A TECHNICAL REPORT ON STUDENT INDUSTRIAL WORK

EXPERIENCE SCHEME (SIWES)UNDERTAKEN AT FANMILK PLC,

ELEYELE INDUSTRIAL LAYOUT, IBADAN, OYOSTATE.

BY

OLADIMEJI, BASHIRAT ADEDOYIN

(CHM/2018/126)

IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF

THE DEGREE OF BACHELOR OF SCIENCE (B.Sc Hons) INDUSTRIAL

CHEMISTRY SUBMITTED TO THE DEPARTMENT OF CHEMISTRY, FACULTY

OF SCIENCE, OBAFEMI AWOLOWO UNIVERSITY, ILE-IFE, OSUN STATE.

SEPTEMBER, 2023

I
 DEDICATION

To those who stood by me during my darkest days, your endless love and support have given

me such brave wings to fly into the light.

II
 AKNOWLEDGEMENTS

I would like to express my utmost gratitude to Almighty Allah for guidance and grace

throughout my life and towards the successful completion of my internship.

My sincerest gratitude goes to the entire body of staffs at Fan Milk Plc, Mr. Taiwo, head of

human resources fan milk plc. for accepting my application and giving me an opportunity to

exercise my Student Industrial Work Experience Scheme (SIWES) in the company. My

industry based supervisor, Mr. J.C Dimka, and work station supervisors Mr. I Usman, Mr. A.

Akintola, Mr. T. Aderibigbe, Mr K. Olawale, Mr. E. Enyang, and Mr. C. Umenhwa for

their guidance during my training.

I would like to express my gratitude to entire department of chemistry, Obafemi Awolowo

University, Professor E.A. Akinlua, Head of Department of Chemistry, Obafemi Awolowo

University, ile-ife. For this industrial training opportunity. IT coordinators; Prof. O. Adenuga

and Dr. K.N. Awokoya for their guidance, patience and availability at beckon, Dr. O.A

Ogunkunle, for is generous words of encouragements and to all my lecturers for their

seasoned lectures which already gave me an insight to what I learned during my Industrial

Training.

To my parents, Mr. and Mrs. J.A Oladimeji, and my siblings who had put me on the map,

loved, and support me in every situation and decision that I make, there’s no word that can

express the love and gratitude I feel for you all.

To my friends, fellow interns and corp members who have made this experience not only

educative but also memorable, thank you for everything you have given me. Those six months

of training are worth a lifetime of beautiful memories to me.

III
 TABLE OF CONTENTS

TITLE PAGE I

DEDICATION II

ACKNOWLEDGEMENT III

TABLE OF CONTENT IV

INTRODUCTION vi

CHAPTER ONE:

1.1 SIWES Background 7

1.2 Aim and Objective of SIWES 7

1.3 Bodies Involved in the Management of SIWES 8

1.4 History and Background of Fan Milk Plc. 9

CHAPTER TWO:

2.1 Organization Profile, Departments/Units and Organization Chart of

Fan Milk Plc 11

2.2 Safety and Hygiene Evaluation (SHE) Policy 12

CHAPTER THREE:

3.1 Water Treatment plant 16

3.2 Mixing Unit 21

3.3 Processing Unit 23

3.4 Production And Packaging Unit 26

3.5 Ice-Cream Section 27

3.6 PET Production Section 29

IV
3.7 Effluent Treatment Plant (ETP) 32

3.8. Quality Department 37

CHAPTER FOUR

4.1 Summary 48

4.2 Challenges Encountered 48

4.3 Recommendations 48

4.4 Conclusions 49

References 50

V
 INTRODUCTION

I was assigned to the Production Department of Fan Milk Plc during my six-

months of industrial training under the supervision of Mr Christopher Dimka which

offered an invaluable experience in real-world application of academic knowledge in

chemistry, specifically in the food industry.

As an intern of the production department, I was opportune to undergo training on all

the processes that goes into the production across all other relevant departments.

Although I was not at the core of the work done across all those departments but I was

able to watch and learn as much as I can and was saddled with certain responsibilities

while working across various departments/units.

1. Production____ booking of raw, cleaning and packaging materials used for production,

carrying out weight control and leakage test every hour and imputing the data on excel

sheets, filling and submission of hazard forms to the safety department, writing the ageing

report for raw, cleaning and packaging materials

2. ETP____ dosing of chemicals into the effluent mixing tanks, checking the water level at the

CCU and checking of pH every 30 minutes.

3. Mixing____ filling of batching checklist and traceability spreadsheet, weighing raw

materials used for mixing.

4. Water treatment____ carrying out pH, chlorine and turbidity test, dosing of caustic soda and

chlorine into treatment tanks.

5. Quality____ calibration of weight and refractometer, weighing of agar and raw materials,

assist in carrying out hygiene audit, analysis on water and finished Products.

VI
 CHAPTER ONE

1.1 STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

BACKGROUND
In the earlier stage of science and technology education in Nigeria, students were graduating

from their respective institutions without any technical knowledge or working experience. It

was in this view that students undergoing science and technology related courses were

mandated for students in different institution in view of widening their horizons so as to enable

them have technical knowledge or working experience before graduating from their various

institutions.

The Student Industrial Work Experience Scheme (SIWES) was established by the Industrial

Training Fund (ITF) in 1973 to enable students of tertiary institution have technical knowledge

of industrial work base on their course of study before the completion of their program in their

respective institutions. The scheme was designed to expose students to industrial environment

and enable them develop occupational competencies so that they can readily contribute their

quota to national economic and technological development after graduation. The major

background behind the involvement of students in SIWES was to expose them to the industrial

environment and enable them develop occupational competencies so that they can readily

contribute their quota to national economic and technological development after graduation.

The major benefit accruing to students who participate conscientiously in Students Industrial

Work Experience Scheme (SIWES) are the skills and competencies they acquire. The relevant

production skills remain a part of the recipients of industrial training as life-long assets which

cannot be taken away from them. This is because the knowledge and skills acquired through

training are internalized and become relevant when required to perform jobs or functions.

1.2 AIMS AND OBJECTIVES

The Industrial Training Funds policy Document No. 1 of 1973 which established SIWES

outlined the objectives of the scheme. The objectives are to:

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1. Provide an avenue for students in higher institutions of learning to acquire industrial skills

and experiences during their course of study.

2. Prepare students for industrial work situations that they are likely to meet after graduation.

3. Expose students to work methods and techniques in handling equipment and machinery

that may not be available in their institutions.

4. Make the transition from school to the world of work easier and enhance students’

contacts for later job placements.

5. Provide students with the opportunities to apply their educational knowledge in real work

situations, thereby bridging the gap between theory and practice.

6. Enlist and strengthen employers’ involvement in the entire educational process and

prepare students for employment in Industry and Commerce (Information and Guideline

for SIWES, 2002).

