Documentation (Report FORM)

LEMONGRASS LOTION PROCESSING PLANT
VERIFICATION OF PROJECT SUPERVISOR
We hereby declare that this project paper has been read and we have the opinion that the project is appropriate in terms of scope coverage and quality for awarding industrial Diploma Electronics.
Signature Name Supervisor Date Signature Name of Head of Section Date
: : Mr. Fazli bin Mohamad : . : : Mr.Jasmi bin Mohd Saat : .
GERMAN-MALAYSIAN INSTITUTE
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ACKNOWLEDGEMENT
First of all, our group would like to take this opportunity to those who were involved in all stage especially to all Technical Training Officers (TTOs) who had given their full support, guidance and help since the first day we stepped here, in German-Malaysian Institute to gain this precious knowledge and practical skills. Without them, our project wouldnt have successfully done.
To our supervisor, Mr. Fazli who gives his all in helping us in this project, we would like to say a lot of thank you who had provided us a neat, consistent and filly pledge throughout the entire project. Not to be forgotten, Our Head of Section of Process Instrumentation and Control, Mr. Jasmi bin Saat who provided us a better idea and guide us in this project. An appreciation goes to the technicians as well for giving the full commitment to help us when we are having issues regarding to the instruments.
Last but not least, a million thanks to our family who are being supportive and willing to help in financial aspect.
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Table of Contents
Contents VERIFICATION OF PROJECT SUPERVISOR .......................................................................... 1 ACKNOWLEDGEMENT ............................................................................................................ 2 List of Figures ............................................................................................................................ 6 CHAPTER 1 : INTRODUCTION ................................................................................................ 7 1.1 PROJECT BACKGROUND ............................................................................................. 7 1.2 PROBLEM STATEMENT ..................................................................................................... 8 1.3 PROJECT OBJECTIVE........................................................................................................ 8 CHAPTER 2: LITERATURE REVIEW AND PROJECT DESCRIPTION ..................................... 9 2.1 PROJECT SPECIFICATION ........................................................................................... 9 2.2.1 Electrical Features ....................................................................................................11 2.2.2 Instrument / control Features ....................................................................................12 2.2.3 Physical Features .....................................................................................................13 2.3 Safety Features ...................................................................................................................14 2.3.1 Electrical Safety ........................................................................................................14 2.3.2 Mechanical Safety ....................................................................................................14 2.3.3 Plant Safety......................................................................................................................17 2.4 Principle of Operation ..........................................................................................................17 2.4.1 Piping and Instrumentation Diagram .........................................................................17 2.4.2 Machine Layout ........................................................................................................18 2.5 Electrical Wiring Diagram ....................................................................................................23 2.5.1 Control Circuit...........................................................................................................23 2.5.2 Control Circuit 240VAC ............................................................................................24 2.5.3 Main Circuit ..............................................................................................................24 2.5.4 Programmable Logic Control (PLC) ..........................................................................25 2.5.4 PLC Wiring Diagram .................................................................................................26 2.6 CONTROL STRATEGIES / THE SIGNAL FLOW DIAGRAM...............................................27 2.2 PROJECT FEATURES .......................................................................................................11
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Chapter 3 3.1 Feasibility Studies ...............................................................................................................30 3.1.1 Result of Interview ...............................................................................................30 3.1.2 Process Parameter and Instrumentations .................................................................30 3.1.3 Experiment of Making Lemongrass Lotion manually .................................................31 3.2 Secondary Sources .............................................................................................................33 3.3 Project Schedule .................................................................................................................37 3.3.1 Gantt Chart ...............................................................................................................37 3.4 Safety..................................................................................................................................37 Chapter 4 4.1 Process Plan .......................................................................................................................38 4.1.1 Block Diagram ..........................................................................................................38 4.1.2 Flow Chart ................................................................................................................39 4.1.3 Machine Sequences .................................................................................................40 4.2 Quality Plan.........................................................................................................................40 4.2.1 Quality Checking ......................................................................................................40 4.3 SAFETY .........................................................................................................................41 4.4 Standard Operating Procedure............................................................................................46 4.5 Project Schedule .................................................................................................................47 4.5.1 Task Content ............................................................................................................47 4.5.2 Task Sequence ........................................................................................................49 4.5.3 Group Member Task Distribution ..............................................................................51 4.5.4 Time Allocation .........................................................................................................51 4.6 Instrumentation, Equipment and Engineering Cost..............................................................52 4.61 Electrical Cost ...................................................................................................................52 4.6.2 Mechanical Components ..................................................................................................53 4.6.3 Instruments Components .................................................................................................54
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CHAPTER 5 ..............................................................................................................................55 FINDING AND ANALYSIS ........................................................................................................55 5.1 Result and Finding ..............................................................................................................55 5.1.1 Procedure .................................................................................................................55 5.1.2 Results and Discussion ............................................................................................57 5.1.3 Calculation of Tuning Method (CHR) Without Overshoot .......................................58 5.2 Checklist Test for All Electrical Equipment ..........................................................................60 5.3 Problem Encountered and Countermeasure .......................................................................61 5.4 Recommendation ................................................................................................................62 CHAPTER 6 ..............................................................................................................................63 Conclusion ................................................................................................................................63
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List of Tables
Table 2.1: Properties of Essential Oil ........................................................................................36
List of Figures
Figure 2.2.1: Warning................................................................................................................15 Figure 2.2.2: Caution.................................................................................................................15 Figure 2.2.3: Danger High Electricity .........................................................................................15 Figure 2.2.4: Danger Hot Surface..............................................................................................16 Figure 2.2.5: Danger Corrosive .................................................................................................16 Figure 2.3.1: Piping and Instrument Diagram............................................................................. 14 Figure 2.3.2: Illustration of Assembly Drawing...........................................................................19 Figure 2.3.3: Illustration of Front View .......................................................................................20 Figure 2.3.4: Illustration of Side View ........................................................................................21 Figure 2.3.5: Illustration of Top View .........................................................................................22 Figure 2.4.1: Wiring Diagram of Control Circuit .........................................................................23 Figure 2.4.2: Wiring Diagram for 24V Control Circuit ................... Error! Bookmark not defined. Figure 2.4.3: Wiring Diagram of 240VAC Control Circuit ...........................................................24 Figure 2.4.4: Wiring Diagram of Main Circuit .............................................................................25 Figure 2.4.5: PLC Wiring Diagram.............................................................................................26 Figure 4.1.1: Block Diagram...29 Figure 4.1.2: Flow Chart Stage 1..30 Figure 4.1.3: Flow Chart Stage 2..31 Figure 4.1.4: Flow Chart Stage 3..32
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CHAPTER 1
INTRODUCTION
1.1 PROJECT BACKGROUND

