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A STeMPJE analysis of the drum dryer used in the potato flake line manufactured by Tummers Methodic assignment for the course 0E310 product policy. The course is set up to give student more insight into the policy a company needs to develop in order to make a success of a product.
A STeMPJE analysis of the drum dryer used in the potato flake line manufactured by Tummers Methodic assignment for the course 0E310 product policy. The course is set up to give student more insight into the policy a company needs to develop in order to make a success of a product.
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A STeMPJE analysis of the drum dryer used in the potato flake line manufactured by Tummers Methodic assignment for the course 0E310 product policy. The course is set up to give student more insight into the policy a company needs to develop in order to make a success of a product.
Droits d'auteur :
Attribution Non-Commercial (BY-NC)
Formats disponibles
Téléchargez comme PDF, TXT ou lisez en ligne sur Scribd
A STeMPJE analysis of the drum dryer used in the potato flake
line manufactured by Tummers Methodic
Assignment for the course 0E310 Product policy Study: Technology and Society Faculty: Technology Management
Instructor: Marc de Vries
Company: Tummers Methodic
Marcel Bogers (s471944)
August 2002
Preface
Product policy is a very interesting subject in the scope of the study program of Technology and Society at the Eindhoven University of Technology. The course 0E310 Product policy is set up to give student more insight into the policy a company needs to develop in order to make a success of a product. The students are taught that product polity is not merely to think a bit about a product and to introduce it. The course shows there are several ways to look at products and their policies. And within the different kind of product a wide range of different factors are relevant. A specific kind of analysis is given, namely the STeMPJE analysis. The six different factors, Scientific, Technological, Market, Politic, Juridical, and Esthetical, give the basis for the name of this multifactor analysis.
In the scope of this course this assignment is written. It gives a STeMPJE analysis of a drum dryer of the manufacturing company Tummers Methodic from Hoogerheide, The Netherlands. I have written this report with great pleasure and I have learn very much of it, about both the STeMPJE analysis as well as the potato flake line. I want to thank Tummers Methodic, especially everyone who helped me writing this assignment, for letting me write this report about its product. In particular, I want to thank Fons Tummers (president-director at Tummers Methodic) for lending me his `Potato Bible. And also, I want to thank my father, Frank Bogers (account-manager at Tummers Methodic), for all the information he provided me of, and for the recommendations and improvements.
I also want to use this preface to ask the reader to be very careful with this information, because a part of it is confidential.
Then, I want to wish Tummers Methodic all the luck they need to maintain a successful product policy.
Eindhoven, The Netherlands August 12 th 2002
Marcel Bogers Table of contents
Preface ..................................................................................................... 2 Table of contents........................................................................................ 3 Introduction............................................................................................... 4 1. The drum dryer as a part of a potato flake line........................................... 5 2. STeMPJE analysis of the drum dryer.......................................................... 7 2.1 Scientific factors ................................................................................ 7 2.2 Technological factors .......................................................................... 7 2.3 Market factors ................................................................................... 8 2.4 Political and juridical factors .............................................................. 10 Safety regulation ................................................................................ 10 Patent policy ...................................................................................... 10 2.5 Esthetical factors ............................................................................. 10 Conclusions and recommendations ............................................................. 11 Bibliography ............................................................................................ 12 Appendices.............................................................................................. 13 Appendix A: Sample of potato flakes........................................................ 14 Appendix B: Overview of flake line........................................................... 15 Appendix C: Drum surfaces, drum capacities, and steam capacities ............. 16 Appendix D: Separate drum.................................................................... 17 Appendix E: Waste conveyor, preflaker .................................................... 18 Appendix F: Effect of drum speed and solids content of potatoes on potato flake production rate ............................................................ 19 Appendix G: Effect of drum speed on potato flake sheet density.................. 20 Appendix H: Steam measurements.......................................................... 21 Appendix I: CE-logo............................................................................... 22 Appendix J: Risk analysis of a belt conveyor (example) .............................. 23 Appendix K: Picture of moving satelite role scraper.................................... 24 Appendix L: Lay-out of a potato flake line................................................. 26
Introduction
This assignment is part of the course 0E310 Product policy. This course is part of the curriculum of the study Technology and Society at the Faculty of Technology Management at the Eindhoven University of Technology. One third of the grade of the course consists of this assignment.
In this assignment a product has to be chosen, for which a multifactor analysis has to be made. The product in this assignment is a drum dryer, which is a part of a potato flake line. In chapter 1 an overview is given of an entire potato flake line. Special attention will be given to the drum dryer, which is almost at the end of a flake line. Although the drum dryer is the main subject of this assignment, some knowledge of an entire flake line is necessary to understand the characteristics of the drum dryer. In chapter 2 a multifactor analysis is given of the drum dryer. The conclusions will give an overview of the relevant factors, and then some recommendations are given.
