Nigerian Universities Research Topics: PROPOSED CORN MILLING FACTORY UBIAJA (TOWARDS EFFECTIVE PLANNING FOR HYGIENE AND FIRE SAFETY)

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TABLE OF CONTENTS

Title page

Certification

Dedication

Acknowledgement

Table of contents

List of figures

List of tables

Abstract

CHAPTER ONE

1.0 Introduction

1.1 Preamble

1.2 Significance

1.3 Research areas

1.4 Aims and objectives

1.5 Methodology and data source

1.6 Expected contribution to knowledge

CHAPTER TWO

2.0 Literature review

2.1 Preamble

2.2 Corn milling systems

2.2.1 Dry milling

2.2.2 Wet milling

2.3 Vertical and horizontal processing

2.4 Proposed milling operator

2.4.1 Corn reception/pre cleaning

2.4.2 Corn cleaning

2.4.3 Temperily

2.4.4 Degerming

2.4.5 Polling and grading

2.4.6 Milling

2.4.7 Finished products

2.4.8 Quality control

2.5 Agricultural potential of Ubiaja

2.5.1 Physical setting (topography)

2.5.2 Climatic condition of Ubiaja

2.6 Corn preservation

2.6.1 Insect activity

2.6.2 Mould growth

2.6.3 Moisture accumulation

2.6.4 Storage adour

2.6.5 Germination

2.6.6 Weight of grain

CHAPTER THREE

3.0 Case studies

3.1 Relevance of case studies

3.2 Ideal flour mills Kaduna

3.2.1 Brief history

3.2.2 General planning

3.2.3 Administrative building

3.2.4 Production

3.2.5 Workers facilities

3.2.6 Maintenance unit

3.2.7 Hygiene

3.2.8 Fire safety

3.2.9 Merits

3.2.10 Demerits

3.3 Northern Nigeria flour mill, Kano (Ewu Flour Mill Ewu Edo State)

3.3.1 Brief history

3.3.2 General planning

3.3.3 Administrative building

3.3.4 Workers welfare

3.3.5 Production

3.3.6 Maintenance

3.3.7 Hygiene

3.3.8 Fire safety

3.3.9 Merits

3.3.10 Demerits

CHAPTER FOUR

4.0 Hygiene in industrial buildings

4.1 Introduction

4.2 Contamination during reception/storage of raw material

4.3 Contamination during processing

4.4 Contamination during warehousing

4.5 Design consideration

4.5.1 General planning

4.5.2 Changing rooms

4.5.3 Waste disposal

4.5.4 Warehouse design

4.5.5 Production hall design

4.5.6 Gilo design

CHAPTER FIVE

5.0 Fire safety in industrial buildings

5.1 Introduction

5.2 Characteristics of fire

5.2.1 Fire triangle

5.2.2 Origins of fire

5.2.3 Phases of fire

5.3 Fire prevention consideration

5.3.1 Site planning

5.3.2 Structural materials

5.3.3 Segregation

5.3.4 Ignition source

5.3.5 Ventilation

5.3.6 Explosion control

5.4 Fire suppression consideration

5.4.1 Fire control and suppression

5.4.2 Fire escape

5.4.3 Fire points

5.4.4 Smoke control

5.5 Fire detection

5.5.1 Heat detectors

5.5.2 Smoke detectors

5.5.3 Flame detectors

5.5.4 Fire alarm system

5.5.5 Sprinkler system

5.6 Fire extinction equipment

5.6.1 Dry sand, water and fire blankets

5.6.2 Portable chemical fire extinguishers

5.6.3 Automatic sprinklers

CHAPTER SIX

6.0 The site

6.1 Edo State as the location

6.2 Ubiaja as the site

6.2.1 Availability of raw materials

6.2.2 Economic factors

6.2.3 Transport facilities

6.2.4 Manpower resources

6.2.5 Siting and location with respect to the town

6.2.6 Building condition and running of the factory

6.3 Climate data analysis

6.3.1 Rainfall

6.3.2 Temperature

6.3.3 Relative humidity

6.3.4 Sunshine

6.3.5 Physical setting (topography)

6.4 Site analysis

6.4.1 Topography

6.4.2 Vegetation

6.4.3 Micro-climate

6.4.4 Utilities

6.4.5 Accessibility to site

6.4.6 Shape of site

6.4.7 Man-made structure

6.5 Site concept

CHAPTER SEVEN

7.0 Design formulation

7.1 Problem definition

7.2 Design brief development

7.2.1 Administration

7.2.2 Production

7.2.3 Workers welfare facilities

7.2.4 Auxiliary services

7.2.5 Staff welfare

7.3 Schedule of accommodation

7.3.1 Administrative staff

7.3.2 Production

7.3.3 Staff welfare

7.3.4 Auxiliary staff

7.4 Schedule of accommodation

7.4.1 Administration

7.4.2 Production

7.4.3 Workers welfare

7.4.4 Auxiliary services

CHAPTER EIGHT

8.1 Design concept

8.2 Environmental impact analysis

8.3 Design appraisal

8.4 Conclusion and recommendation

CHAPTER ONE

1.0 INTRODUCTION

1.1 PREAMBLE

The technology of agro-allied industrialization is expanding the world over, due to the dare need to feed an increasing population, particularly in urban areas. Through processing perishable farm products are converted to staple foods that are stored and shipped to distant markets. Food processing emphasizes mass production, quality control, effective processing techniques and desired products, for the consumer. According to United Nations estimate (1990), the world’s population of about 3.5 billion will rise to 6.5 billion, in the next 35 years. This crisis the question of how to meet the food demands of the rapid population growth. The United Nations has warned developing countries, particularly Africa, to increase food production, which at present, is grossly inadequate.

Nigeria with a population of about 90 million people was until the late 1960’s when oil was discovered and exportation commenced dependent on agriculture as the main export career. It was during the oil boom of 1970’s that agriculture was pushed to the background. By late 1970’s there was price fall in the global oil market, resulting in poor revenue returns for oil producing countries. Consequently, Nigeria balance of payment became deficient, hence payment for commodities goods and services that could be grown, manufactured or acquired locally became a source of concern to government it was in response to the realities of the global economic recession that Nigeria commenced a programme of mass agricultural production, during the Olusegun Obasanjo regime. In the same vein, the present federal government has made the highest budgetary allocation to the agricultural sector, in the recent budget. There is sound economic and social justification in enhancing agro-allied industrialization of a nation as the determinant of sound agricultural base ties in industrialization. Industrial development is essential in the enhancement of self sustenance and economic growth.

This thesis titled ‘corn milling factory Ubiaja (towards effective planning for hygiene and fire safety)’ seeks to use planning as a tool for the enhancement for hygiene and fire safety in food processing. It will attempt to address the seasonal effect of harvest by the utilization of an effective storage system for uninterrupted supply of grains to the factory. The project shall promote and encourage demand for corn thereby motivating the farmers to increase production.

Ubiaja in its own little way, with major part of its population been farmers, produces corn. Unfortunately, converted attempts are made to utilize the abundant local materials by establishing agro-allied industries, within the state. The farmers are compelled to sell their grains at the heat of harvest, at very low rates, since there are neither adequate storage facilities nor industries to process their grains. Also severe post harvest losses have continue to deter the farmer from accelerating production. If efforts are not made to enhance or encourage farmers by achieving adequate handling, storage and processing of the grains, there will continually be more perishable products are reduced production.

Food production aimed at optimum hygienic conditions is attained and maintained sufficient thought and adequate design consideration of the 3entire processing system. Considerable attention must be given to environmental conditions during transportation, processing and storage of the foods, so that they are not contaminated by micro-organism, insect, rodents, and other chemical materials.

Fire safety in industrial buildings also call for concern in view of the attendant fire risk to the factory and the occupants. The burning issues of fire precaution any and fighting, rest upon the shoulders of the designer. The project shall apply adequate fire safety considerations in harmony with the design.

1.2 SIGNIFICANCE

- The project shall highlight and recommend solutions for the enhancement of hygiene in food processing.,

- It shall contribute to the diversification of Nigeria economic base.

- The work shall be of immense contribution reviving agriculture, hence promoting agro-allied industrialization.

1.3 RESEARCH AREAS

This thesis shall be restricted solving agricultural problems in the following areas:

i. Consideration of hygiene and sanitary requirements.

ii. An investigation into fire safety.

iii. Provision of functional facilities for effective working conditions of the factory.

These facilities shall include office blocks, production halls, storage units, auxiliary facilities and services.

1.4 AIMS AND OBJECTIVES

The federal government of Nigeria intends to explore other revenue yielding ventures to stop the over dependence promising in this respect as the nation is blessed abundantly with vast fertile land. Below are the main aim and objectives of the project:

- Creating hygienic environment and preventing contamination of finished products.

- Forestation and controlling any outbreak of fire within the factory complex.

- Milling the corn produced in Ubiaja and other neighbouring places and states of the federation.

- With the actualization of this project, the farmers will have good and ready market for their grains hence the motivated to step up cultivation.

- The project shall aim at providing effective storage system which will serve not only the factory but the farmers who may bring their grains for storage, instead of hurried by disposing of their grains at low rates.

- This project shall aim at meeting Nigeria rising demand for agro-allied industrialization.

- The proposed factory shall ensure high quality products.

- It shall generate employment opportunities in areas of production, storage, processing and marketing.

1.5 METHODOLOGY AND DATA SOURCE

Hygiene and fire safety in industrial buildings are to be investigated through the examination of various construction materials and application of hygiene and fire safety regulations.

The following methods shall be used in obtaining information/data necessary for the research work:

- Field work: This involves site visits to existing corn milling factories in the country and a study of those outside the country. There will be visits to the proposed site to identify the features on site.

- Printed data: This shall involve gathering literature on corn milling technology with particular reference to hygiene and fire safety, such literature could be obtained from journals, seminar papers, published and unpublished text.

- Indepth interview: This involves gathering information through interviews with experts in corn milling. Hygiene and industrial fire safety, so as to be acquainted with the technological problems involved.

1.6 EXPECTED CONTRIBUTION TO KNOWLEDGE

- The thesis shall be a necessary aid for the enhancement of hygiene and fire precautionary and fighting measure in industrial buildings.

- It shall broaden the knowledge of readers who may need to buttress their knowledge on agro-allied industrialization.

- It shall highlight the use of industrialization at achieving optimum production and varied products.

