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A STUDY ON
CONSUMER BEHAIOUR
ABOUT
EDIBLE OIL
Submitted by :-
Jaspreet Singh
ACKNOWLEDGEMENT
This document dwells upon my project semester training at esteemed
organization “A.P. SOLVEX”.This training is a part of my college curriculum of
BBA that I am currently pursuing “G.H.C.M.T” PATIALA.
For full completion of the Industrial training project report, I would like
to convey my thanks to our Institute’s H.O.D Mr. Manish goyal under who's
leadership the training was organized by our institute. Secondly I am highly
thankful to Mg. Director Mr. Achhru Ram Sharma, Mr. Pawan Kumar Singla,
Mr.Parshotam Dass Garg & Mr. Arun Kumar Goyal for permitting me to get
useful information about the process in the solvent plant & physical
deacidification plant. I would also like to thank Mr. D.K.Kaushal (Quality Con-
trol) for giving me complete and useful information regarding the process
control and about various tests performed in the Q.C.Lab. There co-operation
helped me in completing this industrial training Project Report.
At the long last, I would like to say that without the help of above mentioned
people’s my stay at the industry would not have been memorable one.
PREFACE
I had learnt a lot from my training, specially the basic things, which are important
from every aspect. I have done survey of consumers who are consuming the
cooking oils.
Consumer is considered to be very support and part of company. Because
consumer is main part of every organization. If there is no proper service to the
consumer than the company goes no longer with higher benefits.
This report is written in simple and understanding style, it is divided into
two parts. First part comprises of introduction to A.P. Solvex history and its
present status. Second part comprises of introduction to consumer’s behavior
about edible oil. as the report comprises just a sample of 50 consumers, for
further studies my research can be great help.
CONTENTS
CHAPTER-1
1. General information regarding industry
2. location of plant
3. Introduction to plant
4. Additional information
(a) By products produced during the process
(b) Research & development
(c) Store & purchase department
(d) Personnel & administration department
(e) Quality control
(f) Raw material
(g) Properties of finished oil
(h) Auxiliary services
CHAPTER-2
1. Analysis and interpretation
2. limitation of study
3. Findings
4. Conclusion
5. Bibliography
GENERAL INFORMATION REGARDING INDUSTRY
A.P. Solvex Limited was originally incorporated as a Private Limited
Company on 13.11.1992 under the name and style of A.P. Solvex (P) Ltd. The
Company had become a deemed limited Company by virtue of turnover
exceeding the prescribed limits. Accordingly name and style of the
Company was changed to A.P. Solvex Limited. The Company has a
capability to extract approximately 16 TPD oil and refines about 50 Ton oil
per day & 35 ton oil is purchased from other plants for refine. Although the
overall scenario of the oil extraction and processing industry is in a bad shape
but A.P. Solvex Limited is an exception to it. The reason behind this is
the professional management and innovative technique developed by the
Company under the able guidance and direct supervision of its highly qualified
Managing Director Sh. A.R. Sharma.
The Company have produced refined rice bran oil for the first time in
India through the most economical process of physical refining. This unique
product has been highly appreciated by the good Companies like
Hindustan Lever Limited and Raghuvar India Limited. These Companies
have started buying this product at a very attractive price.
LOCATION OF PLANT
The proposed unit will be set up with in the existing premises of the Company at
village Manwala, Saron Road, Dhuri, in District Sangrur which is a 'A
Category Area and such the unit will be eligible for state subsidy @ 30% of
FCI as well as Sales Tax Exemption for 10 years subject to 300% of FCI. As
the project is proposed to be set up within the existing premises project cost has
been significantly reduced as a lot of existing infrastructure can be easily
utilized for the proposed unit also. Further in day to day running also the
proposed unit will save a lot on account of various administrative expenses etc.
The proposed site is approachable by meddled road. Further the proposed
location is also ideal from the point of view of availability of raw material. As in
addition to the Solvent Extraction Unit of the Company there are a number of
solvent extraction units in this District and the adjoining districts which will
prefer to supply low FFA oils produced by them to the Company due to the
transportation economies and tax saving as compared to supply of the same to
the deacidification units located out side the State.
INTRODUCTION TO PLANT
The Company is presently engaged in extraction of low FFA rice bran oil
from raw rice bran and up-gradation of the same into Raw Grade I oil which is
supplied to the Vanaspati Manufacturing and is used by them in making
vanaspati after further refining at their end. Refining plant will further upgrade
the oil. So that the same is suitable for direct hydrogenation by Vanaspati
manufactures without any further refining.
The industry can be divided into two main plants :-
1. SOLVENT EXTRACTION PLANT
2. REFINERY PLANT.
1. SOLVENT EXTRACTION PLANT : -
1. Extraction Section.
2. Distillation Section.
2. REFINERY PLANT
1. Degumming Section.
2. Bleaching Section
3. Deacidifying Section
4. Dewaxing Section
5. Saponification Section
SOLVENT EXTRACTION PLANT
Solvent extraction plant is that unit of plant where oil is extracted from pellets
by solvent extraction process.Oil can be extracted either by mechanical
expression or solvent extraction. But seeds with lower oil content is
generally solvent extracted. This is because amount of oil that
1cannot be recovered by mechanical expression (i.e. Expellers) increases
That is why solvent extraction process is used for the extraction of oil from rice
bran, since it contains 12% to 18% oil contents that can not be recovered by
mechanical expression.Principle upon which solvent extraction process is
based states that oil bearing material is suspended in a suitable solvent to get
the oil content in the material completely dissolved. This oil solvent mixture
(Miscella) is further processed to separate the oil completely without any
wast age of solvent used.
Solvent Extraction Process is a physical process. It is of
three types : -
1. Continuous Process.
2. Semi-Continuous Process.
3. Batch Type Extraction Process.
Semi-Continuous Solvent Extraction Process is preffered than other processes
since, due to closed vent system hexane losses in semi-continuous process is
less than other process (i.e. 2 Ltrs. per ton in semi-continuous process & 6 Ltrs.
per ton in continuous process). Also it leads to lesser residual oil in de-oiled
cake. More over, A Semi-Continuous plant is cheaper in initial capital outlay.
Thus semi-continuous plant is more suitable and is used in the industry. In a
semi-continuous plant there is a battery of 10 - 14 extractors for
simultaneous extraction & the distillation process is continuous like the one
in the continuous plant.In the semi-continuous process raw material is fed into
the extractor in batches & solvent is sprayed on it till oil contents in the
rice bran are completely dissolved. Thus while one extractor is being loaded
the other is ready for deoiling operations.
SOLVENT USED :-
Various solvents like carbon disulphide (CS2), acetone, hexane etc. can
be used for the extraction of oil. But by trail and error hexane has been found
to be the best solvent for extraction of oil from Oleginous material. CS2 is
quite expensive, more over it is gas at normal temperature & pressure.
That is why hexane is used as solvent because it is
a relatively cheaper, immsiciable in water and its specific gravity is 0.667.
Main considerations while choosing suitable solvent are edibility of oil,
high solubility level of solvent and its low boiling point.
SOLVENT EXTRACTION PLANT CONSISTS OF : -
1. EXTRACTOR BATTERY
2. DISTILLATION SECTION
Number of equipments are used in these sections namely : -
Extractors, Miscella Storage Tank, Oil storage Tank, Hexane Storage Tank,
Heater, Flasher, Stripper, Solvent Water Separator,Catchall, Condensers etc.
MATERIAL OF CONSTRUCTION : -
Most of the equipments in the solvent plant are made up of mild steel as it is
relatively cheaper, hard and neutral to oil and hexane.
INSULATING MATERIAL : -
Fiber glass acts as insulating material to avoid heat losses during process in
the solvent plant.
EXTRACTOR BATTERY
EQUIPMENTS USED : -
EXTRACTOR :- 10 IN NUMBERS.
It is a cylindrical vessel with dished ends and false bottom with filter media.
It is provided with steam jacket and leveler. The capacity of one extractor is
3 Metric Ton. Hexane is sprayed over pellets in extractor resulting in the
formation of miscella. De-Oiled cake remained on filter media as The height
and diameter of extractors is 9 ft & 5 ft. respectively.
