4. Fruit washing tank

Figure19: Jwala Fruit Washing

Suitable for various fruits like mango, guava, apple and vegetables like potato, carrot, cucumber,
beetroot, peas etc.

Complete stainless steel body and supports.

Products are subject to
o Soaking
o Agitation
o Fresh water rinsing
Specially designed takeoff conveyor to transfer the product from the washing tank to the
discharge end.
Sturdy construction; streamlined appearance.
Sanitary design and ease in cleaning.
Compact unit with a wide range of capacity.

23

Pipe Sizing
1. Stainless Steel Seamless Pipe

Figure 20: Stainless Steel Seamless Pipe

These pipes are used in:

Heat-exchangers
Condenser
Boiler
Economizers
Super-heater
Pre-heater
Oil coolers
Sizes
Products
Heat Exchanger Tubes
Instrumentation Tubes
Pipes

Size / Range
10.00 mm to 50.80 mm OD
6.00 mm to 25.40 mm OD
1/8" to 6" NB

24

2. Stainless Steel pipe

Figure 21: Stainless Steel SUS 439 pipe

Beside these, TSA also supplies other SUS 439 products such as:

SUS 439 Coil and SUS 439 Plate :

Thickness : 0.4mm - 3.0mm (2B, 4B, HL,BA, Mirror)
Thickness : 3.0mm - 6.0mm (1B)

SUS 439 Angle, Flat Bar and Rod

25

Actuators
1. VCB, 2 Port Solenoid Valve for Warm Water, Single Unit

Figure 22: Solenoid Valves

Series VC is a multipurpose, direct operated, 2 port solenoid valves for air. Special construction
reduces operating resistance and moving parts for improved longevity and wear resistance. A
built-in rectifier eliminates AC coil burning and buzzing. The VC enclosure is IP65 equivalent.

Fluid: heated water (99C or less)

Max. operating pressure (MPa): 3.0
Effective area (Cv): 0.16 to 2.1
Coil rated voltage: 100, 110, 200, 220, 230VAC (50/60Hz)
Ambient temp: -20 to 100C
Fluid temp: 99C or less

2. LVM09/090, 2/3 Port Solenoid Valve for Chemicals

Figure 23: Solenoid Valve for Chemical

26

Series LVM is a compact, direct acting, 2/3 port solenoid valve for chemicals. The unique
construction reduces residual liquid to a minimum. Superior resistance to chemicals requires less
maintenance. Service life (based on SMC test conditions) is 10 million cycles or more.

Orifice diameter: 1.1mm

Available with power-saving circuit
2 port N.C. or N.O. types; 3 port Universal type
Diaphragm choice of EPDM, FKM or Kalrez
Wetted part material: PEEK (body/plate)

3. NVM800, 800 Series, 3 Port Mechanical Valve

Figure 24: Solenoid Mechanical valve

The VM series is a mechanical, poppet valve. Their compact size requires little mounting space.
The VM series offers a wide variety of actuator styles and flow capacity up to 1.0 Cv.

Fluid: air
Operating pressure: -100kPa to 1.0MPa
Effective area (Cv): 6mm 2 (0.33)
Ambient and fluid temperature: -5 to 60C (no freezing)
Port size (nominal size): 1/8 (6A)
North American threads (NPT)

27

Pumps
1. Lobe Pump

Figure 25: Pumps for fruits

These pumps offer a variety of lobe options including single, bi-wing, tri-lobe (shown), and
multi-lobe. Rotary lobe pumps are non-contacting and have large pumping chambers, allowing
them to handle solids such as cherries or olives without damage. They are also used to handle
slurries, pastes, and a wide variety of other liquids. If wetted, they offer self-priming
performance. A gentle pumping action minimizes product degradation. They also offer
reversible flows and can operate dry for long periods of time. Flow is relatively independent of
changes in process pressure, so output is constant and continuous.
Advantages

Pass medium solids

No metal-to-metal
contact
Superior CIP/SIP
capabilities
Long term dry run
(with lubrication to
seals)
Non-pulsating
discharge

Disadvantages

Requires timing gears

Requires two seals
Reduced lift with thin
liquids

28

2. Helios Hygienic Pump

Figure 26: Hygienic pump

Polished stainless steel is used for all metal parts in contact with the product and reliable
operation and reduced downtime is further enhanced by the inclusion of a sealed pin joint.
Capacity
Pressure
Temperature
m/h Up to 180 bar Up to 24 C -10 up to 100
gpm Up 660
psi Up to 347 F 14 up to 212

29

ESTIMATION COST
In view of size of the market and the ensure economic viability of the project, rated production
capacity of 150 tons per year with 2 shift working and 300 working days in advisable.

