Factory Organisation PLANT L。eATl。N The location of the dehydration factory must be considered very carefully, because, whereas at one time proximity to the source of raw materials was of paramount importance, availability of an adequate labour force and the provision for effluent disposal will, perhaps, constitute a more pressing requirement A rural environment is obviously better than a location in a highly industrialised area, because operation involves the utilisation of a considerable amount of open space for the rec materials, particularly where vegetable dehydration is being undertaken This chapter, in dealing with factory planning, proceeds on the premise that vegetables are the principal raw material to be processed Fruit dehydration is dealt with in Chapter 7 On the assumption that the labour availability factor has been resolved, and co-operation from the Local authority on effluent disposal has been secured, it is important that the location should be a focal point for the intake of indigenous raw material within a radius of some 80 kilometres. In the case of highly perishable vegetables, such as vined peas and green beans, availability should be within half that radius. These figures are relevant where the scale of ope s an intake of 70-80 tons of produce per day, which is, in effect, a viable level upon which to work. This would be regarded as a medium size plant Production on a larger scale would call for a wider area of raw material
2 Facto ry 0 rgan i sat io n PLANT LOCATION The location of the dehydration factory must be considered very carefully, because, whereas at one time proximity to the source of raw materials was of paramount importance, availability of an adequate labour force and the provision for effluent disposal will, perhaps, constitute a more pressing requirement. A rural environment is obviously better than a location in a highly industrialised area, because the operation involves the utilisation of a considerable amount of open space for the reception and storage of raw materials, particularly where vegetable dehydration is being undertaken. This chapter, in dealing with factory planning, proceeds on the premise that vegetables are the principal raw material to be processed. Fruit dehydration is dealt with in Chapter 7. On the assumption that the labour availability factor has been resolved, and co-operation from the Local Authority on effluent disposal has been secured, it is important that the location should be a focal point for the intake of indigenous raw material within a radius of some 80 kilome-. In the case of highly perishable vegetables, such as vined peas and green beans, availability should be within half that radius. These figures are relevant where the scale of operation presupposes an average intake of 70-80 tons of produce per day which is, in effect, a viable level upon which to work. This would be regarded as a medium size plant. Production on a larger scale would call for a wider area of raw material 21
availability but, in the ensuing chapters, it is intended to concentrate on the problems of the medium size operator, coming into the industry for the first time, or developing into dehydration from some other food processing activity. It is, perhaps, more likely, at this stage of the growth of dehydration, that development in Europe will be at this sort of level, rather than at that applying in the US, where plants with an intake capability of upwards of 500 tons a day are not uncommon RAW MATERIAL Once the vegetable programme has been established, an efficient procurement system is an absolute necessity, as it is vital that the plant be fed with a round-the-clock supply of raw material for many months of the year, with no hiatus or short-fall due to weather conditions, or any other circumstances. Binding contracts must be made with reliable growers to ensure this and also to ensure that suitable varieties of vegetable-ones that lend themselves favourably to the process-are grown. Random purchasing on the open market is a system not to be relied upon by the dehydrator, because wherever the price is right the variety will be wrong, and vice versa The one exception, when this procedure is varied, is in the case of potatoes, and spot purchases are often made as the season proceeds. Whilst there is an element of risk in this particularly in a of low solids and a short crop- potato prices tend to be more stable than those for some other crops, and availability is spread over a much longer period fro.? some particular potato products, however, do call for speclalvarieties as a first choice. Potato granules and flakes, for example, should be made igh starch content tubers and, if these types are not grown in the traditional growing areas, special plantings under contract may have to be made adjacent to the plant location. On the other hand, some processors find that, to meet a cost problem with some potato products, they have to process culls from ware(table grade)potatoes, and, in this case, contracting is not usually possible. Grading stations can usually supply large quantities of this material, which is satisfactory for the manufacture of some grades of dehydrated product, and long term arrangements can always be made for intake from such sources, provided certain basic quality requirements are covered Contracts The procurement contract with the grower can take one of two forms, either: (1)A contract wherein the purchaser undertakes to buy from the vendor a specific tonnage of vegetables at a fixed price per ton, delivered to the factory over a specified period, or (2)a contract wherein the purchaser
