Final ITR ADM SKY

Industrial Training Report
By- Shubham Kumar Yadav & Shreya Pandey

ADM AGRO INDUSTRIES INDIA PVT. LTD.
AN OVERVIEW OF ADM INDIA
2
Proprietary business information of ADM.

Archer Daniels Midland (ADM) is an American Global food processing and commodities trading
corporation, headquartered in Chicago, Illinois. This company operates at more than 270 plants and 500 crop procurement
facilities worldwide, where cereal grains and oilseeds are processed into products used in food, beverage, nutraceutical,
industrial, and animal feed markets worldwide.
In India, ADM’s principal business is the processing of oilseeds into edible oils, animal feeds and feed
ingredients. ADM also markets a range of ADM food ingredients to leading food manufacturers, provide animal nutrition
products to poultry and dairy farmers, originate and trade corn and wheat, offer cargo services and warehousing
facilities for businesses and operate a training and incentive program in association with Maharashtra government
to assist Indian farmers to improve crop quality and increase yields.
Operations include the head office in Gurgaon and oilseeds processing plants in Latur and Dharwad.
The oilseeds processing business involves processing various oils and oilseeds – Soybean, Sunflower and Cotton, to
produce crude and refined oil, meal and lecithin. This meal is primarily used in the production of animal feeds, while the
oil is refined into edible oils, sold in bulk and under own brand names Health Fit and Parampara to household and
institutional
Vision of ADM
ADM's purpose is to unlock the power of nature, to
enrich the quality of life. We're a global leader in human
and animal nutrition and the world's premier agricultural
origination and processing company.
CONTENTS
3

 Safety Induction
 About Soybean
 Preparatory Section
 Solvent Extraction Plant (SEP)
 Refinery
 Lecithin Production
 Thermic Fluid Boiler
 Acid Oil Plant
 Boiler
 DM PLANT
 Oil Tank Farm 4150 Storage
 Quality Control Lab
 ETP(Effluent Treatment Plant)
 Oil Packaging Section
4
SAFETY INDUCTION

• Free from Danger
• Control of Incidents
Safety is prevention of accidents which results personal injury and property damage.
IMPORTANCE
• Helps improve employee safety.
• Uncover unsafe behaviors, procedures and conditions that may otherwise go unnoticed.
• Helps in motivating the employees
INITIATIVES
WHAT IS ACCIDENT.? 5

Theory Of Accident
An undesired and unexpected event which may
Social / Personal Factor
result to incident or may not cause injury or
property damage called accident Faults
ACCIDENT
Unsafe Act / Unsafe Condition
Accident
Injury
Note- Accident don’t happen but they are caused.

6
AGENDA

 Personal Protective Equipments
• Personal protective equipment’s are helmet, googles, mask, gloves, safety shoes and earplugs .
• Designed to protect body from injury or infection and prevent hazardous injury.
 Work Permits
• It acts as an administrative layer of protection for performing any type of non-routine activity.
• It ensures if all the necessary precautions are taken care of before starting any kind of non-routine work.
• The objective of work permit is for construction, maintenance, replacement of a part or repairing .
 LOTO Procedure
• It is a technique used to prevent accidents from any energy sources prior to start of work by placing lock
on energy isolating devices.
• It applies to all energy sources including electrical, mechanical, hydraulic, pneumatic, chemical, thermal,
and gravity .
7
SOYABEAN

Soy vegetable oil, used in food and industrial applications, is another
product of processing the soybean crop. Soybean is the most important
protein source for feed farm animals (that in turn yields animal protein for
human consumption).
Soybean oil of typical composition performs well as a salad oil, but it is
usually hydrogenated for use as a margarine stock or frying oil.
Further, these seeds are extracted to obtain crude soybean oil and meal.
Apart from this, lecithin is also obtained by removing the gums present in
them through degumming process.
Palmitic acid 10 -12%

Stearic acid 4-7%
Oleic acid 17-23%
Linoleic acid 49-51%
Linolenic acid 7-10%
CLEANING PREPRATION SECTION
9
 The path flow of seeds from unloading section to Cleaning is shown below :

