28-08-2014, 04:26 PM
This project file has been made on the operation of food production and packaging .I had tried to make this project file on 6 Months industrial training as precise knowledge about the different process of making corn flakes at industrial level. This project report includes the basic process of making corn flakes from raw material and different stages from it is passed. Some other sections of this project file includes about the all different types of machines which takes a part in manufacturing of corn flake. The basic principle and theit diagram are shown as there are essential. All units including from power generation to their cleaning boiling, roasting ,milling, processing are included in this After all the packaging of material into sealed packet is also described in this report file. In this project report I have tried to explain with proper figures and their components working process
Company Profile Amrapali Biotech India Private Limited FIG:- 1. 1corn Flakes We are a rapidly growing unit in FMCG industry offering a diverse range of confectionery products or processed snack foods like pickles, jams, sauces, snacks, cornflakes and candies. Our range of confectionery and snack food products are marketed under the brand name MUM'S for food industry. These are highly appreciated for freshness, aroma and delicious taste across the globe. Our processing unit is well equipped with vacuum concentrate plant that assists us in meeting the bulk orders of our domestic and international clients. We adhere to stringent quality control parameters to ensure that our entire range of food products is of CGMP and BIS standards with hygienic conditions. Our quality range of food products has helped us in acquiring a large number of clients which includes some internationally reputed names such as Wallmart and Spencors. Incepted in the year 2007, Amrapali Biotech India Private Limited is engaged in manufacturing, exporting and supplying a wide range of pickles, jams, sauces, snacks, cornflakes for food industry. We are moving ahead with our vision of providing quality food products that are marketed under the brand name “MUM'S” all over the world. These are processed using natural ingredients such as corn, herbs, fruits & vegetables, spices, edible oils andsugar that are procured from our reliable vendors. We are planning to expand in the food industry by introducing products such as cornflakes, twenty-twenty snacks, jams, pickles, sauces in the global markets. These are processed as per CGMP and BIS standards to maintain consistency in the quality of our entire range of food products. We lay emphasis on maintaining proper hygienic conditions during production process, storage, packaging and transportation to ensure that our entire range of food products is fresh, highly nutritious and has longer shelf life. In order to reach more clients our organization is also supported by our additional branches that are located in Ghazipur (U.P.) and Udaipur(Rajasthan). With a vast experience, our team of production & marketing has enabled us to carve a niche in the competitive market. Their hard work and vision has helped to establish ourselves as the first choice of the customers and employees in a global scenario. 2 Product Portfolio We are one of the renowned names in the FMCG industry manufacturing and exporting a wide spectrum of wide range of pickles, jams, sauces, snacks, cornflakes under the brand name “MUM'S” for food industry. Our range of food products is processed using natural ingredients such as corn, herbs, fruits & vegetables, spices, edible oils and sugar that are procured from our reliable vendors. These find wide application in various areas including retail outlet and domestic market. Following are some of the salient features of our range of pickles, jams, sauces, snacks, cornflakes: · Highly nutritious · Fresh · Rich aroma · Longer shelf life Processing Unit We have a large and spacious processing unit that enables us in the voluminous production of our entire range of pickles, jams, sauces, snacks, cornflakes. Our processing unit is well equipped with vacuum concentrate plant that further helps us in fulfilling the exact requirements of our domestic and international clients. Our range of food products is rigorously checked at every level of production process, right from the selection of the ingredients to the final dispatch of our consignments to maintain consistency in its quality. Proper hygienic conditions are also maintained across processing unit to ascertain that our range of food products is of CGMP and BIS standards. Some of the machines used in our processing unit comprise: · Extruding machines · Pulverizing machines · Packing machines These machines are regularly upgraded to meet the exact requirements of our clients within the stipulated time frame. Team We nurture a qualified and experienced team of professionals who constantly support in various business processes. Our team coordinates efficiently to provide our clients a wide spectrum of fresh pickles, jams, sauces, snacks, cornflakes. Our food experts and quality analysts work hard to maintain the quality of our entire range of food products which further helps in acquiring a large client base across the globe. Moreover, our sales and marketing experts make proper market surveys in order to keep us abreast of the changing market trends. 3 Our Dedicated Professionals Comprise: · Machine operators · Food experts · Quality auditors · Skilled workers · Sales and marketing personnel Our Strength Some of the factors that distinguish us from our competitors comprise: · Robust infrastructure · Optimum quality · Ethical business practices · Wide distribution network · Competitive pricing · On time delivery Warehousing And Packaging We have a large and spacious warehouse which helps in safe storage and easy retrieval of our finished food products. Our warehouse personnel maintain proper hygienic conditions across the entire warehouse to ensure that our range of pickles, jams, sauces, snacks, cornflakes are fresh and highly nutritious for long time span. In addition, we also hygienically pack our entire range of food products as per the requirements of our clients for its safe transportation. This further helps us to maintain consistency in the quality of our range of food products. Present Supply And Demand Currently, there is only one recently established private company in the country engaged in the Manufacture of corn flakes. The planned annual production capacity of this new company is 288 Tons. The ingredients of the product of this company are corn flour, chocolate powder and Chocolate color. Data on actual production of this plant could not be obtained. Moreover, corn Flakes are also imported from abroad. Assuming that the domestic plant produces at its full capacity.The 2006 statistical abstract confirm that there are 12.2 million people living in the urban places of Ethiopia. With average family size of 5, this represents roughly 2.5 million families. If we conservatively assume that only 2.5 percent of these families are able to demand the product, the number of families with potential demand will be 62,500 families. With further conservative assumption of 1 kilogram of cornflakes consumed per a family per week with the reduced price, the annual demand would be 3000 tons of corn flakes. This demand analysis increases when the international community and demand of hotels, restaurants and cafes is added in the computation. Retail Price Of Imported Corn Flakes Weight (in gram) Price 330 65 500 90 500 gm combo 125 4 Plant Capacity The demand projection obtained in the previous section indicates the presence of ample demandfor the product when prices are relatively reasonable and proper promotion is performed. Accordingly, given this demand and the planned technology, the envisaged plant is set to produce 1,000 tons of corn flakes annually. Production Program The program is scheduled based on the consideration that the envisaged plant will work 275 days in a year in 2 shifts, where the remaining days will be holidays and for plant and machinery maintenance. During the first year of operation the plant will operate at 70 percent capacity andthen at 80 percent in the 2 nd year and at 90 percent in the 3 rd year. The capacity will grow to 100percent starting from the 4 th year. This consideration is developed based on the assumption thatmarket and logistics barriers would take place for the first two to three years of operation Availability And Source Of Raw Materials The major raw material used for the manufacture of corn flakes is maize (hybrid yellow and white corns). In Ethiopia, maize is widely produced in all parts of the country where in 2005/06, alone 33.4 million quintals were produced throughout the country. In the same year Amhara region produced 35% of the total cereal production in the country which roughly implies that 11.7 million quintals of maize is the share of the region. The varieties grown are mixtures of white, yellow and purple seeds where it is largely produced by the private farms. The fact that corn does not constitute one of the staple foods in the Amhara Region points the presence of ample maize (corn) for the envisaged plant. Sugar is another raw material used for the manufacture of corn flakes. There are three large-scale sugar establishments in the country. These establishments have a production capacity 280,000 tons of sugar annually. White sugar, which is used in the manufacture of corn flakes, is mainly exported to the neighboring countries such as Djibouti, Kenya and Yemen in quantities ranging between 30,000 to 50,000 tons per annum. In addition to the existing cane sugar establishments, new sugar projects are currently under construction. Production Process The milling process removes the corn kernels from the cobs and turns them into flaking sized 'grits'. Malted barley can be added to enhance the flavor of the Corn Flakes. The corn grits are cooked in steam pressure cookers, at temperatures exceeding 100C. This cooking process lasts for an hour and softens the hard grits. During cooking additional water is incorporated in the form of steam which condenses and the water content in the batch rises to 30-35%. Then the hotgrits are transported from the cookers to large driers via the network of pipes. The grits spendseveral hours in the hot-air driers in order to reduce their moisture content. The corn grits are milled using rollers, which squeeze the grits flat.The flakes are then tumble toasted in huge cylindrical ovens. The air in the ovens is heated by600C0 gas flames and the flakes are tossed around in a rotating drum. The drum is angled so thatthe flakes whirl around and pass through it quite quickly, and stops them spending too long in thefierce heat. 5
CHAPTER-1. CORN FLAKE PRODUCTION UNIT 1.1 Introduction We are professional manufacturer of food machinery. We have many years experience in this industry. Our machine has been exported many countries,like Russia,German,Ukraine,South Africa, they have obtained much praise for their reliability and full automatic from our clients.Corn flakes can be flavored with sugar,honey,coco and cheese,etc.Corn flakes are a popular breakfast cereal manufactured by twin- screw extruder through the treatment of corn flakes of grain, served with milk and marshmallows, were a very popular food among the families. 1.2 Features 1)Corn flakes is one kind of crispy food which is processed by this line and adopt grist as basic material 2)It is fast and nourishing food with given structrue,such as granule shape,flake shape and animal shape. 3)For the cornflakes processing line, different process get different snacks,and different taste. 1.3 Raw Materials Kinds of cereals, such as: corn flour, rice flour, corn grits, millet and so on. FIG:-1.2CORN FLAKE 1.4 Process Flow Mixer---extruder---vibrate cooler---rollers drying machine---flaking, air conveyor and rosting---high temperature inflate---second vibrate cooler---sugar spayer---multi-layer oven---cooling 6 FIG:-1.3CORN FLAKES PROCESS LINE 1.5 Process To Make Classic Cornflakes I) Raw Material: The best material is hard dent corn, because of its transparency after gelatinization andgood looking of the products. II. Adopting the drying-degerming method. First, to regulate the moisture with the hot steam and hot water exceeding 90℃.And then to pre-grind the corn without germ. The mixture would separate out grits after evenly sieving. III. Ingredients: To add the salt, malt and the other ingredients with the water during cooking the grits, it can make the water content up to 20％～35％, then to cook the grits with steam of 1.47X105P until gelatinized to semi-transparent. IV. Drying: to dry and extrude the grits at 66℃ until the moisture is 19％～20％, cool it down to 30～40℃. Then to press the flake to 0.7～1mm with steel roller. Before pressing, the corns should be made dispersedly to ensure the chips evenly distributed. V. Roasting: Temperature: 250～350℃, Time: 20～150 seconds. to make the moisture down 7 to 10％. To fry the chips with the temperature not exceed 200℃，the corn chips would be crispy. VI. Spraying enhancer: To spray with nutrient substance to make it intensified corn chips or spread on sugar, flavor if necessary. The process of Heshan China corn flakes machines is shown as follows: Corn →Cleaning →Peeling and Degerming →Classifying →Cooking →Drying & Rlending →Rolling, Flaking or Extruding →Toasting →Cooling →Packing →Finished Products 1.6 Modern Process To Make Bran Flakes, Wheat Flakes, Multigrain Flakes, Frosted Flakes, Direct Expanded Cereals Mixing →Conditioning → Extruding →Pulse Drying →Vibrate Feeding → Rolling, Flaking or Extruding →Fluid Bed Toasting→ Cooling → Packing → Finished Products The high speed rolling machine is a key unit in the system of Heshan China corn flakes achines It is composed of a pair of alloyed steel roll which rotate on opposite directions, high strength frame, hydraulic controlling system, auto adjusting roll seam system, cooling constant temperature system of the rolling, transmission system and control system. For the rolling machine, it has high requirements to rolling technology; First, it requires high hardness of roller surface. If it can not meet the standard, the surface , not smooth as that, would be damaged after a period of using to effect the rolling. We can make the hardness of the surface more than 65 degrees with special technology. It allows you to use them more than ten years. Second, it requires high accuracy requirements. If it can not meet the standard, you may find that the rolling can not evenly, it would be serious vibrating and noisy .Thus it requires us to control the processing procedure strictly, it has to make sure that the cylindricity of rolling is on 3μm. The rolling machine adopts hydraulic pressure control system, the roller can be adjusted the pressure to perfect situation according to the product characters to ensure the product quality. The servo regulating system of the roller allows you to adjust the gag in the range of 0-2mm. It is number display; you can read them easily and accurately. We design the cooling water tunnel inside the roller, so it can avoid the rolling gap changing occurred by expand with heat and contract with cold during working, as it would impact the rolling quality .To ensure the rolling can work in a constant temperature condition we design a circulating cooling water & constant temperature control system which has the high pressure water pump for the cooling water tunnel inside the roller . The accidental legacy of corn flakes goes back to the late 19th century, when a team of Seventh-day Adventists began to develop new food to adhere to the vegetarian diet recommended by the church. Members of the group experimented with a number of different grains, including wheat, oats, rice, barley, and corn. In 1894, Dr. John Harvey Kellogg, the