availability but, in the ensuing chapters, it is intended to concentrate on the problems of the medium size operator, coming into the industry for the first time, or developing into dehydration from some other food processing activity. It is, perhaps, more likely, at this stage of the growth of dehydration, that development in Europe will be at this sort of level, rather than at that applying in the US, where plants with an intake capability of upwards of 500 tons a day are not uncommon. RAW MATERIAL Once the vegetable programme has been established, an efficient procurement system is an absolute necessity, as it is vital that the plant be fed with a round-the-clock supply of raw material for many months of the year, with no hiatus or short-fall due to weather conditions, or any other circumstances. Binding contracts must be made with reliable growers to ensure this and also to ensure that suitable varieties of vegetable - ones that lend themselves favourably to the process -are grown. Random purchasing on the open market is a system not to be relied upon by the dehydrator, because wherever the price is right the variety will be wrong, and vice versa. The one exception, when this procedure is varied, is in the case of potatoes, and spot purchases are often made as the season proceeds. Whilst there is an element of risk in this particularly in a Season of low solids and a short crop - potato prices tend to be more stable than those for some other crops, and availability is spread over a much longer period. Some particular potato products, however, do call for special varieties as a first choice. Potato granules and flakes, for example, should be made from high starch content tubers and, if these types am not grown in the traditional growing areas, special plantings under contract may have to be made adjacent to the plant location. On the other hand, some processors find that, to meet a cost problem with some potato products, they have to process culls from ware (table grade) potatoes, and, in this case, contracting is not usually possible. Grading stations can usually supply large quantities of this material, which is satisfactory for the manufacture of some grades of dehydrated pmduct, and long term arrangements can always be made for intake from such sources, provided certain basic quality requirements are covered. Contracts The procurement contract with the grower can take one of two forms, either: (I) A contract wherein the purchaser undertakes to buy from the vendor a specific tonnage of vegetables at a fixed price per ton, delivered to the factory over a specified period, or (2) a contract wherein the purchaser 22
undertakes to buy the produce of a specific acreage laid down by the vendor, at an agreed price per acre In the first instance, the grower must cover all contingencies arising from total or partial crop failure, and carry a not inconsiderable element of risk of the purchaser buying in against him in the event of a crop failure The second form of contract implies that the processor takes over some of this risk but, in return, has a reasonable chance of buying his product cheaper, if he has an efficient fieldsman service to supervise the grower and ensure a high level of good husbandry. cases, the processor will elect to supply the seed at arieties and, in some The contract, in whichever form, will specify agreed cost to the grower. Further stipulations will cover the quality standard, the rate of intake r day and the period over which intake will be accepted. The contract will also state whether the produce is to be delivered in bulk, or in containers and how accepted weights will be established. There is invariably provision for arbitration in the event of a dispute. It is important that the quality clause in the contract should be most specific, so that the grower is made aware of the standard of grading or dressing required. The processor will also underline his right to oversee, through his fieldsmen, the sowing, planting, cultivation and harvesting of the crop Supervision must also be exercised with types of fertilise weedicide and pesticide used in connection with the cultivation, as dangerous residuals can sometimes affect the produce at maturity. All these factors must be fully considered and covered in the document but, as this procurement procedure has been adopted for many years by canners and freezers, and has equally been accepted by growers, either individually or by their Associations, where group negotiations arise, the dehydrator shoul not really have any difficulty in getting all the above clauses implemented LAB。 UR REQUIREMENTS In selecting a site for the factory, the consideration of suitable labour availability will have been made. On the assumption that the location is rural, certain advantages as to quality of labour are usually apparent, in that both male and female operatives who have agricultural backgrounds and traditions often integrate very satisfactorily into vegetable processing as this is, in effect, an extension of their way of life The labour content of the putative 70-80 ton per day plant will vary according to the type of drying plant selected and the range of products to be handled but some guide can be given if certain assumptions are made at this point. Let it be supposed that the operation is mounted on a ten months
