“Food Factory Engineers: A STEAM-Based Engineering Challenge”

For 16-year-old students – Focus on Process Engineering, Automation & Sustainable Design

🎯 Game Overview

Objective: Teams act as Food & Beverage Process Engineers, designing and optimizing a production line for a food product (e.g., yogurt, juice, bread) using engineering principles, automation, and sustainability.

STEAM Integration (Engineering-Focused):

🔧 Engineering – Production line design, efficiency optimization, automation
⚙️ Technology – Sensors, robotics, AI in food manufacturing
📊 Math – Cost analysis, production scaling, energy calculations
🌱 Science – Food chemistry, microbiology, thermodynamics
🎨 Arts – Packaging design, branding, ergonomic machine interfaces

🛠️ Game Structure (Engineering Challenges)

1️⃣ Phase 1: Process Design (Flowchart & Systems Engineering)

Challenge:

• Teams pick a food product (e.g., bottled juice, chocolate bars, potato chips).
• Must map out a production process (from raw materials to packaging) using:
  • Flowcharts (identifying critical control points)
  • Equipment selection (mixers, pasteurizers, conveyors, fillers)

Engineering Focus:
✔️ Lean Manufacturing – Eliminate bottlenecks
✔️ Hazard Analysis (HACCP) – Identify safety risks

2️⃣ Phase 2: Automation & Robotics (Mechatronics Challenge)

Challenge:

• Teams must automate at least one step in their production line.
• Options:
  • Robotic arm for packaging (using LEGO Mindstorms/VEX if available)
  • Sensor-based sorting (e.g., separating defective products)
  • Automated filling system (simulated with Arduino/Scratch)

Engineering Focus:
✔️ PLC Programming (If/then logic for machines)
✔️ Efficiency Optimization (Cycle time reduction)

3️⃣ Phase 3: Sustainable Engineering (Energy & Waste Reduction)

Challenge:

• Teams must reduce energy use or waste in their process.
• Examples:
  • Heat recovery system (Reusing steam energy)
  • Zero-waste packaging (Biodegradable or reusable)
  • Water recycling in cleaning processes

Engineering Focus:
✔️ Life Cycle Assessment (LCA) – Environmental impact
✔️ Energy Efficiency Calculations (kW/h savings)

4️⃣ Phase 4: Cost & Scalability (Industrial Engineering)

Challenge:

• Teams receive a budget constraint (e.g., $100,000).
• Must calculate ROI (Return on Investment) for:
  • New machinery vs. manual labor
  • Scaling production (10x output—does the system handle it?)

Engineering Focus:
✔️ Cost-Benefit Analysis
✔️ Production Line Balancing

🏆 Final Presentation: “Pitch Your Factory”

Teams present their engineered food production line to “investors” (teachers/peers), covering:
✅ Process efficiency (How fast can it produce?)
✅ Automation level (Where did they apply robotics?)
✅ Sustainability improvements (Energy/waste reduction)
✅ Cost-effectiveness (ROI calculations)

Winner Criteria:
🥇 Most Efficient & Automated Design
🥈 Best Sustainable Engineering Solution
🥉 Most Cost-Effective Scaling Plan

🛠️ Required Tools (Flexible Options)

• Digital Simulations: Factory I/O, TinkerCAD, Excel
• Hands-on Kits: LEGO Mindstorms, Arduino, Raspberry Pi
• Low-Tech Option: Paper prototyping + calculations

🔧 Why This Game?

✔️ Teaches real-world food engineering (like industrial engineers at Nestlé or PepsiCo).
✔️ Combines automation + sustainability (key in modern manufacturing).
✔️ Encourages systems thinking & problem-solving.