Report For Oil Processing

ACKNOWLEDGEMENT
It’s a great pleasure to express my full thanks to HOD Dr. G A Usmani Sir and training in charge
Dr. H V Patil Sir for allowing me to carry out my in-plant training in AAK KAMANI Pvt. Ltd. I
am grateful to Mr. Ganesh Doifode sir, Vice President for accepting and permitting me to train at
AAK KAMANI Pvt. Ltd. With sense of gratitude and indebtedness I place on record my sincere
thanks to Mr. Manoj Gawande, Production Manager for his guidance, initiation, encouragement
and ever willing help which responsible for the completion of my successful training. I thank Mr.
Mahesh Bari sir and Mr. Pravin Pandey sir for helping and guiding me. I wish to acknowledge my
sincere thanks to the AAK KAMANI representatives Mr. Mahesh Ganwat sir (HR Manager) and
Mr. Shinde sir for the cooperation and encouragement. I am also thankful to Mr. Himanshu Shukla,
R&D Officer and Dr, P. D. Meshram sir and to all the operators of every plant who directly or
indirectly helped me during my training period.
UICT, NMU, Jalgaon

In-Plant Training Report
INDEX
Sr. No. Content Page No.

1 Introduction 2
2 AAK Kamani’s Products 4
3 Security 12
4 HR and Admin 13
5 Store 16
6 Oil section 18
7 Weighbridge 20
8 Accounts 21
9 Refining process plant 22
10 Dewaxing 26
11 Neutralization 27
12 Bleaching 30
a) Continuous Bleaching of Desmet Plant
b) Continuous Bleaching of Lipico Plant
13 Deodorization 37
14 Hydrogenation 49
15 Palm oil fractionation 55
16 PKS plant 58
17 Filling 59
18 Dispatch 61
19 Quality control and R&D 63
20 Acid oil plant 74
21 RO and ETP 76
22 Project 79
UICT, NMU, Jalgaon Page 1

INTRODUCTION
Company Profile
Kamani oil industry established in the year of 1962 at Chandivali Estate, Saki Vihar Road,
Andheri, East, Mumbai-400 072.the main director of kamani oil industry’s Mr. Nandlal Chawla.
They moved ahead with a manufacturing interest for Vanaspati Edible Oils. Kamani Oil Industries
Pvt Ltd is one of the leading manufacturing organization in the field of specialty oils and fat
products in India. We are the first Indian vegetable oil industry to be HACCP certified. Our mission
is to constantly innovate & improve our products to provide value to our customers while
maintaining a deep respect for environmental, industrial & food safety. We will constantly educate
ourselves on nutrition to provide healthy oils to the community. The company is dedicated to
providing highest quality oil and fats to the customers and has a wide range of products for
specialized applications to the food industry.
The company has a state of art production facility which has been constantly upgraded to
ensure production flexibility. Our product range includes whole range of vegetable oils, bakery
shortenings, margarines, confectionery fats, and dairy fats replacers, nutritional and healthy oils.
The company as today forayed into trading of agriculture products along with manufacturing of
vanaspati and edible oils with its business interest in many areas extensive distribution networks
and value added thoughts and services from our the company has diversified into different areas
and has become the empire pharmaceutical products and animal fodder wind power generation.
Besides it parent retrivities of manufacturing of vanaspati and edible oils. With its first class links
and contacts with its customers within India. AAK KAMANI PVT LTD. is one of the key players
in edible oil sector in countrywide. With state of art infrastructure and service to support for the
company today can adopt to any type of changing scenario.
The group turnover today exceed 36000 crore. The company is proud of having a large
integrated edible oil & fats complex. At Honad, Tal-khalapur, dist-Raigad, Maharashtra, with an
excellent team of qualified trend, committed and efficient employees, marshaled together with
exemplary team of managers. It consists of following founder directors.
Mr. Nandlal Chawla
Mr. Prakash N. Chawla

Salient Feature of Kamani Oils Ltd., khopoli
1. Name of Company:- kamani oil Pvt. Ltd.

2. Address:- Village- Honad, Khopoli Road, Taluka- khalapur, Dist- Raigad, Khopoli-410203,
3. Main Office:- kamani oil Pvt. Ltd. Chandivali Estate, Saki Vihar Road, Andheri East, Mumbai
400 072, Maharashtra
Information Regarding Industry
1. Year of establishment:- 1962

2. Major shareholder:- Mr. Nandlal Chawla
Mr. Prakash N. Chawla
3. Total Capital:- 36000 Crore
4. Area Occupied:- 23 Acres Construction
5. Products Exported:- Refine oils, Shortening & Margarine
6. Man Power:- Mgmt –60, Staff – 145
Worker – 70, Contractor –10
Contract Labour – 250, Security – 30
7. Transport Facility:- Trucks, Tankers & Trailers
8. Turnover:- 30Crore/month

PRODUCT DETAILS
KAMANI OIL INDUSTRIES PRODUCTS:
1) CONSUMER PRODUCT:
Klassic brings out the natural flavour of the food cooked in it and extends the freshness of
the same. Its cooking comfort makes every day cooking a pleasure, therefore making Klassic an
excellent cooking medium. Klassic is MUFA rich oil and hence has a high smoke point and shelf
life. This makes it suitable for deep-frying and safe for re-use. Thus, giving you the classic
advantages of health and economy. Klassic is produced using the best quality groundnuts (G.L.C.
Tested), in India's 1st HACCP (Global Food Safety System) certified vegetable oil refinery. Thus,
assuring you that the quality and purity of the oil.
Availble- 15 Ltr Jar/tin.

Komal Refined Sunflower Oil is visually appealing with its light yellow colour and superior
clarity. Processed to perfection, therefore possessing a bland taste to allow the natural flavour of the
food to come through. Refined Sunflower oil is rich in natural Vitamin E, which acts as an
antioxidant. It's health benefits, high smoke point and bland flavour, make it an excellent choice as
a cooking medium. Komal is produced using the best quality sunflower oil (G.L.C. Tested) in
India's 1st HACCP (Global Food Safety System) certified vegetable oil refinery. Thus assuring you
that the best of quality and purity.
Available- 15 kgs, Jar/tin
Karuna Vanaspati has a grainy texture with no oil separation. It is absolutely odorless and
bland to taste. It extends the shelf life of the product fried in it. It has god stability against
oxidation. Karuna Vanaspati is an ideal fat for general purpose cooking and frying. It is
recommended for the use of making sweets and snack foods.
Availables in 15kg tin.
2) PRODUCTS FOR FOOD AND RELATED INDUSTRIES :
Oils and fats form a critical ingredient in any food application. They help make the food
nutritious and enhance its taste. KOI offers a wide spectrum of oils and fats to suit every
customer’s needs. There is a continuous interface with the customers to understand their
requirements and provide technical support. Company research and development with its advanced
testing facilities is at the service of the customers for any kind of trouble-shooting issues and
provides cost–effective solutions, besides new product development. Company products find
diverse applications in areas like bakery, ice cream, confectionery, catering, snack food, frying,
pharmaceuticals and health food (nutritional supplements).

 BAKERY FAT / MARGARINE:
Great efforts are undertaken to fulfill the quality demands of bakers to satisfy their
customers. By understanding bakers’ needs, we have been able to provide the bakery industry with
a range of bakery shortenings and margarines to add profitability and value to their finished
products.
 FOR KHARI/ PUFF PASTRIES:
Specialty fat for Khari / Puff Pastry.

For Bakers preferring a HARDER consistency.
Specialty fat for Khari / Puff Pastry.

For Bakers preferring a SOFTER consistency.
Margarine for Khari / Puff Pastry.
Benefits : Gives good shine to products.

Good plasticity spreads easily.
Good layer separation.
Imparts long shelf life.
Pack Size Available:20 kg Carton
 FOR CAKES:
Margarine suitable for Cakes.
Benefits : Light, Spongy and Fluffy Cakes.

Excellent mouth feel.
Imparts long shelf life to the product.
Pack Size Available: 20 kg Carton

Aerated Fat suitable

for Icing and Creaming
Benefits : Excellent Icing having good mouth feel and fluffiness. Suitable for layering
and decoration. Nitrogen aerated cream extends shelf life. Excellent
brightness and visual appeal.
Pack Size Available: 14 kg Carto
FOR BISUCITS AND COOKIES:
Ideal for lighter and crisp Biscuits / Cookies.
Pack Size Available :20 kg Carton
 FRYING OILS & FAT
Snack food manufacturers require, that in addition to great taste, their products should
have extended shelf life and visual appeal. After working closely with our customers, we have
developed a complete range of frying oils.
Refined Vegetable Oil
 Ideal for frying application

 Imparts good taste, shine & crispiness to the product
 Extends shelf life of the product
 High smoke point
 Optimal oil absorption
Pack size available: 15 Kgs tin

Refined Coconut Oil
 Premium quality oil used for frying of nuts

 Low oil absorption
 High shelf life
 Imparts excellent shine to the finished product
Vanaspati
 Ideal fat for frying of sweets & snack

 Suitable for mixing with dough
 It has grainy texture
 Extends shelf life to the product fried
 ICE CREAM:
After thoroughly researching dairy fats, we have developed an alternative that is

now used by ice cream manufacturers. Our products give value to our customers. They accrue
financial and health benefits from the use of our products.
 Ideal replacer of dairy fat in frozen desserts

 Easy to mix and has better
temperature stability than dairy fat
 Absolutely bland in taste
 Convenient storage at room temperature
 100% fats

Pack Size available: 15 kgs Tin
 Premium quality coating oil for chocobars

 Clear & bland with excellent shine
 Desirable Melt Off
 Longer Shelf Life
Pack Size available: 20 kgs Tin
 Budget Oil for chocobars

 Clear & Bland in taste
 Longer Shelf Life
Pack Size available : 15 litres cartoon
 CHOCOLATE & CONFECTIONARY:

Company has developed an alternative to cocoa butter. By substituting cocoa
butter chocolate with these lauric–based “CBS” (cocoa butter substitutes), the manufacturer
achieves financial advantages and also a more efficient production process. Unlike cocoa
butter, CBS does not require tempering in chocolate process, which makes the production
process both simpler and safer for the chocolate manufacturer. These fats offer considerable
cost advantages compared to cocoa butter
Cocoa Butter Substitute for moulded chocolate
 Is a lauric based CBSideal for moulded chocolate products

 Has a good snap even at ambient temperature
 Displays good heat resistant compared to cocoa butter
 Has a steep melting curve giving good flavor release &mouth feel
 Requires single stage tempering unlike cocoa butter
 Is cheaper than cocoa butter & hence reduces cost of final product

