Preface -- Contents -- Chapter 1: Introduction -- 1.1 Introduction -- References -- Part I: Process Considerations -- Chapter 2: Process Specification -- 2.1 Introduction -- 2.1.1 Evolution of the Design -- 2.1.2 Flowsheeting -- 2.2 Batch Processes: Scheduling and Its Implications -- 2.3 Estimating Material and Energy Requirements -- 2.3.1 Mass Balancing -- 2.3.1.1 Law of Conservation of Mass -- 2.3.1.2 Closed and Open Systems -- 2.3.1.3 The Choice of Basis -- 2.3.1.4 Losses -- 2.3.1.5 The Concept of Steady State -- 2.3.1.6 Batch Processes -- 2.3.1.7 Unsteady Systems -- 2.3.1.8 Inert Materials -- 2.3.1.9 Wet and Dry Basis -- 2.3.1.10 Multistage Processes -- 2.3.1.11 Systems with Recycle -- Trial and Error: ``Tearing ́́-- Analytical Solutions -- 2.3.2 Energy Balancing -- 2.3.3 Stored and Internal Energy: Enthalpy -- 2.3.3.1 Single Components -- 2.3.3.2 Mixtures -- 2.3.3.3 Biochemical Reactions -- 2.3.4 Examples of Energy Balance Calculations -- 2.3.4.1 Continuous Heat Exchangers -- 2.3.4.2 Evaporators -- 2.3.4.3 Coupled Heat and Mass Balances -- 2.3.5 Energy Integration -- 2.4 Conclusions -- References -- Chapter 3: Food-Processing Equipment -- 3.1 Introduction -- 3.2 Food-Processing Equipment in a Production Plant -- 3.2.1 Today -- 3.2.2 Vision for the Future -- 3.3 Description of Food Processes and Equipment in Different Sectors of the Industry -- 3.4 Raw Materials -- 3.5 Mixing and Emulsification -- 3.6 Filtration -- 3.7 Centrifugation -- 3.7.1 Liquid-Liquid Centrifuges -- 3.7.2 Centrifugal Clarifiers -- 3.7.3 Desludging, Decanting, and Dewatering Centrifuges -- 3.8 Extrusion Cooking -- 3.9 Heat Processing -- 3.9.1 Thermal Preservation Processes -- 3.9.1.1 Sterilization and Pasteurization -- 3.9.1.2 Blanching -- 3.9.2 Conversion Processes -- 3.9.2.1 Boiling -- 3.9.2.2 Baking and Roasting -- 3.9.2.3 Frying.

3.9.3 Processes Effecting a Temperature Change -- 3.9.3.1 Tempering -- 3.9.3.2 Cooling/Chilling -- 3.9.4 Processes Involving Phase Transitions -- 3.9.4.1 Freezing -- 3.9.4.2 Thawing -- 3.9.5 Removal of Water -- 3.9.5.1 Evaporation -- 3.9.5.2 Dehydration -- 3.10 Irradiation -- 3.11 Food Storage -- 3.12 Packaging -- References -- Chapter 4: Hygienic Design of Food-Processing Equipment -- 4.1 Introduction -- 4.2 Materials of Construction -- 4.2.1 Selection -- 4.2.2 Surface Finishes -- 4.2.3 Examples of Doś and Dont́s -- 4.3 Fundamentals of Hygienic Design -- 4.4 Design Principles -- 4.4.1 Permanent Joints -- 4.4.2 Semipermanent Joints -- 4.4.3 Fasteners -- 4.4.4 Drainage -- 4.4.5 Internal Angles and Corners -- 4.4.6 Dead Spaces -- 4.4.7 Bearings and Shaft Seals -- 4.4.8 Controls -- 4.4.9 Equipment Location and Installation -- 4.4.10 Examples of Doś and Dont́s -- 4.5 Examples of Hygienic Design -- 4.5.1 Pumps -- 4.5.2 Pipelines and Fittings -- 4.5.2.1 Steel Pipe -- 4.5.2.2 Plastic Pipe -- 4.5.2.3 Connections -- 4.5.2.4 Installation of Pipelines -- 4.5.2.5 Dead-Legs -- 4.5.2.6 Air Pockets -- 4.5.2.7 Pipework Insulation -- 4.5.3 Valves -- 4.5.4 Post-process Can Handling -- 4.5.5 Product Transfer Systems -- 4.6 Closure -- References -- Chapter 5: Movement of Materials -- 5.1 Introduction -- 5.1.1 Bulk Conveying -- 5.1.2 Unit Loads -- 5.1.3 Pallets and Palletization -- 5.1.3.1 Pallets -- 5.1.3.2 Palletization -- 5.1.3.3 Overwrapping -- 5.1.3.4 Order Picking -- 5.2 Conveying Equipment -- 5.2.1 Air-Cushion Conveyors -- 5.2.2 Apron Conveyors -- 5.2.3 Belt Conveyors -- 5.2.3.1 Steel-Band Conveyors -- 5.2.3.2 Wire-Mesh Belts -- 5.2.3.3 Woven and Spiral Belts -- 5.2.3.4 Wire-Link Belts -- 5.2.3.5 Woven-Spring Steel Belts -- 5.2.3.6 Flat-Strip Belts -- 5.2.4 Chain Conveyors -- 5.2.5 Flight Conveyors -- 5.2.6 Overhead-Chain Conveyors -- 5.2.7 Roller Conveyors.

