Intuitive process creation 5M of chemical engineering

5M of chemical engineering

1. Process Creation by IntuitionProcess Creation by Intuition

2. Man learn in three ways….
1
st
, through imitation, that’s the easiest,
2
nd
, through experience, that’s the hardest,
3
rd
, through meditation, that’s the noblest

3. Why did you choose
Chemical Engineering?

4. Each of us have some chemical Each of us have some chemical
engineering (i.e., process design) engineering (i.e., process design)
experience!!!experience!!!
….Believe it, or not…

5. Basic Needs: Basic Needs:
Any example?Any example?
•E.g. Food?
•Shelter?
•Clothing?
•Medication?
•Transportation
•Cosmetics
• …….

6. Basic Needs (Physical)Basic Needs (Physical)
•Food
•Clothing
•Shelter
Health &
Medication

7. Other NeedsOther Needs
•Transportation
•Cosmetics/Cosmeceuticals

8. How to get them?How to get them?
•Buy,
Let’s try to make all the things
that we could make!……
Make !
or

9. Key Terminology-Chemical Key Terminology-Chemical
EngineeringEngineering
..is the field of study that
involves the process of
converting resources into
value-added products

10. What is Chemical Engineering?What is Chemical Engineering?
..is the field of study that involves the process
of converting resources into value-added products
through the application of basic sciences (math,
chemistry, physics and biology) and engineering
principles for the development, design, operation
and maintenance of processes
Mathematics
Chemistry
Physics
Biology
Economics
Natural Gas
AirEnergy
Minerals
Plants/Crops
Petroleum

11. Let’s start with the Let’s start with the
most basic need!most basic need!
Example of food as a basic need:
Rice….Let’s make “Biryani Rice”

12. The 5M of Converting Resources
to Value Added Products in
Chemical Engineering
Mini Project: Create a Process to
Produce e.g. Biryani Rice, Bread,
cookies, cakes and etc
Using…..

13. 5M’s of 5M’s of
Chemical EngineeringChemical Engineering
•Materials – ingredients and the product (what,
how much, where, cost) ?
•Method (steps...any recipe? Own recipe?...or
process (of making..))
•Machinery/Tools/Equipment (what, how big?,
how many, where, cost, any tools already
available?, any new one? limitations)
•Manpower (skill required? how many? who?, who
to do what (job-spec)?
•Money (net income?)
We need 5M to convert resources into VA products!

14. Some Key TerminologiesSome Key Terminologies
•Create Steps = Synthesise/Design a Process
•Recipe/Steps = Methods, Processes/Operating
Procedure
•Tools = Equipment, Unit Operations
•Variables = Process Conditions
•Net income = Gross Profit/Profitability
Analysis
•Recipe Improvement = Debottlenecking,
Process Improvement, Optimisation

15. Methods (Recipe)Methods (Recipe)
•Steps involved – e.g. wash, heat, mix, stir,
cool)
•Key variables for each step
–Amount of each material…i.e composition
–Temperature? Pressure? Additives? Colour? Smell?,
–Duration?

16. The 5M of Chemical
Engineering
Student Project:
Create a Process
Manufacture Bahulu
Kemboja

17. ““Bahulu KembojaBahulu Kemboja””
•Introduction
–Also known as “Kuih Bakar’
–Traditional ‘kuih’
–Pandan flavour
–Home based business
–Market demand wide; morning breakfast,
gathering, official function etc.
–Prod. development; how to make the ‘kuih’
last longer, taste good with competitive price.

18. M1-MaterialsM1-Materials
Raw Materials:
 Pandan Leaf
 Sesame Seed
 Flour
 Sugar
 Coconut Milk
 Eggs
 Water

19. STANDARD OPERATING PRACTICE FOR STANDARD OPERATING PRACTICE FOR
BAHULU KEMBOJABAHULU KEMBOJA
PROCESS METHOD
BLENDING
- Crushing
- Filtration

-Pandan leafs to be cut to small pcs
-Transfer cut pandan leaf into blender jar
- Pour 700ml water into blender jar
- Blend few minutes until all pandan leaf crushed
- Pour the blended pandan leaf into plastic container by pass
through plastic filter
M2-Methodology

