Đồ án tốt nghiệp Công nghệ thực phẩm: Calculation and Design Of A Factory Producing Chocolate With A Capacity Of 2200KG Per day

Equipment diagram of chocolate production process according to YX production line .... Introduction of cocoa beans: Cocoa belongs to the family sterculiaceae, genus Theobroma, species C

LITERATURE OVERVIEW

Overview of raw materials

Cocoa, a member of the Sterculiaceae family and Theobroma genus, originates from the tropical forests of Central and South America Its wild ancestors were cultivated extensively by the indigenous Aztecs and Mayans in Central America and Mexico, leading to the widespread cultivation we see today.

Cocoa was introduced to Vietnam by Western missionaries many years ago and is now extensively cultivated, particularly in the Central Highlands, which offers ideal growing conditions Research indicates that cocoa trees in this region flower and bear fruit year-round, yielding an average of 3 kg of dry seeds per 5-year-old tree Previously, investment in cocoa cultivation was limited due to challenges in harvesting, preservation, and distribution However, with advancements in technology and growing consumer demand for cocoa products, there has been a notable increase in investment in cocoa farming.

Flowers, measuring approximately 15mm in diameter, can be yellow, red, white, or purple, varying by species They emerge directly from the stem and branches, are bisexual, and primarily rely on insects for pollination Only 0.5% of flowering plants yield fruit, with 90% of young fruits typically drying up and falling off.

General shape of cocoa fruit:

Cocoa fruit varies in size, typically measuring between 15 to 20 cm in length and weighing around 200 grams or more, depending on the variety The shape of the fruit can differ among species, appearing long, round, or oval, and it comes in a range of colors, including red, green, and yellow.

Cocoa fruit typically contains 25 to 80 beans, which are egg-shaped, slightly flattened, and usually exhibit a pale reddish-lilac hue Each cocoa bean is encased in a thin, fragile outer shell known as the hard shell, along with a delicate, fatty white silk shell that envelops the seed core and partitions it into angular cells.

• Cocoa beans have not kernel, fat, 2 - 3cm long, surrounded by a white mucus layer with a sweet, slightly sour taste

The color of cocoa endosperms ranges from the white of Criollo to the deep purple of Forastero, with Trinitario hybrids exhibiting intermediate shades The embryo features numerous wrinkles and overlapping lobes, encased in a thin, shiny membrane At the base, a 6-7 mm long rootlet connects to a rudimentary sprout, surrounded by lobes, forming the cocoa bean's sprout.

Cocoa comes in two main species, Criollo and Forastero, but researchers have developed a hybrid known as Trinitario, which is now globally cultivated This hybrid effectively combines the benefits of both original cocoa species, making it a popular choice among cocoa growers worldwide.

Table 1.1 Characteristics of cocoa groups

The embryo emulsion is characterized by a high cocoa butter content, comprising approximately 31.3% of its mass, along with minimal seed shell and absent mucilage Cocoa butter primarily consists of triglycerides derived from glycerol and unsaturated fatty acids, contributing to its unique properties.

Cocoa butter, derived from cocoa beans, features small white crystals and a distinctive aroma, melting at temperatures between 16 and 37 °C based on its crystalline form This ingredient plays a crucial role in enhancing the flavor of cocoa.

Fruit shape long, tapered, pointed tip Round, oval Long

Deep grooves are not clear Fruit peel texture thin, soft, little wood tissue

Hard, thick, rich in wood Mostly hard

Yellow-red with small brown spots

Green yellow Not certain flower Pale pink pistil Purple pistil Green and red

Bean 20 – 40 beans 30 – 60 beans More than 40 beans

1.1.2 The chemical composition of cocoa :

Table 1.2 Chemical composition of fresh cocoa beans

Mucus is composed of a significant amount of sugars, including glucose, fructose, and sucrose, along with water, and contains citric acid that stabilizes its pH at 3.5 In cocoa beans, protein content varies, with the fruit peel containing 18%, the pulp 0.6%, and the embryo 8.4%, primarily consisting of the protein components albumin and globulin.

Cocoa contains important alkaloids, with Theobromine (3,7-dimethylxanthine) being a key component This mild stimulant induces a sense of excitement in the body, though its effects are significantly less intense than those of caffeine Theobromine is present in cocoa at levels ranging from 1% to 4% (w/w), while caffeine is found in much lower amounts, typically between 0% and 2%, making cocoa a milder alternative to coffee.

Top of cocoa Seed coat

To reap the health benefits of cocoa, it's essential to choose products from reputable sources Incorporating a small piece of dark, unsweetened, or unprocessed chocolate can enhance both the flavor and nutritional value of your diet Here are some key health advantages of cocoa.

The oxygen we breathe is essential for our body’s functions, but it also generates free radicals that can harm our organs Cocoa is rich in antioxidants that effectively neutralize these free radicals In fact, chocolate's antioxidant capacity is 4-5 times greater than that of black tea and 2-3 times higher than green tea or wine, thanks to flavonoids and essential minerals like zinc, manganese, and copper.

• Encourages the production of good cholesterol

Blood carries cholesterol through carrier proteins, with good cholesterol being transported to the liver for excretion, while bad cholesterol accumulates in arteries, leading to cardiovascular diseases Chocolate and cocoa can help protect organs from bad cholesterol due to their flavonoid content, which reduces bad cholesterol levels and promotes good cholesterol production Additionally, vitamin B3 in chocolate lowers the risk of blood clots.

Consuming 6g of dark chocolate daily can significantly lower blood pressure, according to a study published in the German magazine Jama Conducted at a Cologne hospital with 44 participants aged 56 to 73, the study revealed that individuals with an average blood pressure of 147/86 experienced notable reductions after following an 18-week diet of dark chocolate In contrast, those who consumed white chocolate did not see similar benefits, as white chocolate lacks the beneficial polyphenols found in dark chocolate.

Additives

To ensure compliance with technological standards in food production, processing, handling, packaging, transportation, and preservation, it is essential to adhere to the regulations set forth by the Ministry of Health Specifically, the use of additives must align with the approved list and allowable limits outlined in the Ministry of Health's directive (3742/2001/QD-BYT dated August 31, 2001).

Good Manufacturing Practices (GMP) ensure compliance with regulations regarding the use of food additives throughout production, handling, processing, preservation, packaging, and transportation These practices aim to minimize the quantity of additives required while ensuring that their presence does not alter the physicochemical properties or nutritional values of the food Additionally, the usage of food additives must align with the manufacturer's certified declarations from a competent authority.

Salt NaCl is used primarily as a flavor enhancer in foods and is identified as one of the basic tastes Salt Nacl when used must ensure it meets TCVN 3973 - 84 standards

Guar gum, a polysaccharide composed of galactose and mannose sugars, is derived from the seed endosperm of the legume Cyamopsis tetragonolobus Commonly known as E 412, guar gum serves multiple purposes in food production, primarily acting as a thickening agent, filler, emulsifier, and stabilizer.

Guar gum exhibits stability in solutions with a pH range of 5-7 but loses its activity in extreme pH conditions, particularly at pH 3 and 50°C While it is not significantly affected by strong ions, exposure to strong acids can lead to hydrolysis and a reduction in its properties, and strong alkalis also diminish its effectiveness Additionally, guar gum is insoluble in most solvents.

Maltodextrins, defined by the US Food and Drug Administration (FDA) as non-sweet polysaccharides with the formula (C6H10O5)n.H2O, are derived from the incomplete hydrolysis of starch through enzymatic or acidic processes Their dextrose equivalents (DE) range from 4 to 20, influencing their properties Commonly utilized as a binder for ingredients and a flavor carrier, maltodextrins play a crucial role in food formulation.

This mixed product contains dextrose, 4-methyl-5-thiazoleethanol, 2-acetylpyrazine, and ethylmaltol, presenting in a fine granular form with a white color and a meaty aroma It has a sweet and brackish taste, melting at 90.2°C Ethylmaltol is utilized to enhance the product's flavor and aroma, effectively eliminating unpleasant odors while ensuring a long-lasting scent.

Potassium sorbate (C5H7COOK) is a white crystalline powder that is highly soluble in water and slightly soluble in oil It serves as an effective preservative due to its potent antiseptic properties against yeasts and molds, while exhibiting minimal effects on different bacteria.

Lecithin is a thick, odorless fluid with a mild aroma and bland taste, partially soluble in water and capable of forming emulsions It is utilized to enhance water absorption, reduce mixing time, and improve product stability, while also extending storage life and controlling viscosity.

Introduction of chocolate

Chocolate is a sweetened food derived from the seeds of the Theobroma cocoa tree, cultivated for over three millennia in Mexico and Central America The Olmecs of south-central Mexico were the first to document its use around 1100 BC Mesoamerican cultures, including the Mayans and Aztecs, created chocolate beverages, with the Aztecs referring to it as "xocoatl," meaning "bitter water." The cocoa seeds have a naturally intense bitter flavor that requires fermentation to enhance their taste.