2.. SOLVENT STORAGE TANK : MADE UP OF MILD STEEL
It is a tank in which hexane is stored. It is underground since hexane is
highly inflammable. Capacity of hexane storage tank is approximately 2400 to
3200 Liters.
3. MISCELLA STORAGE TANK : MADE UP OF MILD STEEL
Miscella storage tank is a tank in which miscella (mix. of oil & hexane)
obtained during extraction process is stored. Its capacity is 90 MT.
2. DISTILLATION SECTION : -
It is a cylindrical vessel provided with steam coil made up of mild steel. It is
a device used for heating miscella. As a result of which hexane vapors
evaporate . They are 2 in numbers.
Capacity of heater is 600 to 700 Kg.
B. FLASHER : 2 IN NUMBERS.
HEXANE
It is a cylindrical vessel with dished ends made up of mild steel. It is
provided with a sprayer. In flasher hexane vapors are separated from miscella.
After passing through second flasher 90% hexane is removed from miscella.
They are two in numbers.
C. STRIPPING COLUMN :-
In the stripping column, the last traces of solvent are removed under high
vacuum of 600. Stripping is the process in which solute (hexane) is
converted from liquid phase to gas phase. Column is equipped with trays with
holes. Oil having small traces of hexane is introduced from top. It follows
Zig-Zag path & is heated by pressured steam introduced from bottom at 105'C
temperature. Since, boiling point of hexane is very low, hence it evaporates, is
sent to condenser for re-use. In this way oil free from hexane (0.02%) is
obtained .
D. CONDENSER : -
It is a device used for condensing vapors . Surface condensers are used for
condensing vapors of hexane. The solvent thus recovered is sent for further re-
use.
E. CATCHALL : -
It is a water pool in which uncondensed hexane vapors are discharged deep
below the water level. There are four catchall in the plant. This mixture of
hexane and water is sent to hexane-
water separator.
HEXANE WATER SEPARATOR : -
In the hexane-water separator hexane is separated from water. Hexane thus
obtained goes to hexane storage tank where as water goes back to catchall.
G. OIL STORAGE TANK : -
There are four oil storage tank in plant. Capacity of each is approximately 6
ton. In it raw oil obtained during extraction process is stored.
DAILY CONSUMPTION OF RAW RICE BRAN IN SOLVENT PLANT :-
Capacity of one extractor = 03 MT
Number of extractors = 10
Feeding of extractor = 0.30 hours
Extraction Time = 2.30 hours
Decanting of deoiled cake = 1.30 hours
Desolventization of Deoiled Cake = 1.30 hours
Therefore Total time cycle of one extractor = 6 hours.
It means one extractor complete 4 cycle in a day.
One Extractor works = 04 times in day
Ten ......do...... = 4 x 10 ....do.... = 40.
Therefore Total number of batches = 40
Consumption of rice bran per day = Capacity of one extractor
x Number of batches
= 3 x 40 = 120 TPD.
PROCESS DESCRIPTION
The process in brief constitutes treating of the raw material with Solvent
Hexane resulting in a solution of solvent and oil. This solution terned the
Miscella is further subjected to distillation and stripping to separate the oil and
solvent. The extracted meal containing solvent is freed from its solvent content
by a process called desolventisation. The solvent is liberated from the oil and
the deoiled meal in a vapour form. This vapourised solvent is condensed to
liquid form in a battery of condensers and is finally recovered fully. This
recovered solvent by means of stripping, distillation, desolventisation etc. is
reused in further extraction.
The following stages are involved in the process of solvent extraction of oil :
-
1. Extraction of miscella from pre-processed raw material.
2. Desolventization of extracted meal.
3. Distillation of miscella.
4. Desolventization of oil by stripping.
5. Solvent recovery by condensation for re-use.
1. EXTRACTION OF MISCELLA FROM PRE-PROCESSED RAW
MATERIAL
Firstly pellets brought from preparatory section through conveyor belt are
fed into the extractor to its working capacity through hopper. It takes
approx. 0.30 hours. The extractor is then evacuated and the solvent is pumped
into the extractor from the top to such a level at which pellets are suspended
in it completely. Hexane circulates in the extractor and dissolve all the oil
contents, present in it at a temp. of 55'C to 60'C. Thus a mixture of oil and
hexane is obtained
known as " Miscella" . Extraction time is 2.30 hours. During extraction
process deoiled cake is also produced that contains 0.6 to 1 % oil contents in it.
The process is continued till the
residual oil in the deoiled cake is reduced to 0.2 to 0.3 %.
Miscella thus produced is sent to miscella storage tank from where it is
pumped to distillation section.
02. DESOLVENTIZATION OF EXTRACTED MEAL : -
Deoiled cake is produced as extracted meal during extraction process. It is
collected over the filter media. After complete extraction and pumping out of
solvent, the extracted meal still contains some contents of hexane in it that are
removed from it by the process of desolventization with open steam entering
below the false bottom. Hexane vapors thus obtained during desolventization
of extracted meal are led into the surface condensers for re-use.
Desolventization of Deoiled cake takes approx. 1.30 hours . Thus the solvent
free deoiled cake is taken out of the extractor through manhole.The
process of taking deoiled cake out of the extractor is known as decanting
and it takes approx.1.30 hours.This deoiled cake thus produced is sent for cooling
and filled in bags.It can be used as cattlefeed.
03. DISTILLATION OF MISCELLA : -
Miscella from the miscella storage tank (obtained during extraction
process) is pumped into the distillation section to get hexane free oil. Hexane is
separated from oil by equilibrium or flash distillation. It is a continuous
process & carried out in two stages. In the first stage of distillation miscella is
introduced to the heater and heated to a temp. of 65-70'C. This preheated
miscella
is sent to the flasher where it is sprayed from top. As a result of which
hexane vapors evaporated goes to condenser and miscella from bottom of flash
chamber is sent to heater.In the second stage of distillation, miscella is heated to
a 70 -100'C temp. in a heater and then it is sprayed in the flash
chamber from top. Thus 90 % hexane vapors evaporates due to their low
boiling point i.e. 65'C and sent to condenser for re-use. Also oil having
small traces of hexane vapors is
drained off and sent to the vacuum stripper.
04. DESOLVENTIZATION OF OIL BY STRIPPING : -
The last traces of hexane present in oil are removed by stripping. Stripping
is the process in which solute (hexane) is converted from liquid phase to gas
phase. In the stripping column, miscella is introduced from top under high
vacuum of 600 and it moves slowly down following the Zig-Zag path.
Miscella is heated by pressurized steam added from bottom at a high temp.
of 105'C. Hexane vapors thus evaporates due to their low boiling point and
sent to condensers . Oil thus obtained is free from hexane (0.02%) and
moisture and sent to oil storage tank. From where it is pumped to Refinery
Plant to get edible oil for direct human consumption.
5. SOLVENT RECOVERY BY CONDENSATION FOR RE-USE : -
Hexane vapors obtained during desolventization of extracted meal ,distillation
of miscella and stripping, processes are condensed in the condensors for
further use. For the condensation of
vapors, shell and tube type surface condensers are used. In surface
condensers, Shell contains hexane vapors & water circulates in tubes. As a
result of which liquid hexane is obtained and sent to hexane storage tank.
Also uncondensed hexane vapors are pumped to catchall by using vacuum
pump. The mixture of hexane and water thus obtained is sent to hexane-water
separator from where hexane goes to hexane storage tank and water is pumped
to catchall.
NATURE OF RAW OIL OBTAINED AFTER EXTRACTION
Oil extracted from rice bran can be divided into three parts based upon
percentage of free-fatty acid present they are : -
1. Edible or Raw Grade I oil having low FFA.
2. Non-Edible or Raw Grade II oil having high FFA.
3. Semi-Edible Raw Grade II oil has to be processed to get Raw Grade I oil.
Percentage of Free fatty acid depands completely upon type of rice bran
used.In our plant percentage of FFA in Raw oil is generally 26% to 30%. If
say for some reason the percentage of
FFA exceeds 30% the oil is first neutralized in neutralizer by adding NaOH
before taking it to refinery. Raw oil contains moisture content upto 15 to 17%
& Hexane to about 0.02%. It is Non-Edible oil, it contains gums, soaps and
waxes in addition to free fatty acids due to which it is dark brown in color and
gives foul smell. This raw oil is refined in refinery section
to produce Edible oil.
