Block Diagram (BD)
Introduction
Definition The Block Diagram shows the different unit operations and their sequences of
a manufacturing process in a simplified form.
Typical Block Diagrams established at Nestlé or Nestec are:
Process Block Diagram (PBD)
Filling and Packing Block Diagram (F&PBD)
Utilities Block Diagram (UBD)
Purposes The Process Block Diagram serves as a reference or as a basis to establish
documents or to carry out following tasks:
During the Pre-project Study:
Depicting the process
Establishment of the cost estimate ( 20%)
During the Project Concept Study:
Establishment of the Project Concept (The Process Block Diagram is part of
the document)
Establishment of the Manufacturing Flow sheet
Establishment of Layouts (1:200) and Master plan
Revision of the cost estimation ( 15%)
During the Basic Design Phase:
Establishment of detailed Mass Flow Balances
Later on:
Training
Basic Document for plant/production manager
Standard costing
Quality management
When is it The Process Block Diagram is established during the Feasibility Study as part
established of the Pre-project Concept or during the Project Concept Study. It is requested
for the approval of the Project Concept.
During the Basic Design Phase the Process Block Diagram serves as a basis
to establish a detailed Process Block Diagram with a mass balance.
Evaluation of Investment
Conceptual Study Phase
Venture/Idea
Process Block Feasibility Study, Pre-
Diagram Concept, Location
Approval in Principle
Project Concept Study,
Conceptional Engineering
Project Approval
Basic Design (Major items of
Design Phase
Block Diagram with
equipment selected)
mass balance
Detail Design (Major
contracts prepared)
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Content and Presentation
Content Essential:
Naming of the main process operations and sequences of unit operations
In- and output material
Flow directions of the main material
Key process parameters (temperatures, pressures, flows...), they can either
be shown on the Block Diagram or on a separate data list.
Complement:
Naming of the products between the operations
Product mass flows for continuous processes or batch sizes and cycle times
for discontinuous processes. It allows the establishment of mass balances
(separate sheet)
Indication of energy and utility requirements
Estimation of the dimensions of the main elements (Preliminary sizing)
Packaging material input
Energy flows allowing the establishment of energy balances (separate sheet)
Presentation All relevant process operations are symbolized by simple geometric forms like
rectangles, ellipses, etc. Normally the mass flow goes from the left to the right
or from the top to the bottom of the page. The product flows between the
process operations are symbolized by lines. Arrows indicate the input and
output of materials and products.
A separate sheet with process parameters can be added in cases where a
large amount of data has to be shown.
The whole Block Diagram should be drawn on one sheet (suggested format:
A4)
Recommended PC based software (e.g. Visio, Excel, ...)
tools
Examples Overview:
Symbols: List of symbols used for the examples
Example 1: Process Block Diagram with essential content
Example 2: Process Block Diagram with extra content
Example 3: Process Block Diagram with mass balance
Example 4: Filling and Packing Block Diagram with essential content
All drawings shown were created to serve as examples on how Block
Diagrams should look like and are not meant to be technically realistic nor
represent a safe setup!
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Symbols
Symbols
Input Input of raw materials to create the product
Output Output of products or by-products
Step A Process step/unit A
Product flow beween process steps/units
Step B Process step/unit A
Input Input of utilities, energy, packing material, …
Output Output of utilities, energy, …
Information Information field
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List of symbols which are used to design the following examples
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Examples 1
Process Block Diagram for Virtual Plant
Raw Materials A Raw Materials B Ingredient A
Ingredient B
Ingredient C
…
Handling/Mixing Handling / …
Conveying/Dosing Dosing Others
Continuous Mixing
T°C 15
TS (%) 45
Standardization
T°C 85
TS (%) 41
Pasteurisation
T°C 130
TS (%) 40
Drying
T°C 50
TS (%) 97
kg/l 0.1
Milling / Sifting
T°C 30
MP Bag/Trace
TS (%) 97.5
Elements
kg/l 0.3
Storage in Big Bags
Handling/dosing
Dry-Mixing kg/h 400
TS (%) 97.5
kg/l 0.4
Storage in Big Bags
Filling (bag-in-box)
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Process Block Diagram with essential content as it is required for the Project
Concept
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Examples 2: Process Block Diagram with supplementary content
Process Block Diagram Virtual Plant
Vitamins 2 kg/batch
A 204 kg/batch
B 79 kg/batch
C 19 kg/batch Townwater
D 162 kg/batch 12 barrels/d 26 barrels/d 7 m3/d 4 barg
Dry Prod C Proc D Water Steam Powder
Ingredients
Batch Manual Continuous Continuous Steam Batch 50-60 °C
Preparation Handling Dosing Dosing Pasteurizing 2x 1 m3
1,6 kg/min. 6,2 kg/min. TS=57%
Batch Size 216 kg
1120 l
Batch 27 min. Steam Heating Water Continuous
Mixing 517 kg/batch Dosing
4 barg 63 °C
3 Batches/hour
3.1 kg /min.
Steam Heating Water
4 barg 76 °C
Continuous
Dosing
17,4 kg/min.
Continuous
Wet Mixing
28.3 kg /min. @ 79%TS
Steam 11kg/min 12barg
Cooling Water 2000 l/min 31°C
Drying Water 5,1kg/min
Town Water 19 kg/min 33°C
Comp. Air 121 Nl/min 5barg 183 m3/min.
152 °C
103 gH2O/m3
1 Barrel = 200 l = 300 Kg Prod. A
= 200 kg Prod. B
Plant capacity is based
Container Filling on:
Container A-110 - 48 weeks / year
3 m3 - 7 days / week
Filling ~1130 kg - 3 shifts /day
Virtual product 32000 kg/day
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Example 3: Process Block Diagram with mass balance
Diagram for Virtual Plant with Mass Balance
A 215 kg/h
Raw Materials A Raw Materials B B 66kg/h
C 20kg/h
D 1 kg/h
E 4 kg/h
Handling / Mixing / Handling / Dosing F 4 kg/h
Conveying / Dosing G 6 kg/h
Water 365 kg/h
Continuous Mixing
70 kg/h kg/h 680
TS % 45
Steam Standardization
15 kg/h kg/h 750
TS % 41
Steam Pasteurisation
kg/h 765
TS % 40
580 kg/h
Steam Drying
kg/h 315
TS % 97.5
kg/l 0.1
Milling / Sifting
90 kg/h
kg/h 310
MP Bag / TS % 97.5
Trace Elements Storage in Big Bags kg/l 0.3
Handling/dosing Dry-Mixing
kg/h 400
kg/l 0.45
Storage in Big Bags
Filling (bag-in-box)
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Example 4: Filling and Packing Block Diagram with essential content.
Filling and Packing Block Diagram for Virtual Plant
Noodle Tomato sauce Cheese
Hand dispenser Sauce dispenser Auto dispenser
Foil tray dispenser Conveyor
Lidder Crimper
Conveyor
Check weight Manual weight
adjustment
Metal detector
Conveyor
Freezer
Conveyor
Handling/dosing Cartoner
Caser
Case Printer
Conveyor
Palletizer
Conveyor
Freezer storage
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