Pack size available: 20 Kg Carton
Cocoa butter substitute for enrobing
 Is a lauric based CBS ideal for enrobed products and

panning application
 Gives a sharp melt off.
 Needs minimum tempering compared to cocoa butter
 Has an excellent oxidative stability
Pack size available: 20 kg Carton
Cocoa butter substitute for center filling
 Is a lauric based CBS suitable for soft centered candies

like Eclairs
 Has an excellent mouth feel & flavor release
 Gives excellent gloss to the product
 Has a sharp melt off
The confectionery fat
 Is a lauric based fat ideally suited for hard boiled confectionary

products
 Is a low melting product with high oxidative stability
 Is bland in flavor & odour
s

The confectionery oil
 Is a non lauric oil specially designed for Choco paste

 Is absolutely bland in flavor and taste
 Having low melting point, it remains as clear oil at ambient
temperature
 Has high oxidative stability & extends shelf life to the product
Pack size available: 15 kg Tin

SECURITY
Security is an important section in every industry which plays an essential role of in/out
records, received & dispatch records along with discipline in factory.
In Kamani oil Pvt. Ltd. There are two types of security present. (1) security by company,
(2) security by contractor. The Kamani oil Pvt. Ltd. Honad, has three security officers by company.
There are 30 guards on contract. There are 15 guards & 1 shift officer at day time, & 15 guards & 1
shift officer at night time. The in /out records include no. of visitors, labours, security guards,
vehicle and many more important things. The record of all labours in each shift, total no of labour,
total guards present in each shift with super wiser and vehicles inside the industry kept towards
security in-charge.
The records about discipline, theft/pilferage and major/minor accidents happened in

industry. It is also kept by security. If any theft found inside the factory he/she punished according
to his/her thievery. In every industry, there are some accidents happens with labours. These are
divided into three types-first aid, minor and major. Major accident includes loss of limp or life. In
oil industry, especially in edible oil refinery there are so many chance of fire because a lot of
chemical or hydrogen gas. These records are also kept in security system. The fire which
extinguished within 03 minutes is called as minor fire whereas which cannot extinguish within 03
minute is called as major fire.

HR & ADMIN
A Human Resource Management System (HRMS) or Human Resource Information

System, refers to the systems & processes at the intersection between human resource management
(HRM) and information technology.
The Concept of Human Resource Management (HRM)

The HRM concept is elaborated from different and varying view point. More so, the various
definitions of the concept, context and scope of HRM and its associated processes are presented.
HRM Definition
HRM as the part of the organization that is concerned with people dimension and it is
normally a staff or support function in the organization. HRM role is the provision of assistance in
HRM issues to line employees, or those directly involved in producing the organization goods and
services.
Fields of HRM
Survivors see HRM as strategic and target oriented composition, regulation and
development of all areas that affect human resource in a company. Efficient and effective
management of these resources to a large extend, affects human resource behavior, and
consequently the performance of the organization as a whole. Moreover, the survivors identified
HRM with the field it covers.
These include
1) Planning aspects-personnel requirements analysis and personnel asset
analysis,
2) Change aspects-recruitment, personnel development and labor displacement.

HRM Process
This sub section illustrates the process involved in executing the HRM function. Each of the
function: planning, recruitment, selection, orientation, and training, performance appraisal etc. goes
through a process.
1. Planning process
Human resource planning process reviews human resources requirements to ensure that
organization has the required number of employees, with the necessary skills, to meet its goal,
also known as employment planning. HRP is a proactive process ehich both anticipates &
influence an organization future by systematically forecasting the demand for & supply of
employees under changing condition and developing plan & activities to satisfy these needs
.key steps include forecasting demand for labor considering organizational strategic &tactical
plans, economic condition, market & competitive trends, social concerns, demographic trends.
2. Recruitment process
Recruitment is process of searching for & attracting an adequate no. Of qualified job
candidate, from whom the organization may select the most appropriate to field its staff needs.
The process begins when the need to fill a position is identified & it ends with receipt of
resumes & completed application forms. The result is a pool of qualified job seekers from

which the individual best matching the job requirement can selected. The steps in recruitment
process include identification of job openings.
3. Selection Process
Selection is the process of choosing individuals with the relevant qualification to fill
existing of projected opening. Data & information about application regarding current
employees, whether for a transfer or promotion or outside candidate for first time position with
firm are collected & evacuated. The steps in selection process, in ascending order include
preliminary reception job applicant, initial applicant screening selection testing, back ground
investigation. However, each step in the selection process, from preliminary applicant
reputation &initial screening to the hiring decision, is performed under legal and organizational
constraints that protect the interest of both applicant & organization.
4. Employee Compensation & benefits process

Employee compensation involves all form of pay or rewards accrued to employees&
arising from their employment. This however consists of two main components; direct financial
payment & in direct payment. While direct financial payment are in the form of wages, salaries,
incentives, commission & bonuses, indirect payment are in the form of financial benefits like
employer paid insurance & vacation.
Benefits are indirect financial payment given to employees. These may include
supplementary health & life insurance, vacation, pension, education plans &discount on say
company products. Furthermore, income & medical benefits to illness and their dependent,
regardless of fault are all part of employees compensation.

STORE
Procedure for store

1) Purpose: To receive, store & issue of material (excluding row oil) such as packaging
material tools, chemical processing aids equipment etc. from different supplier.
2) Scopes: To assist in verification of material received & provide supporting information for
effective purchase action.
3) Responsibility: store in charge and store supervisor.
Procedure:
1) When the material arrive at the gate, security inform to store and gate confirmation from
store about the material over phone, then person is sent to store to store with the challan.
2) Store supervisor inspects the material and checks with the P.O and allow supplier to take
material inside.
3) For packaging material quality is checked for packing item by packing supervisor and after
getting approval from QA Department the vehicle as unloaded.
4) The quantity as tallied with the challan and in case of discrepancy store department deducts
the weight from the challan, for the chemicals such as bleaching earth/carbon phosphoric
acid. The material is weighed at weigh-bridge and subsequently unloaded in plant. Store
inform to Q.C lab for quality approval after getting quality approval. Approved material is
marked with the green tag for identification of accepted material of material is rejected and
laying in factory it is marked with red tag. If material could not be analyses due to certain
reason, it is marked with yellow tag for identification of material on hold
5) The packing material is randomly checked by packing supervisor or concerned person as
per specification on approval store go-down in specific allotted areas.
6) Receipt the material is recorded in the material receipt resister.
7) For CPD requirement, marketing department inform to Purchase department directly for
purchase.

Storage of Food Chemical and Non Food Chemical

1) Food chemical are stored in designated area whereas nonfood chemical such as laboratory
reagent and laboratory chemical are stored in a separate designated area.
2) Processing aids such as bleaching earth, caustic and hydrochloric acid are unloaded and
stored near the plant after getting the approval from QC Department.
Procedure for issuing the material

1) store will issue material on basis of material requisition received form production
department
2) Material will be issue on first in first out basis.
3) Issue of chemical and engineering material will be recorded in the issue register.
4) Store department will mark which material to be release or to be kept on hold or to be used
on trial basis.
Procedure for rejection of material

1) If chemical or any engineering item are rejected by quality control lab or engineer, the
purchase department is informed party and supplier, the lot is returned back to party
cancelling supplier challan and by making store gate pass.
2) In the case of packing material such as jars and laminate the rejection is known during the
filling process/ the rejected material is kept aside and the sent to the supplier against
replacement is quantity is deducted from their bills.

OIL SECTION
It is the section which maintains the tank farm stock (deep) record daily and unloads
tanker which come from JNPT and tanker which are come out side of state. This department is
running in G +3 shift.
Total Tank In Tank Farm- 50

Refined Oil Tank- 24
Crude Oil- 26
Tanker sampling receipt of oil
Tanker receipt (Raw &Refined Oil)

1) Incoming of the tanker
2) Acceptance of the oil on quality specification.
3) Accounting of the oil
Tanker Sampling
The tanker should be checked for tampering the person who will be sampling
tanker should be clean his hands properly prior to opening of seal, all the challans and weight
slip must be checked.
The representative sample should be drawn as given below
A) Bottom sample- the open bottom valve slowly and the oil, if tanker has compartment collect
sample from bottom of each compart by opening valve. Collect equal quantity material
from each compartment in bucket this is bottom sample.
B) Top sample- the top sample is drawn by means of sampling tube, the tube is rinsed well
before drawing sample. Collect equal quantity material from each compartment in bucket
this is bottom sample.

C) Average sample- top and bottom A & B mix well this food in two 500ml bottles & labeled
appropriately.
1) Type of oil
2) Date of receipt
3) Tanker nos.
4) Original of oil
5) One of bottle is send for check QC
Caustic Lye:
Tanker receipt have following step involves
1. Incoming of tanker
2. Acceptance of caustic on quality specification issuing for process.
Tanker Sampling:
1. The tanker should be checked for tampering of oil prior to opening of seal.
2. All challans and weight slips must be checked at time of sampling.
3. A lab assist from QC department will be present along with sample bottle.
4. The person who will be sampling the tanker has to wear rubber gloves
5. The representative should be drawn as given bottom sample, open bottom valve
slowly drain out little caustic lye. The valve rinse the bucket with lye, if the tanker
has compartment then sampling will be done.
6. Collect the sample of from bottom of each compartment by opening valve.
Collect equal quantity from each compartment in bucket. This is bottom sample.

WEIGHBRIDGE
Weigh bridge is also important section on every industry which plays an essential role of
measurement of in/out material. In Kamani oil Pvt. Honad, the established weighbridge is made by
ROCKWAY WEIGHBRIDGE TECHNILOGIES. The bridge is operated on specialized software
provided by ROCKWAY WEIGHBRIDGE TECHNILOGIES. Normal weight system is used for
the quantitative measurement of all type of material to be checked. The specifications of Weight
Bridge is as below
1) Capacity:- 80MT
2) Minimum weight:- 250 Kg
3) Least count:- 10Kg
4) Length:- 40 Feet
5) Width:- 3 Meter
The daily average 100 tanker/truck in/out from this weigh-bridge.