. As part of the three years (6 semesters) training program conducted in German-Malaysian Institute, students in 5th semester are required to do an industry based project related to their specialization. After we did some researches, we made up our mind to create an industrial based project that is Lemongrass Lotion Process Machine.
A lotion is a low- to medium-viscosity, topical preparation intended for application to unbroken skin. By contrast, creams and gels have higher viscosity. Lotions are applied to external skin with bare hands, a clean cloth, cotton wool or gauze. Many lotions, especially hand lotions and body lotions are formulated not as a medicine delivery system, but simply to smooth, re-hydrate, and soften the skin. These are particularly popular with the aging and aged demographic groups, and in the case of face usage, can also be classified as a cosmetic in many cases, and may contain fragrances. Lemongrass is an herb with a mild citrus flavour. Its commonly used in Asian cuisine to flavour soups, seafood, curries. According to Gourmet Sleuth, lemon grass works well when combined with garlic and cilantro. It also can be used to brew tea. Lemon grass belongs to citronella family, and can be planted in the garden to ward off insects, or used to make soaps and candles.
So, to create another form of product, we came out with an idea to create lemongrass lotion. It has value in clearing cellulite as well as toning the skin, opening blocked pores and helping with acne. The antiseptic properties are useful in treating athletes foot and any other fungal infections. People may have allergic reaction to lemongrass oil but mostly it is less possibility of irritation or allergy when it is used in concentration lower than 3%. Lemongrass oil
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also becomes more benefit when it is combined with any other herbs such as tea tree, lavender, jasmine and many more.
1.2 PROBLEM STATEMENT

Lemongrasses have some benefits as a traditional medicines to cure fungal infections and as insect repellent. Based on the researches, lemongrass are seldom used as lotion. Mostly, it is available in essential oil. So we came out with an idea to produce a lotion which have lemongrass essential oil in it. In our project, we had decided to make lemongrass lotion process in a small plant.
1.3 PROJECT OBJECTIVE

In order to make our project is successfully done; the several objectives that we should achieve have been finding out in our project. The objectives of our project are to achieve set point of temperature which are 0c - 90c. In this range of temperature, the glycerine, emulsifying wax, cocoa butter and essential oil can bind together into one solution as they have different density. Furthermore, we also have an objective to achieve the set point of pH value which are 5.4 5.6. This range of pH value has been stated that it is the most suitable pH value for human skin. Last but not least, of course we want to be able to produce lemongrass lotion in semi-automated plant.
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CHAPTER 2
LITERATURE REVIEW AND PROJECT DESCRIPTION

2.1 PROJECT SPECIFICATION
We have 3 major processes which are mixing, heating and also neutralization. For mixing, emulsifying wax, glycerine, cocoa butter and lemongrass essential oil were added into mixing tank with agitator. The ratio of the materials is 1:2:2. During this process, the pH of the mixture might be too acidic or too alkali which are not good to our skin. Next process is heating to ensure that the mixture is completely dissolved so it will create a smooth texture of lotion. This process occurs when the mixing process are on progress. The suitable temperature for this process is 0C - 90C. The most important process in this project is pH manipulation. This is to ensure that the mixture will not cause any irritation to human skin. During this process, balancing and maintaining the pH value are needed. The suitable value for human skin is pH 5.5. To complete all this process, we use Programmable Logic Control to monitor and control the process. Behind is our project specifications.
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Project Title Main Process
Lemongrass Lotion Processing Plant To control the pH value of the lotion in the mixing tank
Voltage Supply Type of Process Operation Mode Inflow
24VDC, 240VAC, 415VAC Batch process Automatic and manual Emulsifying wax Vegetables glycerine Cocoa butter Lemongrass essential oil
Outflow Total Process
Lotion Mixing Heating Neutralization
Piping Sensor and Instrument
Stainless steel RTD PT100 Temperature controller pH analyzer Solenoid valve Ball valve Manual valve PLC Siemens S700 Pump Agitator motor Clamp heater Raw material tank Mixing tank Product tank
Other equipment
Tank
Table 2.1: Project Specification
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2.2 PROJECT FEATURES

In order to complete the produce the product and process system, this project consists of several major features that are very important. Few standard features are to be set when implementing this project. Below are the features of some instruments that are being applied in most process plants. There are 3 elements in project features which are: 1. Electrical 2. Instrument/ Control 3. Physical
2.2.1 Electrical Features

Type of voltage Features
AC Supply (1 phase and 3 Phase ) DC Supply (24V)
To supply voltage to the system and equipment To supply voltage to the system and equipment
Table 2.2.1: Electrical Features
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2.2.2 Instrument / control Features
Type of Instrument
Features
Temperature Controller (TC)
To control the temperature in mixing tank so that it can achieve the set point and activate the agitator
Ball Valve (BV)
To execute the raw materials from the respective tanks
Temperature Transmitter (TT)
To transmit the temperature signal inside the mixing tank
Agitator (AG)
To stir the materials inside the mixing tank at desired speed
SCADA
To monitor and control the process
Table 2.2.2: Instrument/control Features
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2.2.3 Physical Features
Type of Instrument
Features
Emulsifying wax Tank
To store the emulsifying wax
Cocoa butter and Glycerin Tank
To store the cocoa butter and glycerin
Essential oil Tank
To store the lemongrass essential oil
Mixing tank
To heat and mix all the raw materials with agitator
Table 2.2.3: Physical Features
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2.3 Safety Features
Safety is the most important thing that should be considered in designing a system. There is wide range of main safety available to meet with different applications and performance aspects by different field.
2.3.1 Electrical Safety

