edible oil tranning report

Report onProduction of Vanaspati & oils

KANPUR EDIBLES PVT LTDKanpur Uttar Pradesh

Under the supervision ofMr. PRAVESH TIWARI (HR -EXECUTIVE )

Submitted by: JEESHAN

DR.AITH KANPUR,UTTAR PRDESHB.tech (Chemical engg.)

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ACKNOWLEDGMENTMy project dealing with “Production of Vanaspati & oils”. I owe a heart-felt gratefulness to some of the people for being completion of the report, present all the time whenever any help was required in At the outset, I would like to thank Mr. Pravesh Tiwari (HR) for giving me the approval to this project in the organization. I wish to acknowledge the entire HR Team at KANPUR EDIBLES PVT. LTD.Special appreciation extended to Mr. Pravesh Tiwari who helped me to shape the direction of my research work. This project would not have been possible without his help.A heartfelt thanks to the respondents surveyed whose ideas, critical insights and suggestions have been invaluable in the preparation of this report.

Signature of student

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Candidate’s Declaration

We hereby declare that the work presented in the report in partial fulfillment of the requirement for the award of

degree of B.Tech (Chemical Engg.) in DR.A.I.T.H. ,KANPUR (AKTU), is record of our work done under the

guidance of Mr.Pravesh Tiwari (HR) of KANPUR EDIBLES PVT. LTD. KANPUR,U.P.

DATE: Signature of student

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CONTENTS HISTORY

5 AIM / VISION / MISSON

6 ADRESS OF BRACH OFFICES

7 QUALITY POLICY

10 CAPICITY OF PLANT

11 KEPL PROFILE

12 AMAZING CONSUMAR SUPPORT 13 INCREDIBLE GROWTH

14 QUALITY TO SWER BY

15 UNENDING ENOVATION

16 STATE OF THE ART EDIBLE OIL FACTORY IN 17

INDIA KEPL PLANT

18 KEPL PRODUCT

19 REFINARY PLANT

23 PHYSICAL REFINING

23 CHEMICAL REFINING

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FUNCTION OF CHEMICAL USE 28 DIFFERENT PROCESSES OF REFINING 29 HYDRGENETION

44 APPENDIX

47 REFERENCE

49

HISTORY

KANPUR EDIBLES PRIVATE LIMITED,( KEPL ) is Flagship Company of Mayur Group promoted by well known business family of Kanpur. “MAYUR” & “COOK N FRY” are the brands under which KEPL sells its range of Edible Oil, Vanaspati and Bakery Shortening. The company was incorporated in year 1990 to produce refined oil with a capacity of 25TPD which currently is at 320TPD and added new capacity for Vanaspati @ 200TPD and Solvent @ 500TPD. MILE STONES In Year 1994 Mayur Group took over KEPL from Hira Panna Group.In year 1997 Vanaspati Plant was installed. In year 1998 a new Refinery plant was installed under the name of Kanpur Extraction Pvt. Ltd. ( a Group Company ). This

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plant was subsequently acquired by Kanpur Edibles Pvt. Ltd in 2006. In year 2002 A V Agro Products Pvt. Ltd., having Edible oil plant was taken over by the present management and same was acquired by KEPL in 2008.In Year 1994 Mayur Group took over KEPL from Hira Panna Group. In year 1997 Vanaspati Plant was installed. In year 1998 a new Refinery plant was installed under the name of Kanpur Extraction Pvt. Ltd. ( a Group Company ). This plant was subsequently acquired by Kanpur Edibles Pvt. Ltd in 2006. In year 2002 A V Agro Products Pvt. Ltd., having Edible oil plant was taken over by the present management and same was acquired by KEPL in 2008.Mayur Group has a flagship company ‘Kanpur Edibles Pvt. Ltd’ also known as KEPL. Kanpur Edibles Pvt Ltd manufactures soybean oil, Mustard Oil, Sunflower Oil, under the brand name of ‘Cook n Fry’. It also manufactures Mayur Vanaspati, Mayur Kacchi Ghani oil and Nutreum Soya Chunks.

Aim / Vision / MissionWe at the Mayur Group of Companies envision to metamorphose our medium scale group into a major player of the oil market. We are continuously striving to achieve the benchmark by churning out top quality products, widening consumer base, forging more interpersonal relations with our esteemed consumers. We also yearn and strive for disbursement of Good Management Practice (GMP) to our already exclusive set of workmen, technicians, R & D engineers and laboratory scientists to become more conscientious towards their work. And ultimately to provide the very purpose of our business, the customer, the very best

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and nothing else. Our Mission is to augment managerial and technical resources coupled with skill sets to plan and sustain economic development in our industry, which in turn gives greater significance and there by ameliorating the potency of our service commitments towards our customers which we intend to satiate through pro active marketing techniques.