ACCOUNT
For the financial transitions, there is special department by name Account Department in
every industry. The basis objective of accounts department is to keep records of financial
transaction on an accurate, transparent & time bound manner. Account department is also
responsible for preparing accounts of the council on monthly basis & yearly basis are also placed
before the council in its meeting.
The main duties performed by the officers of account are as follows

1. To record initial entries of all financial transaction in focus.
2. Preparation & submission of monthly account.
3. Preparation & submission of monthly progress reports of works in progress/targets.
4. To prepare & submit the annual account of the factory.
5. To control the budgets & maintain the account books of records for budgetary control.
6. To pass all bills of expenditure after proper scrutiny & exercising all the checks.
7. Prepare passing salary bills for all regular employees& filling of monthly, yearly Income
Tax.
8. Passing of bills relating to TA/DA Advance, final bills of TA/DA etc.
To make payment of all vouchers as passed & received on day to day basis.

REFINING PRACTICES IN PLANT
Crude oil must refine to remove free fatty acids (FFA), phosphatides or mucilaginous
material that impact flavor, odor, and appearance of the finished product.
Aim of Edible Oil Refining:
More than 95% of the constituents of most crude oils and fats consist of mixtures of
triglycerides. The non-triglycerides fraction contains variable amounts of phosphatides, free fatty
acids (FFA), oxidation products, unsaponifiable matter (tocopherols, sterols, hydrocarbons, etc.).
The quantities of these minor components in crude oils vary with the oil source, extraction process,
season and geographical origin. They can have different effects on the nutritional, functional and
organoleptic properties of the oil.
The general objective of refining is to remove those components that have an adverse effect
on the overall oil quality with the least possible damage to the triglycerides. At the same time
minor components with a known positive impact have to be retained as much as possible in the oil.
Some components, such as fatty acids, mono and diglycerides and phosphatides are of
glyceridic origin. Although phosphatides protect the crude oil from oxidation, they need to be
removed because of their negative effect on the color and taste of the oil. Other minor components
can be isolated in the unsaponifiable fraction. The main components of the unsaponifiable fraction
(0.3-2.0%) include: sterols, tocopherols, hydrocarbons, pigments (gossypol, chlorophyll, and
carotene) and vitamins (vitamin E).
There are two types of refining process in common use today: physical and chemical
refining similar steps are taken in both processes but with distinct objective generally vegetable oils
like palm and palm kernel oil are physically refined for it is more economical the choice process
relies normally on the convenience and the cost of the process.
Crude oil processing to refining of various seed oils and has delivery capability from single
section to a complete refinery. We focus on energy conservation, lowest utility requirement, less
effluent discharge, low environmental pollution, highest yields and best quality products.

Two Steps Involve in Refining Processes:
1) Physical Refining
2) Chemical Refining
Physical Refining: (Flow sheet)

Chemical Refining: (Flow sheet)

The Most Common Steps of Oil Processing Includes
Plant process wise
PLANT I
1. Dewaxing
2. Neutralization
3. Bleaching
4. Deodorization
PLANT II
5. Hydrogenation
6. Inter-esterification
PLANT III
7. Fractionation of palm oil
PLANT IV
8. PKS
PLANT V
9. Acid oil plant

DEWAXING

Capacity- 50 TPD
 Manufacture- Glamtech Ind.

Area- 600 sq. feet
 Two crystallizer with one precoating tank
Dewaxing is an operation designed to retain brightness of refined oils specifically of

sunflower and corn oils through filtration.
The process in removing small quantities of material that causes cloudiness when the oil is
kept at ambient or low temperature. These solid substances can be saturated long chain glycerides
or waxes thanks to the relatively small amount of these components winterizing is a cost-effective
process. In order to obtain bright shining oil with good stability, the wax content needs to be
reduced to a minimum level preferably less around 10 ppm. To achieve this variables of time,
temperature require special control to produce oil.
The process is conducted in four steps:
 Oil is pre cooled crystallizer up to 9 degree with help chilled water it inlet temperature is 2-
6 degree Celsius.
 Filter aid (1%) is added and the oil is cooled very slowly.
 Oil is few times for maturation.
 Cooled oil is than filtered. Filter oil temperature should not be goes above 15degree
Celsius.

NEUTRALIZATION

Plant capacity- 200 T/D
 Washing/ neutralization-Mfg- mectech (West Fallia Separator)

Neutralization area- 600 sq. meter
The first step in the conventional chemical refining process consists of neutralization. In
this step, the FFA, phosphatides and a large portion of the pigments are treated with caustic soda
and removed from the oil by centrifugation. In general, the neutralization consists of three steps:
neutralization, washing and drying. For trouble free neutralization, the phosphorous content of the
crude oils should not exceed 250 ppm. This means that most seed oils require water degumming
prior to neutralization resulting in less emulsification and consequently lower oil losses. The alkali
solution reacts preferentially with FFA to form water-soluble soaps. Residual phosphatides present
in degummed oil or all the Phosphatides of crude oil react with the caustic solution to form oil
insoluble hydrates.
Prior to the addition of any chemical agent the crude oil is heated to the optimum
processing temperature. For the most oils such as soybean, linseed, till or sunflower oil the
optimum temperature is approximately 90°C. However, more sensitive oils such as cottonseed and
rice bran oil should not be heated above 65°C to avoid color fixation.
In the first stage, caustic soda is added to the crude oil. Depending on the type of oil and the
initial %FFA content. The caustic is prepared by dilution of Sodium hydroxide with softened water
to a specific gravity of about 18-20°Be. The higher the initial FFA content, the more concentrated
the NaOH solution added to avoid emulsification. Intensive mixing with dynamic (centrifugal) or
static mixers is necessary to ensure good contact between the caustic soda and the oil. At this stage,
the caustic soda converts FFA and NHPs into water-soluble sodium salts. In this way, it is possible
to obtain residual FFA and phosphorous levels below 0.1% and 10 ppm respectively. Generally, a
small excess of 10-20% on top of the stoichiometric quantity of caustic soda is added to promote
the saponification reaction. However, excessive saponification has to be avoided to prevent
excessive loss of oil.
The alkali solution is added slowly to the oil and allowed to mix thoroughly. The fatty acid
soaps and phosphatides form a stable thick emulsion with the oil. This emulsion may be partially
broken by heating the oil-soap-stock-water mixture and then passing it through a refining
centrifuge where the lighter density oil is separated from the higher soap-stock water portion.

CONTINUOUS NEUTRALISATION PROCESS:
1) First make caustic mixture, should be 20°be (14 – 15%)
By below calculation can calculate caustic quantity
2) Keep temperature of hot water tank should be 85 to 95°C.

3) Oil take from crude oil tank in charging tank which continuous heat through plate heat
exchanger to keep temperature 75 to 85°C.
4) Phosphoric acid (98%) dosed 0.05 to 0.2 % as per quality and type of oil mixed with oil in
knife mixer and send to RT 1 tank.
5) After that this oil heated by plate heat exchanger and sends to knife mixer.
6) Caustic dose by caustic pump which is set as per FFA of oil in knife mixer, Every 15 to 20
minutes sample check with add HCL if color becomes pink means caustic set is ok.
7) Then this mixture of oil and caustic send to RT2 tank.
8) Then this oil passed through plate heat exchanger which temperature maintains 95
to 100°C.
9) Then this passed to soap separator (west fallia separator) to remove soap and FFA of oil.
nd
10) Then this oil cooled through plate heat exchanger and transfer to 2 separator for
washing with water to remove remaining soap and FFA.
11) Every 15 to 20 minutes sample check with add HCL, if color becomes pink means caustic is
present in oil.
12) After that neutral oil continuously goes in process tank and same time soap also goes
to soap tank.
13) After that check wash oil sample for FFA and soap ppm , if FFA is more than its control
by set caustic dosing as per requirement and if soap ppm is more than its control by adjust
by hot water and citric acid dosing.
Factors that have influence separation efficiency include: -

1. Differences in density between the phases
2. Feedstock temperature with higher temperatures improving efficiency.
3. Viscosity differences
4. Centrifugal force
5. Centrifuge residence time

BLEACHING

Bleaching- one slurry make up tank & one bleacher of Desmet Plant & continuous
bleaching with Two PLF

Bleaching- one slurry make up tank & one bleacher of Lipico Plant & continuous bleaching
with Two PLF

Area- 20 sq. meter each
Bleaching is the term given to describe the adsorptive cleansing process associated with
edible oil refining. This process, involves acid pretreatment, introduction of and a retention period
with a bleaching agent and removal of the clay and absorbed materials.
The bleaching process removes color bodies, residual soaps, and phosphatides from crude
or alkali refined oil. The color bodies are mainly chlorophyll, carotenoid and xanthophyll. The hot
(105°C) vegetable oil is slurries usually with acid activated bleaching earth or clay. The bleaching
clay or earth is generally calcium montmorillonite or natural hydrated aluminum silicate,
commonly called bentonite. Non-acid bleaching clay (attapulgite), silicon dioxide and activated
carbon may also be used as absorbents.
The quality of the bleaching earth is of the almost importance. If the granulometry of the
earth is too fine the precoating 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 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.
Oils with very low phosphatide content, for example palm oil is not degummed separately
but only undergo dry acid degumming prior to bleaching.

The phosphatides are adsorbed on the bleaching clay and removed as such from the oil.
After addition of acid a sufficient residence time is given then oil is dosed with the clay and other
agents such as filter aids. Prior to bleacher oil must be heated to bleaching temperature. Under
vacuum conditions, the oil is agitated in the compartmentalized bleacher for several minutes and
then delivered to one of two bleaching filters for removal of solid materials.
In soybean oil refining, color reduction occurs at each step, nevertheless, the most
significant reduction of chlorophylls occurs in the bleaching step. Acid-activated bleaching clay is
most effective in adsorbing chlorophylls and decomposing peroxides and it is commonly used for
soybean oil. The chlorophyll content in normal crude soybean oil (1–1.5 ppm) can be reduced by
25% by alkali refining and bleaching with acid earth further reduced chlorophylls. The subsequent
hydrogenation and deodorization remove or degrade red and yellow pigments more than
chlorophyll so incomplete chlorophyll removal by bleaching causes the refined oil to appear
greenish. The refined and bleached oil is particularly susceptible to oxidation and is less stable than
the crude, degummed, refined or deodorized oils.
The heated oil is sent to the bleacher. The bleacher continuously receives the oil/earth
mixture from the mixer. A uniform retention time is obtained in the vessel by connecting it with
buffering tank. The mixture is agitated by spurge steam injection through nozzle and crown
installed at the bleacher bottom. This agitation under vacuum avoids decantation and maintains the
dispersion of earth in the oil. The mixture reaches the normal level of the bleacher and the level is
maintained constant by returning filtered oil through level controller valve.