20. M2-MethodologyM2-Methodology
PROCESS METHOD
MIXING
- Pre-Heating

-Mixing
-Transfer pandan jus and coconut jus until steel bowl
- If mixed pandan and coconut become light green, add 1-2
tea spoon of green color flavor.
- Heat until its boil
- Pour the heated pandan extract and coconut milk into the
blender jar and transfer all the flour, sugar and eggs
- Blend few minutes until its properly mix
-Transfer into plastic bowl

21. M2-MethodologyM2-Methodology
PROCESS METHOD
MOULDING
- Mould Pre-
heating
- Pour 1 tea spoon of cooking oil until the steel mould.
- Heat on gas oven until oil boil
- Pour mixed cake ingredient into the mould using plastic jar
until mould level
- Distribute sesame seeds evenly on the surface

22. M2-MethodologyM2-Methodology
PROCESS METHOD
HEATING
(BAKING)
- Switch on oven and set oven temperature knob at desired
temperature.
- Transfer all the mould into the oven
- Set oven timer knob at desired time for bottom heating
- Switch on top heater once bottom heating complete.
- Heat top surface until its turn to brownish color.
- Transfer all the mould out from oven when the top heating
complete.

23. Knife
Blender
Plastic filter
Steel bowl
Mould
Oven
Spoon
M3- Machinery/Equipment

24. M4-ManpowerM4-Manpower
MAN POWER QUANTITY PRICE COST / UNIT
Wages 1 man RM60. 00/day 3.85

25. M5-Money: CostingM5-Money: Costing
RAW MATERIAL QUANTITY (5
units OF CAKE)
PRICE, RM COST/UNIT
(5 units OF
CAKE)
Flour 350g 1.30/kg 0.455
Sugar 500g 1.50/kg 0.750
Pandan extract 20-30leaf 1.00/100leafs0.20 – 0.30
Coconut milk 700ml 1.00/L 0.70
Eggs 4nos 0.2/nos 0.80
Sesame Seeds 10-15g 3.00/kg 0.03 – 0.045
Oil 5-10ml 9.00/5kg 0.009 – 0.018

26. UTILITIES QUANTITY PRICE COST / UNIT
(5units OF
CAKE)
Electricity 3.33KW 0.218/KWH 0.72594
Fuel Gas (LPG) 50 – 100g 18.50/14kg tank0.06 – 0.13
Water 700ml 0.57/m
3
0.0004
Selling price = RM2.70/nos x 5 units = RM13.50
GROSS PROFIT MARGIN
= RM5.72 (73.65%)
TOTAL COST, RM
(5units OF CAKE)
7.77
M5-Money: Costing

27. Semi-Batch ProcesSemi-Batch Proces
Application: Application: Intermediate scale Intermediate scale of productionof production
Pandan Juice
Coconut Milk
Heated CSTR
(Primary Mixing)
Electric Heating
Source
Flavour
Oven
(Baking)
To Packaging
Sugar
Flour
CSTR
(Secondary Mixing)
Moulding
Conveyor
Eggs
Preheated
Mould

28. ContinuousContinuous (Automatic) (Automatic)
ProcessProcess
Application: Application: Large scale Large scale productionproduction

29. Group Mini Project (1/2)Group Mini Project (1/2)
Your team are chemical engineers with a very business minded
way of thinking.  Your team has decided that you want to
commercialize one of your daily needs item in mass production. 
1) Identify the daily needs item and evaluate 2 ways of making
it in terms of the 5 M criteria.  Provide details for each M of
the 5 Ms. Use your chemical engineering instinct and daily
experience to create a process to make this item.
2) Identify also the market needs and demands for this daily
item in Johor, Malaysia or globally.
3) Select only one way of making the item that your team have
evaluated previously and explained your team reasons for making
the decision.

30. Group Mini Project (2/2)Group Mini Project (2/2)
4) Scale up the 5 M process to 1000 times per day production from
the current recipe’s.   Recalculate the 5 M and find ways to reduce
further the cost of the production. 
E.g. Can any by products be recycled or recovered or sold to different
companies? Do you need to buy 1000 of the same equipment or you can work
efficiently by making process scheduling?
5) Specify other key design considerations/ factor and provide details
for each of these factor to convert the home-based process into
commercial production. (E.g. control systems/automation)
6)  Identify, for each layman equipment, what is the name of the
equipment in an industrial scale?  (E.g. oven is called furnace in an
industry)  Attached the pictures and descriptions of the equipment as
well.
Your team are required to present and submit the final report to a
board of directors in order to secure funding to initiate this project.  

31. Thank YouThank You