Hats and Head Gears production process

Raw Materials

The main raw materials of hat and other headgears production plant are woolen fabrics, HDPE, fiber glass, etc.

The production process of hats and other head gears plant involves the following major manufacturing operations.

A-Production Process of Hat

1. First, the hair tip is cut
   

Glucose production process

Raw Materials

The raw materials required for the plant include maize starch, activated carbon, soda-ash, HCL acid, and water.

• Maize Starch
• Activated Carbon
• Soda-ash
• HCl Acid
• Water
• Packaging Material
• Electricity
• Fuel Oil
• Process and Potable Water

Slurry of starch of about 60 % water is prepared and treated with HCL acid in a converter where the reaction takes over at 150 ⁰C and maintained for 15 minutes. The treated slurry is then transferred to wooden vats where it is neutralized with soda-ash solution. Then it is filtered and further refined by activated carbon. Then it passes through a vacuum evaporator where it gets the required concentration. After being cooled the liquor is packed ready for shopping

Alternatively, maltose syrup and high-DE glucose syrups can be produced by two-stage acid/enzyme or enzyme/enzyme saccharification process.

Machinery and Equipment

• Slurry preparation tank
• Converter
• Glow tank
• Wooden vat
• Filter press
• Refining vessel
• Vacuum evaporator
• Pumps

Abrasive Cloth Making Process

Raw Materials

· Aluminum Oxide

· Silicon Carbide

· Treated Cloth

· Phenol formaldehyde resin

· Other inputs (Glue, ink, etc)

Production starts when the make coat is applied to one side of the backing material. The abrasive grains are then applied using an electrostatic deposition process, in which the grains are given an electric charge. Finally, another layer of adhesive-the size coat-is applied.

The next step, applying the abrasive mineral, is the most important in the manufacturing process because it determines the orientation and density of the mineral. The backing is passed, adhesive side down, over a pan of abrasives that have been electro-statically charged-given an electric charge opposite to the backing. The opposite charge causes

Small scale Paper Making Process

The process of making paper is based on the fact that wet cellulose fibers bind together when dried under restraint. The processing of paper usually involves the initial separation of the cellulose fibers to form a wet pulp, some form of treatment, such as beating and refining, while in the pulped state, to enhance the quality of the final product, then forming of the sheet paper by hand molding or by paper making machine, and drying.

Some further processing is often carried out before or during drying to acquire the desired finish.

Flow sheet of pulp and paper making process

Raw Materials

Sources of fiber include straw from wheat, barley or rice, bagasse, maize stalks, bamboo, cotton cuttings, lint and fluff, rags (from cotton material), hemp and sisal from old ropes and jute. chemicals required are NaOH, Chlorine and CaO.

The stages involved in transforming raw materials

Production Process of Mini Cement Plant

The technology of cement production involves several unit operations, and are complex to enumerate. However, the major unit operations are the following:-

- Preparation of raw mix
• Quarrying, crushing and transportation

• Proportioning of the ingredients
• Grinding of raw mix
- Calcinations and storage
• Homogenizing of raw mix

• Burning of raw mix in vertical shaft kiln and storing of clinker
- Production of cement

• Grinding of clinker and gypsum (96/4%)
• Packing of cement

Raw Materials

The major raw materials required for the production of cement are limestone, clay, sandstone, gypsum and pumice.

The dry process of cement production is employed here although

Granite Cutting Process Description

Dimension stone is the collective description of natural stone, which has been extracted from the earth in an orderly manner, further worked by cutting and processing, then used in various building activities either structurally or for decorative purposes. It includes panels and tiles from marble, granite, slate, sandstone basalt and other related materials

The successful and economical working of granite quarries depends upon an intelligent application of a knowledge of the structure of the rock and its natural divisions in the mass, as well as upon improved methods, tools, and machinery for quarrying. The topographical location of the quarry and its relation to facilities for transportation are important factors that affect the productiveness and greatly modify the actual cost of operations in a given place.