.
Bleacher/Slurry tank.
Filtration by PLF:
The mixture in bleacher is pumped to the filters (PLF). PLF is hermetic filters equipped
with stainless steel filter elements to remove bleaching earth and precipitated matters. The filters
work discontinuously so alternately PLF is used for continues filtration. When the filter cake
becomes too thick, filtration is stopped and the filter is cleaned.
PLF (Pressure Lift Filter)

When the filtration is finished and the oil is drained from the filter, the filter cake of spent
bleaching earth contains about 80% of oil. This oil can be partly recovered by blowing the cake
with steam. The oil is entrained by the steam and separated from. After blowing with steam for
about 30 min., the cake is discharged through the bottom of the filter by vibration of the filter
screens. The steam escapes to the atmosphere after passing through the scrubber. The small amount
of steam that condenses it is drained to the sewer after decantation. When high level the valve is
opened and the separated oil is sent to the bleached oil tank (BOT).
The two filters are mounted in parallel for continuous filtration.
Prior to entering the deodorizing section, the oil is pumped through polishing filters where
remaining particles are retained.

Polish filters
CONTINUOUS BLEACHING PROCESS DESMET PLANT:
1) Oil from Neutral oil tank (T 501) is heated continuous through plate heat exchanger
and goes in slurry tank and dosed phosphoric acid as per requirement.
2) Due to oil bleachability, flow rate and powder mixture should be bleaching earth 0.05 to 3%
and carbon 0.05 to 2 %.

3) Bleacher vacuum should be 650 to 700 mm Hg and keep oil temperature 95°C to 120°C.
4) Filtration is continuous done through pressure lift filter, for open new filter circulation is
done for 15 to 20 minutes from pressure lift filter to bleacher and when powder is
completely remove from oil then passed this oil through polish filter bags to bleached oil
tank. Take care that powder will not contaminated with oil.
5) After that bleach oil send to process tank (bleach oil tank BOT 801/1/2).
6) Sample should be check on every 2 hours interval.
CONTINUOUS BLEACHING PROCESS LIPICO:

1) From process oil tank oil continuous heat through plate heat exchanger no. 1
2) After that this oil heat up to 130°C through plate heat exchanger no. 2 by boilers steam.
3) Phosphoric acid (H3PO4) dosed 0.05 to 0.2 by dosing pump.
4) Make the mixture of oil and phosphoric acid in mixer.
5) After this oil comes in slurry tank.
6) Oils flow rate and powders (bleaching earth) mixture set by PLC.
7) Due to oil bleachability, powder mixture 0.05 to 3% and carbon 0.05 to 2% necessary.
8) Slurry tanks/Bleacher vacuum 200 to 250 mm Hg and buffer tanks vacuum 100 mm Hg.
9) Keep the bleacher temperatures 95°C to 120°C.
10) Filtration is continuous done through pressure lift filter (PLF) for open new filter circulation
is done for 15 to 20 minutes from pressure lift filter to bleacher and when powder is
completely remove from oil then passed this oil through polish filter bags to bleached oil
tank. Take care that powder will not contaminated with oil.
11) Then drains this bleached oil in process tank (Bleached oil tank).
12) Check the sample on every 2 hours interval.

DEODORIZATION
 PLC OPERATED PLANT
 Deodorization: Mfg. by Desmet ballestra
 Capacity- 200 TPD
 Deodorization: Mfg. by Lipico Refinery
 Capacity- 300 TPD
Deodorization is usually the last step in edible fats and oils processing. The purpose of
deodorization is to remove the remaining traces of volatile components, including flavor and odor
compounds (mostly aldehydes and ketones), color bodies, FFA, pesticides and herbicides, moisture
and dissolved gases. The goal of deodorization should be to obtain a nearly flavorless and odorless
product with low FFA (normally less than 0.05%) and light color.
Deodorization is primarily a high temperature, high vacuum steam distillation process to
remove volatile, odoriferous materials present in the edible oils and fats. These odoriferous
compounds are stripped from the relatively nonvolatile oil because of the differences in the
volatility between triglycerides and the flavor compounds. The thermal treatment occurring during
the deodorization process also heat bleaches the oil by destruction of carotenoids at elevated
temperatures. The flavor and oxidative stability of the oil increases by removal of odor and flavor
compounds and by thermal decomposition of peroxides.
The total deodorization process comprises a number of processing steps as given below.
 De-aeration of the oil.
 Heating of the oil to deodorization temperature.
 Steam stripping of the oil in deodorizer.
 Cooling of the oil.
1) De-aeration:
The bleached oil is feed in to de-aerator tank (kept under vacuum) between the
bleaching section and the deodorizing section. The vacuum line is connected through vacuum
assembly. Temperature is maintained by passing steam through the coils and spurge steam is
injected for agitation, which leads to good de-aeration. Level switches are provided for high
and low level.
2) Heating of oil to Deodorization temperature:
The oil is heated at the deodorizing temperature in the upper stage of the deodorizer
with high-pressure steam. Spurge steam is injected for deodorizing purpose and to promote
agitation in order to increase the heat exchange. Initial deodorization and partial fatty acid
distillation take place in this tray.
0
In continuous operation, bleached oil feed at 90-95 C by pump is preheated in the heat
exchanger with deodorizing oil (oil to oil) then it again preheated in PHE with steam up to 120-
130 .
After two PHE heat exchange oil feed to first Shell and tube heat exchanger, in which
o
hot deodorizing oil (250-260 C) heated bleached oil up to 190-200 . Then oil feed to second
STHE in which thermic fluid or Geka boiler system (Thermosyphan) is used. The oil heated up
to 240-250 . Also super saturated steam of is used in deodorizing for Steam stripping.
A final heating is performed in the deodorizing trays in order to gently reach the final
deodorizing temperature.
Two-temperature deodorization brings the following advantages:


Low temperature during optimal residence time for deodorizing

Higher temperature for final stripping of undesirable compounds.

Low trans-summarization and polymerization

Gentle deodorization at relatively low temperature

Controlled distillation of tocopherol and other minor components

Negligible carry-over
3) Steam Stripping In Deodorization:
In deodorizer, steam is spurge into the de-aerated oil. External heating plus the steam
heats the oil to more than 200°C under high vacuum. As the oil passes through several trays or
compartments with a specified residence time, the volatile components are stripped away and
separately condensed. The oil flows by gravity through an overflow in each stage and from
stage to stage through steam lift pumps in order to distillate the free fatty acids and odorous
matters. The combination of the action of the rings (perfect and even steam distribution
throughout the entire deodorizing tray) and of the steam lift pumps (intensive agitation,
bringing the oil from the bottom of the tray back to the top area where deodorization/distillation
occurs) ensures an optimal deodorizing quality with minimum steam consumption.
4) Cooling of oil:

Thereafter the oil passes through the shell and tube heat exchanger first where the
deodorized oil is further cooled by incoming bleached oil. Then the oil passes through the plate
heat exchanger with cool bleached oil. Finally the oil is passes through the plate heat exchanger
with cool water. The temperature is set at 45°C.
Polishing filters:
The deodorized oil is filtered through the polishing filters to remove any impurities, which
might still be in suspension. The size of the screen is below 10 microns. This operation is called oil
polishing, and gives the oil its ultimate brilliancy. From here the oil is sent to storage tank and from
there for final packing.
Chelating agents including phosphoric acid, citric acid and lecithin may be added to deodorized
oil to deactivate trace metals. Depending on the end product, stability may be enhanced not only by
using proper deodorization conditions but also by adding antioxidants, including TBHQ, BHA,
BHT, ascorbic palmitate, natural extracts, or tocopherols. Nitrogen blanketing may also be used to
protect the heated oil from oxidation during storage. It is theorized that the development of
substances detrimental to flavor occur rapidly at temperatures present in the deodorizer and without
constant removal of these volatile components, the oil quality is affected.
FFA Recovery:
The vapors leaving the deodorizer through the ducts contain fatty acids, odoriferous
substances, unsaponifiable matter, water vapor and entrained oil. This fatty material is recovered in
°
the fatty acids recovery circuit by cooling the vapors with liquid fatty acids at 45 to 50 C.
A very large gas/liquid contact surface is obtained by spraying liquid fatty acids through a
set of sprayers installed in the connecting pipes between the deodorizer and the condenser
Spraying cold fatty acid on specially designed structured packing in fatty acid condenser
further enhances this large contact. The liquid phase and the vapor phase are traveling in co-current
flow in order to limit the pressure drop to a minimum. The gases are further sent to scrubber, where
the finer fatty acid distillate droplets are separated. The two effects lead to a negligible fatty acid
carry over to the vacuum unit and to the hot well. The droplets thus formed are collected in the
bottom part of vessels from where they are pumped through PHE for cooling and finally pumped in
to storage tank.

Operating Parameters:
 Temperature: 250°C (other oil), 260°C (cpo)
 Vacuum: 2-3 torr

2
 Stripping steam: 0.2 to 2.5 kg/cm
2
 Booster Steam (H.P.):8-10 kg/cm (designed), 11kg/sq.cm (operated)
0 0
 Final Oil Temp: 50 c (+/- 5 c)

LIPICO PLANT
PHYSICAL REFINING:
Physical refining means neutralization process of oils and fats by separation, through
distillation by injected steam, of the fatty acids present in the oils and fats.
 The oils and fats are heated up to high temperature (230-250°C) so as to remove the fatty acids
by distillation in a steam current and at these temperatures many oils and fats undergo certain
modification to their molecular structure and consequently their chemical and physical
characteristics are modified (such as color, taste, spectrophotometric properties etc.).
 Before being neutralized by distillation the oils and fats have to be perfectly purified and
bleached and these operations are often so expensive that they cancel out the advantages of
having a higher yield of neutral oil.
Generally the operation is carried out under the following conditions:
1. Absolute pressure: 1-2 torr
2. Striping steam: 40-50 kg/ton of oil
The requirement of physical plant:
a) Prevention, as far as possible, of air entering the apparatus.
b) Installation of efficient high vacuum producing equipment.
c) Careful designing of steam pipes since the volume of steam and air at low absolute pressure
is enormous.
Advantage is that while in the caustic soda process the fatty acids are converted into soap
stock- which must be further processed to obtain acid oil containing about 70% fatty acids but
physical refining procedure yields directly distilled fatty acids 85-90% free fatty acid (F.F.A.)