superintendent of The Battle Creek Sanitarium in Michigan and an Adventist, used these recipes as part of a strict vegetarian regimen for his patients, which also included no alcohol, tobacco, or caffeine. The diet he imposed consisted entirely of bland foods. A follower of Sylvester Graham, the inventor of graham crackers and graham bread, Kellogg believed that spicy or sweet foods would increase passions. [ This idea for corn flakes began by accident when Kellogg and his younger brother, Will Keith Kellogg, left some cooked wheat to sit while they attended to some pressing matters at the sanitarium. When they 8 returned, they found that the wheat had gone stale, but being on a strict budget, they decided to continue to process it by forcing it through rollers, hoping to obtain long sheets of the dough. To their surprise, what they found instead were flakes, which they toasted and served to their patients. This event occurred on August 8, 1894, and a patent for "Flaked Cereals and Process of Preparing Same" was filed on May 31, 1895, and issued on April 14, 1896. [1][3][4] The flakes of grain, which the Kelloggs called granose, were a very popular food among the patients. The brothers then experimented with other flakes from other grains. In 1906, Will Keith Kellogg, who served as the business manager of the sanitarium, decided to try to mass-market the new food. At his new company, Battle Creek Toasted Corn Flake Company, he added sugar to the flakes to make them more palatable to a mass audience, but this caused a rift between his brother and him. To increase sales, in 1909, he added a special offer, the Funny Jungleland Moving Pictures Booklet, which was made available to anyone who bought two boxes of the cereal. This same premium was offered for 22 years. At the same time, Kellogg also began experimenting with new grain cereals to expand his product line. Rice Krispies, his next great hit, first went on sale in 1928.There have been many mascots of Kellogg's Cornflakes. The most popular one is a green rooster named Cornelius (Corny) Rooster, which has been the mascot since his debut. In earlier commercials, he had a speaking part and his catch phrase was "Wake up, up, up to Kellogg's Cornflakes!" He was voiced by Dallas McKennon and Andy Devine. Later, he stopped talking and simply crowed. The concept of using a stylized cockerel originated in a suggestion by Kellogg family friend Nansi Richards, a harpist from Wales and a Welsh language proponent. The Welsh word for cockerel is ceiliog (pronounced Kellogg). 9 CHAPTER-2 DANFOSS VLT MICRO DRIVE FC 51 2.1 Introduction The Danfoss VLT® Micro Drive is a genuine VLT® frequency converter with unsurpassed reliability, user-friendliness, condensed functionality, and extremely easy to commission. Terminal numbers are named in the same manner as in the rest of the VLT® family. It’s developed and manufactured by Danfoss Drives, the leading drives experts since 1968 and creators of VLT® – The Real Drive. 2.2 User Friendly · VLT Micro Drive share the user-friendliness of the VLT family. · Plug and play - minimum effort minimum time · Minimum Commissioning - save time · Copy settings via local control panel - simple set up of multiple drives · Intuitive parameter structure - minimal manual reading 2.3 Reliability VLT Micro Drive is a full member of the VLT® family sharing the overall quality of design, reliability and user-friendliness. High quality components and genuine VLT® solutions makes VLT® Micro Drive extremely reliable. · Optimum heat dissipation – Longer lifetime · High quality electronics/capasitors – Low lifetime cost · All drives full load tested from factory – High reliability · Earth fault, temperature and short circuit protection – Lean operation · Circuit boards well protected and coated – Increased robustness FIG:-1.4 MICRO DRIVE 10 2.4 Small Drive – High Performance Despite the compact size and the easy commissioning, VLT® Micro Drive can be set up to perform perfectly even in complex application set-ups. Approximately 100 parameters can be set to optimize energy efficiency and operation. · Process PI-controller – No need for external controller · Automatic Energy Optimizer (AEO) – Less energy consumption · Automatic Motor Adaptation (AMA) – Exploit motor’s full potential · 150% motor torque up to 1 minute – Replace need for bigger drive · Flying start (catch a spinning motor) – Lean operation – more up-time · Electronic Thermal relay (ETR) – Replace external motor protection 2.5 Real Space Saving Side-By-Side A compact book style design allows real side by side mounting without derating. 2.6 Minimum Penetration Of Dust VLT® MICRO Drive is designed to keep the forced ventilation away from the electronics. Printed circuit boards are well protected inside the drive. 2.7 Built-In Rfi Radio disturbance from motor cables is limited with the built-in RFI filter allowing for 15 m motor cables (screened). Meets EU norms. FIG:-1.5 VLT DRIVE 2.8 Built-In Brake Functions With built in DC and AC brake functions, VLT® Micro Drive can transform kinetic energy in the application into braking power to slow down the motor. A brake chopper is built-in the drives from 1.5 kW upwards. 2.9 Effective Heat Sink An effective heat sink easily removes heat from the electronics, extending lifetime and reliability of the drive. 11
CHAPTER-3 CONTACTOR RELAYS FIG:-1.7 CONTACTOR Contactor relays are switching devices for control and auxiliary circuits and are used to control, provide signals and interlock switching devices and switchgear panels. It goes without saying that the 3RH1 SIRIUS contactor relays have connection designations in compliance with the standard and use a connection system which is both time and cost saving – fulfilling the requirements from the field. The 3RH1 contactor relays and the size S00 motor contactors are the same size and have the same optical design; this represents a significant advantage, especially when it comes to accessories. They are designed for AC or DC operation and are available with screw or spring-loaded technology. The basic version of the contactor relays has 4 poles but this can be extended up to 8 poles using auxiliary contact blocks which can be snapped-on.When a relay is used to switch a large amount of electrical power through its contacts, it is designated by a special name: contactor. Contactors typically have multiple contacts, and those contacts are usually (but not always) normally-open, so that power to the load is shut off when the coil is de-energized. Perhaps the most common industrial use for contactors is the control of electric motors. 12 The top three contacts switch the respective phases of the incoming 3-phase AC power, typically at least 480 Volts for motors 1 horsepower or greater. The lowest contact is an "auxiliary" contact which has a current rating much lower than that of the large motor power contacts, but is actuated by the same armature as the power contacts. The auxiliary contact is often used in a relay logic circuit, or for some other part of the motor control scheme, typically switching 120 Volt AC power instead of the motor voltage. One contactor may have several auxiliary contacts, either normally-open or normally-closed, if required. The three "opposed- question-mark" shaped devices in series with each phase going to the motor are called overload heaters. Each "heater" element is a low-resistance strip of metal intended to heat up as the motor draws current. If the temperature of any of these heater elements reaches a critical point (equivalent to a moderate overloading of the motor), a normally-closed switch contact (not shown in the diagram) will spring open. This normally-closed contact is usually connected in series with the relay coil, so that when it opens the relay will automatically de-energize, thereby shutting off power to the motor. We will see more of this overload protection wiring in the next chapter. Overload heaters are intended to provide overcurrent protection for large electric motors, unlike circuit breakers and fuses which serve the primary purpose of providing overcurrent protection for power conductors. Overload heater function is often misunderstood. They are not fuses; that is, it is not their function to burn open and directly break the circuit as a fuse is designed to do. Rather, overload heaters are designed to thermally mimic the heating characteristic of the particular electric motor to be protected. All motors have thermal characteristics, including the amount of heat energy generated by resistive dissipation (I 2 R), the thermal transfer characteristics of heat "conducted" to the cooling medium through the metal frame of the motor, the physical mass and specific heat of the materials constituting the motor, etc. These characteristics are mimicked by the overload heater on a miniature scale: when the motor heats up toward its critical temperature, so will the heater toward its critical temperature, ideally at the same rate and approach curve. Thus, the overload contact, in sensing heater temperature with a thermo-mechanical mechanism, will sense an analogue of the real motor. If the overload contact trips due to excessive heater temperature, it will be an indication that the real motor has reached its critical temperature (or, would have done so in a short while). After tripping, the heaters are supposed to cool down at the same rate and approach curve as the real motor, so that they indicate an accurate proportion of the motor's thermal condition, and will not allow power to be re-applied until the motor is truly ready for start-up again. Shown here is a contactor for a three-phase electric motor, installed on a panel as part of an electrical control system at a municipal water treatment plant: 13 FIG:-1.8 CONTACTOR INTERNAL STRUCTURE Three-phase, 480 volt AC power comes in to the three normally-open contacts at the top of the contactor via screw terminals labeled "L1," "L2," and "L3" (The "L2" terminal is hidden behind a square-shaped "snubber" circuit connected across the contactor's coil terminals). Power to the motor exits the overload heater assembly at the bottom of this device via screw terminals labeled "T1," "T2," and "T3." The overload heater units themselves are black, square-shaped blocks with the label "W34," indicating a particular thermal response for a certain horsepower and temperature rating of electric motor. If an electric motor of differing power and/or temperature ratings were to be substituted for the one presently in service, the overload heater units would have to be replaced with units having a thermal response suitable for the new motor. The motor manufacturer can provide information on the appropriate heater units to use. A white pushbutton located between the "T1" and "T2" line heaters serves as a way to manually re-set the normally-closed switch contact back to its normal state after having been tripped by excessive heater temperature. Wire connections to the "overload" switch contact may be seen at the lower-right of the photograph, near a label reading "NC" (normally- closed). On this particular overload unit, a small "window" with the label "Tripped" indicates a tripped condition by means of a colored flag. In this photograph, there is no "tripped" condition, and the indicator appears clear. As a footnote, heater elements may be used as a crude current shunt resistor for determining whether or not a motor is drawing current when the contactor is closed. FIG:-1.9 MOTOR CONNECTION WITH CONTACTOR 14
CHAPTER-4 RELAY 4.1 Introduction A relay is an electrically operated switch. Many relays use an electromagnet to mechanically operate a switch, but other operating principles are also used, such as solid-state relays. Relays are used where it is necessary to control a circuit by a low-power signal (with complete electrical isolation between control and controlled circuits), or where several circuits must be controlled by one signal. The first relays were used in long distance telegraph circuits as amplifiers: they repeated the signal coming in from one circuit and re-transmitted it on another circuit. Relays were used extensively in telephone exchanges and early computers to perform logical operations. A type of relay that can handle the high power required to directly control an electric motor or other loads is called a contactor. Solid-state relays control power circuits with no moving parts, instead using a semiconductor device to perform switching. Relays with calibrated operating characteristics and sometimes multiple operating coils are used to protect electrical circuits from overload or faults; in modern electric power systems these functions are performed by digital instruments still called "protective relays". Basic Design And Operation FIG:-1.10 BASIC DESIGN 4.2 Simple Electromechanical Relay . FIG:-1.11 SIMPLE ELECTROMECHANICAL RELAY Small "cradle" relay often used in electronics. The "cradle" term refers to the shape of the relay's armature.A simple electromagnetic relay consists of a coil of wire wrapped around a 15 soft iron core, an iron yoke which provides a low reluctance path for magnetic flux, a movable iron armature, and one or more sets of contacts (there are two in the relay pictured). The armature is hinged to the yoke and mechanically linked to one or more sets of moving contacts. It is held in place by a spring so that when the relay is de-energized there is an air gap in the magnetic circuit. In this condition, one of the two sets of contacts in the relay pictured is closed, and the other set is open. Other relays may have more or fewer sets of contacts depending on their function. The relay in the picture also has a wire connecting the armature to the yoke. This ensures continuity of the circuit between the moving contacts on the armature, and the circuit track on the printed circuit board (PCB) via the yoke, which is soldered to the PCB.When an electric current is passed through the coil it generates a magnetic field that activates the armature, and the consequent movement of the movable contact(s) either makes or breaks (depending upon construction) a connection with a fixed contact. If the set of contacts was closed when the relay was de-energized, then the movement opens the contacts and breaks the connection, and vice versa if the contacts were open. When the current to the coil is switched off, the armature is returned by a force, approximately half as strong as the magnetic force, to its relaxed position. Usually this force is provided by a spring, but gravity is also used commonly in industrial motor starters. Most relays are manufactured to operate quickly. In a low-voltage application this reduces noise; in a high voltage or current application it reduces arcing.When the coil is energized with direct current, a diode is often placed across the coil to dissipate the energy from the collapsing magnetic field at deactivation, which would otherwise generate a voltage spike dangerous to semiconductor circuit components. Some automotive relays include a diode inside the relay case. Alternatively, a contact protection network consisting of a capacitor and resistor in series (snubber circuit) may absorb the surge. If the coil is designed to be energized with alternating current (AC), a small copper "shading ring" can be crimped to the end of the solenoid, creating a small out-of-phase current which increases the minimum pull on the armature during the AC cycle. [1] A solid-state relay uses a thyristor or other solid-state switching device, activated by the control signal, to switch the controlled load, instead of a solenoid. An optocoupler (a light-emitting diode (LED) coupled with a photo transistor) can be used to isolate control and controlled circuits. 