10
 PREPRATION & SOLVENT EXTRACTION PLANT

The Extraction of Crude Oil and production of High Protein content meal from soybean seed involves
several steps as listed below:-
1) Oil seed Go-down
2) Cleaning Section
3) Preparation Section
4) Solvent Extraction Plant
5) De- oiled cake Go-down
20XX 10
11
Rotary Drum:-

• The roller is installed tipsily on the rack. The motor contact with
the roller by the couple though reduction gears. The roller
rotates around its axis drove by the motor.
• When the materials enter into roller, the materials on the

surface of screen will overturn and roll as the screen. Because
the whole slant set is running and turning.
• Materials overturn and run ceaselessly. So if there are

materials locked in the hole of screen, they will be ejected, 12 mm
which can prevent the screen hole from blocking.
MOTER SPEED 1430 rpm

GEAR RATIO 62.4
MESH SIZE 10 – 12 mm
Speed reduced to gear box 22 rpm
12
SEED CLEANER :-

 The seeds are fed into the hopper and they are
guided to fall on the first sieve.
 The first sieve is a scalping screen which scalps all MESH 10 mm

the foreign materials larger and heavier than seed
MESH 3 mm
and the entire quantity of seed passes through the
first sieve. VIBRATING MOTER
 The second sieve is a cleaning sieve which
removes all the unwanted particles larger in size
than the seed
DE- STONER 13

Destoners operate using the idea of a fluidized bed to separate material based on their bulk density. Bulk density
is the material weight per cubic space it takes up.
WORKING PRINCIPAL:- Bulk density difference between oil seed and foreign matter
Bulk Density of soya seed is 0.7- 0.8gm/ml
ID FAN :-
It is contented to generate a negative pressure(20- 30
mm wc ) in seed cleaner , so that all fine dust are remove ID FAN
from it .
MESH 2-3 mm
Inclination (ϴ):-
MESH 2 mm
De-stoner is incline at (7 to 12 degree due, to
that seed move forward with help of gravity
and the heavy material move backward fall VIBRATING MOTER
down .
14
 Preparation Section:-

The seeds from the cleaning section are forwarded to the preparatory section via conveyor. In the preparatory
section, the seeds are passed through crackers, cooker, flakers, expander and cooler and also through hull
removing section if high – protein meal is to be produced.
RE-90 CK-102
RE-103 Rotary
CK-101 EL-104 COOKER RE-108 EL-109 RE -110
magnet
CK-100
FL -114
FL-115
(L-path) RE-119A FL-116
RE-119 B PALLET COOLER EXPANDER RE-121
conveyor FL-117
FL-118
Cyclone
SEP
RE-119 A SC-125
RE-
200
15

Crackers:
Cracker comprises of two pairs of corrugated rolls arranged one

on top of the other so that the first set of rolls feeds the second s
Here, each pair has one holding roll and one cutting roll. In the
case of soybeans, the seed is cracked to 1/8 th of its original size.
· CK – 100, CK – 101, CK-102
 Each cracker having two set of rolls ( 3 cracking). Horizontal projection

 Fines not more than 2.5%
 Whole seeds percentage should be NIL.
5 TPI(thread per inch)

Motor 1460 rpm 2 mm thickness(gap)
Diameter of Roller 250 mm 7 TPI
Length of Roller 1330 mm

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 Cooker:

 The cracked seeds are conditioned or cooked in a vessel.
This vessel comprises of several compartments and each Compartment
compartment is supplied with jacketed steam and open steam
as per the requirement (generally depends upon the seed
moisture) so as to maintain them at desired temperature.
 The main purpose of cooker is to soften the seeds for the

efficient formation of flakes of desired thickness.
 Generally, the outlet temperature of seeds after cooking is

about 70-75(ºC). Now, these cooked seeds are fed to flakers
for further processing.
Open
steam
Moisture out steam 10-13%(depend on seed )
Motor 1440 rpm / 60HP
Gear box ratio 42:1 Motor shaft
Gear Box
Open steam 4 -6 kg/cm2
 Flaker: 17