In every process plant that operates, safety is important to avoid any accident or hazards from occurring. For lemongrass lotion processing plant, the electrical safety has been installed to avoid any accidents when the process occurs. The table below shows the safety precautions in this plant;
Main supply protection
Main Circuit Breaker (MCB) Earth Leakage Circuit Breaker (ELCB) Grounding Emergency switch ON-OFF push button Safety and Faulty indicator and buzzer Fuse Installation tapes Plastic partition housing Cable labelling
Switching and indicator
Current protection Wiring and terminations
Table 2.3.1: Safety Precautions for Electrical
2.3.2 Mechanical Safety
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In this plant, there are few moving and hot object which need more attention for safety concern. Injuries or fatal incidents could happen if these safety precautions are ignored. In this case, the safety signs must be put at the piping and also tanks where people can easily see it.
Figure 2.3.1: Warning Warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Figure 2.3.2: Caution Caution indicates a potentially hazardous situation which, if not avoided, may result minor or moderate injury. This category also includes potential equipment damage.
Figure 2.3.3: Danger High Electricity
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Danger electricity indicates a potentially dangerous voltage which, if not avoided, could result in shocked or short circuit.
Figure 2.3.4: Danger Hot Surface Caution (hot surface) indicates a hazard situation which, if not avoided, could become serious injury or skin burned.
Figure 2.3.5: Danger Corrosive All these signs we put on control panel, tanks and also the pipings to make sure people will notice the safety sign.
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2.3.3 Plant Safety

This project is implementing a heating, mixing and neutralization process which involves hot operating temperature which is at 60C. At this point of operating temperature, burned-skin could happen if the operator did not carefully follow the plant safety operating procedure.
1. Please ensure all electrical cables are fully insulated 2. Please ensure that all hot surfaces are fully insulated 3. Please ensure hands are dried before operating electrical devices 4. Please obey all the hazard signs placed at hazardous area at plant 5. Please ensure that pressure supply to plant instruments is according to the instruments specifications 6. Please use the emergency stop button at control panel in case of any breakdown while operating plant
2.4 Principle of Operation 2.4.1 Piping and Instrumentation Diagram
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Figure 2.4.1: Illustration of Piping & Instrument Diagram
This is our Piping and Instrument Diagram. We used Microsoft Visio to sketch this diagram. It takes about a month to complete this diagram since the approval of this diagram is not lenient. Our P&ID diagram needs approval of our supervisor, Mr. Fazli bin Mohamad, Senior Technical Training Officers, Head of Section PIC, Mr. Jasmi bin Saat.
2.4.2 Machine Layout 2.4.2.1 Assembly Layout
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Tower lamp
Raw material tanks
Control panel
Motor
Dosing pump Mixing tank Alkali tank
Container
Figure 2.4.2.1: Illustration of Assembly Drawing
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2.4.2.2 Front View
Figure 2.4.2.2: Illustration of Front View
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2.4.2.3 Side View
Figure 2.4.2.3: Illustration of Side View
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2.4.2.4 Top View
Figure 2.4.2.5: Illustration of Top View
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2.5 Electrical Wiring Diagram 2.5.1 Control Circuit

L 240VAC
MCB 6A
1 R1 3 R2
1 R3 3
1 R4 3
1 R5 3
1 R6 3
1 R7 3
A1
K2
A1
K3 BV1 BV2 BV3 DP BV OUT
A2 N
A2
BALL VALVE 1
BALL VALVE 2
BALL VALVE 3
BALL VALVE OUT
0VAC
AGITATOR
DOSING PUMP
HEATER
Figure 2.5.1: Wiring Diagram of Control Circuit
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BV OUT OFF
8 5
RED
BV OUT ON
8 R7 6
GREEN
DOSING PUMP OFF

8 5
DOSING PUMP ON
8 R6 6
GREEN
BALL VALVE 3OFF

8 5
RED
BALL VALVE 3 ON
8 R5 6
GREEN
BALL VALVE 2 OFF

8 5
RED
BALL VALVE 2 ON
8 R4 6
GREEN
BALL VALVE 21OFF

8 5
RED
2.5.2 Control Circuit 240VAC
GREEN
AGITATOR OFF
8 5
RED
GREEN
HEATER OFF
8 5
RED
240VAC
MCB 6A
8 R1 6
HEATER ON
GREEN
2.5.3 Main Circuit

8 R2 6 N
AGITATOR ON
8 R3 6
BALL VALVE 1 ON
Figure 2.5.2: Wiring Diagram of 240VAC Control Circuit
RED
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ELCB
L1
N
MCB 1 6A
K1
MCB 2 6A
MCB 3 6A
MCB 4 6A
MCB 5 6A
MCB 8 6A
MCB 6 20A L N
L L EPB L N N
PLC
G
43 31
POWER SUPPLY 24VDC
TEMPERATURE CONTROLLER
N G
AC REGULATOR
K2
L N
DOSING PUMP
G
FREQUENCY INVERTER HEATER

G
START
K1
44
K1
32
24V
+ RTD
K3
STOP V U W
GREEN RED
K1 PE
Figure 2.5.3: Wiring Diagram of Main Circuit
2.5.4 Programmable Logic Control (PLC)
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24VDC
TEMP. CONT START STOP
pH CONT
I0.0
I0.1
PIW 288
PIW 292
PLC S7
Q4.0 Q4.1 Q4.2 Q4.3 Q4.4 Q4.6 Q4.7 Q5.0 Q5.1 Q5.2 Q5.3
R1 R2 R3 R4 R5 R6 R7
0VDC
HT
AGI
BV 1
BV 2
BV 3
DP
BV OUT
BUZZER
Figure 2.5.3: PLC Wiring Diagram
2.5.4 PLC Wiring Diagram
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24VDC/PLC
Q4.0
2
Q4.1
2
Q4.2
2
Q4.3
2
Q4.4
2
Q4.6
2
Q4.7
2
Q5.0
Q5.1
Q5.2
Q5.3
R1
7
R2
7
R3
7
R4
7
R5
7
R6
7
R7
7
BALL VALVE OUT
BALL VALVE 1
BALL VALVE 2
BALL VALVE 3
BUZZER
AGITATOR
0V
DOSING PUMP
YELLOW
2.6 CONTROL STRATEGIES / THE SIGNAL FLOW DIAGRAM

