Brief Project Report Ball-Lollipop Making Plant

Brief Project Report

Ball-Lollipop Making Plant

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Project Report Ball-Lollipop Making Plant

Content	Annexure
Process	2.0
Plant & Machinery	2.1
Fuel/Power/Water	2.2
Man Power Required	2.3
Raw Material Required	2.4

Process : Annexure 2.0

COOKING

First Method :- There are two Methods for Cooking of Candy Mass. One is open fire Cooking in the open type over any type of Coal or diesel Bhatti with Manual Stirring, Manual Handling or Cooked Mass to the Vacuum Pan than to the Cooling Plate. This process is caused to pollution also

Second Method :- Other method of cooking is with steam jacketed stainless steel cooking with motorized chamber stirring. The quality of the product made with this system is excellent moderate and there is no manual handling of cooked batch. There is no pollution in the cooking area Thus this system is suggested in this report.

Steam is generated in the boiler with help of fuel and this boiler is kept away from the cooking or processing area to maintain the cleanliness. Steam is supplied to the cooker through the pipeline. While operating the cooker, put sufficient water in cooking chamber, add sugar, liquid glucose, switch on the stirrer (Alternately sugar, liquid glucose syrup can be pumped from the pre-dissolved tank) when sugar is dissolved put other ingredients in cooking chamber step by step. When the desired temperature is achieved, vacuum is applied and valve is opened. It sucks cooking mass into lower pan, cooking chamber’s valve closed. Here vacuum is applied further for 4-5 minutes to remove the moisture of mass. This improves the quality and clarity of sweets. Next step is to release the vacuum and thick syrup of lower pan is poured on cooling plate by tilting the pan. Here color, flavors and other things are added to the batch

Batch Roller :- Put the Sugar batch in Batch roller after cooling on Cooling Plate. Batch roller produce a thick Conical shaped rope of Sugar. This rope is further fed to three-stage rope Sizer

Three Stage Rope Sizer :- Rope Sizer give the required dia to Sugar rope according to Forming Die and then the rope coming out from rope Sizer is fed to Forming Machine.

Ball-Lollypop Forming :- In forming machine put the Lollypop Sticks in Hopper at a time (Hopper Capacity one Kg Stick at a time). Coming rope from Three-stage rope Sizer further fed to sizing wheel of Lollypop forming Machine. These Sizing wheel are according to final size and weight of Lollypop. Sugar rope go through Flaps , at the same time pressure gutka push the stick into the Sugar automatically. After forming of Lollypop, a stick puller knife lift the Lollypops one by one and ready pieces are discharged on the Vibrator Conveyor than Three Way cooling conveyor after cooling, Ball-Lollipops are ready for packing.

PACKING PROCEDURE

First Method

Double End Twist Wrapping : - The Ball- Lollypops after Three Way Cooling Conveyor are puts into the hopper of twist wrapping machine. This wrapping machine is fully automatic. The sweets are delivered by Vibrator to the feeder plate where every Ball-Lollipop is lifted one by one, wrapped with one or two wrapper, twisted from both Side ends at the speed of 110 PCs. per minute

Second Method

Pouch Style Packing :- Form fill and seal machine is used to pack lollipops in pouches with stick. . In this machine lollipops are manually placed on the moving disk of Machine. Paper coming from real breket fed through Paper shoot, where to round sealers are installed for center sealing. At the same time Disk drops Lollypops one by one in to the one side opened pouch. After that pouch fed through lower sealers, where the sealers sealed other side of pouch.

Plant & Machinery : Annexure 2.1

S.NO.	Machines	Required
1.	Steam boiler capacity 400 kgs. of steam per hour & tested working pressure of 15 kgs / sq.cm. with water lifting pump. Burner, Blower (for oil fired boiler) Fuel Tank & other accessories such as safety valves etc.	ONE

Stainless steel steam jacketed cooking pan with stirrer with digital temperature indicator, time delay relay, Vacuum Pump and motors

ONE

Cooling Plate with water circulation cooling system

TWO

Batch Former capacity 45 kgs. per batch with stainless steel rollers, electronic reverse and forward system for rollers & motorized lifting

ONE

Rope Sizer three stage with three set of gun metal sizing rollers including one set of vertical pulling head.

ONE

Automatic Flap Type Ball-lollipop Forming Machine production capacity upto 1000 kgs. per shift.

ONE

Three Way Cooling Conveyor with conveyor wire mesh belts of 4", 8" & 12" size

ONE

Extra Die (as Degine required) approx

ONE

9.	Automatic Ball-Lollipop Wrapping Machine (Double End Twist) with Photo-Cell Unit Complete	TWO
10.	F.F.S. (Pouch Packing) machine for Ball-Lollipop Packing	ONE

Fuel / Power / Water Requirement : Annexure 2.2

Fuel / Power / Water Consumption

S.NO.

Name of Machine

Load

Nos.

Total Load

Steam Boiler

2 h.p.

One

2 h.p.

Vacuum Cooker

Stirrer

5 h.p.

1.5 h.p.

One

5 h.p.

1.5 h.p

Batch Roller

Heater

0.5 h.p

3 k.w

One

0.5 h.p.

3 k.w

Rope Sizer

1 h.p.

One

1 h.p.

Ball-Lollipop Forming Machine

2 h.p.

One

2 h.p.

Three-Way Cooling Conveyor

3 h.p.

One

3 h.p.

Automatic Ball-Lollipop Wrapping Machine (Double End Twist) with Photo-Cell Unit Complete

2 h.p.

Two

4 h.p.

F.F.S. (Pouch Packing) Machine for Lollypop Packing

Heaters

1 h.p.

2 k.w

Two

Four

1 h.p.

8 k.w.

WATER

1. About 10 Liters Water required per Minute for Cooling Plate

( This Water can be recirculated after cooling)

2. About 40 Liters Water is required for circulation in Vacuum Pump (Vacuum Cooker)

(This Water can be recirculated after Vacuum)

3. About 300 Liters Water per hour for the Boiler even this can be collected in the foam of steam condensates and circulated again

FUEL

An Oil fired Boiler Consume Apex 8 - 10 Liters of LDO ( Light Diesel Oil) per Hour

(This Boiler can operate up to three Vacuum cookers. There is less consumption of fuel for each batch if more then one Vacuum cooker is installed

Man Power Required : Annexure 2.3

S.NO.

REQUIRED FOR

NOS.

Boiler and cooling Plate

One

Vacuum Cooker

One

Weighing & Dosing

One

Forming Machine

One

Automatic Chupa-Chup Lollypop Wrapping Machine (Double End Twist) with Photo-Cell Unit Complete

One

F.F.S. (Pouch Packing) Machine for Flat Lollypop Packing

One

Handling

Three

Packing & Storage

Four

Man Power Required : Annexure 2.4

RAW MATERIAL REQUIRED

Sugar (Sucrose)

Liquid Glucose

Citric Acid

Flavors and colors

Packaging material

Paraffin wax

Dusting powder

Other material for special products and raw materials application.