1.

0 INTRODUCTION

1.1 INSTANT CUP NOODLES

Cup Noodle in Japan, and the product has inspired numerous competitors, such
as Maruchan's Instant Lunch.Instant noodles were invented in 1958 by Momofuku Ando, the
Taiwanese-born founder of the Japanese food company Nissin. He used Chicken Ramen as the
first instant ramen noodles.In 1970, Nissin formed the subsidiary Nissin Foods (USA) Co. Inc, to
sell instant noodles in the United States. Nissin recognized that the bowls traditionally used to
package instant noodles in Asia were not common in the U.S, so they used the paper cup
designed by Ron R. Matteson. In 1971, they introduced instant ramen packaged in a foam cup.
The three original Cup O' Noodles flavors in the US were beef, chicken and shrimp. Pork flavor
was added in 1976. In 1978, Nissin Foods offered more new varieties of Top Ramen and Cup O'
Noodles. The product was known as Cup O' Noodles in the United States until 1993.

In 1998, Cup Noodles Hot Sauce Varieties introduced (Beef, Chicken, Pork and Shrimp). [1]On a
trip to the U.S. in 1966, Mr. Ando noticed Americans curiously eating forkfuls of noodles out of
cups, instead of using bowls and chopsticks. With that simple observation, the worldwide Cup
Noodles® phenomenon was born. Shortly after, Nissin officially put down its roots in the U.S. In
1972, our Gardena, CA, plant started production of Top Ramen®—the first instant ramen
manufactured and sold in the U.S. And ever since, Nissin Foods USA has launched a continuous
stream of new and innovative products for hungry, noodle-loving Americans. [1]

2.0 AUTOMATION SYSTEM

Automation is the technology by which a process or procedure is performed without human

assistance.[3] Automation [4] or automatic control is the use of various control systems for
operating equipment such as machinery, processes in factories, boilers and heat treating ovens,
switching on telephone networks, steering and stabilization of ships, aircraft and other
applications and vehicles with minimal or reduced human intervention. Some processes have
been completely automated.

Automation covers applications ranging from a household thermostat controlling a boiler, to a

large industrial control system with tens of thousands of input measurements and output control
signals. In control complexity it can range from simple on-off control to multi-variable high level
algorithms.
In the simplest type of an automatic control loop, a controller compares a measured value of a
process with a desired set value, and processes the resulting error signal to change some input to
the process, in such a way that the process stays at its set point despite disturbances. This closed-
loop control is an application of negative feedback to a system. The mathematical basis of
control theory was begun in the 18th century, and advanced rapidly in the 20th.

Automation has been achieved by various means including mechanical, hydraulic, pneumatic,
electrical, electronic devices and computers, usually in combination. Complicated systems, such
as modern factories, airplanes and ships typically use all these combined techniques. The benefit
of automation include labor savings, savings in electricity costs, savings in material costs, and
improvements to quality, accuracy and precision.

AUTOMATION SYSTEM

2.1 TYPES OF AUTOMATION

Automation of production systems can be classified into three basic types:

1. Fixed automation (Hard Automation)

2. Programmable automation (Soft Automation)

3. Flexible automation.

1. Fixed automation (Hard automation): Fixed automation refers to the use of special purpose
equipment to automate a fixed sequence of processing or assembly operations. Each of the
operation in the sequence is usually simple, involving perhaps a plain linear or rotational motion
or an uncomplicated combination of two. It is relatively difficult to accomodate changes in the
product design. This is called hard automation.

Advantages:

1. Low unit cost

2. Automated material handling

3. High production rate.

Disadvantages:

1. High initial Investment

2. Relatively inflexible in accommodating product changes.

2. Programmable automation: In programmable automation, the production equipment is

designed with the capability to change the sequence of operations to accomodate different
product configurations. The operation sequence is controlled by a program, which is a set of
instructions coded. So that they can be read and interpreted by the system. New programs can be
prepared and entered into the equipment to produce new products.

Advantages:

1. Flexible to deal with design variations.

2. Suitable for batch production.

Disadvantages:

1. High investment in general purpose equipment

2. Lower production rate than fixed automation.

Example: Numerical controlled machine tools, industrial robots and programmable logic
controller.
3. Fixed Automation: (Soft automation): Flexible automation is an extension of programmable
automation. A flexible automation system is capable of producing a variety of parts with virtually
no time lost for changeovers from one part style to the next. There is no lost production time
while reprogramming the system and altering the physical set up.