For our project, we used continuous closed loop for heating and pH manipulation.
HEATER
GREEN
RED
Figure 1.5.4: PLC Wiring Diagram
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Heating Process
Controller Set Point Final Control Element (FCE) Process Sensor
Temperature Controller(TZN4H Autonics) Range: -40 - 5c 0c - 90c Clamp Heater Heating PT 100
Type of Control
Continuous
pH Controller
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Controller
pH Controller(Rosemount Analytical 1056)
Set Point
5.4-5.6
Final Control Element (FCE)
Dosing pump
Process
pH level
Sensor
pH Transmitter
Type of Control
Continuous
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GERMAN-MALAYSIAN INSTITUTE Page 29
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METHODOLOGY
3.1 Feasibility Studies
MARDI is the one of my main researches on making this project more successful. To get more information from them, we conducted an interview with the Chief Unit for Essential Oil Research of Mardi, Khalisanni Khalid (sanni@mardi.gov.my). As a result for this interview, we managed to find out the suitable essential oil and how to produce lotion includes the process flow, temperature needed in the process, the ratios of raw material, and slightly help us about the P&ID.
3.1.1 Result of Interview

From the result of the interview, Mr. Khalisanni, our respondent gives us two type of essential oil as suggestion which is tea tree oil and lemongrass essential oil. But we choose lemongrass essential oil because of its properties and less production of lemongrass essential oil. We also have been provided with information on how to produce the lotion. Mr. Khalisanni gives us the process sequence, suitable temperature and also suitable pH value. He also gives the ratio of the raw material which is 1:2:2 represents, lemongrass, cocoa butter and glycerin and emulsifying wax respectively. Besides, he give us an idea to design our Piping and Instrument Diagram (P&ID) with our desired specifications.
3.1.2 Process Parameter and Instrumentations
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After conducting the Market Research at MARDI, we had clasify the feasibility study in two type which are process parameter and instrumentation. Table below shown the detailed of the process parameter:
Process Parameter
Instrumentation / Electrical
Heating
The measuring element that we used to measure
The temperature required in the temperature is PT 100 and the controller that making of lemongrass lotion is control the temperature is Temperature Controller 0 c - 90 c model TZN4H Autonics. Apart from that, we are also use the close loop which is PID control and tuning. The source for heating that we used in our project is clamp heater. The reasons we used clamp heater compare than other sources because Only involve a temperature range between 80C - 90C
Mixing To blend the mixture
The voltage supply for agitator is three phase and and the frequency used is 50Hz. The controller that speed. The control method use is PLC Sequence Initiated.
produce a smooth texture for we use is Frequency Inverter to control the lotion
Measuring pH of Lemongrass Lotion The optimum pH to give a lotion in good for human skin is between pH 5.4 5.6
The measuring element to measure the pH value is pH sensor and the controller that we used to control and set the value of pH is pH controller model Rosemount Analytical 1056.
3.1.3 Experiment of Making Lemongrass Lotion manually GERMAN-MALAYSIAN INSTITUTE Page 31
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We did the experiment of making lemongrass lotion in manually. The ingredients that we prepare to make is according to ratio that we have mentioned earlier but in small scale. We did this experiment at laboratory and all apparatus we use is thermometer, beaker, Bunsen burner and stirrer.
The ingredients of making lemongrass lotion
During heating process
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During our experiment, firstly we mix all the raw materials and start heating process. First temperature reading is 60c but the mixture is not completely dissolve. So we heat it again until it reaches the desired concentration of lemongrass lotion. After 5c, then only we achieve our desired mixture and pH value.
3.2 Secondary Sources

4 Most lotions are oil-in-water emulsions using a substance such as cetearyl alcohol to keep the emulsion together, but water-in-oil lotions are also formulated. The key components of a skin care lotion, cream or gel emulsion (that is mixtures of oil and water) are the aqueous and oily phases, an emulgent to prevent separation of these two phases, and, if used, the drug substance or substances.
A wide variety of other ingredients such as fragrances, glycerol, petroleum jelly, dyes, preservatives, proteins and stabilizing agents are commonly added to lotions. Lotions can be used for the delivery to the skin of medications such as antibiotics, antiseptics, antifungal, corticosteroids, anti-acne agents, soothing, smoothing, moisturizing or protective agents (such as calamine).
Studies had been done on how to the essential oil and the process of making lotion. We have done some researches on internet. The health benefits of Lemongrass Essential Oil can be attributed to its properties like analgesic, anti-depressant, anti-microbial, antipyretic, anti-septic, astringent, bactericidal, carminative, deodorant, diuretic, febrifuge, fungicidal, galactogogue, insecticidal, nervine, sedative and tonic.
One of the research state that to produce a smooth texture of lotion, we must add emulsifying wax to bind together the mixture between the water and oil solution. Furthermore, the addition of cocoa butter and vegetables glycerin are for moisturizing skin.
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The ingredients for Emulsifying Wax NF are: Cetearyl Alcohol, Polysorbate 60, PEG-150 Stearate, and Steareth-20. It has the characteristics of cetyl alcohol combined with the viscosity building effect of stearyl alcohol as an effective thickener and helps form stable emulsions
The most common form of cocoa butter has a melting point of around 3438 C (93100 F), rendering chocolate a solid at room temperature that readily melts once inside the mouth. Cocoa butter displays polymorphism, having , , ', and crystals, with melting points of 17, 23, 26, and 3537 C respectively. The production of chocolate typically uses only the crystal for its high melting point. A uniform crystal structure will result in smooth texture, sheen, and snap.
10
Overheating cocoa butter converts the structure to a less stable form that melts below room temperature. Given time, it will naturally return to the most stable crystal form. This phenomenon is taken advantage of in the polymorphic transformation theory of chocolate bloom. It is based on the fact that bloomed chocolates are always found to contain the most stable polymorph of cocoa butter. According to this theory, bloom occurs through the uncontrolled polymorphic transformation of cocoa butter from a less stable form to the most stable form.
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Vegetable glycerin is also known as vegetable glycerol. It is a carbohydrate that is usually derived from plant oils. It is used as a sweetener and as an ingredient in a number of cosmetic products. Vegetable glycerin is also used in place of alcohol to extract botanicals.
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Glycerin is an organic compound composed of three carbon atoms, hydrogen atoms, and three OH groups. These OH groups form hydrogen bonds with water, slowing down its movement and giving liquid glycerin the property of syrup. It is also resistant to freezing, a property used in storing sensitive liquids, such as enzymes, in laboratory freezers.
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13
Vegetable glycerin is also used as a substitute for alcohol, in making botanical extracts. The advantage of this is that people who do not want to be exposed to alcohol can still have access to the botanical products. The disadvantage is that the resulting products have a much shorter shelf life.
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Its solubility in alcohol and water had led to great utility in the manufacturing of products. Glycerin is used in a large number of cosmetic and household products, such as toothpastes and shampoo. It is also a component of glycerin soap, which is often used by people with sensitive skin. This soap acts as moisturizer to prevent the skin from drying out. For this reason, glycerin lotion is also popular.
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Thickness and consistency are key factors in lotions and creams, it is important to understand the manufacturing process that determines viscosity.
16
Manufacturing lotions can be completed in two cycles which are, emollients and lubricants are dispersed in oil with blending and thickening agents or perfume, color and preservatives are dispersed in the water cycle.
17
Active ingredients are broken up in both cycles depending on the raw materials involved and the desired properties of the lotion or cream.
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The pH of a substance is measured on a scale of 0 to 14, with 0 being the most acidic and 14 being the most alkaline. 7 is neutral, the pH of pure water. Each number on the scale is 10 times as strong as the number preceding it. Normal adult skin is somewhat acidic, having an approximate pH range of 4 to 6. This low pH is caused by carbon dioxide in the air.
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Alkaline substances with a pH higher than 8 can be very irritating to the skin, as can acids with pH levels of 3 or below. Exposing your skin to an alkaline substance can make it more vulnerable to irritation and infection, including acne.
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At pH or 9 to 11, it can remove your acid mantle and extract protective lipids from your skin. If you have naturally dry skin or suffer from eczema, your skin has a more alkaline pH, in which case these soaps can increase your levels of irritation. In fact, a 2002 study published in the International Journal of Dermatology found that "most products recommended for sensitive skin have a considerable irritation effect, which is related to the pH of the product."
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Careful note should be taken in choosing the right mixing equipment for lotion manufacturing to avoid agglomerates and long processing times. It can make all the difference in manufacturing time and costs. Conventional agitators can present a number of problems including agglomerates and longer processing times. On the other hand, high shear in-line mixers can produce quality lotions and creams without many of the complications encountered with conventional mixers.
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We also refer to our senior and interview them about the process should be more concentrated on while running the process. Other than that, we also asked them about the equipment required and material used and making project running smoothly.
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From our survey, there are few reasons why we choose lemongrass as our essential oil.
Source Lemongrass Jasmine Ylang Ylang
Cost RM29.90 RM49.90 RM49.90
Access Easy Hard Hard
Storage Easy Easy Easy
Long lasting Medium Long Long
Table 1.1: Properties of Essential Oil
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3.3 Project Schedule 3.3.1 Gantt Chart

