Feasibility studies and preliminary factory design

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1 Feasibility studies and preliminary factory design Feasibility NO Return of investment YES Design & Tenders Construction Budget To decide about an investment, the feasibility study is the first step that allows the estimation of the potential risks and the return of the investment in terms of time and income. Based on market research that considers the potential business growth, the competition, the distribution and sales possibilities as well the price levels, the capacity of the factory is estimated. From the capacity of the factory the land can be located and the factory preliminarily designed to obtain the budget cost for the building, and all the related mechanical and electrical plants. The running cost can also be estimated in relation to the production, the location and the services available nearby. Comparing the costs estimated in the previous steps plus the financial costs with the potential income from the sales, the return of the investment can be calculated and if satisfactory the project can start. The final project with tender documents is issued. Suppliers are going to be selected and the quotation checked to comply with the specifications. When the suppliers selection is done construction design can be provided and the works can start up to the testing and commissioning of the whole factory. 10/3/2011 Pertegato Ing. Giancarlo 1

Based on market research that considers the potential business growth, the competition, the distribution and sales possibilities as well the price levels, the capacity of the factory is estimated.

2 Summarizing: The advising services are provided step by step with the benefit that a wrong investment can be recognized from the beginning minimizing the wasted costs. The cost for the go ahead on any project is the best investment because a project on wrong assumptions or data could be catastrophic Generally speaking the engineering and advising costs can vary between 1.5 and 7.5% of the total investment inversely to the amount (the higher the investment the lower the %) Input Feasibility study Preliminary project and lay-out Investment approval and final project with tender documents issuing Contract with suppliers, construction design and project start up 10/3/2011 Pertegato Ing. Giancarlo 2

advising costs can vary between 1.5 and 7.

3 Tendering Tendering Three working steps Checking Data Final Data Target Target Needs Checking Preliminary Final Feasibility Project Tenders Tenders Construction Interconnections Interconnections Impact Impact 10/3/2011 Pertegato Ing. Giancarlo 3

Feasibility Project Tenders Tenders Construction

4 Advantages The design in several steps allows to modify the project according to the data acquisition and strategies with minimal impact when changes occur. Any change in the design phase has a costs incomparably lower than in construction phase. Invest in engineering means to minimize changes and modification during construction reducing the wasted costs generated by such changes Some projects are shown in the next slides 10/3/2011 Pertegato Ing. Giancarlo 4

Any change in the design phase has a costs incomparably lower than in construction phase.

5 Lanitis Bros. Ltd. TANKER 1 TANKER 2 TANKER 3 TANKER 4 10/3/2011 Pertegato Ing. Giancarlo 5

6 LIFT RAW MATERIAL BUFFER CANTEEN CANTEEN CANTEEN DRY (UHT) - DRIVE IN DRESSING ROOMS AND TOILETS RAW MATERIAL COLD DRESSING ROOMS AND TOILETS RE-ADJUSTMENT SUGGESTED TO AVOID CROSS CONTAMINATION RAW MATERIAL COLD RAW MATERIAL COLD Raw Material Store for: 1. Straws for TBA 3 and TBA - 19 Prisma 2. Carton Boxes for TBA 3 250/1000 & TBA 19 Prisma (for all different kinds) 3. Schrink for TBA 19 line & TBA 3 line 4. Glue for the carton Boxes and Straws 5. Paper reels for the 3 machines, strip and aluminum strips for the pull tab 6. Chemical liquids for the macines (Peroxide, external Cleaning, Acid, LFT) 7. Trolley for lifting and turning the reels 8. Raw materials needed for Mac Donalds 9. Ready product storage DISPATCHING LIFT 21-FRESH MILK GRAVITY COLD 4 5b ANARI cold store 22-COLD FOR READY PALLETIZED GOODS FOR LOCAL MARKET 4 9-PACKING ROOM 7-COLD h=3.7m h=3.7m BLAST COOLER 4-FOLDING & SALTING U.H.T. FILLING 1-HALLOUMI PRODUCTION h=4.9m MILK FILLING/PAKING PACKING IN BOXES h=4.9m h=4.9m 6-BRINING U.H.T. Operator side Vacuum p acked por t i ons ( 3 x 3) D r iv en belt Turning Unit Ex ist i ng bel t co nveyor with C onver ger Q u eui ng conveyor Wei gh -p rice l abe l i ng machine conve yor metal detec tor m ount ed D r i ven con veyor with reject arm Outle tfor di ve rted products Stan dar d out l et D i ver t in g poi nt (option) Mul tivac exit con veyor Separating wal 3-ANARI PRODUCTION 3-HALLOUMI COOKING POWER GENERATOR HV TRANSFORMERS CRATES h=3.7m CRATES WASHING 17-FETTA MATURING FETTA PRODUCTION KEFALOTIRY 12-KEFALOTIRY 13-KEFALOTIRY PRODUCTION PRESSING 10 BRINING 10 h=4.5m MILK PASTEURIZATION h=3.5m (lowered for technical space) 18-FETTA STORAGE 4 19-HALLOUMI STORAGE 4 15-KEFALOTIRY STORAGE 4 CHEESE PRODUCTION BUFFER TANKS LABORATORY C.I.P. MILK MIXING ROOM 20-DRIVE IN EXPORT CHEESE -18 PROCESSED CHEESE 23-DRIVE IN COLD 4 24-DRIVE IN YOGURT COLD 4 COW 100T COW 100T SHIP 40T GOAT 40T -25 C Store -45 C Freezer YOGURT RIPENING YOGURT BLAST COOLER -1 TANKER 1 TANKER 2 TANKER 3 TANKER 4 LIFT MILK RECEPTION 28-FUTURE PACKED CHEESE DRIVE IN COLD TRADING AND DISPATCHING COLD S 1ST FLOOR (FUTURE PROVISION) 25-FUTURE FRESH MILK GRAVITY COLD 4 WORKSHOP SEWAGE TANKER LIFT 29-DISPATCHING GRAVITY COLD 4 PACKAGING 30-BUFFER COLD 4 UNPACK ROOM 15 RE-PACKING ROOM 15 (CLEAN ROOM) DISPTACHING 15 SLICING TRADING AND DISPATCHING COLD S GROUND FLOOR (FUTURE PROVISION) RECEIVING/DISPATCHING OFFICES AND FACILITIES Christis Dairies Ltd. Limassol Cyprus 2-MOULD WASHING/STORAGE 8-ACCESS FROM BASEMENT 14-KEFALOTIRY MATURING 18 ROW MATERIAL MAIN ELECTRIC BOARD 10/3/2011 Pertegato Ing. Giancarlo 6

Schrink for TBA 19 line & TBA 3 line 4. Glue for the carton Boxes and Straws 5. Paper reels for the 3 machines, strip and aluminum strips for the pull tab 6.

7 Kasih Food Production Co. 10/3/2011 Pertegato Ing. Giancarlo 7

Title: Material Tracking in a Food Factory

Title: Material Tracking in a Food Factory Author: James T. Luxhoj, Ph.D. Department of Industrial Engineering Rutgers University P.O. Box 909 Piscataway, New Jersey 08855-0909 Warning: This document may