This multifactor analysis consists of six major factors, which give an overview of the entire development of a specific product. These factors are: scientific, technological, market, political, juridical, and esthetical factors. In chapter 2 all these factors will be discussed individually. This will be done mainly for the drum dryer. Partly some general characteristics of the drum dryer are important. But in this assignment the development of the drum dryer manufactured by one company is specifically regarded. The company is Tummers Methodic from Hoogerheide in The Netherlands. It is also known as Tummers Machinebouw.
1. The drum dryer as a part of a potato flake line
Potato flakes are dehydrated mashed potatoes made by applying cooked, mashed potato to the surface of a single-drum dryer fitted with applicator rolls, drying the deposited layer of potato solids rapidly to the desired final moisture content, and breaking the sheet of the dehydrated potato solids into a suitable size for packaging. (Talburt & Smith, 1987; p. 557) In appendix A a sample of some potato flakes is attached.
The following steps are essential for the production of potato flakes: peeling, cooking, drying, flaking and packing. First, the potatoes are peeled (and washed). To achieve a uniform process, e.g. during cooking, the potatoes are sliced. Sometimes blanching and cooling may be omitted in the process to achieve the required specifications of the product. The main parts of the input product to make potato flakes are waste streams of the first processes. The cooked product will be mashed in the ricer. Then, the product will be pumped to the drum dryer. From this drum a film of dry product is scraped, and this film is broken up into easily transportable flakes in a pre-flaker. These flakes are broken up in even smaller flakes in the flaker. Then the flakes will be packed. In figure 1.1 a picture of the whole potato flake line is shown. And in figure 1.2 the potato flake process is given schematically. This figure is useful to identify the most important elements of the production process. However, it cannot be applied directly to the manufacturing of a flake line by Tummers Methodic. An overview of the whole flake line from Tummers Methodic can be seen in Appendix B. In appendix L a technical lay-out of such a flake line with all machinery is given.
Figure 1.1 The whole potato flake line (source: www.tummers.nl)
Figure 1.2 Potato flake process (source: Talburt & Smith, 1987; p. 568)
This assignment handles about one of the most important elements of the potato flake line, namely the drum dryer. This drum dryer is the essential step between the feed mash and the dry, and more handily, flakes. The next chapter will go into the drying process more in-depth.
2. STeMPJE analysis of the drum dryer
2.1 Scientific factors
Not much can be said about the scientific factors. Some static models, about e.g. mechanics or pressure, are used marginally. And if there are used, is it mainly as the almost obvious input for technical calculations. On the whole, only technological knowledge is used. The main base for maintenance and development are experiences and measurements. No scientific models are developed.
2.2 Technological factors
As said in the previous section, technological factors are the main basis for the entire process concerning the drum dryer. Tummers Methodic uses several technologies and product to manufacture a drum dryer. Very often the design and manufacturing is based on experience. When the drum dryer is in process as part of a flake line in a plant, it is being controlled almost mainly by observation and experience. The supervisors just look at the product which comes from the drum and when there seems to a problem they make some adjustments. An example. The film of dry product, which is scraped of from the drum, breaks on several places. This could mean the knife is dirty or too little additives are used. Then one, or more, of these factor can be adjusted.
Together with the drying many other processes, like potato peeling and cutting, are part of the whole flake line. The waste streams of these processes provide a valuable and low cost raw material to produce high quality potato flakes. If insufficient waste product arrives from these processes to ensure the full input of the flake line, whole potatoes may be sliced to compensate for any shortcomings. In such a way a constant input to the cooking line is achieved. (www.tummers.nl) This technique is easy to use and to control.
A normal drum is has a diameter of about 2 meter, and it has six applicator rolls. The mash is fed to the top of the drum at a central point. To give an indication of the size and the capacity of these drums, a table with some combinations of diameters and lengths and the surfaces is given in Appendix C. A picture of a drum separate from the flake line can be seen in Appendix D. Some space between the applicator rolls is necessary to allow steam to escape, and for accumulation of mash in the trough between the roll and the drum dryer surface. Now, in short the exact drying process will be discussed. When the drum passes the first applicator roll it takes along a film of mash of approximately 0.05 mm. While it passes the second roll another 0.05 mm is added. At the end, after the sixth roll, a film of 0.30 mm is the result. Between the rolls the film is dehydrated a bit, but the real drying process starts after the last roll. The moisture percentages (usually between 6 and 8 %) can be adjusted with the speed of and the steam input of the drum. And the dried product drops into a preflaker, which breaks the flakes in still relatively large pieces. The waste product falls into a collecting screw conveyor. A picture of a preflaker and a screw conveyor is shown in Appendix E. If the mash is dried well, the dried product will come off the drum naturally, and the drum surface is kept quite clean. Otherwise, the product is scraped off with a knife. The applicator rolls have a distance to the drum that varies from 6 to 10 or 12 mm. These distances can be set, dependent on the quality of the potato. But usually the same distances are used, because the same kinds of potatoes are used. The mash that doesnt stay at the drum is scraped of the applicator roll and falls onto a lower one.