There are certain precautions that must be considered for safe and economical
production of oil these are as follows :
1. Time delay between production and consumption of rice bran should be as
small as possible.
2. Pellets entering extractors must not have high moisture content.
3. Extractors, Heater, Stripper & Flashers must be properly installed with
glass wool to avoid heat loss during the process.
4. The plant must undergo timely repairs.
5. Hexane must be handled carefully as it is highly inflammable.
6. Extraction plant should be 100 ft. away from boiler. Hexane should be
stored in underground solvent storage tanks.
7. Boiler must have 50 ft. high boundary wall and the plant should be
accurately designed to have efficient extraction of oil. It must be flexible to
any change in present process.
R E F I N E R Y P L A N T
The process of upgradation of raw oil to get Edible Oil is called refining .
Refining is necessary for raw oil to make it suitable for human consumption
since raw oil obtained during extraction process, contains Gums, Waxes, Free
Fatty Acid (Which are responsible for foul smell).
TYPE OF REFINING
There are two types of refining namely : -
(i) Chemical Neutralisation followed by bleaching and filter action.
(ii) Physical Deacidification .
Raw rice bran oil contains approx. 30% FFA. The percentage of vary
FFA may be from 4 to 70 % depends upon type of rice bran used.
In the Chemical neutralisation Process, oil is neutralized with caustic soda. FFA
present in the oil reacts with caustic soda and the soap stock is formed. But at
the same time caustic soda reacts with neutral oil and converts it into soap.
The soap stock thus formed is separated either by gravity or by centrifuge.
In this process lot of free oil goes along with soap stock. Thus this process
involves oil loss that ranges from 2.5 to 3.00 times of FFA.In the case of
Physical refining, first oil is degummed & bleached. After that FFA is
distilled in the deacidifier. In this process no neutral oil is converted into soap
and FFA is recovered in the form of Fatty Acids only. The losses in this
process is around 1.1 time FFA. Thus, Physical Refining is much more
economical and viable
process. Our Company have produced refined Rice Bran Oil for the first
time in India through the most economical process of Physical Refining.
DIFFERENT PROCESSES INVOLVED IN REFINERY ARE : -
1. DEGUMMING : Process of removal of gums by using (H3PO4) O.1N
dilute Phosphoric Acid
2. BLEACHING : Process of removal of color from the oil by using
bleaching earth & activated Carbon.
3. DEACIDIFICATION : Removal of FFA from oil under high vacuum is
called - deacidification.
4. DEWAXING : Process of removing waxes from oil.
5. SAPONIFICATION : Process of formation of soap stock from oil on treating
with some alkali is called desaponification.
PROCESS DESCRIPTION :-
1. DEGUMMING SECTION : In this section,degumming is carried
out.Degumming is the process of removal of gums from oil using O.IN
H3PO4. it is a physical process in which H3PO4 acts as absorbent. Heavier
gums thus produced are separated by centrifuge machine.
NAME OF THE EQUIPMENTS USED : -
Crude oil tank, Agitators, centrifuge machine,Gum Storage tank, mixer,
degummed oil storage tank.
CRUDE OIL TANK :-
Oil obtained in extraction plant is pumped to crude oil
tank where dil H3PO4 is added from the top. The mixture in the crude oil tank
is heated to the Temp. of 70-80 'C. It is equipped with stirrer, heating coils,
and gear-motor system. It is a cylindrical vessel made up of stainless
steel.
Stirring in the crude oil tank is done for uniform heating and for thorough
mixing of H3PO4. Stainless steel is used for constructing tank as it is
neutral towards H3PO4. 1/2 kg. H3PO4 is added per ton of oil. From crude oil
tank, oil goes to agitators.
AGITATORS :-
In agitators, hydration time i.e. 45 min. to 1 hour is given to the mixture. There
are three agitators in the industry. The residence time of oil in each agitator is
approx. 15 to 20 min. It is a cylindrical vessel open at one end. It is provided
with stirrer through gear-motor system & heating coils. The Temp. of mixture is
maintained at 70-80' C. In the agitator, absorption is completed. Stirring is
done for uniform heating. The vessel & heating coils are made up of stainless
steel as it is
neutral towards H3PO4.From the agitators oil containing gums is sent to
centrifuge machine.
CENTRIFUGE MACHINE : -
In centrifuge machine, gummed are separated from oil. It is based on the
principle according to which (Gums) heavier particles move towards
periphery on rotating.
CONSTRUCTION OF CENTRIFUGE : -
Centrifuge machine is made up of stainless steel. It consists of a vessel which
is provided with shell containing fan made up of stainless steel. The fan rotates
at 14,000 r.p.m.
WORKING : --
Oil having gums is introduced to the machine from the bottom into the inner
shell. The fan rotates at high velocity due to which gums move away from the
oil and gets deposited on the periphery
of the vessel. Due to centripetal force. Centrifuge machine is also provided
with hot water and steam supply in order to avoid any accumulation of gums
in the machine as shown in fig.
In this way, gums are completely removed from oil and are stores in gum
storage tank. Gums are long chain hydrocarbons and are used for
manufacturing soaps, rubbers etc.Degummed oil goes to degummed oil storage
tank and it contains approx. 0.5% moisture contents. Degummed oil thus
obtained is sent to Bleaching section.
2. BLEACHING SECTION :-
The process of bleaching is basically absorption of coloring pigments on the
surface of activated bleaching earth.
BLEACHING AGENT : --
The mixture of bleaching earth and activated carbon is used as bleaching
agent. The ratio of Indian earth to that of activated carbon is 7:1 (By
Weight).Bleaching earth also known as Indian earth removes yellow color
of the oil where as activated-carbon absorbs reddish color of the oil.
EQUIPMENTS USED IN BLEACHING SECTION : -
Bleacher, Vacuum Vessel, Vessel Containing Mixer of Bleaching Earth And
Activated Carbon And Filter Press.
BLEACHER :-
It is cylindrical vessel made up of stainless steel. It is fixed with stirrer
through gear-motor system. It is also provided with heating coils. Bleacher is
connected with oil charging line and also a bleaching earth dosing line as
shown in fig. stirring is done to mix oil with bleaching earth. Bleacher is
connected to vacuum vessel.Vacuum is created in the bleacher due to which it
sucks bleaching earth. Mean while oil enters through oil charging line and
mixed with
earth. Bleaching continues to about approx. 1 hour at a temp. 105'C + 1;C
after which oil is cooled to about 80-90'C temp. and sent for fileration.
Bleacher is also provided with by-pass line as shown in fig. to control the
quantity of oil entering the Bleacher.There are three bleachers in the plant.Color
content in oil before bleaching = 63.5 which is reduced to 32.5 units after
bleaching. Therefore bleachibility percentage of oil is 48.818 %.. The moisture
contents present in bleached
oil is 0.1%.Vacuum is created to lift bleaching earth and also to decrease the B.
Pt. of oil. From bleacher the bleached oil is sent to filter press.
FILTRATION :-
It is the removalof solid particles from a fluid by passing the fluid through a
filtering medium on which the solids are deposit Spent bleached earth (In
Solid form) is filtered from bleached oil through plate and frame filter press.
CONSTRUCTION OF FILTER PRESS : -
Filter press is made up of cast iron as it is relatively cheaper. Filter press
contains a set of plates designed to provide a series of chambers or
compartments in which solids may collect. The plates are covered with a filter
media such as canvas, Slurry which admitted to each compartment under
pressure, liquor passes through the canvas & out a discharge pipe leaving a wet
cake of solids (spent earth) behind.
WORKING : -
Plates & frames sit vertically in metal rack with cloth covering the face
of each plate & are squeezed tightly together by a screw or a hydraulic ram.
Slurry enters at one end of the assembly of plates & frames. It passes through a
channel running length wise through one corner of theassembly. Auxiliary
channels carry slurry from the main in let channel into each frame.Here the
solutes (Spent earth) are deposited on the cloth covered faces of the plates.
