Industrial & Process Engineering requirements

Table Of Contents
Table Of Contents..................................................................................................................... 1
List Of Tables............................................................................................................................ 1
1. Staffing requirements.......................................................................................................1
1.1 Plant Manager.......................................................................................................... 2
1.2 Production Supervisor..............................................................................................2
1.3 Quality Control Manager/Technician........................................................................2
1.4 Lab Technicians.........................................................................................................2
1.5 Maintenance Technician/Engineer...........................................................................2
1.6 Packaging Line Operators......................................................................................... 3
1.7 Quality Assurance Inspectors....................................................................................3
1.8 Logistics and Warehouse Staff..................................................................................3
2. Quality.............................................................................................................................. 3
2.1 Quality Management System (QMS)........................................................................4
2.2 Product Quality Assurance....................................................................................... 4
2.3 Regulatory Compliance.............................................................................................5
3. Equipment requirements..................................................................................................6
3.1 Fruit Reception and Preparation...............................................................................7
3.2 Extraction and Processing.........................................................................................7
3.3 Packaging and Bottling..............................................................................................8
3.4 Utilities and Support Systems...................................................................................8

List Of Tables
Table 1: Workplan for fruit juice product certification..............................................................5
The consultant will assess the availability of the following at the fresh fruit processing
factory:

1. Staffing requirements
Staffing requirements for a large-scale fruit juice processing factory are crucial for
ensuring smooth operations, maintaining quality standards, and complying with
safety regulations. Here's a detailed overview of the technical requirements and roles
of various staff members:

1.1 Plant Manager

 Role: Oversees all aspects of factory operations, including production, quality
control, maintenance, and staffing.
 Responsibilities:
 Strategic planning and goal setting.
 Budgeting and resource allocation.
 Ensuring compliance with regulatory standards.
 Managing staff and fostering a positive work environment.

1.2 Production Supervisor

 Role: Manages the day-to-day production activities on the factory floor.
 Responsibilities:
 Scheduling and coordinating production runs.
 Monitoring production processes to ensure efficiency and quality.
 Training and supervising production staff.
 Troubleshooting equipment issues and coordinating maintenance.

1.3 Quality Control Manager/Technician

 Role: Oversees quality assurance and quality control processes to ensure
product quality and safety.
 Responsibilities:
 Developing and implementing quality control procedures.
 Conducting inspections and tests on raw materials, in-process
products, and finished goods.
 Analyzing data and identifying trends to improve processes.
 Maintaining records and documentation for regulatory compliance.

1.4 Lab Technicians

 Role: Perform analytical tests and quality checks on raw materials, in-process
samples, and finished products.
  Responsibilities:
 Conducting chemical and microbiological analyses of juice samples.
 Calibrating and maintaining laboratory equipment.
 Documenting test results and maintaining accurate records.
 Assisting with troubleshooting and problem-solving.

1.5 Maintenance Technician/Engineer

 Role: Ensures the proper functioning and maintenance of equipment and
machinery.
 Responsibilities:
 Performing preventive maintenance tasks on production equipment.
 Troubleshooting and repairing equipment breakdowns.
 Ordering spare parts and coordinating repairs with external vendors.
 Ensuring compliance with safety regulations and maintenance
schedules.

1.6 Packaging Line Operators

 Role: Operate and monitor packaging equipment to ensure efficient and
accurate bottling and packaging of juice products.
 Responsibilities:
 Setting up and adjusting packaging machinery.
 Monitoring production output and quality.
 Performing routine maintenance and cleaning of equipment.
 Ensuring compliance with packaging specifications and standards.

1.7 Quality Assurance Inspectors

 Role: Conduct visual inspections and quality checks on packaging materials,
labels, and finished products.
 Responsibilities:
 Inspecting bottles, caps, and labels for defects or damage.
 Verifying product integrity and adherence to specifications.
 Sampling and testing finished products for quality attributes.
 Rejecting or approving products based on inspection results.

