FT23401 UNIT OPERATIONS IN FOOD INDUSTRIES

QUESTION BANK – Part C- 15 Marks

UNIT 1 EVAPORATION

Question 1: Application: In a food processing plant, you are tasked with designing an evaporation system
for concentrating a fruit juice with varying sugar content. Apply the principles of single and multiple effect
evaporation to propose a suitable system. Justify your choice based on the characteristics of the fruit juice
and the desired concentration outcome.

Bloom's Taxonomy Level: Apply

Question 2: Application: You are managing a dairy processing unit that produces various dairy products.
Propose a strategy to overcome challenges related to fouling in evaporators. Apply your knowledge of liquid
characteristics and the performance of evaporators to suggest modifications in the process that would
minimize fouling and enhance overall efficiency.

Bloom's Taxonomy Level: Apply

Question 3: Application: Imagine you are tasked with improving the energy efficiency of an existing once-
through evaporator system in a beverage manufacturing plant. Apply the principles of heat balance,
economy, and capacity to propose modifications or enhancements that align with the course objective of
understanding basic principles and the course outcome of applying these principles in the process industry.

Question 4: Design a novel evaporator system that combines features from once-through and
circulation evaporators. Explain how this hybrid system addresses the limitations of each type
and enhances overall performance.

Bloom's Taxonomy Level: Apply

Question 5: Given a specific food processing scenario, recommend the most suitable type of
evaporator (once-through, circulation, short tube, or long tube) and justify your choice based
on the principles of evaporation.

Bloom's Taxonomy Level: Apply

 UNIT 2 - MECHANICAL SEPARATION

Question 1: A beverage production company is using a rotary vacuum filter to clarify fruit juice. Explain the
selection criteria for the appropriate filter media in this process. Consider factors such as particle size,
chemical compatibility, and durability. Provide a detailed explanation of how the chosen filter media aligns
with the objective of mechanical separation and the desired outcome in the production of clarified fruit juice.

Answer: Solution: In the context of a rotary vacuum filter for fruit juice clarification, selecting the right
filter media is crucial. The filter media should have a pore size that effectively captures the desired particle
sizes present in the juice. It should be chemically compatible with the juice to avoid any contamination.
Durability is essential to withstand the mechanical stresses during the filtration process.

For fruit juice clarification, a filter media with a fine mesh, often made from materials like stainless steel or
food-grade synthetic materials, is preferred. This aligns with the mechanical separation objective by
efficiently removing particles without compromising the quality of the juice. The outcome is a clarified fruit
juice free from undesirable particles, meeting the production objectives.

Bloom's Taxonomy Level: Apply (Selection Criteria), Evaluate (Explaining Alignment)

Question 2: A wastewater treatment plant uses gas-cyclones for the separation of suspended particles.
Discuss the role of settling under sedimentation in enhancing the efficiency of gas-cyclones. Provide a
detailed explanation of how the principles of settling contribute to effective particle separation in gas-
cyclones, and elaborate on the potential outcomes of optimizing this process in the context of wastewater
treatment.

Answer: Solution: In gas-cyclones, settling under sedimentation plays a crucial role in enhancing particle
separation efficiency. As particles are entrained in the gas stream, the principle of settling ensures that these
particles settle under the influence of gravity. This settling process aids in the separation of particles from the
gas stream, contributing to the overall efficiency of gas-cyclones.

Optimizing settling under sedimentation in gas-cyclones involves considerations such as the design of the
cyclone, particle size distribution, and gas flow rates. By maximizing the settling effect, larger and heavier
particles can be efficiently separated, leading to improved outcomes in terms of cleaner gas emissions from
the wastewater treatment process.

Bloom's Taxonomy Level: Apply (Principles of Settling), Evaluate (Optimization Outcomes)

Question 3: A chemical manufacturing plant utilizes a filter press for solid-liquid separation. Explain the
impact of constant pressure filtration on the cake formation and overall efficiency of the filtration process.
Discuss how variations in pressure influence the cake resistance and the filtrate quality. Provide a detailed
analysis of how adjusting the constant pressure can be employed to optimize the solid-liquid separation
process in this industrial application.

Answer: Solution: Constant pressure filtration significantly impacts cake formation and the overall
efficiency of the filtration process. At higher pressures, the formation of a denser filter cake occurs, leading
to decreased porosity. This, in turn, increases the resistance to filtration, influencing the efficiency of the
process.

Adjusting the constant pressure allows for optimization of the solid-liquid separation process. By carefully
selecting the pressure, it is possible to control the cake resistance and filtrate quality. Higher pressures may
lead to better cake formation but could also increase resistance. Balancing these factors is crucial for
achieving the desired outcome in terms of efficient solid-liquid separation in chemical manufacturing.

