Effective Workplace Cleaning

Cleaning at workplace is an important part. It helps control or eliminate workplace Danger. In clean or organise workplace employee feel happy, healthy or does work with dedication. It has a direct effect on employee’s work. Its leave a good impression on Client also, visiting for meetings.

Cleaning just not only about cleanliness, but it also includes keeping work area neat and clean, floor free of slip and maintaining hall and removing all the waste material. This requires paying attention on important detail such as the layout of the workplace, the adequacy of storage facilities and good housekeeping which is also a basic part of danger, incident, and fair prevention.

Effective cleaning is not only for one time or occasionally it’s Included in daily task for everyone on personal. The practice extends from office to industrial workplace, including factories, warehouse, and manufacturing plants that have its own special difficulties or challenges like hazardous materials, combustible dust. Cleaning should have management, commitment so worker realize its importance. 

  • Purpose of workplace cleaning

                   

  • Housekeeping improve productivity because all employee or workers work in fresh mood or stay safe or healthy and help prevent injuries and moral or decrease the illness of workers.
  • It can help make a good impression on visitors, Safety consultant for the workers’ compensation.
  • Every worker should play a role in clean, even if that means keeping his or her own workplace clean.
  • If the Goods place on the right place, then it will not take too much tome to finding them. If any item or goods is out of stock, then we can order on time.

Poor Housekeeping like tripping over loose objects here and there on floors, stairs and platforms, being hit by falling object, misplace material looking disorderly, In factory equipment in poor condition, these can be cause of a variety of incidents.

For avoiding these hazards, it must maintain order throughout a workday. It’s not a single person responsibility It’s a teamwork.

  • How we can do workplace cleaning:

 a. Avoid slips, trips, and falls

  • Report to all and clean-up spills and leaks
  • Keep exits clean of objects.
  • For help with blind sport installing mirrors or warning.
  • Replace as quick as much worn, ripped and damage flooring.
  • Install anti-slip floor and use mats, platform mats

b. Dust Control and Pest Control

  • Vacuuming method or Use Sweeping and water wash for cleaning
  • Blow-Down using compressed air for unreachable or unsafe area.
  • Clean wall, ceiling machinery and other place regularly.
  • Use pest control spray fog every week or month.
  • Don’t throw waste who produce mosquito or other type of pest.

 c. Tracking materials Avoid

  • Work area mats should be clean which help prevent the spread of hazardous.
  • Use different mop for different type of dirt, like for cleaning oil, dust, water.

d. Material Store Properly.

  • Storage should not have an accumulation of material that present hazards, fire, or pests.
  • Maintain manufacturing floor, maintenance area, storage, or warehouse, or that area which create problem with storage.
  • Unused equipment or material stored out of the workers reach or avoid workplace as a storage.

e. Safety falling objects

  • Place all object in proper manner for avowing to falling on employee or workers
  • Keep all big box or object on lower shelves and keel all equipment away from desk or table.
  • Keep clean or empty the area where workers walking regularly.

f. Use and inspect personal protective tool

  • Wear safety summons like safety gloves which is protected by broken glass or other harmful waist, safety clothe and shoes when work with electric equipment or Glass when doing dust’s work.
  • Regular inspect for clean and fix tool, remove as soon as possible if find any damage on work area 

g. Determine Frequency

  • All workers should take participate, at least keeping own workplace clean.
  • If anyone seen anything which create any problem, then informed
  • In the end of shift everyone needs to check or remove unnecessary material from workplace.

 


h. Eliminate Fire Hazards

  • Keep materials in the workplace which is needed for job. Unneeded material moved in relative storage.
  • Quick burning or flammable material put on designated area away from ignition source.
  • Don’t go close in contaminating cloths with flammable liquids.
  • Keep free passageways and fire door for emergency.
  • Don’t store any item on stairwells.
  • If any issue is coming in electrical area, put warning or fix them on priority.

 

  • How we can plane on Workplace

 

  • Use dustbin near Desk and throw Different waste in different Dustbin.
  • Clean desk daily, check all electric equipment on daily basis.
  • If working in Factory, then clean all took or equipment after use.
  • Check all machine before and after use. It reduces the incident.
  • Remove unused material or item instantly, it creates more space.
  • Inform Immediately If notice anything wrong with electrical equipment.

 

  • Reference

Programmable Logic Controller

PLC is an industrial grade computer used in automation industry to make system reliable through logic. It was invented by General motor, in America and Dick Morley was considered father of PLC. Dick Morley has identified the problem in industry that before PLC there is hardware wiring and this hardware nature made it difficult for design engineer to find troubleshooting and system is also not reliable. Now a days PLC is used in every automation industry and there are so many Industry providing automation digital solution like Schneider electric, Allen Bradley, Siemens industries and so on.

Working of PLC

PLC works in program of scan cycle where it read executes it program repeatedly and there is ladder logic and scan cycle consist of 3 steps.

  1. Read input
  2. Execute the program
  3. Write output

It follows the sequence of instruction and works in real time that is millisecond and in milliseconds for the processor to evaluate all the instruction and update all the output according to instruction.

Component of PLC

 They have three components, and these are: processor, power supply input/output section                               

  • Processor

It is brain of system of plc system, is a solid state device designed to perform a wide variety of production, machine tool and processor control function. Conventionally electromechanical device, relays and their associated wiring formerly performed these function. It operates in 5volt supply and supplied by power supply. Once the ladder diagram program is entered into processor, it remains until changed by the user with one of programming devices and program unaltered through power failure.

  • Power supply

It work is to convert line voltage into 24 dc voltage to provide internal circuitry. Basically, it is combination of transformer, rectifier and capacitor. In some cases, it also provides an isolated VDC supply to power dc input circuits, switches and indicators. There are so type power supply found in PLC like DC/DC converter power supply, Frequency converter plc power supply, Linear plc power supply and Switching plc power supply.

  • PLC Input/Output

Electrical noise like spike in power lines or load kick back would have series impact on PLC internal circuits this is where input/output portion play a very important role. The I/O both protect CPU from electrical noise. The I/O section is where status signal is filtered to remove noise level and CPU decision are made and put into operation. The PLC inputs provide their status to a storage area within the CPU AND outputs are driven from similar stored status in the CPU. Real world devices like push buttons, limit switches and sensor are connected through input modules in the PLC. These modules detect a change in state of input signal and provide a stored image to input element in ladder logic. The input element simulates action of relay contact within PLC. In turn, output element are energized which produces desired output signal to drive load such as motor controller, contactors, via output modules in the I/O.