1.8 Logistics and Warehouse Staff

 Role: Manage inventory, shipping, and receiving activities to ensure timely and
efficient supply chain operations.
 Responsibilities:
 Receiving and inspecting incoming raw materials and packaging
supplies.
  Storing and organizing materials in the warehouse.
 Fulfilling production orders and coordinating shipments.
 Maintaining accurate inventory records and tracking systems.

2. Quality

Ensuring the quality of products and adherence to regulatory standards are paramount in the
operation of a large-scale fruit juice processing factory. Here's a detailed overview of the
technical requirements, quality systems, and regulatory compliance measures:

2.1 Quality Management System (QMS)

2.1.1 Documentation and Procedures:

 Standard Operating Procedures (SOPs): Documented procedures for all aspects of
production, from receiving raw materials to packaging finished products.
 Quality Manuals: Comprehensive manuals outlining quality objectives, policies, and
responsibilities.
 Record Keeping: Protocols for maintaining detailed records of production processes,
quality checks, and corrective actions.

2.1.2 Training and Personnel:

 Staff Training: Comprehensive training programs for all employees on quality control
procedures, food safety practices, and regulatory compliance.
 Qualified Personnel: Hiring qualified personnel with relevant experience and expertise in
food processing and quality assurance.

2.1.3 Continuous Improvement:

 Quality Audits: Regular internal audits to assess compliance with quality standards and
identify areas for improvement.
 Corrective and Preventive Actions (CAPA): Procedures for addressing non-conformances,
implementing corrective actions, and preventing recurrence.
 Quality Metrics: Monitoring and analyzing key performance indicators (KPIs) to track
quality trends and performance.

2.2 Product Quality Assurance

2.2.1 Raw Material Selection and Inspection:

 Supplier Qualification: Establishing criteria for selecting and approving suppliers based on
quality, safety, and reliability.
  Incoming Material Inspection: Inspecting and sampling incoming raw materials for quality
attributes such as freshness, ripeness, and cleanliness.

2.2.2 Production Processes:

 Process Controls: Implementing controls to ensure consistent processing parameters such
as temperature, pressure, and pH.
 Hygiene and Sanitation: Strict sanitation protocols for equipment, facilities, and personnel
to prevent contamination and ensure product safety.
 Product Traceability: Traceability systems to track raw materials, ingredients, and finished
products throughout the production process.

2.2.3 Testing and Analysis:

 Laboratory Testing: Conducting routine testing and analysis of raw materials, in-process
samples, and finished products for quality attributes such as acidity, sugar content, and
microbial load.
 Sensory Evaluation: Organoleptic testing by trained panelists to assess product
appearance, flavor, aroma, and texture.
 Third-Party Testing: Periodic testing by accredited laboratories to verify product quality
and safety.

2.3 Regulatory Compliance

2.3.1 Food Safety Regulations:

 Hazard Analysis and Critical Control Points (HACCP): Implementing a HACCP plan to
identify and control food safety hazards throughout the production process.
 Good Manufacturing Practices (GMP): Adhering to GMP guidelines for food processing
facilities, including hygiene, sanitation, and personnel practices.
 Food Labeling Requirements: Ensuring accurate and compliant labeling of products,
including ingredient lists, nutritional information, and allergen declarations.

2.3.2 Environmental Regulations

 Waste Management: Implementing systems for proper disposal of waste materials,
wastewater treatment, and pollution prevention.
 Environmental Permits: Obtaining permits and approvals from regulatory agencies for air
emissions, wastewater discharge, and hazardous waste management.

