年产10万吨酸奶设计说明书.doc

airport was built during the war, but for some reason it could not be used then. Last year, however, it came into use. Over a hundred people must have been driven away from their homes by the noise. I am one of the few people left. Sometimes I think this house will be knocked down by a passing plane. I have been offered a large sum of money to go away, but I am determined to stay here. Everybody says I must be mad and they are probably right.Lesson22 A glass envelope 玻璃信封My daughter, Jane, never dreamed of receiving a letter from a girl of her own age in Holland. Last year, we were travelling across the Channel and Jane put a piece of paper with her name and address on it into a bottle. She threw the bottle into the sea. She never thought of it again, but ten months later, she received a letter from a girl in Holland. Both girls write to each other regularly now. However, they have decided to use the post-office. Letters will cost a litt1e more, but they will certainly travel faster. Lesson23 A new house 新居I had a letter from my sister yesterday. She lives in Nigeria. In her letter, she said that she would come to England next year. If she comes, she will get a surprise. We are now living in a beautiful new house in the country. Work on it had begun before my sister left. The house was completed five months ago. In my letter, I told her that she could stay with us. The house has many large rooms and there is a lovely garden. It is a very modern house, so it looks strange to some people. It must be the only modern house in the district.Lesson24 It could be worse 不幸中之万幸I entered the hotel managers office and sat down. I had just lost &50 and I felt very upset. I left the money in my room, I said, and its not there now. The manager was sympathetic, but he could do nothing. Everyones losing money these days, he said. He started to complain about this wicked world but was interrupted by a knock at the door. A girl came in and put an envelope on his desk. It contained &5o. I found this outside this gentlemans room she said. Well, I said to the manager, there is still some honesty in this world !lesson25 Do the English speak English? 英国人讲的是英语吗？I arrived in London at last. The railway station was big, black and dark. I did not know the way to my hotel, so I asked a porter. I not only spoke English very carefully, but very clearly as well. The porter, however, could not understand me; I repeated my question several times and at last he understood. He answered me, but he spoke neither slowly nor clearly. I am a foreigner, I said. Then he spoke slowly, but I could not understand him. My teacher never spoke English like that! The porter and I looked at each other and smiled. Then he said something and I understood it. Youll soon learn English! he said. I wonder. In England, each