Production Line Instant Noodle [PDF]

Zitiervorschau

1.0 INTRODUCTION 1.1

INSTANT CUP NOODLES

Cup Noodle in Japan, and the product has inspired numerous competitors, such as Maruchan's Instant Lunch.Instant noodles were invented in 1958 by Momofuku Ando, the Taiwanese-born founder of the Japanese food company Nissin. He used Chicken Ramen as the first instant ramen noodles.In 1970, Nissin formed the subsidiary Nissin Foods (USA) Co. Inc, to sell instant noodles in the United States. Nissin recognized that the bowls traditionally used to package instant noodles in Asia were not common in the U.S, so they used the paper cup designed by Ron R. Matteson. In 1971, they introduced instant ramen packaged in a foam cup. The three original Cup O' Noodles flavors in the US were beef, chicken and shrimp. Pork flavor was added in 1976. In 1978, Nissin Foods offered more new varieties of Top Ramen and Cup O' Noodles. The product was known as Cup O' Noodles in the United States until 1993. In 1998, Cup Noodles Hot Sauce Varieties introduced (Beef, Chicken, Pork and Shrimp). [1]On a trip to the U.S. in 1966, Mr. Ando noticed Americans curiously eating forkfuls of noodles out of cups, instead of using bowls and chopsticks. With that simple observation, the worldwide Cup Noodles® phenomenon was born. Shortly after, Nissin officially put down its roots in the U.S. In 1972, our Gardena, CA, plant started production of Top Ramen®—the first instant ramen manufactured and sold in the U.S. And ever since, Nissin Foods USA has launched a continuous stream of new and innovative products for hungry, noodle-loving Americans. [1] 2.0

AUTOMATION SYSTEM

Automation is the technology by which a process or procedure is performed without human assistance.[3] Automation [4] or automatic control is the use of various control systems for operating equipment such as machinery, processes in factories, boilers and heat treating ovens, switching on telephone networks, steering and stabilization of ships, aircraft and other applications and vehicles with minimal or reduced human intervention. Some processes have been completely automated.

Automation covers applications ranging from a household thermostat controlling a boiler, to a large industrial control system with tens of thousands of input measurements and output control signals. In control complexity it can range from simple on-off control to multi-variable high level algorithms.

In the simplest type of an automatic control loop, a controller compares a measured value of a process with a desired set value, and processes the resulting error signal to change some input to the process, in such a way that the process stays at its set point despite disturbances. This closedloop control is an application of negative feedback to a system. The mathematical basis of control theory was begun in the 18th century, and advanced rapidly in the 20th.

Automation has been achieved by various means including mechanical, hydraulic, pneumatic, electrical, electronic devices and computers, usually in combination. Complicated systems, such as modern factories, airplanes and ships typically use all these combined techniques. The benefit of automation include labor savings, savings in electricity costs, savings in material costs, and improvements to quality, accuracy and precision.

AUTOMATION SYSTEM 2.1

TYPES OF AUTOMATION

Automation of production systems can be classified into three basic types: 1. Fixed automation (Hard Automation) 2. Programmable automation (Soft Automation) 3. Flexible automation.

1. Fixed automation (Hard automation): Fixed automation refers to the use of special purpose equipment to automate a fixed sequence of processing or assembly operations. Each of the operation in the sequence is usually simple, involving perhaps a plain linear or rotational motion or an uncomplicated combination of two. It is relatively difficult to accomodate changes in the product design. This is called hard automation.

Advantages:

1. Low unit cost

2. Automated material handling 3. High production rate.

Disadvantages:

1. High initial Investment 2. Relatively inflexible in accommodating product changes.

2. Programmable automation: In programmable automation, the production equipment is designed with the capability to change the sequence of operations to accomodate different product configurations. The operation sequence is controlled by a program, which is a set of instructions coded. So that they can be read and interpreted by the system. New programs can be prepared and entered into the equipment to produce new products.

Advantages:

1. Flexible to deal with design variations. 2. Suitable for batch production.

Disadvantages:

1. High investment in general purpose equipment 2. Lower production rate than fixed automation. Example: Numerical controlled machine tools, industrial robots and programmable logic controller.

3. Fixed Automation: (Soft automation): Flexible automation is an extension of programmable automation. A flexible automation system is capable of producing a variety of parts with virtually no time lost for changeovers from one part style to the next. There is no lost production time while reprogramming the system and altering the physical set up.