Cacao tree seeds are inherently bitter and require fermentation to enhance their flavor Chocolate is composed of various compounds that can influence body chemistry, including Anandamide, Arginine, Caffeine, Dopamine, Methylated xanthines (such as theobromine, caffeine, and theophylline), Monoamine oxidase, Oxalic acid, Phenethylamine, Phenylalanine, Serotonin, Sugar, and Theobromine.

After fermentation, cocoa beans undergo drying, cleaning, and roasting processes The removal of the shell produces cocoa nibs, which are ground into cocoa mass, a rough form of pure chocolate This cocoa mass, often liquefied before molding, is referred to as chocolate liquor and can be separated into cocoa solids and cocoa butter Unsweetened baking chocolate primarily consists of cocoa solids and cocoa butter in varying ratios The majority of chocolate consumed today is sweet chocolate, a blend of cocoa solids, cocoa butter or other fats, and sugar Milk chocolate, a variant of sweet chocolate, includes milk powder or condensed milk for added creaminess.

Cocoa solids are rich in alkaloids like theobromine, phenethylamine, and caffeine, which can influence physiological functions and serotonin levels in the brain Studies suggest that moderate chocolate consumption may help reduce blood pressure However, it's important to note that theobromine can be toxic to certain animals, particularly dogs and cats.

Dark chocolate, with 136 calories and essential nutrients like 33mg of magnesium and 1.19g of protein per ounce, has evolved significantly since its origins Initially consumed by the Mexicans, chocolate was transformed in Europe through the addition of refined sugar and milk In the 19th century, John Cadbury pioneered an emulsification process that led to the creation of the modern chocolate bar Today, chocolate is a beloved flavor worldwide, inspiring a multitude of products, including the widely popular chocolate chip cookies in Europe and North America Additionally, chocolate is often gifted in various shapes during holidays and is enjoyed in beverages like chocolate milk and hot chocolate.

Although cocoa originated in the Americas, today Western Africa produces almost two-thirds of the world's cocoa, with Côte d'Ivoire growing almost half of it

The sensory experience of chocolate is a delight to the senses, offering a range of appealing qualities that make them a popular candy Here's a description of the sensory characteristics of chocolate:

The perception of flavor is largely influenced by smell, as olfactory receptors in our nose are essential to this experience When consuming food, aromatic molecules are released and ascend to the olfactory receptors via the back of the throat, enhancing the overall flavor profile This is particularly evident in chocolate, where the rich and diverse aromatic molecules play a significant role in creating its complex flavors, making high-quality chocolates stand out with their unique aromatic characteristics.

Sight plays a crucial role in shaping taste preferences, as the visual appeal of food significantly influences our perception of flavor For instance, high-quality chocolate is typically expected to exhibit a glossy finish, vibrant color, a satisfying snap, and the absence of fat or sugar bloom When these visual characteristics are lacking, consumers often associate them with a diminished taste experience.

Different foods contain a variety of volatile and non-volatile chemical compounds that activate our taste and smell receptors For instance, allicin is the compound responsible for garlic's unique flavor Similarly, the flavor profiles of chocolate are influenced by the type and origin of cocoa beans, as well as the fermentation and roasting processes, resulting in distinct tastes such as those found in dark Madagascar chocolate compared to milk Swiss chocolate.

The texture and temperature of a substance play a crucial role in shaping our flavor perception Various textures, such as creamy, crunchy, fizzy, or icy, can enhance or modify the overall tasting experience Specifically for chocolate, three key parameters define its texture: smoothness, meltiness, and hardness Smoothness relates to how chocolate glides in the mouth, determined by the particle size achieved during refining Meltiness refers to the extent to which chocolate melts in the mouth, influenced by the fat-to-solids ratio Hardness indicates how challenging it is to chew and the force required to bite into the chocolate, also affected by the fat/solids ratio Ideally, chocolate should be firm with a satisfying snap at room temperature, melting easily in the mouth and providing a soft sensation on the palate.

Trigeminal sensations, experienced through the trigeminal nerve, include feelings like the coolness of menthol and the burn of chili peppers While not classified as tastes, these sensations play a significant role in shaping overall flavor perception.

Flavours often interact and combine to create unique taste experiences, rather than existing in isolation For instance, the blend of sweet and salty in salted caramel results in a distinct flavour that transcends its individual components Similarly, chocolate can showcase complex flavour profiles, particularly in dark chocolates, where bitter and sour notes from Fino de Aroma cocoa liquor combine with sweetness from sugar, resulting in a harmonious balance of bitter, sour, and sweet.

Genetics, personal experiences, and cultural backgrounds significantly shape individual flavor preferences and perceptions While some people may be genetically inclined to perceive certain compounds as extremely bitter, others may not detect that bitterness at all This unique palate means that one person might taste hints of cherry in a chocolate, while another might discern notes of citrus.

Overall, the sensory experience of chocolate is a delightful combination of visual appeal, texture, sweet aroma, and rich flavor They offer a satisfying treat for those seeking a naturally sweet and wholesome.

Status of cocoa and chocolate

Vietnam is home to three primary cocoa-growing regions: the Central Highlands, the Southeast, and the Mekong Delta Each region boasts unique soil characteristics, water sources, and climates, leading to distinct flavors in the cocoa beans Additionally, farmers employ varied processing methods post-harvest, further enhancing these regional differences Despite these variations, Vietnamese cocoa is renowned globally, often regarded as "the best in the world."

Cocoa is primarily intercropped with crops such as coconut, cashew, and various fruit trees, unlike the specialized cultivation seen in major exporting countries like Côte d'Ivoire, Ghana, and Indonesia In Vietnam, cocoa cultivation is concentrated in the Mekong Delta, particularly in Tien Giang, Ben Tre, Hau Giang, Vinh Long, Tra Vinh, and Soc Trang Additionally, the Central Highlands feature cocoa farming in Dak Lak, Dak Nong, and Lam Dong provinces, while the Southeast region focuses on Binh Phuoc and Dong Nai for cocoa production.

The global demand for chocolate is on the rise, particularly in North American, Asian, and European markets, creating a significant challenge in securing sufficient cocoa supply Cocoa is primarily cultivated in developing countries across Africa, Asia, and the Americas, where it is often grown in small, fragmented plots rather than concentrated areas.

Markets for chocolate: chocolate are a popular product and have a significant market demand, both domestically and internationally Here are some potential markets for distributing chocolate:

The Vietnamese chocolate market is rapidly diversifying, offering an array of product lines and brands, including dark, milk, and white chocolate, as well as chocolate with nuts Consumers can easily access these products through convenience stores, supermarkets, and online platforms Local businesses are innovating by developing unique chocolate varieties that incorporate special flavors and combine traditional ingredients like nuts and indigenous Vietnamese fruits, enhancing the overall chocolate experience in Vietnam.

Asian consumers, particularly in countries like China, India, and Japan, view chocolate as an exotic delicacy and a luxury gift, presenting significant export opportunities for Vietnamese chocolate The premium chocolate market is evolving, with innovative trends such as transparent sourcing of unique ingredients and products tailored to specific lifestyle needs, which enhance its competitive advantage.

The global chocolate market is experiencing significant growth due to rising consumer demand for chocolate and its related products, driven by its nutritional benefits and stress-relieving properties As a high-value industry with substantial development potential, chocolate manufacturers are continually innovating to capture consumer interest Distribution channels have expanded from traditional retail to online platforms, catering to evolving consumer preferences To successfully navigate international markets, producers and exporters must adhere to specific regulations and requirements, while conducting thorough market research and forging partnerships with distributors or importers to enhance market access.

FACTORY DESIGN AND PRODUCTION PROCESS SELECTION

Factory construction site

The location of the factory is very important, to ensure that the factory works well during the production period and the factory is built to satisfy the following conditions:

- Near the national electricity grid

Lam Dong's advantageous geographical position near cocoa cultivation areas significantly lowers transportation time and costs for raw materials destined for chocolate processing Furthermore, the city features a robust transportation infrastructure that streamlines the movement of goods and products efficiently.

Lam Dong city boasts a skilled and dedicated workforce specializing in agriculture and chocolate processing, which guarantees the professional and efficient functioning of its chocolate processing facilities.

Lam Dong boasts a vibrant tourism industry and a diverse consumer market for chocolate products The growth of tourism in the region opens up valuable opportunities to tap into both domestic and international chocolate markets.

Lam Dong's temperate climate, characterized by mild temperatures and low humidity, creates an ideal environment for chocolate production The region's conditions support proper dehydration of cocoa fruit, essential for quality chocolate The cool temperatures help preserve the cocoa's natural flavors and nutritional content, while reduced humidity minimizes the risk of mold growth during production, ensuring the safety and quality of the final product.