1.3 BODIES INVOLVED IN THE MANAGEMENT OF SIWES

The bodies involved are: The Federal Government, Industrial Training Fund (ITF). Other

supervising agents are: National University Commission (NUC), National Board for Technical

Education (NBTE) and National Council for Colleges of Education (NCE)

The functions of these agencies above include among others to:

1. Ensure adequate funding of the scheme;

2. Establish SIWES and accredit SIWES unit in the approved institutions;

3. Formulate policies and guideline for participating bodies and institutions as well as

appointing SIWES coordinators and supporting staff;

4. Supervise students at their places of attachment and sign their lob-book and IT forms;

5. Vet and process student’s log-book and forward same to ITF Area office;

6. Ensure payment of allowances for the students and supervisors.

8
Therefore the success or otherwise of the SIWES depends on the efficiency of the Ministries,

ITF, Institutions, Employers of labour and the general public involved in articulation and

management of the program. Thus the evaluation of SIWES in tertiary institutions in meeting

up with the needs for the establishment of the program is necessary.

1.4 HISTORY AND BACKGROUND OF FAN MILK PLC.

Fan Milk Plc was founded in 1961 at Aalborg, Denmark, and its Nigeria subsidiary was

founded in 1963 by Danish merchant and industrialist Erik Emborg with a recombination-plant

and head office at Ibadan, a distribution centre in Lagos and less than 30 employees. The plant

produced fresh milk from imported milk powder. Initially, the product range was white milk,

chocolate milk, cottage cheese and set yogurt. The main outlet was bicycle vendors supplied

with cold products from a growing number of smaller depots. In 1970s Fan Milk introduced

yogurt drink, ice lollies, ice cream and new Tetra Pak packaging technology. The new products

became very popular in the market and generated the financial strength to set up further depots

and, in 1981, a second recombination plant in Kano. At the outset, the foreign partner owned

96 per cent of Fan Milk Plc, When the government introduced The Nigerian Enterprises

Promotion Decree in the late 1970s, Fan Milk Plc increased its capital and invited more

Nigerians to invest which created a 60 per cent Nigerian participation in the company. During

1980s and 1990s, import restrictions, economic difficulties, devaluations and shortages of fuel

weakened Fan Milk Plc. In 1998 the foreign partner and the Industrialization Fund for

Developing Countries (Denmark) agreed to an infusion of capital which let the company

restructure finances, refurbish cold rooms, increase the number of depots and recently

introduced a new product Fan Dango, a fruit drink which became an instant success in the

market. The expansion and rehabilitation programme returned Fan Milk Plc to profitability.

Today, Fan Milk Plc directly employs over 800 people, 2 distribution centres and 50 depots

9
doing business with loyal bicycle vendors and agents with its administrative headquarter in

Lagos state. Fan Milk Plc has sister companies in Ghana, Togo, Benin, Burkina Faso and Cote

d'Ivoire.

Over the years, they have been producing, and distributing healthy juice and dairy

products which are either in a frozen or non frozen form.Fan Milk Plc is popular for products

such as Superyogo, Fanvanille. Go Slo, Raspberry Ripple Ice cream etc.

10
 CHAPTER TWO

2.1 ORGANIZATION PROFILE, DEPARTMENT/UNIT AND ORGANOGRAM OF

FAN MILK PLC

2.1.1 The Organization Profile gives brief information about the company. Some of the

information that may be found in the organization profile may include;

Company Name: Fan Milk Plc

Year of Branch Establishment: 1963

Location: Eleyele Industrial Layout, 200284 Eleyele, Ibadan, Oyo State.

Parent Organization: Danone Group

Employment Capacity: 800+ staff members and 20,000+ agents and vendors.

2.1.2 There are several department/work stations where various functions are carried out

toward ensuring proper production. These departments/work stations are of them are listed

below;

1. Administrative Unit

2. Production Department

3. Safety Department

4. Mixing Unit

5. Quality Department

6. Supply Chain Unit

7. Engineering Department

8. Utility Department

9. Casting Unit

2.1.3 The organogram also known as an organization chart is a diagram showing the break

down of the organization structure and the hierarchical relationships between workers across

various units and departments. The organogram of Fan Milk Plc as shown in fig 2.1 shows the

level of authority from the managing director all the way down to the IT students.

11
Fig 2.1 Fan Milk Plc Organogram

2.2. Safety and hygiene evaluation (SHE) policy is a policy put in place to ensure a safe and

healthy work environment for workers. Safety induction is an awareness program about likely

accidents that may occur within the factory and how to remain safe under such situation.

Safety induction is a compulsory requirement that must be taught to staffs and visitors before

they can enter the factory. Some of the things taught at the induction include guidelines for

working at height, around hazardous energy, confined spaces, driving safety, machine safety,

emergency exits, fire alarm and the most important of it all being personnel protective

equipment (PPE).

2.2.1 Personal protective equipment, commonly referred to as PPE, is equipment worn to avoid

various hazards in manufacturing facilities. Gloves, protective hearing gear (earplugs, muffs),

hard hats, goggles, respirators, and full-body suits are just a few examples of PPE. Employers

12
must provide their employees with the proper PPE for the specific task. Failure to do so can

result in serious injuries or even death.

PPE ensures more safety and reassurance in a dangerous manufacturing environment. It can be

the difference between a minor injury and a life-threatening one.

While many argue that PPE can interfere with work or be uncomfortable, the benefits of

wearing it far outweigh the drawbacks. Fan Milk Plc have policies in place that require

employees to wear certain types of PPE while working in certain areas of the factory.

There are many personal protective equipment types, each with a specific purpose. The type of

PPE you need will depend on the hazards present in your workplace. For example, laboratory

staffs working with chemicals make use of different equipment than engineers working on the

machines.

2.2.2 The usage of Personnel Protective Equipment (PPE) is very important in the company.

Some of the reasons for their usage is explained below:

1. Protection — PPE protects workers from injuries caused by exposure to hazardous

materials, including chemicals, noise, heat, and flying debris. It can also help prevent or

reduce the severity of injuries that do occur. Workers are the backbone of any operation,

and their safety should be a priority.

2. Morale — A safe workplace is also a happy workplace. When workers feel confident that

they are protected from potential injuries, they are more likely to have a positive attitude

and be motivated to do their best work which can lead to increased productivity.

3. Compliance — In some cases, wearing PPE may be required by law or regulation. For

instance, OSHA (Occupational Safety and Health Administration) has noise exposure

limits that require workers to wear hearing protection when working in loud environments.

4. Cost savings — Injuries can be costly, both in terms of medical expenses and lost

productivity. By preventing injuries, PPE can help save money for employers and workers

13
 alike. Expenses related to workplace injuries and illnesses are estimated to cost more than

$170 billion annually.

The types of PPE used within the factory differs depending on the hazards to which your work

station is subject. Below are some PPE used within fan milk plc, where, when and how they

are used

1. Face masks — These are worn on the production floor, in the laboratories, mixing section,

effluent treatment plant and ammonia plant. They to prevent staffs from inhaling toxic

chemicals, and also to ensure the safety of food products during production. Wearing a

mask at work will also prevent long-term respiratory problems

2. Protective clothing —different work stations requires different protective clothing. This

could include items such as gloves, lab coats, mop caps, departmental uniforms, Clean In

Place (CIP) uniform and safety boots. The type of clothing you need will depend on the

nature of the work you are doing, for instance; the gloves used by workers packing on the

product line differs from the ones used in laboratories.

3. Earplugs or earmuffs — certain parts of the factory can be noisy especially when some

machines are turned on, so it is important to protect your hearing. Earplugs or earmuffs

will help to reduce the noise levels that you are exposed to. Such places may include, PET

production and processing unit.