The manufacturing process of granite blocks and slabs involves the following operations: quarry opening; blasting; cutting; polishing and ornamenting.

Quarrying for dimension stone requires a specialized method of extraction. Normal

Crust Leather Production Process with flow sheet

Raw Materials

The main raw materials for production of crust leather from wet-blue leather stage are wet-blue leather, oils, synthetic tannins, vegetable tannins, aniline dyes, sodium bicarbonate, sodium acetate and formic acid.

Flow sheet of crust leather production

Acetylene Production Process description

Acetylene is an organic compound produced from the exothermic reaction of calcium carbide and water.  Either as liquid or gas, it is highly explosive since it is an endothermic compound and decomposes into the elements carbon and hydrogen. Acetylene is used as raw material to produce different chemicals such as vinyl chloride (a chemical used to produce PVC), 1, 4-Butanediol, vinyl acetate, etc. In addition, it is used as fuel in gas welding.  Acetylene with oxygen produces high temperature flame (3500 ^o C) which is used to cut and weld different metallic products.

Raw Materials

The major raw materials of the production of acetylene are calcium carbide and water.  Other auxiliary materials are nitrogen, iron oxide and silica gel. 

The size of calcium carbide shall first be reduced to fine powder by pulverizer.  The pulverized carbide is then added though a gas tight hopper-valve arrangement to the acetylene gas generator in which the quantity of water used is sufficient to discharge the calcium hydroxide as lime slurry containing 85-90% water.  The temperature is kept below 90^oc and 2 atm. the gas generator.

The impure acetylene (C2H2) from the generator is scrubbed with water.  The continuous supply of cooling water in to the scrubber is also used as a source of water for the reaction with carbide.  After the scrubber, the gas is purified and dried with iron-oxide and silica gel.        

                 

The production process is environmental friendly. The by product slaked lime is used for construction purpose and PH adjustment in industry.

Main Equipments

1. Water tank
2. Carbide feed mechanism
3. Carbide buffer
4. Acetylene generator
5. Pulverizer Scrubber
6. Purifier
7. Nitrogen cylinders
8. Pumps

Bee Venom, Propolis, Pollen and Royal Jelly Processing Part TWO

Continued from Part ONE

c) Royal Jelly Collection

Royal jelly is produced by stimulating colonies to produce queen bees outside the conditions in which they would naturally do so (swarming and queen replacement). It requires very little investment but is only possible with movable comb hives. Expert personnel are required, who are able to devote considerably more time than is commonly required for the production other bee products. Without this prerequisite it is possible to only occasionally collect the contents from cells of natural swarms-and this amounts to no more than a gram or two per hive.

The basic requirements are movable comb hives, preferably some queen excluders, queen cups(made from wax or plastic), a transfer needle, a spoon or suction device to remove royal jelly, dark glass vials and a refrigerator. Special hive modifications may be used for large scale production. Feeding with sugar syrup (1:1 in sugar/water) increases cell acceptance, even when flowers are available.

Mature queen cells, i.e those with larvae four days old (3 days after grafting), must be brought quickly into the extraction room. The open, narrow part of the cells is cut to facilitate and speed up collection. Then the larvae are removed with a pair of soft forceps, taking care not to harm them and contaminate the jelly. The royal jelly is extracted by emptying each cell with a small spatual, by sucking it up with a special moth operated device, with a pump operated device or by centrifugal extraction. Following extraction the cells are immediately ready for another rearing cycle.

The royal jelly must be filtered using a fine nylon net (nylon stockings are excellent) to eliminate fragments of wax and larvae. Metal filters should not be used. The jelly should be placed into dark glass vials or food-grade plastic containers, avoiding any excessive exposure to air. It should be refrigerated immediately. Any material or equipment contacting royal jelly-including hands-must be clean and disinfected using heat or pure alcohol. The laboratory must be kept impeccably clean and extraction should never be done outside or in sunlight.

