VC2014_0020

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Abstract Virtual Concept Workshop 2013Innovation on Product design and manufacture, Medellin, Colombia

Paper Number - 1- Copyright of Virtual Concept

Industrialization of transformation process and packaging of panela

Gamboa C, Wilson 1 , Duran Q, Mayerline 2 , Luque P, Anglica 3 , Gmez G, Ana 4 , Angel C, Carlos 5 y Velasco, Oscar 6

Kilometer 2 va San Gil Charal Santander Colombia(7) 7245757 ext. 275

E-mail : {wgamboa, mduran, aluque, agomez2, cangel1, ovelasquez}@unisangil.edu.co

Short Abstract: This article presents the analysis results

of technical variables, economic policy and logistics, for thedesign and construction of panela packaging in different presentations with a national and international marketregulation and quality standards. Through the implementationof the results this study, the small and medium producers canreduce costs, implement quality in the process, reduce productlosses, expand its product portfolio and market, all tending toindustrialize the process, improve competitiveness and

productivity of the sector.

Key words : Central packing, panela, pulverized panela,good manufacturing practices, packaging logistics.

1- Introduction

The information presented in this article explains the results ofthe research project: " Design of a packaging plant for panelain different presentations, under current regulation andstandardization of processes ", which is to determine thetechnical, economic characteristics, regulations and process es,

packaging system for panela in different presentations formarketing at national and international level. The project beganwith the search for primary and secondary information, about

panela (in its various presentations ), prices, packaging, packaging and presentations , previous studies and related tothe topic made by entities o r individuals , companies and people

allied the distribution chain.To get the results and s hare them with the productive sector, ananalysis was performed on alternative packaging, where theconsumer profile was identified: who buys, where they buy,the price they would pay for the product, applications that can

be given and other information neces sary for theimplementation of the production and sale of panela inColombia and other countries.With the development of this project, information related to the

packaging p roduction process was obtained, from the receptionof the raw material (sugar cane extract: panela from trapiches) to the marketing of the product,. This was obtained through theanalysis of market trends, current rates sweeteners, appliedtechnology to the economical sector, the problems of existing

packaging, presentations and acceptability, performance and

efficiency in production and physicochemical conditions of

the product.The project is supported by strategically linking theuniversity with the productive sector, this proposal and itscorresponding implementation, has the backing ofFEDEPANELA - Comerpanela and Agroindustrial Centerand Management - SENA - Regional Cundinamarca, Villetaand finance by COLCIENCIAS, institutions that take part onthe fundamental stages of chain production of panela inColombia.

2- Transformation process industrialization

Panela is a traditional food of excellent nutritional benefits, but its production chain has little incorporated technology intheir production process, packaging and distribution. It is ahygroscopic product qualities, which means that absorbs orloses moisture by exposure to the environment. By their

physicochemical characteristics, panela mus t be properly packed to keep its organoleptic properties and preserve thequality of your presentation. Panela is susceptible to bealtered when there are high concentrations of reducingsugars, sucrose and low levels of high humidity. Withincreasing absorption of moisture, softens panela, changescolor, increases and decreases reducing sugars sucrose, underthese conditions is susceptible to contamination bymicroorganisms. [G1] The industry of panela has been used for several years, andhas been sold on s hrink packaging, to isolate individual unitsand as a wrap, but this method does not ensure product

protection agains t external agents that contaminate it or promote its deterioration.It is clear that panela packing methods such as block,granulated and pulverized have completely different handlingconditions in comparison to other foods, and theenvironments and equipment used require adjustments thatcan be implemented in the industry of panela; also, materialsshould allow the management of panela considering their

physicochemical conditions with the purpose of provide protection during handling and use.
mailto:%7Bwgamboamailto:mduranmailto:[email protected]:[email protected]:mduranmailto:%7Bwgamboa

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Virtual Concept Workshop 2012 Process and packaging of panela