CHAPTER TWO

2.0 LITERATURE REVIEW

2.1 PREAMBLE

Corn known botanically as zeamays linnacus, is a green plant that produces one of the worlds most versatile seed crops. It belongs in seeds of cultivated grasses and is a cross-pollinated, manoecious plant with the male and female flowers located in different inflorescence of the same stalk, (Ingleth, 1970). In the United States, corn evolved as an indispensable food staple since the colonial pioneering days and has remained the largest cereal in the United States agriculture. The origin and dependence of corn on man for perpetuation is shrouded in mystery. The continued development of corn is enhanced by spaced planting of the seed by man over the years.

Corn is a food staple in many parts of the world because of its versatile food uses, grain size, good yield, ease of cultivation and preparation. The art and technology of corn processing is associated with the United States who are the leading producers of corn. Early American use of corn was to boil, parch and grind the kernels. This required laborious effort to prepare the products. Today, technological progress has made it possible for corn to be processed into different food products, which require less time for preparation.

2.2 CORN MILLING SYSTEMS

In planning for efficient milling system, the capacity of seed flow type and cost of equipment, size and type of building needed and source of adequate and dependable power should be of concern to the Designer. Basically, there two methods of corn milling: Dry and wet milling system. Corn is wet milled to obtain starches, syrups and sweeteners. For dry milling, the major products are flaking grits, brewer grits, corn meal and corn flour.

2.2.1 DRY MILLING

Corn is dry milled by two general system-degerming or non degerming. The non-degerming method produces meal with little or no removal of germ, producing rich, only flavour. For degerming method, corn is degermed without prior addition of moisture to produce grits, meal and flour (Asiedu, 1990 p. 154).

2.2.2 WET MILLING

This process commences with soaking the kernels to prepare them for subsequent separation into various components. Separation of the components is achieved by grinding, screening and centrifugal action, to obtain starch, oil and feed (ibid p. 151).

2.3 VERTICAL AND HORIZONTAL PROCESSING

The dry and wet milling process could be carried out by vertical or horizontal circle. In vertical process, use made of gravitational force in material transportation. Corn is carried by elevator to the top floor and emptied into large holding bins. Milling machines are placed in a vertical series on lower floors and seed flow from one machine down into the next by gravity, until processing is completed and corn is bagged on the ground floor. This system has the advantage of minimum expense for elevating equipments but building costs and supervision problems are undesirable factors.

In horizontal processing, corn is moved from one machine to the next by elevators placed between the machines. The advantages of this system over the farmer are that the building risks are much less, while supervision and maintenance are better enhanced.

2.4 PROPOSED MILLING OPERATION

From the researchers pre-feasibility study, a dry milling plant that will mill corn into grits, meat and flour, will be more viable than a wet milling plant that produces starches, oil and feed, hence a dry milling system is recommended.

This milling operation consists of the following stages:

i. Corn reception/pre-cleaning

ii. Corn cleaning

iii. Tempering

iv. Degerming

v. Rolling and grinding

vi. Milling

vii. Finished products

viii. Quality control

2.4.1 CORN RECEPTION/PRE-CLEANING

The corn which is brought for milling may contain some impurities from the field, during storage or during transportation to the factory. The impurities may be vegetable, animal or mineral matter. These impurities are removed by the use of wire mesh screen which is mounted about the reception pit. Hence all non-grain particles, partially those bigger than the grain size are retained by the mesh. The corn that passes through the mesh from the reception pit is transported by chain conveyors into bucket elevators, which convey the corn into in-take silos.

However, if the corn is not dried enough, it is taken through a drier chamber which dries the corn as required before storage. Also if the corn is infested by termites, it is treated to anti-termite infection before storage.

2.4.2 CORN CLEANING

From the in take silo, the raw material is moved through bucket elevators to a cleaning unit which removes impurities found in the corn, by the use of magnets, milling separators, scorer aspirators, dry stone or specific gravity table and electrostatic separator. 3 products are obtained at this stage viz the over tail (big non-grain particles), the offals (fine particles) and the required corn.

2.4.3 TEMPERING

Tempering is the addition of moisture to corn in controlled amounts to achieve a particular milling operation. For this milling system. It shall be increased to 14% and allowed to stabilize for about 16hours.

2.4.4 DEGERMING

Degerming is done by the removal of the hull, tip cap and germ from the endosperm. This ensures maximum yield of corn, with low fibre content and low fat content.

2.4.5 ROLLING AND GRADING

This process further releases germ and hull from the endosperm by the use of corrugated roller mills separation of a single stock (endosperm particles) into two or more groups according to particle size is achieved. This process produces a number of products which include large, medium and fine homing germ roll stock and meal.

2.4.6 MILLING

Milling is done on roller mills whose typical flow contains as many as 16 distinct stages, all using fluted rolls. The products are sifted in plain sifters. The mill is divided into a series of break section, reduction and quality rolls. The break system releases the germ as intact particles and cracks the longer grits to produce grits of medium size. Grits, meal and flour are obtained as products from the milling process.

2.4.7 FINISHED PRODUCTS

The finished products are stored temporarily in in-side silos. When bagging is required, the products are released from the inside silos into the automatic bagging machines for bagging and sewing of the bags. The bagged products are then stored in ware houses, ready for marketing.

2.4.8 QUALITY CONTROL

Tests are carried out from the milling system to ascertain the quality of the grains and the milled products. These tests include protein tests, sedimentation tests and physical tests.

2.5 AGRICULTURAL POTENTIAL OF UBIAJA

Ubiaja is blessed with abundant agricultural resources. It is known for producing food crops to cater for the needs of its people. This is because it has abundant fertile land through out the nook and cranny of the place. Here agricultural potentials have been influenced by her privileged location on a plateau within the forest zone with patches of savanna features of sporadically scattered scenes of grassland. Being at the lower part of the plateau, the area has outlets as streams, springs for the subterranean water which can aid an all year farming for the production of corn. The main crops known in Ubiaja are rubber, oil palm, corn, cocoa, yam, cassava, rice and plantain sugar cane, cashew, oil palm (and its derivative products), groundnuts, soya beans, tomatoes cotton and tobacco are also produced. Fruits like pineapples, coconuts, oranges, avocados, as well as green leafy vegetables, all grow abundantly in the land.

However optimum production of the farmers is hampered by lack of adequate storage facilities, poor renumeration for their yield during peak harvest periods and lack of industries to purchase and store or will their grains. On her part the local government is committed to encouraging mechanized farming, liberal credit facilities and subsidized input facilities to the farmers.

2.6 CORN PRESERVATION

The preservation of corn is effectively enhanced by the charging of air or gas by exposing the corn to the chemical purifying action of air. This method called aeration, ensures that the germination of seed crop is preserved. The airflow rate for aeration is between 7 and 10 per ton, which is moderate where grains are in on-floor stores, low volume ventilation using small number of fans is enough. During aeration the ambient air temperature should not exceed the required grain temperature. Also the relative humidity should be such that moisture accumulation does not occur.

Immediately the grain is brought into the silo, it should be aerated for about one day. Thereafter, depending on the temperature and moisture content tests, the aeration fans are run for 8 to 10 hours per week.

There should be no stepping of walls of the silos in contact with the grains, so as not to hinder the free flow of grains and free movement if cleaners. Cleaning of the silos is done by the upward and downward movement of brushes which clean the walls of the silos. The brushes are held in position by a collection of spakes. Suction fans are amount on the roof of the silos to draw up the air from the bottom of the silo to the outside.

The setting of the power of the pumping machine, determines which compartment of the silos is filled.

The period low volume ventilation of the grains ensures the followings:

i. Reduction of insect activity

ii. Retardation of mould growth

iii. Prevention of spoilage by moisture accumulation

iv. Prevention of storage odour

v. Prevention of germination

vi. Increasing weight of grain

Moisture content	To prevent heating and mould growth	To prevent heating by insects	To Preserve Germination for 8 months
	⁰C ⁰F	⁰C ⁰F	⁰C ⁰F
17%	13 55	Below 17 63	10 50
18%	11 52	Below 17 63	8 46
19%	9 48	Below 17 63	7 45
20%	8 46	Below 17 63	5 41
21%	6 43	Below 17 63
22%	5 40	Below 17 63

Table 1

Safe Storage Temperature of Grains.

Moisture content	Relative Humidities percent at the Temperature States
19%	84%	86%	87%
18%	81%	84%	83%
17%	76%	78%	79%
16%	71%	75%	76%
15%	66%	69%	71%
14%	59%	63%	65%
13%	53%	59%	59%
12%	47%	50%	52%

Table 2

Equilibrium Moisture Contents of Grain at Varying Temperatures and Relative Humidities.

2.6.1 INSECT ACTIVITY

Insect reproduction does not take place at temperatures below 60⁰F. however, grains which are stored at temperatures approaching, 70⁰F can be not bed for insect growth. Consequently, temperatures in the silo should be regulated by aeration so as not to exceed 60⁰F in order to cut off insect infection.

2.6.2 MOULD GROWTH

At harvest, the temperature of corn is about 75⁰F. This temperature, with moderate moisture content is conducive for rapid mould growth. When this temperature is brought down and estimated to an average ambient of about 50⁰F, mould growth is largely cut off.

2.6.3 MOISTURE ACCOMMODATION

This corn close to the walls of silos and near the surface tend to be cooled by ambient conditions, while that at the centre remains warmer. When heat migrates from the warmer to cooler areas and when warmth reaches the cooler parts, the moisture latent in it condenses, thereby resulting in the accommodation of condensation on the top surface or against the walls. By Aeration, the grains are cooled uniformly thereby forestalling moisture accumulation.

2.6.4 STORAGE ODOUR

Aeration ensures the freshness of corn by retarding mould and insect growth, as well as preventing the sourness of fermentation. Grains which undergo regular aeration in the silos, retain their fresh smelling odour, thereby winning market acceptance.

2.6.5 GERMINATION

Since normal grains retain the condition to which they are put into the silo, germination is preserved.

2.6.6 WEIGHT OF GRAIN

Aerated grains can be stored at 18% moisture content, instead of 13% to 14% prescribed for unventilated stores. This has the advantage of preventing loss of about 501b in every ton of harvested grain.

CHAPTER THREE

3.0 CASE STUDY

3.1 RELEVANCE OF CASE STUDIES

In addition to investigations through texts, it is wise and helpful for researchers to visit existing projects which bear resemblance with their proposed project. So as to be acquainted with the existing situations. This helps in utilizing the merits of the study and avoiding the demerits.