undertakes to buy the produce of a specific acreage laid down by the vendor, at an agreed price per acre. In the first instance, the grower must cover all contingencies arising from total or partial crop failure, and carry a not inconsiderable element of risk of the purchaser buying in against him in the event of a crop failure. The second form of contract implies that the processor takes over some of this risk but, in return, has a reasonable chance of buying his product cheaper, if he has an efficient fieldsman service to supervise the grower and ensure a high level of good husbandry. The contract, in whichever form, will specify varieties and, in some cases, the processor will elect to supply the seed at an agreed cost to the grower. Further stipulations will cover the quality standard, the rate of intake per day and the period over which intake will be accepted. The contract will also state whether the produce is to be delivered in bulk, or in containers and how accepted weights will be established. There is invariably provision for arbitration in the event of a dispute. It is important that the quality clause in the contract should be most specific, so that the grower is made aware of the standard of grading or dressing required. The processor will also underline his right to oversee, through his fieldsmen, the sowing, planting, cultivation and harvesting of the crop. Supervision must also be exercised with types of fertiliser, weedicide and pesticide used in connection with the cultivation, as dangerous residuals can sometimes affect the pduce at maturity. All these factors must be fully considered and covered in the document but, as this procurement procedure has been adopted for many years by canners and freezers, and has equally been accepted by growers, either individually or by their Associations, where group negotiations arise, the dehydrator should not really have any difficulty in getting all the above clauses implemented. LABOUR REQUIREMENTS In selecting a site for the factory, the consideration of suitable labour availability will have been made. On the assumption that the location is rural, certain advantages as to quality of labour are usually apparent, in that both male and female operatives who have agricultural backgrounds and traditions often integrate very satisfactorily into vegetable processing as this is, in effect, an extension of their way of life. The labour content of the putative 70-80 ton per day plant will vary according to the type of drying plant selected and the range of products to be handled but some guide can be given if certain assumptions are made at this point. Let it be supposed that the operation is mounted on a ten months’ 23
programme over the following range of vegetables: peas, green beans, potatoes (granules and cubes), cabbage, leeks, carrots, celery, beetroot and The process staff will require to operate on a three shift system, usually ix days per week, with a plant cleaning shift and a maintenance shift in addition at the weekend. Local custom may require that this system be covered by four teams to avoid excessive overtime at weekends but it is by o means uncommon in some factories for staff to accept this overtime, the three eight hour shifts being covered by three teams changing their shifts by rota every week. The many types of dehydration plant will be considered in detail in the following chapters but, for the purpose of assessing the process labour ontent of a typical medium size plant, it could be assumed that the following dryers would be required to handle the above ten month programme For Granules: an Air-Lift dryer with a capacity of 1.5 tons of raw potatoes per hour For peas, green beans, cabbage, celery and leeks one Hot Air Through Conveyor Band Dryer, with a capacity of up to 3 tons of prepared raw egetables per hour-the capacity will vary according to the type of vegetable and size of cut For root vegetables and potato cubes: one Hot Air Through Conveyo Band Dryer with the same capacity as mentioned for other vegetables These dryers would not be operating concurrently throughout the whole of the season but would come into operation in accordance with the availability of the crops. It is vitally important that at certain times some excess drying capacity is available to cope with gluts, or a dryer breakdown, hence the advisability of duplicating the band dryer. Some important crops, which have a short harvest period, such as peas and French beans, can overlap and, in these circumstances, shortage of drying capacity can have dire cor appn The process labour to man this scale of operation, per shift,would be ly as fol Shift Superintendent: 1 Forewomen Quality Control Male Plant Operators: 10 2(maintenance duties only) Electrician 1(maintenance duties only)
programme over the following range of vegetables: peas, green beans, potatoes (granules and cubes), cabbage, leeks, camts, celery, beetroot and turnips. The process staff will require to operate on a three shift system, usually six days per week, with a plant cleaning shift and a maintenance shift in addition at the weekend. Local custom may require that this system be covered by four teams to avoid excessive overtime at weekends but it is by no means uncommon in some factories for staff to accept this overtime, the three eight hour shifts being covered by three teams changing their shifts by rota every week. The many types of dehydration plant will be considered in detail in the following chapters but, for the purpose of assessing the process labour content of a typical medium size plant, it could be assumed that the following dryers would be required to handle the above ten month programme: For Granules: an Air-Lift dryer with a capacity of 1.5 tons of raw potatoes per hour; For peas, green beans, cabbage, celery and leeks one Hot Air Through Conveyor Band Dryer, with a capacity of up to 3 tons of prepared m vegetables per hour- the capacity will vary according to the type of vegetable and size of cut; For mot vegetables and potato cubes: one Hot Air Through Conveyor Band Dryer with the same capacity as mentioned for other vegetables. These dryers would not be operating concurrently throughout the whole of the season but would come into operation in accordance with the availability of the crops. It is vitally important that at certain times some excess drying capacity is available to cope with gluts, or a dryer breakdown, hence the advisability of duplicating the band dryer. Some important crops, which have a short harvest period, such as peas and French beans, can overlap and, in these circumstances, shortage of drying capacity can have dire consequences. The process labour to man this scale of operation, per shift, would be approximately as follows: Shift Superintendent: 1 Foreman: 1 Forewomen: 1 Male Plant Operators: 10 Fitters: 2 (maintenance duties only) Electrician: 1 (maintenance duties only) Boilerman: 1 Quality Control: 2 24