The commercial production of royal jelly requires a methodical approach, good organization and precise timing. Constant attendance is essential as one day off can eliminate two days of production. In order to have a weekly day of rest (e.g Sunday) no queen cells would be introduced on Thursday, which means that there will also be no collection on the following Wednesday.

These techniques are suitable for both small and quite large enterprises. Depending on the intended market, the approach can be either one of low cost or one in which all collecting, Processing and distribution takes place in highly controlled environments. The latter will result in a product which is better suited for industrial use.

Royal jelly has a limited shelf-life. Early beliefs in the extreme instability of royal jelly activity, based on the alleged rapid loss of the “queen determination” factor have not been confirmed. Since neither the mode of activity nor the actual effects of royal jelly are known, there are no data available on changes in its biological effectiveness on human after long term storage.

Since royal jelly is an emulsified product and not cellular tissue, freezing presents no particular problem and common household freezers can be used.

Like all other bee products, royal jelly has its own microbiological protection and presents few microbiological storage problems when it is in its natural state. This protection however is not absolute and certain hygiene precautions must be observed during production and storage. Hygienic working conditions and clean containers are a minimum requirement, and airtight containers should be used to provide additional protection not only against contamination but also against oxidation.

d) Venom Collection

Early collection methods required surgical removal of the venom gland or squeezing each individual bee until a droplet could be collected from the tip of the sting. Since the early 1960;s, extraction by the electro-shock method has been continuously improved and is now standard procedure.

Different extraction or collection methods result in different compositions of the final products. Venom collected under water to avoid evaporation of very volatile compounds seems to yield the most potent venom. Venom collected from surgically removed sacs showed different protein contents from the collected with the electroshock method.

Venom collection apparatus for placement at different levels within a segmented bee colony structure, said apparatus comprising:

a) A housing member having a front wall, opposing, sidewalls and a back wall and being dimensioned to fit within the segmented colony structure:

b) A frame member removable mounted in said housing and having a central opening therein to permit the movement of bees there through.

c) An array of spaced electrical conductors extending across the opentining in said frame member, said conductors being spaced to permit the passage of bees there through:

d) First access means opening adjacent to at least one wall of said housing member and positioned beneath said frame member to provide an external access path for bees in the colony:

e) Means for establishing a voltage difference between adjacent conductors in said array whereby bees passing through said array from said first access means encounter adjacent conductors and are eclectically stimulated and

f) Collection means removably mounted in said housing member for withdrawal there from and located beneath said first access means and external access path, said collection means receiving venom from bees excited by contact with adjacent conductors in the spaced overlying from member.

The various trap designs stimulate bees by applying a mild electric shock through wires above the collecting tray.

When shocked, bees sting the surface on which they are walking. In some traps, this may be a glass plate or a thin (0.13mm thick) plastic membrane, nylon taffeta or silicon or silicon rubber under which a collecting plate (preferably made of glass) or absorbent tissue receives the venom. Venom dries rapidly on glass plates and can be scraped off with a razor blade or knife. Absorbent tissue is washed in distilled water to extract the venom, which then should be freeze-dried. Collection on glass is generally easier and produces a product which is easier to store, ship and process. During handling of dry bee venom, protective gloves, glasses and dust masks should be worn to avoid any contact with, or inhalation of the highly concentrated venom.

It is unlikely that a bee will eject all the contents of its venom sac, even after repeated stinging. Therefore, typically, only 0.5 to 1.0 jil of venom can be collected per be, with an average of ten stings per bee. This results in less than 0.1 ijg (0.11 jig-Cranes, 1990) of dry venom per bee. Consequently, at least 1 million stings are required to make one gram of dry bee venom.