3.2 IDEAL FLOUR MILLS FADUNA

3.2.1 Brief History

The ideal flour mills, Kaduna is located along the Kaduna-Abuja by-pass opposite Nasarrawa village. Established in 1982, it occupies an area of about 2.5 hectares. It was designed by a swiss firm who are the technical partners. The mill is operated in the vertical milling process. At inception, an ‘A’ was installed to mill wheat at a capacity of 320 metric tons per 24 hours by 1986, a new mill, called ‘B’ mill with capacity of 520 metric tons per 24 hours was installed to mill wheat, bringing the total installed capacity of wheat to 840 metric tons per 24 hours. Later in the year, the government of Nigeria banned the importation of wheat. This made the management to convert ‘A’ mill from wheat milling to corn milling at 200 metric tons per 24 hours daily. While the ban on wheat lasted, the factory depended on local wheat. For now, the ban on wheat importation has been lifted and optimum wheat milling is in progress.

Drawing here

3.2.2 General Planning

The location of functions within the site lacks good functional relationship. This could be seen from the location of workers’ facilities away from the production hall and lack of traffic separation for heavy duty vehicles and cars.

3.2.3 Administrative Building

The administrative building is a two storey building, built on a square spiral staircase. There are corridors around the central staircase which lead to the offices. Natural lighting and ventilation are poor within the central core, while toilets positioned in this area have attendant problems of ventilation and sewage disposal. The administrative building is exposed to dust from the off loading bag. The orientation of the main axis along the east-west direction is another weakness of the design.

3.2.4 The Production Hall

The production hall is a three storey building built of steel columns and metal sheet cladding. It was designed for vertical milling of wheat. At present it mills corn at an installed capacity of 170 Metric tons per 24hours and wheat at an installed capacity of 520 metric tons per 24 hours. Raw materials bought to the factory are stored in 20,000 metric tons capacity silos. The silos have 20 compartments of 1000 metric tons each. Situated at the southern wing of the production hall are silos for the storage of finished products. The finished products silos are made up of 10 cells of 50 metric tons each.

3.2.5 Workers Facilities

The workers facilities block which has changing rooms and restaurant is placed away from the production hall. Workers on assumption of duty travel past the production hall, and administrative block, before getting to their changing rooms. There are no covered walkways between changing rooms, Restaurant and the production hall,

Diagram here

Leave 15 lines for every drawing.

Fig 2 Eastern Elevation of ideal flour mills, Kaduna

Diagram Here

Fig. 3 Northern Elevation of ideal flour mills, Kaduna

Hence workers may get wet in event of rain. At break times, workers are fed from the company’s restaurant, by the use of meal tickets from the management. This motives the staff and encourages higher productivity.

3.2.6 Maintenance Unit

The maintenance unit is located nearer the administrative building and the workers facility unit, than the production hall, it is meant to serve. However, filter- mechanics are positioned permanently in the production hall. Repairs are either done with the production hall or carried out in the maintenance unit. Equipment are transported to the maintenance unit by trolleys. The unit has two workshops, namely mechanical and carpentry. The main jobs done in the workshops are fabrication, plumbing, carpentry, painting and general mechanical works.

3.2.7 Hygiene

Hygiene standards are achieved by total exclusion or sealing-off the milling processes from activities which tend to lower the quality of the designed products. The company had tried to achieve hygiene by providing control measures, from the reception of raw materials, through processing stages to packaging and ware housing. The silos provided are such that they could be washed when required. The silos are protected from rodents’ attack, so as to preserve the quality of the grains. The production hall is sealed off from flies and other insects by use of minimum openings hence ventilation is artificial activities on site are zoned. Such that operations which are unclean are never mixed with those that are clean. An example is the raw material reception which is an unclean area and the finished products warehousing which is a clean area. Storage of finished products is done on wooden platforms.

3.2.8 Fire Safety

The management of ideal flour mills provides regular training of members of staff on the selection and suppression of fires. The filter mechanics are particularly conversant with operations of the limited fire equipment. Management has been requested to install water hydrants within the site. It is hoped that the request will receive favourable attention this year.

Automatic fire alarm systems are installed with the factory complex. These initiates alarm signals, which are received by the signal control panels and converted/ transmitted to alarm indicating device. This device then audibly and visually warns the occupants of the presence of alarm.

The only equipment for fire suppression are portable fire extinguishers, which are located throughout the complex. The researcher finds them incapable of extinguishing major fire outbreaks, since they can contain only small fires.

3.2.9 Merits

- Good natural lighting within the production system.

- Good welfare services.

- Efficient quality control measures.

3.2.10 Demerits

- The factory uses a multi-storey building to house its milling equipment, with attendant high building and operation costs.

- Lack of traffic separation for heavy duty vehicles and cars.

- Poor functional relationship of units.

- The administrative building is exposed to dust from the off loading bay.

For fire suppression. These are considered incapable of extinguishing major fire outbreaks.

3.3 NORTHERN NIGERIAN FLOUR MILL KANO

3.3.1 Brief History

The northern Nigerian flour mill, Kano was established in 1975 situated in the Bompai Industrial Estate, the factory is jointly owned by Kano State investments and properties co-operation a group of Nigerian business men and expatriate technical partners. The initial capacity of the factory was 80,000 tons of what perannum. Today it has been expanded to mill 150,000 tons of what per annum while the ban on wheat importation lasted, the factory made use of locally produced wheat, whose quantity was too low, compared to the installed capacity of the plant. With the lifting of the ban of wheat importation, optimum production has commenced.

3.3.2 General Planning

On a general note, functional and sequential relationship is not adhered to, in the planning of the factory complex. The blocks are sited arbitrary just to serve their primary purpose. There no covered walkways to protect workers facilities are placed nearer the administrative building than the production hall.

3.3.3 Administrative Building

The administrative building is a one storey structure of reinforced concrete cladding, with continuous glazed windows along its two long sides. The windows though positioned in the east and west are unshaded.

Circulation within the building is through a central corridor which is poorly lighted and stuffy at the ends. This hampers good ventilation and effective lighting within the building.

The toilets in the building which are positioned towards the frontage for use by the managing directors and board members are not appealing to the façade.

Diagram here

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Fig. 2 Eastern elevation of ideal flour mills Kaduna

Diagram here

Fig 3 Northern Elevation of ideal flour mills, Kaduna

Occupants in this building stand the risk of been rapped in the event of fire outbreak. This is because there is only one centrally located staircase in the building.

3.3.4 Worker’s Facilities

Workers facilities in a factory include changing rooms, restaurant and recreation rooms. The factory’s restaurant provides skeletal services to the workers as such they eat at a mini-market across the road which is not good enough. Recreation rooms do not exist in this factory. The changing room is positioned far away from the production hall, closer to the administrative building. Since the connection between the changing room and the production hall is uncovered, the worker will get wet, at times of rain, hence stand the risk of electric shocks at their machines.

3.3.5 Production Hall

The vertical milling system is employed at the factory. This makes use of the four storey production hall building, for the different functions carried out in the milling process. This vertical milling system requires great heights of about 30m and multiple floors to operate.

The production block is made of structural concrete columns and beams, with concrete block wall cladding. Cleve-storey windows provide both ventilation and lighting. Lighting in the hall is supplemented with artificial lighting. The longer axis of the hall is along the east west geographical axis.

The building is made up of screen room, conditioning unit, grinding unit, sifting unit, purifier unit and flour packing section. It has a conveyor belt system which transports raw materials from the in-take pit through the head house into the silos. There are nine cylindrical silos for raw material storage, positioned adjacent the production hall.

Diagram here

Fig 5

Northern Elevator of Northern Nigeria flour mills, Kano

Diagram here

Fig. 6.

Southern elevation of Northern Nigeria flour mill, Kano.

3.3.6 Maintenance Unit

The maintenance unit is placed adjacent the production hall. It maintains company vehicles, repairs/services machines, electrical equipment, air-conditioners and refrigerators repairs of heavy sections of the milling machines are done in the production hall.

The maintenance unit is made of steel portal frames, with equipment store, offices and a maintenance workshop.

3.3.7 Hygiene

The company has provided hygienic control measures from grain reception through processing to warehousing. Dirty zones such as the workshops and raw materials reception are positioned away from the warehouse storage. A finished products is done on wooden platforms.

3.3.8 Fire Safety

Just like ideal flour mills, the filter machines in Northern Nigerian flour mill, Kano are trained to detect and suppress small fires, by the use of portable fire extinguisher. Automatic fire alarms are installed to initiate alarm signals. For the administrative building, there is an enclosed staircase, centrally located. Occupants of this building may be trapped during fire outbreaks, particularly if that fire originates from the ground flour.

3.3.9 Merit

- Good quality control measures are enhanced in the production system.

3.3.10 Demerits

- The vertical milling system is very expensive.

- No traffic separation for heavy duty vehicles and cars.

- Poor functional relationship of units-blocks are located arbitrary.

- No adequate fire suppression system is installed.

3.4 SIHALA FLOUR And GENERAL MILLS (PVT). LIMITED IN 1-9 INDUSTRIAL ZONE, ISLAMABAD

3.4.1 Brief History

Sihala Flour & general mills (pvt). Limited (SFM) was established in 1969. The main function of the mill is processing of wheat and then the production of five products viz; Atta Maida (Rocket) Fine (Rocket) Bran Snji etc from it. The capacity of SFM was 220 tons per day and it has been increased to 360 tons per day since 1995.

The tradition of offering the highest quality of products to customers while exceeding government set specifications has been the tradition and is part of company policy SFM has always been a pioneer in the field of flour milling. They are also the pioneers in constructing concrete silos to meet requirements for storage.

Sihala flour mill (SFM) was the first to produce fortified flour in Pakistan. The ministry of health in its pilot project select SFM as the first mill to start providing fortified flour in 2006.

Sihala flour mills has successfully achieved ISO/IEC 22000:2005 (Food Safety Management System) on 16 February 2010. It has successfully completed and exceeded all requirements set forth in ISO/IEC 9001. 2008 on 03 November 2009. Bureau verities a leading certification authority conducted the audits and has issued the certificates. The mill is also HCCP, 22000 certified. HACCP is a food safety risk management system that addresses biological, chemical and physical hazards through anticipation and prevention rather than by a finished product inspection. The good manufacturing practice (GMP), or Good hygiene practice (GHP), or Good Agriculture Practice (GAP) certifications are required prerequisites for an effective HACCP System.

3.4.2 Main Process in the Sihala flour mill

The main process of flour making includes the following steps:

1. Preparing the wheat where the wheat is weighed, inspected and graded.

2. Cleaning; the removal of impurities like stones, dirt metals and other seeds.

3. Tempering; during this stage the wheat is soaked in water to make it easier to remove the outer bran layer.

4. Gristing; this involves mixing different wheat to create a specific kind of lour.

5. Milling involves a number of repeated steps

5.1 The wheat is ground by a machine equipped with rollers that break it into pieces.

5.2 Then it is put through sifters. The resulting meal starts out coarse and with repeated grinding and sifting becomes fine white flour, wheat bran and wheat germ (The germ of a cereal is the reproductive part that germinates to grow into a plant. Wheat germ is a concentrated source of several essential nutrients including vitamin E, Folate (Folic acid), phosphorus, thiamin, zinc and magnesium as well as essential fatty acids and fatty alcohols) found in the wheat grains. The milling process can either produce distinct products wheat bran, refined white flour, wheat germ that can be packaged and sold separately, milled together to produce a whole grain flour, or blended to form different flour.