man speaks a different language. The English understand each other, but I dont understand them ! Do they speak English ?lesson26 The best art critics 最佳美术评论家I am an art student and I paint a lot of pictures. Many people pretend that they understand modern art. They always tell you what a picture is about. Of course, many pictures arc not about anything. They are just pretty patterns. We like them in the same way that we like pretty curtain material. I think that young children often appreciate modern pictures better than anyone else. They notice more. My sister is only seven, but she always tells me whether my pictures are good or not. She came into my room yesterday. What are you doing ? she asked. Im hanging this picture on the wall, I answered. Its a new one. Do you like it ? She looked at it critically for a moment. Its all right, she said, but isnt it upside-down ? I looked at it again. She was right! It was!Lesson27 A wet night 雨夜Late in the afternoon, the boys put up their tent in the middle of a field. As soon as this was done, they cooked a meal over an open fire. They were all hungry and the food smelt good. After a wonderful meal, they told stories and sang songs by the camp fire. But some time later it began to rain. The boys felt tired so they pet out the fire and crept into their tent. Their sleeping-bags were warm and comfortable, so they all slept soundly. In the middle of the night, two boys woke up and began shouting. The tent was full of water! They all leapt out of their sleeping-bags and hurried outside. It was raining heavily and they found that a stream had formed in the field. The stream wound its way across the field and then flowed right under their tent!Lesson28 No parking 禁止停车Jasper White is one of those rare people who believes in ancient myths. He has just bought a new house in the city, but ever since he moved in, he has had trouble with motorists. when he returns home at night, he always finds that someone has parked a car outside his gate. Because of this, he has not been able to get his own car into his garage even once. Jasper has put up No Parking signs outside his gate, but these have not had any effect. Now he has put an ugly stone head over the gate. It is one of the ugliest faces I have ever seen. I asked him what it was and he told me that it was Medusa, the Gorgon. Jasper hopes that she will turn motorists to stone. But none of them has been turned to stone yet!Lesson29 Taxi! 出租汽车！