  • PLC Programming

PLC are simply to program. They use a relay ladder language that is similar to magnetic relay circuitry. Engineers, and electrician can learn to program the PLC without extensive training or experience. There are numerous advantages in using PLC versus a relay or solid electronics. In a PLC, changes can be accomplished quickly and inmost cases, without hardware modification to the controller.

Advantages

The advantages one gets with PLC are-

  1. Less wiring.
  2. Easier and make faster response in real time.
  3. It make trouble shooting easier and reducing downtime.
  4. High reliable and flexible.
  5. Low power consumption.
  6. Capable of handling complex logic.

Conclusion

PLC applications are typically customized system. It is low compared to cost specific custom- built control design. It requires less maintenance due to absence of moving parts, thus making things they work better. Overall, PLC appear to be an excellent solution for many different problems.

References 

  1. https://www.unitronicsplc.com/what-is-plc-programmable-logic-controller/?__cf_chl_managed_tk__=pmd_fcc46ff256a5f8fc95b6a9ac40d67fed824816f5-1626427881-0-gqNtZGzNAuKjcnBszQgO
  2. https://www.galco.com/comp/prod/plc.htm#:~:text=Programmable%20Logic%20Controllers%20have%20three,(I%2FO)%20section.&text=The%20processor%2C%20or%20the%20brain,%2C%20and%20process%2Dcontrol%20functions.

 

Earthing

Earthing is arrangement by which an electrical installation is connected to means of earthing. This is usually for safety purposes although sometimes also for functional purposes, for example in case telegraph lines which use earth as conductor to save cost of return wire over a long circuit. If there is fault in electrical installation, a person could get an electric shock by touching a live metal part because electricity uses the body as path to earth. Earthing provides an alternate path for fault current to flow of earth. It can be seen in power system networks, industries, domestic homes, commercial buildings.  

In this below diagram, we can easily see that equipment body leakage current leakage from equipment body, pass to a human body as there is no grounding of equipment or device. This increases the risk of electrical shock. Hence earthing play an immense important role in industries, commercial building, home etc.

Electrical system without earthing

In this below diagram, with grounding of equipment, the whole leakage of current in equipment  body passes through low resistance path called ground wire so there is a negligible chance of electrical shock.                      

Electrical system with earthing

 

Method of earthing

There are various types of earthing is done like rod earthing, strip earthing, plate earthing, pipe earthing and earthing through water mains but pipe and plate earthing is preferred so much.

  • Earthing mat

 It is done by number of joining of rod through copper conductor and it reduces overall grounding resistance of system. Such type of earthing helps to limiting the potential. This type of earthing used in where there is a high fault current is to be experienced. While designing this system following points must consider.

  • Earthing electrode

 In this earthing, we may use wire, rod, pipe and inserted vertically or horizontally into ground and In distribution system there is rod of nearly 1m is used and inserted vertically into ground but in generating substations there is earthing mat is used rather than Earthing electrode.

  • Pipe earthing

This type of earthing is mostly used and this is considered best method as compared to other type of earthing for same soil condition. In this earthing, the galvanized steel or perforated pipe of approved length and diameter depend upon types of soil and current carried by that rod is placed upright in wet soil as shown in figure. Normally size of pipe is of 40mm diameter and 2.5m in length for ordinary soil but for dry soil length may increase. When there is summer then moisture of soil decrease which cause increase in ground resistance some arrangement of water is done for water accessible or 3 or 4 buckets of water is put into a pipe which is connected to soil pit. In soil pit, there is mixed of charcoal and salt around the pipe to reduce the effective resistance of soil.

  • Plate earthing

In this earthing, either copper plate of 60cm×60cm×3m or galvanized iron rod of 60 cm× 60 cm×6mm is buried in ground with it face vertically to ground and depth is not less than 3m from ground level. The ground wire connected to copper plate through nut or bolt. Copper wire is not used mostly because of high costing. The layer of soil and coke is placed in soil pit.

  • Earthing through water mains

In this type of grounding, the copper or GI wire is connected to water mains through water pipe and water pipe is directly connected to earth as shown in fig. when the fault condition occurs the whole leakage current passes through water steel pipe and earthed.                     

                                       

References 

  1. https://circuitglobe.com/methods-of-earthing.html
  2. https://www.electricalindia.in/electrical-safety-earthing/

 

Vacuum Circuit Breaker

The vacuum interrupter technology was first introduced in the year of 1960 but still is a developing technology.  A circuit breaker is a device that interrupts an electric circuit to prevent unwarranted current caused by short circuit, typically resulting from overload. It’s basically functionality is to interrupt current flow after a fault is deducted. This is kind of circuit breaker where arc quenching takes place in a vacuum medium. The operation of switching on and closing of current carrying contacts and interrelated arc interruption takes place in vacuum chamber in a breaker is called vacuum interrupter. Vacuum offers high insulating strength.

  1. Construction

The vacuum circuit breaker consists of fixed contact, moving contact and an arc shield mounted in a vacuum interrupter. The outer insulating body is made with glass and has high vacuum capacity. The movable part is connected to control mechanism by stainless steel bellows. Arc shield prevents deterioration of internal dielectric strength by preventing metallic vapors from falling on inside surface of outer insulating body. To reduce possibility of leak, permanent or tight sealing is done. Vacuum has high dielectric strength as compared to air so vacuum circuit breaker is preferred where arc interruption need high in place of air circuit breaker.

  1. Working principle

When breaker operates, the moving contact separates from fixed contact and an arc is struck between the contacts. The production of arc is due to ionization of metals ions and depend very much upon materials of contact. The arc is quickly extinguished because metallic vapours, electrons, and ions produced during arc are diffused in a short time and seized by surface of moving and fixed member and shields. Since vacuum has very fast rate of recovery of dielectric strength because dielectric strength of vacuum is eight times greater than air and four times greater than sf6.

