Development of pilot plant scale instant porridge production line for contribution to stunting prevention

Abstract

This study aims to develop an efficient and hygienic pilot plant–scale production line for instant porridge as complementary food to support stunting prevention efforts in Indonesia. A descriptive engineering approach was applied, utilizing Operation Process Charts (OPC), Multi-Product Process Charts (MPPC), and routing sheets to model production flows, determine machinery requirements, and evaluate layout alternatives. Pilot-scale trials were conducted using a steam jacket kettle, drum dryer, disc mill, and vibrator screen to assess process capacities and product quality. The findings show that a three-batch cooking system provides the highest operational efficiency, allowing continuous drying at a rate of 5 kg of paste per hour and yielding 7.5 kg of instant porridge flakes per day. Three facility layout configurations—straight-line, zig-zag, and U-shaped—were identified as feasible design options, with the straight-line layout offering the shortest material movement and lowest contamination risk. Chemical, physical, microbiological, and sensory analyses confirmed that the product meets national standards for instant complementary foods. The study concludes that the proposed production line is technically feasible, scalable, and suitable for adoption by Micro, Small, and Medium Enterprises (MSMEs). Its implementation may enhance production efficiency, ensure food safety, and expand access to nutritious complementary foods, thereby contributing to national stunting reduction initiatives.