ADDRESS OF BRANCH OFFICES:

S.N PLACE ADDRESS TELNO CONTACT PERSON

1 DelhiJMD OILS PVT.LTD.

5/24 Ramesh Nagar Delhi

9811192973 K.K.Goyal

2 Parwanoo

Near fire station , N.H.No.22Sector 3

Parwanoo, Dist. Solan (H.P.)

01792 - 235480,

098160-27090

Mr. Sanjeev Agrawal

3 Jammu Behind Ware House , 0191 - Mr. Jai Jagbushan

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Jammu

2457555,0191 -

2437555, 094191 –

90555

Gupta

5 Kanpur84/21.Plot No.7,

Faizal Gang, Kanpur (U.P.)

Mr. Rajesh Kumar Srivastava

6 Haridwar

Village - Giapota,Missarpur Laksar Road,

Dist. Haridwar,Uttranchal

Mr. Shashi Prakash Sharma

7 Karnal

Sector No.10, First Floor,

Super Market Old, Gur Mandi,

Karnal(Haryana)

094160-39600,04160-28962,0184-2253262

Mr. Bharat Wadhwa

8 Chandigarh

G.NO.8, Station Road,

Cement Godown Area, Near Om Kata, Village - Tirwa,

Chandigad

9872888699Mr.Harikishan Jayprakash and

Mr. Vipin

9 Ludhiana

Outside Octori Post, Inside Navneet textile,

Bhatian Road, Opp. Tin Factory,

Ludiana

098961-79100,

98152-79200, 0161-2827047

Mr. Tilak Raj and Mr.Yashpal

10 Kolkata

D-46,Bhiplobi Barin Ghose ,

Sarin, Old Britania Godown ,

Kolkatta - 80 (W.B.)

------ Mr. Arun Abha Basu

11 Jaipur E-168, Road No.9 J,

VKIA,Jaipur,

9829072966,9829072955/,

3209905,2332189.

Mr. Vinay /Jaggith Singh

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Rajasthan

12 Jodhpur

F-II/11 Mandour Krishni Mandi,

Mandour Road, Jodhpur

02912638094,95,098290-

21685,0931-4716003

Mr. Kishanlal Punglia

13Shri

GangaNagar

B-2, Industrial Estate, Opp. Police Line,

Shri Ganganagar, (Raj.)094170-21490 Mr. Manmohan

14 Roorki

C/o R.K. Trading,vill&po-Gagret,Bhaiwan Road ,Dist-UNA (HP)

9814122324, Mr,Gautam

15 GagretVillage & P.O. Gagret,

Bhanwain Road, Dist. UNA (H.P.)

9814345329 Mr,Mukesh

16 Gorakhpur

Mehewa,Near NarainTransport Co.

Transport Nagar, Gorakhpur (U.P)

09415275741 Mr,Manish Aggrawal

17 Haldwani

Haldwani Barelly Road, Opp. Commercial Motor,

Haldwani,Dist. Nainital,

Uttranchal

18 Kota76, New Dana Mandi,

Near New Airport, KOTA

19 RanchiAMY 67,

PANDRA, RANCHI

20 Udaipur 1 k/11 Machala Marg, Udaipur

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Quality PolicyWe Kanpur Edible Pvt. Ltd. are commited to provide

complete satisfaction to our customers with respect to quality, reliability, and delivery. And attain quality

leadership for all the products that are offered by us.We shall achieve this continual improvement of process, products, services, and systems, designed to meet the

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expectations of the customers and thereby faster good partnership with them.

Capacity of planta) Tank farm : 20000 MT oil storage capacity

b) Plant Capacity : 800 MT/Day oil refinery & 200 MT hydrogenation plant

c) R.O. plant : 30 M3 /day of R.O. water & 20 M3 /day of DM water (boiler)

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d) Boiler : 16 MT of steam generation

e) Power supply : 1100 KVA of power on demand from GEB

KEPL PROFILEMotto of the company is: “Continuous Pursuit Of

Excellence!”Years of unparallel excellence in the field of consumer goods coupled with ceaseless customer support and

quality has made us the shining sparkler amongst our competitors in the industry.