4.3 Types Of Latching Relay FIG:-1.12 LATCHING RELAY A latching relay has two relaxed states (bistable). These are also called "impulse", "keep", or "stay" relays. When the current is switched off, the relay remains in its last state. This is achieved with a solenoid operating a ratchet and cam mechanism, or by having two opposing 16 coils with an over-center spring or permanent magnet to hold the armature and contacts in position while the coil is relaxed, or with a remanent core. In the ratchet and cam example, the first pulse to the coil turns the relay on and the second pulse turns it off. In the two coil example, a pulse to one coil turns the relay on and a pulse to the opposite coil turns the relay off. This type of relay has the advantage that one coil consumes power only for an instant, while it is being switched, and the relay contacts retain this setting across a power outage. A remanent core latching relay requires a current pulse of opposite polarity to make it change state. A stepping relay is a specialized kind of multi-way latching relay designed for early automatic telephone exchanges.An earth leakage circuit breaker includes a specialized latching relay.Very early computers often stored bits in a magnetically latching relay, such as ferreed or the later memreed in the switch.Some early computers used ordinary relays as a kind of latch— they store bits in ordinary wire spring relays or reed relays by feeding an output wire back as an input, resulting in a feedback loop or sequential circuit. Such an electrically-latching relay requires continuous power to maintain state, unlike magnetically latching relays or mechanically racheting relays.In computer memories, latching relays and other relays were replaced by delay line memory, which in turn was replaced by a series of ever-faster and ever- smaller memory technologies. 4.4 Reed Relay FIG:-1.13 REED RELAY A reed relay is a reed switch enclosed in a solenoid. The switch has a set of contacts inside an evacuated or inert gas-filled glass tube which protects the contacts against atmospheric corrosion; the contacts are made of magnetic material that makes them move under the influence of the field of the enclosing solenoid or an external magnet.Reed relays can switch faster than larger relays and require very little power from the control circuit. However, they have relatively low switching current and voltage ratings. Though rare, the reeds can become magnetized over time, which makes them stick 'on' even when no current is present; changing the orientation of the reeds with respect to the solenoid's magnetic field can resolve this problem.Sealed contacts with mercury-wetted contacts have longer operating lives and less contact chatter than any other kind of relay. 17 4.5 Applications · Amplifying a digital signal, switching a large amount of power with a small operating power. Some special cases are: A telegraph relay, repeating a weak signal received at the end of a long wire Controlling a high-voltage circuit with a low-voltage signal, as in some types of modems or audio amplifiers, Controlling a high-current circuit with a low-current signal, as in the starter solenoid of an automobile, · Detecting and isolating faults on transmission and distribution lines by opening and closing circuit breakers (protection relays), FIG:-1.17 A DPDT AC COIL RELAY A DPDT AC coil relay with "ice cube" packaging · Isolating the controlling circuit from the controlled circuit when the two are at different potentials, for example when controlling a mains-powered device from a low-voltage switch. The latter is often applied to control office lighting as the low voltage wires are easily installed in partitions, which may be often moved as needs change. They may also be controlled by room occupancy detectors to conserve energy, · Logic functions. For example, the boolean AND function is realised by connecting normally open relay contacts in series, the OR function by connecting normally open contacts in parallel. The change-over or Form C contacts perform the XOR (exclusive or) function. Similar functions for NAND and NOR are accomplished using normally closed contacts. The Ladder programming language is often used for designing relay logic networks. o The application of Boolean Algebra to relay circuit design was formalized by Claude Shannon in A Symbolic Analysis of Relay and Switching Circuits o Early computing. Before vacuum tubes and transistors, relays were used as logical elements in digital computers. See electro-mechanical computers such as the ARRA, Harvard Mark II, Zuse Z2, and Zuse Z3. o Safety-critical logic. Because relays are much more resistant than semiconductors to nuclear radiation, they are widely used in safety-critical logic, such as the control panels of radioactive waste-handling machinery. 18 · Time delay functions. Relays can be modified to delay opening or delay closing a set of contacts. A very short (a fraction of a second) delay would use a copper disk between the armature and moving blade assembly. Current flowing in the disk maintains magnetic field for a short time, lengthening release time. 19
CHAPTER-5 PACKING MACHINE FIG:-2.1 PACKING MACHINE 5.1 Specifications 1.Specialized suitable for flaky cornflakes package 2.Accurate scale achievable 3.Specialized customizable 5.2 Main Specification: - Weighing Accuracy: +/-0.1% - Power: 220V, 50/60Hz, 4.8kw - Max. Film width: 520mm - Packing Speed: 30~60bags/min (depends on the volume per bag) - Air consumption: 0.6Mpa 20 5.6 Main Configuration Principle: - Low position feeding - Uninterrupted lift delivery - Multi-heads electronic weigher achieve accurate weighing - Vertical automatic bag making and packing machine 5.7 Packaging Output Style: Pillow Bag (back sealing type) or Solid angle (gusset) Bag. 5.8 Application Range: This is a very board application packing line, can cover all kinds of easy sliding solid body, include granule, easy fragile, flaky, strip objects etc. on the other hand, accurate measurement is the another characteristic. 5.9 Standard Configuration: - Z-type Elevator (Various type of elevator optional) - 10 to 16 heads electronic weigher - Vibration Feeder - Supporting platform - Automatic bag making and packing machine(CYL-520) - Finished conveyor 21 CHAPTER-6 PRESSURE COOKER Corn flakes are food made by combining corn with sugar, vitamins and minerals to make them as Nutritious as possible. For producing the fancy flakes specially designed flaker will be used. At Present, corn flakes are popularly known as breakfast food in the world at large and generally Taken with milk. Maize is the major raw material used for the manufacture of corn flakes .To fill the cooker, the maize grits and other ingredients appropriate for the recipe are introduced into the container via a pipe. The product is steamed in the interior of the cooker, which is manufactured of high-quality stainless steel, in accordance with the condition of the product.During the cooking process, the cooker rotates and thus contributes to the homogenization of the product. Pressure is released via release valves at the end of this process. After opening the cover the product is then thrown out downward into the discharge hopper with each revolution of the cooker, until the entire content is emptied. FIG:- 3.1 COOKER 6.1 Technical Details:- Capacity: 0.5 - 0.8 t/h,Drive: 2.2 kw,Dimensions: 2815 x 1660 x 1860 6.2 Ingredients Used During Cooking 1. Corn 2. Sugar 3. Salt 4. Baking powder 5. Malt 6. Sodium by carbonate 6.3 Cooking Processes 22 Start corn feeding machine and feed corn inside the cooker up to 400kg And wash it with water, after washing mixed all ingredients in proper amount.Corn(400kg)-sugar(27kg)- salt(7kg)-malt(2kg) bakingpowder(250gm)sodium by carbonate(380gm) 6.4 Processes 1. Start steam feeding inside the cooker up to 15min. 2. Open pressure valve after 15min. 3. Again starts the steam feeding until cooker pressure reaches up to set level. 4. Chek until it gone ripe. The milling process removes the corn kernels from the cobs and turns them into flaking sized 'grits'. Malted barley can be added to enhance the flavor of the Corn Flakes. The corn grits are cooked in steam pressure cookers, at temperatures exceeding 100C. This cooking process lasts for an hour and softens the hard grits. During cooking additional water is incorporated in the form of steam which condenses and the water content in the batch rises to 30-35%. Then the hot grits are transported from the cookers to large driers via the network of pipes. The grits spend several hours in the hot-air driers in order to reduce their moisture content. The corn grits are milled using rollers, which squeeze the grits flat. 23
CHAPTER-7 DRYER 7.1 Corn Flakes Dryer This is Corn flacks Continuous process dryer. Machine construct of ms structure with all product contact part made of SS-304 and food grade PVC material. Machine runs start from raw material feeding unit continuous feed material to dryer chamber, where material pass through heated dry air zone, one by one stage and evaporated moisture sucked through a exhaust fan to free environment. Machine control through a electronics control panel to set deferent parameters like heating temp, air quantity, residual time, federate, exhaust temp to set for all type of product range. Application of hot air (convective or direct drying). Air heating increases the drivinforce for heat transfer and accelerates drying. It also reduces air relative humidity, further increasing the driving force for drying. In the falling rate period, as moisture content falls, the solids heat up and the higher temperatures speed up diffusion of water from the interior of the solid to the surface. However, product quality considerations limit the applicable rise to air temperature. Excessively hot air can almost completely dehydrate the solid surface, so that its pores shrink and almost close, leading to crust formation or "case hardening", which is usually undesirable. For instance in wood (timber) drying, air is heated (which speeds up drying) though some steam is also added to it (which hinders drying rate to a certain extent) in order to avoid excessive surface dehydration and product deformation owing to high moisture gradients across timber thickness. Spray drying belongs in this category. Fig:-4.1 DRYER Indirect or contact drying (heating through a hot wall), as drum drying, vacuum drying. Again, higher wall temperatures will speed up drying but this is limited by product degradation or case-hardening. Drum drying belongs in this category.Dielectric drying (radiofrequency or 24 microwaves being absorbed inside the material) is the focus of intense research nowadays. It may be used to assist air drying or vacuum drying. Researchers have found that microwave finish drying speeds up the otherwise very low drying rate at the end of the classical drying methods.Freeze drying or lyophilization is a drying method where the solvent is frozen prior to drying and is then sublimed, i.e., passed to the gas phase directly from the solid phase, below the melting point of the solvent. It is increasingly applied to dry foods, beyond its already classical pharmaceutical or medical applications. It keeps biological properties of proteins, and retains vitamins and bioactive compounds. Pressure can be reduced by a high vacuum pump (though freeze drying at atmospheric pressure is possible in dry air). If using a vacuum pump, the vapor produced by sublimation is removed from the system by converting it into ice in a condenser, operating at very low temperatures, outside the freeze drying chamber.Supercritical drying (superheated steam drying) involves steam drying of products containing water. This process is feasible because water in the product is boiled off, and joined with the drying medium, increasing its flow. It is usually employed in closed circuit and allows a proportion of latent heat to be recovered by recompression, a feature which is not possible with conventional air drying, for instance. The process has potential for use in foods if carried out at reduced pressure, to lower the boiling point.Natural air drying takes place when materials are dried with unheated forced air, taking advantage of its natural drying potential. The process is slow and weather-dependent, so a wise strategy "fan off-fan on" must be devised considering the following conditions: Air temperature, relative humidity and moisture content and temperature of the material being dried. Grains are increasingly dried with this technique, and the total time (including fan off and on periods) may last from one week to various months, if a winter rest can be tolerated in cold areas. 25
CHAPTER-8 POLISHER 8.1 Polishing Polishing is the process of creating a smooth and shiny surface by rubbing it or using a chemical action, leaving a surface with a significant specular reflection (still limited by the index of refraction of the material according to the Fresnel equations.) [1] In some materials (such as metals, glasses, black or transparent stones) polishing is also able to reduce diffuse reflection to minimal values. When an unpolished surface is magnified thousands of times, it usually looks like mountains and valleys. By repeated abrasion, those "mountains" are worn down until they are flat or just small "hills." The process of polishing with abrasives starts with coarse ones and graduates to fine ones. FIG:-5.1 POLISHER Polishing with very fine abrasive differs physically from coarser abrasion, in that material is removed on a molecular level, so that the rate is correlated to the boiling point rather than to the melting point of the material being polished. 8.2 Corn Peeling Machine, Corn Flakes Making Machine Types: YMHLN-115 YMHLN-150 YMHLN-200 JLSM-30/60 Features ★Innovative design, advanced structure, nice exterior; ★Reasonable structure, reliable performance; 26 ★Great sanitation thanks to bran powder collector; ★Change belts without removing spindle, easy operation, widely used; ★High throughput capacities, high quality, smooth kernels; ★excellent design provides Flexibility with regard to existing spatial conditions. 8.3 Functional Description After the raw materials flow into the hopper, grains begin to rub against each other under the action of the roll rotor and screen jacket. When the product achieves certain accuracy, the product will flow out from the outlet. Meanwhile, high-pressure wind is sprayed into the hulling chamber continuously; it enhances the polishing process and takes away part of the heat. It produces corn with a shiny, uniform, dust-free and low temperature finish. This machine is a special equipment which is mainly applied for corn hulling, de-germinating, polishing. It is the most ideal machine for small and medium-sized corn processing plants. It can also be used in rice processing line after modification.We are one of the brilliant manufacturer, exporter, trader, and supplier of quality assorted range of Maize Polisher in the biggest stage of global market. Our's is a highly advanced machine mainly utilized for removing and polishing of number of Cereal grains like Maize, Wheat, Barley, Pulses, etc. Also our machine can be used in breaking small mud balls. These are perfectly fabricated by optimum grade of metals and alloys under latest upgraded technology in adherence with predefined set of industrial standards. We offer thees at competitive market price.This machine is new specialized equipment applied for corn hulling, de-germinating, polishing and the removal of tip cap. Raw grains are hulled, de-germinated and polished under the intensive processing of rotating cylinder and screen after the raw materials are delivered into the hulling chamber. The end products achieve the required accuracy after kernel and bran are separated with the help of wind.The machine is not only can be used alone, but also compatible with complete sets. It is anideal equipment for small and medium size grain processing plants. 8.4 Features 1.Innovative design, advanced structure, nice exterior; 2.Reasonable structure, reliable performance; 3.Great sanitation thanks to bran powder collector; 4.Change belts without removing spindle, easy operation, widely used;5.High throughput capacities, high quality, smooth kernels;6.Excellent design provides Flexibility with regard to existing spatial condition. 27