 Flake thickness may vary between 0.30 and 0.4 mm.
Since the flakers operate with constant roll rpm and at a Feed
constant roll gap it is important that they are being fed Roller
with constant capacity based on a constant bulk density.
Any deviation in bulk density or capacity will be Flaker
reflected in a varying flake thickness. roller
 Roll hydraulic pressure(50- 60 kg/cm²) set to maintain thickness

of flakes as 0.35 mm (critical flake thickness)
Moisture content 9-10%
FL -114 Roller Dimension Motor Pully length Finial rpm roller
FL- 115 1200*600 1480 rpm 30” 800 rpm Roller 1 Roller 2
FL-116 1220*500 1480 rpm 25” 800 rpm
FL -117 1200*600 1480 rpm 30” 800 rpm
0.35 mm critical thickness

FL -118 1200*600 1480 rpm 30” 600 rpm
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Expander / extruder:

Expander and extruder both work in similar fashion but the basic difference between the
expander and extruder system is that the extruder’s product is of defined shape (pellets,
etc.), where as, the expander’s product is of undefined shape.
The flakes formed by the flakers are fed to expander where their moisture content is slightly
increased as they are heated to form cakes which in turn results in increasing their temperature and
their bulk density also increases in this process.
6. Rotation of screw is about 20 rpm .
7. Moisture of collets up to 12 %
8. Temperature: 100-105 Hydraulic P 40-50 Kg
9. Motor is 1440 rpm / 200 HP
10. Gear box Ratio 5.6 :1 Screw
Open steam
12 inch
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 OIL SEED CRITICAL LIMITS
DOC CRITICAL LIMIT
Moisture content >12% (less than ) Protein content 44. to 45 % (normal doc
Oil content 19% max 20% Fiber content 6 to 7 %
Damage seed Max 5%
Foreign matter 2.15% FLACKER

Moisture content 9-10%
Bulk density 0.7 to 0.8 g/ml COOKER
(loose form)
Moisture Content 10-13%
Moisture content 11 to 12%
SOLVENT EXTRACTION
 PRE AND SEP SECTION 21
FLOW DIAGRAM FOR OILSEED PROCESSING

OIL SEED FLACKER
CLEANING EXPANDER MISCELLA MEAL DOC
DRYNG AND
DESOLVENTIZATION
DESTONING COOLING
AND TOSTING
OIL SOLVENT
MAGMATIC SOLVENT EXTRACTION

PLANT
SEPERATION
DISTILLATION SOLVENT
CRACKER
OIL COOLING
SEED COOKER
HEXANE
SOLVENT EXTRACTION PLANT 22

This includes four major operations:
• Extraction
• De-solventization – Toasting
• Miscella filteration (Distillation)
• Mineral oil section
23
Extraction

• It is Multistage countercurrent extraction process
• Concentration of miscella in the extractor hoppers decreases with increase in miscella stage, where
concentration of miscella of 8th spray pump should be less than 0.1 %
• Temperature of the extractor- 55-60◦C
• Meal leaving extractor contains 25-30% hexane by weight
• Factors affecting extraction-
1. Moisture
2. Temperature
3. Contact time
4. Fines
5. No of miscella stages
6. Miscella flow rate
7. Hydrocyclone
24

25
Desolventizer Toaster

• Process of recovering solvent from the meal is carried out in DT
• DT has three different types of trays-
1. Pre desolventizing trays
2. Stay bolt tray
3. Sparge tray
• DT consist of DT plug Screw, Vapour Nozzles, DT cyclone
• DT dome temperature- 75-80◦C
• DT outlet parameters- temperature- 100-105◦C, retention time- 45-50min
Factors affecting are -
1. Temperature
2. Contact time
3. Doom temperature
26