Contact materials must have following properties:

  • High density.
  • Contact resistance must be less.
  • High arc resist capability.
  • A boiling point must be high to diminish arc erosion.
  • Thermal conductivity is high to dissipate quickly the large heat produced throughout arcing 
  1. Ratings and specification of vacuum circuit breaker

The rating of circuits breakers is generally given in MVA. VCB comes a wide variety ranging from 250 to 1500MVA. According to European standard, the commonly available preferred values for rated current are 25A, 32A, 40A, 50A, 63A, 80A, 100A, 125A

  1. Advantages
  • It does not require any additional filling of oil or gas.
  • The VCB is fast in operation so ideal for fault clearing and suitable for repeated operation comfortably
  • Vacuum circuit breaker is almost maintenance free and minimum maintenance required as compared to other circuit breakers.
  • No exhaust of gas to atmosphere and noiseless operation.
  • No fire hazards
  • The dielectric strength of vacuum is greater than air and sf6 circuit breaker. High dielectric strength makes possible to quench a vacuum arc within very small gap.
  1. Disadvantages 

  • The main disadvantages of this circuit breaker is that it become uneconomical at voltage exceeding 38kv because at more than 38kv, two number of vacuum circuit breaker are required to be connected in series.
  • VCB production is uneconomical if produced in small quantities.
  1. Conclusion

Now a days, vacuum circuit breakers applications to not only medium voltage power systems but also for in high voltage transmission systems. It is because it has so many advantages characteristics such as high interruption capability, long operation life, safety and high-cost performance. After Kyoto protocol in 1997, sf6 circuit breaker is one of major problem of global warming gases, since then vacuum circuit breaker uses become widespread.

  1. Reference

  1. https://www.elprocus.com/vacuum-circuit-breaker-working-applications/
  2. https://circuitglobe.com/vacuum-circuit-breaker.html

 

Transformer

It is static device used to step up and step down of voltage level without change in frequency and power. Transformer works on the mutual induction principle. This principle states that when electric current flows in primary winding supply then due to alternating nature of supply voltage, it develops varying nature of flux and whenever varying mutual flux linked to a secondary winding through core then according to faraday law, whenever either conductor cuts a magnetic flux or magnetic flux cuts a conductor, EMF produced in conductor, hence in this way, EMF developed on secondary winding.

The basic phenomenon behind working of transformer is mutual induction between two winding linked by a common magnetic flux. Transformer consist of two inductive coils, LV and HV winding. These windings are electrically separated but magnetically linked to each other. When LV or HV winding are supplied of ac supply then alternating magnetic flux developed in the winding and it get linked to load side by a common path that phenomenon is called mutual induction. Due to this, alternating EMF is produced in load side whenever circuit will be closed the current flows in load side.

  1. Types of Transformer

According to change in level of voltage, there are two type of transformer –

1.1.  Step up transformer

1.2.  Step down transformer

  • Step up transformer

 It is used to step up the level of voltage. This transformer increases voltage from primary to secondary winding. In this transformer, secondary turns are more than primary turns. This transformer has made long distance transmission power practical because it steps up the voltage and corresponding it decrease current at same ratio hence, due to decreases the current level there is much less power losses in line. This is used generally for long distribution.

  • Step down transformer

This transformer decreases level of voltage from primary to secondary. In this transformer, secondary turns are less than primary turns. It is used mainly in distribution and load side. This transformer has a wide variety of application like distribution side and electronic devices etc. When it comes to operating voltage, the step up transformer application can be roughly divided into two groups: LV (voltages up to 1kv) and HV (voltages above 1kv). 

  1. Construction of transformer

The construction of transformer is of iron core laminated with steel bands core lamination are constructed from insulated metal thin metal strips. These laminations are separated and wound around the limp using a sheet of coat. The laminations are separated and wound around the limb using a sheet of coat or parchment. The winding consists of two types, main and secondary winding. These winding are isolated from each other and are made by electrical coil.

  • Core

The core of transformer is typically built with high permeability materials, such as silicon steel laminations. Based upon configuration of main and secondary windings, a transformer core may be formed in two ways.

  • Core type construction

In core type construction, as shown in fig, the coils are wound around two limb of rectangular magnetic core. Each limb carries one half of primary winding and one half of secondary winding so as to reduce leakage reactance to minimum possible. The LV is wound on inside nearer to core while the HV winding wound on inside nearer to core while HV winding is wound over LV winding away from the core in order to reduce amount of insulation material required. 

  • Shell type construction

In shell type construction, the coils are wound on central limb of a three limb core. The entire flux passes through central limb and divides in two parts going to side limbs shown in fig. Sandwich type winding is used in such a construction. This type of construction is popular in low voltage application like transformer used in electronic devices, power electronics converters.                                     

                             

                            


                                                      Fig: Shell and core type construction

  • Conservator

A cylindrical tank plays a key role in transformer. It is arranged over the main tank roof so that sufficient space can be provided to expand to transformer oil. Once the temperature increases, then oil volume can also be increases, then oil volume can also be increased. Then oil goes to conservator tank after cooling down it returns to main tank. The shape of conservator tank in transformer is cylindrical where both ends of oil container are closed. One side of the container is provided for cleaning purpose.

 

   

                                                    Fig: Conservator tank

  • Breather

 As a temperature of transformer increases, the insulating oil in transformer heats up.   When oil heats up and spreads, the transformer breathes air in and oil is cooled down and oil level is consumed. The oil level in chamber rises and reduces as breather brings the air in and out to cool the air. The air carries moisture, which contaminates oil and thus deteriorates the consistency of oil. The breather is packed with silica gel to remove moisture content. The key feature of silica gel is to isolate moisture from oil while preserving the consistency of insulating oil. The color of silica gel becomes pink as it absorbs moisture from oil

                                                                 Fig: Breather

 

  • Radiator

The basic function of radiator is to cool down the transformer oil. Oil immersed power transformer is generally provided with detachable pressed sheet radiator with isolating valves. But in case of small size distributing transformer, the radiators are generally integrated parts of transformer body and projected from main tank. The working principle of radiator is very simple. It just increases the surface area for dissipating heat of oil. Under loaded condition, warm oil increases in volume and enter into upper portion of main tank. Then oil enters in radiator through top valve and cools down by dissipating heat through thin radiator wall. This cold oil comes back to main tank through bottom radiator valve.