Advantages:

1. Continuous production of variable mixtures of product. 2. Flexible to deal with product design variation.

Disadvantages:

1. Medium production rate 2. High investment. 3. High ‘unit cost relative to fixed automation 2.2

ADVANTAGES AND DISADVANTAGES

Perhaps the most cited advantage of automation in industry is that it is associated with faster production and cheaper labor costs. Another benefit could be that it replaces hard, physical, or monotonous work.[5] Additionally, tasks that take place in hazardous environments or that are otherwise beyond human capabilities can be done by machines, as machines can operate even under extreme temperatures or in atmospheres that are radioactive or toxic. They can also be maintained with simple quality checks. However, at the time being, not all tasks can be automated, and some tasks are more expensive to automate than others. Initial costs of installing the machinery in factory settings are high, and failure to maintain a system could result in the loss of the product itself. Moreover, some studies seem to indicate that industrial automation could impose ill effects beyond operational concerns, including worker displacement due to systemic loss of employment and compounded environmental damage; however, these findings are both convoluted and controversial in nature, and could potentially be circumvented.[6] The main advantages of automation are: 

Increased throughput or productivity.

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Improved quality or increased predictability of quality.

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Improved robustness (consistency), of processes or product.

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Increased consistency of output.

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Reduced direct human labor costs and expenses.

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Installation in operations reduces cycle time.

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Can complete tasks where a high degree of accuracy is required.

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Replaces human operators in tasks that involve hard physical or monotonous work (e.g., using one forklift with a single driver instead of a team of multiple workers to lift a heavy object)[36]

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Reduces some occupational injuries (e.g., fewer strained backs from lifting heavy objects)

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Replaces humans in tasks done in dangerous environments (i.e. fire, space, volcanoes, nuclear facilities, underwater, etc.)

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Performs tasks that are beyond human capabilities of size, weight, speed, endurance, etc.

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Reduces operation time and work handling time significantly.

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Frees up workers to take on other roles.

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Provides higher level jobs in the development, deployment, maintenance and running of the automated processes.

The main disadvantages of automation are: 

Possible security threats/vulnerability due to increased relative susceptibility for committing errors.

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Unpredictable or excessive development costs.

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High initial cost.

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Displaces workers due to job replacement.

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Leads to further environmental damage and could compound climate change.[37]

2.3

EFFECT OF AUTOMATION TO CUP NOODLES INDUSTRY

The noodles must be preserved for a long time thus deep frying methods were used to rehydrate the noodles. This deep fried method is dangerous because it could inconvenient temperature or cause burn risk. Hazardous work environment for humans when the work environment is unsafe, unhealthful, hazardous, uncomfortable for human. This where the machine will used thus it could be remove the risk of hurting the working which could also reduce the effect on economy of the company for worker treatment. There will be more efficient if machine does all the manufacturing process work. Thousands of noodles must be made every day and it could cause fatigue to worker if using the manual production.Repetitive work cycle if the sequence of elements in the cycle is the same & the elements consist of relatively simple motion cause the worker become fatigue quickly. However, the robot capable performs with consistence and repeatability and it could maintain the efficiency in working Since the noodle making is continuous process, by using automated line the work production become more efficient. The work space is less needed since the machine are arranged in continuous line. Less wage needed to pay the worker if increased in using of automation system. The worker needed only for some small process and maintenance engineer.

3.0

MANUFACTURING PROCESS

Instant ramen noodles are made with wheat flour, water, salt, and kansui, an alkaline water that adds elasticity to the noodles. First, the ingredients are kneaded together to make a dough. Next, this dough is rolled out and cut into thin noodles. The noodles are then steamed and are finally packaged after dehydration. Advanced technologies are used in every step of the manufacturing process. Dehydration is especially important for the preservability of instant ramen, so noodle makers have experimented with many methods. [4]. In the rolling process, when the dough is rolled out, depending on some characteristics of wheat flour such as moisture and protein content, harvest season and region, etc., the thickness of dough sheets varies at the same roller gap and workers frequently should adjust the roller gap to maintain the uniform thickness. But, the roller gap adjustment is a very difficult job for the workers because a worm gear which adjusts the roller gap has a backlash not to be controlled and there is no display device to estimate the roller gap. the rolling process, even though the roller gap is set to the same value, depending on some characteristics of wheat flour such as moisture and protein content, harvest season and region, etc., the viscosity and stiffness of the dough vary and the fluctuation of the roller gap is necessarily occurred when the dough is rolled out. Therefore, workers should frequently adjust the roller gap to maintain the uniform thickness.