4. Safety glasses/goggles — Often there is a risk of flying debris or chemicals getting into

the eyes when working with chemicals in the laboratory, or getting affected by the

ultraviolet radiation from certain equipments. Wearing safety glasses will help to protect

the eyes from these hazard.

5. Hard hats— Essential in some work environments where there is a risk of objects falling

from above or workers falling at heights above 2metres. They protect your head from

impact and help to prevent serious injuries

14
6. Safety Harness — When working at heights, there is a risk of falling. Wearing fall

protection, such as a harness, will help to prevent serious injuries if you do fall

7. Fire extinguishers — Fire extinguishers are essential in any workplace, but they are

especially important in manufacturing facilities like fan milk. Having a fire extinguisher

close at hand can help to prevent serious injuries or damage to property

8. First aid kit — A first aid kit is available in all workplaces. This is because accidents can

happen at any time, and it is important to be prepared for them. First aid kits should

include bandages, disinfectant, and pain relief medication as well as showers and eye wash

in cases of chemical spills.

After the careful assessment and selection of PPE, training is given to employees on What PPE

to use and when to use it, Limitations of the PPE, How to use it, necessary adjustments,

Inspection and maintenance, PPE fitting and How to obtain required PPE. Re-training should is

also done from time to time. Also safety hazard forms are filled

15
 CHAPTER THREE

3.1 THE WATER TREATMENT PLANT

The water treatment plant is under the utility department of Fan Milk Plc. It is in charge of

providing and treating all the water needed for production processes. There are two water

treatment plant, there is the old plant and the new plant. The stepwise process of water

treatment in the old water treatment plant and the new water treatment plant is illustrated in fig

3.1a and fig 3.1b respectively.

3.1.1 Some of the equipment that is used in treatment of raw water are briefly discussed below

1. Raw Water Tank___ Raw water from Eleyele dam is pumped into the raw water tank in the

plant through underground pumps.The raw water tank has a capacity of one hundred and

thirty thousand (130,000) litres, 1kg Cl2(g) and 4.5kg of Al2(SO4)3.14H2O is dosed into the

raw water tank.

2. Sedimentation Tank___ Sedimentation tank, also called a settling tank allows suspended

particles to settle out of water as it flows slowly through the tank, thereby providing some

degree of purification. A layer of accumulated solids, called sludge, forms at the bottom of

the tank and is periodically removed. In drinking-water treatment, coagulants such as alum

are added to the water before sedimentation to facilitate the settling process, which is

followed by filtration and other treatment steps. There are two sedimentation tanks in Fan

Milk water old water treatment plant and they are used alternately, each sedimentation

tank has a capacity of a hundred thousand (100,000) litres. 500g of Cl2 is dosed into the

sedimentation tank.

3. Sand Filters___ The sand filters contain five layers of different particles sizes which

increases downwards. It’s function is to remove suspended matters as well as floating and

sinkable water particles. The inlet of this tank in at the bottom and outlet at the top

16
 therefore the water flows upward. The treatment plant has two sand filter tanks which are

the primary and secondary sand filters

4. Carbon Filters___ Carbon filters contain activated carbon which helps to remove

contaminants such as metals or residual chlorine responsible for taste, odour and colour of

water during treatment.The treatment plant has two carbon filter tanks which are the

primary and secondary carbon filters.

5. UV Sterilizer___ UV water sterilizer system utilizes Ultraviolet light to combat waterborne

pathogens while adding nothing to the water except UV light. UV is a safe, economical

way to remove illness-causing microbes in water. The treatment plant has two UV

Sterilizer which are the primary and secondary UV Sterilizers. The secondary UV

Sterilizer is four times(4x) more effective than the primary UV Sterilizer.

6. Big Underground Tank___ The big underground tank has a holding capacity of four

hundred and eighty thousand (480,000) litres. The water level is measured using tiles on

the wall of the tank and each tile represents forty thousand (40,000) litres. Depending on

the pH of the water a little amount of chlorine is dosed into the tank.

7. Small Underground Tank___ The small underground tank has a holding capacity of a

hundred thousand (100,000) litres, the water level is measured using tiles on the wall of

the tank and each tiles represents ten thousand (10,000)litres. No chemical is dosed into

this tank.

8. Micron Filters___ Micron filters remove dirt, debris, and even microscopic particles from

water. The pore size of a filter cartridge is measured in microns which is short for one

micrometer, or one-millionth of a meter . The smaller the micron rating, the finer the

particulate removed. Any particle smaller than 35 microns is too small to see without a

microscope while particles filtered from a 25, 20, or 10 are invisible to the naked eye. In

17
 Fan Milk water treatment plant, the micron filters used have a pore size of 10 microns,

5microns and 0.5 microns.

9. The BIODOS BIO-COMPACTOR___ The BIODOS BIO-COMPACTOR UNIT is a high-

rate solid and Turbidity purification, contact clarifier that combines optimized flocculation,

sedimentation of sludge and lamellar settling device to achieve very high hydraulic

loadings and treatment efficiencies. It is well proven in the field of physical and chemical

treatment of Drinking water and has been employed for a wide range of River Raw Water,

municipal and industrial applications.

Raw
Water Primary
Sedimenta Primary Carbon
Tank tion Tank Sand Filter
Filter

Seconda Secondar Small

Big ry Sand
Undergro y Carbon Undergro
Filter Filter und Tank
und Tank

5 Micron 0.5 Micron

10 Micron Filter Filter The Factory
Filter

Fig3.1a Flow Diagram Of The Old Water Treatment Plant

3.1.2 Some Chemicals are Used In The Treatment Plant, Chemical Reactions And Their
Functions

18
1. Aluminium sulphate Al2(SO4)3.14H2O is used for coagulation of water particles, however

it can lead to reduction in pH causing the water to become acidic as a result of ionization

of salt in water.

Al2(SO4)3.14H2O(s) ⇌ 2Al3+ + 3SO42-(aq) +14H2O(l)

Al2(SO4)3.14H2O(s) ⇌ 2Al(OH)3(aq) + 8H2O(l) + 3H2SO42(l)

2. Chlorine Cl2 (g) is used as a disinfectant in the chlorination of water, it helps to kill harmful

microorganisms in the water. HOCl and OCl- provide free chlorine residue in water.

Cl2(g) + H2O(l) ⇌ HOCl(l) + HCl(g)

HOCl(l) ⇌ H+ + OCl-
3. Caustic soda NaOH(s) increases the pH of water and can easily change hard water to a

much closer approximation to neutral when injected into the water treatment system.

Caustic soda decreases the solubility of dangerous metals, such as lead and copper (II).

The reaction of addition of caustic soda to water is exothermic.

NaOH(s) + H2O(l) ⇌ Na+ + OH- + H2O(l) H is negative.

3.1.3 Test Carried Out In The Water Treatment Plant

1. Chlorine test is done to check for free chlorine in the water. DPD (N, N diethyl-p-

phenylene diamine) powder, a free chlorine reagent that causes color change to pink in the

presence of chlorine is added into a vial of sample water. The vial is inserted into the

digital colorimeter that reads the intensity of the color change by emitting a wavelength of

light and automatically determining and displaying the color intensity (the free and/or total

chlorine residual) digitally. The result range is 0<2ppm

2. Turbidity is the measure of relative clarity of a liquid. it is caused by particles suspended

or dissolved in water that scatter light making the water appear cloudy or murky.