  • Bushings

Bushings are the insulation system in construction of transformer that enables an electrical conductor to safely transfer electrical energy through it. When a significant volume of electrical energy travel through it, it provides electrical field power to withstand insulation of conductor. In small transformer, solid porcelain type bushing   is used, and in large transformer, oil filled condense type bushing is used.

                                                                 Fig: Bushing

                                                              

  • Buchholz relay

In order to protect of transformer from internal short circuit due to oil, buchholz relay is used for oil immersed transformer, buchholz relay is an oil and gas actuated relay which sense the fault occurring in the part immersed in transformer. Whenever short circuit occurs in transformer then oil generates enough heat and become decompose itself into hydrogen and monoxide gases and these gases travel through pipe and relay is also mounted on pipe between main tank and conservator tank and these relay sense the gas and activate the tripping circuit.

                                                            Fig: Buchholz                                                              

  1. Distribution voltages classes and standard ratings of transformer

Transformer are used wide variety of purposes, with complete range of voltage and power ratings as well as many special features for particular applications.

The following cover main types:

  • Small transformer

They are used for stationary, portable or hand held power supply units. They may be used to supply three phase power up to 40kva at frequencies up to 1mhz. 

  • Distribution Transformer

 They are used to distribute power to domestic premises. They may be single phase or three phase. They have rating ranging from16kva up to 2500kva and this type of transformer like 11, 6.6, 3.3, 440 sand 230V. 

  •  Supply Transformer 

They are used to supply larger industrial premises or distribution substations. Ratings ranging from 4mva to 30mva, with primary winding rated up to 66kv and secondary up to 36kv. The primary winding has a highest voltage ranging from 3.6kv to 36kv, the secondary winding voltage does not exceed 1.1kv. 

  • Transmission transformer

          They are among largest and highest voltage transformer in use. They are used to transmit power between high voltage networks and Rating ranging from 60mva to 1000mva and winding are rated at 33, 66,132, 275 and 400kv.       

  •  Power or step up transformer 

Power is usually generated in large power station at typically 11kv-20kv, and this transformer are used to step up voltage. These transformers are usually rated at 400, 500, 630,800 or 1000mva and transmit power at 66, 110,132,220, 400 and 765kv. 

  1. References 

  1. https://www.electricaleasy.com/2014/03/electrical-transformer-basic.html

Lightning Protection Unit

Lightning is an atmospheric discharge of electricity from thunder, occurs during thunderstorms. The atmospheric discharge lightning can travel at speed of light and its temperature can reach up to 30,000 degree Celsius. The effect of lightning strike may cause thousands of death every year. It is a natural phenomenon occurring at any day and this discharge produce a wide range of electromagnetic radiation.

Lightning protection unit are designed to protect the building structures, industrial appliances, commercial building, HT substation, electrical equipments, communication transmission lines  etc. from damage effect of lightning strike. It play a very important role in safety from lightning storms. A lightning strike could bring thousands of mega ampere current within milliseconds. As a result, failure of home and industrial appliances, fire in building structures, home etc. and may cause death also.

                                       Fig: Effect of lightning strike on building

                                         Fig: Building with lightning protection unit

 

As we can relate with both of the figure above , effect of lightning on building without and with light protection unit.

  1. Components of lightning protection devices

    • Air terminal

Air terminal is used to intercept lightning strike. It provide a low resistance path to lightning strike and it is connected to down conductor and down conductor is connected with earthing electrode which is directly kept into soil mud. Whenever lightning strike hits, the whole current is discharged through air terminal- which is  connected to ground electrode instead of building structure.      

  • Down conductor

Down conductor provide a low resistive path to lightning current from air terminal to ground electrode. It should be installed vertically and straight to avoid the bending of down conductor. This shall ensure minimum inductance because of resistance in the path of discharging current and surges.

  •     Grounding

 It play a very important role in discharging lightning current. It dissipates all the lightning current into a big mass of soil. The soil resistivity should be less than 10 ohm for comfortable discharge of current, according to electrical standard. A typically earth electrode of copper alloy is deep driven vertically into the soil. Soil have finit conductivity so that current discharges easily. The mixing of charcoal and salt is done in soil pit to decrease the resistivity of soil.

  1. Lightning Arrestor

These devices are designed to protect the transmission line, insulations, switchgears, transformers communication line by the effect of lightning strike. They directly installed to power substation , distribution system or telecommunication line. It has ground termininal and high voltage terminal and whenever lightning travel along the power line to arrestor then current through surges diverted by arrestor to earth. In telegraphy and telecommunication, it is placed where wires enter a structure so that preventing damage to electronic instrument and ensuring safety near to them. Their purpose is basically to limit the rise in voltage when power lines are struck by lightning.

    

                                                  Fig: Lightning arrestors

Small version of light arrestor is called surge arrestor. That are generally used for protection from surges produced in transient condition and they are not used directly to protect from lightning. The most common surge arrestor is non linear metal oxide resistor type in porcelain or silicon rubber housing that are fitted parallel to circuit and connected to earth griding.

 Types of Lightening Arrestors 

  • Station class

Typically used in power stations or substations  and other high voltages structure and areas. It is designed to protect equipment above 20MVA range. 

  • Intermediate class

Designed to used in medium voltage equuipment areas, electrical substaions, transformer or other substation equipment and it is designed in range of 1 to 20 MVA.

  • Distribution class

Most commonly found on transformers and are commonly used in equipments rated at 1000kva or less.

  • Secondary class

Found in homes and commercial buildings and provide  least amount of protection to electrical system.

  1. Conclusion

All electrical equipment in an electrical system needs to be protected from voltage surges. The rating of arrestor, the class of arrestor and location of arrestor all play a important role in the surge protection. In protection of substation, we use different class of lightning arrestors to protect the electrical equipment and In ships, water is used to discharge voltage.

  1. References

  1. https://www.electricaltechnology.org/2020/03/surge-arrester-suppressor-lightning-arrester-rod.html

Flooring In Food Industry

Flooring is the general term for a permanent covering of a floor, or for the work of installing such a floor covering. The food industry is one of the most challenging ones when it comes to the field of flooring. Many factors are to be considered in the selection of flooring materials and their finish. Floors in food manufacturing or food preparation premises must be able to be cleaned effectively and thoroughly, must not absorb grease, food substances, or water, harbor pests or bacteria, and should be laid to a safe design so as not to cause the pooling or ponding of the water. Different grades of flooring are needed for the different areas found within the food environment. For example, production areas often need a hard-wearing, chemical-resistant floor finish, which can stand up to heavy machinery and general wear and tear.