But, the roller gap adjustment is a very difficult job for the workers because a worm gearbox in the conventional system which adjusts the roller gap has a backlash not to be controlled and there is no display device to estimate the roller gap. Because of these reasons, whenever product items in the same production lines are changed, the roller gap adjustment of each product depends on the experience of the worker.[5] Momofuku Ando, the founder of Nissin, succeeded in making the first instant ramen after much trial and error. Tempura, a traditional Japanese deep-fried food, gave him the idea of removing moisture from the noodles by frying them in oil at a high temperature. This method makes it possible to dehydrate the noodles almost completely. Moreover, it has the added advantage of leaving countless minuscule holes on the surface, making it easier for the noodles to rehydrate when steeped in hot water. Recently, a new method of dehydrating ramen noodles has emerged: "blow-drying" them at a high temperature instead of frying. This was actually tried in the early days of instant ramen, but it was unpopular because the noodles did not loosen in the soup easily and because they became rubbery. In the late 1990s, thanks to refinements in blow-drying technology and in the combination of ingredients, a dehydration method was developed in which the noodles are exposed to hot air at 80 degrees Celsius (176 degrees Fahrenheit) for 30 to 60 minutes. Known as "nonfried noodles," ramen products made in this way have become popular for being low in calories. One important merit of instant foods is that they can be stored for long periods. To ensure preservability, the water content cannot exceed 12%. Fried instant noodles have a water content of between 3% and 6%, while non fried noodles measure around 10%. Compared to fried noodles, which have tiny holes, non-fried noodles take about two extra minutes to rehydrate. This problem should eventually be solved, though, with the development of even newer technology. Dehydration is only one aspect of instant ramen production, but this overview has been enough to show us how hard ramen makers have been working to develop various methods of production in pursuit of an ever-better eating experience.

3.1

CUP NOODLES PRODUCTION LINE

Equipments Brine metrology mixer

Remark Power: 1.5 kw Pump power 0.75 kw Capacity of 1000 l/units

Supply metering device

Volume: 140 liters with LCD Pump power: 0.75 kw,

Double speed dough mixer

Power: 18.5 kw Capacity: 350 kg/pan

Disc curing machine

Power: 4 kw Tray 2200 mm * 500 mm

Continuous rolling machine

Paste width: 800 Power:7.5+11+7.5×2=33.5kw

Single-layer steaming machine

Length: 36 meters Power: 3 kw power (VVVF) Fan 0.37 kw x 2 units

Cutting and folding machine

Main drive: 1.5 kw Air knife:0.9 kw *2, Cutting speed≤60 time/minute

Fried dryer

Main drive: 5.5kw Circulating pump: 22 kw Gear pump: 3 kw Air knife 0.9 kw *4

Strong Air cooling device

Power: 1.1 kw Exhaust fan: 0.37*14 kw power

Shunt conveyor

Power: 2.2 kw (VVVF)

Conveyor Products conveyor

Power: 0.37 kw * 3 Power: 0.37*3 main drive

Electric control cabinet

Frequency control motor speed PLC program control

Advantages of this production line: (1) The dough mixing machine is designed with double shafts and double speeds for optimal dough mixing effect. (2) The calendar ratio of noodle maker is designed logically, and the clearance between rollers is easy to change. (3) Single layer or multi-layer steaming machine is designed with originative structure, where the temperature remains proper and the pasting degree of noodles keeps higher. (4) After being cut off, the dough keeps high proportion to be placed in a box, meanwhile, it is unnecessary to stop the machine to finely adjust the weight of the dough. (5) High heat exchange rate in frying, it keeps no pollution on the oil and the oil content in the dough keeps lower. (6) High-precision sensors and control elements, sound quality, stable and reliable. (7) The rollers adopt centrifugal casting with cold and hard alloy, processed with accuracy, and the hardness on the surface of the products reach over HRC45, featured of abrasion resistance and long service life. [4]

REFERENCES 1. Groover, Mikell (2014). Fundamentals of Modern Manufacturing: Materials, Processes, and Systems. 2. Rifkin, Jeremy (1995). The End of Work: The Decline of the Global Labor Force and the Dawn of the Post-Market Era. Putnam Publishing Group. pp. 66, 75. ISBN 0-87477-7798. 3. Hou, G.G.: Asian Noodles: Science, Technology, and Processing. Wiley (2010) 4. Web Japan, http://web-japan.org/kidsweb/hitech/ramen/ 5. Process automation, retrieved on 20.02.2010 Archived 17 May 2013 at the Wayback Machine. 6. Rainer Walz; Joachim Schleich (September 27, 2008). The Economics of Climate Change Policies: Macroeconomic Effects, Structural Adjustments and Technological Change.

7. D. Yang (Ed.): Informatics in Control, Automation and Robotics, Volume 2, LNEE 133,

pp. 225–229.