Date of Defense


Date of Graduation



Chemical and Paper Engineering

First Advisor

James Springstead

Second Advisor

Said AbuBakr


The purpose of this project involves the optimization of a marshmallow syrup process, sponsored by the owners of the line, the Kellogg Company was the sponsor. This report shows the work that was done for the period of three months, and covers the objective of the project, as well as the problem statement. The Kellogg Company currently produces a Syrup as an ingredient in the production of several cereal bars. The process is divided in four sections: Gelling Mix Tank, Syrup Mix Tank, Syrup Cool Tank and Syrup Use Tank. The entire process itself takes around 80 to 120 minutes resulting in a poor operational effectiveness, waste and cost.

The aim for this project is to optimize the cycle times, so that the amount of energy use for each batch can be reduced by altering the heat transfer method and rates of the process. Two final options were proposed. The first option represents their current batch process, but with the addition of a heat exchanger in between their two mixers. The second option achieves the secondary goal of creating a continuous process. The process uses a pre-mixer, as the first receiver of ingredients, followed by a scraped heat exchanger a second inline mixer, then two scraped heat exchangers and lastly one more inline mixer.

The syrup production rate is estimated to be 80lb/min. An economic analysis of the continuous process found approximately $2MM in potential savings for expenditures the best-case scenario and $8K in saving for the worst-case scenario. In conclusion, the two option are suitable for the company but will take further research and testing too explore the equipment cost, investment and compare it to the budget. It is recommended that the Kellogg Company achieves the rate of the current process and then scale it up in increments until achieving the final scale up production goal.

Access Setting

Honors Thesis-Open Access