CHAPTER-9 FLAKER These high quality Flaker Machines are made by using very high quality raw material which ensures hassle free work performance at its user end. These Flaker Machines are widely finds its valuable application in various industrial sectors.Flaker Machine (for solvent extraction Plant). These are made up from optimum grade components and raw material that are procured from authorized vendors of the market. Offered by us in different sizes and specifications, our products are acclaimed for their. We are greatly supported by a modernized infrastructure set up for carrying trade operations in a swift way. This set up is armed with hi-tech instruments, tools and machines that are required by the specialized experts for having speedy working. All the task of our firm are carried out by a team of proficient professionals in an organized manner. For attaining the organizational targets, every member of our team works in coordination with one another and with customers. Due to the relentless efforts of our employees, sound facilities and competitive pricing policy, we have gained the loyalty of a large number of clients, across the market. FIG:-6.1 FLAKER 9.1 Technical Specification & Features Model: 2 rolls machine / 4 rolls machine. Frame: Heavy Duty 5" X 2.5" and 6" X 3" channel as per size of machine. Feeding System: Latest Vibrating Hopper with Controlling regulator. Roll Production: Full length magnetic sheet is fitted to avoid any iron particle entering in to machine. Cooling System: Rotary joints/detachable water tank is fitted to avoid rolls from heating. 28 Bearing: Double row spherical self aligned bearing are fitted for longer life and smooth operation. Pressure: Hydraulic Jacks and pump are used to apply pressure up to 350 bars. Pulley: Complete sets are provided with the machine. Chain: Bearing operated chain is fitted. Production: 200kgs/Hour to 1000kgs/Hour. The flakes are then tumble toasted in huge cylindrical ovens. The air in the ovens is heated by 600C0 gas flames and the flakes are tossed around in a rotating drum. The drum is angled so that the flakes whirl around and pass through it quite quickly, and stops them spending too long in the fierce heat. The flakes are then coated with chocolate on demand and also sprayed with flavors, minerals to make them as nutritious as possible. The Corn flakes are then bagged up with the help of a bagging machine, which uses rolls of polythene. The alternative technology is related to the volume of production. That is, for a large quantity of production (such as 600-800kg/hr) the alternative option is more appropriate. This choice requires a fully automated system at all steps-in production, packaging and boxing. It is suitable to the largest volume markets that may require exporting to neighboring countries. Nonetheless, for a capacity of production envisaged by the plant under study, such choice of technology is notfeasible.The most common process is the "tempering degerming." The first step in this process is todry clean the corn, separating fines and broken from the whole corn. Occasionally wetcleaning follows to remove surface dirt, dust and other matter. The clean corn is temperedto 20 percent moisture. While moist, the majority of the outer bran or pericarp, germ, andtip cap are removed, leavingthe endosperm. The bulk of the corn endosperm, known as the"tail hominy fraction," proceeds through the degerminator, is dried, cooled, and sifted. Apportion of this "fraction" is isolated as large flaking grits. Further separation is accomplished using roller mills, sifters, grinding tables, and aspirators so that an infinite variety of smaller grits, meals and flours can be produced. Turnkey plants for dry milling are available from Buhler India and some Italian companies. These will be expensive. Some of the flour mill manufacturers in Indiacan provide the plant with partly imported equipment. Flaking machine (not for breakfast cereal) from whole corn are available at low cost in India. Masa flour production is simple operation. Value addition possibilities are many but some of the early plants have not succeeded. 29
CHAPTER-10 ROSTER 10.1 Introduction A roster is a list of names of people involved with some organization or assignment. It can be a list of people and additional information, like the times when they are required to work or a list of students in a class room. The term roster is often used to describe participants of an event. The term is most commonly associated with sports. Examples are a team roster or depth chart in which the person's place on the team would be decided. The names of the places on a roster can be such terms as Starter or Backup, or for American football, First String, Second String, or Third String .A "railway roster" refers to a detailed list of the types and wheel arrangements of steam, diesel or electric locomotives based at a particular shed, or of model locomotives on a particular model railway .A roster is also used in video games. It is usually the amount of characters in the game. Most games have small rosters but fighting games may have large ones .Roster is also the name of the contact list for the Instant Messaging Protocol XMPP. A "Martini Roster" is based on the TV advertisement for the drink with the same name: "Anytime, Anyplace, Anywhere." This means management can make staff work whenever they want. FIG:7.1 ROSTER We are the leading manufacturer of roster plant 1000kghr which is made by using superior quality of raw materials and is available at very reasonable price range to our clients. It is known for its durability and reliability all across the globe. It is light weighted and is very useful and easy to use and install. It has long service life and has excellent performance and functioning. · Heaters : 1 kw 36 Industrial Aliment · SS Sail Double Jacket heat proof glass wool 2” · Sail Drive: 2 HP DC Motor 2 Nos. with gear box variable speed with control penal · distal temperature meter 0 To 300ºC · SS hopper: Vibrator Feeding · App. Capacity - 1000 kg/hour 30 · App. Machine Size (LxWxH) -18'x5'x11' · Weight – 3500 Kgs · The Corn Belters were named after a fan vote to determine the name. A publicity stunt occurred after the four finalists were unveiled: Normal Nuts: an homage to the Beer Nuts brand based in nearby Bloomington (NOTE: The entries were originally "Nuts," but the ownership modified it to avoid conflict with the California League's Modesto Nuts) Normal Night Hawks; a popular alliterative nickname. Normal Corn Belters: a reference to Illinois' location in the Corn Belt. "Belt" is also a slang term meaning to hit the ball hard. Normal Coal Bears; submitted by fans of political satirist and The Colbert Report host Stephen Colbert (pronounced just like "coal bear"). Since the character often encourages these fans (known as the "Colbert Nation") to vote for things to be named after him, the team is hoping he'll give them some attention (similar to the Ontario Hockey League's Saginaw Spirit, whose mascot is named Straggle Colleague the Eagle and has gotten the team and league mentioned often on the show). [1] [2] In addition to the reference, Illinois (especially the west side of Bloomington-Normal) also has a strong heritage in coal mining, as reflected by future rival the Southern Illinois Miners. [3] Voting was originally set to take place until April 27. On the first day of voting, the Coal Bears had a significant 95 percent lead in the poll. However, that lead would significantly decline in the next two days to 24 percent with "Nutz" leading at 75 percent. Many fans suspected voting fraud, as "Nutz" had business ties and an "anti-Coal Bears" conspiracy was suggested by the fan-run normalcoalbears.com. On April 24, owner Steve Malliet announced that due to these allegations, he was starting the poll over again, this time requiring every voter to submit various information to enforce a "one fan, one vote" policy. This system was easily overcome by the same local hackers that had rigged the results of the earlier poll with a python script, and the name that had been last in the original round of voting was bumped to the top via another script that was able to leverage a flaw in the voting site's CAPTCHA mechanism. While "Nutz," "CornBelters," and "Coal Bears" were kept, "NightHawks" was dropped because of the term's other meaning as a position of responsibility in the Ku Klux Klan. In addition, two other choices were added:Normal Fellers; an homage to Jesse W. Fell, the founder of Illinois State University (ergo, the founder of the city of Normal), as well as the term "Feller" referring to "regular guy". Normal CamelBacks; an homage to Camelback Bridge, built to allow steam locomotives to pass underneath and currently arching over Constitution Trail. It is listed on the U.S. National Register of Historic Places. 31
CHAPTER-11 GASIFIRE Biomass gasification means incomplete combustion of biomass resulting in production of combustible gases consisting of Carbon monoxide (CO), Hydrogen and traces of Methane (CH4). This mixture is called producer gas. Producer gas can be used to run internal combustion engines (both compression and spark ignition), can be used as substitute for furnace oil in direct heat applications and can be used to produce, in an economically viable way, methanol – an extremely attractive chemical which is useful both as fuel for heat engines as well as chemical feedstock for industries Since any biomass material can undergo gasification, this process is much more attractive than ethanol production or biogas where only selected biomass materials can produce the fuel. Besides, there is a problem that solid wastes (available on the farm) are seldom in a form that can be readily utilized economically e.g. Wood wastes can be used in hog fuel boiler but the equipment is expensive and energy recovery is low As a result it is often advantageous to convert this waste into more readily usable fuel from like producer gas. Hence the attractiveness of gasificationHowever under present conditions, economic factors seem to provide the strongest argument of considering gasification . In many situations where the price of petroleum fuels is high or where supplies are unreliable the biomass gasification can provide an economically viable system – provided the suitable biomass feedstock is easily available (as is indeed the case in agricultural systems). The production of generator gas (producer gas) called gasification, is partial combustion of solid fuel (biomass) and takes place at temperatures of about 1000 degree C. The reactor is called gasifier. The combustion products from complete combustion of biomass generally contain nitrogen, water vapor, carbon dioxide and surplus of oxygen. However in gasification where there is a surplus of solid fuel (incomplete combustion) the products of combustion are (Figure 1) combustible gases like Carbon monoxide (CO), Hydrogen and traces of Methane and non useful products like tar and dust. The production of these gases is by reaction of water vapor and carbon dioxide through a glowing layer of charcoal. Thus the key to gasifier design is to create conditions such that a) biomass is reduced to charcoal and, b) charcoal is converted at suitable temperature to produce CO and H 2 .As was mentioned earlier the main applications of biomass gasifier are : a) Shaft power systems b) Direct heat applications c) Chemical production In the shaft power systems the main agriculture applications are driving of farm machinery like tractors, harvesters etc. There are quite a number of manufacturers catering to the on-farm machinery gasification systems. Small scale electricity generation systems also provide an attractive alternative to utilities. Another useful application of producer gas units is in irrigation systems. This seems to be the most to be the most important application in developing countries. There is no reason why such systems cannot become popular in developed countries especially when there have been quite a number of solar powered irrigation systems installed. Direct heat systems, because of their simplicity, may prove to have biggest applications in agriculture. Among them are grain drying, green house heating and running of absorption refrigeration and cooling systems. Again these systems can be coupled to other renewable energy systems like solar for thermal applications. Another interesting application for direct heat (external combustion) application is running of Stirling engines. These engines have very high efficiencies and may prove to be a better alternative than internal combustion engine running on producer gas. 32
CHAPTER-12 NITROGEN PLANT 12.1 Introduction The technology of air-to-nitrogen production with the use of adsorption processes in nitrogen generators is well studied and widely applied at industrial facilities for the recovery of high- purity nitrogen.The operating principle of a nitrogen generator utilizing the adsorption technology is based upon the dependence of the adsorption rates featured by various gas mixture components upon pressure and temperature factors. Among nitrogen adsorption plants of various types, pressure swing adsorption (PSA) plants have found the broadest application world-wide.The system's design is based on the regulation of gas adsorption and adsorbent regeneration by means of changing pressures in two adsorber–adsorbent-containing vessels. This process requires constant temperature, close to ambient. With this process, nitrogen is produced by the plant at the above-atmospheric pressure, while the adsorbent regeneration is accomplished at below-atmospheric pressure.The swing adsorption process in each of the two adsorbers consists of two stages running for a few minutes. At the adsorption stage Oxygen, H 2 O and CO 2 molecules diffuse into the pore structure of the adsorbent whilst the nitrogen molecules are allowed to travel through the adsorber–adsorbent-containing vessel. At the regeneration stage the adsorbed components are released from the adsorbent vented into the atmosphere. The process is then multiply repeated. FIG:-8.1NITROGEN PLANT The swing adsorption process in each of the two adsorbers consists of two stages running for a few minutes. At the adsorption stage Oxygen, H 2 O and CO 2 molecules diffuse into the pore structure of the adsorbent whilst the nitrogen molecules are allowed to travel through the adsorber–adsorbent-containing vessel. At the regeneration stage the adsorbed components are released from the adsorbent vented into the atmosphere. The process is then multiply repeated. Food and beverage industries The moment food or beverages are produced, or fruits and vegetables harvested, an aging process kicks in until the complete decay of the products. This is caused by bacteria and other organisms. Generators are used to flood the products with N2 that takes out the oxygen and prolongs the product lifetime significantly because these 33 organisms cannot develop. Furthermore, chemical degradation of food caused by oxidation can be eliminated or stopped.Analytical chemistryNitrogen generators are required for various forms of Analytical chemistry such as Liquid chromatography–mass spectrometry and Gas Chromatography where a stable and continuous supply of Nitrogen is necessary.Aircraft & motor vehicle tiresAlthough air is 78% Nitrogen. Most aircraft tires are filled with nitrogen, and there are many tire and automotive shops with nitrogen generators to fill tires, the advantage is that nitrogen in a tank is dry. Often a compressed air tank will have water in it that comes from atmospheric water vapor condensing in the tank after leaving the air compressor.