Particulate matter can include sediment - especially clay and silt, fine organic and

19
 inorganic matter, soluble colored organic compounds, algae, and other microscopic

organisms. Turbidity test is carried out by inserting a vial of sample water into the digital

colorimeter. The metre reads the turbidity and displays the result on the screen and the

results varies depending on where the water sample is taken from. For instance the result

range of sample water from the sand filter inlet is >/=7 sand filter outlet is </=0.5.

3. pH is a measure of how acidic or basic water is. The range goes from 0 - 14, with 7 being

neutral. pH of less than 7 indicate acidity, while a pH of greater than 7 indicates a base. pH

is a measure of the relative amount of free hydrogen and hydroxyl ions in the water. pH

test is done by inserting a vial of sample water into a digital pH metre. The result is

displayed on the screen and it varies depending on which inlet or outlet the water sample

was taken from. For instance water samples from the raw water tank tend to be acidic

while the one from the micron filters are neutral.

Big
Raw The BIODOS Sand Sand Undergro
Water BIO-COMPACTOR Filter Filter und Tank
Tank

10 0.5
Carbon 5 Micron
Carbon Micron
Filter Micron Filter
Filter Filter
Filter

Small
Undergro The Factory
und Tank

Fig.3.1b Flow Diagram Of The New Water Treatment Plant

20
3.2 INTRODUCTION TO THE MIXING UNIT

The mixing unit is responsible for incorporating raw materials according to approved recipe by

authorized personnel to create product mix. The mixing is closed to unauthorized personnel,

there is a hand and safety boot washing system as shown in fig 3.2 at the entrance to prevents

dirt from outside getting into the unit.

3.2.1 Procedures For Mixing

Mixing day store___ these is where all powdered raw materials such as maltodextrin, spray

skimmed milk powder (SMP), purity, cassava starch, whey powder, full cream milk, refined

sugar, raw cocoa powder used for mixing are stored.

Flavour room___ flavours and inclusions such as raspberry sauce, caramelized peanut, vanilla

flavour, green apple flavour etc are stored in this room at a very low temperature.

De-bagging section___ the de-bagging section is where raw materials such as sugar, whey

powder and skimmed milk powder (SMP) are poured down the kek gardner machine which

has a funnel like opening to commence the mixing process.

Almix tank___ powdered ingredients poured down the kek gardner machine are sucked into the

almix tank through a vacuum. The almix tank already contains water and the ingredients is

mixed continuously while been sent back and forth between the almix tank and selected

mixing tank until homogenity is achieved. The tanks are connected through a connector on the

flow plate. Raw materials from production clerk such as acesulfame k (an artificial sweetner

which is a hundred times sweeter than sugar) and sucralose is poured down the funnel on the

almix tank .

Mixing tanks___ there are four (4) mixing tank labelled 301,302,303 and 304. Tanks 301 and

302 are used for mixing water based products 1.e fan dango while tanks 303 and 304 are used

for mixing milk based products such as ice cream, fanvanille, superyogo etc.

21
Chocolate slurry tank___ raw cocoa powder for chocolate flavoured product is heated at a

temperature of 920C to eliminate microbes present in it.it was noticed that heating the raw

cocoa powder at the processing section only does not bring out the desired chocolate flavour

and colour, also the shelf life of product is reduced hence the heating at the mixing section is

suggested.

Emulsifier/ oil tank___ emulsifier such as FS, palsgaard and FCM are poured inside this tank

and palm kernel oil is also dosed inside automatically. The amount of palm kernel oil dosed is

controlled through the data that has been imputed on the HMI system in the mixing section.

Heater is used to prevent the oil from congealing.

HMI___ human interpret machine (HMI) is an automated system based on data input that

controls all activities done in the mixing section such as CIP, downloading mix amount, oil

dosage, heating and mix transfer processes.

CIP is done after mixing each products.

Batching checklist is filled to track batch number, manufacturing date and expiry date of raw

materials used for each mix.

Traceability is done to record all raw materials received and used during the mixing process.

Fig 3.2 The Hand And Boot Washing System At The Entrance Of The Mixing Section.

22
Note that the addition of water in excess during mixing can reduce the pH of ice cream

causing it to be watery.

3.3. INTRODUCTION TO THE PROCESSING UNIT

The processing unit perform series of mechanical and chemical operations on products in order

to improve products taste, appearance and shelf life.

3.3.1 Some of the activities that takes place in the processing unit are briefly explained below

1. Homogenization___ homogenization is a process of reducing a substance, such as the fat

globules in milk, to extremely small particles and distributing it uniformly throughout. in

this process, a solution whose components are ordinarily immiscible such as milk is mixed

to uniformity so that its components can be

2. emulsified. Since Fan Milk majorly deals with milk based products, homogenization is an

important step for production.

3. Pasteurization___ Pasteurization is a process of food preservation involving treatment of

packaged or non-packaged foods with mild heat at a temperature less than 1000C for the

main purpose of eliminating pathogens and extending shelf life. Pasteurization can alter

the sensory, feel and nutritive value of food. It is u8sed in the dairy industry for making

starter cultures used in the production of cheese, yogurt, buttermilk and some ice creams.

4. Innoculation___ This is the addition of water and Skimmed Milk Powder (SMP) to the bulk

starter to form starter culture during yogurt production. This process is executed by

intentionally depositing microbes into ingredients for making yogurt which leads to the

production of lactic acid, aroma compound, exopolysaccharides and inhibitors which

enhance the taste aroma and flavour of the final product. The tank capacity for

innoculation is 4000 liters and the process takes up to takes 8 hours.

i. 400 starter = 12000 liters of yogurt

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5. Fermentation___ This is a process in which milk is converted into yogurt by introducing

bacteria which converts the lactose sugars in the milk into lactic acid. The lactic acid is

what causes the milk, as it ferments, to thicken and taste tart. Because the bacteria have

partially broken down the milk already, it is thought to make yogurt easier for us to digest.

Fermentation process takes up to 4hours.

6. Flow Plate___ Flow plates are stainless steel plates with several nozzles that are used to

divert the flow from common sources to different destinations. The flow plates are durable,

of high quality, and have a superior steel finish. The flow plate connects to the mixing

lines, aging tank, fermentation tank, CIP lines and storage tanks.

7. Agitation___ Agitation refers to forcing a fluid by mechanical means to flow in a

circulatory or other pattern inside a vessel. Since the mixing process involves the addition

of immiscible components, inside the storage tanks post processing are agitators for

continuous mixing. However agitation is stopped for superyogo-containing tanks because

it affects its viscosity I.e it causes the superyogo to become light.

When a product mix is sent for processing, the balance is the reception point. There are three

sensors on the balance tank which regulate the flow rate in the tank. The bottom sensor is for

preventing dryness, the middle sensor is for ensuring balance and the top sensor prevents

overflow.

Note that Inoculation and fermentation process are peculiar to yogurt products I. E superyogo,

and pH of yogurt is usually </=4.4.

There is a pump connected to the balance tank that sucks in the mix and allows it to pass

through the two filters before going into the pasteurizing unit. The pasteurizing unit consists

of the pasteurized and the holding unit. Four processes take place in pasteurizing, they are

preheating, heating, pre-cooling, and cooling. The order at which these processes takes place

varies for milk based and water based products as shown in fig3.3a and fig3.3b.