6. Blending; different components are blended back together to form different flours. For example, whole wheat flour is a blend of white flour and wheat bran.

7. Enriching and fortifying the addition of vitamins and minerals identified in government regulations.

3.4.3 Hygiene

The workplace environment affects the health of workers. Unhygienic conditions are observed in the workplace environment of flour mills as fine organic flour dust gets airborne in the indoor environment of the flour mills (Wagh et al, 2006).

Due to the above statement the company recognizes the fact that workers agricultural industry are highly exposed to harmful factors in their work environment, such as dust, unfavourable microclimatic condition, excessive noise and insufficient light. This has made her conscious of hygiene and safety of the workers and all staffs of the company.

3.4.4 Merits

1. Proper record keeping of accidents and injuries are maintained and are computerized.

2. Personal Protective Equipment (PPE) are available and are in use e.g. raps and masks.

3. There is a complete checkup of both workers and machines. Workers are medically checked on evey six months.

4. A good housekeeping was observed throughout the mill area. The flour were clean and free of dust and any other contaminants. All the machines were in good condition.

5. The electrical wires were managed in a nice and safe manner. No broken plugs, sockets and switches were seen during the visit. No machine was exposed to any live wire. Appropriate fire fighting equipments were maintained at proper places.

6. Inductive training of three days is conducted for every new employee for personal safety, food safety and process safety before going to job. Then there is job training after one month and 3-6 months respectively. The worker are closely observed and if they seem ill-trained, they are given one more month training. There is refresher training after every 6 months.

There are also system of drill after every six months in which employees are communicated the fire and other related hazards. The supervisor is trained for the first aid along with employees and best trainee and person performing the drill is encouraged by announcing special prizes.

Employees are well trained on the startup operation and shutdown procedures of all equipments.

3.4.4 Demerits

1. Dust was not seen in the mill area. But there was no arrangement for the measurement of the dust in the factory work area. The results of the past study suggest that even with the most up-to-date technology and proper cleaning operations in place, the flour milling industry may not be able to reduce the flour dust levels to below the TLV of 0.5 mg/m³. As shown in a study that chronic obstructive lung disease is one of the major occupational diseases/morbidity of concern in India (Saiyad and Tiwari 2004).

2. The noise level was not measured but as most of the plant was mechanically operated, so a high noise rate was observed. No ear muffs were provided to the employees as they consider them a hindrance during work. The ear muffs are highly recommended for the employees.

3. In the main process area, proper hand rails were provided. All the bags and sacks were transported and transferred on the hand rails to final storage. But at the time of loading to the trucks, the workers were carrying three bags of 20kg each at a time, on their backs which had a collective weight of 60kg/worker/unit time of transport to the truck. It was told by the authority that the hazard was communicated to them but there is an inherited ignorance among these local workers and they work in their own style.

3.4.5 Recommendations

The mill was safe with respect to OH & S issue, but based upon the above conclusions, the following recommendation are made:

1. Ear muffs are recommended in the process area in all the situations.

2. Proper lifting hazard minimization is highly recommended.

3. The results of the past study suggest that even with the most up-to-date technology and proper cleaning operations in place, the flour milling industry may not be able to reduce the flour dust levels to below the TLV of 0.5 mg/m³. So the face masks in the work area are highly recommended.

CHAPTER FOUR

4.0 HYGIENE IN INDUSTRIAL BUILDINGS

4.1 INTRODUCTION

Food, when properly and carefully handled during processing nourishes the body and provides energy and good health. However, if such food gets contaminated, it becomes dangerous for human consumption. It therefore becomes imperative for the designer to ensure optimum hygiene standards during food processing. He should produce a hygienic oriented design, which would prevent the contamination of the final products. Basically, contamination can surface during 3 main phases of the milling system, namely: During reception/storage of raw material during processing and during storage of finished products.

4.2 CONTAMINATION DURING RECEPTION/STORAGE OF RAW MATERIALS

Raw materials which are brought to the factory may already be contaminated while on the farms, in the markets where they were traded or during transportation to the factory, on reception, proper physical and chemical tests should be conducted to ascertain the quality of the grains. Further, the foreign matter in the grains should be removed, after which the grains should be properly washed, cleaned, rinsed and sorted, to ensure that no contaminant is found in them.

4.3 CONTAMINATION DURING PROCESSING

Notwithstanding the fact that modern milling factories are mechanized, lack of proper zoning and appropriate arrangement of equipment and machines can cause unbearable hygienic problems during processing for instance, if the raw material storage, production area and finished products warehousing are jamb together, cross-infestation of the finished products may easily occur. There is therefore the need to segregate such activities with a view to achieving hygienic operations. In the same vein, workers in particular areas, say in raw materials reception, should not undertake functions in the finished products area as the may be the conveyors or carriers of such contaminants. Machinery and equipment in the factory emit heat which makes the workers to sweat. This perspiration could be a source of contamination as the dooplets of the sweat may find their way to the products been conveyed. The entire milling system should be engaged, such that there will be no contamination whatsoever from the environment.

4.4 CONTAMINATION DURING WAREHOUSING

Finished products are not to be stored near raw materials, as odour tainting, dirts and cross-infestation may occur floors for storage of finished products should be resistant to food acid and washing detergents.

4.5 DESIGN CONSIDERATIONS

Design consideration for solving hygienic problems in an industrial set-up are as follows:

4.5.1 General Planning

The factory layout should be properly zoned. Such that there would be segregation of dirty zones from clean zones both outside and within the milling area. Dirts and wastes should be removed with ease such that there will be no room for invasion by rodents, insects and flies, which multiply in dirty and untidy environment.

4.5.2 Changing Rooms

Well equipped changing rooms should be provided, close to the production hall, such that the workers can change and possibly clean-up before entering the production hall. This will encourage personal cleanliness thereby averting contamination of equipment and products.

4.5.3 Waste Disposal

Not all materials that enter the site, leave in form of finished products others accumulate as waste or leave as effluent. Waste handling should be properly carried out on site so that they are not allowed to accumulate thereby contaminating the products and even impairing efficiency of the milling process. Health officials involved in waste disposal should be called upon on a regular basis to ensure the cleanliness of the site.

4.5.4 Warehouse Design

According to Wood (1975), warehousing that would ensure good hygienic practices should be built with these requirements in mind.

- To prevent Infestation and in order that good have house hygiene be maintained and effective pest control carried out, the floor should be made or constructed sufficiently above ground level and should incorporate a water vapour barrier such as damp proof membrane. The building should have a concrete floor and walls of brick or concrete blocks.

- To prevent mould growth, ventilation of storage space is important and should be such that complete ventilation control is possible allowing it to take place during periods of low ambient relative humidity and as required for working condition. Ventilation openings should be fitted with non corrosive mesh screening, capable of excluding flying insects.

- The floor, walls and roof structure of storage premises should be such that can be cleaned, brushed, washed and sprayed with insecticide when necessary.

4.5.5 Production Hall Design

There should be adequate ventilation openings, fitted with non-corrosive mesh along the walls. Good ventilation keep-off underisable odours and reduces objectionable moisture in the atmosphere mechanical ventilators are encouraged. Lighting is needed for proper cleaning of interior portions of the production hall as rodents and insects are attracted to dark spaces, moist places and unclean places. Provision of windows, roof lights and artificial lighting is desirable. Machines installed in the production hall should be raised for easy cleaning and for the prevention of rusting of the machines. Floor and wall finishes should not wear away easily when cleaned, washed or brushed.

4.5.6 Silo Design

Silo could be constructed in reinforced concrete or steel sheets. They take a variety of shapes and sizes depending on the desire, economy, safety and efficiency. Steel construction is more demanding in handling and assemblage. On the other hand, reinforced concrete silos require less skill and workmanship to erect. Reinforced concrete silos are fire proof, vermin proof and airtight. The have an advantage of allowing moisture penetration where there are variations in outdoor-indoor temperature. Their tremendous weight however makes them vulnerable to mind pressure. The bottoms of silos are of different geometry, depending on the discharge techniques employed. They could be flat, supported or suspended hopper, of self supporting hoppered bottom. The discharge opening of the silo should be about 0.85m, while the thickness of the walls should be 400mm so as to curtail the adverse effect of solar radiation on the grains inside the silos.

CHAPTER FIVE

5.0 FIRE SAFETY IN INDUSTRIAL BUILDINGS

5.1 INTRODUCTION

Architects have a responsibility to integrate fire safety measures into their designs, rather than allow for distortion and disruption of their works to make provisions for fire safety. Fire safety is important in factories in view of the high cost of erecting the factories and the fate of the works who may be trapped in such an outbreak. The designer has to ensure that his design conforms with statutory requirements of fire safety. He should help minimize risks by identifying potential hazards and making appropriate provisions. The designer’s knowledge in properly locating the building on site, process input and choice of materials can ensure the rapid evacuation of occupants and eventual control of any fire outbreak.

It is in view of the menace of recent fire outbreaks and their unbearable implication on Nigeria’s economy that the researcher intends to use fire prevention and suppression consideration in his proposed corn milling factory.

5.2 CHARACTERISTICS OF FIRE

Fire is the rapid oxidation of combustible material producing heat and light. It is a process of burning involving a chemical reaction of two or more combustible substances with oxygen, resulting in the evolution of heat and light.

5.2.1 FIRE TRIANGLE

For fire to occur, 3 elements must be present simultaneously. These are:

1. Combustible material

2. Heat

3. Oxygen

Once any of these elements is excluded, there will be no fire

i. Combustible material: This could be in term of solid, liquid or gaseous fuels, example furniture, petrol and propene respectively.

ii. Heat: Heat is the attainment and maintenance of certain minimum temperature. It is a measure of the degree of hotness (or coldness) of a body, necessary to raise the temperature of a substance before ignition and fire outbreak.

iii. Oxygen: Oxygen is said to be a gas that has no colour, taste or smell. It is present in air and necessary to the existence of all forms of life. Combustion cannot continue if the surrounding atmosphere is deficient in oxygen.

5.2.2 Origin of Fire

Fires have three main origins namely.

i. Natural origin

ii. Accidental origin

iii. Incendiary origin

i. Natural origin: Natural fires can be as a result of spontaneous heating or lighting. Lighting strikes result in fires when heat is produced to ignite combustible materials.

ii. Accidental origin: This fires are cause by error, possibly by electrical arcing sparking, overheating of equipment or explosion.

iii. Incendiary origin: Incendiary fires are those maliciously set by intruders, juveniles, disgruntled employees of arsonists.