Pre-requisite for flooring

The floor finish has several different functions in a factory. The main parameters to be considered in the selection of flooring material is: 

  1. Hygienic and easy to clean surface

As part of its HACCP quality system, a producer must assure himself that a floor will not compromise food safety. The easiest way to do this is to use a flooring system that has appropriate third-party certification for use in food handling facilities. Also, a floor should be dense, impervious, and with bacterial cleanability comparable to stainless steel

  1. Safe working environment

The floor must provide a safe working environment for operatives so it must have an appropriate level of slip resistance. The correct level of slip resistance, for any given area, will depend upon activities taking place. 

  1. Durability

Durability comes from a combination of physical and chemical properties. It requires resistance to chemicals and thermal shock, as well as mechanical abrasion and impact.

Floor Zoning

A zoning plan on the surface of the floor is a good idea if a food plant has identified any areas at risk of cross-contamination or other hazards and is looking to segregate areas or zones by different processes or procedures or to designate different levels of hygiene through a simple color-coded system.

Although there is no universal system or language in place, pigmented flooring materials can be used to designate walkways or hazard risks in line with individual company policies and practices. The zoning helps to identify the high-risk and low-risk areas. Sensitive wet and dry processing areas need floors that deliver the ultimate in hygiene performance. In these environments, steam cleanable products are often sought. For sensitive areas, such as tray washrooms, antimicrobial floors are often chosen.

Flooring Options

There are many different food processing floor options available in the marketplace.  Epoxy and urethane systems are readily available.  However, cementitious urethane floors are considered the modern, high-performance, standard for food and beverage safe flooring in processing facilities. The ceramic tiles, Dairy tiles, and hard non-reactive stones were the most used ones in the previous decades. 

The flooring options can be classified into two main categories Tiles/Stones, and floor coatings.

  1. Tiles/ Stones

When looking at food processing floor options, dairy brick, and quarry tile quickly come to mind.  These are products that have widely been used in the food processing industry.  At one time, these products were the only systems available (before the advent of seamless polymeric floors).  These systems are only a viable choice for new construction or long production shutdowns.  Drawbacks include the added thickness of these systems, along with a prolonged installation duration.  These issues make brick and tile difficult or impossible for renovation and fast turnaround projects.

Mandanna Stone Tiles are the most commonly used tiles in the dairy industry in India. Mandana Sandstone is a chocolate-colored sandstone with colors ranging from dark red-brown to plum. This is hard-wearing & frost-resistant sandstone.

  1. Floor Coatings

Floor coatings are tough, protective layers used in applications where heavy surface wear or corrosion is expected. Food processing plant flooring options are different types of coating, which go onto something like concrete flooring.

  • Epoxy Coatings

There are numerous types of food-grade epoxy flooring available in the market. They are a fantastic option and are incredibly durable, with many benefits. They can withstand exposure to agents like acids and alkalis, which have the potential to damage other kinds of flooring.

There is also the option to include additives—like anti-skid additives—to the epoxy mix to create an even better product. Certain types of food-safe epoxy coating options, like novolacs, also offer greater chemical and heat resistance. Epoxy coatings cure quickly, which means less downtime within the facility, unlike other options on the market. Epoxy coatings are also a visually appealing option, with the ability to add aggregates like quartz or marble into the mixture.

  • Urethane Coatings

A polyurethane coating (or urethane floor coating), is a highly flexible, highly abrasion-resistant floor coating that is known for its shine and longevity. These can have a more considerable upfront cost but will last much longer than other flooring options.

Additives in the urethane mixture provide these floors with superior resistance to thermal cycling, which helps add to its long-lasting nature. This helps to make them a popular choice in food processing plants that work with meat and poultry products+++. Like epoxies, urethane can have decorative touches added to it to make the flooring more visually appealing.

  • Methyl Methacrylate(MMA) Coatings

Methyl methacrylate (MMA) systems offer food manufacturing and processing environments certain performance advantages compared to alternative resin materials, most notably their ability to cure at an incredible speed and be installed at extremely low temperatures.

MMA resin can fully cure in just one to two hours, making it an ideal choice for operational facilities looking to minimize downtime and disruption as well as fast-track new-build construction projects. MMA resin material demonstrates a high level of resistance to a range of acids and alkalis. Although MMAs have a unique odour during installation, the odour is harmless and can be minimised during installation with proper ventilation.

  • Poly Ureas Coatings

For a flooring option that does well in demanding environments, there are polyureas coatings. These coatings are impact resistant. They are the quickest to cure and give off virtually no odor. Because polyureas coatings are flexible flooring, they are also better able to withstand extreme temperatures found in various facilities.

Cleaning and Maintenance

An effective cleaning and maintenance routine should be in place to preserve the aesthetic and performance of the floor finish but more importantly to reduce the risk of microbial contamination. Between wash cycles, resin-based flooring materials should, where possible, be maintained in a dry state and at low relative humidity conditions.

Flooring must be sloped at around 1.5-2% to allow water to drain correctly. Resin flooring will not be affected by most special-purpose cleaning materials when these are used in accordance with the Chemical Cleaning Manufacturers’ instructions. Specific cleaning instructions should also be sought from the resin flooring manufacturer.

With so many options to choose from, selecting a fit-for-purpose flooring solution that can withstand the operational demands of food manufacturing, processing, and packaging environments can be challenging. On top of this, stringent health, safety, and hygiene standards, as well as budget constraints, must be considered.

