An ideal system of production is one in which you can maintain a continuous flow of raw materials to achieve the final product. This continuity must also be true to space-time, that is to say, the different stages of production should be as closely linked as possible.
The manufacturing process consists of three phases:
-In phase 1 is done making marmaladefrom the mixing itself until the marmalade is ready to be packaged .
-In phase 2 containers are handled and carried out a parallel with the development of the marmalade .
-Finally Phases 1 and 2 converge in phase 3, which is made from packaging of the product until the issue of the marmalade.
This process issummarized in the following diagram
Description of the process
Phase 1: Development of the marmalade
➢ Mix ingredients.
The various ingredients except the fruit are transported and dispensed in
as a feeder for the pectin and the acid from their respective
drums and sugar from a silo to the mixer. The cans of fruit are placed on a conveyor belt and at the end of it, will beavailable with an automatic dump the drum, introducing the contents into a hopper, which in turn fuels to a carrier capable of propellers transporting 2500kg/h.
Raw materials are mixed in two stainless steel horizontal tanks
opposing propellers fitted with agitation, so that the line is continuous, the process is conducted alternately, while one tank is feeding the line, the other is carrying out themix. The agitation of the mixture of ingredients is soft, not breaking the pieces of fruit.
To the mixture is made in the most homogeneous as possible in the tanks
mixture will perform a warm-60 º C.
➢ Stew (First stage)
The mixture is sent through a lobe pump to heater vane scrapers where the temperature is raised up to 90-95 degrees, high enough temperature for the treatment of thisproduct because it has a pH below 4.5. We have chosen this type of pump, as it does not break the pieces of fruit, it will work as follows; be fed alternating between the two mixing tanks and a tank will always be fed to the line. The Theoretical flow expected from the feeds it is equal to about 5,000kg/h.
The heater is a vertical cylinder design, which has a central shaft with vanesscrapers. Moreover, the heating fluid (steam), enter top shirt
concentric to the product chamber, which heats it. The product comes out on top heated to 95 º C. The heat transfer of steam to the product is favored by
stirring and scraping of the blades. The speed of rotation of the blades is about 200 rpm (according to information found) to avoid damaging the fruit pieces.
➢ Stew (Second stage)After the first stage of cooking, the product goes to another boiler which is a
heater, scraper blades of the same specification as that used in the 1st phase done. With this second stage, terminating the process of cooking the marmalade.
➢ Maintenance of the cooking temperature.
After the operation described above, the cooked mixture passes into tube maintenance in order to enter thesugar in fruit, thus avoiding syneresis phenomena in the jars of marmalade, keeping the temperature of the marmalade from 90 to 95 º C. This is normally kept three to eight minutes, which in this case is the optimal time is estimated in Annex 4 (machinery and equipment), calculating the dimensions of the tube timely maintenance.
➢ Pre-packaged cooling.
The prolonged heating affects theappearance, as well as resistance
storage of the finished product. After his discharge from the kilns, the marmalade has a temperature above 90 º C, and as the investment of sugar is greatly influenced by temperature, it is clear that we need an efficient cooling system to monitor and verify the proper functioning of the manufacturing. Another factor to consider is the danger of a change in color...