Advantages:

1. Continuous production of variable mixtures of product.

2. Flexible to deal with product design variation.

Disadvantages:

1. Medium production rate

2. High investment.

3. High ‘unit cost relative to fixed automation

2.2 ADVANTAGES AND DISADVANTAGES

Perhaps the most cited advantage of automation in industry is that it is associated with faster
production and cheaper labor costs. Another benefit could be that it replaces hard, physical, or
monotonous work.[5] Additionally, tasks that take place in hazardous environments or that are
otherwise beyond human capabilities can be done by machines, as machines can operate even
under extreme temperatures or in atmospheres that are radioactive or toxic. They can also be
maintained with simple quality checks. However, at the time being, not all tasks can be
automated, and some tasks are more expensive to automate than others. Initial costs of installing
the machinery in factory settings are high, and failure to maintain a system could result in the
loss of the product itself. Moreover, some studies seem to indicate that industrial automation
could impose ill effects beyond operational concerns, including worker displacement due to
systemic loss of employment and compounded environmental damage; however, these findings
are both convoluted and controversial in nature, and could potentially be circumvented.[6]
The main advantages of automation are:

 Increased throughput or productivity.

 Improved quality or increased predictability of quality.

 Improved robustness (consistency), of processes or product.

 Increased consistency of output.

 Reduced direct human labor costs and expenses.

 Installation in operations reduces cycle time.

 Can complete tasks where a high degree of accuracy is required.

 Replaces human operators in tasks that involve hard physical or monotonous work (e.g.,
using one forklift with a single driver instead of a team of multiple workers to lift a heavy
object)[36]

 Reduces some occupational injuries (e.g., fewer strained backs from lifting heavy
objects)

 Replaces humans in tasks done in dangerous environments (i.e. fire, space, volcanoes,
nuclear facilities, underwater, etc.)

 Performs tasks that are beyond human capabilities of size, weight, speed, endurance, etc.

 Reduces operation time and work handling time significantly.

 Frees up workers to take on other roles.

 Provides higher level jobs in the development, deployment, maintenance and running of
the automated processes.
The main disadvantages of automation are:

 Possible security threats/vulnerability due to increased relative susceptibility for

committing errors.

 Unpredictable or excessive development costs.

 High initial cost.

 Displaces workers due to job replacement.

 Leads to further environmental damage and could compound climate change.[37]

2.3 EFFECT OF AUTOMATION TO CUP NOODLES INDUSTRY

 The noodles must be preserved for a long time thus deep frying methods were used to
rehydrate the noodles. This deep fried method is dangerous because it could inconvenient
temperature or cause burn risk. Hazardous work environment for humans when the work
environment is unsafe, unhealthful, hazardous, uncomfortable for human. This where the
machine will used thus it could be remove the risk of hurting the working which could
also reduce the effect on economy of the company for worker treatment.

There will be more efficient if machine does all the manufacturing process work.
Thousands of noodles must be made every day and it could cause fatigue to worker if
using the manual production.Repetitive work cycle if the sequence of elements in the
cycle is the same & the elements consist of relatively simple motion cause the worker
become fatigue quickly. However, the robot capable performs with consistence and
repeatability and it could maintain the efficiency in working

Since the noodle making is continuous process, by using automated line the work
production become more efficient. The work space is less needed since the machine are
arranged in continuous line. Less wage needed to pay the worker if increased in using of
automation system. The worker needed only for some small process and maintenance
engineer.

3.0 MANUFACTURING PROCESS

Instant ramen noodles are made with wheat flour, water, salt, and kansui, an alkaline water that
adds elasticity to the noodles. First, the ingredients are kneaded together to make a dough. Next,
this dough is rolled out and cut into thin noodles. The noodles are then steamed and are finally
packaged after dehydration. Advanced technologies are used in every step of the manufacturing
process. Dehydration is especially important for the preservability of instant ramen, so noodle
makers have experimented with many methods. [4].

In the rolling process, when the dough is rolled out, depending on some characteristics of wheat
flour such as moisture and protein content, harvest season and region, etc., the thickness of
dough sheets varies at the same roller gap and workers frequently should adjust the roller gap to
maintain the uniform thickness. But, the roller gap adjustment is a very difficult job for the
workers because a worm gear which adjusts the roller gap has a backlash not to be controlled and
there is no display device to estimate the roller gap. the rolling process, even though the roller
gap is set to the same value, depending on some characteristics of wheat flour such as moisture
and protein content, harvest season and region, etc., the viscosity and stiffness of the dough vary
and the fluctuation of the roller gap is necessarily occurred when the dough is rolled out.
Therefore, workers should frequently adjust the roller gap to maintain the uniform thickness.
But, the roller gap adjustment is a very difficult job for the workers because a worm gearbox in
the conventional system which adjusts the roller gap has a backlash not to be controlled and there
is no display device to estimate the roller gap. Because of these reasons, whenever product items
in the same production lines are changed, the roller gap adjustment of each product depends on
the experience of the worker.[5]

Momofuku Ando, the founder of Nissin, succeeded in making the first instant ramen after much
trial and error. Tempura, a traditional Japanese deep-fried food, gave him the idea of removing
moisture from the noodles by frying them in oil at a high temperature. This method makes it
possible to dehydrate the noodles almost completely. Moreover, it has the added advantage of
leaving countless minuscule holes on the surface, making it easier for the noodles to rehydrate
when steeped in hot water.