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AMAZING CONSUMER SUPPORT

With enviable brand equity, steadily enhancing customer base and trusted quality, JMD Oils today

proudly stands as a stalwart in its own right. It is no surprise then that JMD Oils is a front-runner in its

segment and consumers have reiterated their loyalty to our brands repeatedly.

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INCREDIBLE GROWTHWith an enviable presence in the consumer goods

market, KEPL decided to move ahead judiciously with its plan of diversification. In this objective, we ventured

successfully into real estate and capital investment as well. Our growth has been stupendous and continuous in

whatever field we ventured in.

What began as a small seed of entrepreneurial excellence decades ago, has blossomed into a matured organization with a full-fledged growth, expansion and diversification plan. Our metamorphosis from the small

home–run business to a professionally managed 14

business house has been a journey in learning, experience and tremendous growth that has made us a

power house in terms of products, experience and business acumen.

QUALITY TO SWEAR BYProfit has never been our guiding principle, but merely a reward for the hard work done. Our true inspiration is our belief in the principle of providing the best products and services of the superlative quality at the most unsurpassable price to our esteemed customers.

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UNENDING INNOVATIONS

Our rigorous R&D, refined processes, stringent quality control and state-of-the-art technologies have paid us

rich returns as we can now claim to be the forerunner in our field with an exceptional and dedicated customer base. Use of the latest technologies and techniques

gives us an edge over all others in the market.

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STATE OF THE ART EDIBLE OIL FACTORY IN

INDIAOur newest addition is the factory in Gujarat setup in 150 acres land one of the

largest edible refining facility that can process 400 Million Tons of soybean in a day, 400 MT Palm Oil Processing, 400TPD PALM OIL Fractionation plant and 200MTD Hydrogenation plant in one single location and is strategically located

35km from the Kandla port in the Kutch district of Gujarat.

This location is in close proximately to the port having an advantage to service most of the states in northern India like Punjab, Rajasthan, Uttar Pradesh,

Himachal Pradesh, Jammu & Kashmir etc.

Our clear focus is on development and augmentation. All our future diversification and expansion plans are all-comprehensive. Quality-driven

development and market-directed diversification is our magnificent mantra and it is sure to bring good cheer to all our customers, and all stake holders.

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KEPL PLANTThe key to fast growth of KEPL has been the adaption of latest

technology and equipments. KEPL's state of the art plant is equipped with world's finest technology " Soft

Column " deodorizer based on Swedish Technology

imported by Alfa Laval (India) Ltd.

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KEPL PRODUCTS

Sr No Commodity Brand Case Volume

A

1 1 Litre pouch 12 X 1Litre pouch 12 Litre

2 2 Litre Jar 10 X 2 Litre Jar 20 Litre


4 15 Litre Jar - ECO. 15Litre Jar- ECO 15Litre

5 15 Litre Jar – PRIMIUM 15Litre Jar – PR 15Litre

6 15 Litre Tin 1 X 15 Litre Tin 15Litre

B

1 1 Litre pouch 12 x 1 Litre pouch 12 Litre

2 1 Litre per bottle 12 x 1 Litre per bottle 12 Litre


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4 15 Litre Jar 15 X 1 Litre Jar 15Litre