Captain Ben Fawcett has bought an unusual taxi and has begun a new service. The taxi is a small Swiss aeroplane called a Pilatus Porter. This wonderful plane can carry seven passengers. The most surprising thing about it, however, is that it can land anywhere: on snow, water, or even on a ploughed field. Captain Fawcetts first passenger was a doctor who flew from Birmingham to a lonely village in the Welsh mountains. Since then, Captain Fawcett has flown passengers to many unusual places. Once he landed on the roof of a block of flats and on another occasion, he landed in a deserted car park. Captain Fawcett has just refused a strange request from a businessman. The man wanted to fly to Rockall, a lonely island in the Atlantic Ocean, but Captain Fawcett did not take him because the trip was too dangerous.Lesson30 Football or polo? 足球还是水球？The Wayle is a small river that cuts across the park near my home. I like sitting by the Wayle on fine afternoons. It was warm last Sunday, so I went and sat on the river bank as usual. Some children were playing games on the bank and there were some people rowing on the river. Suddenly, one of the children kicked a ball very hard and it went towards a passing boat. Some people on the bank called out to the man in the boat, but he did not hear them. The ball struck him so hard that he nearly fell into the water. I turned to look at the children, but there werent any in sight: they had all run away! The man laughed when he realized what had happened. He called out to the children and threw the ball back to the bank. Lesson31 Success story 成功者的故事Yesterday afternoon Frank Hawkins was telling me about his experiences as a young man. Frank is now the head of a very large business company, but as a boy he used to work in a small shop. It was his job to repair bicycles and at that time he used to work fourteen hours a day. He saved money for years and in 1938 he bought a small work-shop of his own. During the war Frank used to make spare parts for aeroplanes. At that time he had two helpers. By the end of the war, the small work-shop had become a large factory which employed seven hundred and twenty-eight people. Frank smiled when he remembered his hard early years and the long road to success. He was still smiling when the door opened and his wife came in. She wanted him to repair their sons bicycle! Lesson32 Shopping made easy 购物变得很方便People are not so honest as they once were. The temptation to steal is greater than ever before-especially in large shops. A detective recently watched a well-dressed woman who always went into a large store on Monday mornings. One Monday, there were fewer people in the shop than usual when the woman came in, so it was easier for the detective to watch her. The woman first bought a few small articles. After a little time, she chose one of the most expensive dresses in the shop and handed it to an assistant who wrapped it up for her as quickly as possible. Then the woman simply took the parcel and walked out of the shop without paying. When she was arrested, the detective found out that the shop-assistant was her daughter. The girl gave her mother a free dress once a week !lesson33 