Liquor (i.e. oil) passes through the cloth down grooves in the plate faces and
out the press. Filtration is continued until oil no longer flows out of the
discharge or the filtration pressure suddenly rises. These occur when the frame
are full of solids (spent earth) and no more slurry is admitted & press is said to
be Jammed. Wash liquid may then be added to remove soluble imparities from
the solids after which cake may be blown with steam or to display as much
(oil) liquor as possible. Press is then opened and the cake of spent bleached
earth removed from canvas and sent to bin storage.
Spent earth contains 25% (Approx.) oil & it can be used as fuel in the furnance.
Bleached oil after filtration is sent to deacidification section.
3. DEACIDIFICATION SECTION : --
In deacidification section, the process of deacidifying is carried out. it is
the process of physical removal of free fatty acids by steam distilation.
NAME OF THE EQUIPMENT USED IN DEACIDIFICATION SECTION : -
Heat Exchanger, Buffer Cooler, Deareator, Deacidifier, Vacuum Vessels,
Fatty Acid Separator, Water Chiller. The description of these equipments is
given as : -
1. HEAT EXCHANGER :-
It is made up of stainless steel. It is a device used for the heat exchange b/w
(two fluids) i.e. bleached oil and outgoing deacidified oil. The simple double
pipe exchange is inadequate
for flow rates that cannot be readily handled in a few tubes. Where one shell
servers for several tubes that heat exchange is more economical. There are
three heat exchange in the plant. There are single 1-1 pass counter flow
heat exchanger.Baffles are installed in the shell. Baffles are perforated to
receive the tubes. Liquid (Oil) i.e. bleached oil flows through the tubes and
deodourised or deacidified oil circulates in the shell.
2. BUFFER COOLER :-
In buffer quantity of material always remained constant i.e. total fluid
entering buffer must be equal to fluid send after heat transfer. It is a device
used for heat transfer during different stages of deacidification. It is made up
of stainless steel. Surface of content b/w two fluids is increased in buffer
cooler so, it is more efficient then heat exchanger.
3. DEAREATOR : -
It is a device which is used for the removal of FFA causes foul smell under high
vaccum.It is provided with heating coils and steam supply for stirring. There
are 6 to 7 deareators in the
plant. It is made up of stainless steel. In deareator, the temp. of the oil is
raised to approx. 220'C to 240'C. Thus maximum percentage of FFA are
removed in deareator.
4. DEODOURIZER :-
It is a equipment which is used for removing undesired smell created during
the process. Smell is mainly due to presence of FFA. In deodorizer, temp. of
oil is raised to 260 to 280'C temperature.
It is made up of stainless steel. There are seven compartments out of which one
is situated at the center called the central compartment and other six
compartments are situated on the peri-phery of this central
compartment.Central compartment is provided with heating coils for direct
heating. Steam is introduced from the bottom of central compartment for
stirring. Steam is bubbled at high pressure from the oil to avoid the burning of
oil near the heating coils. In the heating coils of central compartment
thermofluid at 280'C to 300'C is circulates.Peripheral compartments are
provided with steam jacket for surface heating of oil in deacidifier.
5. FATTY ACID SEPARATOR : -
It is a device in which vapors of FFA (removed by deareater and deacidifier)
are condensed by spray of cold fatty. Thus vapors of FFA are sent to fatty acid
separator where they are condensed and stored in storage tank.
6. SOLENOID VALVE : -
It is connected to fatty acid separator. It
controls the level of fatty acid & once high level is achieved the excess fatty
acids are pumped to storage tank.
7. WORKING OF SOLENOID VALVE : -
It is an automatic electric valve which consists of a diaphragm connected with a
movable piston. This piston blocks the passage line of fatty acid. When level
of fatty acid is quite high, Diaphram bends & the piston moves downward
and thus valve is then opened.
8. WATER CHILLER : -
It is a device in which fatty acids are cooled in water chiller and sprayed
over vapors of fatty acids in fatty acid separator.
PROCESS DESCRIPTION OF DEACIDIFICATION : -
Bleached oil from bleached oil tank is pumped through a external heat
exchanger and then pumped to buffer cooler tank where it exchanges heat with
outgoing deacidified oil. In this process temperature of oil is raised to 75-
80'C. The preheated bleached oil then goes to deareator where it is heated
under high vaccum.In the deareator maximum percentage of FFA are removed
and are sent to fatty acid separator through vacuum system. Thus temp. of oil in
the deareator is approx. 220-240'C. Oil is heated by heating coils that contain
thermofluid. Steam is also added from the bottom of deareator for stirring the
oil to avoid burning of oil near heating coils. Thus oil from deareator is
introduced to deodorizer. Oil goes to the central compartment of deacidifer
where it is heated by thermofluid circulating in the heating coils at a temp. of
approx. 260-280'C.
The fixed quantity of oil from central compartment is transferred to the
peripheral compartment by steam pump. The transfer of this oil is controlled
by electro-mechanical programmer.In each peripheral compartment, oil remains
for about 90-100 mints where it is deacidified by bubbling open steam.After
the deacidification, oil from peripheral compartment is drained to the buffer
tank cooler for heat exchanging with incoming bleached oil and pumped out
of buffer tank cooler through heat exchanger, final cooler and polishing filter
to the storage tank and sent to dewaxing section.The deareator, deacidifier and
buffer tank cooler is maintained under 2 torr.
The fatty vapors from the deacidifier, deareator and buffer tank cooler passes
through connecting pipes into fatty acid separator. In the connecting pipes,
several nozzles are placed through which fatty acid circulates continonsly at
controlled temp.In the fatty acid separator, cool fatty acid coming from water
chiller is sprayed over fatty vapors & thus it condenses the fatty vapors and
water vapors goes through vacuum system. Fatty acids are collected in fatty
acid separator.
Solenoid valves in fatty acid separator controls the level of acids. Fatty acid is
drained to water chiller from where it goes to fatty storage tank.
Oil obtained after deacidification, contains 0.25% FFA. FFA thus removed
during deacidification are basic raw material for soap industries. Thus
deodorized oil is send for dewaxing from storage tank as shown in flowsheet.
4. DEWAXING SECTION : -
The process of removal of different types of waxes present in the oil by
refrigeration is called dewaxing.
Refrigeration of oil is done due to which waxes solidified earlier then oil as
M. Pt. of waxes is higher as compared to oil these waxes are separated from oil
by filtration process using
frame & plate filter press. Process of dewaxing is carried out in agitators.
AGITATORS :-
Oil is cooled to a temp. of about 30'C at which waxes solidify. It is made up of
stainless steel. It is provided with cooling coils. Cold water flows in these coils
which absorbs heat from oil and get heated. Thus oil having waxes is sent for
filtration to filter press where waxes are separated from oil. These waxes
are sent to soap industries. Dewaxed oil thus obtained contains 0.02 %
waxes and is sent to saponification section.
5. SAPONIFICATION SECTION :-
The process of making soap by the hydrolysis of oil or animal fat on treatment
with some alkali such as KOH or NaOH is called saponification
heat => Oil + Alkali => Soap + Glycerol or Animal fat
Thus the process of splitting the oil or fat into soap and glycerol is known as
saponification.
REACTION INVOLVED ARE
RCOOH + NaOH ----->RCOONa + H2O
(Fats) (soap)
C3H5 (O2CR)3 + 3NaOH ------> 3RCO2Na1C3 H5(OH)3
Oil (soap)
BY PRODUCTS PRODUCED DURING THE PROCESS :-
By-products formed during the process are also sold to different factories
engaged in processing the particular material.De-oiled Cake produced after
extraction is packed after cooling. It can be used as cattle feed.WAXES,
GUMS (removed at degumming section) and FREE FATTY ACIDS are
consumed by soap and rubber factories FFA present in oil are Linoleic
Acid,Oleic Acid, Palmatic Acid, Steric Acid, Linolenic Acid.. Linoleic Acid is
found in higher percentage in rice bran oil .
SPENT BLEACING EARTH after bleaching is an efficient fuel for as it
contains 25% oil in it.
RESEARCH & DEVELOPMENT SECTION : -
The Company has plants to produce fully refined rice bran oil as a direct cooking
medium.
The Company has produced fully refined rice bran oil in laboratory scale &
machinery to produce the same at plant scale is being designed.The Company is
in touch with oil Technological Research Institute, for suitable technology to
produce value added products from its by-products i.e. Gums & Waxes.