It is very important to maintain a sufficient sheet density. But of course the production rate has to be optimised. Therefore a good combination of drum speed, steam pressure, mash solids, dryer output, and sheet density is necessary. Drum speed was directly proportional to product output but was inversely proportional to sheet density. See Appendix F and G. However, above a certain drum speed, increase in steam pressure could not reduce the product to desired moisture content in a single pass on the drum dryer. (Talburt & Smith, 1987; p. 581) The steam capacities are given in Appendix C. In Appendix H the influence of different combinations of steam and speed can be seen. These are measurements of drum 3 at Mydibel. The diameter of this drum was 2000 mm and the length 5200 mm.
To guarantee quality Tummers Methodic takes educated specialist to the production plant. They also educate people internally.
2.3 Market factors
The potato flake lines have their origin in the United States. The drying principle was recognized as early as 1845. From that time onwards several studies and experiments have been done. From the 1950s lines were developed there. (Talburt & Smith, 1987; pp. 557-559 / www.tummers.nl)
Tummers Methodics policy is very close to the wishes of their (potential) customers. It has distinguished itself by realizing many complete production lines. They start with basic project engineering, detailed machine designs, fabrication of the individual machines, design and building of the control system and end with the installation, commissioning and after-sales service. (www.tummers.nl) And it turns out that their customers line this kind of policy. Tummers Methodic can manufacture an entire production line just out of a single idea. They can care for everything, from the design to the maintenance. And as they say themselves: "The Tummers Methodic drum dryer has been well developed in every detail to enable effective drying of the potato mash. The perfection in design ensures a long lifetime, a maximum yield and product loss that is reduced to the bare minimum. (www.tummers.nl) Tummers Methodic is known for the fine-tuning and the adjustment possibilities of its flake line. It has a high extent of flexibility en it comes towards the needs of the user. Very important with this is the design of the correct lay-out considering expansion possibilities, existing production lines, supply, and waste. (Primeur 2001) So, with their insight in the market demand they should be able to seize a large group of satisfied customers.
Potato flakes share their retail market with potato granules. (Talburt & Smith, 1987; p. 562). The production process is a bit different, but it will be left out of consideration in the scope of this analysis. The flakes and granules have different characteristics, see table 2.1.
Main characteristics of granules Main characteristics of flakes Small degree of free starches High degree of free starches High dumping weight Easy to adjust dumping weight Small adjustments in seize of diameter Easy to adjust seize of diameter Difficult to dissolve in cold water Easy to dissolve in hot and cold water High returns Table 2.1: Main characteristics of granules and flakes (source: Tummers Methodic)
Because of the differences between granules and flakes they have different application areas. Restaurants prefer granules, because of the high dumping weight, resistance to heavy stirring, and a good attraction of boiling water. Flakes, with their good attraction of cold water, are mainly used as a food ingredient, especially in the snack industry. The Pringle, the pile-up-chips of Proctor and Gamble since 1971, has been very important for the production of potato flakes. But in spite of the different characteristics and processing granules and flake share the same application areas too. These common application areas are: Bakeries Preserved food Soups Deep frozen meals Chips Thickeners Meat
For Tummers Methodic the upmost important market is that of potato flakes. These flakes are mainly used as ingredients for Pringles (chips), potato snacks, pastas, tickeners, and soup.
The main customers are: Lamb Weston Meijer 1 (The Netherlands), Mydibel (Belgium), Farm Frites (Belgium and The Netherlands), Hoff Potetindustrier (Norway), CTS (Belgium), Ballymoney Foods (Ireland), Marbo (Yugoslavia), Vorenesh (Russia), Zhangye (China), and Nutricia 2 (Indonesia).
New markets are especially the food industry in Poland, the Czech Republic, Yugoslavia, Russia, and the Middle East. And a very newly developing market is the food industry in China.
Potato World News says about the success in China: "The Dutch engineering company of Tummers Machinebouw, which is well-known to readers of Potato Business World, recently revealed that it has completed two interesting and speedy agreements for flake lines. (Potato World News, 2000)
1 Lamb Weston Meijer has taken over the well-known Danisco Foods Bergen op Zoom (formerly Fri dOr) about two years ago. 2 Nutricia uses the drum not to make flakes, but to process baby food. 2.4 Political and juridical factors
These two factors are taken together because they show a great amount of overlap. These factors mainly consist of two aspects: safety regulation and patent policy. These two aspects will be discussed successively.
Safety regulation
Recent years safety regulation has become a very important issue in the manufacturing industry. Especially within the framework of European integration higher safety standards have arisen. The main term in this field is `CE-marking. These directives form the most important part of the safety measurement that have to taken into account. The goals of the legislator are: safety and health, and free trade.