24
 Balance Pump First Second
Tank Filter Filter

First Stage
Preheating
Homogenization

Holding
Second Stage
Tubes
Homogenization

Storage
Pre-cooling Cooling Tank

Fig3.3a flow diagram for milk-based products in the processing unit

Balance
Pump First
Tank
Filter

Second
Preheating Heating
Filter

Storage
Pre-cooling Cooling Tank

Fig3.3b The Flow Diagram For Water-Based Products In The Processing Unit

25
Note that water-based products I. E fandango does not require homogenization.

The pasteurizing temperature for the product mix varies from product to product. The heating

and cooling temperatures of some products can be seen in table 3.3c).

Table 3.3c Products Pasteurizing Temperature Table

S/N PRODUCT HEATING TEMP (+/-)10C COOLING TEMP (+/-)10C

1 FANCHOCO 95 45

2 SUPERYOGO 95 45

3 ICECREAM 85 5

4 FANVANILLE 85 5

5 E/PINEAPPLE 85 5

6 E/MANGO 85 5

7 E/APPLE 85 5

8 E/STRAWBERRY 85 5

3.4 INTRODUCTION TO THE PRODUCTION FLOOR/PACKAGING UNIT

The production floor is the most active unit of the company because it is responsible for

ensuring quality is achieved in each production stage through the activities of in-process

checks. Basically, they are responsible for the production and packaging of all fan milk

products.

The production floor is divided into two regions which are the in-feed and the out-feed region.

The in-feed region is where sachet products are packed on the three production line namely

line 1.1, line 1.2, line 1.3. line 1.1 and 1.2 uses the DJ machine for packing and the SCANIMA

and SCANICO freezers respectively for freezing the product before sending it to the out-feed

region for packaging. Line 1.3 uses a THIMMONIER line and freezer and it is completely

automated which makes work more easier for staffs.

26
Documentations of activities that take place on both the in-feed and out-feed regions are

imputed on an excel sheet. These documentations include: leakage test, eight control, mix loss,

total amount packed and staff register are all imputed on the excel sheet for record purposes.

Leakage test is carried out to check the amount of leakage per machine so as to improve where

necessary.

Engineers are on stand-by in case of machine emergencies.

3.5. INTRODUCTION TO THE ICE-CREAM SECTION

The ice cream section is where ice cream products undergoes final processing and packaging.

Ice cream is defined as the frozen dairy production made by proper blending and processing of

cream and other milk product, together with sugar and flavor, with or without stabilizer or

color, and with the incorporation of air during the freezing process. Some of the ingredients

used in the production of ice cream are categorized based on their usage in table 3.5

Table 3.5 Table of Ice Cream Ingredients

S/N CATEGORY EXAMPLES

1. Oil and Emulsifier Palm Kernel Oil (PKO), Palsgaard

2. Sweetener Sugar

3. Stabilizer and Thickeners Maltodextrin

4 Flavour and Colour Vanilla, Banana, Strawberry, Cocoa Powder etc.

5. Allergens Peanut, Almond, Milk, Wheat, Soya, Egg etc

6. Milk Skimmed Milk Powder, Full Cream Milk

Note that palsgaard is an emulsifier used in the production of ice cream, without it, ice cream

will be too light.

27
3.5.1 Some of the activities that takes place in the ice cream section may include the

following

1. Ice cream ageing____ Processed ice cream is sent to the ageing tank to thicken the ice

cream mix, improve scoopability, melt resistance, texture, mouth feel and eat shock. Ice

cream ageing takes at least four (4) hours at a temperature of -40C.

2. Flavour, colour and inclusion____ Plain ice cream is mixed at the mixing unit and sent for

processing. Flavour, colour and addition of inclusion takes place at the ice cream section.

3. Freezing and incorporation of air also takes place in the ice cream section.

4. Overrun is done to check the amount of air that have been incorporated in the ice cream to

expand it during the freezing process. Overrun affects the smoothness, consistency and

taste of ice cream.

5. Traceability is done to keep track of all ice cream mix received and packed, raw and

packaging materials used in the ice cream section. Some of the machines used in the ice

cream section can be seen in fig.3.5

Fig 3.5 Image Of The Ice Cream Section, The Cup And FROSTO Machines.

28
3.6 INTRODUCTION TO THE PET PRODUCTION SECTION OF FAN MILK PLC

The PET section is the unit in charge of production of bottled products. Activities from

blowing preformed PET into bottles to filling and packaging all takes place in this section. The

PET section is not an automated system, so workers are there to monitor each step of

production. The image of the blowing machines and the filling and sealing machines used in

the PET section of Fan Milk Plc can be seen in fig 3.6a and fig3.6b respectively. However the

company is working on a new PET section which is completely automated and does not

require human interference. The new PET section is called ROCKET. Some of the machines

used in the ROCKET section can also be seen in fig 3.6c

3.6.1 Introduction To The Plastic

Polyethylene Terephthalate (PET) is a non-porous thermosetting plastic that is perfect for

manufacturing anything that needs to be water-tight. PET is a popular choice for drink bottles

because it is lightweight, safe, and fully recyclable.

3.6.2 The Mode Of Fabrication Of PET Bottles Using The Blow Moulding Technique

The PET section of Fan Milk make use of a blow moulding method to blow preformed PET

into bottle for production. The PET bottle blow molding process works by reheating a pre-

molded PET preform in an oven,until it reaches a rubbery state, the operator then positioned

them into a mold. High-pressure food-grade compressed air is then injected into the preform

which expands to form the shape of the mold. Once the plastic has cooled, the bottle is

removed and the process is repeated until required quantity is met.

29
Fig 3.6a The Pet Section; The Bottle Blowing Machines.

3.6.3 The procedures involved in production of beverages using PET bottles is briefly

explained below

1. Bottle washing____ The next stage of production is bottle washing and rinsing, with an

automated bottle washing system which has proven effective. The water used in washing

the bottle is a solution of 150ml hydrogen peroxide diluted with 30 litres of pasteurized

water for the sterilization of the bottles.

2. Bottle filling____ The bottles are arranged in the filler which fills up the bottles with the

product through a nozzle. There is a sensor attached to the filler that helps to guard against

over-filling or under-filling.

3. Bottle capping____ There is a capping machine for capping the bottles, the covers are

poured inside the capping machine which automatically caps the bottles and seal it. UV

light is used to disinfect the bottle covers.

4. Bottle labeling and coding____ Labels are put on the bottles manually, after which it is

placed on a conveyor in front of the domino coding machine, to imprint production date,

30
 expiry date, batch number, mix number and production time on the labels. Make up is used

with the ink for the coding machine to avoid blotting, pealing or staining.

5. Label fitting____ The infrared shrink packing machine is used to shrink the labels to fit the

bottles, making it firm and smooth.

6. Product packaging____ A plastic carton machine is used to wrap up the products in a group

of six after which it is sent inside a machine for shrinking and fitting the plastic wraps

around the bottles. the carton of six is picked up at the other end of the machine and

arranged in a jumbo before getting sent to the platform for storage.

7. Cleaning____ CIP is done using 150g sodium benzoate, 150g potassium sorbate, 60g citric

acid and 30 litres of pasteurized water.

