Coconut Sweetening Process Coconut Sweetening Process Elizabeth - PowerPoint PPT Presentation

Coconut Sweetening Process Coconut Sweetening Process Elizabeth Casey Justin Dillingham Mohd Hussain Brady Stewart BAE 4022 – Spring 2006

About Griffin Food Company About Griffin Food Company • Founded in Muskogee, OK in 1908 by John T. Griffin • Major products available: – Syrups – Jellies and preserves – Mustards – Coconut flakes 4/27/2006 2

Problem Definition Problem Definition • Consumers demand the longest length of coconut flakes possible • Flake length of Griffin’s coconut degrades during processing Before After 4/27/2006 3

Competitor Length Comparison Competitor Length Comparison 12 Average Length (mm) 10 8 6 4 2 0 Current Griffin's Bakers Mounds Sample Brand 4/27/2006 4

Project Goals Project Goals • Pinpoint and quantify degradation • Make recommendations to: – Prevent flake length degradation – Increase processing capacity – Improve quality of work for employees 4/27/2006 5

Process Steps Process Steps • Delumping • Conveying to cooker • Cooking and blending • Tempering • Packaging 4/27/2006 6

Delumping Delumping • Clumps of coconut form during storage • Delumper used to separate clumps 4/27/2006 7

Conveying to Cooker Conveying to Cooker • Auger transports coconut from delumper to cooker – Contained within PVC pipe • Frequently clogs • Limits processing speed 4/27/2006 8

Cooking and Blending Cooking and Blending • Double ribbon agitation cooker • Blends slurry, sugar and coconut • Runs continuously during delumping and conveying 4/27/2006 9

Concept Development Concept Development • Quantifying coconut flake length – Modified ASAE Standard S424 – Image Analysis with MatLab • Potential Solutions – Proposal A – Steam Injection – Proposal B – Replacement of Auger Conveyor – Proposal C – Replacement of Cooker 4/27/2006 10

Image Analysis with MatLab MatLab Image Analysis with • Setup camera system • Prepare sample – Separate overlapping material • Capture image 4/27/2006 11

Image Analysis with MatLab MatLab Image Analysis with • Process image in MatLab • Input data into Excel – Calculates average length × area from MatLab actual picture area = Average Flake Length × × 122.97 # of strands MatLab picture area 4/27/2006 12

Results Results 20 Average Flake Length (mm) 16 12 8 4 0 Initial Delumper Auger Cooker Process Step 4/27/2006 13

Proposal A – – Steam Injection Steam Injection Proposal A • Researched direct steam injection systems • FAPC testing – Steam table • Did not meet project goals 4/27/2006 14

Proposal B – – Replacement of Replacement of Proposal B Auger Conveyor Auger Conveyor • Inclined flighted belt conveyor most suitable – Requires half as much power as auger conveyor – Increases capacity – Extremely gentle on product www.kamflex.com 4/27/2006 15

Proposal C – – Replacement of Replacement of Proposal C Cooker Cooker • Focused on tumble blenders • FAPC testing – 8 L V-blender • Patterson Kelley testing – 8 L V-blender with intensifier bar 4/27/2006 16

Proposal C – – Replacement of Replacement of Proposal C Cooker Cooker Type of Blender Percent Degradation Griffin’s Ribbon Cooker 29% FAPC V Blender – Test 1 10% FAPC V Blender – Test 2 34% Patterson Kelley V Blender – Test 1 9% Patterson Kelley V Blender – Test 2 6% 4/27/2006 17

Evaluating Proposals Evaluating Proposals • Potential length improvement • Ease of transition • Cost 4/27/2006 18

Cost Analysis Cost Analysis Equipment New Cost Used Cost Image Analysis $2,879 --- Package Cleated Belt $10,520 $5,000 Conveyor V-Blender with $120,000 $25,000 intensifier bar 4/27/2006 19

Final Recommendations Final Recommendations • Image analysis package – To monitor length quality • Kamflex Series 811 Cleated Belt Conveyor • Patterson Kelley 20 ft 3 V-blender with intensifier bar 4/27/2006 20

Projected Length Improvement Projected Length Improvement 16 14 Average Length (mm) 12 10 8 6 4 2 0 Current Proposed Bakers Mounds Griffin's Griffin's Sample Brand 4/27/2006 21

Acknowledgements Acknowledgements We would like to thank the following people for their help and support: Griffin Food Company BAE Faculty and Staff • Richard Hall • Dr. Paul Weckler • Craig Duncan • Dr. Gerald Brusewitz • David Clary • Dr. Tim Bowser • John Trammel • Roshani Jayasekara 4/27/2006 22