CE is the abbreviation of `Conformit Europenne. If machinery answers the safely demands of the regulation it is marked with the CE-logo, see appendix I.
It is clear that Tummers Methodic has to take the safety regulation into account in order to fulfil the directives. Tummers Methodic will have to make an effort to do this, and they have never had any problems with it. This effort, of course, costs money, e.g. a manual has to be made and this costs about C 80,-. Another example is simply the wages of the employees who have to take time to consider the marking.
Risk analysis is also an important and compulsory part of the CE-marking. In this risk analysis Tummers Methodic has to make an inventory of latent risks. These risk have to be identified on the basis of seriousness, exposure, possibility, and possibility of aversion. Then the magnitude of the risk is determined and a measure is taken. And after this the magnitude of the risk is determined again in the same way as mentioned above. In appendix J an example of such a risk analysis of a belt conveyor is given.
Patent policy
Because of the confidential information it is difficult to say much about the patent policy. Tummers Methodic has some patents which they use in order to gain a monopoly on the market. Because of the close involvement with the market Tummers Methodic is able to innovate and to apply for patents. A recent patent application is that of an automatically moving satellite role scraper. This moving scraper makes it possible to have more control over the mash scraping from one role to another, and it can also be used as an automatic cleaning system. The speed and scraping time can be programmed by PLC, an operating system. In appendix K two pictures of this scraper are given.
2.5 Esthetical factors
Esthetical factors arent of real importance in the case of the drum drier and the whole flake line. The determinative factors for the design are maintenance, ease of cleaning, safety, and functionality.
Conclusions and recommendations
This multifactor analysis shows that the scientific factors arent really important for the product development of the drum dryer at Tummers Methodic. This also counts for the esthetical factors. The factors of concern are the technological, market, political, and juridical factors. Many technologies, mainly based on experience and measurements, are used to manufacture a drum dryer. Examples are steam pressure (temperature) and drum speed. Because of the insight in the market factors Tummers Methodic has been able to achieve a strong position in the market. Important are the services from design to maintenance, and the high flexibility within the customers need. The political and juridical factors also are important for the development of the drum. The development is constraint by the safety regulations on the one hand, but the patent policy gives a possibility of a very strong market position on the other hand.
The recommendations come down to the fact that Tummers Methodic has to go on with the product policy in the way they are doing it now. They have a very strong market position, but they surely have to strengthen it by exploiting the opportunities in the new foreign market. It can give Tummers Methodic a very strong and steady position in the world market of potato flakes. Of course, Tummers Methodic should always keep considering the safety regulations. Perhaps they even can go further than the CE-marking by setting up an own safety plan. In this way they can even answer some more demands from the market. Finally, innovations will always be essential to achieve and maintain a strong market position. Therefore, Tummers Methodic has to develop and distinguish itself as an innovative manufacturer. Bibliography
Books: Avier ingenieurs (1999). Syllabus CE-markering. Avier, Leende. Sarlemijn, A. & Vries, M.J. de (1993). Ontwerpmethodologie en Productbeleid. Technische Universiteit Eindhoven, Eindhoven. Talburt, William F. & Smith, Ora (1987). Potato Processing, fourth edition. Van Nostrand Reinhold Company Inc., New York.
Magazines: Potato Business World 2000 (January/February): Chinese $6m success p. 3, Volume 8 Primeur 2001 (nr. 21) pp. 57-58
Websites: http://www.tummers.nl
Brochures: Tummers Methodic
Appendices
Appendix A: Sample of potato flakes Appendix B: Overview of flake line Appendix C: Drum surfaces, drum capacities, and steam capacities Appendix D: Separate drum Appendix E: Screw conveyor Appendix F: Effect of drum speed and solids content of potatoes on potato flake production rate Appendix G: Effect of drum speed on potato flake sheet density Appendix H: Steam measurements Appendix I: CE-logo Appendix J: Risk analysis of a belt conveyor (example) Appendix K: Picture of moving satellite role scraper Appendix L: Lay-out of a potato flake line
Appendix A: Sample of potato flakes
Appendix B: Overview of flake line
Appendix C: Drum surfaces, drum capacities, and steam capacities
LET OP: Stoominput is afhankelijk van drumsnelheid en totale hoeveelheid puree op de drum. Een overladen drum (te veel puree op de rollen) geeft duidelijk een hoger stoomverbruik dan een drum met voldoende puree op de rollen. Een stilstaande drum, zonder puree, met een inwendige maximale stoomdruk (11.0 bar) heeft nagenoeg geen stoomverbruik. (Source: Tummers Methodic) Appendix I: CE-logo
Appendix J: Risk analysis of a belt conveyor (example)
Appendix K: Pictures of moving satellite role scraper