STORES & PURCHASE DEPARTMENT : -
Purchases are made on the basis of requisition issued by the store or any
concerned department. The requisition is entred in a registered and serial no
is allotted to it. After getting necessary instructions with respect to any
requisition from the Director responsible for purchases the same is passed to
the purchase officer for making necessary purchases. On receipt of the goods
physical verification of the same is conducted and a material Receipt Note is
issued on the basis of Bill / Invoice and necessary entries are made in the store
register. The material are issued to the concerned departments on the basis of
issue slips as per their demand.There is no proper / systematic storage of
materials. It is suggested that the Company should have a proper bin card
system. There are no written purchase orders. It is suggested place all orders in
writing and should keep proper record of the purchase orders. It is for the
suggested that the Company should use computers for proper inventory
management.
REPAIR & MAINTENANCE : -
There is no proper preventive maintenance policy of the Company which is the
main cause of break downs. The should have a proper preventive maintenance
policy to reduce production losses because
of breakdown. The Company have fire fighting equipment but sufficient number
of workers are not trained to handle the same.The Company has installed multi-
cyclones to control pollution
from the Boiler wherein rice husk used as a fuel in a fluidised bed furnace.
PERSONNEL & ADMINISTRATION : -
All the affairs of the organisation are personally supervised by the Directors of
the Company. They are in direct touch with the workers and also involve
themself in day to day working. There are no proper system / procedures
governing accountability and responsibility. Although the Company is paying
the Workers Bonus & Provident Fund , but there is incentive scheme in the
Company.
ADDITIONAL INFORMATION : -
There is no proper management information system. All the sales are made
through brokers /agents. There is no direct contact with the customers.
Manufacturing /Construction Division
The company has two plants:- Solvent Extraction Plant and
Physical Refining Plant.
In the solvent extraction plant oil is extracted of Rice Bran and in the
physical refining plant the oil so produced is refined to make it suitable for use
in Vanaspati manufacturing. The company has a oil refining plant based on
latest technology of ohysical refining wherein fatty acids are taken out from the
oil through evaporation of high tempratures under absolute vaccum.
There is no job card system in the company. The company is dependent on
outside workshops for repairs.the solvent extraction plant, raw rice bran is used
as the basic raw material. It is in the powder shape and contains oil between 12
to 14%.In the physical refining plant Rice Bran Oil containing
about 20% to 25% free fatty acids is used as the basic raw material. It has a
colour of 60 units in 1/4" cell.
QUALITY CONTROL
The company has a Labortaory wherein quality of the
finished products is checked on regular basisMeasuring instruments have been
installed on oil lines to control the flow of oil and also on chemical lines to
ensure use of such chemicals in required proportions.The company has Log
sheets for various sections of the plants to keep a propoer watch on quality &
quality of the finished products is checked at regular intervals and also before
despatch of any consignment.Extraction apparatus is used to check residual oil
content in the Deoiled cakes. Tintometer is used to check the colour of oil.
R A W M A T E R I A L
Rice Bran is used as raw material in the Solvent Plant. It is
of three types :-
(i) RAW RICE BRAN
(ii) RICE BRAN SELA or pre-boiled Rice Bran
(iii) PHAK.
Raw Rice Bran contains 12% to 18% oil contents, Rice Bran Sela contains
high oil contents i.e. 18% to 25% & Phak contains oil contents i.e. 06 % to
11%.As the cost of Rice Bran Sela is higher & it's not easily available. Raw
Rice Bran is preferred over Rice Bran Sela & Phak. Paddy from the fields are
dehusked in the Shellers and rice Kernels thus obtained are separated.The
upper layer of the rice,thus produced is Yellow in color. This rice when
polished gives rice bran and turns white. Rice is polished by two rubber
rollers rotating past each other in opposite direction. Rice Bran is Yellow
coloured powder.
EVALUATION OF RAW MATERIAL
Raw material is evaluated on the basis of % age of Oil contents, FFA etc.
present in it, in quality control section. The cost of Raw material is fixed as per
oil contents. Fresh Rice Bran is preferred because it contains very low per-
centage of Free Fatty Acid (FFA).Low FFA Rice bran is helpful for producing
Edible Oil. Since FFA rapidly increase by the action of enzymes that is why
rice bran should be immediately Fused after its production. But it is not
practically possi
ble to process rice bran immediately as extraction units are at a distant place
from Shellers. 12 hr collection of rice bran yields oil that contains 15 % FFA. 24
hr collection of rice bran yield oil containing 15-30 % FFA. Where as 48 hr.
collected rice yield oil containing greater than 30% FFA. Rice Bran Sela can
be kept for 15 days without any significant increase in percentage of FFA.
P R E P A R A T O R Y S E C T I O N
In the preparatory Section, floury rice bran is converted to dry pellets. For
efficient & thorough extraction of oil in Solvent Extraction Plant, preparation of
raw material is of considerable
significance. Yield of final product (i.e. Refined Oil) depends greatly on
working of preparatory section.Raw Rice Bran is converted to pellets to
facilitate flow of Hexane through it. If floury rice bran is used as such in
extractors, Hexane sprayed on it would not reach the bottom of flour. It is
same as the water collects on the surface when poured into dry flour.
PROCESS FLOW SHEET : -
SCREENING => STEAMING => PELLETING => DYING OF PELLETS
=> TRANSPORTATION OF PELLETS TO EXTRACTORS
EQUIPMENT USED ARE MADE UP OF MILD STEEL
1. SCREENS : -
Screen are used to separate heavier particles from raw rice
bran like stones etc. Screening is done to avoid damage to operating
machinery. Screens are made up of mild steel as it is hard. The diameter of
holes is approx. 1 to 3 mm.
2. SCREW CONVEYOR : -
It is a device which is used for
steaming of raw rice bran. It is equipped with iron blades by which steamed
bran rotates in the forward direction. Thus it takes steamed bran to the
pelleting machine.
PELLETING MACHINE : -
Pelleting machine is a device used to form pellets from steamed raw rice
bran. It consists of rollers and sieved die-FFdplates as shown in fig.
4. ROTARY DRYER : -
Rotary dryer is used for drying the free-flowing granular solids. It may
be directly or indirectly heated. It is also made up of mild steel.
5. CONVEYOR BELT : --
It is the belt used for the transportation of pellets from preparatory to
Extraction Section.
P R O C E S S D E S C R I P T I O N
In preparatory Section, Rice Bran is first screened to remove all the
heavier particle that could harm the machinery. Thus pieces of bricks,stone,nut
bolts etc. are removed from the rice bran. This screened rice bran is collected
in a pit from where it is lifted by bucket elevator and introduced to screw
conveyor. In screw conveyor rice bran is subjected to open steam to temper
it, hence increasing its binding force. After steaming screw conveyor takes
the tempered rice bran to pelleting machine.
P E L L E T I N G M A C H I N E
Pelleting machine is used for the production of pellets from tempered rice
bran.
WORKING OF PELLETING MACHINE
Pelleting machine consists of a sieved die-plate and four rollers. These
roller rotates on the die-plate and press the tempered rice bran through
preformation in die-plate and thus pellets are formed.
NATURE OF PELLETS FOR THOROUGH EXTRACTION
Greater the surface area of pellets exposed to hexane more would be the
extraction. So pellets should be as small and thin as possible but old rice bran
become coarse and pellets of small
diameter can not be made out of it. The diameter of sieves in die-plate
depends entirely upon type of rice bran used. Die-plate is removed from the
pelleting machine if it is Jammed and put to work again after cleaning. One die-
plate can give pellets continuously for 24 hours before it is Jammed.
DRYING OF PELLETS
Pellets from pelleting machine are dried to reduce its moisture content.
Dryer used for this purpose is rotary dryer.
WHY ARE PELLETS DRIED
Dried pellets have low moisture contents which make them porous these
pellets when introduced to extractor would easily adsorb hexane sprayed on
them and thus increase the
efficiency of extraction process.
ROTARY DRYER
Rotary dryers are used for drying granular solids. This may be directly or
indirectly heated. This type of dryer consists of a hollow rotating cylinder
which is at a slight incline to the horizontal. Pellets are fed at the upper end of
the cylinder and moves through the shell by virtue of rotation, heat effect,
slope of cylinder and is discharged at the other end as dried product. In the
dryer hot air is passed over the pellets in a counter current flow which absorbs
the moisture from the pellets and thus dry pellets are removed from the
other end.Shell diameter of rotary dryer usually ranges between 1 mm - 6 m
and length of cylinder is 4 to 10 times. Its diameter its thermal efficiency is 50%
to 80%. So, it is quite efficient.