2.1.2 Source of raw materials and energy

In Lam Dong, dedicated and experienced farmers cultivate cocoa orchards with a focus on natural and safe growth The meticulous harvesting process of cocoa fruits guarantees the highest quality for subsequent production.

Lam Dong's dependable and high-quality raw materials contribute to chocolate that boasts exceptional flavor and adheres to food safety standards, ensuring a delightful and natural experience for consumers.

Lam Dong boasts a robust electrical infrastructure, effectively supporting production activities such as chocolate manufacturing The city's investment in a reliable power supply system ensures stable electricity provision, catering to the demands of both industrial and residential sectors.

Lam Dong's electricity supply efficiently supports industrial zones, including chocolate processing and production facilities, ensuring uninterrupted and continuous operations without power outages.

Boilers use fuel as DO (Diesel Oil) oil, FO (Fuel Oil or also called Mazut Oil) oil, These types are supplied from petrol stations of the province…

➢ Water supply and water treatment problem

The Lam Dong region boasts an abundant and stable water supply, thanks to its numerous lakes, streams, and natural water sources, making it an ideal location for chocolate production.

Lam Dong boasts a robust public water supply system and infrastructure, effectively catering to industrial and production zones This ensures that the chocolate production facility in Lam Dong has an ample supply of water resources necessary for its operations.

At this food processing factory, the wastewater is rich in organic substances, fostering a conducive environment for microbial growth This situation poses a contamination risk to tools, equipment, and raw materials, which can significantly harm environmental health and compromise the quality of the final product.

To address environmental concerns, the company responsibly treats all production and domestic wastewater, ensuring it meets at least the minimum water quality standard of level C before being discharged into the shared wastewater system This commitment to effective wastewater management highlights the company's dedication to protecting the environment and upholding product quality.

Effective management of factory scraps is essential to mitigate pollution in the workplace and the surrounding environment When cocoa fruits are utilized as the main raw material, the resulting scraps can be transformed into microbial fertilizers This not only highlights their valuable potential but also creates an opportunity for factories to sell these scraps, enhancing hygiene and functionality while contributing positively to the economy.

Lam Dong is conveniently located near major economic hubs like Ho Chi Minh City, approximately 323.8 km away However, effective delivery necessitates careful consideration of both distance and travel time when planning transportation from Lam Dong to these urban areas.

Lam Dong has a well-developed transportation system, including roads, airways, facilitating connections to major cities This supports the transportation of products from Lam Dong to key economic regions

The factory focuses on hiring local workers to reduce costs associated with building dormitories, with most employees holding a 12th-grade education By implementing extensive training programs in equipment operation and related skills, the factory develops a skilled and cohesive workforce, promoting efficient operations.

Technological process

2.2.1 Flowchart of the production process of chocolate

Sugar,milk powder Lecithine, cocoa butter

Raw Material Description: The cocoa fruit utilized in this process are of substantial size, with each fruit weighing between 400 to 600 grams

• The cocoa fruits must be in a fresh, intact state, devoid of any signs of damage, pests, or diseases The optimal level of ripeness is essential

Natural preservatives, including citric acid from citrus fruits, ascorbic acid (vitamin C), and sea salt, are effective in preventing bacterial and mold growth, which helps extend the shelf life of cocoa fruits.

The cleaning process is essential for preparing cocoa beans for subsequent stages by effectively removing impurities such as leaves, dry twigs, soil, rocks, metals, and insect corpses Additionally, this process standardizes the size and density of the cocoa beans, eliminating oversized or undersized particles and ensuring uniformity, which is crucial for the efficient production of cocoa in the next steps.

No significant change during cleaning The main change is a decrease in impurity content, and a more uniform particle size

❖ Method: The cleaning process is carried out through these steps:

Cocoa undergoes a sieving process to eliminate impurities and ensure uniform particle size, utilizing two sieves in succession The cocoa stream that flows between these two sieves is the final cleaned product, free from oversized, undersized, and flat particles.

- Clean metal using a magnetic field using a metal removal machine

- Aerodynamic cleaning to remove impurities heavier than cocoa such as sand, soil and lighter impurities such as leaves and branches

Table 2.1 Sunrise Screening equipment specifications m raw materials (in) 312.5kg/h

Use a metal separation device using magnetic force

- Output: cocoa beans have had metals and magnetic impurities removed

Table 2.2 Technical specifications of magnetic separator m raw material (in) 305,6kg/h

The number of machines 2 m raw materials per shift 2445,1kg/shift

- Input: from the magnetic separator

- Output: cocoa beans are stripped of flat seeds, particles or light impurities, at this point the cocoa beans are almost clean, ensuring enough quality to produce chocolate

Table 2.3 Technical specifications of aerodynamic classification equipment mraw material (in) 305 kg/h

Equipment price $2800 m raw materials per shift 2442,41kg/shift

To facilitate the subsequent processes, heat treatment is applied to cocoa shells, which are typically soft and adhere closely to the endosperm This treatment increases the brittleness of the shells, allowing for easier separation from the endosperm and simplifying the peeling process.

Heat application causes physical changes in cocoa beans, particularly affecting the seed coat The polysaccharide-rich shell loses moisture and swells, while the lipid-rich endosperm deforms, leading to a breakdown of the bond between the endosperm and the seed coat.

Physical chemistry: mainly the moisture content in the grain

The endosperm undergoes various chemical reactions, notably the Maillard reaction, which is essential for developing flavor compounds in cocoa However, subsequent processes can lead to the degradation of these flavor components, making it crucial to control the Maillard reaction to preserve cocoa's rich flavors.

Biology: organisms on the grain surface can be inhibited and destroyed by heat

Using infrared radiation as a heating agent This agent can remove impurities without reducing moisture content, has little fat loss, takes up little factory space, and has high efficiency

- Input: from the aerodynamic impurity separation device

- Output: cocoa beans have a crispy shell, preparing for the shelling process

Table 2.4 Technical specifications of drying equipment m raw material (in) 304,39kg/h

Equipment price $4000 m raw materials per shift 2435,1kg/shift

The purpose of the process is to exploit the endosperm This process helps separate the cocoa shell from the endosperm and remove them through a combination of separation methods

The process of cocoa processing involves removing the shell from the endosperm, significantly decreasing the overall volume of cocoa Mechanical forces contribute to the breakdown of some endosperm, further reducing its size It is essential that the remaining shell content after this process is less than 1%, as any shell residue can adversely impact the quality of the final product.

Use a dehulling device that acts as a hammer mill, then use a sieve and wind turbine to separate the shells

After undergoing heat treatment, cocoa beans are processed in dehulling equipment where moving beater arms propel the beans against the walls, effectively breaking their shells The resulting mixture is then separated into shells and kernels using aerodynamic techniques and sieving methods.

The device operates on a principle akin to a hammer mill, where dried cocoa beans are processed through a peeling mechanism The rotating threshing arm induces a circular motion in the beans, causing them to collide with the device's walls and the arm itself, which leads to the breaking of the shells and some seeds Subsequently, a combination of sieves and aerodynamic systems is employed to effectively separate the shells from the seeds.

Figure 2.6 Working principle of Dehulling equipment

- Input: from heat treatment equipment

- Output: endosperm of cocoa beans after dehulling

Table 2.5 Technical specifications of dehulling equipment m input 297,65 kg/h

1 m input per shift 2381,18kg/shift

The process aims to refine and minimize the size of cocoa beans, facilitating the subsequent alkalinization process A smaller particle size enhances the efficiency of alkalinization, allowing the resulting cocoa mass to effectively integrate into the mixing phase of production.

The coarse grinding process in physics primarily alters grain size through mechanical force Additionally, the increase in friction and temperature during this process necessitates the use of a cooling solution.

During the grinding process of cocoa beans, a phenomenon known as liquefaction occurs, resulting in the formation of cocoa mass This process takes place when the cocoa beans are ground to a specific size without being defatted.

- Coarse grinding: is done after going through previous heat treatment to reduce particle size to

200 - 300àm Coarse grinding equipment such as roller mill, hammer mill, disc mill

- Fine grinding: is done before the roasting process in the case of roasting cocoa mass Equipment such as ball mill, shaft mill or combination

Figure 2.8 Operating principle of grinding equipment

Table 2.6 Technical specifications of Grinding equipment m input 295,49kg/h

Number of machines 2 m input per shift 2363,91kg/shift

Shaft crushing equipment features a design with five horizontally stacked stainless steel shafts Data input from the end shaft generates a continuous flow, while the material removal system is located at the top, equipped with an iron razor that effectively scrapes the product off the shafts.

The grinding process generates heat due to friction between the shafts and the material, which can significantly impact grinding efficiency To mitigate this issue, it is essential to cool the device by circulating water through the shafts.