6 15 Kg Tin 1 X 15KG Tin 16.48 Litre

7 1 Litre pouch 12 X 1 Litre pouch 12Litre


9 15 Kg Tin 1 X 15KG Tin 16.48 Litre

C

1 1 Litre pouch 12 X 1Litre POCUH 12Litre


3 15 KG Tin 1 X 15KG Tin 16.53Litre

4 1 Litre pouch 12 X 1Litre POCUH 12 Litre

5 15 KG Tin 1 X 15KG Tin 16.53 Litre

D

1 1 Litre pouch 12 X 1Litre pouch 12Litre

2 15 Kg Tin 1 X 15KG Tin 16.48Litre

E



3 15 Kg Tin 1 X15KG Tin 16.72 Litre







1 500 ml pouch 32 X 500 mlpouch 16.72 Litre

2 1 Litre pouch 16 X 1Litre pouch 16.72 Litre

3 5 Litre Jar 4 X5Litre Jar 16.72 Litre


E20


2 15 Litre Jar 1 X15KG Tin 16.72 Litre

F



G

1 500 ml PB 24 x 500 ml pouch 12 Litre

2 1 Litre PB / Pouch 12 X 1Litre pouch 12 Litre

3 2 Litre Jar 6 X 2Litre Bottle 12 Litre

4 5 Kg Jar 4 X 5Kg Jar 18.2 Litre

5 5 Litre Jar 4 X 5Litre Jar 20Litre

1 500 ml PB

SHEETAL

24 x 500 ml pouch 12 Litre

2 1 Litre PB / Pouch 12 X 1Litre pouch 12 Litre

3 2 Litre Jar 6 X 2Litre Bottle 12 Litre

4 5 Kg Jar 4 X 5Kg Jar 18.2 Litre

5 5 Litre Jar 4 X 5Litre Jar 20Litre

H

1 210 ml PB 48 X 200 ml Pet Bottle 9.6 Litre

2 500 ml PB 24 X 500 ml Pet Bottle 12 Litre

3 1 Litre PB 12 X 1Litre pouch 12 Litre


I



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J



K

1 900 GM ( 4 PC ) 10x900 GM ( 4 PC ) 9 KG

2 900 GM ( 3 PC ) 10x900 GM ( 3 PC ) 9KG

3 180GM 90 x180GM 16.2 KG

4 1 Kg (5 PC) 10 x 1 Kg (5 PC) 10KG

5 1 Kg (3 PC) 10 x 1 Kg (3 PC) 10KG

L

1 1KG Free flow salt 25 X 1KG 25KG

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REFINARY PLANTREFINING:Refining is a process to remove impurities found in the oil which includes physical impurities, FFA (Free Fatty Acids), coloring pigments, Aldehydes, Ketoses, Waxes (if present), gums etc.

Today’s consumer is very demanding. Refining of oil is carried out considering these demands. The aim of edible oil refining is to produce oil:

Having less FFA percentage. Very light in colour.

Should have shining & bright appearance.

Free from any off odour and taste.

Have extensive shelf life and can be stored for a prolonged period of time without deterioration in its quality.

Should be free from any adulteration.

Should be free from physical impurities and any contamination.

Should be free from gums and waxes.

Types of refining : -

1) Physical refining

2) Chemical refining

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1) Physical refining : physical refining is applicable to those crude oils which having high percentage of free fatty acids and lower percentage of gums. Example: crude palm oil (FFA = 5%).

2) Chemical refining : chemical refining is applicable to those crude oils which having moderate or low percentage of free fatty acids and high percentage of gums. Chemical refining is being carried out with the help of chemicals. Examples: Degummed Soybean oil, crude coconut oil, crude groundnut oil, crude cotton seed oil, crude sunflower oil.

PHYSICAL REFININGPalm Refining - Part 1

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CRUDE PALM OIL

PUMP

AGITAROR STEAM COIL

STRAINER

PUMP

FLOWMETER

HEATING PHE (BLEACHED OIL)

HEATING PHE (STEAM PHE)

Oil Temp - 85-90 deg

BLEACHING EARTH

0 FATTY ACIDS

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INTERMEDIATE TANK

PHOSPHORIC ACID

MIXER

RETENTION TANK

FILTER(5 MICRON)

PHE

DEODORISED OIL TO STORAGE

DEODORIZER

FILTER

PLF

BLEACHING EARTH

SPENT EARTH

CHEMICAL REFININGGroundnut Refining - Part 1

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CRUDE GN OIL

PUMP

AGITAROR STEAM COIL

STRAINER

PUMP

FLOWMETER

HEATING PHE (BLEACHED OIL)

Oil Temp - 85-90 deg

CAUSTIC LYE

SOAP

BLEACHING EARTH

SPENT EARTH

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BLEACHER

HEATING PHE (STEAM PHE)

INTERMEDIATE TANK

PHOSPHORIC ACID

MIXER

SOAP SEPERATOR

RETENTION TANK

MIXER

PLF

FILTER

DEODORISER

PHE

FUNCTIONS OF CHEMICAL USED

1) PHOSPHORIC ACID : It converts non hydrated gums into(H3PO4) hydrated gums form by common ion effect.

2) CAUSTIC LYE : It is directly added to the oil and forms soap by(NaOH) reacting with gums.

3) CITRIC ACID : It is used for providing shining appearance to oil.

4) BLEACHING EARTH : It is used to reduce the coloring pigments present naturally in the oil (for e.g. chlorophyll, carotene) and gives better appearance.

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FILTER(5MICRON)

DEODORISED OIL TO STORAGE

DIFFERENT PROCESSES OF THE REFINARY:

DEGUMMING

Basically there are two types of gums which are namely:

a) Hydrated gums: Those gums which are soluble in water and can be easily removed by water washing.

b) Non-hydrated gums: Those gums which are insoluble in water and cannot be removed by water washing. In such cases we have to covert non-hydrated gums into hydrated form by adding food grade phosphoric acid.