5.2.3 Phases of Fire

There are three phases of five viz:

i. Initial or incipient phase

ii. Free burning phase

iii. Smoldering phase

i. Initial Phase: This is the ignition or beginning of the fire

ii. Free burning phase: This is when the fire assumes a temperature of 12000⁰F.

iii. Smoldering phase: This is when there is a drop in temperature of 1000⁰F-1200⁰F due to exhaustion of oxygen.

5.3 FIRE PRESENTATION CONSIDERATIONS

Fire prevention refers to stopping outbreaks of fire, reducing risks of fire spread thereby avoiding danger from fire on the building and its occupants. Below are factors that assist in fire prevention.

5.3.1 Site Planning

For the successful planning of a site, the separation of incompatible land uses from each other and the association of compatible or mutually helpful uses should be of considerable concern to the designer. Wind direction should be considered in locating fire risk functions within the site. Such functions should be placed at the lee-ward part of the site so that eventual fires are not blown over the complex by prevailing winds. Also, site layout should provide adequate driveways and parking spaces on firm, level surfaces for use by fire apparatus. Man-made and natural barriers that would interfere with movement of fire vehicles should be avoided. Where bollards are provided, they should be removable to enable fire fighting vehicles gain access to the factory. In addition radiant heat form a burning building can be propagated to adjacent buildings, if spatial separation distance between buildings, using outside spriklans, use of self supporting barriers and decreasing the area of wall openings. Hydrant points should be located within the premises, at a distance of not more than 60m from the building.

5.3.2 Structural Materials

Structural fire protection involves the design of building elements such as walls, columns, beams, floors and roofs, with specific material or combination of materials which meet minimum fire endurance rating. Fire resistance of concrete columns and beams depends on the thickness, aggregate, moisture, air content and the cover the reinforcement. The use of membrane enclosures like gypsum plaster, mineral wool fibre, inorganic coatings and concrete or brick encasement, increases the fire resistance of structural materials. Also fire retardant paints used for protecting combustible surfaces from fire provide some service as conventional paints with equivalent aesthetic properties.

5.3.3 Segregation

Segregation refers to the placement of electrical fittings and apparatus outside hazard areas. Cables which run through such hazard area have to pass through air-tight ducts. Its major advantage is the reduction of fire risk due to accidental ignition.

5.3.4 Ignition Sources

Potential ignition sources of fire include electrical sparks, mechanical sparks, hot surfaces and electrostatic discharges. Hazard prone operations should be strictly controlled in such situations.

5.3.5 Ventilation

Ventilation in hazardous zones is achieved by the use of continuous monitors or properly sized and spaced built-in roof openings that allow smoke and hot gasses moving upward along the underside of the roof to move and pass through. For low risk area, simple cross ventilation is adequate.

5.3.6 Explosion Control

The dissipation of explosion forces to the outside air rather than being contained in the building reduces damage around it.

The damage done by explosion is reduced when there is rapid release of excess, pressure, flame and unburnt materials to the atmosphere. In buildings prone to explosion, large openings in the building envelop are provided, using weak or weakly fastened cladding, so that they may be blown off at early stage of the explosion.

5.4 FIRE SUPPRESSION CONSIDERATIONS

5.4.1 Fire Control and Suppression

Small fires can be effectively extinguished by the use of portable fire extinguisher.

But for bigger fires, Hose-Reels and automatic sprinkler system provide better services. For hose reels, they have maximum hose of 36m and should be positioned such that no part of the floor is more than 6m from the end nozzle. The most commonly used and reliable suppression system in industrial complexes is the automatic sprinkler system. The sprinkler heads are activated at 68⁰c. They detect fires automatically, transmit an alarm and suppress or extinguish the fire.

5.4.2 Fire Escape

Fire outbreaks are characterized by panic within the complex gutted by fire. Safe and rapid evacuation of the occupants is enhanced by the provision of escape routes which are as short as possible, of adequate capacity, lead to open air at ground level or fire resisting enclosures, and should not be exposed to penetration by smoke or fire. Furthermore the occupants should not go towards the fire in a bid to escape. There should be at least 2 escape routes leading in opposite directions. Escape routes should have sufficient widths to enable the occupants escape within few minutes.

5.4.3 Fire Point

Fire points are groupings of five equipment within a complex. The equipment include: Fire alarm, fire buckets, fire blankets and hose reel. These points should not be more than 30m apart.

5.4.4 Smoke Control

Smoke posses greater hazard to occupants than fire itself, as it contaminates the oxygen content of air within the complex, making breath impossible for the occupants. Escape areas should be smoke free. The use of fire resisting doors and partitions may not necessarily prevent the movement of smoke and toxic gases, but are effective in controlling the spread of fire itself. Smoke curtains offer effective service in controlling smoke.

5.5 FIRE DETECTION EQUIPMENT

Fire detection equipment are numerous in type, size, shape and price, they are triggered by elements of fire: Flame, convected heat, radiant heat, smoke, or a combination of the elements. They sense fire quicker thank the sprinklers so that it can be easily extinguished manually.

5.5.1 Heat Detectors

These are the oldest type of automatic fire detectors. They have the lowest false alarm rate and are slowest in detecting fire they are most appropriate in small confined areas.

5.5.2 Smoke Detectors

Smoke detectors have faster detection capabilities and higher false alarm rates due to increase sensibility. They are not appropriate for production halls due to constant heat generated by the machines.

5.5.3 Flame Detectors

They sense ultraviolet or radiation currents emitted. They have the highest false alarm rate and the fastest detection capability than any other fire detector.

5.5.4 Fire Alarm System

Fire alarm systems are manual or automatic fire devices with protective signaling systems, made of the following important elements.

i. Signal initiating device

ii. Signal Control

iii. Signal indicating device

The signal initiating device, initiates alarm signals. The signal control panels are control units which receive the alarm signals and convert or transmit to the signal indicating device. The signal indicating devices then audibly or visually warn occupants of the presence of an alarm.

5.5.5 Sprinkler System

This system combines detection and suppression of fires. It provides good surveillance and automatic detection and extinguishing devices. It is the most dependable fire safety device.

5.6 FIRE EXTINCTION EQUIPMENT

It is not enough to detect and initiate alarm without actually extinguishing the fire, fire extinction is undertaken by the various methods and equipment, depending on the nature of fire.

5.6.1 Dry Sand, Water and Fire Blankets

These are used to extinguish fires that are at the incipient stage. Depending on the nature of fire, any of the above could be used to extinguish the fire.

5.6.2 Portable Chemical Fire Extinguisher

Portable chemical fire extinguisher are more efficient in extinguishing incipient fires. They however becomes less functional once the fire is out of proportion. They are categorized as follows.

a. Foam Extinguisher: They contain 13% of aluminum sulphate and water, when used, they come between fuel and flame, forming a blanket thereby preventing re-ignition and effectively cool the liquid fuel.

b. Carbon Dioxide Extinguisher: They are used for fires involving highly inflammable liquids and live electrical equipment. They remove oxygen from the environment thereby extinguishing the flames.

c. Dry Powder Extinguisher: They are used in fighting carbonaceous fires involving wood, textiles, paper, flammable liquids and electrical fires.

d. Bromochoro-dichloro-methane: They ensure rapid flame breakdown, are non conductors and leave no residue.

5.6.3 Automatic Sprinklers

The sprinkler system uses underground and over head pilings, with sealed values that open automatically to extinguish incipient fires. The system is most effective in detecting and extincting fires, hence its installation gives psychological and physical assurance to occupants as any fire outbreak is detected and extinguished before any harm is done to life and properties, hence is recommended for the proposed factory.

CHAPTER SIX

6.0 THE SITE

6.1 EDO STATE AS THE LOCATION

Edo State of Nigeria was created on the 27^th of August 1991, when the number of states in the federation were increased to thirty. The state is located in the Central Southern Nigeria. Its capital is Benin City. It is bounded in the North as East of Kogi State, in the South by Delta State and in the West by Ondo State. Edo State, heart beat of the nation has immense agricultural resources because of its geographical location in the rich forest as several zones. Opportunities are therefore available to investors in agricultural sectors. Edo State is a major producer of fruits like pineapple, oranges, banana, pawpaw, sugar cane etc; cassava, plantain, rice, tomatoes, cocoa, rubber, coffee and also notable for corn or maize. The state has large expanses of available land measuring thousands of square kilometers. It is abundantly clean that with the establishment of such factories in the state, Edo farmers will be encouraged to step-up production, since there will be ready market for their crops. Edo State can produce surplus corn and still have excess for exportation if the appropriate authorities encourage mechanization and modern processing in the state.

6.2 UBIAJA AS THE SITE

Ubiaja is the capital of Esan South East Local Government. She can be referred to as the political mother-town of the Esan people of Nigeria. From historical development she was the headquarter of Esan division, which today comprise, Esan South East local government area, Esan central locals government area, Esan North East, Esan West, Owan West, Owan East, Etsako West, Etsako East and Akoko Edo local government areas. She shares similarities with the other 34 Esan villages.

Location of Edo State

Location of Ubiaja

Presently, Ubiaja as the Esan South East capital and local government headquarter lies within latitude 6⁰ 390N and longitude 6⁰22’60E and is approximately 11,000 feet above sea level. The sitting of this factory in Ubiaja is influenced by the following factors:

6.2.1 AVAILABILITY OF RAW MATERIALS

Corn abounds in every part of the town and could be affordably transported to the Ubiaja industrial layout.

6.2.2 ECONOMIC FACTORS

There will ready market for the finished products.

6.2.3 TRANSPORT FACILITIES

Ubiaja is accessible by road, rail, and water.

6.2.4 MANPOWER RESOURCES

The state capital has able manpower of any category that may be required.

6.2.5 SITTING AND LOCATION WITH RESPECT TO THE TOWN

The site of the factory is located in Ubiaja industrial layout area of the town along the Ubiaja Oziaono road Ubiaja where there exist other factories commuter buses ply the route. Water and electricity could easily be tapped to the site. There are no air or water pollution into the site.

6.2.6 BUILDING CONDITIONS AND RUNNING OF THE FACTORY

The technological process and machinery will be prescribed by RONCAGLIA OPR MILL, for 2NOS 200/225 tonnage HELIOS 6005M-10005H.