Out of the darkness 冲出黑暗Nearly a week passed before the girl was able to explain what had happened to her. One afternoon she set out from the coast in a small boat and was caught in a storm. Towards evening, the boat struck a rock and the girl jumped into the sea. Then she swam to the shore after spending the whole night in the water. During that time she covered a distance of eight miles. Early next morning, she saw a light ahead. She knew she was near the shore because the light was high up on the cliffs. On arriving at the shore, the girl struggled up the cliff towards the light she had seen. That was all she remembered. When she woke up a day later, she found herself in hospital.Lesson34 Quick work 破案“神速”Ted Robinson has been worried all the week. Last Tuesday he received a letter from the local police. In the letter he was asked to call at the station. Ted wondered why he was wanted by the police, but he went to the station yesterday and now he is not worried any more. At the station, he was told by a smiling policeman that his bicycle had been found. Five days ago, the policeman told him, the bicycle was picked up in a small village four hundred miles away. It is now being sent to his home by train. Ted was most surprised when he heard the news. He was amused too, because he never expected the bicycle to be found. It was stolen twenty years ago when Ted was a boy of fifteen !Lesson35 Stop thief! 捉贼！Rov Trenton used to drive a taxi. A short while ago, however, he became a bus-driver and he was not regretted it. He is finding his new work far more exciting. When he was driving along Catford Street recently, he saw two thieves rush out of a shop and run towards a waiting car. One of them was carrying a bag full of money. Roy acted quickly and drove the bus straight at the thieves. The one with the money got such a fright that he dropped the bag. As the thieves were trying to get away in their car, Roy drove his bus into the back of it. While the battered car was moving away, Roy stopped his bus and telephoned the police. The thieves car was badly damaged and easy to recognize. Shortly afterwards, the police stopped the car and both men were arrested. Lesson36 Across the Channel 横渡海峡Erna Hart is going to swim across the English Channel tomorrow. She is going to set out from the French coast at five oclock in the morning. Erna is only fourteen years old and she hopes lo set up a new world record. She is a strong swimmer and many people feel that she is sure to succeed. Ernas father will set out with her in a small boat. Mr Hart has trained his daughter for years. Tomorrow he will be watching her anxiously as she swims the long distance to England. Erna年产10万吨酸奶设计说明书目录一、设计说明书第一章 总论第一节 前言1第二节 建设规模及产品方案2第三节 厂址选择概述4第四节 总平面布置情况5第二章 工艺设计第一节 工艺流程设计6第二节物料衡算11第三节车间设备选型14第四节主要生产车间设计15二、附件图1总平面设计图附图1图2设备工艺流程图附图2图3生产车间设备布置图附图3表1设备选择表17表2物料衡算表17一、设计说明书第一章 总论第一节 前言1.1 酸奶简介民以食为天，食以乳为先。