This is the very first step in refining process. Before this step, we had to perform preheating of oil up to 85oC temperature by the help of PHE. Oils susceptible to chemical refining contains non- hydrated gums in moderate amount. So, in degumming process, phosphoric acid is added in the crude oil entering into the refinery process. This acid is food grade and converts non-hydrated gums into hydrated form. The vessel used for the addition of phosphoric acid is equipped

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with agitator for proper mixing. The oil is then treated with water and a reagent agent to forms a complex gums structure that can be removed in the degumming separator.

centrifugal separation

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Oil free of gums and having traces of soapstock is pumped by a pump through a plate heat exchanger where it is heated by steam.Then it is sent to the Centrifugal mixer to be mixed with water and further centrifuged in a centrifuge for water washing. The washedwater is then further sent to the slop oil tank for collection and recovery of ecaped neutral oil which is then taken back to the system by a pump

NEUTRALISATION

The object of neutralizing is the removal of the free fatty acids present in the oil by forming soaps, which have a higher specific gravity than the oil. At the same time some metals, gums, and coloring matter are removed by the soap.

The soap is then separated from the oil by a centrifugal separator. Most of the gums present in the oil are removed with the soap if the oil has been subjected to acid conditioning. The oil flowing out of the centrifugal separator still contains traces of soap. These are removed by washing the oil with water after which the soapy water is removed in a centrifugal separator. The main aim of the acid degumming and/or neutralizing plant is the removal of gums, soaps etc. This can be realized by the sufficient addition of water, phosphoric acid and caustic soda at the correct temperature.

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BLEACHING

The bleaching process consists in removing most of the coloring matter, as well as gums, traces of soap and other impurities remaining in the oil. Most of these products are removed by mixing the oil with an adequate bleaching earth, under vacuum and at a temperature of approximately 90-100oC.The earth is separated from the oil by filtration in a pressure leaf filter.

The oil is then filtered again in a 10µ filter to remove any traces of earth that might accidentally have passed through the main filter. The bleaching process also comprises a bleaching earth extraction section recover the major part of the oil remaining in the filter cake. This operation is realized by blowing sparge steam through the filter cake. The quality of the bleaching earth is of the utmost importance. If the granulometry of the earth is too fine, the recoating of the filter might be difficult and after precoating the filter could clog up very quickly. To avoid this inconvenience, an adequate filter aid can be mixed with the bleaching earth. Another important factor is the activity or bleaching capacity

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of the earth. This factor will determine the amount of bleaching earth that has to be used to obtain the required result.

Most bleaching earth is activated through an acid treatment. It is important that such earth reacts neutrally; otherwise heavy corrosion could occur in the plant. As mentioned earlier, the bleaching process consists of removing not only coloring matter, but also other products such as gums, soaps, etc. The prolonged storage or the excessive heating of the oilseeds during extraction of crude oil by expelling, or the prolonged storage of crude oil at high temperatures can increase and even fix the colour of the oil. It is recommended to take the necessary precautions in order to avoid any increase of colour in the oil during the seed storage and processing, so as to facilitate the bleaching process and to reduce the consumption of bleaching earth.

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PRESSURE LEAF FILTERS

This is used to filter the bleached oil and then separate the bleaching earth which has already absorbed the coloring pigments.This earth then collected in a sump and will be known as “spent earth”. It operating pressure be blow 2 Kg/cm2 . It’s functioning will be in the below order:Filling, Precoating, Filtrations, Drain, Drying, Security drain, Depressurization, discharge, Closed.

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DEODORIZING

Deodorizing is normally the last stage in oil refining and requires the maximum of attention so as to obtain first quality oil. The purpose of this process is making the oil suitable for human consumption by removing substances, which give it undesirable acidity, odour, colour, and taste. The odorous and flavoring matters, which are mainly aldehydes, ketones, alcohols, and hydrocarbons, are removed at the same time as the free fatty acids (FFA). The deodorizer at JMD oils is of 400 MT/day working capacity.

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Being far more volatile than the oil, FFA are distilled by stripping at high temperatures with sparge steam under vacuum. Some sterols such as tocopherol are also removed and the amount evaporated depends upon the temperature and the vacuum at which the deodorizer is operating. The higher the temperature, the

more sterols are removed. The process consists in pre-heating the bleached oil with hot deodorized oil in adequate heat exchangers.

