ORANGE JUICE BOTTLING COMPANY OWERRI IMO STATE (ENHANCING FUNCTIONALITY THROUGH CIRCULATION AND SAFETY)

ABSTRACT

Research  has  shown  that  the  popularization  of  plastic  bottles  in  Bottling  Industries  has remained  on  the  increase  since  middle  of  1960’s,  when  high-density  polyethylene  was introduced. They quickly became popular with both manufacturers and customers due to their lightweight nature and relatively low production costs compared with glass bottles. Except for wine or beer, the food industry has almost completely replaced glass with plastic bottles.

Despite  this  innovation,  there  has  continued  to be a setback  in the Bottling  Industry  in Nigeria;  largely  due  to  inadequate  circulation  facilities  for  human;  machinery/vehicular; material  circulation.The  effect  of  circulation  or the  movement  of people,  materials,  and machinery in industrial operations cannot be relegated to the background. For there to be any meaningful operation and proper functioning, up to the required capacity, in any company/ industry, circulation must be giving its pride of place.

This research work therefore investigates into ways of solving this perceived problem. The research methodology  adopted  to solve this problem  is qualitative  research.  This  lead to: provision   of  adequate  circulation  routes;  proper   separation   of  human,   material,   and machinery routes; adoption of easy/efficient production lines; proper location of loading and off-loading docks; a well laid out site; separation of administrative spaces from production space; etcetera.

If this research is implemented,  it will result in a significant  improvement  on  production flow- from raw-material intake, through the production stages, to the storage docks. Unlike the prevailing conditions, where circulation spaces make it difficult for forklifts and truck to manoeuver,  this proposal overcomes that problem with adequate  space around production stations. Furthermore, the distance between the new preassembly stations and the associated sub-assembly stations are much shorter, which results in reduced wastes caused by scattered production units.

CHAPTER ONE

1.1       INTRODUCTION

The growth and penetration of the industry have been unprecedented, and is comparable to the recent proliferation of home computers. Recently, Nigerian consumers, as well as foreign consumers,  have witnessed  the dramatic expansion of the bottled  beverage  industry.  In a mass change of habit, most Nigerians turned from buying local drinks to bottled drinks. Since the introduction  of bottled  beverages  by the major  beverage  companies,  it has become  a widely accepted way of healthy living (Phoods, 2001). This has caused a major shift in the beverage landscapes, and has had significant impact throughout the country and indeed the world. Consequently,  the rapidly  escalating rate of bottled drink purchases,  partly due to inadequate supply, has instigated some concerns that are not reflected in the overall image of the product. By and large, bottlers have sold their beverages on the basis that they are pure, clean, filtered and safe (Howard, 2003).

This project is a research work on how circulation and industrial safety measure in production can be used or adopted to improve, or enhance functionality in a Bottling Company. It seeks to adopt innovative circulation and safety measures, and effect or implement these systems in order to enhance industrial operation.  The intent of this  research is to study and promote optimal  functionality  in and around  production  spaces by properly integrating  circulation spaces and safety rules, be it for human, machinery, vehicular and/or materials. The design would  allow  an  effective  use  of  vertical  and  horizontal  circulation  facilities  within  the production premises in order to achieve an enhanced functionality and productivity.

1.2      BACKGROUND OF THE STUDY

Well laid out circulation spaces are crucial to the safety and wellbeing of building occupants, and will also increase productivity (Cecily Channell, 2010). In architecture, circulation means

the pathways through a floor plan while safety is defined to be the control of recognized hazards  to  achieve  an acceptable  level  of risk.  These  pathways  are  how  we  experience architecture; the design of these pathways has an enormous effect on the success or failure of a plan/design. Circulation spaces ought to be as interesting as any other part of a building. There are always unique opportunities to make circulation interesting (Time-Saver Standards for Architectural Design Data, 1997).

Obvious pathways include hallways (horizontal circulation) and stairs (vertical circulation). But every space we are able to occupy is part of the circulation system of a building.

In the aspect of safety in building, architectural designs cover many things, such as:

• Building structural safety

• Working environment e.g. space, ventilation, lighting, heating etc.

• Ergonomics

• Worker health

• Machine and process safety

• Protection from chemical exposure

• Personal protective equipment (PPE)

• Fire safety and emergency preparedness

• Kitchen hygiene and food safety

• Hygiene facilities

A bottling company is a commercial enterprise whose work is the bottling of beverages for distribution. Consequently, a bottling company mixes beverages; fills cans with them, seals and makes them available for sale (7UP Bottling Company, 2007).

A bottling company, which if not well handled during design stages for proper  circulation and safety measures,  would negatively,  affect the functionality,  efficiency,  and the entire production process. These impediments range from the overall site planning, articulation of the various components within the building, all having to do with circulation and its safety.