ADVANTAGES OF USING ROTARY DRYER : -
Good air contacting, moderate drying time,greater flexibility of control of air
velocity, high thermal efficiency and low capital
DISADVANTAGES : -
Disadvantages include difficulty in sealing high structural load and non-uniform
residence time.Dried pellets thus produced are lifted by conveyor belt and are
introduced to extractors.The
moisture content in these pellets must not exceed 17% from the rotary dryer.
Pellets are sent to Solvent Extraction plant through conveyor belt. The
moisture content of rice bran enter
ing pelleting machine must not be too high.
From the rotary dryer, pellets are sent to solvent extraction plant through
conveyor belt.
PROCESS DESCRIPTION : -
Firstly oil is mixed with NaOH and hot water in agitators. Free Fatty Acids
present in oil in negligible amount i.e. 0.25 % reacts with Sodium hydroxide
resulting in the formation of soap
and glycerol. Soap thus formed dissolues in hot water but oil remain as such as
it is insoluble in water.
This oil is then send to washers where soap stock is washed away and
separated from oil. Finished oil thus produced goes to finished oil tank .From
these tanks it is loaded in tankers and
send to different Vanaspati factories. Also it can be used directly for human
consumption.
MATERIAL OF CONSTRUCTION
Most of the equipments used in the Refining. Plant are made up of stainless
steel. Since at high temperature fatty acids presents in the oil reacts with Mild
Steel.
INSULATING MATERIAL : -
Fiber glass acts as insulating material to avoid heat losses during process.
REASONS :-
WHEN & WHY
1. Most of the equipments of Refining Plant are made up of stainless steel.
Since at high temp. of 260-280'C FFA present in oil reacts with mild steed
and corrodes it.
2. Buffer cooler is used with heat exchangers to effect greater contact
surface area for exchange of heat, to act as a buffer storage tank which can
work out deacidification section
for 3 to 4 hours thus causes the greater efficiency of cooling / heating process.
3. Thermofluid is used as heating agent in deareator and deacidifier. Since ,
we have to create a high temp. of 260-280'C in these equipments.
DEMENSIONS OF EQUIPMENTS USED IN REFINERY PLANT.
1. DEAREATOR made up of stainless steel dimensions of deareator are
1.5m dia X 3.5m height coil. Surface area is 32 sq. mtrs. of 2
2. DEACIDIFIER made up of stainless steel , consists of several compartments
of 5mm partitions dimensions of vessel is 3.2m dia X 4.1m height coil surface
area 23 sq. meters of 2.
3. BUFFER COOLER dimension of Buffer cooler are 1.4m dia X 4m height.
Coil surface area 27 sq. metres of 2.
4. HEAT EXCHANGER made of stainless steel. Its surface area is 48 Sq.
meters.
QUALITY CONTROL
Quality is defined as the set of specifications which are prescribed by the
regulatory agencies on the basis of requirements by customers. It is also defined
as the degree of excellency i.e. how much the product is pure on the basis of set
of specifications.
THE PURPOSE OF THE QUALITY CONTROL IS TO ENSURE : -
1. That the final oil meets the prescribed standards.
2. That the oil production lines and refinary systems are functioning
properly.
3. That the product is being prepare according to requirement.
4. The cleaning and proper working of plant.
These things must be regularly followed on the day to day basis to ensure a
consistently a high quality product.Each tanker leaving the plant should be as
near perfect as possible. A high quality product is necessary in order to repeat
sales and to increase the profit of plant
TESTING
AIM : Test to check percentage of oil contents in raw rice bran.
APPARATUS USED : Heater, Round flat bottom flask, Surface condenser,
Recycling tube.
PROCEDURE :
Hexane first heated to 65'C (which is boiling point of Hexane) thus
vapors of hexane are formed which reach the condenser placed at the top.
Here these vapors get condensed
and liquid hexane is sprayed on the sample of the rice bran placed in
recycling tube. Hexane dissolves oil contents presents in rice bran. Thus
mixture of hexane and oil starts
collecting in the recycling tube. It is recycled to the flask containing hexane.
All this process is repeated 5-6 times. The process continues for about 2:30
hours. In the end oil contents are left in the flask. Weigh these oil contents
from which percentage of oil contents can be calculated.
OBSERVATIONS :
Weight of rice bran taken = 40 g = w
Volume of hexane used = 50 ml
Weight of oil extracted = 5.2 g = x
CALCULATIONS :
Percentage of oil contents can be calculated by using following
expression :-
Percentage of oil contents = x/w X 100
Oil contents = 5.2/40 X 100 = 13%.
RESULT : Oil contents in the sample of rice bran is 13 %.
AIM : Test to check percentage of FFA present in raw Rice Bran Oil.
APPARATUS USED : Flask, Weighing Machine, Heater.
REAGENTS USED : Neutral spirit (mixing of ethanol and NaOH) NaOH
solution of 0.1 Normality.
INDICATOR USED : Phenol phthalein is used as indicator.
END POINT : Yellow to Light Pink.
PROCEDURE : Take the empty flask Weigh it using weighing
machine. Put some quantity of raw rice bran oil in it and weigh it again. Add
approximately 50 ml. of neutral spirit
to it. Heat the flask for 5 minutes on heater. Put 2-3 drops of phenol phthalein
in the heated mixture as indicator.
Titrate it against 0.1 N NaOH solution taken in burette. Note the volume of
NaOH used during titration.
OBSERVATIONS :
Weight of empty flask = 85.9910 g
Weight of flask with oil = 87.1710 g
Volume of oil used = 1.149 g
Normality of NaOH = 0.1 N
Volume of NaOH used = 12.7 ml.
CALCULATIONS :
Percentage of FFA can be calculated by using following
expression : -
i.e. Percentage of FFA = 28.2 x N x V /W
Where N = Normality of NaOH = 0.1 N
V = Volume of NaOH used = 12.7 ml.
W = Weight of oil used = 1.149
Therefore percentage of FFA = 28.2 x 0.1 x 12.7/1.149
= 31 %
RESULT : FFA in raw rice bran oil = 31%
Thus we conclude if percentage of FFA in Rice Bran oil is 15-31% rice bran
is 24 hours collected. If FFA is less than 15%rice bran is 12 hours collected.
Percentage of FFA in raw rice bran oil may vary between 4% to
70 %
0.25% of FFA is left after deacidification in finished oil.
PRECAUTIONS : -
01. Weight of flask and sample must be accurate.
02. Readings should be taken carefully . Read the upper meniscus of
NaOH.
03. Make sure that sample used is dry.
AIM : To determine the moisture contents and insoluble volatile matter.
APPARATUS USED : Moisture dish (made up of aluminum steel its
thickness is 0.45 to 0.56 mm, diameter of dish is approx. 70 to 80 mm),
Desiccator, Air oven (preferably electrically heated
with temperature control device), Weighing machine.
PROCEDURE : Take an empty dish and weight it on weighing
machine.Put some raw oil in it and weigh it again. Place the dish in oven at
110'C for one hour to remove moisture content
of the oil .Place the dish in the desiccator for 10 minutes.
Weight the dish again after cooling in desiccator.
OBSERVATIONS :
Weight of empty dish = 49.7649 g
Weight of dish with oil before drying = 60.7730 g
............do......after drying = 60.6726 g
CALCULATIONS :
TOTAL weight of oil = 60.7730-49.7649) g
W = weight of oil = 11.0081 g. before drying
wt of oil = (60.6726-497649)
= 10.9077 g. after drying
Therefore percentage of moisture content = W-w/W*100
= 11.0081-10.9077/11.0081 X 100
i.e. moisture content = 0.912%
RESULT : In the raw oil obtained after extraction moisture
Content is 0.912
AIM : To determine percentage of insoluble impurities using
centrifuge machine.
APPARATUS USED : Sample of oil to be tested , Centrifuge
machine, Centrifuge tube.