Paper Number -2- C opyright Virtual Concept

In previous studies [M1], has been established that thegranulated and / or pulverized panela is the most accepted

presentation in external markets. The most important justification is that the rapid rhythm of life in our societydoesnt allow the conventional preparation of panela, sincemost consumers are looking for healthy and good quality food

products .Panela depending on their uses can supply other marketsinstead of thinking into one for this product. Panela cancompete, among others, with juices or artificial flavors inrefreshing drinks market, with cocoa, coffee, tea or aromatic inthe market for hot drinks. Or can compete in the market ofnatural products and health. Another great niche market thatinroads can panela is as input to industrial changes in the foodmarket and organic products such as sauces, cakes and pastries,chocolates, desserts, jams and compotes, sweets, breads andcookies, frieds, meats, and others.Since the process of packing panela is still low-tech in mostmills or traders due to the scarce and expensive machinery

there, and complications in the use of the product, it is essent ialfor the distribution and marketing the use of appropriateequipment for packing in small, medium and large mills, inorder to market the product. This improvement on technologygives the producer the opportunity to expand their market andfor consumers the opportunity to acquire a quality product,with easy access , utility and great benefits.The packaging headquarters is designed as a functional modelat the service of panela producers in the region, with the idea totransform and give added value to their products, mainly onhomogenization, drying, packaging and new presentationswithout entering in competition among themeselves. Thecenter is not intended to produce or have its own brand. With

this service, producers, especially small ones, do not requirelarge investments in equipment and technology, the center willensure quality in accordance with current regulations and theapplication of good manufacturing practices throughout thetransformation processes.The packaging headquarters main characteristics are:- Have a clear process diagram, applying theories of time andmotion.- Distribution of the process areas- Design of the sanitary requirements and managementenvironments for handling panela (low humidity environments)infrastructure.- Study materials for packaging panela, environmentally

friendly and economically affordable for producers withoutaffecting raise product costs .- Methodology for the implementation of phytosanitarystandards, good manufacturing practices in packaging andcoding.- Study of national and international standards for import andexport of sugar.- Reliable and safe electromechanical equipment within the

premises of the plant

To follow present the element of the flowchart in the processof headquarters pack:

- Input and reception of the product.- Review and weighing (database producer, type of

panela, production s ite, production date, batch, etc.).

- Moisture and microbiological analys is- Homogenization and particle size reduction- Drying controlled- Input the product packaging chain square, round,

pill, pulverized and s tick-pack.- Adaptation and adjustment of equipment according

to the s ize and presentation of panela.- Packaging of each panela or according to the presentation (by blocks of 4, 5 or more panelas per package).

- Product labeling (laser printing with the productinformation: weight, batch, production date, expirydate, bar code, etc.).

- Checking the quality of the packaging.- Product Storage.- Distribution.

3- Design of prototype packaging

According to the technical specifications generated in theanalysis (dimensions, volumes, materials) three types ofmachinery equipment were designed and built to completethe packing process , these are: homogenizer panela, infraredrotary dryer and stick pack packing. The design ofmechanical devices was made from the extreme conditions ofwork, for this, the materials and its properties were studiedincluding: material strength, corrosion, behavior in averagetemperatures and other.For the construction of the equipment some recommendedmaterials were used on machines that process food products(stainless steel 304). The use of these materials allow a fastand reliable cleaning process, allowing the production of

products that meet the standard requirements of theColombian Technical Standard N.1311 (ICONTEC),ensuring excellent quality packaging, easy handling andincreased p roduction of panela in different p resentations.

3.1 Homogene izer of panela

This equipment is part of the second stage of the process of pulverization panela. In this, the crystal or grain istransformed into a pulverized and homogeneous product. Thehomogenizer works from the physical principle of thecyclone separator, which basically consists of a feed hopper(entry pulverized panela, granular or clods), a metering augerspeed controlled, double rotor blades and concentric disk(spiral) in the direction of clockwise, a section of lowerhorizontal pipe upward vertical cylindrical collector andterminating in a conical section, where the primary materialflow enters the top of the cyclone and moves downwards,depositing the material of the larger particles in a closedvacuum hopper capacity 50kgs. The smaller particle sizematerial is removed by the effect of the secondary flow to theoutside and recovered by means of a filter or sleeve. The

prototype is composed of a 5Hp motor needed to move thedisc at about 3000 rpm, one motoreductor for the motion ofthe screw feeder to 0-60 rpm, and a panel control is used toexecute start, stop, emergency stop, speed control meteringauger and electrical safety functions. The computer has a

proces sing capacity of 300kgs hou r, with humidity ranging

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between 1 and 2%. In addition to the equipment, it can makemixtures of products or food ingredients with panela, obtainingas a result a product with soft and homogeneous texture.