Physical refining plants have to meet the following requirements:
a) They should work in a safe and continuous way at a pressure of 1-2 torr.
b) They should have sufficient retention times for the oil in the neutralization stage, in fact to
have also proper deodorizing the retention time should be 90 – 100 minutes.
c) Use as much as possible heat exchangers between the neutralized and deodorized oil
coming out of the neutralizing unit and the acid oil flows in the plant because it is just the
calories consumption which affects more the cost of the operation.
d) Use thermal fluids whose temperature is easily adjustable because even a few degrees of
temperature difference can negatively affect the whole process. Nowadays this no longer
represents a problem thanks to self-adjusted diathermic fluid heating units.
e) Use live steam injection system which makes it possible to spray it uniformly in the whole
oil mass during the entire path in the neutralizing and deodorizing column.
f) The oil layers should not be very thick.
g) Use carefully designed pieces of equipment to avoid that fatty acid traces pollute the water
of the barometric leg.

CONTINUOUS DEODORISATION PROCESS LIPICO:
1) Bleach oil (110°C to 120°C temp) passed to deodorizer from bleached oil tank by pump
through plate heat exchanger through vacuum heat exchanger.
2) After that oil passed through final vacuum heat exchange.
3) Required temperature comes in final vacuum fluid heat exchanger by thermic fluid and used
open steam for heating.
st
4) After that oil comes continuous in deodorizer’s 1 tray through stripping column.
st nd rd
5) After that this oil step by step overflows from 1 to 2 then 3 tray.
6) Open steam system in deodorizer and vacuum fluid heat exchanger, vacuum heat exchanger
2
0.07 to 2 kg/cm controlled by PLC system.
7) After that this oil cooled by vacuum heat exchanger by bleached oil.

8) After that oil passed through plate heat exchanger no. 1 for cooling by crude oil.
9) After that oil passed through plate heat exchanger no. 2 for cooling by water.
10) Final oil temperature 50 to 70°C controlled and filters through polish filters and sends to
storage tanks (R3 or R4).
LIPICO FLOW CHART:
Crude oil temp - 50°C - 60°C
Flow rate of oil – 13000 – 15000 lit/hr
0
Oil temp through PHE-90 c (oil to oil PHE)
0
Oil temp through PHE- 120 c (oil to steam PHE)

Degumming tank (H3PO4 dosing)
Bleacher temp - 120°C (bleaching earth dosing)
Buffer tank temp - 120°C
Pressure in PLF – 0.1 – 2.5 bar
Polish Filter
Bleached oil temp - 125°C
0
Oil temp through PHE 190 c (oil to steam PHE)
Vacuum heat exchanger 1 temp - 215°C
Vacuum heat exchanger 2 temp - 250°C - 265°C
Deodorized temp - 255°C - 260°C
Final oil temp – 50 °C - 60°C
Fatty acid distillate temp - 60°C - 65°C

CONTINUOUS DEODORIZATION DESMET:
st
1) From bleach oil tank oil transfer to BOT (801/1,801/2) which comes in Deodorizer’s 1 no. tray
by PLC in definite quantity which is control by PLC system.
st
2) After this bleach oil temperature 120 to 135 °C control by PLC system, 1 no. trays valve drain
nd
in 2 no. tray
nd
3) Deodorizer’s 2 no. trays oil temperature 180 to 195°C comes due to heats oil by thermosiphon
nd rd
then 2 no. trays drain valve open it and oil drops in 3 trays. During this period oil continuous
st
comes in 1 no. tray of Deodorizer’s from bleach oil tank
rd
4) Deodorizer’s 3 no. trays required temperature is 225 to 270°C by the Geka boiler.
th
5) After that this oil drains in 4 no. trays and deodorized.

6) Deodorizer temperature and time controlled by PLC
th th
7) Then this oil drains in 5 no. tray and again deodorized and drained to 6 no. tray
th th
8) This 6 trays oil is cooled by thermosiphon up to 170 to 180°C and drain to 7 no. tray.
th
9) Deodorizer’s 7 no. trays oil is cooled up to 110 to 120°C by water from reverse osmosis (RO)
plant.
th
10) Last this oil comes in buffer tray means 8 no. tray and cooled through PHE up to 40 to 60°C
th
11) Fatty acid transfer from Tray no 9 by fatty scrubber and store in fatty acid storage tank
12) Then transfer this oil from final polish filter for polishing and transfer to the storage tank R1 or
R2 tank
DESMET PLANT
DESMET PLANT FLOW CHART:
Crude oil temperature - 60°C to 70°C
Flow rate of oil - 11000 to 14000 lit/hr
Oil temperature through PHE - 75°C - 90°C

Slurry tank temperature - 75°C- 80°C
Oil temperature in bleacher - 90°C - 110°C
Pressure in PLF – 0.1 – 3.5 bar
Polish filter
Bleach oil tank temperature - 80°C- 90°C
Through final PHE oil temperature- 110°C
Feeding in Deodorized oil temp - 110°C - 115°C
Deodorized 1 trays temp - 140°C
0
Cooling through PHE – 50 to 60 c
Fatty acid distillate temp- 50°C - 55°C

HYDROGENATION

Manufacture- by Mectech

Capacity- 200 TPD

Plant area- 700 sq. feet

PLC Operated plant
Hydrogenation of a fat is the direct addition of hydrogen at the double bond in the fatty
acid chain. This reaction, which is accelerated in the presence of a catalyst-almost always
nickel converts oleic acid to stearic acid. This reaction is normally performed batch-wise in a
hydrogen pressurized stirred reactor. The agitation is necessary to suspend the catalyst and to
effect solubilisation of the hydrogen, thus enabling it to react on the surface of the catalyst with
the double bond in the oil. Hydrogenation is unique among the unit processes employed in oil
and fats manufacture in that it alters the molecular structure and composition of the glycerol
ester.
Hydrogenation is generally performed for one of two specific reasons:

1) Improving the flavor stability of fats and oils by retarding their deterioration through
oxidation
2) Consistency and other properties like SFI (Solid Fat Index) added to the oil, so that it
matches in physical condition with genuine Ghee.
On further processing in specialty fats hydrogenated fat is initial raw material. That
means it converts liquid oils into plastic fats usable in a wide variety of cooking and backing
applications.
The hydrogenation reaction requires a catalyst. In the edible oil industry, the catalyst of
almost universal choice has been Nickel. Nickel catalyst used in both fatty acid and edible oil
hydrogenation is usually in a finely divided form as is appropriate for batch slurry processing.
The catalyst is suspended in the oil during hydrogenation and is afterward removed by filtration.
Catalyst employed for triglyceride hydrogenation decrease in activity with use. The degree of

inactivation principally depends on the purity of the feedstock. Catalyst is sometimes reused.
However, since the impurities that collect on the catalyst also have an effect on selectivity, fresh
catalyst is usually employed in some applications. Since acids chemically react with nickel to
form non catalytic soaps, only a single use is possible for fatty acid hydrogenation.
(a.) Consumption of Hydrogen gas is calculated by this formula:
Consumed H2 gas = 0.9 * IV reduction (cubic meter/ton)
Suppose,
IV of refined oil is 128, and we want the IV of hydrogenated oil is 110.
IV reduction = 128 – 110 = 18 unit
By this formula, Consumed H2 gas = 0.9 * 18
= 16.2 (cubic meter/ton)

Theoretically, 0.9-m3/ton hydrogen consumed of any type of oil, for dropping of one unit of IV.
(b.) Hydrogenation:
Hydrogenation consists of direct addition of hydrogen at the double bonds in the fatty acid
chains of the triacylglycerol, or oils. For hydrogenation to take place, gaseous hydrogen, liquid oil,
and nickel catalyst are placed in a specially designed reaction vessel under controlled temperature
and pressure.

The process can be described as follows:
1) First, bleached and deodorized oil taken from charging tank and check iodine value of
sample.
2) Then this oil send to autoclave through cooler. Capacity of autoclave is 13 ton.
3) Oil temperature keep maintain for lauric and oleic 150°C and for palmitic 180°C in
autoclave.
4) After that add fresh catalyst or spent catalyst as per oil type and H2 gas added as 0.2 to
2
2 kg/cm pressure as per oil type.
5) In this tank the oil is steam-heated, during which, it is evacuated off any gases. After
desired temperature and pressure is reached, the oil is sent to the holding tank during
this process check samples melting point and iodine value.
6) Measured amount of hydrogen is incorporated into the oil after brief period of agitation
of oil and nickel catalyst in an autoclave, kept for 3-4 hours.
7) If melting point and iodine value comes in range then this oil drop in cooler.
8) Again oil charge to same autoclave and keep coolers temperature 95 to 110°C.
9) The oil is filtered in a candle filter. During filtration filling, coating, pre-filtration,
circulation, emptying, cake drying, venting and discharge steps are carried out.
Candle filter
10) Finally filtered hydrogenated oil is then pass through PHE of cooling water to
decrease temperature and gets stored in hard oil tank. The stored oil is again bleached
and deodorized to get the final product.
The most important factors governing the product are the number, size, and structure of the
crystal solids dispersed in the liquid oil. A slowly cooled fat crystallizes in relatively few and large
granular clusters. Such a fat exhibits less plasticity and is not as firm as is a rapidly chilled fat
where many small and well-dispersed crystal solids are developed. A fat with large crystals has a
‘gritty’’ feel in the mouth and can best be demonstrated by heating and subsequent cooling of a
commercial shortening product.
The properly prepared product appears homogeneous and has an agreeable mouth feel, an
uncontrolled heating and subsequent cooling operation produces a fat with large crystals, in which
the liquid and solid portions may separate. Because crystals of the solid fat fraction are
polymorphic (existing in more than one crystalline form), quick solidification and subsequent
plasticizing functions require careful control to ensure functional products with stable crystalline
structures. The conditions of super cooling can be established to take advantage of crystal
reorientation, or tempering, which is allowed to take place during storage. Proper crystal
reorientation yields a higher melting product and a more stable crystal pattern.