The pre-heated oil is then further heated under vacuum in the oil heater to the required temperature to achieve distillation conditions of the fatty

acids contained in the oil. The heated oil flows to the deodorizers. In the deodorizer the oil is kept for sufficient time to remove the undesirable odour and flavours, destroy some carotenoid pigments and reduce the fatty acids content to the required level. After deodorizing, the oil is discharge under vacuum into the oil cooler and from there pumped to heat exchangers to be cooled to the correct temperature. From the coolers, the oil flows to storage after passing through the

polishing filters of 5 microns.

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THE DEWAXING PROCESS

Definition & OverviewDewaxing : Separation of waxes, esters of long chain fatty acids and long chain primary alcohols present in mainly sunflower and maize oil.

Winterisation: Separation of saturated triacylglycerols from e.g. cottonseed oil and partly hydrogenated oils.Some oils are dewaxed before packing so as to remove waxes, which are dissolved in the oil. Most of the oils do not need dewaxing as they contain little or no waxes. Only sunflower oil & Rice Bran oil contain appreciable quantities of wax to give a hazy appearance during winter season due to precipitation of dissolved waxes and hence require to be dewaxed. Dewaxing is carried out by chilling the oil up to 1015°C followed by filtration of precipitated solids.

The oil thus treated gives a sparkling appearance even in winter temperatures.Winterisation is another name to the process of dewaxing. The name winterization appears as during winter when the temperature is low, waxes present in the oil crystallizes, they give hazy appearance to the oil.

Description Dewaxing (also called winterization) of sunflower oil is essential when the oil is to be used as salad oil. The presence of wax makesthe oil appear cloudy at room temperature. The oil normally becomes cloudy in 5–6h but with proper dewaxing the oil remains clearafter 24h of storage at 0˚C.The following steps are used to dewax sunflower oil:

Crude oil is refined and bleached to low phosphorus (<1ppm) and low moisture content (<0.1%).

The oil is heated to 55˚C to make sure the oil is fully liquid.

The oil is cooled slowly to 7–8˚C. Cooled oil is held in a specially insulated tank with a special slowspeed

mechanical agitator. Preferably, the oil is held for 12–24h at this temperature. The oil is mixed with diatomaceous earth/filter aid through an inline

mixing system and filtered through a pressure leaf filter precoatedwith diatomaceous earth/filter aid.

The filtered oil is collected, checked for cold test and filterable impurities, and then deodorized.

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The deodorized oil is checked again for cold test along with the other analyses listed earlier.

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DRY FRACTIONATION

Overview : The widespread use of the three oil modification processes hydrogenation, interesterification and fractionation extendedThe range of applications of the triglyceride oils. These processes principally serve the purpose of modifying the melting properties of oils and fats in order to improve their functional properties in specific applications, but the processes are also used to improve the stability of the oils and fats thus processed.

In edible oil processing, a fractionation process consists of a controlled cooling of the oil, thereby inducing a partial, or ‘fractional’,crystallization. The remaining liquid (olein) is then separated from the solid fraction (stearin) by means of filtration or centrifugation.

Natural oils and fats have different characteristics due to the fact that they are composed of a great number of different triglycerides.These contain fatty acids with carbon chins of different lengths and with different degrees of unsaturation.

Triglycerides with a high degree of unsaturation, indicated by a high iodine value, have a lower melting point than those containing more saturated fatty acids. If oil is cooled to a certain temperature, the high melting triglyceride (Stearin) will crystallize while the low melting ones will remain fluid. The stearin can then be separated from oil (Olein) by different methods and the fat/oil is thus divided into two fractions:

Stearin with a high melting point and olein with a low cloud and melting points. This technique is called fractional crystallization and used to obtain oils or fats more suitable for example, as cooking oils or for margarine /shortening production.Three palm oil fractionation processes which are in use:

through batch crystallization of oil without using additives by controlled cooling and subsequent continuous filtration.

