DESIGN PROJECT PROPOSAL
Group Number: 6 Section: ME - 4202
Design Project: Proposed Design of a Seashell Calcium Powder
Manufacturing Plant Located at Roxas City, Capiz
Capacity:
Location: Roxas City, Capiz
1. BACKGROUND OF THE PROJECT
This proposal focuses on the establishment of a Seashell Calcium Powder Manufacturing Plant
designed to process discarded seashells into fine calcium powder for agricultural, industrial, and
construction applications. Seashells such as oyster, clam, and mussel shells are rich in calcium carbonate,
a valuable raw material commonly used as soil conditioner, animal feed supplement, filler material, and
cement additive.
Roxas City, Capiz, known as the Seafood Capital of the Philippines, generates large volumes of
seashell waste daily from seafood markets, restaurants, and processing facilities. These shells are often
disposed of in open dumps or coastal areas, causing sanitation problems, unpleasant odors, and
environmental pollution. The lack of proper waste processing facilities highlights the need for a
centralized manufacturing plant to convert this waste into useful products.
The growing demand for calcium-based materials in agriculture and construction presents an
opportunity to utilize seashell waste as an alternative and sustainable raw material. Calcium powder
derived from seashells offers a low-cost and eco-friendly substitute for commercially mined limestone,
reducing environmental degradation caused by quarrying activities.
This project aims to design a manufacturing plant that efficiently converts seashell waste into
calcium powder using simple mechanical and thermal processes. The design will focus on process flow
optimization, equipment selection, plant layout, dust control, and worker safety while ensuring product
consistency and quality. By transforming waste into a marketable product, the proposed plant contributes
to environmental sustainability, waste reduction, and local economic development.
The manufacturing process includes:
1. Collection and preparation of raw materials (seashells)
2. Washing and drying
3. Crushing and milling
4. Sieving
5. Packaging
List of Main Equipment
● Raw material receiving bins
● Washing tanks with water circulation system
● Rotary or tray drying system
● Jaw crusher or hammer mill
● Ball mill or fine grinding mill
● Vibrating sieve
● Dust collection system
● Conveyor system
● Packaging machine
2. DESIGN STRATEGY
The design strategy for the proposed Seashell Calcium Powder Manufacturing Plant focuses on
efficient waste utilization, simple process integration, and safe plant operation. The primary objective is
to create a streamlined production system that minimizes manual handling while maximizing material
recovery and product quality.
The design will consider site-specific conditions in Roxas City, including proximity to seafood
processing areas, accessibility for transport, and availability of utilities. The production layout will follow
a linear flow to reduce material backtracking and energy consumption. Equipment selection will prioritize
durability, ease of maintenance, and cost efficiency.
Dust control and proper ventilation will be integrated into the design to ensure worker safety and
environmental compliance. The plant will adopt energy-efficient drying and milling systems to reduce
operational costs while maintaining productivity. Through proper layout planning and equipment
integration, the plant will be capable of meeting its daily production target while maintaining consistent
calcium powder quality.
MANUFACTURING PROCESS FLOW
Receiving and Storage → Washing → Drying → Crushing →Milling →Sieving → Packaging →
Storage
PROCESS DESCRIPTION
The manufacturing process of seashell calcium powder is designed to ensure efficiency, safety, and
consistent product quality. The steps involved are described as follows:
1. Collection and Receiving
Seashell waste is collected from seafood markets, restaurants, and processing plants within Roxas City.
Upon arrival, the shells are weighed and inspected to remove non-shell contaminants such as plastics or
organic waste.
2. Washing
The collected shells are washed in large washing tanks to remove salt residues, dirt, and remaining
organic matter. This step reduces odor and improves the quality of the final calcium powder.
3. Drying
Washed shells are dried using sun drying or mechanical dryers to remove moisture. Proper drying
prevents microbial growth and improves crushing efficiency.
4. Crushing
Dried seashells are fed into a crusher to reduce them into smaller fragments. This process prepares the
material for fine grinding and ensures uniform milling.
5. Milling
Crushed shells are further processed using a ball mill or grinding mill to produce fine calcium powder
with the desired particle size.
6. Sieving
The milled powder is sieved to ensure uniform particle size. Oversized particles are returned to the
milling process. Quality control checks are conducted to verify fineness and purity.
7. Packaging and Storage
The finished calcium powder is packed into sacks or containers using a packaging machine. The
packaged products are labeled and stored in a dry, well-ventilated storage area for distribution.
3. PRODUCT VARIATIONS
To cater to different market needs, the manufacturing plant will produce the following product variations:
A. Agricultural-Grade Calcium Powder
Used as soil conditioner to improve soil pH and crop yield.
B. Construction-Grade Calcium Powder
Used as filler material in cement, blocks, and other construction products
4.. DESIGN OPTIONS