5.2.8 Screw Conveyors -- 5.2.9 Skate Wheel Conveyors -- 5.2.10 Slat Conveyors -- 5.2.11 Spiral Conveyors -- 5.2.12 Pusher-Bar Conveyors -- 5.2.13 Towline Conveyors -- 5.2.14 Vibrating Conveyors -- 5.3 Chutes -- 5.4 Cranes and Hoists -- 5.4.1 Cranes -- 5.4.2 Hoists -- 5.4.2.1 Pneumatic Hoists -- 5.4.2.2 Electric Hoists -- 5.5 Elevators -- 5.5.1 Package Elevators -- 5.5.1.1 Rigid-Arm Elevators -- 5.5.1.2 Swing-Tray Elevators -- 5.5.1.3 Finger-Tray Elevators -- 5.5.2 Bulk Elevators -- 5.6 Magnetic Handling Systems -- 5.7 Manual Handling -- 5.8 Pneumatic Conveying Systems -- 5.9 Trucks -- 5.9.1 Hand Trucks -- 5.9.2 Powered Trucks -- 5.9.2.1 Automated Guided Vehicles -- 5.9.2.2 Forklift Trucks -- 5.9.2.3 High-Lift Trucks -- 5.9.2.4 Low-Lift Trucks -- 5.9.2.5 Tractor-Trailer Systems -- 5.10 Handling of Liquids -- 5.10.1 Pumps -- 5.10.2 Pipelines -- 5.10.3 Flow Measurement -- 5.11 Accumulation and Intermediate Storage of Materials -- 5.11.1 Accumulation -- 5.11.2 Intermediate Storage -- 5.11.2.1 Bins and Tote Bags -- 5.11.2.2 Racking Systems -- 5.12 Weighing -- 5.12.1 Load Cells -- 5.12.2 Automatic Weighers -- 5.12.2.1 Checkweighing -- 5.12.2.2 Static Weighing -- 5.12.2.3 Dynamic Weighing -- 5.13 Factors Affecting Choice of Conveying System -- 5.13.1 Hygiene and Potential Contamination -- 5.13.2 Dust -- 5.13.3 High- and Low-Temperature Handling -- 5.14 Transportation to and from the Factory -- 5.14.1 Loading Bays -- 5.14.2 Transportation of Foods -- 5.14.3 Refrigerated Transport -- References -- Chapter 6: Productivity Issues: Industrial Engineering and Operations Management -- 6.1 Introduction -- 6.2 Factory Location -- 6.2.1 Constraints -- 6.2.2 Quantitative Factors -- 6.2.3 Qualitative Factors -- 6.2.4 Summary -- 6.3 Plant Capacity -- 6.3.1 Specifying Initial and Future Design Capacity -- 6.3.1.1 Initial Capacity -- 6.3.1.2 Future Capacity.