27
Meal Dryer

• Purpose of meal dryer is to minimize the temperature of meal leaving DT
• Vibrators are used to separate lumps formed in DOC
• Hammer mills are used to crush material into smaller pieces
Parameter Limit
Moisture < 12.5%
ROC < 0.9 %
Protein 45% & more
Urea activity 0.05- 0.3%
Flame test -ve
Sand < 2%
Crude fiber < 4-6%
Hexane < 250 ppm
 FLOW DIAGRAM FOR DISTILLATION SECTION 28

Miscella TANK Heater 2
OIL STRIPPER
ECONOMISER-1
Heater -3
FLASHER-1
Vacuum dryer
ECONOMISER-2
Heat Exchanger (Final Oil
to Miscella)
FLASHER-2
Heat exchanger (final to

Heat Exchanger (Final fresh miscella)
Oil to Miscella)
PHE WATER TO OIL

Heater-1
OIL STORAGE TANK

FLASHER-3
29
Distillation

Flasher
Economizer/ first effect Heater 1 Temperature- 95-100°C
Temperature- 65-70°C Temperature- 90-95°C Vacuum- 550 mm Hg
Vacuum - 300-350mm Hg Miscella Con- 92-96%
Miscella Con- 75%
Heater 2
Temperature-100-115°C
Vacuum Dryer Temp

Heater 3 Stripper
120-125 °C
Temperature-120- 125°C Temperature- 115°C
Vacuum 730-740 mm Hg
Miscella Con- 98-99%
Crude oil- up to 99.95%
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Crude Oil Parameters

FFA Content <1%
Colour (1/4” cell) <40 units
M&V <0.25 %
Sediments <0.25 %
MIV <0.5%
Flash point >150°C
Phosphorous Content >800 ppm
Moisture Max 0.25

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Mineral oil

• Consist of absorber column with pall rings which absorbs Hexane going out with gaseous steam
leaving vent condenser and stripper.
• Pall rings- used as packing material to increases absorption area
• Vent blower- Connected to mineral oil absorption section which removes unabsorbed gases
• Factors affecting absorption & stripping are-
1. Moisture
2. Temperature
Mineral oil Temperature Moisture

Absorber 30-35◦c <3%
Stripper 105-115◦c <0.5%
 CONDENSER 32

• Shell and tube heat exchanger is the most widely
used heat exchanger and are among the most
effective means of heat exchange.
• Shell and tube heat exchanger is a device where
two working fluids exchange heats by thermal
contact using tubes housed within a cylindrical
shell.
• The fluid temperature inside the shell(HEXANE )
and tube(COLD WATER ) are different and this
temperature difference is the driving force for
temperature exchange.
• Used for wide temperature and pressure range,

Shell and tube heat exchangers are compact in
design, easy in construction and maintenance and
provide excellent heat exchange.
 FLOW DIAGRAM FOR ALL CONDESER 33

1. EXTRACTOR CONDENSER
EXTRACTOR HEXANE
EXTRACTOR
CONDENSER
MOTHER TANK
2. DISTILATION CONDENSER
FLASHER-1
DISTILATION
FLASHER-1 CONDENSER
FLASHER-1
3. VD CONDENSER 34

VD HEXANE VAPOUR
VD CONDENSER
OIL STRIPPER
4. DT CONDENSER
SCRUBBER
DT
CONDENSER
INDIRECT DT
HEXANE
5. VENT CONDENSER
EXTRACTOR
CONDESOR
DT CONDENSER
DISTILATION VENT
CONDENSER CONDENSER MISSCELA TANK
VD CONDENSER
REFINERY
36
REFINERY

 Crude soybean oil produced by extraction plants contains several impurities. It
is important to remove these impurities present in it. In the production of
edible oils, a number of purification steps are carried out to remove the
impurities. The underlying objective of these purification steps are to
retain the desirable components to the maximum extent with minimum
possible loss of oil. The combination of various purification steps to
achieve such objectives is termed as “Refining” process.
 Major Steps Involved in Soyabean oil Refinery are :-
Degumming  CRUDE OIL PRAMETER

Neutralization Colour <40
Bleaching FFA Max 1%
Deodorization
P content 800 ppm
Sediment 0.25% max
MIV 0.5% max
 FLOW DIAGRAM FOR CRUDE SOYABEAN OIL REFINING PROCESSING 37