Bloom's Taxonomy Level: Apply (Impact Analysis), Evaluate (Optimization Strategies)

Question 4: A pharmaceutical industry relies on liquid-liquid centrifugation for the separation of different
liquid phases. Discuss the factors influencing the rate of separation in a centrifuge. Consider parameters such
as rotational speed, liquid density, and the type of centrifuge. Provide a comprehensive explanation of how
understanding these factors enables the effective application of liquid-liquid centrifugation in the
pharmaceutical manufacturing process.

Answer: Solution: The rate of separation in liquid-liquid centrifugation is influenced by several factors.
Rotational speed is a critical parameter, affecting the centrifugal force applied to the liquids. The density
difference between the liquid phases determines the efficiency of separation. The type of centrifuge, whether
it's a high-speed or low-speed variant, also plays a significant role.

Understanding these factors is essential for effective application in the pharmaceutical manufacturing
process. Adjusting the rotational speed can enhance separation efficiency, while selecting the appropriate
centrifuge type ensures compatibility with the specific requirements of the pharmaceutical industry. This
understanding aligns with the course objective of comprehending the mechanism of mechanical separators
and applying these principles in industry.

Bloom's Taxonomy Level: Apply (Factor Analysis), Understand (Application Explanation)

Question 5: A food processing plant utilizes a filter press for the separation of solid particles from a liquid.
Discuss the implications of filter cake resistance on the capacity and economy of the filtration process.
Provide a detailed explanation of how variations in filter cake resistance impact the overall performance of
the filter press and suggest strategies for optimizing the filter cake resistance to achieve higher capacity and
improved economy in the context of food processing.

Answer: Solution: Filter cake resistance has significant implications for the capacity and economy of a
filtration process using a filter press. Higher filter cake resistance leads to increased resistance to flow,
reducing the overall capacity of the filter press. This results in longer filtration times and decreased
throughput.

Optimizing filter cake resistance is crucial for improving the efficiency of the filter press. Strategies may
include selecting the appropriate filter media, adjusting the pressure, and optimizing the cake thickness.
These strategies help minimize resistance and enhance the overall capacity and economy of the filtration
process in food processing.

Bloom's Taxonomy Level: Apply (Implications Analysis), Evaluate (Optimization Strategies)

UNIT 3 - SIZE REDUCTION

Question 1 In the pharmaceutical industry, a company needs to produce a powdered drug with a specific
particle size distribution for better bioavailability. Design a size reduction process using appropriate
equipment and explain the reasoning behind your choices. Consider factors such as the drug's properties,
required particle size, and production scale.

Answer: To design a size reduction process for the pharmaceutical industry, the choice of equipment plays a
crucial role. In this case, using a hammer mill for initial coarse grinding followed by a ball mill for fine
grinding could be effective. The hammer mill breaks down larger particles, and the ball mill refines the
particle size further. The closed circuit grinding ensures precise control over the particle size distribution.
This approach aligns with the course objective of gaining knowledge on size reduction operations and the
outcome of applying principles in the process industry.

Bloom's Taxonomy Level: Create, Apply

Question 2 An agro-processing unit aims to produce powdered spices with enhanced flavor and aroma.
Propose a size reduction strategy using appropriate mills and discuss how the choice of equipment impacts
the quality of the final product.

Answer: For producing powdered spices with enhanced flavor and aroma, a combination of attrition and
ball mills can be employed. Attrition mills help maintain the natural properties of spices, while ball mills
ensure a fine particle size. The choice of mills is crucial to preserve the essential oils and flavor compounds.
This application aligns with the course outcome of applying size reduction principles in the process industry.

Bloom's Taxonomy Level: Analyze, Apply

Question 3 A mining company needs to process ore to achieve optimal liberation of valuable minerals.
Design a comminution circuit, considering factors such as ore hardness, liberation size, and energy
efficiency. Justify your choices of crushers and mills in the circuit.

Answer: For optimal liberation of valuable minerals, a comminution circuit involving a jaw crusher for
primary crushing, a gyratory crusher for secondary crushing, and a ball mill for fine grinding could be
designed. The choice of crushers and mills is based on ore hardness and liberation size. This circuit ensures
efficient extraction of valuable minerals, aligning with the course objective and outcome.

Bloom's Taxonomy Level: Create, Apply

Question 4 A chemical manufacturing unit aims to produce fine powders for use in catalyst formulations.
Design a size reduction process, considering factors such as the chemical nature of the powders, required
particle size distribution, and potential hazards. Discuss safety measures in the chosen process.

Answer: In the production of fine powders for catalyst formulations, a combination of a ball mill and an
attrition mill could be employed. The chemical nature of the powders requires a gentle process to avoid
undesirable reactions. Safety measures include using inert atmospheres to prevent oxidation and employing
explosion-proof equipment where necessary. This application aligns with the course objective and outcome.