The shaft speed of these shafts rotates at an increasing speed from top to bottom The last shaft can rotate 200 rpm

Drive capacity corresponding to 1m length: 20kW

Pressure on a shaft corresponding to a length of 1m: 28000 N

Axle size: LxL 40cm x 140-180cm

The fermentation process of cocoa beans aims for perfection, as it generates organic acids like lactic and acetic acid Excessive acidity can lead to a sour taste, negatively impacting the product's sensory quality To counteract this, the alkalinization process neutralizes the acids and enhances the formation of flavor compounds, ultimately improving the overall quality of cocoa.

Physics: in the case of alkalinization of cocoa mass, the viscosity of cocoa mass will decrease due to increased temperature

Physical chemistry: Cocoa butter crystals will liquefy, water will evaporate, causing moisture content to decrease thanks to the effect of temperature

- Mainly neutralizes organic acids in cocoa mass, considered satisfactory when pH returns to neutral

- Besides, hydrolysis reactions still take place such as hydrolysis of lipids, proteins helping to form pre-flavor components for cocoa

- At the same time, polyphenol condensation reactions and Maillard reactions also occur, contributing to the color and characteristic flavor of the product

CALCULATION DESIGN OF CHOCOLATE PRODUCTION SYSTEM

Factory production plan

The factory operates continuously with three 8-hour shifts per day, only halting production on holidays and during specific maintenance periods These maintenance intervals occur during Tet and October, focusing on the preservation and repair of machinery and equipment, as cocoa fruit raw materials are scarce during these months.

Here are some key details for the year 2024:

Total number of days in 2024: 365 days

Days off for machinery and equipment maintenance: 31 days

Holidays including New Year, Lunar New Year (8 days), 10/3, 30/4, 1/5, 2/9: 13 days Sundays in a year (excluding 4 Sundays in February): 44 days

Based on this information, the production schedule can be calculated as follows:

Number of production shifts: 277 days × 3 shifts = 831 shifts

Total production hours: 831 shifts × 8 hours = 6648 hours

This production schedule optimizes the utilization of available working days, ensuring efficient production output for the year 2024

Cocoa is a perennial industrial crop that produces fruit year-round, with peak seasons occurring from October to December and April to June in Lam Dong During off-peak periods, each cocoa tree yields approximately 4 to 5 fruits.

Table 1.1: Raw material harvesting chart

Material balance

The formula for calculating the volume of material coming out at each stage:

Gnv:The initiala quantity of input material of the n t stage

Gnr: Amount of product formed in the n th stage xn: Loss of the nth stage compared with the n th – 1 stage

The formula for calculating the volume of materials entering each stage is:

Material loss at each stage:

Material balance for chocolate products

The finished product of chocolate with the yield is:

Calculation for 1 ton of cocoa powder: G 0 = 1000 kg

Calculated for the production of cocoa powder with a high fat content of 10% Mass of cocoa butter obtained after pressing butter G 1 , loss of 0.5%:

Weight of cocoa powder after pressing butter G 2 :

Fat content reduced from 55% to 10% and loss of 0.5%:

Time to press one batch of avocados: T 1 = 15 minutes = 0.25 hours

Calculate the device to operate 4 hours a day

Number of batches of avocado pressing equipment made in 1 day:

Loading volume for one batch:

Table 3.2: Loss rate of chocolate products

- Losses depend on input materials

- Volume of initial cocoa beans: mo = 2.55 tons/day

- Impurities in the original cocoa beans: 2% (w/w)

- mloss: Volume of loss (kg/day)

- mi: Volume of impurities (kg/day)

3.3.1.Screening m1: Weight of cocoa beans after screening (kg/day)

- Weight of cocoa beans after sifting: mo = m1 + mi + mloss→ 2550 = m 1 + m i + 0.2% * 2550 (1)

- Impurities in the original cocoa beans: 2% (w/w)

2% * mo = mi + mloss (impurities) → 2% * 2550 = mi + 0.2% * 2% * 2550 (2) From (1) and (2) → m 1 = 2494.1 kg/day; mi = 50.8 kg/day

3.3.2 Demagnetization m2: Mass of cocoa beans after demagnetization (kg/day) mKL: Mass of metal (kg/day) Metal in cocoa kenel after demagnetization: 0.01% (w/w)

- Mass balance equation: m1 = m2 + mKL + mloss→ 2494.1 = m2 + mKL + 0.1% * 2494.1 (3)

- Metal balance equation: 0.01% * m1 = mKL + 0.01% * mloss

From equations (3) and (4) → m 2 = 2491.35 kg; mKL = 0.249 kg/day

3.3.3 Classify m3: Weight of cocoa beans after sorting

- Weight of cocoa beans after sorting: m3 = m2 * (1 - 0.3%) = 2491.35 * (1 - 0.3%) = 2483.87 kg/day

3.3.4 Drying m4: Mass of cocoa beans after drying msteam 1: Mass of steam

- Mass balance equation: m3 = m4 + msteam 1 + mloss → 2483.87 = m4 + msteam 1 + 0.1% * 2483.87 (5)

From equations (5) and (6) → m4 = 2428.87 kg; msteam 1 = 52.51 kg

3.3.5 Dehulling m5: Weight of cocoa beans after dehulling mshell: Weight of shell

- Mass balance equation: m4 = m5 + mshell + mloss→ 2428.87 = m5 + mshell + 0.2% * 2428.87 (7)

From (7) and (8) → m5 = 2411.25 kg; mshell = 12.76 kg

3.3.6 Grinding m6: Mass of liquid cocoa after grinding

- Mass balance equation: m5 = m6 + mheat 2 + mloss→ 2411.25 = m6 + mheat 2 + 0.2% * 2411.25 (9)

From (9) and (10) → m6 = 2401.37 kg; mheat 2 = 5.05 kg

3.3.7 Alkalization m7: Mass of liquid cocoa after alkalization mK2CO3: Mass of K2CO3

→ We use mK2CO3 = 2.5% * liquid mcocoa = 2.5% * m6

- Mass of liquid cocoa after alkalization m7 = m6 + mK2CO3 – mloss

- Mass of K2CO3: mK2CO3 = 2.5% * m6 = 2.5% * 2401.37 = 60,03 kg

3.3.8 Roasting m8: Volume of liquid cocoa after roasting (kg/day) mCK: Mass loss of dry matter (kg/day) → m CK = 5% * m7 (kg/day)

3.3.9 Mixing m9: Mass of chocolate after mixing (kg/day) mlipid (1): Mass of lipid in cocoa mass (kg)

→ m lipid (1) = 50% * m 8 mlipid (2): Mass of lipid in chocolate (kg)

→ m lipid (2) = 45% * m9 msugar: Mass of sugar (kg) mbutter: Mass of cocoa butter (kg) mlec: Mass of lecithine → m lec = 0.3% * m9

- Mass balance equation: m8 + msugar + mlec + mbutter = m9 + mloss

- Lipid balance: mlipid (1) + m butter = mlipid (2) + mloss

From (11), (12), (13) → m 9 = 2280.72 kg/day; msugar = 281.13 kg/day; mbutter = 59.69 kg/day; mlec = 0.3% * m9 = 0.3% * 2280.72 = 6.84 kg/day

3.3.10 Refining m10: Weight of chocolate after refining (kg/day)

- Mass of chocolate after pouring into mold: m11 = m10 – mloss = 2279.57 - 0.1% * 2279.57 = 2277.29 kg/day

- Mass of chocolate after tempering: m12 = m11 – mloss = 2277.29 - 0.01% * 2277.29 = 2277.06 kg/day

- Mass of chocolate after frame separation: m13 = m12 – mloss = 2277.06 - 0.01% * 2277.06 = 2276.83 kg/day

- Mass of chocolate after wrapping: m14 = m13 – mloss = 2276.83 - 0.01% * 2276.83 = 2276.6 kg/day

With the mass of the chocolate package being about 100g → There are 2276.6/0.1 ≈ 22766 chocolate packages.

Energy balance

TF = 25°C, cocoa bean in put temperature;

TP = 60°C , cocoa bean output temperature;

Do the calculation: xwF F + A Ha1 = xwP P + A Ha2

∆ĤF = (xSF CpS + xwF CpW ) (TF – 0)

∆ĤP = (xSP CpS + xwP CpW ) (TP – 0)

From (1) and (2), we have: A = 5134,54 kg and Ha2 = 0.022 kg moisture/kg dry air

Ha1 = 0.012 kg moisture/kg kkk;

Do the calculation: xwF F + A Ha1 = xwP P + A Ha2

∆ĤF = xSF CpS (TF – 0) + xwF CpW (TF – 0)

∆ĤP = xSP CpS (TP – 0) + xwP CpW (TP – 0)

From (3) and (4), we have A = 26544,36 kg and Ha2 = 0.027 kg moisture/kg dry air

Ha1 = 0.012 kg of moisture/kg of dry air

Tp = 70 o C, the temperature of the chocolate

Do the calculation: xwF F + A Ha1 = xwP P + A Ha2

∆ĤF = xSF CpS (TF – 0) + xwF CpW (TF – 0)

∆ĤP = xSP CpS (TP – 0) + xwP CpW (TP – 0)

From (5) and (6), we have: A = 2029,79 kg and Ha2 = 0.01198 kg moisture/kg dry air

Ha1 = 0.012 kg of moisture/kg of dry air

Do the calculation: xwF F + A Ha1 = xwP P + A Ha2

∆ĤF = xSF CpS (TF – 0) + xwF CpW (TF – 0)

∆ĤP = xSP CpS (TP – 0) + xwP CpW (TP – 0)

Ha1 = 0.012 kg of moisture/kg of dry air

Do the calculation: xwF F + A Ha1 = xwP P + A Ha2

∆ĤF = xSF CpS (TF – 0) + xwF CpW (TF – 0)

From (9) and (10), we have: A = 3200,69 kg and Ha2 = 0.012 kg moisture/kg dry air.