In our Gantt chart show the process planning from the beginning of the project till end of project. We start with proposal stagein Semester 5 which is brainstorming, researches and proposal project. For implementation stage which is in semester 6, we start to design our structures, electrical wiring, PLC programming and many more as you can see in our Gantt chart in Appendix A.
3.4 Safety
Safety is the state of being safe the condition of being protected against physical, social, spiritual, financial, political, emotional, occupational, psychological, educational or other types or consequences of failure, damage, error, accidents, harm, or any other event which could be considered as non-desirable. This can take the form of being protected, from the event or from exposure to something that causes health or economic losses. It can include protection of people or profession.
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CHAPTER 4
PROJECT IMPLEMENTATION
4.1 Process Plan 4.1.1 Block Diagram
Cocoa butter, glycerin, emulsifying wax ( raw material)
Mixing process
Heating process
Flow the product into the output tank.
Balancing the pH value
Figure 4.1.1: Block Diagram
Figure above shows the block diagram. Firstly, all the raw materials were added into mixing tank for mixing process. After that, heating process will take place which involve 60c of temperature. Next, in order to achieve 5.5pH, manipulating is needed to ensure the mixture is not too acidic or alkali. After all the set points achieve, the mixture will flow to product tank.
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4.1.2 Flow Chart
Figure above shows the stage 1 of our process. Firstly, the ball valve in respective tank will open to flow the raw material into mixer. After all materials put into the tank, the mixer tank will heat up the material until the temperature reach 85C by using clamp heater. After heating, the agitator starts to blend the material to make sure the mixture blends well. The pH controller will maintain the value of pH at 5.4 5.6. If the pH value achieves the set point then the agitator and the heater will turn off. The mixture is now ready to flow into the product tank.
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4.1.3 Machine Sequences

Step 1: Adding the raw materials into raw material tanks Emulsifying wax, cocoa butter, glycerin and essential oil will be fill into the tanks. After the entire ingredient has been added, the machine is start operated by push the start button at control panel and the ball valve will open and flow all the raw materials into mixing tank.
Step 2: Heating After all the raw materials are filled into the tanks, the heater will turn on until 60c to activate the agitator.
Step 3: Mixing After the temperature reach 60c, the agitator will activate and start the mixing process until the timer that have been set by programmer stop.
Step 4: Dosing Dosing pump will on only after when the desired pH value did not reach the set point.
4.2 Quality Plan 4.2.1 Quality Checking