PROCEDURE : Take 10 ml of oil obtained after removing moisture
content in a centrifuge tube .Leave it for 10 minutes in a centrifuge
machine to settle down the insoluble impuri-ties. Note the insoluble
impurities from centrifuge tube and calculate percentage of insoluble
impurities.
OBSERVATIONS :
Weight of oil taken = 10 ml = Y
Reading of insoluble impurities = 0.2 ml = x
CALCULATIONS :
Percentage of insoluble impurities can be evaluated by following
expression.
Percentage of insoluble impurities = x/y x 100
..............do.............. = 0.2/10 x 100
..............do.................. = 2%
RESULT : Percentage of insoluble impurities = 2
PRECAUTIONS : -
01.Weighing must be accurate.
02.Drying should be at a temperature of 110'C.
03.Cooling should be done for appropriate time.
AIM : To perform flash test to check the quality of rice bran
oil.
APPARATUS USED : Beaker, Heater, Raw Rice Bran Oil,
Thermometer.
PROCEDURE : Heat the oil in beaker to a certain temperature,upto
which it produces flash if burning splinter is introduced to it. Flash point is
that temperature when the solution produces flash on introducing a burning
splinter.
OBSERVATIONS : Flash point of raw oil is 130'C.
CONCLUSION : Flash test is performed to check the purity and quality of
oil. It estimates the quantity of hexane left in the oil.Greater the value of flash
point, better would be the quality
of oil obtained or vice-versa.
PRECAUTIONS : -
1. Note the temperature at which flash is produced carefully.
2. Make sure that given sample of oil is absolute clean and free from
turbidity.
3. Bring the burning splinter near to oil sample carefully.
AIM : Test to check the color of given sample by using Lovibond
Tintometer.
APPARATUS USED : Lovibond Tintometer, filter paper, cell of 1.4 inch.,
sample to be tested, Heater, Beaker, Oven etc.
PROCEDURE : Take some amount of given sample in a beaker.
Allow it to heat for 5 to 10 minutes. Filter the given sample with the help
of filter paper in order to remove last traces of impurities like waxes. Pour it
in 1.4 inch Cell and place it in oven for 10 to 15 min. to remove moisture
contents.Thus given solution becomes absolute clear and it is free from
turbidity. Place this Cell in Tintometer.Adjust red, yellow, blue slides in
Lovibond Tintometer to match the color shade of oil. Observe the color of oil
and color of slides through eye piece.
OBSERVATIONS :
Y = Total number of yellow slides = 28 units
R = Total number of red slides = 10.3 units
CALCULATIONS : - Expression to measure color is : -
Y+5R = Readings
i.e. 28+5x10.3 = 28+51.5
i.e. Color contents = 79.5 units.
RESULT : Color content of oil is 79.5 units.
PRECAUTIONS : -
01. Oil to be tested must be completely dried.
02. Readings must be noted carefully.
03. Use blue slide to match the color of oil with that of slides.
AIM : To check saponfication value of oil.
APPARATUS USED : Flask, Burrette Desiccator, Oven. Pipette, Heater,
Flat bottom flask, Condenser , measuring cylinder, Burette.
REAGENTS USED : KOH solution and 0.5 N HCl solution.
PREPARATION OF KOH SOLUTION :
Dissolve known weight of KOH powder in 20 ml. of distilled water add
500 ml. of methanol to it. The solution , thus obtained is aq. KOH solution.
PROCEDURE : Test involves two titrations : -
FIRST TITRATION : Titrate aq. KOH solution against 0.5 N HCl. Add 2-3
drops of phenolphthalein as indicator.
INDICATOR : Phenolphthalein.
END POINT : - Pink to Colourless
OBSERVATIONS :
Volume of aq. KOH in Titration Flask = 100 ml.
Volume of 0.5N Hcl used (from barrette) = 14.6 ml.
Thus blank reading for 100 ml. aq. KOH solution is 14.6 ml.,
Normally of HCl used = 0.5 N.
SECOND TITRATION : Take known weight of oil in a round bottom flask
.Add 50 ml. of aq. KOH solution to it. Heat the solution thus obtained at a
temperature greater than 70'C to remove
moisture content for 15 minutes.
Titrate the solution (after heating) against 0.5 N HCl.Note the volume of Hcl
used. Take HCl in burrette and the solution in titration flask .Use
phenolphthalein as indicator.
INDICATOR : Phenolphthalein is used as indicator.
END POINT : - Pink to yellowish brown.
OBSERVATIONS :
Weight of empty beaker = 104.4465 g
Weight of beaker containing oil = 10.4449 g
Weight of KOH powder taken = 19 g
Volume of HCl used = 30.1 ml.
Thus blank reading for this titration is 30.1 ml.
Volume of solution used for titration is 25 ml.
CALCULATIONS :
Weight of oil taken = 5.9984 g
Volume of HCl which reacts with oil can be calculated as
follows.
For the solution of oil and KOH containing 50 ml. KOH
volume of HCl used = 30.1 ml.
Therefore if there would be 100 ml. of KOH in double the amount of oil the
black reading would be (B)
= 2x30.1 ml.
=60.2 volume of HCl used for 100 ml. aq. KOH (S)
= 14.6. Thus volume of Hcl that reacts with oil
= 60.2-14.6.
Therefore saponification value of oil would be : -
SV = 56.11 x (B-S) x N /W
Where N is normality of HCl =0.5
W = Weight of oil.
SV = 56.11 x (60.2-14.6) x 0.5 /5.9984
= 188.83
RESULT : SV of oil = 188.83 units.
CONCLUSION : -
Greater the saponification value of oil better will be the quality of oil.The
tendency of oil to form soap is called its saponification value (S.V.)
Saponification value of oil must be above 170.
PRECAUTIONS : -
1.Make sure that sample of oil is absolutely clear and free from turbidity.
2.Reading should be noted carefully.
3.Note the weight of flask and oil accurately on weighing ma
chine.
AIM : To perform Gums in the sample of oil.APPARATUS USED : Centrifuge
tube, Pipette, Centrifugal machine.
PROCEDURE
Take 0.5 ml. of phosphoric acid in centrifuge tube and add 10 ml. of raw oil
carefully in the centrifuge tube with the help of pipette. After addition of both,
shake them for somtimes to mix
the content properly and to aerate the mixture. Put the tube into the centrifugal
machine, Switch on the machine. After 5 minutes switch off the machine and
take out the tube. Note the reading at
the bottom of the tube.And calculate the %age of gums.
% Gums = ------- X 100
10
where,
R= is the reading of the tube.
AIM : To test quantity of unsaponifiable matter in oil.
APPARATUS USED : Separating funnel,Measuring flask, Weighing machine
, Oven.
REAGENTS USED - PETROLEUM ETHER.
PROCEDURE :
Take solution obtained after saponification test. Put it in separating funnel.
Add 50 ml of petroleum ether and shake it. Two layer of different color are
formed. Upper layer is of
yellow color where as color of lower layer is red .Drain off the red colored
layer. Put this red layer in other separating funnel . Add 50 ml petroleum
ether and repeat the experiment
till red layer disappears.
Weigh an empty round bottom flask. Put different yellow layers from
separating funnels in it. Distill petroleum ether from the solution. After that
keep it at a temperature of 80'C in a oven for 30 minutes. Cool it in desiccator
. Weight the flask again. Find percentage of FFA in it.
OBSERVATIONS : -
Percentage of FFA of oil = 0.3
loss in weight = 6.25 g
CALCULATIONS :-
Let G = 0.3 x 0.282 x 0.1/w
where W is Weight of oil using during saponification test.
G = 0.3 x 0.282 x 0.1 / 5
= 0.16
Unsaponifiable matter = 6.25-0.16
= 6.09.
RESULT : Unsaponifiable matter in oil is 6.09 g.
CONCLUSION : -
Lower unsaponifiable matter in oil means that quality of oil is good.
PROPERTIES OF FINISHED OIL
Finished oil produced in the industry is Rice Bran oil. It is an Edible oil of
RAW GRADE I and has following properties
01. The flash point of rice bran oil is approx. 120-130'C. Greater the value
of flash point, better will be the quality of oil.
02. Percentage of FFA in finished oil is 0.25 Linoleic (C17H31) type
fatty acids are present in high percentage than other types of FFA in Rice Bran
Oil.
