Intermediate Food Process Engineering

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About Course

Size it, design it, commission it and keep it running. This course takes food process engineering from fundamentals to real design calculations.

Engineers and technologists are asked to choose pumps for thick products, size heat exchangers and holding tubes, cut evaporator steam use, set dryer conditions and tune control loops. Each of those decisions has a food safety and a cost side, and both depend on getting the calculations right.

Intermediate Food Process Engineering is a 20-hour online course for process technologists, engineers and technical managers who design, commission or improve food processes. It builds on the fundamentals of balances, heat transfer and fluid flow, and works through design problems from dairy, brewing, beverages, meat, bakery and ingredients plants.

What the course covers

Six modules: rheology and non-Newtonian flow; heat exchanger design and thermal processing; evaporation and concentration; drying and freezing calculations; mechanical separations and mixing; and instrumentation, control and energy efficiency.

Each module closes with a design activity, a knowledge check and a game: work out why a pasteuriser would not divert, follow a milk droplet through a spray dryer, and choose the right sensor for each job. Every lesson has a Listen to this lesson option. All activities, knowledge checks and games are compulsory and open in order.

The course ends with a capstone project and a proctored final assessment: 40 questions drawn at random, so every attempt is different. 60 minutes, 70 percent to pass, 3 attempts.

Your certificate

Pass the final assessment and you receive an ASC Food Safety Certificate of Achievement for Intermediate Food Process Engineering. It shows your name, the course, the completion date and a unique verification ID with a QR code, so an employer or auditor can check it online at ascfoodsafetytraining.com. You can download it from your dashboard as soon as you pass.

The course was developed by ASC Food Safety’s multidisciplinary team of industry professionals, led by Mthokozisi Nkosi, with contributions from specialists in brewing, dairy processing, meat processing and nutrition. It follows international references: Codex Alimentarius, ISO 22000 and WHO and FAO guidance.

What Will You Learn?

  • Characterise non-Newtonian foods with power-law and Herschel-Bulkley models and calculate pipe pressure drops, pump operating points and NPSH
  • Size plate and tubular heat exchangers with LMTD and effectiveness-NTU methods, and design holding tubes and regeneration sections that meet lethality targets
  • Compare single and multiple-effect, TVR and MVR evaporators and membrane concentration using mass, energy and cost balances
  • Apply psychrometrics, drying-rate theory, spray dryer balances and freezing-time methods to predict process performance and refrigeration loads
  • Scale up centrifuges, filters, membranes, mixers and homogenisers using sigma theory, cake filtration, flux models and dimensionless groups
  • Select and calibrate process instruments, tune control loops and specify flow diversion logic for pasteurisers
  • Audit plant energy use, quantify steam and compressed-air losses and track performance with energy KPIs and baselines

Course Content

Module 1: Rheology and Non-Newtonian Flow
How real foods flow, how to measure it, and how to turn flow curves into pipe pressure drops, pump choices and cavitation-free suction designs.

  • Lesson 1: Learning Outcomes
  • Lesson 2: Measuring and Modelling How Foods Flow
  • Lesson 3: Pressure Drop in Pipes: Newtonian and Power-Law Fluids
  • Lesson 4: Pumps, System Curves and NPSH
  • Lesson 5: Design check: hot-fill sauce line
  • Module 1 knowledge check
  • Game: Pick Your Pump

Module 2: Heat Exchanger Design and Thermal Processing
Sizing and rating heat exchangers, designing regeneration and holding tubes, calculating lethality and keeping under-processed product out of the pack.

Module 3: Evaporation and Concentration
Taking water out efficiently: evaporator balances, multiple effects, vapour recompression, falling-film design and membrane concentration.

Module 4: Drying and Freezing Calculations
Psychrometrics, drying curves, spray dryer balances, freezing-time prediction and refrigeration loads for dryers, blast freezers and cold stores.

Module 5: Mechanical Separations and Mixing
Centrifuges, filters and membranes as resistance and settling problems, and how mixing tanks and homogenisers scale.

Module 6: Instrumentation, Control and Energy Efficiency
Keeping measurements honest, loops stable and critical control points secure, and finding and fixing the energy a plant wastes.

Course assessment and Feedback
The final assessment for the Intermediate Food Process Engineering.

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