3.2 Infrared rotary dryer

Because of the hygroscopicity of panela, temperature andrelative humidity have great influence on their conservation.The drying system is characterized by being free of gas or anyother fuel and low power consumption, and allows reduction ofmoisture less 2% powder panela. The propos ed system cons istsof rotating drying cylinder of stainless steel, where the

pulverized is deposited panela, drying approximately 50kg in a programmed time or controlled from a programmable logiccontroller (PLC) with a touch screen. In this screen, theoperator types the desired temperature and drying time. Thelimited literature found, recommended drying panela to atemperature of 55 C [F1], and time is dependent on theamount to dry. A metal frame and a fundamental element lampinfrared radiation, which consists of three quartz tubes of 2mlong that inside each contains a resistor, support the equipment.The tubes are supported in an elongated capsule (semicircularhood) aluminum that focuses radiation onto the surface of thestainless steel sheet. The height of the lamp can be gradualaccording to the exposed surface. To make the temperaturecontrol was available infrared temperature sensor directedtowards the surface of the powdered panela.

3.3 Stick- pack packaging for panela three-waypulverized

The prototype packaging powdered panela three-way StickPack, dosing, filling, sealing and cutting bag pillow (StickPack), from a coil of biaxially oriented polypropylene. Theautomatic control of the packaging process, is performed by aPLC DR16A XBM, which monitors control variables anddosing times of the heat sealing temperature, roll speed,volume and pressure of the pneumatic system. Additionally,the team has a Human Machine Interface HMI touch panelMT6070IH where the operating conditions of the system,monitoring the process variables and control of it are recorded.The prototype under full operation, reached a yield of 120

packages per minute, equivalent to 60 kg / hour. Each of thethree ways of packaging consists of three rollers which provide

packing material and a pho tocell that gives the order to cuteach stick pack to pas s the cut indicator; each roll of packagingis printed an indicator of black co lor photocell detects and so rtseach cut formed tube .The packaging is a polypropylene, this material is the mostsuitable for the packaging of hygroscopic food and the use of

packaging material is minimal. Each tube st ick pack uses arectangle (length 100 mm and width 80 mm). The packaging

proces s must yield from 90 to 120 packages / min, that is, between 30 and 40 pouches per minute per path , add ing theamount of product , equivalent to 60 kg / hour . The dosingsystem and packaging material supply is automaticallycontrolled to ensure continuous s upply of sugar. The sealing ofthe envelopes is performed with a film of paper , which is

pulled by means of a controllable system ( time, voltage ,length, etc . ) And the speed is controlled by the PLC , whichallows " accelerating " and " decelerating " according to the

speed of the computer and the working phase (stop and torn), so that an accurate and uniform length stick pack isguaranteed for the entire production. The seal system has theTL46-WL-815 (multicolor photocell) sensor. The sensorreaches a switching frequency of 30kHz. Additionally, thesealing system has a transverse sealing jaw is guided by

separate air cylinders. The distance between the jaws isadjustable according to the selected volume of panela.Transverse sealing bar is pneumatically activated by meansof pressure regulation. The adhesive system and cutting isdone with a solder plate used for high strength biaxiallyoriented polypropylene type material bag cutting bladeelectronically activated.