Company Profile Amrapali Biotech India Private Limited FIG:- 1. 1corn Flakes We are a rapidly growing unit in FMCG industry offering a diverse range of confectionery products or processed snack foods like pickles, jams, sauces, snacks, cornflakes and candies. Our range of confectionery and snack food products are marketed under the brand name MUM'S for food industry. These are highly appreciated for freshness, aroma and delicious taste across the globe. Our processing unit is well equipped with vacuum concentrate plant that assists us in meeting the bulk orders of our domestic and international clients. We adhere to stringent quality control parameters to ensure that our entire range of food products is of CGMP and BIS standards with hygienic conditions. Our quality range of food products has helped us in acquiring a large number of clients which includes some internationally reputed names such as Wallmart and Spencors. Incepted in the year 2007, Amrapali Biotech India Private Limited is engaged in manufacturing, exporting and supplying a wide range of pickles, jams, sauces, snacks, cornflakes for food industry. We are moving ahead with our vision of providing quality food products that are marketed under the brand name “MUM'S” all over the world. These are processed using natural ingredients such as corn, herbs, fruits & vegetables, spices, edible oils andsugar that are procured from our reliable vendors. We are planning to expand in the food industry by introducing products such as cornflakes, twenty-twenty snacks, jams, pickles, sauces in the global markets. These are processed as per CGMP and BIS standards to maintain consistency in the quality of our entire range of food products. We lay emphasis on maintaining proper hygienic conditions during production process, storage, packaging and transportation to ensure that our entire range of food products is fresh, highly nutritious and has longer shelf life. In order to reach more clients our organization is also supported by our additional branches that are located in Ghazipur (U.P.) and Udaipur(Rajasthan). With a vast experience, our team of production & marketing has enabled us to carve a niche in the competitive market. Their hard work and vision has helped to establish ourselves as the first choice of the customers and employees in a global scenario. 2 Product Portfolio We are one of the renowned names in the FMCG industry manufacturing and exporting a wide spectrum of wide range of pickles, jams, sauces, snacks, cornflakes under the brand name “MUM'S” for food industry. Our range of food products is processed using natural ingredients such as corn, herbs, fruits & vegetables, spices, edible oils and sugar that are procured from our reliable vendors. These find wide application in various areas including retail outlet and domestic market. Following are some of the salient features of our range of pickles, jams, sauces, snacks, cornflakes: · Highly nutritious · Fresh · Rich aroma · Longer shelf life Processing Unit We have a large and spacious processing unit that enables us in the voluminous production of our entire range of pickles, jams, sauces, snacks, cornflakes. Our processing unit is well equipped with vacuum concentrate plant that further helps us in fulfilling the exact requirements of our domestic and international clients. Our range of food products is rigorously checked at every level of production process, right from the selection of the ingredients to the final dispatch of our consignments to maintain consistency in its quality. Proper hygienic conditions are also maintained across processing unit to ascertain that our range of food products is of CGMP and BIS standards. Some of the machines used in our processing unit comprise: · Extruding machines · Pulverizing machines · Packing machines These machines are regularly upgraded to meet the exact requirements of our clients within the stipulated time frame. Team We nurture a qualified and experienced team of professionals who constantly support in various business processes. Our team coordinates efficiently to provide our clients a wide spectrum of fresh pickles, jams, sauces, snacks, cornflakes. Our food experts and quality analysts work hard to maintain the quality of our entire range of food products which further helps in acquiring a large client base across the globe. Moreover, our sales and marketing experts make proper market surveys in order to keep us abreast of the changing market trends. 3 Our Dedicated Professionals Comprise: · Machine operators · Food experts · Quality auditors · Skilled workers · Sales and marketing personnel Our Strength Some of the factors that distinguish us from our competitors comprise: · Robust infrastructure · Optimum quality · Ethical business practices · Wide distribution network · Competitive pricing · On time delivery Warehousing And Packaging We have a large and spacious warehouse which helps in safe storage and easy retrieval of our finished food products. Our warehouse personnel maintain proper hygienic conditions across the entire warehouse to ensure that our range of pickles, jams, sauces, snacks, cornflakes are fresh and highly nutritious for long time span. In addition, we also hygienically pack our entire range of food products as per the requirements of our clients for its safe transportation. This further helps us to maintain consistency in the quality of our range of food products. Present Supply And Demand Currently, there is only one recently established private company in the country engaged in the Manufacture of corn flakes. The planned annual production capacity of this new company is 288 Tons. The ingredients of the product of this company are corn flour, chocolate powder and Chocolate color. Data on actual production of this plant could not be obtained. Moreover, corn Flakes are also imported from abroad. Assuming that the domestic plant produces at its full capacity.The 2006 statistical abstract confirm that there are 12.2 million people living in the urban places of Ethiopia. With average family size of 5, this represents roughly 2.5 million families. If we conservatively assume that only 2.5 percent of these families are able to demand the product, the number of families with potential demand will be 62,500 families. With further conservative assumption of 1 kilogram of cornflakes consumed per a family per week with the reduced price, the annual demand would be 3000 tons of corn flakes. This demand analysis increases when the international community and demand of hotels, restaurants and cafes is added in the computation. Retail Price Of Imported Corn Flakes Weight (in gram) Price 330 65 500 90 500 gm combo 125 4 Plant Capacity The demand projection obtained in the previous section indicates the presence of ample demandfor the product when prices are relatively reasonable and proper promotion is performed. Accordingly, given this demand and the planned technology, the envisaged plant is set to produce 1,000 tons of corn flakes annually. Production Program The program is scheduled based on the consideration that the envisaged plant will work 275 days in a year in 2 shifts, where the remaining days will be holidays and for plant and machinery maintenance. During the first year of operation the plant will operate at 70 percent capacity andthen at 80 percent in the 2 nd year and at 90 percent in the 3 rd year. The capacity will grow to 100percent starting from the 4 th year. This consideration is developed based on the assumption thatmarket and logistics barriers would take place for the first two to three years of operation Availability And Source Of Raw Materials The major raw material used for the manufacture of corn flakes is maize (hybrid yellow and white corns). In Ethiopia, maize is widely produced in all parts of the country where in 2005/06, alone 33.4 million quintals were produced throughout the country. In the same year Amhara region produced 35% of the total cereal production in the country which roughly implies that 11.7 million quintals of maize is the share of the region. The varieties grown are mixtures of white, yellow and purple seeds where it is largely produced by the private farms. The fact that corn does not constitute one of the staple foods in the Amhara Region points the presence of ample maize (corn) for the envisaged plant. Sugar is another raw material used for the manufacture of corn flakes. There are three large-scale sugar establishments in the country. These establishments have a production capacity 280,000 tons of sugar annually. White sugar, which is used in the manufacture of corn flakes, is mainly exported to the neighboring countries such as Djibouti, Kenya and Yemen in quantities ranging between 30,000 to 50,000 tons per annum. In addition to the existing cane sugar establishments, new sugar projects are currently under construction. Production Process The milling process removes the corn kernels from the cobs and turns them into flaking sized 'grits'. Malted barley can be added to enhance the flavor of the Corn Flakes. The corn grits are cooked in steam pressure cookers, at temperatures exceeding 100C. This cooking process lasts for an hour and softens the hard grits. During cooking additional water is incorporated in the form of steam which condenses and the water content in the batch rises to 30-35%. Then the hotgrits are transported from the cookers to large driers via the network of pipes. The grits spendseveral hours in the hot-air driers in order to reduce their moisture content. The corn grits are milled using rollers, which squeeze the grits flat.The flakes are then tumble toasted in huge cylindrical ovens. The air in the ovens is heated by600C0 gas flames and the flakes are tossed around in a rotating drum. The drum is angled so thatthe flakes whirl around and pass through it quite quickly, and stops them spending too long in thefierce heat. 5
CHAPTER-1. CORN FLAKE PRODUCTION UNIT 1.1 Introduction We are professional manufacturer of food machinery. We have many years experience in this industry. Our machine has been exported many countries,like Russia,German,Ukraine,South Africa, they have obtained much praise for their reliability and full automatic from our clients.Corn flakes can be flavored with sugar,honey,coco and cheese,etc.Corn flakes are a popular breakfast cereal manufactured by twin- screw extruder through the treatment of corn flakes of grain, served with milk and marshmallows, were a very popular food among the families. 1.2 Features 1)Corn flakes is one kind of crispy food which is processed by this line and adopt grist as basic material 2)It is fast and nourishing food with given structrue,such as granule shape,flake shape and animal shape. 3)For the cornflakes processing line, different process get different snacks,and different taste. 1.3 Raw Materials Kinds of cereals, such as: corn flour, rice flour, corn grits, millet and so on. FIG:-1.2CORN FLAKE 1.4 Process Flow Mixer---extruder---vibrate cooler---rollers drying machine---flaking, air conveyor and rosting---high temperature inflate---second vibrate cooler---sugar spayer---multi-layer oven---cooling 6 FIG:-1.3CORN FLAKES PROCESS LINE 1.5 Process To Make Classic Cornflakes I) Raw Material: The best material is hard dent corn, because of its transparency after gelatinization andgood looking of the products. II. Adopting the drying-degerming method. First, to regulate the moisture with the hot steam and hot water exceeding 90℃.And then to pre-grind the corn without germ. The mixture would separate out grits after evenly sieving. III. Ingredients: To add the salt, malt and the other ingredients with the water during cooking the grits, it can make the water content up to 20％～35％, then to cook the grits with steam of 1.47X105P until gelatinized to semi-transparent. IV. Drying: to dry and extrude the grits at 66℃ until the moisture is 19％～20％, cool it down to 30～40℃. Then to press the flake to 0.7～1mm with steel roller. Before pressing, the corns should be made dispersedly to ensure the chips evenly distributed. V. Roasting: Temperature: 250～350℃, Time: 20～150 seconds. to make the moisture down 7 to 10％. To fry the chips with the temperature not exceed 200℃，the corn chips would be crispy. VI. Spraying enhancer: To spray with nutrient substance to make it intensified corn chips or spread on sugar, flavor if necessary. The process of Heshan China corn flakes machines is shown as follows: Corn →Cleaning →Peeling and Degerming →Classifying →Cooking →Drying & Rlending →Rolling, Flaking or Extruding →Toasting →Cooling →Packing →Finished Products 1.6 Modern Process To Make Bran Flakes, Wheat Flakes, Multigrain Flakes, Frosted Flakes, Direct Expanded Cereals Mixing →Conditioning → Extruding →Pulse Drying →Vibrate Feeding → Rolling, Flaking or Extruding →Fluid Bed Toasting→ Cooling → Packing → Finished Products The high speed rolling machine is a key unit in the system of Heshan China corn flakes achines It is composed of a pair of alloyed steel roll which rotate on opposite directions, high strength frame, hydraulic controlling system, auto adjusting roll seam system, cooling constant temperature system of the rolling, transmission system and control system. For the rolling machine, it has high requirements to rolling technology; First, it requires high hardness of roller surface. If it can not meet the standard, the surface , not smooth as that, would be damaged after a period of using to effect the rolling. We can make the hardness of the surface more than 65 degrees with special technology. It allows you to use them more than ten years. Second, it requires high accuracy requirements. If it can not meet the standard, you may find that the rolling can not evenly, it would be serious vibrating and noisy .Thus it requires us to control the processing procedure strictly, it has to make sure that the cylindricity of rolling is on 3μm. The rolling machine adopts hydraulic pressure control system, the roller can be adjusted the pressure to perfect situation according to the product characters to ensure the product quality. The servo regulating system of the roller allows you to adjust the gag in the range of 0-2mm. It is number display; you can read them easily and accurately. We design the cooling water tunnel inside the roller, so it can avoid the rolling gap changing occurred by expand with heat and contract with cold during working, as it would impact the rolling quality .To ensure the rolling can work in a constant temperature condition we design a circulating cooling water & constant temperature control system which has the high pressure water pump for the cooling water tunnel inside the roller . The accidental legacy of corn flakes goes back to the late 19th century, when a team of Seventh-day Adventists began to develop new food to adhere to the vegetarian diet recommended by the church. Members of the group experimented with a number of different grains, including wheat, oats, rice, barley, and corn. In 1894, Dr. John Harvey Kellogg, the superintendent of The Battle Creek Sanitarium in Michigan and an Adventist, used these recipes as part of a strict vegetarian regimen for his patients, which also included no alcohol, tobacco, or caffeine. The diet he imposed consisted entirely of bland foods. A follower of Sylvester Graham, the inventor of graham crackers and graham bread, Kellogg believed that spicy or sweet foods would increase passions. [ This idea for corn flakes began by accident when Kellogg and his younger brother, Will Keith Kellogg, left some cooked wheat to sit while they attended to some pressing matters at the sanitarium. When they 8 returned, they found that the wheat had gone stale, but being on a strict budget, they decided to continue to process it by forcing it through rollers, hoping to obtain long sheets of the dough. To their surprise, what they found instead were flakes, which they toasted and served to their patients. This event occurred on August 8, 1894, and a patent for "Flaked Cereals and Process of Preparing Same" was filed on May 31, 1895, and issued on April 14, 1896. [1][3][4] The flakes of grain, which the Kelloggs called granose, were a very popular food among the patients. The brothers then experimented with other flakes from other grains. In 1906, Will Keith Kellogg, who served as the business manager of the sanitarium, decided to try to mass-market the new food. At his new company, Battle Creek Toasted Corn Flake Company, he added sugar to the flakes to make them more palatable to a mass audience, but this caused a rift between his brother and him. To increase sales, in 1909, he added a special offer, the Funny Jungleland Moving Pictures Booklet, which was made available to anyone who bought two boxes of the cereal. This same premium was offered for 22 years. At the same time, Kellogg also began experimenting with new grain cereals to expand his product line. Rice Krispies, his next great hit, first went on sale in 1928.There have been many mascots of Kellogg's Cornflakes. The most popular one is a green rooster named Cornelius (Corny) Rooster, which has been the mascot since his debut. In earlier commercials, he had a speaking part and his catch phrase was "Wake up, up, up to Kellogg's Cornflakes!" He was voiced by Dallas McKennon and Andy Devine. Later, he stopped talking and simply crowed. The concept of using a stylized cockerel originated in a suggestion by Kellogg family friend Nansi Richards, a harpist from Wales and a Welsh language proponent. The Welsh word for cockerel is ceiliog (pronounced Kellogg). 