Hydrogenation:
Table 1:
Oil Type Heating Temp °C Catalyst Kg Catalyst Type Cooling Temp °C
PKO 150 13 Kg 2021 120

PKS 150 10 Kg 2021 110-170
Mix Oil 150 8 Kg + Spent Catalyst 4013 110-160
Soya 150 20 Kg 6016 110-120
Palm Olein 170 13 Kg 1051 110-155
Palm Stearin 150 15 Kg 4013 110-120
Coconut 170-180 13 Kg 2021 110-120
Quality test for hydrogenated oil:
Determination of Nickel in vanaspati:
Procedure:
Nickel can be determined both by spectrophotometric method as well as by Atomic

Absorption Spectrophotometer using graphite furnace.
The Spectrophotometric method involves burning of 20 – 25 gm of vanaspati in a platinum
0
dish on a low flame, followed by ashing in muffle furnace at 500 C, dissolving the ash in about 5
ml of conc. HCl followed by removal of excess acid by evaporation to dryness and dissolving the
residue in water and making up to a known volume. An aliquot of the solution (5 - 10 ml) is taken
in a 25 ml
Volumetric flask 0.5 ml saturated Bromine water is added, allowed to stand for 1 minute,
followed by addition of 1 ml of ammonia and 2 ml of 0.1 % dimethyl glyoxime solution in 95 %
alcohol and mixed. The final volume is made up to 25 ml with alcohol and the absorbance maxima
are recorded at 445 nm within 10 Minutes of addition of the dimethyl glyoxime solution.
A standard stock solution of Nickel is prepared separately by dissolving 2.2617 gm of
Nickel Sulphate (A.R, 99.9% Pure) in 30 ml of conc. HCl and making and making up the volume
to 500 ml with distilled water. This solution contains 1000 ug Ni / ml Working standards are
prepared by diluting the stock solution to give 0.1 – 1.0 ug / ml Nickel. A calibration graph is
prepared with different working standards and the amount of nickel in the sample is extrapolated
from the standard graph.
Vanaspati Quality Parameters:

A) Physical Parameters:
1) Organoleptic parameters: Bland with no rancidity, Free from other flavor.
2) Physical Appearance: Shall not contain any coloring and flavoring material.
3) Appearance: Clear on melting.
4) Color unit: Max 6
5) Melting Point - 41
B) Chemical Parameters:
1) %FFA- 0.1
2) Baudin test- 2
3) Peroxide Value- Up to 1.5
4) Nickel (ppm)- 0.5
5) Mineral test- Negative
6) Caster oil test- Negative

FRACTIONATION OF PALM OIL
Plant Capacity: 600 T/Day

Crystallizers: 6 Crystallizers, 40 T each
2Crystalizers, 20 T each
Agitators – Pitch Blade Type
Filter press: Membrane filters 2 Nos.
LIPICO
Filtration area 265 Sq. Mt.
Filtration Options:
1. Filtration
2. Squeezing
3. Air Blower
4. Cake discharge
5. Washing
Specifications:
Palm Oil –
0
Melting point 37-40 C
%FFA 0.13 – 0.17
I.V. 53 - 54
Olein –
0
Claude point 4 –5 C
%FFA 0.10 to 0.15
Yield 80 %
I.V. 57 (for super olein it is 62)
Stearin
0
Melting Point 50 – 55 C
Yield 20 %
I.V. 32 – 37 (avg. 33)

Process description:
1. Bleached refined & deodorized palm oil from plant – 5 is first fed to crystallizer.
0 0
2. The oil enters at 60 C is cooled up to 20-24 C by means of cooling coils at agitation of
50Hdz.
3. The retention time is up to 8HR. The crystals are formed at specific temperature and
disperse in oil phase.
4. The mixture is passed through pressure suction where pressure is adjusted for filtration
(i.e. feed and pressure)
5. Then filtration is started at the pressure 2-4 bar. Feed pump is cut off at time pressure.
The filtration takes place in following manner –
1) Filtration
2) Squeezing
3) Air blower
4) Cake discharge
5) Washing
Membrane consists of polypropylene cloth. During filtration olein is removed and

stearin cake remains behind the membrane. This is followed by squeezing to remove
trapped oil and then inert air is passed to remove oil remained in course. i.e. air blow. This
oil is again send to crude palm oil tank. The cake is discharged at bottom. The filtered
membrane is washed by wash oil or olein.
Recipe for Crystallization
Water temperature Set point Time set Agitation

Step No.
Start End point (min.) Speed
1. 60 50 40 50
2. 50 40 30 50
3. 40 28 30 50
4. 28 28 30 45
5. 28 35 0 45
6. 35 35 80 45
7. 35 30 60 40
8. 30 16 50 35
9. 16 20 30 35

PKS PLANT
Plant 100 T/Day

Capacity:
PLC operated plant
Crystallizers: 2 Crystallizers
Agitator – Pitch Blade Type
Cold room: Tray 529

19 cycle per Hr.
Filter press: Membrane filters 1 Nos.
Filtration Options:
1. Filtration
2. Squeezing
3. Air Blower
4. Cake discharge
5. Washing
Process:
crude oil
Crystallizer 1(36 )
Crystallizer 2(28 )
Cold room(10-20 )
filter
stearine olein
I.V-7-9 I.V-22
UICT, NMU, Jalgaon

Page 58
PACKAGING SECTION: (Filling Section)
In this section total four line of jar of tin filling. Filling line manufacture by J-Instrument
Ltd. & drum filling line manufacture by BIZERBA.Capacity-9000jar filing per day & drum
capacity 25 drum per hour
Flowchart of Packaging Process:

Refined oil storage tank
Churn tank (additives –vitamins and anti-oxidants are added)
Polish bag –filter 1
.Polish bag –filter 2
Service tank(Day Tank)
Filling (Packaging machine)
Film Roll Jar Tin Drum(HDPE OR MS) Tin
Secondary packaging
Food grade audit by Q/C
Dispatch

This department has its own tank farm in which there are nine tanks viz., DT-1 to DT-9.
TANK 1008 and 3001 - 3023 tanks are for refined oils. Batches for vanaspati are prepared in tanks
FOT-1 – FOT-4 in which Sesame oil and vitamins are also added.
Refined Oil Packing: Refined oil is packed in following different packaging material.
 Tanker filling
 Jar filling
 Bag in box filling
Packaging Section:
In this department refined oil and vanaspati is packed in different types of packs. Refined
oil is packed and sold under the brand name of “KOMAL, KLASSIC, etc” and the hydrogenated
oil is packed and sold under the brand name of “KARUNA,K-CARE, K-MEETHA,
KOOLEX,BSI, KOATINA, K2000, CHOKITA, KREAMLITE, KCUISINE, KOMLETE,
KITA, etc” vanaspati. Capacity of small pack department is 400-500 tons/day.
Bakery Shortening Products
Sr.No. Type of product Name of the product Type of oil

1 Refined oil KOMAL Sun flower oil
2 Refined oil KLASSIC Ground nut oil
3 Refined oil KISAN Mustard oil
4 Refined oil coco silver Coconut oil
5 Hydrogenated oil K-AMY Oil blend shortening
6 Hydrogenated oil MEETHA Oil blend shortening
7 Hydrogenated oil KOOLEX Oil blend shortening
8 Hydrogenated oil BSI Oil blend shortening
9 Hydrogenated oil KOATINA Oil blend shortening
10 Hydrogenated oil K2000 Oil blend shortening
11 Hydrogenated oil CHOKITA Oil blend shortening
12 Hydrogenated oil KREAMLITE Oil blend shortening
13 Hydrogenated oil KCUISINE Oil blend shortening
14 Hydrogenated oil KOMLETE Oil blend shortening
15 Hydrogenated oil KITA Oil blend shortening

Dispatch
Objective of standard operating procedure for finished goods, store activities, issue a
systematic storage of finished good fluent out flow of finished to various outlet in view of
achieving and maintaining above objective. It is necessary to have well deligation of authority
DOA for all FG storage & dispatch activity which is as below.
Delegation
Name of function
 Receipt of production slip
 According to FG received at FG Warehouse
 Arrangements of FG receive form Tin/Jar filling point.
 Maintain FG store hygienic condition.
 Remove/repairing of leaked packing.
 Checking & acceptance of arrangement of FG stocking.
 Transfer approval of FG to tracks.
Receipt of production slip
 Loading/warehouse will receive FG from filling department on daily basis

along with production issue slip based on actual quantity of finished goods.
 Before passing production slip, loading incharge will check that all carton, tins with
batch nos. date of mfg. QC passing are marked.
 If the tin are dented the same will be returned to production (Filling) department.
Review of old, slow-moving & obsolete items
As the FG warehouse are dealing with a no. of items there is a possibility of few items being
slow moving & obsolete or never expiry/damage packing. An age-wise list of these items should be
analyses with help of QC & production for liquidified of such goods.
Interaction with external/internal auditors
As the FG warehouse is dealing with a no. of items both inward & outward & other on daily
basis at FG (Warehouse) it necessary have proper evaluation of activities taking place from time to
time.

Dispatch team will prepare & complete all transaction registers by each month end & kept the same in
order for verification of auditors. Dispatch team will co-operated the auditors in best possible manner
& whatever observation are noticeable by auditors shall be explained & cleared to items.
Arrangements of finish goods:
 All goods shall be kept in FG store on pallets & will be arrange oil variety wise.
 The FG stores have a major responsibility of maintaining good condition. It should
arrange for controlling rats, pests & bird & if required proper treatment should be given
periodically.
 There should be proper passage in between each stacking so that inspection of
each packing.
 Proper space should be provided for free movement of forklift so that lifting & movement
of goods can be done easy manner.
Loading activities
 Based on loading advised presented by dispatch department through truck driver.

 Dispatch incharge will make arrangement for loading of tin/carton.
Loading slip should be specially contain vehicle no., name of the driver, destination of
travel, type of oil, quantity of packing/ tin & it should be approved by dispatch department.

QUALITY CONTROL
Quality assurance department is the heart of any oil processing industry. Quality can be
defined as degree of excellence or satisfaction of the growing consumer demands also it can be
referred as measurable quantitative physical standard by which its value is judge. It is composite of
significant characteristic, required to make the product acceptable. Therefore necessitates the
conformance of requirements. This department assures us about the quality of a product.
In quality control, the surveillance of laboratory procedures is systematic, periodic and

documented. Quality control checking ensure that the manufacturing practice is ethical and all the
relevant test are carry out followed by its documentation.
This department is provided with pre-specified sets procedures which are to be followed
during the quality checking whether it is of the raw material or that of the finished product they
have their own pre-specified standards.
All incoming raw materials are checked before accepting and stored in the storage tank also
the packaging materials are checked for their specified parameters
Responsibilities of Q. A. Department:
 The evaluation of quality standards of raw materials, product used in manufacture and the
finished product obtained.
 The evaluation of optimum quality for raw material and for outgoing products.
 To improve the quality and productivity by Process control and experimentation.
 Developing procedures that aid in meeting consumers demand and quality consciousness
both within and outside the organization.
 To advice and assist in inspection.
 Selection of sampling plans that maximize the probability of detection of defect while
minimizing the amount of work needed.
 It helps in building of a brand name for the company by assuring the quality products to
the consumer.
 It helps in analysis of customer complaint report.
 It helps to identify the losses caused due to malfunctioning of the machine, investigate
reasons for poor quality final products.
 To study an experiment using special process for eliminating defects.
 To prepare plant control program for management.