6.3 CLIMATIC DATA ANALYSIS

The climatic data of a place where a project is located influences the planning of the site and the detail design o the constituent units themselves. The basic climatic factors are as follows:

6.3.1 RAINFALL

Ubiaja is a rainforest region, with 1800mm (71in) to 2000mm (79in) of rainfall each year. Ubiaja has a tropical climate characterized by two distinct seasons. The wet season occurs between April and October with a break in August, and an average rainfall ranging from 150cm (59’) in the extreme North of the state to 250cm (98’) in the south. The dry season lasts from November to April with a cold harmattan spell between December and January. The climate is humid tropical in the south and sub-humid in the north.

6.3.2 TEMPERATURE

The mean annual temperature for Ubiaja tabular view for temperature and precipitation per month

Temperature			Precipitation
Months	Normal	Warmest	Coldest	Normal
January	-	33.5⁰C	20.3⁰C	1
February	-	34.9⁰C	22.8⁰C	1
March	-	34.7⁰C	23.9⁰C	3
April	-	33.6⁰C	23.9⁰C	6
May	-	32.0⁰C	23.1⁰C	12
June	-	30.5⁰C	22.6⁰C	13
July	-	29.5⁰C	22.3⁰C	15
August	-	29.6⁰C	22.3⁰C	15
September	-	30.2⁰C	22.1⁰C	17
October	-	31.2⁰C	22.3⁰C	12
November	-	22.6⁰C	21.6⁰C	1
December	-	32.9⁰C	20.0⁰C	0

Table 4

Monthly temperature and precipitation for Ubiaja 28.06.2013.

Source: Enugu weather station: 137m.a.s.i 130.okm away from Ubiaja

6.3.3 RELATIVE HUMIDITY

The mean relative humidity for ubiaja is

6.3.4 Sunshine

Solar radiation for Ubiaja is high between

6.3.5 Wind

6.4 SITE ANALYSIS

The essence of site analysis is to enable the designer to know the characteristic of the proposed site. So as to meet any particular response and harmonize his design with the site. This will ensure the maximum exploitation of the potentials of the site thereby ensuring an integration of the natural and cultural factors into the design.

6.4.1 TOPOGRAPHY

Esan plateau: The plateau is a continuation of the sandstone of the northern plateau and ranges from 213 to 305 meters (700 to 1000ft). the north and south fall steeply to the role and Niger valleys while the south and west are gradual gradients to the Benin lowlands.

The vegetation is a virgin land hence, the site is emmarted as an industrial area, however, no physical developments have commenced on the site. Some economic trees and shear butter trees does the site with shrubs and grass cover.

6.4.3 MICRO CLIMATE

The sun path through the site is generally from the East-North-East to West-South-West. The effect of the sun in the East could be tolerated, while that from the west is uncomfortable, as such, opening towards the west should be avoided.

6.4.4 UTILITIES

The main utilities within the site are the tarred roads which surrounds the site and traverse the entire industrial estate. There is also pipe borne water and electricity opposite the site.

6.4.5 ACCESSIBILITY TO SITE

The site is situated at the right hand side along Ubiaja Illushi road it has good network of tarred roads round it, hence it is easily accessible.

6.4.6 SHAPE OF SITE

The site is rectangular with the north and south ends smaller than the East and west ends. The slope of the land is from the north and to the south end.

6.4.7 MAN-MADE STRUCTURES

There are no main-made structure on the site. It is totally virgin, with relative vegetation cover over the entire site.

6.5 SITE CONCEPT

The Ubiaja industrial estate is an effort by the local government to lay a solid foundation for the towns industrial development. Infrastructures developed on site are network of tarred roads electricity, pipe borne water and site clearance. The proposed corn milling factory is to be sited at plot 3 of the layout as there is already an existing poultry farm hose in plot 1 while plot 2 is meant for other purpose.

It was decided that the ingress and egress should be tapped from the network of artirear roads within the complex, instead of using the main road which passes by the site. That will cut the cost of providing roads to the site. Two road will be tapped from the artivear road, one for cars and the other for trucks.

It was found out that the natural landscape slopes towards the south-west direction, hence in the effluent discharge shall be towards that direction. The site is vast hence there will be no need for any pre-conceived forms in the spatial arrangement.

The administrative building is located towards the main entrance of the site, for that is the public area. The production is at central core, for that is the main activity which every other one depends on the sustenance. The raw materials storage is at the east, towards the trucks entrances, for the enhancement of easy supply of raw materials and subsequent disposal of the over tails and other wastes.

CHAPTER SEVEN

7.0 DESIGN FORMULATION

7.1 PROBLEM DEFINITION

The factory is desired to mill 450 metric tones of corn per 24 hours. It has to be located at the Ubiaja industrial layout, Ubiaja. Ubiaja is one the largest towns in Edo State. The town has good road distribution network and is readily accessible. Power supply to the factory should be adequate to run the heavy machines. The factory should ensure good hygienic and fire safety standards. Accessibility and circulation should not be haphazard. The production flow should be simple and functional in order to maximize production staff strength should be harmonized with the realities of work requirements. There should be strong physical relationship between all the functions with in the complex, while the complex should be aesthetically pleasing, so as to simulate the workers.

7.2 DESIGN BRIEF DEVELOPMENT

The complex shall consist of the following units:

a. Administration

b. Production

c. Workers welfare facilities

d. Auxiliary services

e. Parking

7.2.1 ADMINISTRATION

The administrative unit shall accommodate the following:

i. General managers, secretary and clerk

ii. Company secretary and clerk

iii. Personnel manager and clerk

iv. Finance manager and clerk

v. Marketing manager and clerk

vi. Public relation officer and clerk

vii. Chief security officer

viii. Administrative officers (2)

ix. Finance officers (2)

x. Legal officer (1)

xi. Cashiers (2)

xii. Administrative clerk (3)

xiii. Finance clerks (4)

7.2.2 PRODUCTION

Production is made up of the following components

a. Raw materials silos

b. Milling line

c. Finished products storage

a. Raw materials silos: Corn is a seasonal crog, hence, here is the need to stock pile the commodity during peak harvest period so as to ensure stable processing, all year round since the raw material are expected to remain in the silos for long period. A reinforced concrete silo 40m wide x 40m long x 15m high is recommended.

b. Milling line: The recommended plants to be installed are 2 NO. RONCAGLIA OPR FLOUR MILLS SERIES “HELIOS” MODEL 6005 M-10005H, they have combined production

Plate 4

Typical factory building

Plate 5

Typical wave house situation

Plate 6

Milling machines

Plate 6b

Milling machines

Plate 7

Control board

Plate 8

Products obtained by baking the grits

Capacity of 400/450 metric tones per 24 hours. The standard building size per plant is as follows:

Length – 70 metres

Width – 20 mnetres

Height – 5 metres

C finished products storage

Four main products to be obtained from the factory are:

- Corn flour

- Corn meal

- Grits

- Bran (by product)

Ten cylindrical silos of 250 metric tones each shall installed for the storage of the unbagged finished products, while a warehouse will be provided for the storage of the bagged products. Bagging and storage of the bran and corn meal will be done in separate apartments so that they do not mix with the other products. The area for bagging and stalking of bran and corn meal shall be 1600m² while that of the other products shall be 2400m².

7.2.3 WORKER WELFARE

These are facilities which cater for the welfare of the factory workers. They include:

a. Staff canteen and kitchen

b. Changing/locker rooms

c. First aid room

d. Common room

7.2.4 AUXILIARY SERVICES

The auxiliary services for the factory are as follows

a. Generator house/transformer house

b. Gate

c. Weight bridge house

d. Maintenance services

e. Boiler house

7.2.5 PARKING FACILITIES

Parking facilities should be provided for all classes of operations, both for workers and visitors. These facilities shall include:

a. Parking for unloading trucks

b. Parking for dispatch trucks

c. Staff parking

d. Customer parking

e. Bicycle and motor cycle parking

7.3 STAFF SCHEDULE

7.3.1 ADMINISTRATION

Staff	No of staff per shift	No of shifts	Total no of staff
General manger	1	1	1
Company secretary	1	1	1
Managers	3	1	3
Admin-officers	2	1	2
Accountants	2	1	2
Finance officers	2	1	2
Admin clerks	3	1	3
Finance clerks	4	1	4
Cashiers	2	1	2
Salesmen	4	1	4
Chief security officer	1	1	1
Chief store officer	1	1	1
Typist	2	1	2
Tea girls	2	1	2
Cleaner	3	1	3
Drivers	10	-	10
Public relations officer	4	1	1
Sub total			76

7.3.2 PRODUCTION

Staff	No of staff per shift	No of shifts	Total no of staff
Chief miller	1	3	3
Supervisors	2	3	6
Machine attendants	4	3	12
Quality control officer	1	3	3
Laboratory attendants	2	3	6
Record clerk	1	3	3
Cleaners	2	2	4
Forklift attendant	5	3	15
Warehouse supervisor	1	3	3
Loaders	8	2	16
Sub total			71

7.3.3 STAFF WELFARE

Staff	No of staff per shift	No of shifts	Total no of staff
Nurses	1	3	3
Catering officer	1	1	1
Cooks	4	2	8
Stewards	4	3	12
Changing room attendants	2	1	2
Sub total			26

7.3.4 AUXILIARY STAFF

Staff	No of staff per shift	No of shifts	Total no of staff
Chief engineer	1	3	3
Auto mechanics	2	1	2
Electricians	2	3	6
Carpenters	2	1	2
Filter mechanics	4	3	12
Store attendants	1	3	3
Labourers	4	1	4
Security men	4	2	8
Neigh bridge attendant	1	1	1
Sub total			39

Summary

Administration – 44

Production – 71

Staff welfare – 26

Auxiliary staff 39

Grand total = 180

7.4 SCHEDULE OF ACCOMMODATION

7.4.1 ADMINISTRATION

ACCOMMODATION	AREA (M²)	REMARKS
Reception lobby	50	Working space for receptionist, show rooms for display, waiting.
Public relations officer	20	Working space, 2 visitors, sofa, 2 file cabinets and a bookshelf.
General office	40	Working space for 4 clerks/typist and 2 messengers, file cabinets.
Marketing manager	20	Working space 2 visitors, sofa 2 file cabinets and a bookshelf.
Sales office	40	Working spaces for 4 clerks, 1 circulation space.
Accountants	20	2 accountants’ tables, 2 sofas, 2 visitors chairs, 2 file cabinets and circulation space.
Cashier	16	Working space, 2 visitors sofa around a coffee table, 2 file cabinet, bookshelf, toilet and circulation space.
Secretary to general manager	16	Working space, 2 visitors chairs, 1 typist, 2 file cabinets and circulation space.
Admin office	20	Office for 2 admin officers, 2 visitors chairs, 2 file cabinets and circulation space.
Accounts office	40	Working space for 3 accounts clerk, 1 typist, 5 file cabinets and circulation space.
Conference room	120	Large conference table for 45 people at a sitting coffee room and circulation.
Telephone exchange	16	Telephone exchange machine, cables and telex, working space for 2 operators, waiting room and circulation.
Security officer	20	Working space, 2 visitors sofa, 1 file cabinet.
Chief store officer	20	Working space, 2 visitors sofa, 1 file cabinet.
Tea room	16	Working space for tea girl
Data bank	40	Working space for data room attendant store and reading space for 8 people, space for computer hardware.
	554