9 CHAPTER-2 DANFOSS VLT MICRO DRIVE FC 51 2.1 Introduction The Danfoss VLT® Micro Drive is a genuine VLT® frequency converter with unsurpassed reliability, user-friendliness, condensed functionality, and extremely easy to commission. Terminal numbers are named in the same manner as in the rest of the VLT® family. It’s developed and manufactured by Danfoss Drives, the leading drives experts since 1968 and creators of VLT® – The Real Drive. 2.2 User Friendly · VLT Micro Drive share the user-friendliness of the VLT family. · Plug and play - minimum effort minimum time · Minimum Commissioning - save time · Copy settings via local control panel - simple set up of multiple drives · Intuitive parameter structure - minimal manual reading 2.3 Reliability VLT Micro Drive is a full member of the VLT® family sharing the overall quality of design, reliability and user-friendliness. High quality components and genuine VLT® solutions makes VLT® Micro Drive extremely reliable. · Optimum heat dissipation – Longer lifetime · High quality electronics/capasitors – Low lifetime cost · All drives full load tested from factory – High reliability · Earth fault, temperature and short circuit protection – Lean operation · Circuit boards well protected and coated – Increased robustness FIG:-1.4 MICRO DRIVE 10 2.4 Small Drive – High Performance Despite the compact size and the easy commissioning, VLT® Micro Drive can be set up to perform perfectly even in complex application set-ups. Approximately 100 parameters can be set to optimize energy efficiency and operation. · Process PI-controller – No need for external controller · Automatic Energy Optimizer (AEO) – Less energy consumption · Automatic Motor Adaptation (AMA) – Exploit motor’s full potential · 150% motor torque up to 1 minute – Replace need for bigger drive · Flying start (catch a spinning motor) – Lean operation – more up-time · Electronic Thermal relay (ETR) – Replace external motor protection 2.5 Real Space Saving Side-By-Side A compact book style design allows real side by side mounting without derating. 2.6 Minimum Penetration Of Dust VLT® MICRO Drive is designed to keep the forced ventilation away from the electronics. Printed circuit boards are well protected inside the drive. 2.7 Built-In Rfi Radio disturbance from motor cables is limited with the built-in RFI filter allowing for 15 m motor cables (screened). Meets EU norms. FIG:-1.5 VLT DRIVE 2.8 Built-In Brake Functions With built in DC and AC brake functions, VLT® Micro Drive can transform kinetic energy in the application into braking power to slow down the motor. A brake chopper is built-in the drives from 1.5 kW upwards. 2.9 Effective Heat Sink An effective heat sink easily removes heat from the electronics, extending lifetime and reliability of the drive. 11
CHAPTER-3 CONTACTOR RELAYS FIG:-1.7 CONTACTOR Contactor relays are switching devices for control and auxiliary circuits and are used to control, provide signals and interlock switching devices and switchgear panels. It goes without saying that the 3RH1 SIRIUS contactor relays have connection designations in compliance with the standard and use a connection system which is both time and cost saving – fulfilling the requirements from the field. The 3RH1 contactor relays and the size S00 motor contactors are the same size and have the same optical design; this represents a significant advantage, especially when it comes to accessories. They are designed for AC or DC operation and are available with screw or spring-loaded technology. The basic version of the contactor relays has 4 poles but this can be extended up to 8 poles using auxiliary contact blocks which can be snapped-on.When a relay is used to switch a large amount of electrical power through its contacts, it is designated by a special name: contactor. Contactors typically have multiple contacts, and those contacts are usually (but not always) normally-open, so that power to the load is shut off when the coil is de-energized. Perhaps the most common industrial use for contactors is the control of electric motors. 12 The top three contacts switch the respective phases of the incoming 3-phase AC power, typically at least 480 Volts for motors 1 horsepower or greater. The lowest contact is an "auxiliary" contact which has a current rating much lower than that of the large motor power contacts, but is actuated by the same armature as the power contacts. The auxiliary contact is often used in a relay logic circuit, or for some other part of the motor control scheme, typically switching 120 Volt AC power instead of the motor voltage. One contactor may have several auxiliary contacts, either normally-open or normally-closed, if required. The three "opposed- question-mark" shaped devices in series with each phase going to the motor are called overload heaters. Each "heater" element is a low-resistance strip of metal intended to heat up as the motor draws current. If the temperature of any of these heater elements reaches a critical point (equivalent to a moderate overloading of the motor), a normally-closed switch contact (not shown in the diagram) will spring open. This normally-closed contact is usually connected in series with the relay coil, so that when it opens the relay will automatically de-energize, thereby shutting off power to the motor. We will see more of this overload protection wiring in the next chapter. Overload heaters are intended to provide overcurrent protection for large electric motors, unlike circuit breakers and fuses which serve the primary purpose of providing overcurrent protection for power conductors. Overload heater function is often misunderstood. They are not fuses; that is, it is not their function to burn open and directly break the circuit as a fuse is designed to do. Rather, overload heaters are designed to thermally mimic the heating characteristic of the particular electric motor to be protected. All motors have thermal characteristics, including the amount of heat energy generated by resistive dissipation (I 2 R), the thermal transfer characteristics of heat "conducted" to the cooling medium through the metal frame of the motor, the physical mass and specific heat of the materials constituting the motor, etc. These characteristics are mimicked by the overload heater on a miniature scale: when the motor heats up toward its critical temperature, so will the heater toward its critical temperature, ideally at the same rate and approach curve. Thus, the overload contact, in sensing heater temperature with a thermo-mechanical mechanism, will sense an analogue of the real motor. If the overload contact trips due to excessive heater temperature, it will be an indication that the real motor has reached its critical temperature (or, would have done so in a short while). After tripping, the heaters are supposed to cool down at the same rate and approach curve as the real motor, so that they indicate an accurate proportion of the motor's thermal condition, and will not allow power to be re-applied until the motor is truly ready for start-up again. Shown here is a contactor for a three-phase electric motor, installed on a panel as part of an electrical control system at a municipal water treatment plant: 13 FIG:-1.8 CONTACTOR INTERNAL STRUCTURE Three-phase, 480 volt AC power comes in to the three normally-open contacts at the top of the contactor via screw terminals labeled "L1," "L2," and "L3" (The "L2" terminal is hidden behind a square-shaped "snubber" circuit connected across the contactor's coil terminals). Power to the motor exits the overload heater assembly at the bottom of this device via screw terminals labeled "T1," "T2," and "T3." The overload heater units themselves are black, square-shaped blocks with the label "W34," indicating a particular thermal response for a certain horsepower and temperature rating of electric motor. If an electric motor of differing power and/or temperature ratings were to be substituted for the one presently in service, the overload heater units would have to be replaced with units having a thermal response suitable for the new motor. The motor manufacturer can provide information on the appropriate heater units to use. A white pushbutton located between the "T1" and "T2" line heaters serves as a way to manually re-set the normally-closed switch contact back to its normal state after having been tripped by excessive heater temperature. Wire connections to the "overload" switch contact may be seen at the lower-right of the photograph, near a label reading "NC" (normally- closed). On this particular overload unit, a small "window" with the label "Tripped" indicates a tripped condition by means of a colored flag. In this photograph, there is no "tripped" condition, and the indicator appears clear. As a footnote, heater elements may be used as a crude current shunt resistor for determining whether or not a motor is drawing current when the contactor is closed. FIG:-1.9 MOTOR CONNECTION WITH CONTACTOR 14
CHAPTER-4 RELAY 4.1 Introduction A relay is an electrically operated switch. Many relays use an electromagnet to mechanically operate a switch, but other operating principles are also used, such as solid-state relays. Relays are used where it is necessary to control a circuit by a low-power signal (with complete electrical isolation between control and controlled circuits), or where several circuits must be controlled by one signal. The first relays were used in long distance telegraph circuits as amplifiers: they repeated the signal coming in from one circuit and re-transmitted it on another circuit. Relays were used extensively in telephone exchanges and early computers to perform logical operations. A type of relay that can handle the high power required to directly control an electric motor or other loads is called a contactor. Solid-state relays control power circuits with no moving parts, instead using a semiconductor device to perform switching. Relays with calibrated operating characteristics and sometimes multiple operating coils are used to protect electrical circuits from overload or faults; in modern electric power systems these functions are performed by digital instruments still called "protective relays". Basic Design And Operation FIG:-1.10 BASIC DESIGN 4.2 Simple Electromechanical Relay . FIG:-1.11 SIMPLE ELECTROMECHANICAL RELAY Small "cradle" relay often used in electronics. The "cradle" term refers to the shape of the relay's armature.A simple electromagnetic relay consists of a coil of wire wrapped around a 15 soft iron core, an iron yoke which provides a low reluctance path for magnetic flux, a movable iron armature, and one or more sets of contacts (there are two in the relay pictured). The armature is hinged to the yoke and mechanically linked to one or more sets of moving contacts. It is held in place by a spring so that when the relay is de-energized there is an air gap in the magnetic circuit. In this condition, one of the two sets of contacts in the relay pictured is closed, and the other set is open. Other relays may have more or fewer sets of contacts depending on their function. The relay in the picture also has a wire connecting the armature to the yoke. This ensures continuity of the circuit between the moving contacts on the armature, and the circuit track on the printed circuit board (PCB) via the yoke, which is soldered to the PCB.When an electric current is passed through the coil it generates a magnetic field that activates the armature, and the consequent movement of the movable contact(s) either makes or breaks (depending upon construction) a connection with a fixed contact. If the set of contacts was closed when the relay was de-energized, then the movement opens the contacts and breaks the connection, and vice versa if the contacts were open. When the current to the coil is switched off, the armature is returned by a force, approximately half as strong as the magnetic force, to its relaxed position. Usually this force is provided by a spring, but gravity is also used commonly in industrial motor starters. Most relays are manufactured to operate quickly. In a low-voltage application this reduces noise; in a high voltage or current application it reduces arcing.When the coil is energized with direct current, a diode is often placed across the coil to dissipate the energy from the collapsing magnetic field at deactivation, which would otherwise generate a voltage spike dangerous to semiconductor circuit components. Some automotive relays include a diode inside the relay case. Alternatively, a contact protection network consisting of a capacitor and resistor in series (snubber circuit) may absorb the surge. If the coil is designed to be energized with alternating current (AC), a small copper "shading ring" can be crimped to the end of the solenoid, creating a small out-of-phase current which increases the minimum pull on the armature during the AC cycle. [1] A solid-state relay uses a thyristor or other solid-state switching device, activated by the control signal, to switch the controlled load, instead of a solenoid. An optocoupler (a light-emitting diode (LED) coupled with a photo transistor) can be used to isolate control and controlled circuits. 