The Basic Tools of Q. A. Department:


Approved supplier’s list

GMP Handling

CCP inspection

Handling of the non-conformity

Product formulas/recipes

Product standards

Label specifications

Controlling of the hygiene & sanitations records

Recall program

Ware housing, shipping & receiving program
HYGIENE:
“Prevention is better than cure” as it is truly said for hygiene. Any oil industry has to take
care to maintain best hygienically conditions in all the departments. Daily hygiene for the industry
is check to maintain the standard of industry and the quality of the product. Following point should
be kept in mind while making the hygiene report:
 The factory should be located in an open and clean locality.

 The garbage system should be well maintained.
 Windows and ventilation should be big and well clean.
 Personal hygiene of every worker should be maintained.
 Ceiling should be kept free from cobwebs.
 Store room should be free from dampness and rodents.
Quality checks at different stages during refining:
Processing of Crude Palm Oil:
The ultimate aim of the processing of crude palm oil is to obtain various products such as
RBD palm oil, RBD palm olein, or RBD palm stearin that meet the requirement of the end users.
An effective and efficient quality assurance program in a processing plant is essential and should
consist of the following monitoring activities:

a. Raw material:
Each and every delivery must be carefully inspected to ensure that specifications are met
and that the shipment is free from contamination. Good raw material is a prerequisite to good-
quality product.
b. In-process materials:
Regular analyses of important quality parameters will serve as a check that proper
processing has been achieved. Good communication between laboratory and production personnel
is of great importance to ensure success of the quality assurance program.
c. Finished products:
Regular checks on the finished products must be carried out to ensure compliance to quality
specifications before the products are permitted for discharge to storage or shipment.
d. Process control:
Proper processing conditions (dosage of processing aids, Temperature, pressure/vacuum,
flow rate, etc.) Must be closely adhered to and monitored to ensure the oil is processed correctly
and to minimize Undesirable side reactions. In order to assess process efficiency, the oil losses
through spent clay or soap stock (as in the case of alkaline refining only) must.
Quality Analysis of raw materials: Lab tests
 The preliminary tests carried out for crude oil
 Free fatty acid

 Colour (Lovibond)
 Iodine value (IV)
 GLC (GN,CN)
 Moisture
 Unsaponifiable Matter
 Adulteration test
 Determination of Carotenoid content of raw Palm oil
 Determination of Phosphorous in Soyabean Oil

 Test for refined oil are the following:
 Free fatty acid

 Iodine value
 Color
 Moisture
 Adulteration test
 Slip melting point(SMP)
 Cloud point(CP)
 Test for vanaspati & bakery shortening

 Test for presence of Sesame Oil (BAUDOUIN TEST)
 Determination of Argemone oil in edible oil (Ferric Chloride Method)
 Determination of solid fat index by dilatometery
 Coal Analysis:
1) Moisture Contained (%M): The 1 gms of coal is kept in a furnace for 1hrs.then it is
again weighed. So the moister is very easily calculated. The moisture is an important
factor as it reduced the GCV of coal.
2) Gross calorific value (GCV): It is the amount of heat evolved when 1 gms of coal
sample is burnt completely in presence of oxygen. Here the coal has GCV more than
3000kcal/kg is accepted. In Bom Calorimeter the temp is measured T. Then the GCV
is calculated as:
GCV (kcal/kg) = (6318*T)/ (2.71* wt. of the sample).
Along with this Volatile Matter (VM), Ash percentage is also calculated by heating
the 1gms. Coal sample in a muffle furnace to 750-800 for 1-2hrs.

 Feed and Blow down Water of Boiler Analysis:
1) Hardness: 25 ml of water are taken in a flask then solo chrome blank solution is added
with it. Then the purple solution is titrated against EDTA to get the hardness. The
hardness is expressed in terms of ppm.
Hardness (ppm) = (1000* vol. of EDTA *(N))/vol. of the sample.
2) Alkanity: The two types of alkanity are there Phenolphthalein (P) and Methyl orange
(M) alkanity. For feed water the P and for blow down water the M types are calculated.
P/M type = 40*Burette Reading (vol. of STS).

OH Alkanity = (2*P-M).
3) Total dissolved solid (TDS): It is measured in a digital meter. The feed water has a
TDS of less than 100 ppm; whereas blow down has almost 2000 ppm.
4) Hydrogen concentration (pH): It has certain effect in the boiler efficiency. So the pH
is a very important factor. It is measured by using Universal pH indicator solution. In
15lml water5 drops is added to give color. Color code is supplied to calculate the pH of
the solution. Generally the pH of feed is 8.5 while that for blow is 10.
 Bleaching and spent earth analysis:
1) Color Reduction Ability: Here almost 2% (wt.) earths are mixed with CPO. Then it is
tested whether it is more than 95% or not.
2) PH of the Bleached earth: 0.5gms of earth is mixed with 50 ml distilled water then
filtered and final water is tested for pH by using indicator solution.
3) Moisture Content (%): First it is weighed then it is heated for 1 hrs, finally it is
weighed to measure the difference in weight and the moisture is calculated. Its
maximum limit is 5% for a typical bleached earth.
4) Bulk Density & Phosphate test: For a good earth the density is 0.55gms./cc or more.
Using Barium Chloride it is checked whether phosphate is present or not.
5) Oil content in spent earth: It is checked by solvent extraction in Soxhlet extraction

heater using hexane as a solvent. It is measured that its value is less than 20%.

UTILITIES
A. Boiler: Specification
Manufacturer- CETHAR VESSEL LTD (fluidized bed)
Capacity- 16 ton/day
2
Pressure- 17.5 kg/cm
2
Heating surface area- 546 m
Fuel used- Coal
0
Max Temp- 205 c
Circulation type- Natural
Type- Water tube boiler
B. Cooling and Heating Thermosiphon
Manufacture- Geka Boiler

Pressure- 55 Bar Maximum
Fuel used- LDO
Circulation natural
-
Max temp- 286 oC
High pressure natural circulation boiler

Advantages of Thermosyphon:

Thermosyphon uses distilled water as
heat transfer medium which 100% nontoxic
and avoid all problems of contamination
especially when used in food industry

Thermosyphon works on the principle of
natural circulation hence no circulation pump is
required.

Reduction in moving parts improves
reliability and gives electric power saving.
UICT, NMU, Jalgaon
Page 68

Multi start coil ensures no vapor lock and smooth start up.

Thermosyphon comes with completely welded construction and no flange joints. It operates
on close loop concept. This hermitically sealed system gives advantage of low maintenance
and no internal corrosion.

Thermosyphon is fully automatic and suitable for unmanned operations.
REVERSE OSMOSIS PLANT:
Capacity- 12 m3/hr.
RO membrane- Mfg. by GE membrane
Raw water- from tanker(40 tanker in)
Raw water parameter
P.H- 7.5
T.H- 245
T.D.S- 357
Reverse osmosis (RO) is a filtration method that removes many types of

large molecules and ions from solutions by applying pressure to the solution
when it is on one side of a selective membrane. The result is that the solute is
retained on the pressurized side of the membrane and the pure solvent is
allowed to pass to the other side. To be "selective," this membrane should not
allow large molecules or ions through the pores (holes), but should allow
smaller components of the solution (such as the solvent) to pass freely. Reverse
osmosis is most commonly known for its use in drinking water purification
from seawater, removing the salt and other substances from the water
molecules.
This is the reverse of the normal osmosis process, in which the solvent
naturally moves from an area of low solute concentration, through a membrane,
to an area of high solute concentration. The movement of a pure solvent to
equalize solute concentrations on each side of a membrane generates a pressure
and this is the "osmotic pressure." Applying an external pressure to reverse the
natural flow of pure solvent, thus, is reverse osmosis.
UICT, NMU, Jalgaon

Page 69
Raw water tank
Sand filter
Carbon filter
Ultra filtration
Micro filter
RO Rejected RO membrane
Ro permeate water
Storage tank
MB
Cold water tank
The process is similar to membrane filtration. However, there are key differences between
reverse osmosis and filtration. The predominant removal mechanism in membrane filtration is
straining, or size exclusion, so the process can theoretically achieve perfect exclusion of particles
regardless of operational parameters such as influent pressure and concentration. Reverse osmosis,
however involves a diffusive mechanism so that separation efficiency is dependent on solute
concentration, pressure and water flux rate.

Schematics of a reverse osmosis system (desalination)

1:Sea water inflow, a) High pressure pump flow (40%),
2:Fresh water flow b) Circulation pump,
(40%), c) Osmosis unit with membrane,
3:Concentrate Flow d) Pressure exchanger
(60%),
4:Sea water flow
(60%),
5:Concentrate (drain).
Reverse Osmosis is a process in which dissolved inorganic solids (such

as salts) are removed from a solution (such as water). This is accomplished by
household water pressure pushing the tap water through a semi permeable
membrane. The membrane (which is about as thick as cellophane) allows only
the water to pass through, not the impurities or contaminates. These impurities
and contaminates are flushed down the drain. Ultimately, the factors that affect
the performance of a Reverse Osmosis System are:
 Incoming water pressure.

 Water Temperature.
 Type and number of total dissolved solids (TDS) in the tap water.
 The quality of the filters and membranes used in the RO System (see
operating specs).
Basic components common to all reverse Osmosis Systems:
1) Cold Water Line Valve: Valve that fits onto the cold water supply line.
The valve has a tube that attaches to the inlet side of the RO pre filter.
This is the water source for the RO system.
2) Pre-Filter (s): Water from the cold water supply line enters the Reverse
Osmosis Pre Filter first. There may be more than one pre-filter used in a
Reverse Osmosis system. The most commonly used pre-filters are
sediment filters. These are used to remove sand silt, dirt and other
sediment. Additionally, carbon filters may be used to remove chlorine,
which can have a negative effect on TFC (thin film composite) & TFM
(thin film material)
UICT, NMU, Jalgaon

Page 71
membranes. Carbon pre filters are not used if the RO system contains a CTA (cellulose tri-
acetate) membrane.
3) Reverse Osmosis Membrane: The Reverse Osmosis Membrane is the heart of the system.
The most commonly used is a spiral wound of which there are two options: the CTA
(cellulose tri-acetate), which is chlorine tolerant, and the TFC/TFM (thin film
composite/material), which is not chlorine tolerant.
Figure 30:
4) Post filter (s): After the water leaves the RO storage tank, but before going to the RO faucet,
the product water goes through the post filter (s). The post filter (s) is generally carbon (either
in granular or carbon blocks form). Any remaining tastes and odors are removed from the
product water by post filtration.
5) Automatic Shut Off Valve (SOV): To conserve water, the RO system has an automatic shutoff
valve. When the storage tank is full (this may vary based upon the incoming water pressure)
this valve stops any further water from entering the membrane, thereby stopping water
production. By shutting off the flow this valve also stops water from flowing to the drain. Once
water is drawn from the RO drinking water faucet, the pressure in the tank drops and the shut
off valves opens, allowing water to flow to the membrane and waste-water (water containing
contaminants) to flow down the drain.
6) Check Valve: A check valve is located in the outlet end of the RO membrane housing. The
check valve prevents the backward flow or product water from the RO storage tank. A
backward flow could rupture the RO membrane.

