30 Oct 2023
DEPARTMENT OF FOOD AND AGRICULTURAL ENGINEERING
PROCESS AND
MATERIAL FLOW
ABEN 125 – DESIGN AND MANAGEMENT OF AB PROCESSING
SYSTEMS
OBJECTIVES
•Know the activity symbols
•Identify types of process charts
•Construct chart design
•Analyze process through diagrams
•Identify mass and energy involved in the
system
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Introduction
• A complete processing plant consists of a number of unit
operations or processes arranged in a certain sequence
which may be simple, as in feed grinding on the farm, or
complex as in producing cotton seed oil or soybean oil.
• In designing a new plant or rearranging an existing plant
for more efficient operation, a certain established
procedures should be followed to secure the most
satisfactory results.
• These procedures can be shown through the activity
symbols.
Activity Symbols
As standardized by the American Society of Mechanical
Engineers, the process is composed of six types of steps:
1. Operation
2. Transportation
3. Inspection
4. Storage
5. Delay
6. Combined Operation
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Activity Symbols
1. Operation
• alteration of an object's physical and chemical
characteristics,
• assembling or disassembling objects
• arranging/sorting objects for another operation
• providing or receiving information
• planning or calculating
e.g. Drying, hulling, whitening, sorting, cleaning, grading,
mixing, blending
Activity Symbols
2. Transportation
• Any movement of a material from one place to another
unless such movement is an integral part of an
operation,
e.g. grain by elevators, milk by pump, refuse by truck,
fruit by belt, box by employee, grain by truck.
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Activity Symbols
3. Inspection
• an object is examined for identification or verified
for quality or quantity in any of its characteristics.
e.g. moisture content determination of grain,
determining grade of fruit, checking performance of
vegetable washer, noting temperature of pasteurizer.
Activity Symbols
4. Storage
• A storage occurs when an object is kept and
protected against unauthorized removal.
• A desirable interruption of activity
e.g. such as ingredients being held for future use, fruit
being held for optimum market.
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Activity Symbols
5. Delay
• When conditions do not permit or require immediate
performance of the next planned action.
• An undesirable interruption of activity.
e.g. prunes in tray waiting to be dried, material in truck
waiting to be unloaded, employee waiting for machine to
operate.
Activity Symbols
6. Combined Activity
When it is desired to show activities performed either
concurrently or by the same operator at the same work
station, the symbols for those are combined.
e.g. cheese in a processing room is both a storage and an
operation; mixing process may be both an operation and
a transportation.
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Process Charts
•a graphic representation of events and
information occurring during a series or
operations.
Types:
1. Operation Process Chart
2. Flow Process Chart
3. Layout Sheet or Layout Diagram
Operation Process Charts
• also known as outline process chart
• provides a comprehensive overview of a
product's production system, recording main
activities in sequence regardless of location
or performance, regardless of job
completion.
• The method is present, proposed, or revised,
indicating existing conditions, proposed
changes, or revised procedure developed
after previous study.
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Operation Process Charts
Advantages:
•Enhances plant layout
•Specifies basic manufacturing system,
•Determines assembly sequence and
schedule activities, and
•Introduces new technical personnel to the
manufacturing system.
Operation Process Charts
Other conventional details in OPCs
Material added to Material added to Material removed
the main line prior the main line during as a result of an
to operation an operation operation
Material divided
with no operation Optional process
being performed routes indicated
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Operation Process Charts
Considerations:
1. What events can be combined?
2. Can inspections be eliminated?
3. Can delays be eliminated or converted into
storages?
Field-run seed from producer
Operation 1 Quality Inspection
Process Chart
(a)
1 Storage
(b)
Primary separation by
1
Subject Charted: Seed cleaning and Treating screen and aspiration
Chart Type: Material
2 Quality inspection
Method: Present 3 Quality inspection
(d)
Separation by
2
gravity table
5
4 Quality
inspection
Quality
2
1 inspection Storage
Delay
Treating powder
3 Grind by hammer mill
4 Treating operation
Summary
6 Sack
No. Operations 6 5 Sack
No. Inspections 5 3 Storage
No. Delays 1 1 (c)
No. Storages 4 Storage
(e) Weed seed and trash
Clean Seed
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Flow Process Charts
• Chart of all the activities involed in a process
• Similar to an OPC, except that more detail is shown by
including transportations and delays as well as
operations, inspections, and storages.
• The flow process chart may represent the entire
process, but because of the volume of detail it is
generally used for significant parts of it only.
• Includes:
• Operation duration (time to complete)
• Distance traveled (for transport operations)
Flow Process Charts
Displays product flow sequence using
symbols for operation, transportation,
inspection, delay, and storage; recording times
and distances moved along the symbols side.
Types:
1) Man – what the worker does
2) Machine – how the equipment is used
3) Material – what happens to the material
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Flow Process
Chart
Layout Diagram
•This is a graphical plot of operation or
event locations showing the direction of
flow of materials and labor.
•It is usually a plan layout to scale showing
space utilization and direction of
movement of materials.
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Layout Diagram
Information Needed:
1. Relative to the Entire Process
2. Relative to each step listed on the
process charts
Relative to the Entire Process
1.Rate and characteristics of flow in
each line.
a. Rate of flow
b. Frequency
c. Duration
d. Duration of occurrence
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Relative to the Entire Process
2.Characteristics of structure and area
a. Service facilities, roads, railroads,
capacity, connections, relative location
b. Available utilities
c. Orientation and prevailing wind
characteristics
d. Details of structure and area
Relative to Each Step
1. Capacity of unit
2. Labor requirement and characteristics
3. Space requirements for unit, service,
and labor
4. Utilities required
5. Materials required for flow in and out of
unit.
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Layout Procedures
1. The material from one operation should be placed in
such a position that it can be most easily picked up for
the next operation.
2. The distance an operator must move to obtain or
deliver material away from a machine should be
reduced to a minimum.
3. Time spent by a machine performing an operation or
part of an operation which does not require the
immediate attention of the operator or attendant is
idle time as far as the attendant or operator is
concerned.
Plant Layout
Diagram
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Layout Diagram Symbols
Layout Diagram Symbols
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Layout Diagram Symbols
Layout Diagram Symbols
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Layout Diagram Symbols
Layout Diagram (Process)
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Material Balance
Material balance calculations are
employed in tracing the inflow and outflow
of material in a process and thus establish
quantities of components or the whole
process stream.
The principle is based on the Law of
Conservation of Mass.
Material Balance
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Material Balance
Energy Balance
An energy balance around a system is based on the first law
of thermodynamics: the law of conservation of energy.
Mechanical (work), electrical, and thermal energy can all be
reduced to the same units.
Defining the surroundings of the system on which to make an
energy balance is done like material balance calculations.
The basic energy balance equation is:
Energy in = Energy out + Accumulation
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Energy Balance
Energy Balance
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Laboratory Exercise 3
Prepare the following for your processing plant:
1. Operational Flow Diagram
2. Flow Process Chart
3. Process Layout Diagrams and Plant Layout Diagram
4. Mass and Energy Balance