Reference

  1. https://blog.slotdrainsystems.com/food-processing-flooring-101
  2. https://www.blackbearconcrete.com/food-and-beverage-flooring-requirements-blog/
  3. https://www.academia.edu/38300009/Handbook_of_hygiene_control_in_the_food_industry
  4. https://concreteflooringsolutions.co.uk/blog/what-are-the-best-types-of-industrial-flooring/
  5. https://epfloors.com/epoxy-flooring-types/food-processing-floors/food-processing-floor-options/
  6. https://www.flowcreteasia.com/media/8569/fc-asia-floor-failure-in-the-food-industry-ebook-aw-web.pdf
  7. https://www.myprocessexpo.com/blog/industry-perspectives/hygienic-flooring-the-role-of-floor-coatings-in-keeping-food-safe/
  8. https://f.hubspotusercontent10.net/hubfs/1295364/BASF%20Ucrete/Website/Languages/United%20Kingdom/Pdf/18031-basf-whitepaper-uncrete-v6.pdf

 

Carbonated Beverages

People in the past believed that natural springs which were naturally carbonated, could cure many diseases. As such, scientists and inventors thought of ways to artificially produce these mineral waters.  Artificially produced carbonated beverages get their start from this. The first carbonated beverages were just non-flavored carbonated water sold as mineral water tonics.

Flavored carbonated drinks/ soft drinks were initially introduced in the United States in the early 1800s. The purpose of adding flavour was not just to make it taste better, but also to improve on the supposed natural curative properties of mineral water.  Popular ingredients to add were birch bark, dandelions, ginger, lemon, coca, and kola (the latter two combined ended up producing Coca-Cola).

Obviously, as the name explains carbonated beverages are those drinks that have carbon dioxide added to them. Carbon dioxide is a colourless and odourless gas. Usually, flavours and sweeteners are added to them to enhance their palatability. The water always has some amount of dissolved oxygen in it, but carbonated water is the one that is supersaturated with carbon dioxide.

The reaction between carbon dioxide and water produces carbonic acid. It is this carbonic acid that creates the tangling effect on your tongue. 

CO2 + H2O = H2CO3

  1. Bubbling Effect/Sparkling Effect

The maximum amount of carbon dioxide that can get into the water is 8 grams per liter. The excess carbon dioxide will generally only stay in the water when the water is under pressure. Once the pressure is released (i.e. normal atmospheric pressure on the earth is restored), the carbon dioxide will start to escape. Once a bottle or can of a Carbonated Beverage is opened, giving the carbon some way to start escaping, it will, causing the beverage to go flat.

  1. Ingredients

  • Water

Water is the major ingredient in carbonated beverages. It comprises more than 90% of the total volume. The water which is used in the preparation of carbonated beverages must of very high potable standards. Therefore, water pre-treatment is necessary to ensure the high standards of finished beverages.  De-aeration of water is also required to facilitate subsequent carbonation and filling operations to minimize foaming problems.

  • Sweeteners

The sweeteners impart flavour, improve the mouth feel, and adds calories to the beverage.  It is used in the form of sugar syrup and the final concentration of sugar varies between 8 to 14 percent in the finished beverage. 

  • Carbon dioxide

 CO2 gas is inert, non-toxic, almost tasteless, and is easy to produce. It is also available at a relatively lower cost in liquefied form. It is soluble in liquids where its solubility increases when the temperature of the liquid is decreased and it can exist as a gas, liquid, or solid. Purification of CO2 is done by scrubbing with water to remove sulfurous compounds and passing through activated charcoal or carbon tower to remove odorous compounds. Many beverage manufacturers produce their own CO2 on-site by using packaged systems.

  • Acids

 Acids improve the flavour and also contribute towards the preservation of the beverage.  Kola beverages mainly use phosphoric acid for preservation and taste.

  • Flavouring and Colouring agents

The flavouring component has a major influence on the flavour of the final product. They are used at very minor amounts (0.01 to 0.02 %). The nature of flavouring usually is determined by the type of the product. Fruit flavours are most commonly used, except in colas, which are flavoured by extract of cola root together with about 10% caffeine and a mixture of essences. Fruit flavour may be added in the form of juice, as comminuted (in the case of citrus fruit), or as an essence.

Important colouring agents for carbonated beverages synthetic colours particularly certified coal tar colours. Caramel obtained from heated or burnt sugar is a non-synthetic colour and is widely used in cola beverages. Permitted food dyes are generally preferred over natural fruit colours because of their greater colouring power and stability.

  • Emulsifiers, stabilizers, and clouding agents

They are used to improve the stability of the solution, improve the appearance, etc. They should be added in appropriate proportion to ensure the quality of the product during storage. Gum Arabic and modified starches are the most common emulsifiers and stabilizers used in beverage emulsions. However, others include, xanthan, galactomannan, carrageenan, pectin, cellulose derivatives, and alginates

Foaming agents

 

The presence of foams at the top of the bottle for some beverages like cola is considered desirable. The most effective foaming agents are saponins which are extracted either from the bark of Quillaia or Yucca trees. The permitted level is up 200 ppm (in European Union) and 95 ppm in the USA.

  1. Manufacturing Process

  • Syrup Preparation

The syrup is usually prepared by mixing 1 part (volume) syrup to 3-6 parts (volume) water in stainless steel tanks fitted with agitators. In sugar-based products, syrup contains sugar syrup, citric acid, flavouring agents, preservatives, and water. It is initially heated to reduce the microbial load.

  • Mixing

The syrup is pre-prepared, tested, and diverted to proportioner for mixing with water and carbonation. Flow meters are most frequently used for proportioning. The syrup is dosed through a mass flow meter and the water dosing is done volumetrically by using a magnetic induction flow meter.

  • Carbonation and Chilling

Carbonation is the impregnation of a liquid with CO2 gas. The degree of carbonation is judged by the amount of effervescence produced and it is the most important characteristic of carbonated beverages. The level of carbonation varies between 1 to 4.5 volumes of CO2 per litre of beverage accordingly. The maximum amount of carbon dioxide that can get into the water is 8 grams per liter, hence the carbonation is done under very high pressure and reduced temperatures.

  • Bottle Filling

 Carbonated soft drinks are filled into either bottles or cans. Thick-walled, reusable, glass bottles were used for many years, but are being replaced by thin-walled, non-reusable glass and increasingly, PET bottles.

 

Carbonated beverages were initially considered to have medicinal properties. Almost all the initial producers of carbonated beverages were associated with pharmacies. On May 8, 1886, a  local pharmacist, produced the syrup for Coca-Cola, and carried a jug of the new product down the street to Jacobs’ Pharmacy, where it was sampled, pronounced “excellent” and placed on sale for five cents a glass as a soda fountain drink.  Today Coca Cola is one of the largest beverage companies in the world. And today,  carbonated beverages even if they are considered as just refreshing drinks, they are playing a crucial role in the food business.