CALCULATE INVESTMENT COSTS, OPERATING COSTS AND

Equipment and technology

Figure 4.1 YX Chocolate production line

The YX Series Chocolate production line features a cutting-edge design and compact structure, boasting high automation levels to cater to various market demands with diverse shapes, flavors, and sizes This advanced equipment, controlled by PLC, ensures stable performance and enhanced operational efficiency Constructed with SS3043 for all chocolate-contact parts, it prioritizes food safety and hygiene throughout the production process Additionally, the line is supported by skilled engineers trained in equipment operation and maintenance, further optimizing performance and reducing costs.

In particular, electronics and motors can be configured according to customer requirements Chocolate brands that can be produced from this line: Kisses, Dove, Ferrero

Figure 4.2 Equipment diagram of chocolate production process according to YX production line

Main functions of the devices:

The Fat Melting Tank, designed for melting cocoa butter, serves as a heating station that transfers liquid cocoa butter to a material mixing machine via a connected pumping system This setup includes a flow measuring device and boasts automatic temperature control for optimal performance.

- Sugar Grinding Machine: grinds granulated sugar into powder and improves the efficiency of the mixing and fine grinding process later

- Chocolate Conche Machine: a machine that mixes ingredients to create chocolate

- Delivery Pump: pumps chocolate liquid mass to other devices

The Heat Holding Pump is an innovative storage solution designed specifically for chocolate paste, featuring electric heating and an automatic temperature control system This device maintains chocolate at an optimal temperature, reducing moisture content through heat retention and stirring, which enhances viscosity, prolongs shelf life, and improves flavor quality.

A tempering machine is essential for controlling the formation of chocolate crystals at precise temperatures, ensuring optimal quality in the chocolate-making process By carefully managing these temperature variations, the device enhances the chocolate's aroma and flavor, resulting in a superior taste experience.

The Chocolate Forming Machine with Cooling Tunnel is designed to produce chocolate in specified quantities, enabling the creation of unidirectional chocolate, flavored mixed chocolate, and chocolate fillings This versatile equipment operates via a PLC system and allows for the use of interchangeable molds, facilitating the production of chocolates in various shapes.

- Packaging Machine: packs Chocolate into different styles for preservation and storage

Figure 4.3 Chocolate samples are created from the YX production line

4.1.2 Chocolate production line uses equipment from China

Figure 4.4 Chocolate production equipment line

- The production line includes: cocoa butter melting machine, cocoa powder grinding machine, mixing machine, heating and softening machine, chocolate packaging machine

- Chocolate packaging machine is used for products that are heart-shaped, cube-shaped, hemispherical and have a diameter of less than 35mm

- The production line produces high quality products and has been exported to more than 40 countries and regions: USA, UK, France, Belgium

Figure 4.5 Chocolate products from the above production line Table 4.6 Equipment parameters in the Chinese production line

Equipment for cooking cocoa butter

Pump capacity: 0.2kW Heat capacity: 6kW Dimensions:2000x1000x900mm

Total power: 9kW Dimensions: 1100x750x1800mm

Chocolate crusher Volume: 1000l Motor power: 22kW

Heat capacity: 6kW Dimensions: 2970x1320x1790mm

Motor power: 2.2kW Heat capacity: 4kW Dimensions: 1220x1850mm Weight: 1000kg

Productivity: 250l/h Total power: 7.1kW Dimensions: 1130x880x1910mm Weight: 580kg

Productivity: 50 - 150kg/h Cooling time: 18 – 30 minutes

Mold size: 280x200x30mm Weight: 2500kg

Chocolate Pump Materials: stainless steel

Table 4.7 Investment costs in some technology lines

Line equipment of company Ningbo Huadong

Line equipment of company Sanghai Junyu Food

Line equipment of company Chengdu LST Science and Technology Co., Ltd

Line equipment of company DEMSA MAKINA TEKSTIL

AMBALAJ SANAYI TICARET LIMITED SIRKETI

(According to reference source: alibaba.com)

Investing in a fully automatic chocolate production line from Chengdu LST Science and Technology Co., Ltd, priced at 1,633,000,000 VND, ensures high productivity and stable operation This advanced equipment, transferred from China and backed by a 1-year warranty, specializes in producing various chocolate products, including pure chocolate and chocolate-filled cakes, with customizable molds Supported by a team of highly skilled engineers, this production line is optimized for efficiency and has been successfully implemented in countries such as Germany, India, Korea, Canada, Australia, Russia, and Ecuador.

Figure 4.8 Line diagram of Chengdu Chocolate Company LST Science and Technology

Figure 4.9 Product lines produced from Chengdu LST Science and Technology line

Table 4.10 Selected production line parameters

Many chocolate production lines begin with ingredients like cocoa butter and cocoa powder, bypassing the essential step of converting cocoa beans into cocoa mass To align with the factory's original goal of producing chocolate directly from cocoa beans, investment in additional equipment for processing cocoa beans into cocoa mass is required.

Table 4.11 Investment costs for additional equipment

Machine for cleaning cocoa beans 209,179,000 VND Heat treatment machine for cocoa beans 163,348,000 VND

Raw cocoa grinding machine 377,200,000 VND

Summary of devices

Device name Quantity Requirement cyclo containing cocoa beans

* 2 fans support case separation Aerodynamic sorting equipment

* Store cocoa beans after shelling Magnetic sorting device 1

Intermediate tank 2 * 1 tank containing crushed cocoa powder

* 1 tank of cocoa after roasting

Pump 2 * 1 pump supports pumping cocoa after roasting to heat treatment equipment

* 1 pump supports pumping the following mixture mix to the tempering equipment

Conveyor 1 * Transporting chocolate after making

Cool to mold separation table

Equipment to print production date

The device prints the date on the box

Calculation of steam-water-electricity

- Volume of K2CO3 in 1 day: 120.54 kg

- Volume of water to use:

Water for CIP (Clean In Space)

- The process of running CIP after 1 day is carried out as follows:

• Clean the device with warm water at 50℃ for 3 minutes

• Inject 1% NaOH solution cyclically at 7℃ for 10 minutes

• Clean the device with warm water at 50℃ for 3 minutes

• Sterilize the device with hot water at 95℃ for 5 minutes

• Cool the device with water at 25℃ for 10 minutes

- CIP water flow/hour: Q = 7000 kg/h

- Clean the device with warm water at 50℃ for 3 minutes

• Amount of water needed: N1 = Q * T1 = 7000 * 0.05 = 350 kg = 350 L

- Inject 1% NaOH solution cyclically at 75℃ for 10 minutes

• Solution pumping time: T2 = 10 minutes = 1/6 hour

- Clean the device with warm water at 50℃ for 3 minutes

• Amount of water needed: N3 = Q * T3 = 7000 * 0.05 = 350 kg = 350 L

- Sterilize the device with hot water at 95℃ for 5 minutes

- Cool the device with water at 25℃ for 10 minutes

- Total amount of water needed to run CIP for each device in 1 day:

- Need to run CIP for 5 devices in the factory

Total water consumption for 5 devices: VCIP/5 devices = VCIP/1 device * 5

→ CIP tap water for 1 year: 18.10 * 300 = 5430 m 3

- Total cost of technological water: T1 = 9284 * (5430 + 32.5) = 50,713,850 (VND)

The number of people in the factory is 91 people

Amount of water people use in 1 day: Vcn = 91 * 75 = 6825 L ≈ 7 m 3

Amount of water needed to clean inside and outside the factory in 1 day: Vpx = 50 m 3 Amount of water for the dining room: 0.325 m 3

Amount of water for plants: 10 m 3

Total volume of water during the day: V = 67,325 m 3

Loss: 3% → Actual amount of water used in 1 day: Vtt = 67,325 / (1 - 3%) = 69.4 m 3 Amount of water used for fire protection and prevention: 162 m 3