30-50(trimming and selection) Permanent night men 15-25(Trimming and selection) The female labour content will vary according to the types of vegetable being processed. The above numbers in any case assume that, at the selection and packing end of the process, the products are being bulk packed. Where the product is intended for retail distribution in small units, a very much larger female packing staff would be required to operate filling and packing machinery. Such considerations, in this instance, however, have not been taken into account. Male operators will normally substitute for women on the 10pm to 6am shift It is stressed that the figures given can only be taken as a rough guide, d the of two types of dryer, the methods of operating which are efficient and particularly economical in labour content generally The conveyor band dryer, either single or multi pass, is probably more versatile than most in the types of vegetable it will handle, and it is particularly suitable for long sustained runs of one product. Its merits, along with those of other dryers, will be described in later chapters but in the context of the present plant under review, it requires a minimum of staff to operate it. As in the canning and freezing industries, the greatest concentration of female labour is in the trimming and selection departments, and unless strict control is exercised in these areas, as to the numbers and efficiency costs can easily overtake profits Technology has made great strides, however, in reducing the tedium and unrewarding work of product selection, and there are now very efficient colour sorting devices on the market, which effectively select and reject blemished material in the raw state, or after drying. This reduces the labour requirement for trimming and selection, and the development of these machines to the present peak of efficiency has cut the cost of these operations very considerably. As the particle size of dried vegetables rarely exceeds 10mm by 10mm by 10mm, the electronic colour sorter can scan these particles in their trajectory through an optical box against a predetermined coloured background. Any particle, whose colour, by reason of blemish, differs from that which is acceptable, is pushed into a different trajectory by a jet of compressed air and diverted through a waste spout. These machines have high efficiency and perform the task of selection at a fraction of the cost of hand labour Some visual inspection is still advisable after the product has passed
Women: 30-50 (trimming and selection) Permanent night men 15-25 (Trimming and selection) The female labour content will vary according to the types of vegetable being pmcessed. The above numbers in any case assume that, at the selection and packing end of the pmcess, the products e being bulk packed. Where the product is intended for retail distribution in small units, a very much larger female packing staff would be required to operate filling and packing machinery. Such considerations, in this instance, however, have not been taken into account. Male operators will normally substitute for women on the lOpm to 6am shift. It is stressed that the figures given can only be taken as a mugh guide, and they are based on the manning of two particular types of dryer, the methods of operating which are efficient and particularly economical in labour content generally. The conveyor band dryer, either single or multi pass, is probably more versatile than most in the types of vegetable it will handle, and it is particularly suitable for long sustained runs of one product. Its merits, along with those of other dryers, will be described in later chapters but in the context of the present plant under review, it requires a minimum of staff to operate it. As in the canning and freezing industries, the greatest concentration of female labour is in the trimming and selection departments, and unless strict control is exercised in these areas, as to the numbers and efficiency, costs can easily overtake profits. Technology has made great strides, however, in reducing the tedium and unrewarding work of product selection, and there are now very efficient colour sorting devices on the market, which effectively select and reject blemished material in the raw state, or after drying. This reduces the labour requirement for trimming and selection, and the development of these machines to the present peak of efficiency has cut the cost of these operations very considerably. As the particle size of dried vegetables rarely exceeds lOmm by lOmm by lOmm, the electronic colour sorter can scan these particles in their trajectory through an optical box against a predetermined coloured background. Any particle, whose colour, by reason of blemish, differs from that which is acceptable, is pushed into a different trajectory by a jet of compressed air and diverted through a waste spout. These machines have a high efficiency and perform the task of selection at a fraction of the cost of hand labour. Some visual inspection is still advisable after the product has passed 25