Bloom's Taxonomy Level: Create, Apply

Question 5 A fruit processing plant aims to produce fruit powders for use in baking and beverage
industries. Propose a size reduction strategy using suitable mills and discuss how considerations such as fruit
type, moisture content, and preservation of natural flavors impact the quality of the final product.
Answer: To produce fruit powders for baking and beverages, a combination of a freeze dryer for initial
moisture removal followed by a hammer mill for size reduction could be employed. The choice of mills
should consider the fruit type to preserve natural flavors. Careful control of moisture content during the
process is crucial for maintaining quality. This application aligns with the course outcome of applying size
reduction principles in the food processing industry.

Bloom's Taxonomy Level: Analyze, Apply

 UNIT 4 - CONTACT EQUILIBRIUM SEPARATION

Question 1: In a gas absorption process, explain how altering the operating conditions, such as increasing
temperature, can impact the rate of gas absorption. Provide a real-world scenario where adjusting operating
conditions becomes crucial for optimizing the separation process.

Answer: Increasing the temperature in a gas absorption process can enhance the rate of absorption by
promoting the solubility of gases in the liquid phase. For instance, in a chemical industry where the
absorption of a specific gas is critical for a particular reaction, raising the temperature might be necessary to
achieve the desired absorption rate. This illustrates the practical application of adjusting operating conditions
to optimize separation.

Level: Apply

Question 2: Discuss the significance of the type and construction of tower packing in packed towers used
for gas absorption. Provide an example of an industry where the choice of tower packing is crucial for the
success of the separation process.

Answer: The type and construction of tower packing play a crucial role in maximizing the contact surface
area between gas and liquid phases, impacting the efficiency of gas absorption. In a petrochemical industry,
for instance, where the removal of impurities from a gas stream is vital for downstream processes, selecting
suitable tower packing is essential to ensure efficient absorption and separation.

Level: Apply

Question 3: Explain how the nature of adsorbents influences the effectiveness of adsorption operations.
Provide an example from a pharmaceutical industry where the choice of adsorbents is pivotal for a
successful separation process.

Answer: The nature of adsorbents, including their surface area and affinity for specific molecules, affects
the selectivity and efficiency of adsorption operations. In the pharmaceutical industry, during the
purification of drug compounds, the use of specialized adsorbents is crucial to selectively capture and
separate the target molecules from impurities, showcasing the practical application of adsorbent selection in
separation processes.

Level: Apply

Question 4: Describe how the flow through packed towers influences the performance of gas absorption.
Provide a real-world example from an environmental application where optimizing the flow through packed
towers is essential for effective separation.

Answer: The flow through packed towers determines the contact time between the gas and liquid phases,
directly impacting the efficiency of gas absorption. In environmental applications, such as air pollution
control, where the removal of pollutants like sulfur dioxide is critical, optimizing the flow through packed
towers becomes essential to ensure thorough absorption and efficient separation of pollutants.

Level: Apply

Question 5: In an adsorption process, discuss the role of equilibrium concentration relationships in

achieving effective separation. Provide an example from the water treatment industry where understanding
and applying these relationships are essential for successful adsorption.
Answer: Equilibrium concentration relationships dictate the distribution of solutes between different phases
at equilibrium, influencing the effectiveness of adsorption. In the water treatment industry, where the
removal of contaminants from water is vital, understanding these relationships is crucial for designing
adsorption systems that can achieve the desired purity levels in treated water.

Level: Apply

UNIT V - EXTRACTION AND CRYSTALLIZATION

1. Discuss the application of continuous leaching-decantation systems in the pharmaceutical industry. Evaluate
the advantages and challenges associated with using this extraction method for the production of specific
drug compounds. (15 marks, Bloom's Taxonomy: Apply and Evaluate)
2. Evaluate the use of Swenson-Walker vacuum crystallizers in large-scale sugar production. Discuss how the
design and operation of these crystallizers contribute to the efficiency of the crystallization process. Provide
practical examples of their application in the sugar industry. (15 marks, Bloom's Taxonomy: Apply and
Evaluate)
3. Apply the principles of equilibrium crystallization to design a strategy for producing high-purity salt crystals
from a brine solution. Discuss the key parameters that need to be controlled during the process and how this
approach aligns with the course objective. (15 marks, Bloom's Taxonomy: Apply and Understand)
4. Examine the use of basket extractors for leaching coarse solids in the mining industry. Evaluate the
extraction efficiency and environmental impact of this equipment in the extraction of valuable metals from
ore. Relate your discussion to the course outcome of applying contact equilibrium separation. (15 marks,
Bloom's Taxonomy: Apply and Evaluate)
5. Discuss the application of tank crystallizers in the production of specialty chemicals. Evaluate the factors
influencing crystal growth rates and how they can be manipulated for the controlled production of high-
quality crystals. Relate this to the overall goal of applying contact equilibrium separation. (15 marks,
Bloom's Taxonomy: Apply and Evaluate)