A floor plan with good circulation makes every square meter of work space efficient. Good circulation does not necessarily mean that the shortest path between two points  is best. It means that the most architecturally rewarding path between two points is preferred. Traffic patterns are most effective when clear, logical, and unambiguous.  However,  that does not mean they need be boring. In a well-designed floor plan, every event reinforces the theme, variations, and development of the overriding functional requirements and aesthetic purposes. Circulation spaces should be designed as meaningful parts of the whole, and should be such in a manufacturing industry. Safety should also be a priority in a manufacturing industry. It is essential that policy regarding  health, safety and that of risk assessments  are carried out. Accidents in industries can be avoided by keeping the factory tidy, having good procedures, good  technical  solutions,  good  routines  and  adequate  circulation.  Resources  should  be allocated for this, and it requires at least one person dedicated to handle all health and safety issues.  Narrow, dark hallways  are a relic of the past. In many buildings,  efficient  space planning can make hallways all but disappear, blending the circulation spaces with functional spaces,  transforming  hidden  space  into  open,  perceived  space.  This  borrowing  between spaces adds interest and thereby increases value and safety.

1.3      STATEMENT OF THE ARCHITECTURAL PROBLEM

Problems associated with a Bottling Company are many. These range from the general site planning, articulation of the various components of the building itself, internal and external circulation,  the safety needs within the various  components  is vital to  achieving  a good

production/functional  system  as  well  as  aesthetic  architecture.  Majority  of  the  existing

Bottling Companies across Nigeria reveal that;

They do not put or categorize various functions according to the level of sensitivity of the circulation it requires for optimal performance and safety. A floor plan with good circulation makes every square meter of work space efficient and gracefully safe. Good circulation does not necessarily mean that the shortest path between two points is best. (Karlen, 2004).

      Most production halls are inadequate  and are not of the required size.  Production halls are characterized  by the function it encloses. Circulation  spaces  ought to be adequate and interesting as any other part of a building.

      Industrial establishments are associated with problems ranging from the general site planning and the articulation of the various components of the building itself. Also, internal and external circulation within the various components (human, machinery, vehicular), continue to be a major challenge in safety performance.

      Inadequate  loading  bay(s): The impact is usually noticed  during  peak periods,  as loading and off-loading trucks find it difficult to manoeuvre within limited  spaces, during which the entire area is turned into an unwanted scene.

1.4       MOTIVATION

The desire is to transform the great potential inherent in owerri by the establishment of this company. It would create job opportunities for the youths and train individuals in the state, thereby boosting, or acting as a catalyst to the economy of the state in particular and country at large.

Owerri being a place of relaxation, serving as a host to a number of institutions will have a high demand for the product. Its product, Table Water and Orange Juice, would add to the healthy living of the public within and outside of the town.

1.5      AIM OF THE STUDY

The aim of this research work is to investigate in detail means of increasing, or improving the efficiency of industrial production through the provision of adequate circulation spaces and safety measures, in order to achieve optimal functionality in a Bottling Company.

The design shall seek to provide adequate safety measures and solve circulation problems associated with:

i.     Machinery;

ii.      Human/ Material;

iii.      Vehicular.

The project design shall adopt the use of Polyethylene Terephthalate bottles as the bottling material  for production,  its composition,  and its benefits;  and correlate  it  with  means  of enhancing functionality in the bottling processes.

1.6      OBJECTIVES OF THE STUDY

The following objectives would be discussed in detailed:

      Study and understand the circulatory spaces suitable for industrial production in order to achieve safety and optimal functionality.

      Have a thorough understanding of the sizes of humans, materials and machinery, and their space requirements.

      Carry out a comprehensive  research on principles  of industrial  circulation  and  its strategies  on  safety,  in  order  to  have  indebt  knowledge  of  their  application  in industrial designs.

      Carry out an in-depth study on some theories on circulation and safety to understand the individual effect on functionality.

1.7      SIGNIFICANCE OF THE STUDY

This will focus on the low production capacity of bottling companies, due to  architectural inadequacies on safety rules, and overall poor layout of external functions  and circulation (vehicular, machinery and human). Also, the establishment of this industry would create job opportunities for the youths and train individuals in the state, thereby boosting, or acting as a catalyst to the economy of the state in particular and country at large.

1.8      SCOPE OF THE PROJECT

This project is geared towards the studying of optimal circulation and safety in a Bottling

Company and would include these facilities: ADMINISTRATIVE COMPLEX:

Entrance Porche, Reception, Circulation/ Muster Point, Human Resource Office,  Directors Office, Sales Office, Accounts Office, Production Office, Fleet Managers Office, Secretary Work Room, Meeting Hall, Stairs, General Convenience, Janitor, Laboratory, Library/ Data Room, Graphics And Branding.