→ Non-technical water cost: (69.4 * 300 + 162) * 9284 = 194,796,888 VND / year

Steam is supplied to the alkalization process to heat the cocoa and lye mixture

- Specific heat capacity of cocoa liquid: cc = 1.42 kJ / kg.℃

- Specific heat capacity of K2CO3 10%: ck = 3.962 kJ / kg.℃

- Cocoa liquid weight: mc = 4621.07 kg

- Weight of 10% K2CO3: mK2CO3 = 115.5 kg

- Specific heat of the mixture (mass cocoa + K2CO3) chh = (mc * cc + mK2CO3 * ck) / (mc + mK2CO3)

- Actual amount of calories needed to provide alkalization: Qtt = Q1 / (1 - 5%) = 350506.18 / 0.95 = 368953.87 kJ

- Steam volume at 3 bar used in 1 day:

→ Volume of steam for alkalinization in 1 year: 191.48 * 300 = 57444 kg / year

- Specific heat capacity of water: c = 4.18 kJ / kg.℃

- Latent heat of vaporization of water at 3 bar pressure: r = 2141 kJ / kg

- Clean the device with warm water at 50℃ for 3 minutes

• Amount of water used: N1 = 350 kg

• Steam bar 3 can be used: H1 = (N1 * c * (t2 - t1)) / (0.9 * r)

- Inject 1% NaOH solution cyclically at 75℃ for 10 minutes

• 3 steam bars can be used:

- Clean the device with warm water at 50℃ for 3 minutes

• Amount of water used: N3 = 350 kg

• 3 steam bars can be used:

- The device is sterilized with hot water at 95℃ for 5 minutes

• Amount of water used: N4 = 583.33 kg

- Total steam consumption in 1 year: 253.08 * 300 = 75924 kg

Conclusion: In 1 year, the factory needs about 75924 + 57444 = 133368 kg

4.4.3.1 Equipment in the production workshop

→ Electricity cost for equipment in 1 year: 2321 * 3728.68 * 300 ≈ 2,596,279,884 (VND)

→ Lighting electricity cost in 1 year: 2321 * 884.08 * 300 = 615,584,904 VND

CALCULATION FOR ORGANIZATION

Design of main production workshop

After designing and installing equipment in accordance with the continuous production technology line and the design standards of the factory, the main production workshop has the following dimensions

Figure 5 1 The diagram of production process

Cocoa beans are initially processed through a screening device that sorts them by size, utilizing engine power to eliminate smaller particles, including low-quality beans and impurities Only the cocoa beans that meet the quality standards proceed to the next stage of processing.

Cocoa beans are processed through a magnetic separator featuring a cylindrical magnet, with one half generating a magnetic field As the cocoa moves through this device, any metal contaminants are effectively captured by the magnetic field The result is that the cocoa, now free of metal, exits the separator, ensuring a cleaner and safer product.

The cocoa undergoes aerodynamic classification, where larger particles are retained by the sieve, while smaller particles are propelled by a fan into a cyclone, effectively removing impurities.

In the next stage of processing, cocoa beans are transferred to drying equipment where they pass through a tunnel conveyor in an infrared processing area During this phase, the temperature of the beans rises, causing the shells to become brittle and cracked, which aids in the subsequent peeling process without significantly altering the moisture content.

Dehulling equipment, resembling a hammer mill, processes heat-treated cocoa beans by peeling their shells The rotating threshing arm creates a circular motion for the grains, causing them to collide with the device's walls and the arm, which breaks the shells and partially fractures the seeds Subsequently, sieves and aerodynamic systems effectively separate the shells from the seeds.

The material undergoes a grinding process involving five pairs of shafts, where the spacing between each pair gradually decreases, resulting in a finer particle size.

The stainless steel cylindrical alkalizing device features a heating jacket, enabling efficient temperature control An automated pump system facilitates the transfer of the alkaline solution into the device, ensuring a continuous flow through the bottom door.

Next, the Cocoa will be sent to the Convap® Roasting Equipment:

The Convap heat exchanger efficiently transfers heat by pumping the input stream into its lower cylinder, where heating and cooling fluids circulate within a thermostatic jacket Mechanical rotation of blades generates convection, optimizing the heat transfer process.

The device features a blade that consistently scrapes a thin layer of product from the cylinder wall, while a motor at the top regulates the centrifugal operation of the Convap rotor, effectively minimizing the risk of product burning.

- Convap devices usually operate in vacuum conditions In the separator, steam escapes at the top port and the concentrated product exits at the bottom port

In the subsequent stage, the ingredients are transported to the mixing equipment where the stirring paddle ensures an even blend of cocoa powder However, it is important to note that during this process, moisture and flavor components may easily dissipate.

The material undergoes fine grinding through five pairs of shafts, with decreasing distances between them to achieve a finer particle size Subsequently, the chocolate is transferred to a heat mixing device, which ensures a homogeneous mixture of raw materials This crucial step not only determines the product's smoothness but also harmonizes unique flavor combinations.

The liquid chocolate will follow the pipe to the cooling device, the chocolate temperature will be lowered and will be transferred to the molding machine

The chocolate production system efficiently cleans molds before filling them with chocolate, which is then conveyed to a cooling tunnel consisting of six distinct zones Each zone's humidity and temperature are precisely regulated automatically Utilizing robotic arms and vacuum technology, the chocolate is effortlessly extracted from the molds and subsequently transported to the packaging machine.

After being unmolded, the chocolate travels along a conveyor belt where it is checked for defects by a metal detector, then packaged automatically Once wrapped, the chocolate is moved to the carton wrapping area, and finally, the completed chocolate boxes are transported to cold storage by forklift.

Organizational structure

- The number of production days in a year is 277 days

- Equipment will be maintained once every 3 months

- Administrative department works 8 hours/day:

- Main factory and auxiliary parts work 3 shifts/day:

- The production workshop works in shifts, each shift is 8 hours The factory is closed on Sundays, public holidays and Tet holidays of the year

The factory manager plays a crucial role in overseeing daily operations to ensure smooth production processes They manage staff, implement safety protocols, and optimize efficiency while maintaining high-quality standards Responsible for planning, organizing, and coordinating activities, the factory manager aims to meet production targets and deadlines, effectively addressing any arising issues.

The Vice President of Production oversees the entire manufacturing process, managing production schedules, resource efficiency, quality standards, and productivity optimization They develop and implement production strategies that align with the company's goals, playing a crucial role in driving operational excellence, cost-effectiveness, and overall efficiency in production.

The production workshop is responsible for managing all facets of a company's production processes, encompassing manufacturing, quality control, supply chain management, and occasionally research and development It focuses on creating and executing production strategies that align with the company's goals and objectives This role demands strong leadership, strategic planning abilities, and decision-making skills that significantly influence the company's financial performance.

The technical department is responsible for the construction and maintenance of structures, machinery, equipment, and operational programs in factories It oversees all technical, technological, and machinery-related activities within the enterprise, ensuring that these processes run smoothly, efficiently, and swiftly while also addressing and repairing any technical issues that arise.

An electromechanical and refrigeration workshop specializes in the repair, maintenance, and installation of electromechanical systems and refrigeration equipment across various industries, including manufacturing, food processing, and HVAC This workshop focuses on diagnosing and resolving electrical and mechanical issues, performing preventative maintenance to extend equipment lifespan, and ensuring efficient operation of refrigeration systems to effectively preserve perishable goods.

The KCS room, essential for factories, stands for Product Quality Control, where staff are responsible for ensuring that both input and output materials meet quality standards and comply with Ministry of Health regulations They conduct regular quality checks throughout the production process, oversee labor safety, and have the authority to document and address any quality-related issues concerning raw materials and finished products.

The Vice President of Business is responsible for overseeing a company's operations, including strategic planning, business development, marketing, sales, and partnerships This leadership role focuses on developing and executing strategies that drive growth, profitability, and market expansion It requires strong strategic thinking and the ability to identify and seize business opportunities while addressing challenges and mitigating risks Ultimately, the Vice President of Business is crucial in shaping the company's overall direction and success.

The Administration and HR department is essential for effective personnel management and administrative operations within an organization Key functions include recruitment, employee onboarding, training, payroll and benefits administration, performance management, and fostering employee relations Additionally, the department ensures compliance with labor laws and regulations while promoting overall organizational development By supporting employees and streamlining administrative processes, the HR department contributes significantly to the smooth functioning of the company.

The finance department is essential for managing a company's financial operations, encompassing financial planning, budgeting, accounting, and reporting They track income and expenses, oversee cash flow, prepare financial statements, and ensure compliance with tax regulations and financial laws Additionally, the finance team is involved in strategic decision-making, including investment analysis, capital budgeting, and risk management.

The sales department is essential for generating revenue by selling products or services to customers Its responsibilities include prospecting, lead generation, customer relationship management, negotiation, and closing deals Sales representatives engage with potential clients to identify their needs, present tailored solutions, address concerns, and convert leads into sales By meeting or exceeding sales targets and fostering long-term customer relationships, the sales department significantly contributes to business growth and profitability.