牛乳自古以来即被人类饮用，牛乳的组成最为接近人乳，含有人体所需要的全部营养成分，营养最为均衡，在人们的膳食结构中具有其他食品无法替代的地位和作用。由鲜牛乳发酵成的酸乳由于其丰富的营养、特殊的风味、爽滑的质构和良好的生理功能，备受人们青睐。联合国粮农组织（FAO）、世界卫生组织（WHO）与国际乳品联合会（IDF）于1977年对酸乳作出如下定义：酸乳，即在添加（或不添加）乳粉（或脱脂乳粉）的乳（杀菌乳或浓缩乳）中，由保加利亚乳杆菌和嗜热乳酸链球菌进行乳酸发酵制成的凝乳状产品，成品中必须含有大量的、相应的活性微生物。通常根据酸乳成品的组织状态来进行分类，具体可分为凝固型酸乳（发酵过程在包装容器中进行，从而使成品因发酵而保留其均匀一致的凝乳状态）、搅拌型酸乳（成品先发酵后灌装而得，发酵后的凝乳已在灌装前和灌装过程中搅碎而成黏稠且均匀的半流动状态）和饮用型酸乳（类似搅拌型酸奶，但包装前凝块被分散成液体）。饮用酸乳制品对身体有很多益处，乳中许多成分具有很高的营养价值，而且微生物菌群产生的许多代谢产物对人体也极为有益。营养作用：牛奶中乳糖经乳酸菌发酵，其中20%30%被分解为葡萄糖和半乳糖。前者进一步转化为乳酸或其他有机酸，这些有机酸有益于身体健康；后者被人吸收利用，可参与幼儿脑苷脂和神经物质的合成，并有利于提高乳脂肪的利用率。牛奶中的蛋白质经发酵作用后，乳蛋白变成微细的凝乳粒，易于被人消化吸收。酸奶中的磷、钙和铁易被吸收，有利于防止婴儿佝偻病和老人骨质疏松病。牛奶中的脂肪经乳酸菌作用后，发生解离或酯键被破坏，易于被机体吸收。发酵过程中，乳酸菌还会产生人体所必需的维生素B1、维生素B2、维生素B6、维生素B12、烟酸和叶酸等营养物质。缓解乳糖不耐症：乳酸菌产生的乳糖酶能降解牛奶中的乳糖，因此乳糖不耐症患者饮用酸奶就不会出现饮用牛奶时发生的乳糖不耐症，如腹胀、腹痛、肠道痉挛、下泻等。整肠作用：人体肠道内存在有益菌群和有害菌群。在人体正常情况下，前者占优势；当人患病时，有害菌群占优势。饮用酸奶可以维持有益菌群的优势。抑菌作用：嗜热乳杆菌和双歧杆菌不受胃液和胆汁的影响，可以进入肠道，在肠道内存留较长时间。这两种乳酸菌以及在这些乳酸菌影响下生长起来的肠道中的其他乳酸菌，可以产生嗜热乳菌素等抗菌物质，这些物质大都对大肠杆菌、沙门氏菌和金黄色葡萄球菌等有明显的抑菌作用。改善便秘作用：进入肠道中的活的乳酸菌能产生乳酸、醋酸等有机酸。这些有机酸有刺激肠道，加强蠕动的作用，故可以改善便秘。降低胆固醇：牛乳中的乳清酸、乳糖和钙，以及酸奶中存在的羟基戊二酸都有降低胆固醇的作用。抗癌作用：酸奶有抑制3种酶的活性作用，这些酶能引起癌变。另外，酸奶还能激活巨噬细胞，抑制肿瘤细胞，从而起到抗癌作用。1.2 酸奶的发展前景尽管目前我国的乳业市场不断扩大，乳品消费观念在不断提高，但我国年人均乳制品不足20kg的消费量与世界人均100kg、发达国家人均140kg的消费量相比还有较大差距。中国的乳品消费在整体上并没有进入完全理性的轨道。由于营养知识的欠缺，许多人不了解乳品对改善营养、平衡膳食、补钙和增强体质的重要作用，包括对酸乳的认识也不够，因而市场占有率也不太高，不过随着人们对酸乳营养价值的认识，人们对酸奶的态度发生了改变，市场占有份额也逐年增加。随着我国居民生活水平和消费观念的转变，酸奶的消费在以后的较长时间内仍旧会保持迅速的增长势头，这种超常的增长速度在全球酸奶发展史上是非常罕见的，市场前景极为广阔。1.3 本次设计范围本设计主要是年产10万吨酸奶厂车间的工艺设计。设计范围包括厂址选择，制定产品方案，各产品工艺流程的确定，工艺论证，根据物料衡算进行设备选型，对水、电、汽等生产车间必备的生产要素的配给和优化，企业组织及劳动力组成，全厂辅助设施及公用系统，车间生产工艺流程图、车间平面布置图、工厂总平面布置图各一张，经济核算及效益分析。第二节 建设规模及产品方案2.1 生产规模年产10万吨酸奶。2.2 产品方案2.2.1 产品方案确定说明本设计根据产品的种类、包装种类和各产品的产量，并且符合生产向机械化、自动化、连续化发展方向的要求，最终确定了本设计的产品方案。由于酸奶工厂原料基本采用奶牛当日产的牛乳，并且酸奶是消费者每日饮用的产品，因此酸奶工厂全年没有停产时间，按照365日计算。为平衡每月生产的产量，避免出现部分月停产，部分月加工任务过于繁重，结合主要加工酸奶的品种成熟时间情况，初步安排产品生产方案如下（注每月以30天计）：其中玻璃瓶（200g/瓶）和塑料杯（125g/杯）的班产量为50t；屋顶包（500g/包）的班产量为10t；其他品种的班产量均为20t。表1-1 工厂日生产产品方案产品种类包装包装规格灌装机能力产品名称产量（吨/天）凝固型酸奶玻璃瓶200g/瓶12000瓶/小时风味、果料酸奶 6个品种（3个/天）90搅拌型酸奶塑料杯125g/杯12000杯/小时风味、果料酸奶 10个品种（5个/天）8520000杯/小时150g/杯9000杯/小时风味、果料酸奶 6个品种（3个/天）40屋顶包200g/包6000包/小时风味、果料酸奶 10个品种（4个/天）24500g/包121000g/包24合计275表1-2 年产100000t发酵乳制品工厂的产品方案一览表产品名称包装种类一月二月三月四月五月六月七月八月九月十月十一月十二月年产量（t）凝固型酸奶玻璃瓶200g32850搅拌型酸奶塑料杯125g31025塑料杯150g14600屋顶包200g8760屋顶包500g 4380屋顶包1000g8760第三节 厂址选择概述项目厂址选择在蚌埠高新技术产业示范区，蚌埠位于东经11712、北纬3257，淮河中下游，面向长三角，蚌埠是安徽省最大的城市之一，也是安徽省第一个建市的地级市，同时也是安徽省经济命脉，全国重要的交通枢纽，经济腹地十分宽广。跨中国南北分界线，拥有千里淮河第一大港口，是京沪高速铁路一等客站所在地、同时京沪高速铁路由蚌埠火车原上海铁路局蚌埠铁路分局，现上海铁路局蚌埠铁路办事处仍驻蚌埠。蚌埠是中国著名的水陆交通枢扭城市，也是安徽省重要的工业基地。常住人口360万人，其中市区人口近100万人。蚌埠铁路纵横交错，公路如网般密布，临近淮河交通极为便利。此外示范区地势平坦，工程基础条件良好，周围没有污染源等不利于建厂的环境因素。厂址与原料基地之间均为高级公路相通，保证了原料采收期对运输时间的限制。而销售地区也在上述中心城市，便于冷链运输和分销，适于建酸奶加工厂。