PRODUCTION DIVISION:

Production   Halls  (Orange  Juice/  Table  Water),   Warehouses,   Quality  Control   Room, Assembly Hall, Storage Rooms, Storage Tanks, Offices, Conveniences, And Blowing Room.

WELFARE FACILITIES:

Female Cloak Room, Male Cloak Room, First Aid/ Dispensary, General Convenience. MEDICAL/ CLINIC /DISPENSORY:

Nurse Office, Dispensary, Waiting Area, and Quiet Lounge.

CAFETERIA:

Kitchen, Senior Staff Dining, Junior Staff Dining, Store, Cloak Room. MAINTENANCE:

Office, Store, Equipment Store, Conveniences, Working Hall.

1.9      RESEARCH QUESTIONS

1.   Can  there  be  circulation  spaces  and  adequate  safety  in  an Orange  juice  bottling company?

2.   Can  adequate  circulation  spaces  and  safety  enhance  functionality  in  a  bottling company?

1.10     RESEARCH METHODOLOGY

To come up with a good result oriented research, the project will make use of primary and secondary  sources  of  information.  The  primary  sources  and  methods  employed  are  as follows:

  Oral interviews   Live case studies   Direct observation

The secondary sources used are as follows:

  Journals,

  Unpublished works related to the study,

  Text books,

  Relevant thesis reports,

  Newspaper, online and magazine articles

  Internet sources

The information obtained from the various studies shall constitute collected data meant for analysis for meaningful deductions to enable the proffering of functional architectural design solutions.

1.11     LIMITATIONS

The planning and design of Industrial facilities poses peculiar architectural challenges and the success  of  the  thesis  and  project  is  determined  by the  extent  the  issues  are  addressed. However, the following are limitations inevitable in the design thesis.

a.   Unavailability of basic data/drawings from the visited establishments which resulted in spending more time compiling data/drawings.

b.   Un-cooperative attitude of existing industrial building managements in divulging vital information that could assist the author.

c.   The financing of the study.

1.12     STUDY AREA (OWEERI)

Figure 1.1       Location Map of Imo State (Source: Microsoft Encyclopaedia, 2008)

Nigeria is situated in West Africa and has a land mass   of 923,768  sq.km   Bordered  by Republics of Niger and Chad in the North, shares borders with the Republic of Benin to the West, the Republic of Cameroun to the East and the shores of the Atlantic  Ocean to the South. There is about 800km of coastline which gives it maritime  potential for abundance agricultural, industrial and commercial activities.

Nigeria lies within the part of the world described as the tropics. This region lies between south of the earth’s surface. Within this area the sun is perpendicular at noon at least one day of each year. For all the points in this region, the sun is almost vertically overhead during the entire year. The peculiar characteristics of the tropics include high amounts of sunshine, high amount of rainfall, high humidity levels, almost uniform  weather throughout the year and high  temperatures.  Architectural  design  in  the  tropics  must  take  into  consideration  the peculiar climatic features of this region.

Fig.1.2            Map of Owerri (Source: Google earth, 2015)

1.12.1  BRIEF HISTORY OF IMO STATE

Imo  State  came  into  existence  in  1976  along  with  other  new  states  created  under  the leadership of the late military ruler of Nigeria, Murtala Muhammad, having been previously part of East-Central State. The state is named after the Imo River. Part of it was split off in

1991 as Abia State, and another part became Ebonyi State. The main cities in Imo State are Owerri, Orlu and Okigwe. The Orashi River has its source in this state. The local language is Igbo and Christianity is the predominant religion.

1.12.2  GEOGRAPHY AND NATURAL RESOURCES

Imo State lies within latitudes 4°45’N and 7°15’N, and longitude 6°50’E and 7°25’E with an area of around 5,100 sq. km.(Wikipedia, 2009).  It is bordered by Abia State on the East, by the River Niger and Delta State on the west, by Anambra State to the north and Rivers State to the south, and with a population of over 3,132,000 (National Population Census, 2006). Besides Owerri,  Imo State’s major towns are Isu, Okigwe,  Oguta,  Orlu,  Mbaise,  Mbano, Mbieri, Orodo and Orsu.

The state is rich in natural resources including crude oil, natural gas, lead, zinc. Economically exploitable  flora  like  the  iroko,  mahogany,  obeche,  bamboo,  rubber  tree  and  oil  palm predominate.  However with a high population density and over  farming the soil has been degraded and much of the native vegetation has disappeared.

This deforestation has triggered soil erosion which is compounded by heavy seasonal rainfall that has led to the destruction of houses and roads.