4- Identification and characterization of theproposed innovation

It is clear that in the field of Agroindus try panela is necessaryto submit a proposal for training and technical support tofacilitate achieve to obtain finished products that competewith products from the market and protect the product,starting with knowledge in handling and packaging product

packaging.In the case of the departments of Colombia as Cundinamarca,Santander and Boyac, have specifically determined that thefailure the panela market by packaging and packaging usedto market both products and by-products of sugarcaneharvest and therefore are not highly qualified conditions arenot easy to transport and are not resistant to the variousfactors that can affect the final product, which leads to themarketing of these pass through a chain of intermediariesthat takes the value added. [M1]Despite of its importance, the sugarcane agroindustry hastraditionally suffered from a number of problems related tolow agricultural productivity and process deficiencies in

product quality, undes irable impacts on the environment andissues of market and organization o f producers.In the search to improve the quality and competitive

production of panela in Colombia the indus try has developeda varied product portfolio where the traditional panela and

pulverized presentation of the same product have beendeveloped. Currently, in the United States, Costa Rica, Spainand South Korea there are dealers who supply panela todepartment stores to give a good product acceptance. One ofthe main concerns of exporters lies mainly on the range oftraditional presentations of panela on the market, beingaware of the difficulties of achieving a new kind of

presentation of the product on the short term, because the product is mainly handmade and its lower on its levels of production. [FD1]Panela exporters argue that better standardization in

production proces ses facilitates marketing, although they areaware of the difficulties of achieving this in the short term,since it is a handmade product. Panela can compete, amongothers, with juices, artificial flavors, soft drinks, hot

beverages and health and natural products .In s tudies conducted by the Colombian Agricultural Institute

(ICA) and the Dutch government, by the Convention ofDisclosure for Research and Improvement Panelera Indus try(CIMPA), panela spray was the most accepted presentation

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in exhibitions in foreign markets. The justification lies in the bus y life of today's society. The first th ing to do to think aboutoptimal market development panela in the U.S., and the worldin general, is to ensure the quality and presentation of the

product ". [MA1]In the Panela market and its sub-products the country needs

promotion and management st rategies to position the sector atthe national and international scale with quality, relevance,efficiency and capability to adapt to change and innovation,developing products that meet the needs current and future.With all these criteria shown, it is clear that, along with theevolution of food, the development of demand and markets,must keep with the evolution of the packaging. The panelasegment must evolve to improve its processing methods,

packing and presentation of the product. The latter, will probably ens ure a clear vision of the product to conquer newmarkets, presented in easy to use portions, weighing andhomogeneous long life presentation, attractive to consumers.In this way, both small and medium producers will be able to

access the technology developed in Colombia with warrantyand ongoing advice, having the ability to generate a productwith a better presentation, which represents best prices in themarket and therefore higher incomes.

5- Conclusions

Through the implementation of the results of this study, thesmall and medium producers will reduce costs, implementquality in the process, reduce product losses, expand its

product portfolio and market, all aimed at indus trializing the proces s, improve competitiveness and productivity of thesector.The plant innovates in the packaging process, solving problemsrelated to weight, volume, humidity, measurement and

presentation, delivering high quality products to potentialconsumers.

6- References

[F1 ] Fundacin hogares Juveniles campesinos. Manualagropecuario, Tecnologas orgnicas de la granja integralautosuficiente. Tomo I, II. Biblioteca del campo. Bogot,Colombia, 2002

[FD1 ] Fonseca A., Edwuar., Durn C., Nstor. Consejostcnicos para tener en cuenta durante el proceso de produccinde la panela de buena calidad. Ministerio de Agricultura yDesarrollo Rural, Federacin Nacional de Produccin dePanela-FEDEPANELA Bogot DC.

[G1 ] Garca H., et al. Gua tcnica para el manejo integral delsistema productivo de la caa panela Gua tcnica para elmanejo integral del sistema productivo de la caa panela.Ministerio de Agricultura y Desarrollo Rural, Corpoica. 2007.

[M1 ] Martnez C, Hctor J. La cadena agroindustrial de la panela en Colombia, una mirada global de su estructu ra ydinmica, 1991- 2005. Bogot DC, marzo de 2005.

[MA1 ] Martnez, Hctor y Acevedo, Ximena. Caracterstic asy estructura de la cadena agroindustrial de la panela enColombia. Ministerio de Agricultura y Desarrollo Rural.

Observatorio Agrocadenas Colombia. Bogot, Colombia.Diciembre 2002, Actualizacin: agos to de 2004.

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