Item

Qty

Price(RM)

Fruit Washing Tank

Juice Extractors
Steam Jacket Kettles
Stirrer
Boiler
Bottle Washing and Filling Machine
Testing Equipment
Jacketed Ball Valves
Stainless Steel Seamless Pipes
SS Liquid Mixing Tank
Pasteuriser Tank
Butterfly Valves
LVM09/090, 2/3 Port Solenoid Valve for Chemicals
VCB, 2 Port Solenoid Valve for Warm Water, Single Unit

2
2
2
1
1
1
2
5
1
1
1

3
3
3

10 000
85 000
40 000
15 000
60 000
75 000
30 000
15 000
3 000
6 000
7 000
2 000
1 200

Absolute measurement with metal sensor

2 000

Ultrasonic continuous sensor (level sensor)

4 500

Conductivity sensors

1 000

Digital pH sensor

Resistance temperature detectors (Temperature sensor)

2 500

Capacitance Level (Level sensor)

3 000

1
4
1
1
2
1
4
TOTAL

1 700
4 000
2 000
1 300
1 400
7 010
5 400
RM 384,160.00

NVM800, 800 Series, 3 Port Mechanical Valve

Lobe pumps
Safety valves
Globe Valves
Gate Valves
Stainless Steel pipe
Helios Hygienic Pump

30

1 150

CONSTRAINT
A constraint is anything that prevents the system from achieving more of its goal. There are a
few constraints in this plant. The internal constraints are:

Equipment use is overestimates (more cost required)

Equipment use is underestimates (lack of efficiency)
Insufficient technical knowledge for the high technology equipment,
Insight from real plant engineer
Process instruction limited the availability of idea
Not enough engineering software to support the project

The chance to do this assignment is very useful for us to get to know the real plant process. This
is because we use the actual equipment that is used there in the plant.

31

CONCLUSION
Conclusion from this plan is we know how to build a plan process using a technical process like
electrical, mechanical and electronic part. To build a plan processing needs to know the
characteristic of the equipment like sensors and etc. Process of cloudy apple juice need to do
twice process and enzymation because it does can be effective. Also using a steam jacket its can
be save time and The temperature in the jacket can be controlled much more accurately with hot
water than with steam.
From the sensor selection we had learned a lot of type of sensor that are available in the market
and how to select the correct sensor based on the application. Furthermore, we also learned how
to use the sensor and how to calibrate it.

From the software selection, we can say that we had managed to learn a lot of latest software
such as CX-Programmer for PLC, P&ID software, and others. Based on that software we were
managed to develop the smart and efficient soap production process plant as we desired. Besides,
this software helps us to run our project smoothly and the duration of our project become lesser
as we dont have to worry about the time chase anymore.

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REFERENCES
http://www.engineersgarage.com/articles/what-is-level-sensor?page=4
http://www.engineeringtoolbox.com/valves-types-d_218.html
http://www.alfalaval.com/industries/food-dairy-beverages/Documents/Juicy%20apples.pdf
http://www.fao.org/docrep/005/y2515e/y2515e15.htm
http://www.elibrary.dep.state.pa.us/dsweb/GetRendition/Document-48902/html
http://www.westfalia-separator.com/applications/beverage-technology/fruit-and-vegetablejuices/citrus-juices.html
http://www.tepsmarttech.com/turnkey-projects/fruit-juice-plant.html
http://www.dylanwelsh.org/food-processing-plants.html
http://www.endress.com/eh/home.nsf/#page/id/1B0C22334F927D3AC12577C900686598

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