Fig 3.6b The PET Section; The Filling And Sealing Machines.

31
Fig 3.6c The New PET Section (ROCKET)

3.7. INTRODUCTION TO THE EFFLUENT TREATMENT PLANT (ETP)

The effluent treatment plant (ETP) is a wastewater treatment process (WWTP) that is used to

treat wastewater. It's mostly used in industries like pharmaceuticals, textiles, and chemicals

where extreme water contamination is a possibility. Effluent Treatment Plant plays a

significant role in the treatment of industrial wastewater as well as domestic sewage. Organic

matter, inorganic matter, heavy metals, oil & grease, suspended particles, and other

contaminants are treated in the wastewater treatment process of an ETP plant. Chemical

treatment, biological treatment, a combination of chemical and biological treatment, and

thermal treatment are the several types of wastewater treatment plants. A system of combined

chemical and biological treatment is employed in Fan Milk Plc.

Note that;

Effluent: Treated industrial waste water.

Sludge: Solid particles separated from waste water by ETP.

Benefits of ETP include:

1. To clean industry effluent and recycle it for further use

32
2. To reduce the usage of fresh/portable water in industries

3. To preserve the natural environment against pollution

4. To meet the standards for emission of pollutants set by the Government & avoid heavy

penalty

5. To reduce expenditure on water acquisition

3.7.2 The physical Treatment plant of involves the filtration, sedimentation and clarification

of waste water before sending it to the chemical plant for further treatment. Some of the stages

involve in the process are explained below.

1. Receiving pit____ this is where all waste water (other than water from toilet and kitchen)

from all production processes is received. inside receiving pit has a sieve for filtering out

particulates substances such as film cut-offs, nylons and plastics that managed to get into

the pit. There’s also a submersible pump that pumps filtered waste water to the

sedimentation pit.

2. Sedimentation pit____ It is a physical waste water treatment process which uses gravity to

remove suspended solids from water. The waste water travels slowly in this process,

causing the heavy particles to settle to the bottom. Sludge is the term for the particles that

gather at the bottom of the pit.

3. Storage tank____ the storage tanks is where waste water from the sedimentation pit goes to.

There are five (5) storage tanks each of 20,000 litre capacity.

4. Central control unit (CCU)____ the CCU is where waste water is pumped into the buffer

tanks. There is a flow metre that measures the water level in the man-hole.

5. Buffer tank____ the buffer tank has a capacity of 65,000 litres, it helps to manage harmful

chemicals present in waste water by maintaining the pH of the waste water going to the

chemical plant.

33
3.7.3 The Chemical Treatment Plant is a plant where waster water is treated for the sole

purpose of removing all floating and settleable materials such as suspended solids and organic

matter. Chemical unit processes are always used with physical operations and may also be used

with biological treatment processes. chemical processes use the addition of chemicals to the

wastewater to bring about changes in its quality. Effect of chemical treatment of waste water

may include pH control, coagulation, chemical precipitation and flocculation.

Procedure for chemical treatment

1. Chloride tank____ the ferric chloride tank is a mixing tank which serves as a inlet for Ferric

waste water coming into the chemical plant from the buffer tank. Ferric chloride is dosed

into these tank to aid coagulation (i.e collecting the minute solid particles dispersed in

waste water into a larger mass). Waste water coming from production is often basic as a

result of the caustic soda (NaOH) used for CIP, hence, ferric chloride can reduce the pH of

the waste water due to the creation of hydrogen ion in the reaction of ferric chloride with

waste water as shown below

FeCl3(s) ⇌ Fe3+(aq) + 3Cl-(g

FeCl3(s) + 3H2O(l) ⇌ Fe(OH)3(s) + 3H+(g)

2. Caustic soda tank____ caustic soda (NaOH) is dosed into this tank to regulate pH of waste

water, increase metal solubility and conversion of hard water to relatively neutral water. A

universal pH strip is used to check the pH of water in the tank and if the pH is low, caustic

soda (NaOH) is dosed into the tank to increase the pH. The reaction of caustic soda

(NaOH) with waste water is shown below;

NaOH(s) + H2O(l) ⇌ Na+ + OH- + H2O(l) H is negative.

34
3. Neutralization tank____ the neutralization tank is basically a mixing tank with an agitator

inside it. The function of this tank is to maintain the pH range of 6-9 to meet the

requirements of different processing units in the ETP system.

4. Polyelectrolyte tank____ polyelectrolyte ia a neutral compound which is dosed into this

tank to enhance flocculation. Flocculation involves the addition of destabilized particles

together into large aggregates so that they can be easily separated from the water.

5. DAF unit____ DAF stands for dissolved air flotation. The working principle of the DAF

unit involves the use of compressed air from the air compressor and water passing through

the hydrophore via a recycling pump to attach air bubbles to suspended solids thereby to

keep sludge afloat. By keeping the sludge afloat, clean water is seperated from the sludge

in the DAF unit, the sludge is goes down into the sludge outlet and the clean waste water

goes to the biological plant.

The pH of effluent at the chemical plant is continuously checked at an interval of one hour

using a universal pH strip as shown in fig 3.7a. This is done in order to regulate the pH of the

effluent in the chemical plant. The pH of effluent that has been chemically treated is expected

to be neutral I.e 7.

Fig 3.7a Effluent Treatment Plant (ETP); The Chemical Plant

35
3.7.4 The objective of the biological treatment plant is the further treatment of the effluent

from the chemical treatment plant to remove the residual organic and inorganic compounds as

well as harmful microorganisms.The biological plant is divided into three

parts with a filter like demarcator that stops the water from the different parts to mix with each

other. Some of the chemicals used in the biological plant are diammoniumphosphate (DAP),

oxygen activated carbon, chlorine and urea.

There are two fudilated micro reactor (FMR) pumps, one on each side of the plant pumping

water into the plant. Oxygen is dosed into the water through a hose attached to the diffuser

suspended in the water. The diffuser has holes through which air goes into the water. Urea and

diammoniumphosphate are added to the first and second part of the plant where mixing takes

place and activated carbon is added to the water as a filter for removing residual chemicals in

the water. There is a lamella that filters the water allowing all solid particles such as sludge

come together.

The water flows to the third side of the plant where chlorine is added to the effluent as a

purifier/disinfectant. There is a lamella at the end of the third part of the biological plant

through which effluent flows into the stream via a pipe.

3.8. INTRODUCTION TO QUALITY DEPARTMENT

This department is otherwise known as the heart of the industry because it ensures the quality

of materials used and the finished product sold out to consumers for their consumption. They

are mostly concerned with sample analysis, specifications, organization, and documentation to

ensure that the finished product and raw materials are of standard. The quality control has the

power and jurisdiction to approve or reject any component, after adequate laboratory

procedures.

36
3.8.1 Quality assurance and control.

The term quality assurance and control are often used to refer to ways of ensuring the quality

of a service or products. For each analytical procedure, quality assurance and control is

extremely important.

Quality assurance is process-oriented and it focuses on defect prevention while quality control

is product-oriented and focuses on defect identification. However, the objectives of a quality

assurance and control programme include:

1. To document the procedures and methods of sample collections, preparations and

2. Analysis.

3. To provide assurance as to reliability of analysis using replicate samples and cross

laboratory checks.