Solvent Fractionation: through continuous crystallization of the oil in a solvent followed by separation of the liquid and solid fractions through a

continuous drum filter. Solvent fractionation, involves the use of hexane or

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acetone to let the highmelting components crystallize in a very lowviscous organic solvent. This can be helpful with respect to the selectivity of the reaction, but mainly offers advantages in the field of phase separation:

much purer solid fractions can be obtained, even with a vacuum filtration. Being a more expensive process, it is less common than dry fractionation and only comes into the picture when a very high added value of (at least

one of) the resulting fractions makes up for the high cost.Detergent Fractionation: through batch or continuous crystallization of the oil by controlled cooling and separation of the fractions either by gravity or

centrifugation after adding a surfactant.Alternative Routes to Fractionate Palm Oil

Key: CBE =cocoa butter equivalent, CBI = cocoa butter improver, PMF = palm midfraction

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Description

Dry fractionation of oils and fats is the separation of highmelting triglycerides from lowmelting triglycerides by crystallization from the melt. Apart from blending, it is the cheapest process in oils and fats processing. It is a pure physical process compared to other chemical modification processes such as hydrogenation and interesterification which modify triglycerides. Its most important applications are: palm olein used extensively as frying oil, palm super olein as salad oil and frying oil, the palmmid fraction as component of cocoa butter equivalent, palm kernel stearin as cocoa butter substitute.

Dry fractionation, also known as crystallization from the melt, is fractional crystallization in its most simple form, and the economy of the technology allows it to be used for production of commodity fats. Dry fractionation has long been regarded as an unpredictable, tedious and laborintensive process. However, the relatively cheap dry fractionation technique has evolved to the modification technology of the 21st century, as without additives, polluting effluents or postrefining involved, the sustainability and safety of the process is second to none.It should be able to gently cool down a mass of oil and keep the resulting crystal suspension as homogeneous as possible. Note that such gentle cooling means in fact imposing very low supercooling conditions, and it will result in a formation of fewer and larger crystals, because the said conditions simply rule out the existence of a mass of tiny crystals. Fat crystallization is a fairly exothermic reaction (up to 180 kJ can be released for every kg of crystals formed), so the efficiency with which this energy can be removed is an important design feature. For most industrial crystallizers, this ranges between 120 and 200 W/m2.K.Although the triglyceride separation theoretically is already established during crystallization, it is clear that the separation stage itself effectively determines the product yields as well as the stearin quality. As more residual olein can be expelled from the solids cake, the final stearin will be more concentrated in crystals and will turn out ‘purer’ and will display higher and steeper melting. The olein quality is determined entirely by the amount and selectivity of crystallization in the preceding stage. In some applications, the formed crystals are often not sufficiently stressresistant and get squeezed through the filter medium. Obviously, such contamination of crystals in the olein phase affects the efficiency of the fractionation process negatively and results in a liquid phase with inferior

42

cold stable properties. Overall, the ‘permitted’ degree of olein dilution in the stearin cake determines the choice for the applied separation technology.

Figure: press Filter

The development of membranes for use in pressure filtration had a widespread effect on fractionation technology, making both vacuum filtration in dry fractionation as well as LIPOFRAC fractionation almost instantly redundant. By using membrane filter presses, olein yields in palm oil fractionation could be raised to close on 80% when aiming foran increase in Iodine Value of 5 units, and twostage fractionation, which could be used to produce olein of higher Iodine Values or stearin containing less entrained olein, became an attractive proposition.When first introduced, pressure filtration using membranes was carried out at pressures of 68 bar, but in more recent years higher pressures have been used. The use of high squeeze pressure (30 bar) in the filter makes it possible to produce a palm midfraction that matches in its principal characteristics the midfraction obtained by solvent fractionation. Also by changing the sequence of the fractionation stages in a twostage

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process, different qualities of the fractions may be obtained, thus enhancing the versatility of the process.The first step of dry fractionation of palm oil yields olein fractions with a cloud point below 10°C. The olein fractions are used as a substitute for soft oils in frying, cooking and salad oils or are being further fractionated. Together with a further development of singlestage palm oil fractionation by technological improvements, there is an increased tendency to execute a double or triple fractionation of palm oil in order to produce fractions with specific characteristics such as high IV superoleins (IV>65) and hard palmmidfractions (hard PMF) (IV<36).The latter fraction can serve as a feedstock for the production of typical cocoa butter equivalents (CBE), which are nonlauric fats similar in their physical and chemical properties to cocoa butter. They are often prepared by solvent fractionation, though the more contemporary developments within dry fractionation (better suited crystallizers, improved separation technologies) are closing the gap between the quality of solventand dryfractionated hard PMF.

Economics of Fractionation

Dry fractionation has the advantage of basically only requiring crystallisers and filters, though filter costs have risen considerably as the separating performance of the filter has grown. Dry fractionation is also non energy intensive, which obviously is advantageous from the point of view of operating costs.It must be remembered, however, that in the case of fractionation the value of the secondary fraction(s) can play a significant role in the economics of production., and it is in this respect that fractionation is at a disadvantage when compared to the other oil modification processes, i.e. hydrogenation and interesterification , as these processes produce no secondary products that require marketing.