6.3.2 Adaptation of Production Lines to Meet Future Demand -- 6.4 Factory and Equipment Layouts -- 6.5 Lean Manufacturing -- 6.5.1 Fundamentals -- 6.5.2 Implementation -- 6.5.3 Impact on Factory Design -- 6.6 Warehousing -- 6.6.1 The Role of Warehouses -- 6.6.2 Receiving and Shipping Areas -- 6.6.3 Storage Requirements -- 6.7 Conclusion -- References -- Chapter 7: Safety and Health -- 7.1 Introduction -- 7.2 Accident Statistics in the Food and Drink Industry -- 7.3 Specific Causes of Accidents in the Food Industry -- 7.3.1 Workplace Transport -- 7.3.2 Falls from Height -- 7.3.3 Machinery -- 7.3.3.1 Flat Belt Conveyors -- 7.3.3.2 Thermoform, Fill, and Seal Packaging Machines -- 7.3.3.3 Preformed Rigid Container Packaging Machines -- 7.3.3.4 Palletizers and Depalletizers -- 7.3.4 Slips and Trips -- 7.3.5 Handling and Lifting -- 7.3.6 Being Struck by Objects -- 7.3.7 Dust Explosions -- 7.4 Occupational Health -- 7.4.1 Musculoskeletal Disorders (MSDs) -- 7.4.2 Work-Related Stress -- 7.4.3 Occupational Asthma -- 7.4.4 Occupational Dermatitis -- 7.4.5 Rhinitis -- 7.4.6 Noise-Induced Hearing Loss -- 7.5 Risk Assessment -- 7.5.1 Existing Factories -- 7.5.2 Factories at the Design Stage -- 7.6 Managing Occupational Safety and Health -- 7.7 Conclusion -- References -- Chapter 8: Protecting the Environment -- 8.1 Introduction -- 8.2 Elements of Environmental Pollution Relevant to the Food Industry -- 8.2.1 Introduction -- 8.2.2 Air Pollution -- 8.2.2.1 Combustion of Carbonaceous Fuels -- 8.2.2.2 Electricity Use -- 8.2.2.3 Other Greenhouse Gases -- 8.2.2.4 Indoor Air Quality -- 8.2.2.5 Vehicular Transport -- 8.2.3 Water Pollution -- 8.2.4 Solid and Liquid Wastes -- 8.3 ISO 14000 -- 8.3.1 Introduction -- 8.3.2 Structure of ISO 14000 Series -- 8.3.2.1 ISO 14001 and 14004: Environmental Management Systems.

8.3.2.2 ISO 14010 Series and ISO 19011: Environmental Audits -- 8.3.2.3 ISO 14020 Series: Environmental Labeling -- 8.3.2.4 ISO 14030 Series: Environmental Performance Evaluation -- 8.3.2.5 ISO 14040 Series: Life Cycle Assessment -- 8.3.2.6 Other Relevant ISO Standards and Reports -- 8.3.3 ISO 14001 Certification -- 8.4 Guide to the Preparation of an Environmental Management System -- 8.4.1 Introduction -- 8.4.2 Structure of the EMS -- 8.4.3 Initiation -- 8.4.3.1 Commitment -- 8.4.3.2 Initial Environmental Review -- 8.4.4 Environmental Policy -- 8.4.5 Planning -- 8.4.5.1 Environmental Aspects -- 8.4.5.2 Legal and Other Requirements -- 8.4.5.3 Objectives, Targets, and Programs -- 8.4.5.4 Environmental Management Programs -- 8.4.6 Implementation and Operation -- 8.4.6.1 Structure and Responsibility -- 8.4.6.2 Training, Awareness and Competence -- 8.4.6.3 Communication -- 8.4.6.4 Documentation -- 8.4.6.5 Control of Documents -- 8.4.6.6 Operational Control -- 8.4.6.7 Emergency Preparedness and Response -- 8.4.7 Checking and Corrective Action -- 8.4.7.1 Monitoring and Measurement -- 8.4.7.2 Evaluation of Compliance -- 8.4.7.3 Nonconformity, Corrective Action and Preventative Action -- 8.4.7.4 Control of Records -- 8.4.7.5 Internal Audit -- 8.4.8 Management Review -- 8.5 In Conclusion -- Appendix: Checklist to Aid in the Preparation of a Preparatory Review and a Register of Environmental Effects for Food Factori... -- A.1 Introduction -- A.2 Some General Considerations -- A.2.1 Documentation -- A.2.2 Process Considerations -- A.2.3 Emergencies -- A.2.4 Factory Site -- A.3 Air -- A.3.1 Global Warming -- A.3.2 Ozone Layer -- A.3.3 Acid/Alkali Emissions -- A.3.4 Ground-Level Ozone -- A.3.5 Other Aspects -- A.4 Water -- A.5 Land and Resources -- A.5.1 Asbestos -- A5.2 Hazardous Organisms -- A.5.3 Hazardous Wastes -- A.5.4 Radioactive Wastes.

A.5.5 Nonhazardous Wastes.