4. To provide assurance as to the accuracy from using recognized reference standards.

5. To provide a chain of custody of samples.

6. To provide assurance as to the precision and accuracy from the duplicate samples.

Both the quality assurance and control are after quality products and they function to see that

the products being produced are of high quality and standards by performing both chemical

and microbial tests to attest the quality of the products.

3.8.2 Good Laboratory Practice (GLP)

Good laboratory practice (GLP) induction is an orientation program done for new laboratory

assistants, interns or corp members working in any of the laboratories to ensure that they are

familiar with the hazard and safety precautions peculiar to their workspace. Things taught

during the induction include, hazardous chemicals and equipment, emergency exits, how to

take care of chemical spills etc, and personnel protective equipment needed in the laboratory

such as; gloves, face mask, safety goggle, face shield, lab coats etc.

37
3.8.3 Introduction To The Physio-Chemical Laboratory

The physio-chemical laboratory provide an overview of the physical and chemical properties

finished products, raw materials, packaging materials as well as water samples by running

various test, allowing the organization make more informed decision for production processes.

The physical and chemical test parameters carried out in the laboratory and their objectives can

be seen in table 3.8a and 3.8b respectively.

Table 3.8a Physical Test Parameters Table

S/N Physical Test Parameters Objectives

1 Sensory and weight control We check finished products for color, flavor, taste,

weight, sealing and packaging condition.

2 Overrun To get uniform texture and mouth feeling

3 Temperature To prevent the growth of microorganisms

4 pH To determine acidity and alkalinity

Table 3.8b Chemical Test Parameters Table

S/N Chemical Test Parameter Objectives

1 Fat analysis To ensure the proper composition

2 Water analysis To ensure that water is suitable for production

purposes.

3 Titratable acidity To determine the strength of CIP

38
Fig 3.8a Physio-chemical Laboratory Equipment

Common equipment used in the physio-chemical laboratory apart from the ones shown in fig

3.8a may include oven,desiccator, centrifuge,weighing scales etc.

3.8.4 Introduction To The Quality Online Section

Quality online is a sub branch of the physio-chemical laboratory. However, they work on the

production floor and do documentation of quality incidence observations, carry out weight

control, ice cream overrun and take CIP swab.

3.8.5 Introduction To The Microbiology Laboratory

The microbiology laboratory carries out microbial control of production environment,

microbial analysis of raw materials, finished products and water. They are also in-charge of

distillation of water and ringer solution used in laboratory analysis. One of the major analysis

done in the microbiology lab is plating. Refer to fig 3.8b to see the environment of the

microbiology laboratory.

Plating is a technique typically used to separate microorganisms contained within a small

volume of sample which is spread all over the agar plate, resulting in formationof discrete

colonies distributed evenly across the agar surface when the appropriate concentration of cells

is plated.

39
Documentation is done for all analysis carried out in the microbiology laboratory, these

documentation include;

1. Processed water analysis

2. Finished products analysis

3. Traceability

4. Air sampling

5. Recovery water from mixing

6. Quality incidence observation (QIO)

7. Inventory

8. Hygiene audit

9. Raw and packaging materials

10.Raw water from the water treatment plant.

Fig 3.8b The Microbiology Laboratory

40
Table 3.8c Table of Microbial Test Parameters And Objectives

S/N Microbial Test Required Reagent Objectives

Parameters

1 Total variable Plate count agar To count the total number of

count (TVC) (PCA) microorganisms in a product

2 Yeast and mould Oxytetracycline To detect and quantify the amount of

count glucose yeast agar fungal growth on plant material, and

(OGYE) allow for identification of viable yeast

and mold species present in a product

3 Coliform count Eosin methylene blue To identify coliform count that causes

(EMB) diarrhea, urinary tract infection, wound

infection, appendicitis, infection of gall

bladder etc.

4 Enterobacteriacae Violet red bile glucose To identify indicator groups such as

count (VRBG) agar salmonella and shigella which can cause

food spoilage in a products.

5 Swab Ringer solution To verify the effectiveness of hygiene

and cleaning programs put in place.

6 Air sampling To check the microbial load of the air

using air sampler around the factory in order to facilitate a

safe production environment

3.8.6 Introduction To The Research And Innovation Laboratory

The research and innovation laboratory is in charge of developing and commercializing new

ideas, implementing new processes and creating new recipe for production. The aim of the

41
laboratory is to further develop existing products and new ones while cutting cost and

maintaining the quality of products. Other than the equipments shown in Fig 3.8c, other

equipment that can be found there may include pallets, refrigerators etc. .

Fig 3.8c The Research And Innovations Laboratory

3.8.7 The actual work done in the laboratory include running test and analysis on raw, cleaning

and packaging materials.

1. Cleaning

cleaning is done in the lab by using ethanol and cotton to clean the slab and equipment every

morning. This is done as a measure to disinfect the work environment.

2. Room and freezer temperature measurement

The temperature of chest freezers, standing freezer, laboratory and ambient room temperature

is read with a thermometer every morning and the results are documented for record purposes.

This is done to ensure a conducive working environment.

3. Weighing scale calibration

The weighing scale is calibrated every morning using standard masses of 5g, 10g, 50g, 100g,

500g, 1000g and 2000g respectively. These standard masses are weighed with the weighing

42
scale and the result displayed by the scale is compared to those standard masses. Accuracy and

deviations are documented. This is done to accuracy and precision when weighing raw

materials, finished product or chemicals for analysis.

4. Refractometer calibration

A refractometer is an equipment used to determine the water content of a liquid. It uses the

principle of refraction of light and the refractive index changes according to the moisture

content. To calibrate an automatic refractometer in the laboratory;

The refractometer should be stored at a temperature of 200C

Add two (2) to three (3) drops of distilled water to the prism of the instrument. Be sure

to avoid air bubbles and dry spots.

The limit line displayed on the refractometer must be zero. If it is not zero, there’s need

for readjustment by choosing zero on the adjustable numbers displayed.

5. Water Analysis

Water analysis is done on both processed water and raw water from the water treatment plant.

Both water samples are tested for pH, conductivity, total dissolved solid (TDS), chloride and

total hardness. Processed water sample is taken from the first and second condenser outlet

which are; the soft, the boiler and the feed.

I. Procedure for pH Test using a multi-parameter photometer____ insert the pH probe

connected to a multi-parameter photometer into the water sample, the multi-parameter

photometer reads the pH and displays the result on the screen. The result range should be

between 6.50 and 8.50 in two decimal places.

II. Procedure for conductivity using a multi-parameter photometer____ insert the conductivity

probe connected to a multi-parameter photometer into the water sample, press RAN

GE+ALT twice to check for conductivity. The result is displayed on the screen and the

unit for conductivity is microsiemens.

43
III. Procedure for total hardness for processed water____ measure of 5ml processed water

sample, add total hardness reagent (in form of tablets). Continue to add the tablets until a

colour change from purple to blue is observed.

(Number of tablets used x 40) -20 = total hardness of processed water.

Note that result range should be <150

IV. Procedure for total hardness for raw water ____ measure 5ml of raw water sample, add

drops off hardness buffer five times (5x). Add calmagite indicator once and EDTA drops

using a syringe read through the second marking on the syringe

syringe readings x 300 = total hardness of raw water.

V. Procedure for chloride test for processed water____ measure 50ml of processed water

sample, add chloride reagent tablets until a colour change from yellow to brown is

observed.