4.3 Types Of Latching Relay FIG:-1.12 LATCHING RELAY A latching relay has two relaxed states (bistable). These are also called "impulse", "keep", or "stay" relays. When the current is switched off, the relay remains in its last state. This is achieved with a solenoid operating a ratchet and cam mechanism, or by having two opposing 16 coils with an over-center spring or permanent magnet to hold the armature and contacts in position while the coil is relaxed, or with a remanent core. In the ratchet and cam example, the first pulse to the coil turns the relay on and the second pulse turns it off. In the two coil example, a pulse to one coil turns the relay on and a pulse to the opposite coil turns the relay off. This type of relay has the advantage that one coil consumes power only for an instant, while it is being switched, and the relay contacts retain this setting across a power outage. A remanent core latching relay requires a current pulse of opposite polarity to make it change state. A stepping relay is a specialized kind of multi-way latching relay designed for early automatic telephone exchanges.An earth leakage circuit breaker includes a specialized latching relay.Very early computers often stored bits in a magnetically latching relay, such as ferreed or the later memreed in the switch.Some early computers used ordinary relays as a kind of latch— they store bits in ordinary wire spring relays or reed relays by feeding an output wire back as an input, resulting in a feedback loop or sequential circuit. Such an electrically-latching relay requires continuous power to maintain state, unlike magnetically latching relays or mechanically racheting relays.In computer memories, latching relays and other relays were replaced by delay line memory, which in turn was replaced by a series of ever-faster and ever- smaller memory technologies. 4.4 Reed Relay FIG:-1.13 REED RELAY A reed relay is a reed switch enclosed in a solenoid. The switch has a set of contacts inside an evacuated or inert gas-filled glass tube which protects the contacts against atmospheric corrosion; the contacts are made of magnetic material that makes them move under the influence of the field of the enclosing solenoid or an external magnet.Reed relays can switch faster than larger relays and require very little power from the control circuit. However, they have relatively low switching current and voltage ratings. Though rare, the reeds can become magnetized over time, which makes them stick 'on' even when no current is present; changing the orientation of the reeds with respect to the solenoid's magnetic field can resolve this problem.Sealed contacts with mercury-wetted contacts have longer operating lives and less contact chatter than any other kind of relay. 17 4.5 Applications · Amplifying a digital signal, switching a large amount of power with a small operating power. Some special cases are: A telegraph relay, repeating a weak signal received at the end of a long wire Controlling a high-voltage circuit with a low-voltage signal, as in some types of modems or audio amplifiers, Controlling a high-current circuit with a low-current signal, as in the starter solenoid of an automobile, · Detecting and isolating faults on transmission and distribution lines by opening and closing circuit breakers (protection relays), FIG:-1.17 A DPDT AC COIL RELAY A DPDT AC coil relay with "ice cube" packaging · Isolating the controlling circuit from the controlled circuit when the two are at different potentials, for example when controlling a mains-powered device from a low-voltage switch. The latter is often applied to control office lighting as the low voltage wires are easily installed in partitions, which may be often moved as needs change. They may also be controlled by room occupancy detectors to conserve energy, · Logic functions. For example, the boolean AND function is realised by connecting normally open relay contacts in series, the OR function by connecting normally open contacts in parallel. The change-over or Form C contacts perform the XOR (exclusive or) function. Similar functions for NAND and NOR are accomplished using normally closed contacts. The Ladder programming language is often used for designing relay logic networks. o The application of Boolean Algebra to relay circuit design was formalized by Claude Shannon in A Symbolic Analysis of Relay and Switching Circuits o Early computing. Before vacuum tubes and transistors, relays were used as logical elements in digital computers. See electro-mechanical computers such as the ARRA, Harvard Mark II, Zuse Z2, and Zuse Z3. o Safety-critical logic. Because relays are much more resistant than semiconductors to nuclear radiation, they are widely used in safety-critical logic, such as the control panels of radioactive waste-handling machinery. 18 · Time delay functions. Relays can be modified to delay opening or delay closing a set of contacts. A very short (a fraction of a second) delay would use a copper disk between the armature and moving blade assembly. Current flowing in the disk maintains magnetic field for a short time, lengthening release time. 19
CHAPTER-5 PACKING MACHINE FIG:-2.1 PACKING MACHINE 5.1 Specifications 1.Specialized suitable for flaky cornflakes package 2.Accurate scale achievable 3.Specialized customizable 5.2 Main Specification: - Weighing Accuracy: +/-0.1% - Power: 220V, 50/60Hz, 4.8kw - Max. Film width: 520mm - Packing Speed: 30~60bags/min (depends on the volume per bag) - Air consumption: 0.6Mpa 20 5.6 Main Configuration Principle: - Low position feeding - Uninterrupted lift delivery - Multi-heads electronic weigher achieve accurate weighing - Vertical automatic bag making and packing machine 5.7 Packaging Output Style: Pillow Bag (back sealing type) or Solid angle (gusset) Bag. 5.8 Application Range: This is a very board application packing line, can cover all kinds of easy sliding solid body, include granule, easy fragile, flaky, strip objects etc. on the other hand, accurate measurement is the another characteristic. 5.9 Standard Configuration: - Z-type Elevator (Various type of elevator optional) - 10 to 16 heads electronic weigher - Vibration Feeder - Supporting platform - Automatic bag making and packing machine(CYL-520) - Finished conveyor 21 CHAPTER-6 PRESSURE COOKER Corn flakes are food made by combining corn with sugar, vitamins and minerals to make them as Nutritious as possible. For producing the fancy flakes specially designed flaker will be used. At Present, corn flakes are popularly known as breakfast food in the world at large and generally Taken with milk. Maize is the major raw material used for the manufacture of corn flakes .To fill the cooker, the maize grits and other ingredients appropriate for the recipe are introduced into the container via a pipe. The product is steamed in the interior of the cooker, which is manufactured of high-quality stainless steel, in accordance with the condition of the product.During the cooking process, the cooker rotates and thus contributes to the homogenization of the product. Pressure is released via release valves at the end of this process. After opening the cover the product is then thrown out downward into the discharge hopper with each revolution of the cooker, until the entire content is emptied. FIG:- 3.1 COOKER 6.1 Technical Details:- Capacity: 0.5 - 0.8 t/h,Drive: 2.2 kw,Dimensions: 2815 x 1660 x 1860 6.2 Ingredients Used During Cooking 1. Corn 2. Sugar 3. Salt 4. Baking powder 5. Malt 6. Sodium by carbonate 6.3 Cooking Processes 22 Start corn feeding machine and feed corn inside the cooker up to 400kg And wash it with water, after washing mixed all ingredients in proper amount.Corn(400kg)-sugar(27kg)- salt(7kg)-malt(2kg) bakingpowder(250gm)sodium by carbonate(380gm) 6.4 Processes 1. Start steam feeding inside the cooker up to 15min. 2. Open pressure valve after 15min. 3. Again starts the steam feeding until cooker pressure reaches up to set level. 4. Chek until it gone ripe. The milling process removes the corn kernels from the cobs and turns them into flaking sized 'grits'. Malted barley can be added to enhance the flavor of the Corn Flakes. The corn grits are cooked in steam pressure cookers, at temperatures exceeding 100C. This cooking process lasts for an hour and softens the hard grits. During cooking additional water is incorporated in the form of steam which condenses and the water content in the batch rises to 30-35%. Then the hot grits are transported from the cookers to large driers via the network of pipes. The grits spend several hours in the hot-air driers in order to reduce their moisture content. The corn grits are milled using rollers, which squeeze the grits flat. 23
CHAPTER-7 DRYER 7.1 Corn Flakes Dryer This is Corn flacks Continuous process dryer. Machine construct of ms structure with all product contact part made of SS-304 and food grade PVC material. Machine runs start from raw material feeding unit continuous feed material to dryer chamber, where material pass through heated dry air zone, one by one stage and evaporated moisture sucked through a exhaust fan to free environment. Machine control through a electronics control panel to set deferent parameters like heating temp, air quantity, residual time, federate, exhaust temp to set for all type of product range. Application of hot air (convective or direct drying). Air heating increases the drivinforce for heat transfer and accelerates drying. It also reduces air relative humidity, further increasing the driving force for drying. In the falling rate period, as moisture content falls, the solids heat up and the higher temperatures speed up diffusion of water from the interior of the solid to the surface. However, product quality considerations limit the applicable rise to air temperature. Excessively hot air can almost completely dehydrate the solid surface, so that its pores shrink and almost close, leading to crust formation or "case hardening", which is usually undesirable. For instance in wood (timber) drying, air is heated (which speeds up drying) though some steam is also added to it (which hinders drying rate to a certain extent) in order to avoid excessive surface dehydration and product deformation owing to high moisture gradients across timber thickness. Spray drying belongs in this category. Fig:-4.1 DRYER Indirect or contact drying (heating through a hot wall), as drum drying, vacuum drying. Again, higher wall temperatures will speed up drying but this is limited by product degradation or case-hardening. Drum drying belongs in this category.Dielectric drying (radiofrequency or 24 microwaves being absorbed inside the material) is the focus of intense research nowadays. It may be used to assist air drying or vacuum drying. Researchers have found that microwave finish drying speeds up the otherwise very low drying rate at the end of the classical drying methods.Freeze drying or lyophilization is a drying method where the solvent is frozen prior to drying and is then sublimed, i.e., passed to the gas phase directly from the solid phase, below the melting point of the solvent. It is increasingly applied to dry foods, beyond its already classical pharmaceutical or medical applications. It keeps biological properties of proteins, and retains vitamins and bioactive compounds. Pressure can be reduced by a high vacuum pump (though freeze drying at atmospheric pressure is possible in dry air). If using a vacuum pump, the vapor produced by sublimation is removed from the system by converting it into ice in a condenser, operating at very low temperatures, outside the freeze drying chamber.Supercritical drying (superheated steam drying) involves steam drying of products containing water. This process is feasible because water in the product is boiled off, and joined with the drying medium, increasing its flow. It is usually employed in closed circuit and allows a proportion of latent heat to be recovered by recompression, a feature which is not possible with conventional air drying, for instance. The process has potential for use in foods if carried out at reduced pressure, to lower the boiling point.Natural air drying takes place when materials are dried with unheated forced air, taking advantage of its natural drying potential. The process is slow and weather-dependent, so a wise strategy "fan off-fan on" must be devised considering the following conditions: Air temperature, relative humidity and moisture content and temperature of the material being dried. Grains are increasingly dried with this technique, and the total time (including fan off and on periods) may last from one week to various months, if a winter rest can be tolerated in cold areas. 25
CHAPTER-8 POLISHER 8.1 Polishing Polishing is the process of creating a smooth and shiny surface by rubbing it or using a chemical action, leaving a surface with a significant specular reflection (still limited by the index of refraction of the material according to the Fresnel equations.) [1] In some materials (such as metals, glasses, black or transparent stones) polishing is also able to reduce diffuse reflection to minimal values. When an unpolished surface is magnified thousands of times, it usually looks like mountains and valleys. By repeated abrasion, those "mountains" are worn down until they are flat or just small "hills." The process of polishing with abrasives starts with coarse ones and graduates to fine ones. FIG:-5.1 POLISHER Polishing with very fine abrasive differs physically from coarser abrasion, in that material is removed on a molecular level, so that the rate is correlated to the boiling point rather than to the melting point of the material being polished. 8.2 Corn Peeling Machine, Corn Flakes Making Machine Types: YMHLN-115 YMHLN-150 YMHLN-200 JLSM-30/60 Features ★Innovative design, advanced structure, nice exterior; ★Reasonable structure, reliable performance; 26 ★Great sanitation thanks to bran powder collector; ★Change belts without removing spindle, easy operation, widely used; ★High throughput capacities, high quality, smooth kernels; ★excellent design provides Flexibility with regard to existing spatial conditions. 8.3 Functional Description After the raw materials flow into the hopper, grains begin to rub against each other under the action of the roll rotor and screen jacket. When the product achieves certain accuracy, the product will flow out from the outlet. Meanwhile, high-pressure wind is sprayed into the hulling chamber continuously; it enhances the polishing process and takes away part of the heat. It produces corn with a shiny, uniform, dust-free and low temperature finish. This machine is a special equipment which is mainly applied for corn hulling, de-germinating, polishing. It is the most ideal machine for small and medium-sized corn processing plants. It can also be used in rice processing line after modification.We are one of the brilliant manufacturer, exporter, trader, and supplier of quality assorted range of Maize Polisher in the biggest stage of global market. Our's is a highly advanced machine mainly utilized for removing and polishing of number of Cereal grains like Maize, Wheat, Barley, Pulses, etc. Also our machine can be used in breaking small mud balls. These are perfectly fabricated by optimum grade of metals and alloys under latest upgraded technology in adherence with predefined set of industrial standards. We offer thees at competitive market price.This machine is new specialized equipment applied for corn hulling, de-germinating, polishing and the removal of tip cap. Raw grains are hulled, de-germinated and polished under the intensive processing of rotating cylinder and screen after the raw materials are delivered into the hulling chamber. The end products achieve the required accuracy after kernel and bran are separated with the help of wind.The machine is not only can be used alone, but also compatible with complete sets. It is anideal equipment for small and medium size grain processing plants. 8.4 Features 1.Innovative design, advanced structure, nice exterior; 2.Reasonable structure, reliable performance; 3.Great sanitation thanks to bran powder collector; 4.Change belts without removing spindle, easy operation, widely used;5.High throughput capacities, high quality, smooth kernels;6.Excellent design provides Flexibility with regard to existing spatial condition. 27