Order Position Number of workers

Human resources working directly in the main production workshop

Table 5.2: Manpower for the production line Order Position Labor norms

22 Cleaning and laundry staff 2 person/shift 3 6

The largest workforce in a production shift is: 69 + 29 = 98 (person)

So the total workforce of the factory is: 29 + 159 = 188 (person)

5.3.1 Features of the factory construction site

The site features a flat topography with a slope of no more than 1%, making it ideal for factory establishment Its strategic location near the national highway ensures easy access, while the spacious area allows for potential future production expansion.

Build on stable land Through exploration by geologists, the land below has no minerals, so it should be used to open an industrial park

Around the factory, there is a green campus to create a fresh environment suitable for workers and create more aesthetic beauty of the factory

The chocolate production process relies on the transportation of raw materials using buckets and conveyors To meet the technological requirements of this process, we have designed a 1-storey workshop, which facilitates easy equipment arrangement and movement This design also enhances the organization of natural lighting within the space Overall, the 1-storey construction creates a practical and efficient environment for the entire chocolate production process.

5.3.2.1 Traffic problems in the factory

The factory is secured by tall protective walls, ensuring both security and privacy Its thoughtfully designed floor plan features ample space with a level and elevated road layout for efficient drainage Additionally, an extra gate enhances transportation for raw materials, products, and staff, complementing the main entrance This strategic design promotes convenience and boosts productivity by facilitating smooth movement throughout the factory premises.

Based on technology requirements, the number of equipment to choose, we have the size of the main production workshop in the shape of a rectangle

Has a rectangular shape with dimensions:

− Length of main production workshop: 48m

− Width of main production workshop: 16m

− Height: 11m roof is not included

− The house has a reinforced concrete structure − Roof structure includes:

* Cement layer 100mm * Bearing layer

* Corrugated iron layer * Steel frame

House column: bearing column 600 × 400; gable windproof column 400 × 400 (mm)

The foundation is resistant to moisture and loads, the structure consists of:

* Cement layer: 100 (mm) * Bearing concrete layers: 200 (mm)

* Buffer sand layer: 200 (mm) * The bottom layer of compacted earth

The house boasts a well-organized layout, featuring strategically positioned main doors and windows The main doors are constructed with steel, equipped with horizontal push mechanisms for easy access

The primary production workshop is strategically located at the center of the factory's land area, surrounded by interconnected workshops and warehouses, including those for raw materials, finished products, electromechanical operations, and the boiler room To enhance safety, fire extinguishers are conveniently positioned in the corners of the workshop, ensuring quick access for fire prevention and control This careful layout significantly improves the efficiency and safety of factory operations.

In the main production workshop, we build 2 QC and foreman departments with sizes respectively: 6 × 3 × 4 (m) and 6 × 3 × 4 (m)

The packaging for a chocolate production line primarily consists of PE bags, which are essential for storing products and must be preserved with care It is important to maintain a warehouse for packaging storage for a duration of one month The optimal size for the packaging warehouse is 5 × 3 × 6 meters, covering an area of 15 square meters.

Choose 1 room located at the main gate and the other room at the side gate of the factory Choose the size house: 3 × 2 × 3 (m) Area is: 3 × 2 = 6 (m 2 )

− Restroom (1 room for men and other for women): 4 × 4 × 4 (m)

Construction of 2-storey house with size: 30 × 20 × 7 (m)

Total area of administrative area: 30 × 20 = 600 (m 2 )

Calculate for 2/3 of the largest number of employees in 1 shift: 98 × 2

With 98 people is the largest number of employees in a production shift

Standard area is 1.7 m 2 for 1 worker

Calculate more for the corridor and the whole cooking area we choose:

Choose the area of the dining room: 10 × 11 × 3.5 (m) Area is: 10 × 11 = 110 (m 2 )

Calculating plan for factory constructions

Calculate according to the formula:

Fkd: is the factory land area

Fxd: is the total area of the building

Kxd: is the construction coefficient

0.35 = 20989.257 (m 2 ) Choose a construction site with the size 210 × 100 (m), area is 21000 (m 2 )

5.5.2 Calculate the utilization factor K sd

Calculate according to the formula:

Ksd: is the coefficient used to evaluate the economic and technical criteria of the total factory site

Fsd: the usable area of the calculator plant according to the formula:

Fsd = Fcx + Fgt + Fhl + Fxd + Fhr

The total area of the building, denoted as Fxd, is 7346.24 m² Within this area, the space allocated for green trees (Fcx) measures 2938.496 m², calculated as 40% of Fxd The corridor area (Fhl) occupies 1836.56 m², representing 25% of Fxd Additionally, the land designated for traffic (Fgt) covers 3305.808 m², which is 45% of Fxd Lastly, the sidewalk area (Fhr) accounts for 734.624 m², or 10% of the total building area.

Figure 5.3 Factory layout design drawing

Figure 5.4 Workshop layout design drawing

The packaging warehouse and finished product warehouse management departments ensure efficient operations, including a designated disinfection room and filling machines.

The article discusses various types of steel machinery, including 20 mold washing machines, 19 heat treatment machines, and packing machines Specifically, it highlights the production and significance of these steel machines in industrial processes.

The article discusses various refrigeration systems, highlighting 15 units that include a chocolate-containing cyclo container and a tempering machine Additionally, it mentions the presence of two steel conching machines, emphasizing the importance of steel in the production process.

12 re fin e g rin din g m ac hin e 1 st ee l 27 C 48

The article discusses various industrial machines and their components, including 11 mixing machines, 10 cyclones with additives, 6 intermediate tanks, and 6 roasting machines, all made of steel It also highlights the presence of 7 alkalizing tanks, 6 grinding machines, and 5 deshelling machines, alongside 4 heat treatment machines Additionally, there are machines designed for sorting and cleaning, as well as 2 magnetic sorting machines The content emphasizes the use of steel in these machines, showcasing their importance in processing cocoa beans and other materials.

ECONOMIC CALCULATION

Purpose and meaning

Accurate calculation of economic costs is crucial for enterprises and production businesses, serving as the foundation to demonstrate a project's feasibility and practicality The more closely these economic costs align with reality, the greater the plant's operational efficiency and overall feasibility.

It is necessary to ensure the accuracy of the calculation in each period and ensure the reasonableness in each economic time.

Investment costs

Table 6 1 Statistics of investment capital for construction works

Order Name of construction Dimensions

Area (m2) Unit price for a unit m 2 (10 6 VND)

12 Boiler house, power supply area

14 Wet and dry scrap warehouse

22 Room for date printing, labeling, packaging

The amount for investment in building the factory is: T1 = 14692.48 x 10 6 (VND)

• Investment capital for construction of auxiliary works (walls, roads, sewers ) is 30% of T1

• Exploration and design costs are: 10% T1

• The average annual depreciation on construction:

Table 6 2 Statistics of investment capital for equipment in the factory

So the cost of buying the main equipment is: X1 = 11447,56 x 10 6 (VND)

• Investment capital to purchase auxiliary equipment: 20% T1

• Investment capital to purchase inspection and control equipment: 10% T1

• Investment capital to buy industrial cleaning equipment: 5% T1

• Investment capital for equipment assembly: 10% T1

Equipment Quantity Unit price Total cost (VND)

• Other costs (exploration costs, design work costs, transportation costs, equipment loading and unloading costs): 15% T1

• Total investment capital of fixed assets:

Table 6 3 Cost of raw materials to produce 2,55 tons of chocolate/day in 1 year

Number Material Kg/year Unit price

Cost of raw materials to produce 2,2 tons of chocolate/day: T1 = 68781.532060 x 10 6 (VND)

Packaging type Quantity /year Unit price(VND) Total cost (VND/year) Aluminum packaging

In addition, in a year of production, we have to spend about 2.5 billion VND for packaging, packing cartons: T2 = 2.5 x 10 6 (VND)

 The total cost of raw materials to produce 2,2 tons of chocolate/day in year is:

Table 6 5 Cost of fuel and water used in the plant

Energy type Total cost(VND/year) Electricity 3,281,494,788

So the total cost of energy and water is: Tf = 4327.005526 x 10 6 (VND)

• The salary paid to main and auxiliary workers in 1 month: 8 x 10 6 (VND)

There are 159 workers in all So the salary paid to main and auxiliary workers in 1 year is:

• The salary paid to president in 1 month: 22 x 10 6 (VND)

There is 1 president So the salary paid to the president in 1 year is:

• The salary paid to the vice - president in 1 month is: 19 x 10 6 (VND)

There are 2 vice - president So the salary paid to the vice - president in 1 year is:

• The salary paid to employees of departments, divisions and sales in 1 month is:

There are a total of 26 employees So the salary paid to employees in departments, divisions and sales in 1 year is:

• So the salary paid to all employees of the factory in 1 year is:

Social insurance is calculated at 10% of the total factory salary:

That is the cost covered by the circulation of goods, transportation and advertising outside the factory, taken as 10% of the direct costs

The factory borrows capital at an interest rate of 10% per year to pay for construction, equipment purchases, and direct costs:

So the total indirect costs are:

Price to product

Total cost = direct cost + salary cost + social insurance cost + indirect cost

6.3×10 6 = 18950.1537 (VND) With: a is the number of bags produced in 1 year

Selling price plus 5% of product cost:

Economic performance of invested capital

With: a: Number of bags of chocolate produced in 1 year

Z’: selling price for 1 bag of products

Z1: the price of 1 bag of products

So the payback period of the factory is 6 year 6 months

PRODUCT QUALITY AND PRODUCTION SAFETY

Quality control system and food safety assurance

The National Standard TCVN 10727:2015, based on CODEX STAN 87-1981 and revised in 2003, governs the quality and composition of chocolate and chocolate products intended for food use According to Article 2, these products must be primarily composed of cocoa and sugar, with the option to include sweeteners, milk products, flavoring agents, and other food ingredients to enhance their flavor and texture.