7.4.2 PRODUCTION

ACCOMMODATION	AREA (M²)	REMARKS
Reception pit	160	Reception pit to accommodate 2 trucks discharging simultaneously.
Pre-cleaning room/drying room	280	Enough to accommodate 6 grains from 6 trucks.
Dirty corn bins (paladins)	20	Collection fo over tails and other wastes.
Silo (raw materials)	2,000	Concrete cylindrical silo, 15m high to accommodate 50,000 metric.
Milling area	3,600	2n,. roneaglia OPR flour mills.
Packaging areas (products)	300	Packaging area for 560 metric tones.
Packing area (by products)	200	Packaging area for 90 metric tones.
Warehouse (products)	1,900	Stalking of 5,000 metric tones of by-products.
Chief miller	20	Working space 2 visitor sofa 2 file cabinets and a book shelf.
Central control room	30	Control cubicle and working space.
Quality control/laboratory office	50	Working space, 2 visitors sofa, 2 file cabinets, book shelf and laboratory with store.
	9,500

7.4.3 WORKERS FACILITIES

ACCOMMODATION	AREA (M²)	REMARKS
Changing room	50	0.8m² per person
Staff canteen	300	Space for dining, service and circulation for 100 staff at a time.
Kitchen	80
Caterer office	16	Working space/file cabinet and circulation space.
Dry store	20	For non perishable goods.
Wet store	10	For perishable goods.
Pantry	9
Servery (Jur/sur staff)	2-
First and room	32	Working space for nurse, and attendant, shelves for cards, store and circulation space for 6 people.
Common room	32	Circulation space for 32 people.
Toilets/showers	35	5 toilets, 5 showers
	650

7.4.4 AUXILIARY FACILITIES

ACCOMMODATION	AREA (M²)	REMARKS
Offices for auxiliary staff	80	Working space, 2 visitors sofa, 2 file cabinets and a bookshelf.
Filter mechanical workshop	48	Enough space for machines equipment workshop, working space for 4 filter mechanical.
Electrical workshop/carpentry workshop	48	Enough space for machines workshop, working spaces for 2 electricians and 2 carpenters.
Auto mobile workshop	64	Service pit for servicing of vehicle, working spaces for 4 mechanics.
Central store	90	Central store
Generator house	64
Boiler house
Water tank	64	250,000 litres
Weight bridge room	20
Toilets	12
	9,500

Grand total = 11.260m²

Total area of site = 40,000m²

CHAPTER EIGHT

8.0 THE DESIGN

8.1 DESIGN CONCEPT

The marriage of functional requirements, hygienic consideration, simplicity of form, structural system, comfortability of occupants, fire safety and economic enclosement of the production process constituent the design concept. There are no pre conceived spatial arrangements of functions, thereby ensuring maximum flexibility of the production process. Proper utilization of basic hygienic considerations is observed to achieve a hygienic or bacteria free environment. Desirably, horizontality and vertically as expressed in the production process is applied over other functions. The length and breath of the proposed milling line which is 70m x 20m is the guiding factor in the horizontal development.

Fire safety is been integrated into the initial design, rather than being applied at the risk of disrupting and distorting the original intentions. Compartmentation of internal spaces is applied to control the spread of fire from a building gutted by fire to adjoining buildings. Reinforced concrete covered walkways are provided to link the buildings.

Zoning of vehicular traffic is by the segregation of public zones from private zones. Workers facilities are located close to the production and administrative areas, in view of their strong functional relationship.

Adequate ventilation and lighting is provided in the production process, by creating window openings along the walls and the roof structure.

8.2 ENVIRONMENTAL IMPACT ANALYSIS

In designing project of this magnitude, architects have a responsibility to assess the impact of their designs on the environment, so as to ensure that the environment does not suffer negative effects of the project and that the project itself is protected from any adverse consequential development around it. The inter-relationship with the environment may involve physical functional, legal political economic or socio economic relationship. The following factors shall be considered in determining the environmental impact analysis of the project.

8.2.1 ECONOMIC ACTIVITIES AROUND THE SITE

With the commencement of this project, economic activities will abound by the site. There is that need to provide for each activities hence a mini market is proposed opposite the site.

8.2.2 RESIDENTIAL ACCOMMODATION

There will be great demand for residential accommodation near the industrial layout. An area opposite the site has been reserved for residential accommodation. Individual, state developers and companies will be encouraged to build houses to accommodate the factory workers and other people who may come to settle within the estate.

Squatter houses may erupt with the upsurge of people hence there will be the need for developmental control.

8.2.3 SCHOOL

In view of the high number of people that will come to settle within the industrial area, there is the need to have schools where children of the residents can attend.

8.2.4 FACILITIES WITHIN THE AREA

Facility such as bank, police post, shopping complex, restaurant, prayer ground and post office shall be provided within the area. The benefit of these facilities shall be enjoyed by the workers and the other residents of the area.

8.2.5 WASTE DISPOSAL

Waste emitted from an industry can have adverse effect on the environment, particularly if such waste is toxic. The waste expected from the factory are:

i. Over tails, obtained at the pre-clearing of aw materials.

ii. Used engine oil, removed from the electricity generator.

iii. Sewage water.

` The over tails would be collected in waste bins located in the pre-cleaning units, for eventual disposal. Used engine oil, which is removed from the electricity generator shall be sold to grinding machine owners. Water sewage shall be through a network of drainage channels into the artivear and main road channel, which would be constructed by government to serve the whole industrial layout.

8.2.6 EMPLOYMENT OPPORTUNITY FOR RESIDENTS

People who reside within the immediate surrounding will have job opportunities within the factory and would be privilege to partake in socio economic activities around the layout.

8.3 DESIGN APPRAISAL

The I-line production process has been tempered with, without affecting functionality. The length of the milling line of 70m is the main consideration in the design. Two RONCAGUA OPR milling lines with production capacity of 225 metric tons per day, each are provided, staple storage of raw materials is encouraged by the provision of 70,000 metric tons cylindrical silos. Loading of finished products takes place within the warehouse so as to curtail any adverse climatic effect.

The workers’ welfare facilities such as canteen, common room, and locker/changing rooms are provided between the production and administration.

Administration is located closer to the main ingress for the easy access of visitors.

Auxiliary facilities such as generator house, boiler house, over head tank and workshop are provided close to the production, in view of their relationship.

Vehicular traffic is zoned such that movement of trucks is seperated from cars. Bicycle and motor cycle sheds are tucked neatly at the gate house, without any adverse effect on the front façade. This will enable the workers to park their bicycles and motorcycles undercover while they move undercover to the clocking room. Pedestrian circulation is also well worked out such that there are uninimal cross axis of movement between pedestrians and vehicles.

Responses in planning for effective hygienic environment should avoid contamination sources from impairing production segregation of dirty zones from clean ones is ensured by good going, wastes which accompany corn are removed at the reception/pre-cleaning area. While the entire willing system is eucabed. There is quality control laboratory within the production help to effectively monitor the adherence to hygienic stands. There is a second quality control unit at the trucks gage to ascertain the quality of the grains before been accepted.

Automated and anaul fire detectors and suppression systems are provided as well as escape exists. An automatic sprinkler system is installed throughout the buildings. Vents are provided at the roofs for the escape of smoke and gases. All buildings are accessible by trucks, while fire hydrants are located all over the site.

8.4 CONCLUSION AND RECOMMENDATIONS

For Nigeria to produce enough food to feed her citizenry and have surplus for export, she needs to step up her agricultural production, particularly grain processing. Ubiaja been a viable location for the optimal production and processing of Nigeria’s needed grains, in view of harvest fertile lands. Governments should as a matter of urgency step up mechanization of agricultural production in Ubiaja Esan South East Local Government, Edo State.

The people of Ubiaja should be mobilized to increase cultivation, while the government should ensure, that the farmers get appropriate prices for their hard earned yield.

Silos should be established in all the words of the local government to store the surplus grains produced by the farmers during peak harvest periods.

Grits to be produced from the factory would be used for confectioneries as well as by breweries. The corn flaw is a family delicacy in most Nigeria homes, while the bran and meal would be used as animal feeds.

A hygienic environment in a food processing industry is an asset or production, sales, the consumer and the employee’s morale. Factory workers should be instructed on hygiene routine. There should be delegation of individual responsibility segregation of activity areas is essential in forestalling cross infestation. The encasement of the entire production system prevents contamination from the environment.

The expense of installing fire safety measures in industrial complexes should be weighed against the loss of lives and the total loss of the equipment through fire. Even where such fires are small but hamper production, customer may take their businesses some where else. Consequently, all employees should be drilled on fire detection, evaluation and suppression procedures and in handling fire equipment.

This pleasing architectural consideration is aimed at ensuring confortability for workers and efficiency of production.

BIBLIOGRAPHY

Asiedu J.J (1990) Processing Tropical Crops English Language Book Society, Macmillan, Budon.

Barry R. (1984): The Construction of Buildings volume III Granada Publishing Limited, London.

Czerniewski A.R (1985): Industrial Design Theory in Architecture Department of Architecture, Ahmadu Bello University, Zaria.

Gens J.D (1986): Towards Industrialized Buildings Elseuer Publishing Company.

Inglett G.E (1970): Corn: Culture, Processing, Products, Westport and the Avi Publishing Company, Inc.

Iyamado O.R (1990): Bendel Ceramic Industry, Auchi: A Case Study of Fire Safety in Industrial Buildings. An Unpublished M.SC. Architecture Thesis, Presented to Ahmadu Bello University, Zaria.

Jugenheimer R.W (1981): Corn: Improvement, Seed Production and Uses Wiley-Interscience Publication New York.

Kent N.L (1975): Technology of Cereals Pergamon Press.

Lawal M.K (1989): Kano Flour Mill A Tropical Design Approach to Industrial Building. An Unpublished MSC Architecture thesis presented to Ahmadu Bello University Zaira.

Neuert E. (1990): Neufert Architects Data Halsted Press.

Omale A.P (1990): Corn Milling Factory, Makudi Exploiting. Landscape Elements Improving Factory Environment. An Unpublished MSC Architecture Thesis, presented to Ahmadu Bello University Zaira.