Quality checking is important while doing a project this is because, we must make sure all the equipment was in a good working condition. This stage will avoid a problem when doing a project. This is a brief about how we do the quality checking: i. After get the recycled equipment we need to test all the equipment to make sure the equipment is in good condition. ii. iii. Check the equipment by using a multi meter or other suitable equipment Test the equipment based on the manual book that was provided by the manufactures.
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4.3 Safety
No one can argue with the fact that safety is very important. Safety can be described as Relative freedom from danger, risk, or threat of harm, injury or loss to personnel and property, whether caused deliberately or by accident. In order to implement our project which is Automated Watermelon Jam Machine without any accident and injury occur, we have to ensure all the group members must be alert with safety precaution. There has three major section of safety that were observed in our project which are safety at control panel, plant safety and safety in workplace
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1. Safety at Control Panel No 1 Safety MCB This device provides protection for the whole process, in the case of short circuit or current leakage via its magnetic trip element which is to prevent any overload current from electrical power or control circuit. 2 Rotary Fan Rotary fan has a function to flow heat temperature in panel to go outside. Features
Emergency pushbutton
This pushbutton has a function to stop or cut off the power supply when emergency occurs.
Tower lamp
This tower lamp has a function to indicate the status during the operation of project.
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Terminal Block
This terminal block has a function as a connector wire for neutral and grounding wire.
Lableling wire
The purpose of labelling wire is to make easier for troubleshoot the plant. Each of wire that connected with electrical items has been label.
Table 3.3 : List of Safety at Control Panel
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2. Plant Safety No 1 Illustrator / features / items Safety signs Description This signs are located at the plant area and warning to the people that machine is hazardous during operation. It can cause injury if anybody touches it
Mixing tank
All the ingredients should be added into this tank before mixing process start operates.
Table 3.4 : List of Plant Safety
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3. Safety in workplace
No
Features /Illustration Use proper safety wear
Description When doing work in the workplace, all group members required to wear proper safety wear such as safety boot, goggles and gloves.
Clean work place Workplace must be clean all time to avoid any cause injury occur.
Tools must be in good condition
All tools that have been used must be in good condition to avoid any injury occurring to the user. If the tools are occur, it must immediately send to the technician to repair.
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Clean and arrange tools Tools must be clean, arrange and place at the proper place after used.
Table 3.5 : List of Safety in Workplace
4.4 Standard Operating Procedure
Before Start-Up Machine 1. Check all the switches and make sure in OFF condition 2. Check the setting at PC 3. Fill up the raw materials in the tanks
Start-Up Machine 1. Switch on the main switch
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2. Press PLC start button, buzzer delay in 3 seconds 3. Green tower lamp blinking means the process are on the run. 4. All ball valves will on and raw materials will fill into the mixing tank. 5. Heater on until reach 80 degree Celsius. 6. Agitator starts running according to the timer. 7. Agitator stop and pH value will be measured. 8. After pH value reached 5.5, heater will turn off. 9. Ball valve out will on and flow out the output product into storage.
Shut Down Machine 1. Press PLC stop button, then the red tower lamp blinking. 2. Press the stop button on control panel. 3. Switch off the main switch.
4.5 Project Schedule

Project schedule consists of a list of a project's terminal elements with intended start and finish dates. Terminal elements are the lowest element in a schedule, which is not further subdivided. Those items are often estimated in terms of resource requirements, budget and duration, linked by dependencies and scheduled events. To make sure the project is run smoothly, we need to do project schedules that involve the entire task that we need to complete before deadline that was provided by GMI.
4.5.1 Task Content
While doing a Final year project there have three stages that we need to do. Stage 1
Individual proposal Brainstorming Feasibility study
Stage 2
Proposal documentation
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Stage 3
Proposal presentation
Project implementation Mechanical construction Electrical installation Instrument wiring Troubleshooting Final presentation & documentation
Table 4.3.1: Stages of Final Year Project
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4.5.2 Task Sequence

This part is about the step by step of work had taken. After we get into a group, there is a brainstorming where everyone contributes ideas. Secondly is feasibility study to ensure that this project is feasible to be done. Thirdly is project analysis involving the criteria needed in the machine for correct process and to produce quality product. As some of important information gained, we are in the making of this project. Everyone got own task to do with the time duration. We make the process flow of the machine, mechanical and electrical design. Lastly, we compiled all of the information and work that have been done and finish our documentation. After that, get prepared for presentation of proposal. The task sequence we show in our Gantt chart in appendix.
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Brainstorming
Conceptual and Feasibility Study
Project Analysis
Project Planning and Scheduling
Process flow
Mechanical and electrical Design
Documentation
Presentation
Figure 4.3.2: Stages of Final Year Project
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4.5.3 Group Member Task Distribution
Mohd. Shariffudin(Leader) Wiring (Leader) Programming Mechanical Documentation
Fateen Emira
Mohd. Izzuddin
Mohd. Nashruddin
Documentation (Leader) Wiring Programming Mechanical
Programming (Leader) Wiring Mechanical Documentation
Mechanical (Leader) Wiring Programming Documentation
4.5.4 Time Allocation

The Gantt chart at the appendix shows the work and time done by us. All of works are done on time. The chart helps us to manage our time on completing all the works. Everyone got own task and together doing group documentation, industrial visit, implement the pilot plant and project analysis.
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4.6 Instrumentation, Equipment and Engineering Cost

List of the material is very important before we finished the project. It is because we can see clearly the total material have been used. By this method, it easier to calculate the project cost. Many items had to be purchased in order to accomplish our project and solve the problem encounter.
4.61 Electrical Cost
Item ELCB MCB Emergency Push Button Push button Stop button Thermal overload relay Indicator lamp Relay Contact Power Supply Cable 1.5mm (Red) Cable 1.5mm (black) Cable 1.5mm (Green) Cable 1.5mm (yellow) Cable 1.5mm (blue) Agitator Motor Air Service Unit + Connector Pneumatic Frequency Inverter Total
Quantity 1 11 1 1 1 2 5 10 4 1 1 1 1 1 1 1 1 1
Price/unit (RM) 35.50 5.00 18.00 2.00 2.00 5.00 1.50 3.50 5.00 100.00 50.00 50.00 50.00 50.00 50.00 400.00 35.00 600.00
Price (RM) 35.50 55.00 18.00 2.00 2.00 10.00 7.50 35.00 20.00 100.00 50.00 50.00 50.00 50.00 50.00 400.00 35.00 600.00 1620
Table 4.4.1: Electrical cost
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4.6.2 Mechanical Components

Item Quantity Price/unit (RM) Price (RM)
Mixer tank Acid Tank Alkaline Tank Control Panel Platform Emulsifying fire wax tank Cocoa butter tank Glycerine tank Total
1 1 1 1 1 1 1 1
1600.00 625.00 625.00 750.00 280.00 625.00 625.00 900.00
1600.00 625.00 625.00 750.00 280.00 625.00 625.00 900.00 6030.00
Table 4.4.2: Mechanical Cost
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4.6.3 Instruments Components