7) Flow Restrictor: Water flow through the RO membrane is regulated by a flow control. There
are many different styles of flow controls. This device maintains the flow rate required to
obtain the highest quality drinking water (based on the gallon capacity of the membrane). It
also helps maintain pressure on the inlet side of the membrane. Without the flow control very
little drinking water would be produced because all the incoming tap water would take the path
of least resistance and simply flow down the drain line. The flow control is located in the RO
drain line tubing.
8) Storage Tank: The standard RO storage tank holds up to 2.5 gallons of water. A bladder inside
the tank keeps water pressurized in the tank when it is full.
9) Faucet: The RO unit uses its own faucet, which is usually installed on the kitchen sink. In areas
where required by plumbing codes an air-gap faucet is generally used.
10) Drain line: This line runs from the outlet end of the Reverse Osmosis membrane housing to the
drain. This line is used to dispose of the impurities and contaminants found in the incoming
water source (tap water). The flow control is also installed in this line.

ACID OIL PLANT:
Capacity- 25 ton per day

Reactors- Two FRP reactors
Area- 700 sq.feet
Throughout the process in oil industry, waste streams are generated by many of the unit
operations. Most of these waste streams are mixture of oil and oil-soluble products along with
aqueous phase materials. As the oil and water phase has a very high FOG (Fats, Oils, Greases)
concentration, high TSS (Total Suspended Solid), BOD, COD (Chemical Oxygen Demand) loads
and includes a potentially valuable glycerides and fatty acid sources, so acidulation is to be done to
minimize losses.
In Acid oil plant, the soap stock comes through a pipeline from refinery to storage tank and
then it is pumped to a batch reactor. The batch reactor in which, there is a reaction taking place
between soap-stock and 98% sulphuric acid as above. There are two batching reactors and each has
6 MT capacities. In the reactor agitation of soap-stock and sulphuric acid takes place. Per batch
about 200-250 Kg is added after agitation for settling of impurities. The settling time is 2-3 hrs.
After completion of the reaction the acid-oil is transferred to the storage tank, operation, soap
stock, discharge streams from Tank farm collection system, and other waste streams enter in
equalization or holding tank.
Wash waters, fat separator skimming, and other sources may also be added at this point, or
may be introduced into one of the later setting tanks. The mixture is heated and is treated with HCL
acid, at a controlled pH of around 2-2.5. After reacting with the acid, the mixture then enters a
series of holding/settling tanks, where the oil and aqueous phases split. A small amount of aeration
may also be sprayed on the oil surface. Acid oil skimmed from the top surface may be water
washed, boiled.
Soap-stock, which is obtained as a by-product from neutralization, is utilized to prepared
acid oil. It is mainly used in soap and detergent industries and also for industrial. It is a product of
mixture of fatty acid obtained from soap stock with mineral acid lye, sulphuric acid, HCL, HNO 3
etc.
Acid oil can be prepared by acidolysis reaction in which one fatty acid radical is displaced
with another fatty acid radical.

Reactions:
R-COOH + NaOH ----R-COONa + H20

FFA Caustic Soap Water
2R – COONa + H2SO4 ----- 2R-COOH + Na2SO4
Soap Stock Acid Acid oil
Specification for acid oil
TFM 49.7 Min.

IV 122
MIV 3 % Max
SV 190
Mineral acid 0.05 %

EFFLUENT TREATMENT PLANT
Manually operated plant

Capacity- 150m3/day
Chemical consumption every two hour.
Lime- 10 kg.
Alum- 2 kg.
Poly- 50gm
Urea- 2kg
Each and every plant should have its effluent treatment plant. The effluents, which are
discharged, should have no detrimental effects on the environment, and there by follow the
standards as suggested by the Maharashtra pollution control board. Increasing pollution has to be
controlled by taking proper preventive measures. The choice of technology obviously depends on
the type, quantity and characteristics of effluent.
The treatment processes are of three types.
1. Physical treatment process
2. Biological treatment process
3. Chemical treatment process
The effluent treatment plant is of 250 m3/day capacity. The treated effluent is used for
gardening. There is provision for this water for fire extinguishing purpose
From separator 1:
1. Soap separated acid oil tank fatty acid Soap industry
(acidified water)

From separator 2:
2. Wash water Fat trap oil separation
Water [Effluent treatment plant]
Equalizer Pond
Lime - mixer
Mixing tank (Alum and polyelectrolyte dosing)
Primary clarifier
Aeration chamber
Secondary clarifier
Sand filter
Carbon filter
Supernatant tank Discharge
Process:
From acid oil plant, first the effluent comes in fat trap-1 and then to fat trap-2 and then to
oil & grease trap where free oil and grease are separated. The effluent is then taken to equalization
tank having 4pH, which is maintained by dosing sulphuric acid or caustic and aerated continuously.
De-oiler polyelectrolyte (20ppm) is continuously added so that oil comes on the surface, which is
then transferred to sludge tank.

The treated water goes to neutralization tank where pH is maintained at 7 by addition of

lime. Now the water is further moved to primary clarifier where settling of sludge is done. When a
liquid containing solids in suspension is placed in a relatively quiescent state, those
solids having a higher specific gravity than the liquid will tend to settle, and those solids having a
lower specific gravity will tend to rise. These tanks are provided for the removal of (1) settle able
solids capable of forming sludge deposits in the receiving waters, (2) free oil and grease and other
floating material, and (3) a portion of the organic load discharged to the receiving waters.
When primary clarifiers are used ahead of biological treatment, their function is to reduce
the load on the biological treatment units. Efficiently designed and operated primary clarifiers
should remove from 50 to 70% of the suspended solids and from 25 to 40% of the BOD. The
sludge at the bottom is directly connected to sludge drying.
From the top water is transferred to aeration tank 1. The aeration system is activated sludge
process i.e. it has active biomass, which by having its food decomposes and thus treats the effluent.
Advantages for aeration panels are: (1) ultra-fine bubbles are produced that significantly improve
oxygen transfer and system energy efficiency. (2) Large areas of the tank floor can be covered
which facilitates mixing and “lumping” can dislodge oxygen transfer and (3) foulants i.e.
increasing the airflow to flex the membrane.
The water now moves to secondary clarifier where again settling takes place similarly as
primary clarifier. The effluent now moves to aeration tank 2. Thereafter the treated water now
moves to treated water holding tank where chlorine is added for destroying the bacteria. From
holding tank the treated water is allowed to pass through pressure sand filter and activated carbon
filter. Thus, the treated effluent has BOD and COD reduced as per the norms of Maharashtra
Pollution Control Board. This treated water is then used for gardening purpose. Following
specification should be maintained in the waste water-
1) Total suspended solids 10 mg/L

2) pH 5.5 – 9.0
3) B.O.D. 30 mg/L
4) C.O.D. 250 mg/L
5) Oil & Greases 10 mg /L
6) Dissolved Oxygen 3-8.9 mg/L

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ACKNOWLEDGEMENT

UICT, NMU, Jalgaon

Sr. No. Content Page No.

UICT, NMU, Jalgaon Page 1

UICT, NMU, Jalgaon Page 2

Salient Feature of Kamani Oils Ltd., khopoli

1. Name of Company:- kamani oil Pvt. Ltd.

Information Regarding Industry

1. Year of establishment:- 1962

UICT, NMU, Jalgaon Page 3

KAMANI OIL INDUSTRIES PRODUCTS:

Availble- 15 Ltr Jar/tin.

UICT, NMU, Jalgaon Page 4

Available- 15 kgs, Jar/tin

Availables in 15kg tin.

2) PRODUCTS FOR FOOD AND RELATED INDUSTRIES :

UICT, NMU, Jalgaon Page 5

 BAKERY FAT / MARGARINE:

 FOR KHARI/ PUFF PASTRIES:

Specialty fat for Khari / Puff Pastry.

Specialty fat for Khari / Puff Pastry.

Margarine for Khari / Puff Pastry.

Benefits : Gives good shine to products.

Pack Size Available:20 kg Carton

Margarine suitable for Cakes.

Benefits : Light, Spongy and Fluffy Cakes.

Pack Size Available: 20 kg Carton

UICT, NMU, Jalgaon Page 6

Aerated Fat suitable

FOR BISUCITS AND COOKIES:

Ideal for lighter and crisp Biscuits / Cookies.

Pack Size Available :20 kg Carton

 FRYING OILS & FAT

Refined Vegetable Oil

 Ideal for frying application

Pack size available: 15 Kgs tin

UICT, NMU, Jalgaon Page 7

Refined Coconut Oil

 Premium quality oil used for frying of nuts

Pack size available: 15 Kgs tin

 Ideal fat for frying of sweets & snack

Pack size available: 15 Kgs tin

After thoroughly researching dairy fats, we have developed an alternative that is

 Ideal replacer of dairy fat in frozen desserts

UICT, NMU, Jalgaon Page 8

Pack Size available: 15 kgs Tin

 Premium quality coating oil for chocobars

 Budget Oil for chocobars

Pack Size available : 15 litres cartoon

 CHOCOLATE & CONFECTIONARY:

Cocoa Butter Substitute for moulded chocolate

 Is a lauric based CBSideal for moulded chocolate products

UICT, NMU, Jalgaon Page 9

Pack size available: 20 Kg Carton

Cocoa butter substitute for enrobing

 Is a lauric based CBS ideal for enrobed products and

Pack size available: 20 kg Carton

Cocoa butter substitute for center filling

 Is a lauric based CBS suitable for soft centered candies

Pack size available: 15 Kg Carton

The confectionery fat

 Is a lauric based fat ideally suited for hard boiled confectionary

UICT, NMU, Jalgaon Page 10