第四节 总平面布置情况项目占地15000m2，其中生产区占地6000 m2，位于厂区中心；生活区占地1500m2，位于厂区东北角。工厂坐北朝南，从南大门进厂，豁然呈现在眼前的是一个椭圆形的花坛，花坛中心设置有喷泉、假山，这种色彩鲜明、动静结合的搭配，给人一种清新洁净、生机盎然的感觉，烘托出项目产品新鲜、方便、卫生的底蕴，厂区总平面布置见图1。花坛往北便是占地1440m2 的主生产车间，宽敞明亮，布置有现代化的生产线。洗手间、空气净化设备、卫生隔墙等设施一应俱全，全面适应生产的需要。厂区东侧是机修间和锅炉房。厂区西侧布置的是原料库、成品库和办公楼、实验室。工厂的道路均按照工厂设计的标准进行布置，主干道路宽6m，两侧布置有绿化带，环绕整个厂区。并设有人行道和缓冲区，充分做到人车分离、安全生产。厂区的绿化带布置合理，栽种常绿树木和草类，使整个厂区四季如春，显得生机盎然。厂区总平面设计图见附图1。现在食品工厂大多采用轻钢结构的厂房，轻钢建筑材料重量轻、建设周期短，相对建筑成本比较低，同时，轻钢结构厂房相对跨度大，对设备在厂房中的布置影响小，框架结构对于不同功能分隔和以后的变更都非常的方便，因此，本设计也将采用轻钢结构厂房进行设计。我国夏季多为东南风，冬季多为西北风，因此本设计将动力系统和污水处理系统放置在整个厂区的东侧，避免因为风向的问题影响产品质量，同时根据乳制品GMP要求，本设计的厂房具有通排风系统，避免外界的污染进入到车间内部。主车间物流为南北走向，人流为东西走向，因此，在主厂房北侧设置原辅料仓库和容器整理中心，对原、辅料进行储存和瓶、箱等包装容器的初步滔滔和整理.原料经过加工处理，生产出的成品由主厂房南侧经过冷库储存和恒温月台分配后由物流配送系统运送出厂。恒温月台能够避免成品在分配过程中处于高温环境，从而造成对产品质量的影响。主场房人流方向为东西走向，人流经过主厂房一次换鞋、更衣、二次换鞋、消毒池以及风淋间后通过人流通道进入各个生产岗位进行生产。设计中人流路线与物流路线没有交叉，因此能够避免事故和操作失误。第二章 工艺设计第一节 工艺流程设计1.1 凝固型酸奶的工艺流程鲜乳或还原乳 验收 预处理 奶仓牛乳白砂糖 溶解 调配 预热6065 1520MPa 均质 加热灭菌9095、35min 冷却快速冷却至4245直投式发酵剂 接种 灌装直投式菌种：43 发酵46.5h 速冷速冷至1520 冷藏后熟：4冷藏过夜保持冷链贮存或销售1.2 搅拌型酸奶的工艺流程 鲜牛乳 验收 预处理 奶仓 牛乳白砂糖溶解调配 预热（6065） 均质（15MPa） 杀菌(95，5min) 冷却(4245)直投式发酵剂 接种 发酵（终点pH4.6） 破乳、冷却（1520）溶解杀菌 冷却 混合稳定剂、水、白砂糖 均质（15MPa） 冷却（1520）灌装、冷藏保持冷链贮存或销售1.3 操作要点说明（1） 预处理 净化可以除去原料乳中的杂质，使牛乳达到最高的纯净度。为使原料乳中脂肪和无脂干物质之间的比例关系符合制品的要求，可通过闪蒸操作调整其比例关系。（2） 预热 预热一方面可以杀菌，而且由于适当加热，可以使一部分乳清蛋白凝固，提高酪蛋白的热稳定性，以防止灭菌时凝固，并赋予成品以适当的黏度。同时可以钝化酶并降低均质后乳脂肪球的直径，防止均质后的产品中脂肪上浮，增加产品的稳定性。预热温度控制在6065。（3） 均质 均质主要是使原料充分混合均匀，阻止奶油上浮，提高酸乳的稳定性和稠度，并保证乳脂肪均匀分布，从而获得质地细腻、口感良好的产品。均质压力控制在15MPa。（4） 杀菌杀菌目的在于杀灭原料乳中的杂菌确保乳酸菌的正常生长和繁殖，钝化原料乳中的天然抑制物；使乳清蛋白变性，以达到改善组织，提高黏稠度和防止成品乳清西出的目的。杀菌温度控制在95，保温5min进行杀菌。（5） 冷却 冷却主要是为接种的需要。经过热处理的牛乳需要冷却到一个适宜的接种温度，此温度控制在4245内。（6） 接种 接种是造成酸乳受微生物污染的主要环节之一，因此严格注意操作卫生，防止细菌、酵母、霉菌、噬菌体及其他有害微生物的污染。接种时充分搅拌，使发酵剂与原料乳混合均匀。（7） 发酵发酵温度控制在4245，从而为微生物代谢提供最适的温度环境，发酵时间2.5h3h，且期间不搅拌。发酵终点判定：观察发酵乳表面的状态，只要表面呈均匀的凝固样，并且又少量乳清析出，即可初步判断接近发酵终点，再测定pH4.6时即可停止发酵。（8） 破乳、冷却 破碎凝胶体，使凝胶体的粒子直径达到0.01mm0.4mm，并使酸乳的硬度和黏度及组织状态发生变化。搅拌速度不可过快，时间不宜过长。 冷却目的是抑制乳酸菌的生长、降低酶的活性、防止产酸过度、使酸奶逐渐凝固、降低和稳定脂肪上浮和乳清析出的速度。将发酵乳迅速降温至1520。（9） 混合 将经溶解和杀菌的稳定剂、水和白砂糖辅料与发酵乳进行混合。（10） 均质 使混合料液滴微细化，提高料液黏度，抑制粒子的沉淀，并增强稳定剂的稳定效果。均质压力控制在15MPa,均质温度为60左右。均质是为了充分将添加入混合罐中的稳定剂、水和白砂糖辅料混合均匀，从而获得质地细腻、口感良好的产品。（11） 灌装和冷藏采用相应灌装机进行灌装后的成品置于05冷藏12h24h，进行后熟，以产生良好的风味。1.4 酸奶质量标准表2-1 酸奶质量标准项目纯酸牛奶调味酸牛乳、果料酸牛乳全脂部分脱脂脱脂全脂部分脱脂脱脂色泽呈均一一致的乳白色或微黄色呈均一一致的乳白色或调味乳果料应有的色泽滋味和气味具有酸牛奶固有的滋味和气味具有调味乳或果料乳应有的滋味和气味组织状态组织细腻均匀，允许有少量乳清析出果料酸牛乳有果块或果粒脂肪，%3.11.0-2.00.52.50.8-1.60.4蛋白质，%2.92.3非脂乳固体，%8.16.5酸度，T70苯甲酸，g/kg0.030.23山梨酸，g/kg不得检出0.23硝酸盐（NaNO3计）mg/kg11黄曲霉毒素MI,ug/kg0.5大肠菌群MPN/100ml90致病菌（指肠道致病菌和致病性球菌）不得检出第二节物料衡算 根据工厂设计规模、产品方案，通过物料平衡计算，可确定单位时间生产过程中主要原辅料的需求量以及水、蒸汽、能源等流量与耗量，据此就可以计算出全年主要物料、包装材料的采购运输和仓储容量。同时通过物料衡算，还可以根据计算数值经济合理地选择生产设备，并进行车间的工艺布置和各工序劳动力的安排，也是进行经济分析不可缺少的根据。为平衡每月生产的产量，避免出现部分月停产，部分月加工任务过于繁重，结合主要加工酸奶的品种成熟时间情况，初步安排产品生产方案如下（注每月以30天计）：根据酸奶基础配方：2.1 凝固型酸奶鲜牛奶85%，蔗糖7%，稳定剂0.5%，菌种3%，水：余量。凝固型酸奶的日产量为90吨，因此生产凝固型酸奶的原料使用量（以最高使用量）如下：鲜牛奶：90吨*85%=76.5吨