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HYDROGENATION

Hydrogenation is an operation involving the direct addition of hydrogen at the double bonds of the fatty acid chain that enters in the composition of the

triglycerides of the oil. It means converting liquid oils to semisolid, plastic fats suitable for shortening or margarine manufacture. The purpose is to adjust the consistency of the oil. The hydrogenation process is performed by batch. Each

process step is done in a different apparatus.

Cooling up to110-120oC

TO PACKING SECTION

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RBD PALM OIL

Filtration by candle filter (5µ)

Bleaching earth (1%)

BLEACHER

ADDITION OF Ni CATALYST

DEODORISER

FILTER PRESS (5µ)

ADDITION OF VITAMINS & SESAME OIL

AUTOCLAVE FOR HYDROGENATION (170 OC)

SPENT Ni CATALYST

MIXING & FILTERATION

The steps are:

Heating the incoming oil by exchange with the out coming hydrogenated oil.

Final heating of the incoming oil by HP Steam to the required temperature.

Weighing the batch in the measuring tank.

Hydrogenating the batch in the reactor. After the Ni-catalyst is mixed the hydrogen is introduced in the oil and dispersed by the agitator blades.

Cooling by means of the heat exchange with the incoming oil.

Filtration of the oil to remove the catalyst by using 5 microns candle filter.

Oil will be further processed by post refining.

Oil will be subjected to bleaching and then deodorization for complete refining.

Then addition of vitamin and sesame oil will be carried out.

Sample will be checked in the laboratory.

Then after final filtration through 5 microns filter, oil will provided for packaging.

The oil will be filled in the pouches (at 45oC) and in tins (at 50oC).

Then slowly vanaspati oil will be cooled in the cold rooms for proper vanaspati grain formation.

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BY-PRODUCTS OF THE REFINARY:1. Soap & Gums2. Fatty acid distillates

Spent earth with 7-15% oil will be considered as waste product of the refinery.

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References

1. Oil World, Hamburg, Germany2. U.S. Department of Agriculture3. The Hindu Business Line4. Directorate of Vanaspati, Vegetable Oils and Fats5. The Soybean Processors Association of India, Indore, March 20136. LokSabhaUnstarred Question No. 3150, dated on 16.03.20107. GG Patel & Nikhil Research Company presentation8. SEA Annual Report 2011-129. 67th annual convention of Oil technologists’ Association of India (OTA)10. www.fas.usda.gov/psdonline11. SEA Technical Committee (2013)12. Singh. H. P. and B. S. Bisht13. Ernesto Bernadini, "Batch and continuous solvent extraction. Journal of the American Oil Chemists14. Vegetable oil industry/ plant annual report (from 2005 to 2010)15. Toepeer international – Market review 201216. Acalmar Oils & Fats Ltd. Mumbai (2008-09)17. Kumar sant and chauhan-2007, production performance and total factor productivity growth of oilseed in India.18. E. Deffense, in Proceedings of PIPOC Porim International Palm Oil Conference, KualaLumpur, 1993.19. Department of Energy Development and Promotion. 2000. Ministry of Science, Technologyand Environment, Thailand. www.dedp.go.th20. The Edible Oil and Ghee Sector, Environmental Report, April 1999; NationalProductivity Council (NPC), 2002.21. Ministry of State for Environmental Affairs, Egyptian Environmental Affairs Agency, Technical Cooperation Office for the Environment, SEAM Project, 1999.22. M. Akpan, “The Oil War: Local Vegetable Oil Producers Take Their Case against Importation to the Presidency,” 2000. www.newswatchngr.com23. L. F. Pellegrini and S. de Oliveira, “Exergy Analysis of Sugarcane BagasseGasification,” Energy, Vol. 32, 2007, pp. 314-327.

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24. R. P. Singh, “Energy Accounting in Food Process Operations,” Food Technology, Vol. 32, No. 4, 1978.25. CMIE database26. American Oil Chemists' Society. "Symposium: Papers from the Symposium on Extraction Processes, presented at the 73rd AOCS Annual Meeting held in Toronto, Canada, May 2-6,198227. Subramanian, R., Ichikawa, S., Chikawa, S., Nakajima, M., Kimura,T., & Maekawa, T.(2001). Characterization of phospholipidreverse micelles in relation to membrane processing of vegetable oils. European Journal of Lipid Science Technology.

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edible oil tranning report

Engineering

Transcript of edible oil tranning report