Recently, a new method of dehydrating ramen noodles has emerged: "blow-drying" them at a
high temperature instead of frying. This was actually tried in the early days of instant ramen, but
it was unpopular because the noodles did not loosen in the soup easily and because they became
rubbery. In the late 1990s, thanks to refinements in blow-drying technology and in the
combination of ingredients, a dehydration method was developed in which the noodles are
exposed to hot air at 80 degrees Celsius (176 degrees Fahrenheit) for 30 to 60 minutes. Known as
"nonfried noodles," ramen products made in this way have become popular for being low in
calories.

One important merit of instant foods is that they can be stored for long periods. To ensure
preservability, the water content cannot exceed 12%. Fried instant noodles have a water content
of between 3% and 6%, while non fried noodles measure around 10%. Compared to fried
noodles, which have tiny holes, non-fried noodles take about two extra minutes to rehydrate.
This problem should eventually be solved, though, with the development of even newer
technology.

Dehydration is only one aspect of instant ramen production, but this overview has been enough
to show us how hard ramen makers have been working to develop various methods of production
in pursuit of an ever-better eating experience.
3.1 CUP NOODLES PRODUCTION LINE
Equipments Remark
Brine metrology mixer Power: 1.5 kw
Pump power 0.75 kw
Capacity of 1000 l/units

Supply metering device Volume: 140 liters with LCD

Pump power: 0.75 kw,

Double speed dough mixer Power: 18.5 kw

Capacity: 350 kg/pan

Disc curing machine Power: 4 kw

Tray 2200 mm * 500 mm

Continuous rolling machine Paste width: 800

Power:7.5+11+7.5×2=33.5kw

Single-layer steaming machine Length: 36 meters

Power: 3 kw power (VVVF)
Fan 0.37 kw x 2 units

Cutting and folding machine Main drive: 1.5 kw

Air knife:0.9 kw *2,
Cutting speed≤60 time/minute

Fried dryer Main drive: 5.5kw

Circulating pump: 22 kw
Gear pump: 3 kw
Air knife 0.9 kw *4

Strong Air cooling device Power: 1.1 kw

Exhaust fan: 0.37*14 kw power

Shunt conveyor Power: 2.2 kw (VVVF)

Conveyor Power: 0.37 kw * 3

Products conveyor Power: 0.37*3 main drive

Electric control cabinet Frequency control motor speed

PLC program control
Advantages of this production line:

(1) The dough mixing machine is designed with double shafts and double speeds for optimal
dough mixing effect.

(2) The calendar ratio of noodle maker is designed logically, and the clearance between rollers is
easy to change.

(3) Single layer or multi-layer steaming machine is designed with originative structure, where the
temperature remains proper and the pasting degree of noodles keeps higher.

(4) After being cut off, the dough keeps high proportion to be placed in a box, meanwhile, it is
unnecessary to stop the machine to finely adjust the weight of the dough.

(5) High heat exchange rate in frying, it keeps no pollution on the oil and the oil content in the
dough keeps lower.

(6) High-precision sensors and control elements, sound quality, stable and reliable.

(7) The rollers adopt centrifugal casting with cold and hard alloy, processed with accuracy, and
the hardness on the surface of the products reach over HRC45, featured of abrasion resistance
and long service life. [4]

REFERENCES

1. Groover, Mikell (2014). Fundamentals of Modern Manufacturing: Materials, Processes,

and Systems.
2. Rifkin, Jeremy (1995). The End of Work: The Decline of the Global Labor Force and the
Dawn of the Post-Market Era. Putnam Publishing Group. pp. 66, 75. ISBN 0-87477-779-
8.
3. Hou, G.G.: Asian Noodles: Science, Technology, and Processing. Wiley (2010)
4. Web Japan, http://web-japan.org/kidsweb/hitech/ramen/
5. Process automation, retrieved on 20.02.2010 Archived 17 May 2013 at the Wayback
Machine.
6. Rainer Walz; Joachim Schleich (September 27, 2008). The Economics of Climate Change
Policies: Macroeconomic Effects, Structural Adjustments and Technological Change.
7. D. Yang (Ed.): Informatics in Control, Automation and Robotics, Volume 2, LNEE 133,
pp. 225–229.