 

Reference 

  1. https://www.britannica.com/topic/soft-drink
  2. https://www.britannica.com/science/carbonation
  3. https://www.cooksinfo.com/carbonated-beverages
  4. https://www.coca-colacompany.com/company/history
  5. http://ecoursesonline.iasri.res.in/mod/resource/view.php?id=147625
  6. https://www.delightedcooking.com/what-is-a-carbonated-beverage.htm
  7. https://fruitprocessingmachine.com/portfolio-items/carbonated-drinks-production-line/

 

Bilona Ghee

Bilona in Hindi means to churn. The traditional Bilona ghee has got a rich heritage associated with Subcontinental history. Its roots go beyond the Vedas and Puranas. Even in modern history, much before the usage of regular cooking oil, bilona ghee was one of the staple dietary ingredients in Indian cuisine.

Bilona ghee is produced by initially churning the indigenous cow (which is either soured by the addition of curd or naturally, overnight) milk into makkhan (butter). It is then heated and melted to obtain the bilona ghee. It is rich with a nutty flavour and golden yellow colour.

Today, ghee alone is a half-a-billion-dollar industry in India. It witnessed a growth of 11.1% between 2011-18. This obviously means that there is a substantial need for ghee in the country. But many people claim that the industrially produced ghee is no way near the dietary and nutritional quality of traditional bilona.

Details of Production

The traditional production of bilona ghee is quite a lengthy process.

  • Cow milk is initially boiled and cooled.
  • Then an adequate amount of curd is added as a starter culture into this milk.
  • It is then kept at room temperature overnight for curdling.
  • The curd is then churned to extract butter from it.
  • This butter is then boiled so that the water evaporates leaving behind pure ghee.

As you can see, the process is quite slow and traditionally, all of this was made at homes without any use of machines. Bilona ghee is exclusively produced from traditional cow milk, which is rich in a2 proteins. a2 protein is said to be healthier than a1 protein.

A1-A2 milk

In recent years this has been one of the most debated topics in the Food Industry. It all started with the onset of a2 milk company. The difference between both lies in genetic proteins.

Milk is rich in casein proteins, which is the characteristic protein of milk. The casein contains alpha, beta, and kappa casein. The difference is that if the 67th position amino acid in beta-casein in the milk is proline, the milk is a2 and if it is histidine, the milk is a1. The protein a1 when digested breaks down into smaller proteins(peptides) which are assumed to be toxic.

According to the literature, more than 10,000 years ago, and before they were domesticated, cows produced only the a2 beta-casein protein and not the a1 beta-casein protein. However, some 8,000 years ago a natural single-gene mutation occurred in Holsteins, resulting in the production of the a1 beta-casein protein in this breed. This mutation in the beta-casein gene led to 12 genetic variants, of which a1 and a2 are most common.

The mutation was passed on to many other breeds, principally because Holsteins are used to genetically improve the production of other breeds. Slowly, the a1 beta-casein variant became dominant in milk. While dairy herds in much of Asia, Africa, and part of Southern Europe remain naturally high in cows producing a2 milk, the a1 version of the protein is common among cattle in the Western world.

Almost all the traditional Indian milch like Gir and Sahiwal produce a2 milk. The awareness about the a1 and a2 milk among the consumers is also a reason for the quick increase in demand for bilona ghee recently.

Overview on the cost of Bilona ghee

The cost of bilona ghee when compared to the commercially produced ghee. Just one litre of traditional hand-churned bilona ghee requires 25 to 35 litres of milk. On the other hand, commercial production can produce the same quantity of ghee with just 15 to 20 litres of milk.

It requires a higher raw material cost, labour cost, and production cost which will obviously push up the final cost of the product.

Features of Bilona Ghee

Desi Ghee not only adds flavor to your food, but it makes your food balanced. The rich nutty flavour of bilona ghee is one of the most important parameters that it should have. The reason for this flavour is the production of diacetyl and other flavonoid compounds which generates while heating. These compounds are exclusive to the traditional ghee because of their exclusive curdling process.

Ghee is also rich in Vitamin A and E and Vitamin K2. Traditional bilona ghee has a rich golden yellow colour. This is due to fact that it is exclusively prepared from the milk of traditional milch breeds, which is rich in beta-carotenoid pigments.

 

Health benefits of adding Bilona Ghee to diet

  • Boosts the immune system.
  • It is rich in antioxidants and vitamins.
  • Has monounsaturated fatty acids of MUFA.
  • Since it has a high boiling point, it is good for cooking.
  • It is good for the heart since it lowers bad cholesterol and increases good cholesterol.

Bilona ghee has been with our culture since time immemorial. Its rich flavour and colour are an exclusive feature of our subcontinent. It is prepared by churning out butter using traditional wooden or earthen churns and then it is then heated and melted to obtain bilona ghee. The indigenous milk is rich a2 beta-casein proteins. The manufacturers of bilona ghee claim that the presence of a2 proteins makes the bilona ghee superior to any other commercially produced ghee.

Reference

    1. https://en.wikipedia.org/wiki/The_a2_Milk_Company
    2. https://www.navmi.co.in/what-are-desi-cow-bilona-ghee-and-the-process/
    3. https://www.pureecoindia.in/why-a2-milk-is-much-healthier-than-a1-milk/
    4. https://www.pureecoindia.in/why-bilona-ghee-is-doubly-nutritional-than-regular-ghee/
    5. https://www.vaidikmart.com/what-is-desi-cow-bilona-ghee-benefits-of-pure-bilona-ghee/
    6. https://www.thebetterindia.com/194810/lifestyle-organic-bilona-ghee-health-benefits-order-online-india/
    7. https://cdrf.org/2017/02/09/a2-milk-facts/#:~:text=However%2C%20some%208%2C000%20years%20ago,and%20A2%20are%20most%20common.
    8. https://www.thebetterindia.com/194810/lifestyle-organic-bilona-ghee-health-benefits-order-online-india/#:~:text=The%20traditional%20method%20of%20making%20ghee%20(bilona)%20is%20quite%20elaborate.&text=This%20butter%20is%20then%20boiled,without%20any%20use%20of%20machine

Shelf life of Foods

What is Shelf Life?