Owen R.E (1985): Roofs: Essence Book on Building Macmillan Publishers Limited, London.

Perce S.R et al (1989): Plannign the Architects Handbook IIIffe and Sons Ltd.

Wood C.A (1985): Cocoa: Longman Group Limited, London.

Murphy O. Omatseye (2013): Fire Protection of Structural Steel in High Rise Buildings. An Unpublished P.G.D Architecture Thesis Presented to Ambrose Alli University Ekpoma.

Sajida Rasheed, Zahir-ud-Din Khan (2013) Occupational Health and Safety Issues in Sihala Flour and General Mills (PVT) Limited in 1-9 Industrial Zone, Islambad: A Case Study.

Christian Galitsky, Ernst Worrell and Michael Ruth (2003): Energy Efficiency Improvement and Cost Saving Opportunities for the Corn Wet Milling Industry.

Gregony D. Williams, Kart A. Rosentrater (2007): Design Considerations for the Construction and Operation of Flour Milling Facilities Part I: Planning, Structural, and Life Safety Consideration.

Eric L. Van Flect, Omer Frank, Joe Rosenbeck (2009): A Guide to Safety and Health in Feed and Grain Mills.

APPENDIX A

source of the reasons for preferring RONGAGLIA Technology, unique in the world.

Exclusion OPR AIR SIFTER SYSTEM

The horizontal integrated wheat maize/corn technological processing line Roneaglia OPR. The ORIGINAL PNEUMATIC RONCAGLIA AIR SIFTER SPECIAL EXCLUSIVE SYSTEM is internationally PATENTED.

The advanced flour million technology is the Roncaglia pneumatic system through strong nylon sieves (nets) scientifically disposed, where the process is fully pneumatic.

- Sieving by air (under vacuum)

- Refining by air (under vacuum)

- De-branning by air (under vacuum)

- Integrated with milling by roller mill (under vacuum)

BUILDING

Roneaglia OPR flour milling plants are installed in one floor only.

- A single block 5 nuts high (equipments are only 4 nts. High) is sufficient to house the complete plant.

- Existing building can be easily utilized/array

- Hicase of building with height less than 5ints Roneaglia OPR plant can be installed in a special configuration .

- No need of anti-storey building (with consequent much reduced building costs) as required for conventional mills.

- No need of special made building 30 nts. High to house the so-called pre-fabricated (mutilated) conventional mill.

MODULARITY

OPR means modular system OPR exclusive milling system develops horizontally and capacity can be increased anytime by adding other OPR technological processing lines, with no interruption in production.

ERECTION, COMMISSIONING AND TRAINING

All OPR plants are entirely assembled and fully tested in our factories in Italy and are shipped just ready running re-assembling on site is merely a question of few days.

Thanks to their exclusion design, RONCAGLIA OPR flour mills are erected and commissioned in an extremely short time (10-30 days according to capacity) by our Engineers/millers.

OPR specialized engineer/millers will train, on site, local personnel during and after erection and commissioning of the willing plant price of OPR plants is al in and covers everything from initial purchase to plant operation in a once only cost (erection, commissioning and training included).

PERSONNEL FOR MILL RUNNING

- OPR plants are extremely simple to run.

- One operators per shift of 8-10 hours is sufficient to supervise the running of the milling plant.

RETURN ON INVESTMENT

- Only OPR plants rewards client with rapid high returns on invested capital within one year thanks to the limited global investment required from the mill.

Roncaglia opr flour mills series ‘helios’ for maize corn

Model	capacity metric tons maize/24hurs	net weight kgs (approx).	gross weight kgs (approx)	container 20 feet open
Helios 501M-800SH.ECM	15/20	14,500	16,800	5
Helios 100IM-800SH	30/35	18,100	21,600	6
Helios 120IM-100SH	40/45	21,400	29,900	7
Helios 2002M – 800SH	70/75	39,100	48,300	10
Helios 2401M – 100SH	80/90	45,300	54,200	12
Helios 3603M – 100SH	120/135	71,200	80,600	18
Helios 4804M – 100SH	160/180	89,400	95,500	24
Helios 6O05M – 100SH	200/225	108,500	114,200	30

Higher capacity plants are also available, on really competitive basis.

Standard building size	Length	Width	Height
Configuration im: 1M:	m+s 15	m+s 12	m+s 5
Configuration im: 2M	m+s 30	m+s 15	m+s 5
Configuration im: 3M	m+s 50	m+s 15	m+s 5
Configuration im: 4M	m+s 60	m+s 20	m+s 5
Configuration im: 5M	m+s 70	m+s 20	m+s 5

**OPR maize/corn technological processing lines be easily adapted for sorghum (durra) millet/rice.

MAIZE/CORN EXTRACTION

From maize/corn of good quality, cican, sound mercantile, vitreous, with specific weight 76-78kg per hl (100 litres) you will obtain (referred for example to mod HE (IOS 20 IM – 100SH)

	Metric tons
	Per 24 hrs
55% fine maize/corn meal (break fast meal)	24.75
35% coarse maize/corn meal (roller meal)	15.75
10% by-products (bran and germ)	4.50
100%	45.00
Or
68.70% grits for brewery, snacks foods	30.40-31.50
(Fat content below 1%)
12.10% sieved flour	5.40-4.50
9.10 % germ	4.05-4.50
11.10% bran	4.95-4.50
100%	45.00
Or
40% maize/corn meal (breakfast meal)	18.00
40% semolina and/or grits	18.00
20% by-product (bran and germ)	9.00
100%	45.00
Or
55% fine maize/corn meal (breakfast meal)	24.75
25% coarse maize/corn meal (roller meal)	11.25
11% bran	4.95
9% germ	4.05
100%	45.00

Or other possibilities, according to clients requirements.

** Maximum extraction of grits obtained by OPR grits dedicated flour mill.

Note:

RONCAGLIA OPR milling plants produce maze/corn flour without germ, therefore not toxic plants are supplied complete of the determination section to get all final product without germ and to enjoy a larger durability as product can be stored for long time without getting acid.

RONCAGLIA OPR INDUSTRIAL MINING PLANTS MAIZE/CORN SERIES ‘COMB’

The world wide planted Roncaglia OPR Air-Sifter flour mills system has brought a revolutionary change in the milling technology.

Oppicinc Roncaglia S.P.A realized the importance and used of treating the two most grown and available cereals all over the would wheat and maize/corn on the same industrial equipment.

In this connection, the developed the new revolutionary Roncaglia OPR series ‘Comb’ for grinding wheat and alternatively maize/corn too, thus fully satisfying clients requirements.

The wheat plant has been HI-TECH developed and includes:

- Maize/corn cleaning section

- Maize/corn pre-grinding/crushing section

- Maize/corn degerminating section

The formula of processing, on the same plant, wheat and maize/corn is

EXCLUSIVE OPR

The Roncaglia OPR polyvalent flour mills represent a precious and incomparable advantage for clients who can choose to switch from wheat to maize/corn and vice versa when they want, according to final products market demand and cereal availability.

The bio-performance OPR polyvalent flour mills produce top-quality flows/scmolia at high extraction rates.

Roncaglia OPR technology facilitates governments policy to fully exploit local availability of raw materials for the nations welfare.

Those willing to invest in Roncaglia record profit technology willing plants or for move detailed information are requested to contact our headquarter in modern Italy.

O.P.R POLYVALENT MILL

ONE MILL INFINITE POSSIBILITIES

RONCAGLIA OPR POLYVALENT FLOUR MILLS SERIES ‘COMB’ FOR WHEAT MAIZE/CORN

IM – 800STN-ECM COMB	15nt tons wheat or alternatively 20mt tons maize/corn	16,900	21,850	5
IM- 1000STN-ECM COM B	20mt tons wheat or alternatively 25mt tons maize/corn	19,800	24,050	6
IM-1000STN-200COM B	25mt tons wheat or alternatively 30mt tons maize/corn	22,200	26,450	6
2M-1000STN-200COM B	30mt tons wheat or alternatively 40mt tons maize/corn	35,400	41,300	11
2M-1000STN-200COM B	40mt tons wheat or alternatively 60mt tons maize/corn	38,500	46,400	12

Higher capacity plants are also available, on really competitive basis.

Standard building sizes	Length	Width	Height
Configurations 1M:	Mts 15	Mts 15	Mts 5
Configurations 2m:	Mts 25	Mts 15	Mts 5

EXTRACTION

From wheat of good quality clean, sound, mercantile, weighing 80kgs per hl. (100 litres) you will obtain (referred, for example, to mod 1m – 1000 STN – 200 COMB)

	Metric tons
	24 hrs
78-80% flours for bakeries, biscuits, confectionary	19.50-20.00
22-20% bran and middlings	5.50-5.00
100%	25.00-25.00
Or
83-86% flours as above	20.75-21.50
17-14% bran and middlings	4.25-3.50
100%	25.00-25.00

Or other possibilities, according to clients requirements.

From maize/corn of good quality clean, sound, mercantile, vitreous, with specific weight 76-78kgs per hl (100 litres), you will obtain (referred, for example to mod. IM –m 1000 STN – 200 COMB).

	Metric tons
	24 hrs
55% fine maize/corn meal (breakfast meal)	16.50
35% coarse maize/corn meal (roller meal)	10.50
10% by-products (bran and germ)	3.00
100%	30.00
Or
40% maize/corn meal (breakfast meal)	12.00
40% semolina and/or grits	12.00
20% by-products (bran and germ)	5.00
100%	30.00

Or other possibilities, according to clients requirements.

WATER CONSUMPTION

Water used is approx. 50-60 litres every ton of product ground that means to add up to 5-6% of water humidity to cereal, if requested.

ELECTRIC POWER CONSUMPTION

Electric power consumption is approx:

- KWH 9-12 precleaning and cleaning sections every ton of cereal

- KWH 37-45 grinding and sieving sections every ton of cereal

PACKING

All machineries and equipments are packed in strong wooden cases, suitable for safe sea transportation in container.

FACILITIES

Roncaglia OPR flour milling plants can be installed everywhere, even where public facilities are almost absent, even where main electric line is not available or if available as subject to frequent breaks. Since plants can be equipped with a diesel generator unit supplied by our house.

ASSISTANCE

Officina Roncaglia S.P.A give their clients an incomparable service recognized to be the number 1 in the world for pre-and after sale assistance.

ADDITIONAL EQUIPMENTS

Officina Roncaglia S.P.A supply upon chats request the following equipments.

Nigerian Universities Research Topics

PROPOSED CORN MILLING FACTORY UBIAJA (TOWARDS EFFECTIVE PLANNING FOR HYGIENE AND FIRE SAFETY)

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