Collecting be venom requires careful work with the highest degree of cleanliness, since the venom will be injected directly without further processing of sterilization. Protection of the collector against the disturbed bees and highly irrigative dry venom is very important, too. Since people up to several hundred meters away might get stung by the highly irritated bees, further precautions at the time of collection in the apiary must be considered.

When handling dry venom, laboratory gowns, gloves and face masks should be worn to avoid getting venom dust into the eyes and lungs. All equipment should be carefully washed afterwards. Contact between other people and contaminated material should be avoided. People who do not regularly handle bees, who only get stung occasionally or are exposed occasionally to venom dust, run the risk of developing allergies.

Bee Venom, Propolis, Pollen and Royal Jelly Processing Part ONE

Honey bees are the sole sources of honey and bees wax with usual qualities. Honey bees also produce propolis, a gummy substance made from tree sap that has anti-bacterial properties, and royal jelly and pollen for human consumption. Honey bee venom is extracted for the production of anti-venom therapy and is being investigated as a treatment for several serious diseases of the muscles, connective tissue, and immune system, including multiple sclerosis and arthritis

The production process consists of the following operations:

a) Pollen collection

b) Propolis collection

c) Royal jelly collection

d) Venom collection

a) Pollen Collection

Extreme care should be taken that pollen is not contaminated by bees collecting from flowers treated with pesticides. During, and for several days or weeks after treatment of fields or forests in an area of several square kilometers (in a circle of at least 3-42 km diameter) around the apiary, no pollens should be collected. This is independent of the method of pesticide application. Even systemic pesticides have been shown to concentrate in pollen of, for example coconut. Since a pollen pellet is collected from many flowers, even small quantities of pesticides per flower can be accumulated rapidly to reach significant concentrations.

Though pollen pellets are collected before they enter the hive, treatment of colonies for bee diseases, can contaminate the pollen pellets. Though, for example, cleaning of debris from the hive and bees regurgitating syrup, nectar or honey during collection of the pellets.

Pollen pellets are removed from the bees before they enter the hive. There are many designs of pollen traps some easier to clean and harvest, others more efficient or easier to install. The efficiency rarely exceeds 50%, i.e. less than 50% of the returning foragers loose their pollen pellets. Bees are ingenious in finding ways to avoid losing their pellets, like small holes or uneven screens and may even rob pollen from the collecting trays, if access is possible. Under some circumstances, pollen collection methods and regimes may interfere with normal colony growth or honey production. Therefore, standard beekeeping manuals should be consulted for the timing of collections.

Pollen should be collected daily in humid climates but less frequently in drier climates. To avoid deterioration of the pollen and growth of bacteria, molds and insect larvae, pollen should be dried quickly. Ants can remove considerable amounts from pollen traps. Studies indicate that losses can be to 30% in temperate climates.

Pollen needs to be dried to less than 10% moisture content (preferably 5% or 8% according to some laws) as soon as possible after harvesting. A simple method uses a regular light bulb so that the pollen does not heat to more than 40 or 45^oc. For solar drying, the pollen suspended high enough above a pollen itself should be covered to avoid direct sunlight and overheating.

After drying, the pollen needs to be cleaned of all foreign matter. A tubular tumbler out of a wire mash with a fan can clean considerable quantities of pollen pellets. Simpler winning methods can be used too.

Since sunlight, i.e. UV radiation, destroys the nutrient value of pollen, other more subtle characteristics probably suffer worse damage. Storage of dry pollen in dark glass containers, or in dark cool places, is therefore a requirement.

Pollen used for cosmetic purposes should have the same, if not a better, quality than destined for consumption as food. The first quality control is assessment of gross contamination with foreign substances, i.e., parts of bee and hive debris. Further controls might include measurement of moisture content and a bacterial count. Determination of various agrochemicals, including drugs used inside bee colonies is possible and may be required in some circumstances. These analyses require sensitive, expensive chromatographic equipment.

b) Propolis collection

The average production of propolis per colony per year has been described as 10 to 300g but the production depends on the bees, the climate, the forest resources and the trapping mechanism. According to personal observations, it may occasionally be considerable higher. If there is any selection by queen breeders and beekeepers, it has been against heavily propolizing bees, since they make work in the apiary more difficult. Bees which produce larger quantities of propolis could be selected if required. 