 The reference to “shelf” clearly implies that the term is related to the commercial life of the product, thus to a packaged product, delivered through the common routes of distribution, not to a generic, “natural life.”

Shelf life is defined as the period of time under defined conditions of storage, after manufacturing or packing, for which a food product will remain safe and be fit for use. During this period, a food product should retain its desired sensory, chemical, physical, functional or microbiological characteristics and, where appropriate, comply with any label declaration of nutritional information when stores according to the recommended conditions. Therefore, it is obvious that shelf life is a very important and multifaceted requirement of all manufacturers and processed food products.

The safety of food is both a fundamental and legal requirement. It follows that all food product offered for sale must be safe although they do not necessarily have to be of the highest quality.

Since shelf life is such an important requirement, it should be of interest to everyone involved in the food chain. There is the growing realization that a high standard of food safety can only be achieved by adopting a comprehensive and integrated approach, covering the whole of the food chain “from farm to table”. At the other end of the food chain, consumers, too, have a significant part to play. For instance, by minimizing the exposure of foods to high temperatures, particularly during summer months, and by observing carefully any recommended storage and usage instructions, consumers are ensuring that the intended shelf life of their food will not be reduced.

 

Who is responsible for determining the shelf life?

The responsibility for determining the shelf life of the product lies with the manufacturer or the packer. While ideas for new products and for improvements to existing products can originate from within a food business and from external sources such as a current or prospective customer, shelf-life evaluation and testing as very much integral parts of every product development programme. Today, almost without expectations, retailers do independently evaluate the shelf life of food products, particularly their own-label ones.

Labelling of shelf life                            

Food labelling regulations that apply to all food that is ready for delivery to the ultimate consumer or to a catering establishment, subject to certain expectations, is that it should be marked labelled with the appropriate minimum durability indications.

  • In the case of food that is highly perishable and in consequence likely after a short period to constitute an immediate danger to health, a “use by” date.
  • In the case of food other than one specified above, an indication of minimum durability, a “best before date”.

The ‘best before ’ date and the ‘used by’ date must be followed by any special storage conditions which need to be observed, such as ‘keep refrigerated at 0°C to +5°C’ or ‘keep in a cool, dry place”. The date of minimum durability is defined as the date until which the foodstuff retains its specific properties when properly stored.

 

Food that requires ‘use by” dates are following:

  • Dairy products, e.g. dairy-based desserts.
  • Cooked products, e.g. ready-to-eat meat dishes, sandwiches
  • Smoked or cured ready-to-eat meat or fish, e.g. hams, smoked salmon fillets.
  • Prepared ready-to-eat foods, e.g. vegetable salad such as coleslaw.
  • Uncooked or partly cooked pastry and dough products, e.g. pizzas, sausages rolls.
  • Uncooked products, e.g. uncooked products comprising or containing either meat, poultry or fish.
  • Vacuum or modified packs, e.g. raw ready-to-cook packed in modified atmosphere.

The range of product which is given ‘use by’ date differs from country to country. It is the manufacturers and processor’s responsibility to decide to which category their products belong and whether a ‘use by’ or ‘best fore’ date is an appropriate indication. In general, the date must be given as a day, month, and year.

For the ‘best before’ date category, the following forms of durability indication are allowed:

  • Food that will not keep for more than 3 months- ‘best before’ followed by the month and the month.
  • Food that will keep more than 3 months but not more than 18 months- ‘best before end’ followed by the month and the year or the year only.
  • Foods that will keep more than 18 months- ‘best before end’ followed by the month and the year or the year only.

Since food deteriorates continually rather than suddenly, the ‘best before date’ does not automatically mean the food is not fit for consumption or losses all its acceptability immediately after the date.

Once a date mark either ‘use by’ or ‘best before’ is set and declared, it becomes a contract between the food company and its customers to the effect that, provided the food is stored according to the recommended conditions, it should last at least as long as its states shelf life.

Shelf life is defined as the length of time a product may be stored without becoming unsuitable for use or consumption. Shelf life depends on the degradation mechanism of the specific product. Most can be influenced by several factors: exposure to light, heat, and moisture; transmission of gases; mechanical stresses; and contamination by things such as microorganisms.

Reference

  1. https://www.medallionlabs.com/blog/food-manufacturers-shelf-life-testing/
  2. https://www.eurofinsus.com/food-testing/services/testing-services/shelf-life-and-stability/
  3. https://en.wikipedia.org/wiki/Shelf_life#:~:text=Shelf%20life%20is%20the%20length,not%20yet%20unfit%20for%20use).
  4. https://www.google.com/url?sa=i&url=https%3A%2F%2Fonethird.io%2Fdifferent-types-shelf-life-prediction-technology%2F&psig=AOvVaw0j8ZYnI7XIqqbkVwFaKVr4&ust=1620468750721000&source=images&cd=vfe&ved=0CAIQjRxqFwoTCNi5wNiqt_ACFQAAAAAdAAAAABAD
  5. https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.theguardian.com%2Flifeandstyle%2F2014%2Fmar%2F06%2Fguide-to-food-date-labels&psig=AOvVaw1NJd-MAU5p-L4afA_kuks-&ust=1620468465647000&source=images&cd=vfe&ved=0CAIQjRxqFwoTCIihzNipt_ACFQAAAAAdAAAAABAJ
  6. https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.foodmanufacture.co.uk%2FArticle%2F2020%2F05%2F18%2FEuropean-food-labelling-unified-system-urged&psig=AOvVaw37K3cdkC6kZ-A3VbxLT93p&ust=1620468163446000&source=images&cd=vfe&ved=0CAIQjRxqFwoTCMCEzMWot_ACFQAAAAAdAAAAABAb
  7. https://www.google.com/url?sa=i&url=https%3A%2F%2Fpbfy.com%2Fblog%2Ffood-preservation-and-shelf-life-is-flexible-packaging-right-for-you%2F&psig=AOvVaw1jxsjovNidM3nX0y5r0UAQ&ust=1620467204601000&source=images&cd=vfe&ved=0CAIQjRxqFwoTCNCCp4Klt_ACFQAAAAAdAAAAABAK