(Number of tablets used x 20) -20 = chloride content of processed water

Note that result range should be less than 100

VI. Procedure for chloride test for raw water____ measure 5ml of raw water sample, add two (2)

drops of phenylcarbone. Add drops of nitric acid until solution turns yellow, using a

syringe add drops of mecuric nitrate solution until colour changes to purple. Take readings

on the syringe from the second marking.

Syringe readings x 1000 = chloride content of raw water.

VII. Procedure for total dissolved solid (TDS) determination using a multi-parameter

photometer____ insert the probe connected to a multi-parameter photometer into the water

sample. Press RANGE+ALT once to check for TDS. The result is displayed on the screen

and the range must be <500.

6. Fat Analysis

44
fat analysis is done to ensure that the amount of fat present in products is in correct measure.

The instrument used for fat analysis is butyrometer. Taking ice cream a typical example, the

procedure for fat analysis of ice ream is as below;

Add 15,76M H2SO4 to 5ml of ice cream sample, add 1ml of amyl alcohol (C5H11OH)

and 5ml of water, shake well and leave it in the centrifuge for ten minutes. The result range for

ice cream when reading the butyrometer is always around 8.

Note that;

the amount of water added during fat analysis does not necessarily have to be 5ml, instead the

butyrometer should be filled up to the point where the results can be readable.

For Fan Milk products other than ice cream, 10ml 0f the product sample is used for fat analysis

and their result range from 2 to 5.

In situations where more than one type of product is being analyzed, each butyrometer should

be appropriately labeled to avoid mix ups

The process of fat analysis is an exothermic reaction. Once the mixture is shaken, the

butyrometer becomes hot.

7. Titratable Acidity

Titratable acidity is usually conducted on the caustic soda and citric acid used during clean in

place (CIP).

Procedure for checking titrarable acidity for caustic soda (NaOH)____ measure 10ml NaOH, add

two (2) drops of phenolphthalein, titrate the resulting solution against 0.1M of H2SO4 . wait till

an observable colour change is observed then take readings.

Readings x 0.08 = titratable acidity for NaOH. Result range is 1 < 1.5

Procedure for checking titratable acidity for acid____ measure 10ml of add two (2) drops

phenolphthalein and titrate against 0.1M NaOH

Result range for the titratable acidity of acid is 0.8<1.2

45
8. Preparation of Ringer Solution

A ringer solution is a mixture of salts dissolved in water that is used to make an isotonic

solution similar to an animal's body fluids. Ringer's solution is a concentrated water solution

containing Sodium chloride (NaCl), potassium chloride ( KCl), calcium chloride (CaCl2), and

sodium bicarbonate (NaHCO3), as well as other minerals including MgCl2 are commonly used

in Ringer's solution, with sodium bicarbonate (NaHCO3) being used to stabilise the pH. In the

microbiology laboratory, ringer solution is used for plating swab from CIP and hygiene audit.

Reagents used to Prepare a Ringer Solution

I. 7.2 g sodium chloride - NaCl

II. 0.37 g potassium chloride - KCl

III. 0.17 g calcium chloride - CaCI2

Procedure to be followed to prepare a ringer solution

I. In a beaker, add 500 ml of distilled water.

II. Using distilled water, dissolve the reagents in the beaker.

III. Add water to bring the final volume to one litre.

IV. Adjust the pH to 7.3-7.4.

V. Filter the solution through a 0.22-μm filter.

VI. Autoclave Ringer's solution prior to use.

3.8.8 Some of the equipment & machines, item and chemicals that can be found in the

laboratory will be mentioned in table 3.8;

46
Table 3.8 Table Of Equipment & Machines, Item And Chemicals

S/N CATEGORY EXAMPLES

1. CHEMICALS methyl orange, potassium iodide, sulfonic acid, acetic acid, ethyl

alcohol, chlorine tablets, conductivity standard, buffer 4, buffer7,

buffer 10, 15.76M H2SO4, 0.05M H2SO4, 0.1M NaOH, silver nitrate

(AgNO3), ethanol, (EDTA) methanol and phenolphthalein.

2. EQUIPMENTS centrifuge, standing and chest freezers, desiccator, pH metre,

refractometer, oven, leak tester, pipette pump, titrino plus titrator

and accessories, viscometer, glass wares (pipette, burette, conical

flask, beaker etc), turbidity metre, weighing balance, ATP metre,

moisture content analyzer, multi-parameter photometer, magnetic

stirrer, sampling bottles etc.

3. OTHERS tissue, trays, pumice, bowls, bucket, raw materials, reference

samples, packaging materials, cotton wool, personnel protective

equipment (PPE), and stationery

47
 CHAPTER FOUR

4.1 SUMMARY

Having gone through the necessary training involved in student industrial work

experience scheme (SIWES) with the experience gained for six months; it is highly expedient

for me to summarize my report on the platform of what I engaged in during this period. More

so, I want to recall that during my industrial attachment at Fan Milk Plc, I was exposed to

series of work that goes into the production, processing and packaging of the frozen dairies,

yogurt and ice cream we eat with pleasure. This experience has helped me understand the

diverse application and the beauty of being an industrial chemist.

4.2 CHALLENGES ENCOUNTERED

Getting placement for Industrial Attachment is really difficult especially for people without

connections in those organization.

Cash scarcity during the period of cash scarcity, it was really hard to commute to work because

a there was no time to stand in line at banks for cash withdrawal, ridiculous charges are

requested by POS operators and unwillingness of transporters to accept online cash transfer.

Distance It takes a lot of resources and time to get to my place of attachment from my place of

abode. It was physically, mentally and financially draining as I have to wake up early to meet

up with resumption time to my work station which is 8am and I get home really late due to

traffic.

Fuel subsidy removal prior the subsidy removal, the monthly allowance paid by Fan Milk was

only enough to take me to and from work for 10 days, however after the subsidy removal

transportation price was hiked and my transportation expenses was doubled.

4.3 RECOMMENDATION

Fan Milk Plc should provide improve the staff welfare system in order increase workers

morale and productivity.

48
The SIWES body should endeavor to pay the students industrial visits regularly to ensure that

the students are being trained as expected and not used for purposes other than why they are

there and monthly allowances for students on attachment should be paid promptly

The SIWES body and institution should assist students in securing placement for their

internship.

It will be of great benefit if the institution can create a platform whereby student can obtain

pre-SIWES knowledge or excursion programs, before student embark for general 6 months

industrial training programme.

4.4 CONCLUSIONS

My Student Industrial Work Experience Scheme (SIWES) training with Fan Milk Plc has

provided an avenue for me to understand practical aspects of the theoretical knowledge already

acquired in some of the courses I have offered so far as an undergraduate of industrial

chemistry department. Through the training I gained insight and more comprehensive

understanding about the real industrial working condition and has greatly improved my

interpersonal skill. I was also exposed to various instruments/machines, equipment,

professional work methods and ways to safe guard the work environment in industries and

various organizations. This training also gave me the opportunity to interact, share knowledge

and ideas with other students from different institutions. I therefore concludes that SIWES is of

great benefit to students in tertiary institutions. This implies that the proper and effective

administration of SIWES will go a long way in boosting and enhancing the competencies of

the workforce of the country.

49
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