UNIT 3 :COMMINUTION (PRODUCTION LINE, AND GMP

CERTIFIED FACTORY/PACKINGHOUSE)

OUTCOMES

AT THE END OF THIS CHAPTER, STUDENT SHOULD BE ABLE :

• 1) OPERATE AND EXPLAIN MAINTENANCE OF EQUIPMENTS FOR PRODUCTION OF COMMINUTED

RAW PRODUCTS.

• 2) EXPLAIN IMPORTANCE OF SIZE UNIFORMITY IN MAINTAINING CONSISTENCY IN STANDARD AND

QUALITY.

• 3) APPLY PROCEDURE TO SEPARATE IMPURITIES & SELECT RAW MATERIALS OF DIFFERENT TYPES

(ROOT/TUBER/LEAF/FLOWER), DOWNSIZING, FILTER, AND GRADING TO MARKET SPECIFICATION.

3.0 INTRODUCTION

Comminution is the process of breaking large particles into smaller particles, by

crushing, grinding, cutting, or other processes.

Small sized plant materials is important in QA production of bulk product. The

quality of the finished product will change with the change in particle distribution

during the manufacturing process. It is important to continuously monitor particle size

distribution in order to guarantee a constant product quality. These are

prerequisite for product standard assurance (active ingredient content, physical and

chemical quality, and shelf life).

Standard specification mesh sizes of materials depends on type of product (100 -

500 mesh size);

Ex tea – 40 mesh

SIEVER

SIEVE ANALYSIS

MARKET POTENTIAL OF READY TO USE CONCEPT

SMALL SIZING: PRINCIPLE

8

HOW DO WE SEPARATE …?

Ways of size reduction

breaking attrition smashing

splitting cutting crunching

3.2 PRE COMMINUTION TREATMENT

• Screening

- it is necessary to remove or reduce early in the treatment process large suspended solid material

that might interfere with operations or damage equipment.

- an alternative to actual removal of the solids by screening is to reduce the size of the solids by

grinding them while still in the waste stream; this grinding process is called comminution .

• Grading & separation of impurities from raw materials prior mechanizing.

- is based on size, shape, image, weight and color. The aims is to ensure only good quality raw

material is preserved and passed through for further processing.

3.3 EQUIPMENTS

Size reduction can be through the use of high shear forces, graters, cutters or slicers.

Standardized and reproducible working equipment are required in order to ensure the reliability

of the results and to reduce the required working time to the absolute minimum. Cleaning,

calibration and adjustments to machineries is important to make sure the effective production.

Ex :

Grinder – forces produce out through small openings consists of a motor, product tray, grinder screw,

die

Slicer – product holder, cutting blade, conveyor belt, slicer arm

Stuffer – inlet, stuffer body, stuffer drive assembly, product feeder, product outlet, product horn

Chopper – bowl, cutting blade, motor, cover

EQUIPMENTS

Rasper grinder

Superfine grinder

Cutter

Wood chipper

DID YOU KNOW??

FUNCTION & EFFICIENCY OF DIFFERENT

TYPE AND SIZE OF EQUIPMENT?

3.4 OPERATION OF COMMINUTION EQUIPMENT

•PROCEDURE

•EQUIPMENT MAINTENANCE

•TROUBLESHOOTING

TASK

List and explain common failure and troubleshoot action in comminution process

equipment.

- CAUSES

- ACTION

OPERATION : PROCEDURE & TROUBLESHOOTCommon troubleshooting problems –

Motor – electrical overload, dirt

Belting - the belt is misaligned, belt slips while running.

Bearing – abnormal sound - misalignment

RAW MATERIAL LOSSES

FACTORS THAT AFFECT THE RAW MATERIAL YIELDS:

- efficiency of equipment

- equipment handling – human error

- environment of workplace

- Storage condition

3.4 QUALITY ASSURANCE OF COMMINUTE MATERIAL

Criteria’s for product standard assurance on maintaining quality

consistency.

1) Need to conduct sieving analysis for quick assesment of bulk

produce for every production batch.

2) Processing assessment and written report should be done and

include remarks on equipment (such as function

&efficiency,performance of sieves and filters)

3.5 PACKAGING, LABELLING AND STORAGE TECHNIQUE

ADVANTAGES OF SMALL SIZING PACKING

WHO??

homemakers, restaurants,…

WHY??

- Saves time, storage space, shorten cooking/working time.

- Convenient to downstream manufacturers as the preparation is clean and hygienic

- Big potential for export. Packing in any size required by customers.

PACKAGING MATERIALS AND LABELLING

All packaging materials, such as bottlesand other materials, should be storedproperly. Controls on the issue and use ofthese packaging materials should beadequate to ensure that incorrect labelsand cartons are not used

adequate information on the label (or thepackage insert) to inform the users of thecomposition of the product (in addition tothe brand name, if any), indications oractions, directions for use, cautions andadverse reactions if any, and the expirydate

Finished herbal products may containseveral herbal materials and/ or herbalpreparations. Unless otherwise fullyjustified, the full quantitative compositionof the herbal ingredients should bestated on the product label. If this is notpossible, at least the main ingredientsshould be stated on the label while the fullqualitative composition could appear onthe package insert.

the quantity of the herbal material mustbe stated or, if constituents with knowntherapeutic activity are unidentified, thequantity of the herbal material/herbalpreparation should be stated

the quantity of the herbal material/herbal preparation should be given as a range, corresponding to a defined quantity of

constituents with known therapeutic activity

RECALL – THE MINUTE PAPER

• WHAT ARE THE THINGS YOU HAVE LEARNED DURING THIS SESSION?

• WHAT QUESTION(S) REMAIN UPPERMOST IN YOUR MIND?

• IS THERE ANYTHING YOU DID NOT UNDERSTAND?