2.3.3 Quality Certifications

 ISO Certification: Obtaining ISO 9001 certification for quality management systems to
demonstrate compliance with international standards.
 Food Safety Certification: Achieving certifications such as HACCP, Q-mark from UNBS to
ensure food safety and quality.
Table 1: Workplan for fruit juice product certification
Output Activities Cost
Modification and  Transforming the processing area into a
standardization of GMP compliant processing setting.
processing area  Sealing off the blending and packaging areas
Confirming that processing
equipment and accessories
are of food grade
Streamlining the applicable Development of the documentation: manuals,
documentation and SOPs, work instructions, policies, etc
processes
Medical examination and Taking staff to health facility
vaccination of staff
Acquisition of applicable US EAS 77:2019; US 28 EAS 39:2002; US 28 105000/=
standards EAS 39:2002
Calibration of weighing Ascertaining accuracy of the weighing scales
scale(s) by UNBS
Product quality tests pH Can be done in –house
at the factory
Total soluble solids Can be done in –house
Ethanol content at the factory
Brix
Acid insoluble ash Can be tested by UNBS
Arsenic on a quarterly basis
Cadmium
Lead
E.coli
Yeast and molds
Total plate count
Establishment of pre- Availability of hand washing facilities/
requisite programs sanitization.
Pest / insect control measures
Initial product testing Submitting the product sample to UNBS 432,500/=
laboratories
Product label Confirming compliance of the product label
Internal audit To confirm that processes are conducted in
compliance with standards
Registration with UNBS Online application
Application for product Audit fees 1,000,000/=
certification Product testing fees 432,500/=
Issuance of permit by Addressing the Non-conformances observed
UNBS by the UNBS audit team

3. Equipment requirements
Setting up a large-scale fruit juice processing factory requires specific equipment to
efficiently handle various stages of fruit processing, from reception to packaging.

3.1 Fruit Reception and Preparation

3.1.1 Reception Area

 Function: Receives incoming fruit shipments and inspects them for quality and
freshness.
 Equipment: Scales, conveyor belts, inspection tables, and washing stations.

3.1.2 Washing and Sorting Equipment

 Function: Cleans and sorts fruits to remove dirt, debris, and damaged fruits.
 Equipment: Washing tanks, brushes, rotary fruit washers, and sorting
conveyors.

3.1.3 Peeling and Cutting Machines

 Function: Automates the peeling, coring, and slicing of fruits to prepare them
for extraction.
 Equipment: Automated fruit peeling machines, coring machines, and fruit
slicers.

3.2 Extraction and Processing

3.2.1 Juice Extractors

 Function: Extracts juice from fruits efficiently while minimizing pulp and solids.
 Equipment: Belt presses, screw presses, hydraulic presses, or centrifugal
juicers.

3.2.2 Pasteurization System

 Function: Heats the juice to kill pathogens and extend shelf life while
preserving flavor and nutrients.
 Equipment: Heat exchangers, pasteurizers (e.g., plate, tubular), and holding
tanks.
3.2.3 Blending Tanks
 Function: Mixes and blends different fruit juices or concentrates to achieve
desired flavors and compositions.
 Equipment: Stainless steel blending tanks with agitators or mixers.

3.2.4 Filtration Equipment

 Function: Removes pulp, solids, and impurities from the juice to improve
clarity and quality.
 Equipment: Filters (e.g., rotary vacuum filters, cartridge filters) and clarifiers.

3.3 Packaging and Bottling

3.3.1 Bottling Line

 Function: Fills, caps, labels, and seals bottles with the processed juice.
 Equipment: Bottle filling machines (e.g., rotary, volumetric), capping machines,
labeling machines, and sealing machines.

3.3.2 Packaging Materials

 Function: Provides suitable packaging materials for bottling and ensures
product safety and integrity.
 Equipment: Bottle conveyors, shrink wrap machines, and palletizers.

3.3.3 Date Coding and Batch Tracking

 Function: Marks bottles with expiration dates, batch numbers, and other
essential information for traceability.
 Equipment: Inkjet printers, laser printers, or thermal transfer printers for date
coding and labeling.

3.4 Utilities and Support Systems

3.4.1 Water Treatment System

 Function: Provides clean and purified water for processing and cleaning
purposes.
 Equipment: Reverse osmosis units, water softeners, and UV sterilizers.
3.4.2 Compressed Air System
 Function: Supplies clean, dry air for pneumatic equipment and control
systems.
 Equipment: Air compressors, air dryers, and filtration systems.

3.4.3 Refrigeration Units

 Function: Maintains product freshness and quality by cooling and storing juice
at optimal temperatures.
 Equipment: Refrigerated storage tanks, chillers, and cooling tunnels.

3.4.4 Boilers and Steam Generators

 Function: Generates steam used in pasteurization and cleaning processes.
 Equipment: Steam boilers, steam generators, and steam traps.