Item Quantity Price/Unit (RM) Price (RM)
PLC RTD (Temperature Transmitter) Temperature Controller Solenoid valve Dosing Pump Total
1 1 2 2 3
5500.00 250.00 700.00 95.00 55.00
5500.00 250.00 1400.00 190.00 165.00 7505.00
Table 4.4.3: Instruments cost
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CHAPTER 5
FINDING AND ANALYSIS
5.1 Result and Finding 5.1.1 Procedure

i. Mechanical construction
a. Piping connection b. Controlling panel and design c. Design plant and structure
ii.
Programming a. Programming logic control (PLC) i. ii. iii. PLC SIEMEN Simatic 300 Ladder Diagram Wiring analog input
iii.
Electrical and instrument wiring a. Control panel design b. Motor Pump c. Instrument wiring i. ii. Solenoid Valve RTD PT 100
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iv.
Commissioning a. Calibration and troubleshooting b. Tuning the PLC controller c. Test the process system and identified the function and do the troubleshooting if have any problem d. Observe the project while project is running e. Record and collect the data end product
v.
Documentation
a. Prepare all the information of the project. b. Do a documentation based on the final year project documentation handbook.
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5.1.2 Results and Discussion

Below are the Process respond curve (Open Loop) graph that we get during tuning the temperature.
Process Respond Curve ( Open Loop)
TG, 38m TU, 3m
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5.1.3 Calculation of Tuning Method (CHR) Without Overshoot

Max temperature Min temperature = 91.9C = 24.6C
Delay time, Tu = 3 min Respond time, Tg = 41 3 = 38min
Ratio =
= 12.67 = Easy to control
Table of Controllable: Tg/Tu
>10
Easy to conntrol
>6
Still Controllable
>3
Difficult to control
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Constant speed, KS
=(
= 0.73
Constant proportional, KP = 0.59 ( ) ( ) = 10.24
Proportional band, PB =( ) 100
= 9.77
Integral = Tg = 38
Derivative = 0.5 Tu = 0.5(3) = 1.5
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5.2 Checklist Test for All Electrical Equipment

i. Mechanical construction
At this stage, before we do a structure we need to do a drawing, after we comfirmed the drawing we need to measure all the parts, state the sze of the plant base and structure is stated. Arrange the structure for all equipment and tanks.
ii.
Testing and calibration
Testing and calibration is most important step to make sure the electrical equpment is in good condition. Testing and calibration also can avoid any problem that will be encuntered after wiring is done.
iii.
Electrical and instrument wiring installation
While doing the electrical wiring and testing, we also design a electrical wiring diagram. The diagram should be reffered to the PLC program and make sure that the process function according to the sequence.
iv.
Programming installation
In this stage we installed the PLC program to the computer and download to the PLC SIEMEN is created.
v.
Commissioning
This stage finished after completing this entire task. The stages that involved are :-
i. ii. iii. iv.
Mechanical construction Testing and calibration Electrical and instrument wiring installation Programming installation
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5.3 Problem Encountered and Countermeasure

While doing the implementation stage of final year project, a lot of problems that we need to fix. After we get know the problem the best way to solve the problem is take the immediate action to make sure this project can be completed and function well according to plan that have we design. The first step that we need to do is identify the critical part that can cause the problem, we must make sure the problem before starting commissioning the plant is identified. This is because if we can identify earlier we can avoid the problem before it occurred. The table that show the examples of the problem that we found and we take the best action to solve our problem. The entire problem has been divided into several sections depending on its particular field of implementation. All the problems and solution are listed on the table below:
Problem Ph Controller is not functioning Manual HMI cannot integrate with PLC Dosing pump cannot dose the alkali solution
Finding pH sensor board is broken Wrong tagging
Countermasure Replace the sensor board
Check link between PLC and HMI
The tube is leaking
Replace the tube
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5.4 Recommendation
Weaknesses Still in semi-automated process plant Recommendations Upgrade to fully automated plant
The quality of the product is low
Upgrade hygiene and the product is dermatology tested
Do not have cooling process
Add chiller to achieve the cooling down temperature 25 c
Do not have tank cleaning process
Add tank cleaning process to maintain the hygiene of the tank
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CHAPTER 6
Conclusion
This project had achieved the main objective, goals and the rational of this project can be implementing. We apply all the theories and practical knowledge to this project. We have done the preparation together from designing, troubleshooting, measuring and also counter measured the problems with self-esteem and team works spirits. The plan and schedule are perfectly on time. Besides, it also exposes and equips us with clear pictures of the real industrial process when we finish up this project.
This proposal helps us attain precious knowledge ranging from technical to management aspect. For instance it gives the opportunity of polishing the knowledge attained from GMI modules and put it into practical use. Valuable additional knowledge can be gained with materialization of this project proposal. If this project is going to be approving, it will be a new revolution to the industry. We propose that this project to be a final year project of the group.
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Appendix A pH Variables
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Appendix B Gantt chart
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Appendix C Data from Tuning