1.12.3  BRIEF HISTORY OF OWERRI (STUDY AREA)

Owerri is a city in south-eastern Nigeria. It is the capital of Imo State and is set in the heart of the Igbo land. It currently has a population of about 401,973 and is approximately 64 square kilometres in area. The Owerri Slogan is Heartland.

Owerri was the capital of the Republic of Biafra in 1969. The capital of the secessionist state was continuously being moved as Nigerian troops captured the older capitals. Enugu, Aba, and Umuahia were the other capitals before Owerri.

ORIGIN – Owerri was founded by a man called EkwemaArugo. He was the son of Uratta and was forced to leave because he committed an unpardonable sin. Uratta had  eight sons namely Orji, Owaelu, Owalla, Umuori, Umunahu, Okwu, Umuoba and Owerri. Umundula is not named separately because it is related to Orji, just as Owerri was not named separately because he was related to Owalla. The proper name of this  village is Owere. In Igboland, there are several places called Owere. However,  this  particular  Owere village is the most popular. In Igbo language, Owere means an open place of habitation. EkwemaArugo,  who founded  Owere,  had  five  children.  These  children  constitute  the  five  hamlets  of Owere village namely:

AmaawomUmuoduUmuonyecheUmuonyimaUmuororonjo The ancestor EkwemaArugo first settled at a place called UgwuEkwema.  In remembrance of EkwemaArugo,  Owere people have   a   special   celebration   called   OruOwere.   The   festival   is   usually   conducted   at UgwuEkwema.      The      current      Eze      or      traditional      ruler      of      Owere      is Dr.EmmanuelEmenyeonuNjemanze  of the Njemanze Dynasty. He is titled the Ozuruigbo V of Owere. Origin of Owerri (source: Njamanze Iheanacho and Family, 2013).

TRANSPORT AND TRADE – Owerri has an airport 26.6 kilometer southeast of the city, called the Imo Airport which provides service to Abuja, Lagos, Port Harcourt, and  Enugu. Right now, it serves as an alternate  for Port Harcourt, but it does not serve  international purposes. Some major roads that go through the city are; Port Harcourt Rd., Aba Rd., Onitsha Rd., and Okigwe Rd. Roads within the city are; Douglas Rd., Weathral Rd., Tetlow Rd., and Works Rd. Eke UkwuOwere market is the main market in Owerri.  Owerri sits in the rain forest and produces many agricultural products, such as  yams, cassava, taro, corn, rubber, palm products and assorted kinds of fruits.

EDUCATION  – Educational  institutions  in Owerri include Imo State University,  Federal University  of  Technology  Owerri,  Federal  College  of  Land  Resources  Oforola,  Seat  of Wisdom  Seminary  Owerri,  AlvanIkoku  College  of Education,  Federal  Government  Girls College  Owerri,  Owerri  Girls Secondary School,  Government  Secondary School Owerri, Development  Secondary School Owerri,  Emmanuel  College  Owerri,  Holy Ghost  College Owerri, Community Secondary School Oforola Owerri, Federal Polytechnic Nekede Owerri, Government Technical college Owerri, Army Day Secondary School Obinze Owerri.

1.12.4  REASONS FOR TOWN SELECTION (OWERRI)

The  choice  of  town  for  the  proposed  Bottling  Company  for  Owerri  would  portray  the feasibility and viability of the project. Owerri is one of state capitals in Nigeria that needs the presence of industries. One of the first of such repository in this town is Coca Cola Bottling Company, which was established during the tenure of Governor AchikeUdenwa, which lasted from 1997 to 2007.

Owerri,  the  Imo  State  Capital,  lies  at  the  intersection  of  six  major  roads  of  regional importance namely, Aba Road, Port Harcourt Road, Onitsha Road, Orlu Road, Okigwe Road and Mbaise/ Umuahia Road. It is made up of three local government areas namely, Owerri Municipal, Owerri North and Owerri West.

Among others, one of the key factors in locating the company in Owerri is where there  is demand for its Products, and the availability of the needed raw materials. Owerri is a place of relaxation,  and serves as a host to  a number of institutions.  The  proposed Orange  Juice Bottling Company, with optimal circulation and safety for an enhanced functioning will serve as an iconic design,  where safety and circulation  is  given its pride of place in industrial operation. Its product, Table Water and Orange Juice, would add to the healthy living of the public within and outside of the town. Availability of raw materials needed by the company, and basic services among others, make the town a choice location. Some of the raw-materials include:

  Pure and good underground water;

  Orange fruits;

  Polyethylene/ polymers; etc.

Finally, Owerri is chosen considering the high level of product demand in the area, as the town is home to large number of Hotels.

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