Contamination of propolis with wax, pieces of wood, paint and other debris should be avoided. The cleanest collection methods employ special traps placed on top of a hive, below the covers or next to lateral walls inside the hives. Thus bees do not mix as much wax with the propolis and no contamination occur during harvesting. Trap harvesting is also faster and may be more productive. 

Traps are basically screens or special plates with small holes which simulate cracks in the hive walls. Bees try to seal the holes and thus fill the trap with propolis. The most economic trap design is an inner cover with a large hole, covered with regular nylon fly screen, secured in place by the points of nails and a perforated frame. The total area exposed by a screen may have to be varied according to the bees and local conditions. Trap harvested propolis usually fetches a better price because of its cleaner and therefore of better quality.

Light, and in particular air circulation are important to stimulate propolis use. Accordingly, traps placed on top of hives should be covered but the hive cover needs to be propped opened slightly to increase air circulation and to allow in some light. In tropical regions it may be necessary to prevent the entry of too much rain. Also, when using a type of bee sensitive to disturbances or likely to abscond, the lid should not be opened too far otherwise bees might escape. Newly established colonies should be given some time to establish themselves before they are used for trapping.

Propolis is removed from traps by cooling the plastic sheets or fly-screens for a few hours in a refrigerator or freezer. Once cooled, the propolis becomes brittle and can be removed from the screens by simply flexing and brushing them, pulling over a table edge or by using a special high pressure air device. The trap is then ready for re-use.

In general, propolis is fairly stable, but proper storage is important. Propolis and its extracts should be stored in airtight containers in the dark, preferably at less than 10^oc-12^oc and away from excessive and direct heat. For similar reasons, very old propolis from the hive should not be mixed with fresher propolis. Over 12 months of proper storage, propolis will lose very little or non of its antibacterial activities. Alcohol extracts may be stored even longer.

c)Royal Jelly Collection 
     See PART TWO

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Industrial Oxygen Production Process

Aluminum hydroxide production process

Abrasive Cloth Making Process

 

Process Description of Clove Oil Making

Raw Materials

The essential oil content of clove buds, stem and leaves is on average 17%, 6% and 2.5%, respectively.

Water or steam distillations still are popular for the production of clove oil. The first method yields essential oil for perfumery and flavour purposes, and the oil contains 85 to 89% of eugenol. The second method, on the other hand, yields, strong oil, rich in eugenol (91-95% by volume).

Before distillation, the clove buds are milled and must be distilled immediately, to prevent loss of oil by evaporation.

The steam produced in a boiler is introduced into a vessel which contains the buds and water. The buds are located on a grid placed at a certain distance above the level of the water which fills the bottom of the vessel. The water is vaporized indirectly, by steam flowing in a pipe coil submerged by the water. The water vapor plus the distilled oil coming from the evaporator vessel is recovered in a separate water cooled condenser. This mixture flowing out of the condenser is separated by decantation in a Florentine flask, in which two fractions, one lighter, the other heavier, than water are separated. The two fractions must be remixed after water is decanted.

The distillate water should be redistilled to recover all the dissolved oil extracted from the clove by distillation. This process is called cohabation. Finally, the clove oil is packed and dispatched for sales.

Clove oil processing does not cause environmental pollution. The residues of buds after distillation can be dried and used as fuels and their ashes can be used as fertilizers. The water waste after being separated perfectly from the oil does not damage the environment.

Major Equipments

1. Evaporator vessels
2. Condenser (water cooled)
3. Florentine flask
4. Pumps
5. Cooling tower
6. Submersible pump
7. Boiler system Grinding unit

Production of Carbon Brush

Carbon brush is a block of carbon in an engine or generator that conveys current between the moving and the stationary parts. Carbon brushes are used in automobile motor starters, generators, distributors, etc.  It is a product which is replaced frequently.  It is composed of carbon or graphite with or without metal.