National standard TCVN 11038:2015 on Chocolate products - Alginate detection method National standard TCVN 11034:2015 on Milk chocolate - Determination of milk protein content - Kjeldahl method

National standard TCVN 11035:2015 on Milk chocolate - Determination of fructose, glucose, lactose, maltose and sucrose content - Liquid chromatography method

National standard TCVN 10714:2015 (ISO 11053:2009) on Vegetable oils and fats - Determination of cocoa butter equivalent in milk chocolate

National standard TCVN 10715-2:2015 (ISO 23275-2:2006) on Animal and vegetable oils - Cocoa butter equivalents in common chocolate - Part 2: Quantification of cocoa butter equivalents

Labor safety and fire prevention

Labor safety in manufacturing plants is crucial as it significantly impacts the production process, worker health, and machinery condition To ensure a safe working environment, it is essential to educate workers on the importance of safety measures and for factories to implement comprehensive strategies to prevent accidents and hazards.

- Labor organization is not strict

- Workers' awareness of compliance with discipline is not high

- The operating level and technical mastery of workers is not high

- The equipment is not well equipped or not reasonable

• Measures to limit occupational accidents

- Arrange and install equipment to suit production Moving equipment with motors, conveyors must be carefully shielded

- Pressure equipment must have adequate safety equipment such as safety valves and pressure gauges and must be placed away from crowded places such as:

- Heat pipes must have insulated covers and pressure monitors Must check machine parts before operating

- Warehouses storing raw materials and finished fuel must have storage tanks available Prevent unauthorized people from entering production areas Smoking is not allowed in the warehouse

- Everyone in the workshop must perform their functions properly

- Factory discipline must be strict Violations by workers must be properly handled

Proper lighting is crucial for worker productivity and safety, as inadequate illumination can negatively affect performance Key areas such as mixing and pouring molds should be well-lit to enhance precision Additionally, positioning the main door to maximize natural light can further improve working conditions Ensuring optimal lighting not only boosts accuracy but also safeguards employees when operating machinery.

- The loads must have a ground wire and fuse to avoid short circuits

- Need to insulate live parts

- The transformer station is located far from crowded places

- Apply technical measures to reduce the danger in case electricity leaks out

Effective ventilation is essential for maintaining a comfortable workplace in factories, particularly in workshops with high-temperature conditions like heat treatment Installing additional fans can significantly improve air circulation and help mitigate the heat, ensuring a safer and more productive environment for employees.

- Machinery and equipment must be used according to their functions and in accordance with their capacity

- Each type of equipment must have clear records After each shift, machines must be handed over Clearly state the status for the next case to handle

- There must be a cleaning, disinfection, and de-greasing regime to keep the equipment in accordance with regulations

- Regularly monitor the working mode of machines and equipment

Fire and explosions can result from various factors, including contact with flames, the ignition of electric sparks, depletion of water in boilers, and thermal expansion of steam pipes.

To ensure fire safety, it is essential to adhere to regulations governing fire-causing institutions Fire-prone areas should be located downwind, and effective fire-proof measures must be implemented Additionally, organizing a dedicated factory fire brigade is crucial for prompt and responsible fire safety management.

Industrial hygiene is crucial in food factories, as a thorough cleaning regime significantly impacts product quality Inadequate cleaning can lead to contamination by impurities, ultimately damaging the product.

- Must use clean clothes and disinfect them periodically

- Implement health check regime for workers according to certain cycles

- Do not eat or drink during production

- Equipment during downtime needs to be cleaned and disinfected

- Particularly for fermentation tanks, after each fermentation batch, they must be thoroughly cleaned to serve the next cycle

Ensuring factory hygiene is crucial; therefore, it is essential to routinely assess cleaning practices both inside and outside the workshop After each shift, thorough floor cleaning is mandatory Additionally, the factory should be equipped with an efficient water supply and drainage system to maintain a sanitary environment.

- Greatly affects product quality, so water treatment before use is important Water must be treated for hardness, odor removal and hygiene requirements

The primary challenge facing the food technology industry, as well as other sectors, is ensuring the survival of manufacturing facilities A thorough and precise examination of the technological processes is essential To assess product quality effectively, it is crucial to analyze the chemical composition, biological factors, and sensory characteristics, including taste and color.

7.2.3 Waste treatment of the production process

Efficient management of production waste is crucial; it should be swiftly transported from the factory to nearby processing plants Timely resolution of this process is essential to prevent backlogs that could lead to microbial contamination of the products.

Wastewater is laden with organic impurities, creating an ideal environment for microbial growth, which poses significant pollution risks to human habitats Consequently, effective wastewater treatment is crucial for industrial facilities.

There are various wastewater treatment methods, each offering unique advantages The treatment plant employs a combination of mechanical processes, including pre-filtration tanks, settling tanks, and aeration tanks, to create optimal conditions for aerobic microorganisms to effectively break down waste before it is released into the environment.

Fire prevention is a critical concern in today's society, particularly within manufacturing facilities Fire incidents not only result in tragic loss of life but also lead to significant damage to both corporate and private property.

For vegetable and fruit processing plants, the use of generating and flammable equipment such as dryers, boilers, etc needs to comply with regulations on fire safety

7.2.5.1 Rules and regulations on fire protection at the factory

To ensure safety and compliance, the entire enterprise area must be maintained in a clean and aesthetically pleasing condition All access roads, entrances, and exits between buildings and firefighting water sources should remain clear of obstacles It is strictly prohibited to block, pile up, or queue flammable materials within the designated fire prevention zones between structures.

Regarding the preservation of goods:

Arrange and preserve goods neatly, orderly, easily seen, easy to take, easy to check, according to each type, having the same properties, same characteristics, and the same firefighting method

Arranged in rows, with horizontal and vertical aisles to ensure reasonable and convenient Do not stack goods and obstacles on the aisles, near light bulbs, near electrical wires

Exclude conditions that can lead to spontaneous combustion due to heat generation, chemical reaction causing fire and explosion

Goods arranged in warehouses, yards, stations and shops must be placed on shelves or shelves

If stacking piles, they must be stacked firmly and neatly; Outside, near the entrance, the aisles must be as wide as the door's width, but not less than 1m

The arrangement of goods must create convenient escape routes, ensure the quick and safe evacuation of people and goods in case of fire

When operating equipment and technology that utilize flammable liquids or gases, it is essential to regularly inspect their tightness Additionally, any maintenance or repair work involving fire—whether electrical or open flames—at facilities such as stores, warehouses, stations, and workshops must be accompanied by a detailed fire prevention plan.

Once maintenance and repairs are finalized, it is essential to thoroughly clean all materials, tools, and equipment used during the process Additionally, all machines and equipment must be checked and tested according to their specific functions and uses, including verifying the ground wire, if applicable, to guarantee safe operation.

7.2.5.2 Inspection, training and equipment on fire prevention and fighting tasks at the factory

Check the quality of finished products

- The criteria for finished product quality to be checked are:

+ Check the outer packaging shape

+ Determination of sensory criteria of finished products

+ Determination of physicochemical parameters of finished products

+ Determination of microbiological criteria of finished products

- Check products when leaving factory:

+ The container must be sealed, the packaging state must not be defective or peeled off the text on the label

+ Sensory indicators: smell, taste, color, surface state, structural properties

+ Physicochemical indicators: Durable structure, low hygroscopicity, fineness 28-30àm

After a period of research and calculation, I basically completed my project task This includes learning, calculating, determining parameters that affect the process and thereby designing a chocolate production system

Through my research for the project, I gained valuable insights into the operating principles of chocolate production systems and explored the various applications of cocoa beans in processing technology.

While working on the project, I faced significant challenges in locating reference materials and lacked real-world observations of chocolate production systems This limited my ability to generate innovative ideas for calculating and designing advanced chocolate production machines, resulting in numerous errors in my calculations and design drawings.

Finally, I also sincerely thank my teacher for their help in completing this project

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