Ch. Tag Unit sec 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 CH001 TEMP01 C MIN 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.1 85.1 85.1 85.1 85.1 85.2 85.2 85.1 85.1 85.1 85.1 85.1 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2
Days 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000
Time 01:35:20 01:35:22 01:35:24 01:35:26 01:35:28 01:35:30 01:35:32 01:35:34 01:35:36 01:35:38 01:35:40 01:35:42 01:35:44 01:35:46 01:35:48 01:35:50 01:35:52 01:35:54 01:35:56 01:35:58 01:36:00 01:36:02 01:36:04 01:36:06 01:36:08 01:36:10 01:36:12 01:36:14 01:36:16 01:36:18 01:36:20 01:36:22 01:36:24 01:36:26 01:36:28 01:36:30 01:36:32 01:36:34 01:36:36
MAX 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.3 85.3 85.3 85.2 85.1 85.1 85.2 85.2 85.2 85.2 85.2 85.1 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.3 85.2 85.2 85.3 85.3
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000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000
01:36:38 01:36:40 01:36:42 01:36:44 01:36:46 01:36:48 01:36:50 01:36:52 01:36:54 01:36:56 01:36:58 01:37:00 01:37:02 01:37:04 01:37:06 01:37:08 01:37:10 01:37:12 01:37:14 01:37:16 01:37:18 01:37:20 01:37:22 01:37:24 01:37:26 01:37:28 01:37:30 01:37:32 01:37:34 01:37:36 01:37:38 01:37:40 01:37:42 01:37:44 01:37:46 01:37:48 01:37:50 01:37:52 01:37:54 01:37:56 01:37:58 01:38:00 01:38:02 01:38:04 01:38:06 01:38:08 01:38:10 01:38:12
0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
85.2 85.2 85.2 85.2 85.2 85.2 85.2 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.5 85.5 85.5
85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.3 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.5 85.4 85.5 85.5 85.5 85.5 85.5
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000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000
01:38:14 01:38:16 01:38:18 01:38:20 01:38:22 01:38:24 01:38:26 01:38:28 01:38:30 01:38:32 01:38:34 01:38:36 01:38:38 01:38:40 01:38:42 01:38:44 01:38:46 01:38:48 01:38:50 01:38:52 01:38:54 01:38:56 01:38:58 01:39:00 01:39:02 01:39:04 01:39:06 01:39:08 01:39:10 01:39:12 01:39:14 01:39:16 01:39:18 01:39:20 01:39:22 01:39:24 01:39:26 01:39:28 01:39:30 01:39:32 01:39:34 01:39:36 01:39:38 01:39:40 01:39:42 01:39:44 01:39:46 01:39:48
0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
85.5 85.5 85.5 85.5 85.5 85.5 85.6 85.6 85.6 85.5 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.4 85.5 85.5 85.5 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.7 85.7 85.7 85.7 85.7 85.7 85.7 85.7 85.8 85.8 85.8 85.8
85.5 85.5 85.5 85.5 85.6 85.6 85.6 85.6 85.6 85.6 85.5 85.5 85.4 85.4 85.4 85.4 85.5 85.5 85.5 85.5 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.6 85.7 85.7 85.7 85.7 85.7 85.7 85.7 85.7 85.7 85.8 85.8 85.8 85.8 85.8 85.8
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000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000
01:39:50 01:39:52 01:39:54 01:39:56 01:39:58 01:40:00 01:40:02 01:40:04 01:40:06 01:40:08 01:40:10 01:40:12 01:40:14 01:40:16 01:40:18 01:40:20 01:40:22 01:40:24 01:40:26 01:40:28 01:40:30 01:40:32 01:40:34 01:40:36 01:40:38 01:40:40
0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
85.8 85.8 85.8 85.8 85.8 85.8 85.8 85.8 85.8 85.9 85.9 85.9 85.9 85.9 85.9 85.9 85.9 85.9 85.9 85.9 86.0 86.0 86.0 86.0 86.0 86.0
85.8 85.8 85.8 85.8 85.8 85.8 85.8 85.9 85.9 85.9 85.9 85.9 85.9 85.9 85.9 85.9 85.9 85.9 86.0 86.0 86.0 86.0 86.0 86.0 86.0 86.0
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Bibliography

Remington, Joseph Price (2006), Beringer, Paul, ed., Remington: The Science And Practice Of Pharmacy (21st ed.), Lippincott Williams & Wilkins, p. 772, Shadab, Q., Hanif, M. & Chaudhary, F.M. (1992) Antifungal activity by lemongrass essential oils. Pak. J. Sci. Ind. Res. 35, 246-249. How to make a home made lotion recipes, http://www.ravenmoonsoap.com/blog/2013/03/09/Home-Made-Lotion-Recipes.aspx , 2013.
What is lotion?, http://en.wikipedia.org/wiki/Lotion , 2013 Functions of emulsifying wax, http://en.wikipedia.org/wiki/Emulsifying_wax , 2013 Suitable essential oil for lotion, http://www.essentialoils.co.za/dilutions-creamslotions.htm , 2013 Suitable pH transmitter for cosmetics manufacturing, http://www.alliancets.com/site/files/408/29497/109873/159912/Guide_to_pH_Measurem ent.pdf , 2013
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LEMONGRASS LOTION PROCESSING PLANT

VERIFICATION OF PROJECT SUPERVISOR

Signature Name Supervisor Date Signature Name of Head of Section Date

: : Mr. Fazli bin Mohamad : . : : Mr.Jasmi bin Mohd Saat : .

LEMONGRASS LOTION PROCESSING PLANT

LEMONGRASS LOTION PROCESSING PLANT

LEMONGRASS LOTION PROCESSING PLANT

LEMONGRASS LOTION PROCESSING PLANT

LEMONGRASS LOTION PROCESSING PLANT

LEMONGRASS LOTION PROCESSING PLANT

1.1 PROJECT BACKGROUND

LEMONGRASS LOTION PROCESSING PLANT

1.2 PROBLEM STATEMENT

1.3 PROJECT OBJECTIVE

LEMONGRASS LOTION PROCESSING PLANT

LITERATURE REVIEW AND PROJECT DESCRIPTION

LEMONGRASS LOTION PROCESSING PLANT

Project Title Main Process

Voltage Supply Type of Process Operation Mode Inflow

Outflow Total Process

Lotion Mixing Heating Neutralization

Piping Sensor and Instrument

Table 2.1: Project Specification

LEMONGRASS LOTION PROCESSING PLANT

2.2 PROJECT FEATURES

2.2.1 Electrical Features

AC Supply (1 phase and 3 Phase ) DC Supply (24V)

Table 2.2.1: Electrical Features

LEMONGRASS LOTION PROCESSING PLANT

2.2.2 Instrument / control Features

Temperature Controller (TC)

Ball Valve (BV)

To execute the raw materials from the respective tanks

Temperature Transmitter (TT)

To transmit the temperature signal inside the mixing tank

To stir the materials inside the mixing tank at desired speed

To monitor and control the process

Table 2.2.2: Instrument/control Features

LEMONGRASS LOTION PROCESSING PLANT

2.2.3 Physical Features

Emulsifying wax Tank

To store the emulsifying wax

Cocoa butter and Glycerin Tank

To store the cocoa butter and glycerin

Essential oil Tank

To store the lemongrass essential oil

To heat and mix all the raw materials with agitator

Table 2.2.3: Physical Features

LEMONGRASS LOTION PROCESSING PLANT

2.3 Safety Features

2.3.1 Electrical Safety

Main supply protection

Switching and indicator

Current protection Wiring and terminations

Table 2.3.1: Safety Precautions for Electrical

2.3.2 Mechanical Safety

LEMONGRASS LOTION PROCESSING PLANT

Figure 2.3.3: Danger High Electricity

LEMONGRASS LOTION PROCESSING PLANT

LEMONGRASS LOTION PROCESSING PLANT

2.3.3 Plant Safety

2.4 Principle of Operation 2.4.1 Piping and Instrumentation Diagram

LEMONGRASS LOTION PROCESSING PLANT

Figure 2.4.1: Illustration of Piping & Instrument Diagram