CHAPTER-9 FLAKER These high quality Flaker Machines are made by using very high quality raw material which ensures hassle free work performance at its user end. These Flaker Machines are widely finds its valuable application in various industrial sectors.Flaker Machine (for solvent extraction Plant). These are made up from optimum grade components and raw material that are procured from authorized vendors of the market. Offered by us in different sizes and specifications, our products are acclaimed for their. We are greatly supported by a modernized infrastructure set up for carrying trade operations in a swift way. This set up is armed with hi-tech instruments, tools and machines that are required by the specialized experts for having speedy working. All the task of our firm are carried out by a team of proficient professionals in an organized manner. For attaining the organizational targets, every member of our team works in coordination with one another and with customers. Due to the relentless efforts of our employees, sound facilities and competitive pricing policy, we have gained the loyalty of a large number of clients, across the market. FIG:-6.1 FLAKER 9.1 Technical Specification & Features Model: 2 rolls machine / 4 rolls machine. Frame: Heavy Duty 5" X 2.5" and 6" X 3" channel as per size of machine. Feeding System: Latest Vibrating Hopper with Controlling regulator. Roll Production: Full length magnetic sheet is fitted to avoid any iron particle entering in to machine. Cooling System: Rotary joints/detachable water tank is fitted to avoid rolls from heating. 28 Bearing: Double row spherical self aligned bearing are fitted for longer life and smooth operation. Pressure: Hydraulic Jacks and pump are used to apply pressure up to 350 bars. Pulley: Complete sets are provided with the machine. Chain: Bearing operated chain is fitted. Production: 200kgs/Hour to 1000kgs/Hour. The flakes are then tumble toasted in huge cylindrical ovens. The air in the ovens is heated by 600C0 gas flames and the flakes are tossed around in a rotating drum. The drum is angled so that the flakes whirl around and pass through it quite quickly, and stops them spending too long in the fierce heat. The flakes are then coated with chocolate on demand and also sprayed with flavors, minerals to make them as nutritious as possible. The Corn flakes are then bagged up with the help of a bagging machine, which uses rolls of polythene. The alternative technology is related to the volume of production. That is, for a large quantity of production (such as 600-800kg/hr) the alternative option is more appropriate. This choice requires a fully automated system at all steps-in production, packaging and boxing. It is suitable to the largest volume markets that may require exporting to neighboring countries. Nonetheless, for a capacity of production envisaged by the plant under study, such choice of technology is notfeasible.The most common process is the "tempering degerming." The first step in this process is todry clean the corn, separating fines and broken from the whole corn. Occasionally wetcleaning follows to remove surface dirt, dust and other matter. The clean corn is temperedto 20 percent moisture. While moist, the majority of the outer bran or pericarp, germ, andtip cap are removed, leavingthe endosperm. The bulk of the corn endosperm, known as the"tail hominy fraction," proceeds through the degerminator, is dried, cooled, and sifted. Apportion of this "fraction" is isolated as large flaking grits. Further separation is accomplished using roller mills, sifters, grinding tables, and aspirators so that an infinite variety of smaller grits, meals and flours can be produced. Turnkey plants for dry milling are available from Buhler India and some Italian companies. These will be expensive. Some of the flour mill manufacturers in Indiacan provide the plant with partly imported equipment. Flaking machine (not for breakfast cereal) from whole corn are available at low cost in India. Masa flour production is simple operation. Value addition possibilities are many but some of the early plants have not succeeded. 29
CHAPTER-10 ROSTER 10.1 Introduction A roster is a list of names of people involved with some organization or assignment. It can be a list of people and additional information, like the times when they are required to work or a list of students in a class room. The term roster is often used to describe participants of an event. The term is most commonly associated with sports. Examples are a team roster or depth chart in which the person's place on the team would be decided. The names of the places on a roster can be such terms as Starter or Backup, or for American football, First String, Second String, or Third String .A "railway roster" refers to a detailed list of the types and wheel arrangements of steam, diesel or electric locomotives based at a particular shed, or of model locomotives on a particular model railway .A roster is also used in video games. It is usually the amount of characters in the game. Most games have small rosters but fighting games may have large ones .Roster is also the name of the contact list for the Instant Messaging Protocol XMPP. A "Martini Roster" is based on the TV advertisement for the drink with the same name: "Anytime, Anyplace, Anywhere." This means management can make staff work whenever they want. FIG:7.1 ROSTER We are the leading manufacturer of roster plant 1000kghr which is made by using superior quality of raw materials and is available at very reasonable price range to our clients. It is known for its durability and reliability all across the globe. It is light weighted and is very useful and easy to use and install. It has long service life and has excellent performance and functioning. · Heaters : 1 kw 36 Industrial Aliment · SS Sail Double Jacket heat proof glass wool 2” · Sail Drive: 2 HP DC Motor 2 Nos. with gear box variable speed with control penal · distal temperature meter 0 To 300ºC · SS hopper: Vibrator Feeding · App. Capacity - 1000 kg/hour 30 · App. Machine Size (LxWxH) -18'x5'x11' · Weight – 3500 Kgs · The Corn Belters were named after a fan vote to determine the name. A publicity stunt occurred after the four finalists were unveiled: Normal Nuts: an homage to the Beer Nuts brand based in nearby Bloomington (NOTE: The entries were originally "Nuts," but the ownership modified it to avoid conflict with the California League's Modesto Nuts) Normal Night Hawks; a popular alliterative nickname. Normal Corn Belters: a reference to Illinois' location in the Corn Belt. "Belt" is also a slang term meaning to hit the ball hard. Normal Coal Bears; submitted by fans of political satirist and The Colbert Report host Stephen Colbert (pronounced just like "coal bear"). Since the character often encourages these fans (known as the "Colbert Nation") to vote for things to be named after him, the team is hoping he'll give them some attention (similar to the Ontario Hockey League's Saginaw Spirit, whose mascot is named Straggle Colleague the Eagle and has gotten the team and league mentioned often on the show). [1] [2] In addition to the reference, Illinois (especially the west side of Bloomington-Normal) also has a strong heritage in coal mining, as reflected by future rival the Southern Illinois Miners. [3] Voting was originally set to take place until April 27. On the first day of voting, the Coal Bears had a significant 95 percent lead in the poll. However, that lead would significantly decline in the next two days to 24 percent with "Nutz" leading at 75 percent. Many fans suspected voting fraud, as "Nutz" had business ties and an "anti-Coal Bears" conspiracy was suggested by the fan-run normalcoalbears.com. On April 24, owner Steve Malliet announced that due to these allegations, he was starting the poll over again, this time requiring every voter to submit various information to enforce a "one fan, one vote" policy. This system was easily overcome by the same local hackers that had rigged the results of the earlier poll with a python script, and the name that had been last in the original round of voting was bumped to the top via another script that was able to leverage a flaw in the voting site's CAPTCHA mechanism. While "Nutz," "CornBelters," and "Coal Bears" were kept, "NightHawks" was dropped because of the term's other meaning as a position of responsibility in the Ku Klux Klan. In addition, two other choices were added:Normal Fellers; an homage to Jesse W. Fell, the founder of Illinois State University (ergo, the founder of the city of Normal), as well as the term "Feller" referring to "regular guy". Normal CamelBacks; an homage to Camelback Bridge, built to allow steam locomotives to pass underneath and currently arching over Constitution Trail. It is listed on the U.S. National Register of Historic Places. 31
CHAPTER-11 GASIFIRE Biomass gasification means incomplete combustion of biomass resulting in production of combustible gases consisting of Carbon monoxide (CO), Hydrogen and traces of Methane (CH4). This mixture is called producer gas. Producer gas can be used to run internal combustion engines (both compression and spark ignition), can be used as substitute for furnace oil in direct heat applications and can be used to produce, in an economically viable way, methanol – an extremely attractive chemical which is useful both as fuel for heat engines as well as chemical feedstock for industries Since any biomass material can undergo gasification, this process is much more attractive than ethanol production or biogas where only selected biomass materials can produce the fuel. Besides, there is a problem that solid wastes (available on the farm) are seldom in a form that can be readily utilized economically e.g. Wood wastes can be used in hog fuel boiler but the equipment is expensive and energy recovery is low As a result it is often advantageous to convert this waste into more readily usable fuel from like producer gas. Hence the attractiveness of gasificationHowever under present conditions, economic factors seem to provide the strongest argument of considering gasification . In many situations where the price of petroleum fuels is high or where supplies are unreliable the biomass gasification can provide an economically viable system – provided the suitable biomass feedstock is easily available (as is indeed the case in agricultural systems). The production of generator gas (producer gas) called gasification, is partial combustion of solid fuel (biomass) and takes place at temperatures of about 1000 degree C. The reactor is called gasifier. The combustion products from complete combustion of biomass generally contain nitrogen, water vapor, carbon dioxide and surplus of oxygen. However in gasification where there is a surplus of solid fuel (incomplete combustion) the products of combustion are (Figure 1) combustible gases like Carbon monoxide (CO), Hydrogen and traces of Methane and non useful products like tar and dust. The production of these gases is by reaction of water vapor and carbon dioxide through a glowing layer of charcoal. Thus the key to gasifier design is to create conditions such that a) biomass is reduced to charcoal and, b) charcoal is converted at suitable temperature to produce CO and H 2 .As was mentioned earlier the main applications of biomass gasifier are : a) Shaft power systems b) Direct heat applications c) Chemical production In the shaft power systems the main agriculture applications are driving of farm machinery like tractors, harvesters etc. There are quite a number of manufacturers catering to the on-farm machinery gasification systems. Small scale electricity generation systems also provide an attractive alternative to utilities. Another useful application of producer gas units is in irrigation systems. This seems to be the most to be the most important application in developing countries. There is no reason why such systems cannot become popular in developed countries especially when there have been quite a number of solar powered irrigation systems installed. Direct heat systems, because of their simplicity, may prove to have biggest applications in agriculture. Among them are grain drying, green house heating and running of absorption refrigeration and cooling systems. Again these systems can be coupled to other renewable energy systems like solar for thermal applications. Another interesting application for direct heat (external combustion) application is running of Stirling engines. These engines have very high efficiencies and may prove to be a better alternative than internal combustion engine running on producer gas. 32
CHAPTER-12 NITROGEN PLANT 12.1 Introduction The technology of air-to-nitrogen production with the use of adsorption processes in nitrogen generators is well studied and widely applied at industrial facilities for the recovery of high- purity nitrogen.The operating principle of a nitrogen generator utilizing the adsorption technology is based upon the dependence of the adsorption rates featured by various gas mixture components upon pressure and temperature factors. Among nitrogen adsorption plants of various types, pressure swing adsorption (PSA) plants have found the broadest application world-wide.The system's design is based on the regulation of gas adsorption and adsorbent regeneration by means of changing pressures in two adsorber–adsorbent-containing vessels. This process requires constant temperature, close to ambient. With this process, nitrogen is produced by the plant at the above-atmospheric pressure, while the adsorbent regeneration is accomplished at below-atmospheric pressure.The swing adsorption process in each of the two adsorbers consists of two stages running for a few minutes. At the adsorption stage Oxygen, H 2 O and CO 2 molecules diffuse into the pore structure of the adsorbent whilst the nitrogen molecules are allowed to travel through the adsorber–adsorbent-containing vessel. At the regeneration stage the adsorbed components are released from the adsorbent vented into the atmosphere. The process is then multiply repeated. FIG:-8.1NITROGEN PLANT The swing adsorption process in each of the two adsorbers consists of two stages running for a few minutes. At the adsorption stage Oxygen, H 2 O and CO 2 molecules diffuse into the pore structure of the adsorbent whilst the nitrogen molecules are allowed to travel through the adsorber–adsorbent-containing vessel. At the regeneration stage the adsorbed components are released from the adsorbent vented into the atmosphere. The process is then multiply repeated. Food and beverage industries The moment food or beverages are produced, or fruits and vegetables harvested, an aging process kicks in until the complete decay of the products. This is caused by bacteria and other organisms. Generators are used to flood the products with N2 that takes out the oxygen and prolongs the product lifetime significantly because these 33 organisms cannot develop. Furthermore, chemical degradation of food caused by oxidation can be eliminated or stopped.Analytical chemistryNitrogen generators are required for various forms of Analytical chemistry such as Liquid chromatography–mass spectrometry and Gas Chromatography where a stable and continuous supply of Nitrogen is necessary.Aircraft & motor vehicle tiresAlthough air is 78% Nitrogen. Most aircraft tires are filled with nitrogen, and there are many tire and automotive shops with nitrogen generators to fill tires, the advantage is that nitrogen in a tank is dry. Often a compressed air tank will have water in it that comes from atmospheric water vapor condensing in the tank after leaving the air compressor.