03. Moisture content in finished oil is 0.02%.
04. Its saponification value is 175-195 units.
05. Degree of unsaturation of finished oil is about 60%.
06. Since crystrols are present in small amount (i.e. 17%) in rice bran oil
which causes no heart disease.
07. In finished oil 0.25% & 0.05 % Gums & waxes are present.
08. Its Iodine value is 85 to 105 units.
09. Refractive index of finished oil is 1.4600 -1.4700
10. SP. gravity of rice bran oil is 0.910 -0.920.
That is why it is used directly for human consumption and sent to the vanaspati
units.
A U X I L L A R Y S E R V I C E S
Auxiliary services provided in plant includes :-
a) BOILERS
b) CATCHALL
c) REFRIGERATION PLANT.
A) BOILER : -
Company has installed a new Thermax make fluidised bed type fuel efficient
boiler which has reduced its per unit fuel cost drastically.
There are two boilers in the plant out of which one is used to convert water
into superheated steam where as other elevates the temperature of thermofluid
to a maximum of 300'C.
PROCESS DESCRIPTION OF HEATING THERMOFLUID OR WATER IN
FLUIDISED
BED TYPE BOILER.
Boiler consists of a furnace where temperature of bed (Sand bed) is raised to
400'C by heating it with burning coal. This furnace contains coils (made up
of Mild Steel) carrying water that is to be converted to steam. As soon as
temperature of bed becomes 400'C force draf connected to boiler pushes
pressurized air through the nozzles provided under the Sand bed. Due to
which sand jumps to a height of about 1.50 ft. Now, husk is introduced to the
boiler. Husk gains heat from sand andstarts burning. This fire in the furnace
heats the water contained in coils, which then gets converted to steam and goes
to receiver placed at the top of boiler. As the process continues temperature of
bed increase to 600'C.
Boiler is also connected with induced draf which sucks ash from it through
preheater (for water) out from Cyclone. Temperature of ash is 200'C, so it is
used for heating incoming water.
After heating this water, ash goes to cyclones in which heavier ash
particles are separated from smoke.
Ash is disposed in pits where as smoke is discharged to atmosphere
through chimney.
Hard water cannot be used as such in boilers as, the saltspresent in hard water
from scales on the surface of coils when heated and efficiency of boiler gets
reduced.
B) CATCHALL : -
An uncondensed Hexane vapor from condensers in extraction plant is
discharged deep below the water level as these are highly inflammable. If left
as such these vapors being heavier then air come to the surface and form a
flammable fog and can cause fire of the plant.
RESEARCH METHODOLOGY
Research methodology is a way to systematically solve the problem. It may be
understood as a science of study if how research is done scientifically. in it we
study various steps that are generally adopted by researcher in his research
problem along with logic behind them. Research methodology have been
included all the aspects like why a research study has been taken. How the
research problem has been defined. What data has been collected and what
particular method has been adopted, what particular technique for analyzing the
data has been used and lot of similar other questions are usually answered when
we talk of research methodology concerning a research problem or study.
The research design to be used. Data collection method, sampling technology to
be used, feed back to be carried out etc.
(a) Research design: A research design is purely and simply the frame work of
plan for a study that guides the collection and analysis of data. it is blue print that
is followed in completing the study.
(b) Data collection method: in the particular report both the primary as well as
secondary was collected.
*Primary data: primary data is the data, which is, collected through
doing the experiments.
*Secondary data: secondary data is that data, which is collected already
by someone else from different ways.
*Sampling unit: In sampling unit the person who are to be surveyed are
included sampling unit of this research are:
Resident of Dhuri city.
*Sample size: sample size means the number of respondent. in this research the
sample size is 50.
*Sampling technique: Sampling may be probability or non-probability
sampling. On probability sampling is used to conduct the research.
*Non probability sampling: In non probability sampling the chance of any
particular unit in the population being selected is unknown.
*Data Tabulation & interpretation: After collecting the raw data, firstly the
collected the raw data and tabulated and listing was done to make the study
meaningful then by using the percentage statically technique the data was
analyzed and interpreted.
CHAPTER – II
ANALSIS
&
INTERPRETATION
1. Which medium of edible oil do you use?
0
10
20
30
40
50
60
70
vanaspati refined
3-D Column 1
INTERPRETATION
As we seen in the above graph the sale of refined oil is more than vanaspati oil.The 66% people like refined oil and 34%people like vanaspati oil.
2.Which edible oil do use?
05
101520253035404550
Ginni Saffola Ricela Anyother
East
INTERPRETATION
As we seen the above graph the people like 30% ginni,28%saffola,30%ricelaAnd 12%any other.
3. Why do use this oil?
0
5
10
15
20
25
30
35
40
Brand Taste Price Healthfactor
East
INTERPRETATION
As we seen in the above graph, the people like this ricela refined oil,22% due to brand, 38% due to taste,24%due to price,16%due to health factor.
4. How did you know about the product?
INTERPRETATION As we seen in the above graph the consumers aware with 24%with t.v. 36%with news paper,14%with public relation,26%with magazines.
5. How satisfied are you with company brand?
0
10
20
30
40
50
Verysatisfied
Satisfied
East
INTERPRETATION
As we seen in the above graph most of consumers are 46% satisfied,30%very satisfy,24%neutral.
6. Price of the product compare to its quality is:-
0
10
20
30
40
50
VeryGood
Avg. VeryPoor
East
INTERPRETATION:
As we seen the above graph most of people says 46%avg. 40%very good,14%very poor.
7. Which packing style do you more use?
0
10
20
30
40
50
60
1 kg 2 kg 5 kg
East
INTERPRETATION:
The 50% people prefer to 1kg. packing,32% people prefer to 2kg,28%prefer to 5kg. packing.
8. How satisfied are you with the price of the product?
0
10
20
30
40
50
60
VerySatisfied
NotSatisfied
East
INTERPRETATION
As we seen in the graph most of the people very satisfy with 50%,30%neutral,20%not satisfy.
9. How satisfied are you with the quality of product?
0
10
20
30
40
50
Verysatisfy
Neutral NotSatisfy
East
INTERPRETATION
In the graph most of people 46%neutral,34%very satisfy and 20%not satisfy.
10. How satisfied are you with the availability of the product?
0
10
20
30
40
50
Verysatisfy
Neutral NotSatisfy
East
INTERPRETATION:
As we seen in the graph most of the people like 46%availabilty of the product due to manufacturing in city,42%neutral,12%not satisfy.
11. Do you think any free gift or reduction in price help in making choice?
0
10
20
30
40
50
60
70
80
Yes No
East
INTERPRETATION
AS we seen in the graph most of the people 70% says yes and 30% no.
Conclusion
I have gone through the training in this industry and I had learnt a lot from my
training specially the basic, which are more useful to me. here I kept in regular
touch with the chairman as well as the employee of the industry. as our study
structure demands, I just went through that type of work experience. here under
given an under are some of the conclusions or we can say recommendations
which I want to give for more success of the industry.
In this study an attempt has been made to understand the comparative
consumption pattern and consumer behavior regarding edible oils. the nature of
the study is exploratory for this purpose random sampling was used because the
registered user of oil was not restored. We saw most of people prefer the quality
of an edible oils not prefer the price. so company should improve the quality of
the oil.
Limitation of study
Less availability of secondary data:-
No much secondary data on the subject of the study was available.
the researcher had to collect the primary data. the study could perhaps be made
better with the help of secondary data.
Reliability of data :-
Some people were hesitating to respond some question due to lack of
knowledge and awareness about the edible oils.
FINDINGS
1. The most influcing factor which affect the consumer behavior i.e. the quality.
consumer give the first preference to quality at the time of purchasing the oil and
second constraints of consumer is to price.
2. Very important and surprising findings is that most of the consumer are
influenced by advertisement.advertusement play a crucial and vital role to impact
the buying behavior regarding edible oils.
3. The other surprising finding is that consumer behavior is impacted by
promotional strategies like off sale,discount,gift etc.
BIBLIOGRAPHY
* Philip kotler, Marketing Management {9th Edition}
* CR Kothari : Research Methodology, Wishwa prakash : Method and techniques
* www.ricela.com
*www.google.co.in.