The major operations involved in the production of carbon brush include:

-                      Shearing

-                      Finishing

-                      Assembling

-                      Testing

The carbon block imported from abroad is cut into the required sizes.  Circular saw is used for this purpose.  The finishing work is carried out by sanding and finishing machine.  The copper flexible wire, the copper and brush sheets are all prepared to the required specifications so as to fit to the grade and appropriate characteristics of the carbon brush.

The requirement of carbon brushes are good conducting, high contact resistance (on commutators and slip rings), low coefficient of friction, and high durability.

The copper flexible wire and copper and brush sheet are materials required to prepare the brush holding unit.  After the carbon brush is manufactured conductivity testing is carried out by means of a bridge tester.

The strength of the carbon brush is also measured by strength testing machine.  Having completed the manufacturing and final tests of the carbon brush, the product is labeled and packed for market.

Main Materials and Equipments

1. Circular saw 
2. Bench drill (3/4 inches capacity) 
3. Sanding and finishing m/c 
4. Ball press 
5. Conductivity bridge (for testing)  
6. Strength testing m/c 
7. Dies and fixtures

The production process of carbon brush has no adverse impact on environment since the solid wastes that could be regenerated in the production process are recyclable.

Soy Sauce Brewing

Raw Materials

The three main ingredients used in the production of soya sauce are soya bean, wheat, and salt.

Soyabean (or defatted soyabean): the most important raw material for soya sauce protein, is heated by steam so that soya sauce koji of Aspergillus Oryzae will easily work on protein.  The quality and yield (Availability of nitrogen in raw material to product) of soya sauce are swayed by this treatment. High temperature, high pressure, short time treatment will greatly improve the quality and yield of the product. After being steamed, the soya bean is cooled in a cooler down to the designated temperature.

Wheat: another important raw material of soya sauce is heat treated indirectly to produce alfa-starch so that enzyme will work on it easily. Usually heated sand is used for roasting the wheat, then the wheat is cooled in a cooler to the designated temperature, and finally the wheat is crushed by a crusher.

The two kinds of treated raw material are seeded and taken into the koji room. The treatment and humidity are controlled artificially to promote growth of koji fungus, and koji is made in two days. 

Salt: the third raw material of soya sauce, is dissolved in water to make saturated solution of salt. After adjusting the concentration of the saturated solution of salt made it is cooled in a refrigerator to the designated temperature. Then it is mixed with the koji and fermented in the fermentation tank.

The koji and solution of salt fermented in the fermentation tank become moromi (soyabean and wheat which are under fermentation). The moromi is kept under control for a long period of time in a suitable temperature so that it is matured by the action of enzyme, lactobacilli, yeast fungus, etc.

The matured moromi is pressed and separated into raw soya sauce and cake. The raw soya sauce is cooled in a refrigerator and stored in low temperature. The raw soya sauce is sweetened or other additives are added, depending on the tastes of consumers. It is pasteurized by heating and then stored for a fixed period of time for sediment separation. 

Next, the clear soya sauce is further filtered through a filter and made into beautiful, highly fragrant, and tasty soya sauce. Finally, the completed soya sauce is filled in glass bottles or plastic containers by the bottling machine, labeled, and dispatched. The production process does not have any adverse impact on environment.

Raw Materials

1. Raw material storage
2. Soyabean treatment
3. Wheat treatment
4. Mixing and heaping
5. Automatic koji making equipment
6. Koji mixing and transporting
7. Salt water dissolving equipment
8. Moromi fermenting
9. Moromi pressing equipment
10. Raw soya sauce storage
11. Cooling equipment
12. Pasteurization and filtration
13. Automatic bottling equipment
14. Boiler