CRUDE OIL TANK SEPERATOR 2
HEAT EXCHANGER HEAT EXCHANGER

HEATING VACCUM DRYER
(Steam to oil)
POLISH BAG FILTER
NEUTRAL OIL TANK ROT
H3PO4 MIXER
DEAREATOR
OIL TANK FARM
HEAT EXCHANGER
ART Neutral VHE(Vacuum heat
OIL exchanger)
SLURRY TANK
NAOH MIXER BLEACHING
Earth
VHF(Vacuum heat final)
BLEACHER
CRT
DE-ODURIZER(240)
PRESSURE LEAF
FILTER
SEPERATOR 1
COOLING
WWRT(WATER WAHING POLISH BAG FILTER
RENTION TANK )
POLISH BAG FILTER
BLEACHED OIL TANK
38
`COT A COT B
Degumming

Degumming is a process of removing the phospholipid components from crude Heated to 50 c
soybean oil to improve its physical stability and also to reduce several refining losses. PHE 500
Aim Of Degumming: PHE 501 Heated to 60 -65 C
 To reduce the emulsifying action of phospholipids (gums) as they increase oil losses in refining.
NIFE H3PO4
 Gums if present in oil, lead to brown discoloration of oil at high deodorization temperature.
MIXER 1
 Gums may form salts with copper, iron, magnesium, iron leading to oxidative degradation of oil.
 Lecithin formed after degumming also has great market value due to its wide applications.
Retention for 30-
ART tank 35 min
 ART TANK
FFA content 1.2 % max
39
 Types of Phospholipids (Gums):
Capacity of reaction tank: 8MT

 Hydratable Level of tank: 80%
 Non - hydratable
Flow rate: 7TPH
Retention time:30-43min
Most of the gums (around 90%) present in crude soybean oil are hydratable gums.
Retention Time in 30- 45 min

ART Phosphorus ppm in crude soybean oil: 750 ppm
Retention level in ART 80% Crude oil quantity (assume): 7000 kg
% phosphatides: (750*31.7)/10000
Temp of oil Raised 60 -65 C
= 2.377% = (HP & NHP) = 166.39 kg/hr
Crude oil Temp 30- 35 C
So, Phosphoric(purity 85%) added will be 0.0888% of 6.197 kg
H3PO4(phosphoric acid 0.8- 1%
dozing )
Gum 800-900 ppm
Flow Rate oil 7500 -8000 Kg/hr
ART Tank 40
NEUTRALIZATION

PHE 505
Neutralization process consists of removal of free fatty acids present in the oil by
MIXER 506
treating them with alkali and neutralizing them to form soap. Thus, this process is also
known as de-acidification and since alkali is used to remove FFA, thus it can also be
SHEAR MIXER
referred as alkali refining.
Gums, which are non-hydratable phosphatides are undesirable along with free fatty CRT Tank
acids which have low oxidative stability due to which they are more prone to oxidation
resulting in the lower shelf life of oil. These are removed in neutralization.
Separator 1 Soap Tank
Neutralization is achieved by treating the soybean oil with aqueous alkaline
solution of sodium hydroxide to neutralize the free fatty acids. H3PO4
Water
WWRT
Separator 2 Slope
oil tank
Vacuum dryer
Not Tank
41

QUALITY PARAMETER
 SEPERATOR 1
FFA content < 1%
 VACCUME DRYER
Soap in ppm
Color 30 Max
 BLEACHED OIL FFA content < 0.1% max
Colour 20 max P content in ppm <20 ppm
FFA content <0.1% max Soap content <60 ppm
P content <5 ppm
FI (filter ability test ) Max 10 (not less

than 8)
42
 BLEACHER SECTION

• The main purpose of bleaching is to convert primary oxidation compounds to
secondary oxidation compounds i.e. to decompose the peroxides produced by
oxidation into lower molecular weight carbonyl compounds that can be
removed by attaining a certain vacuum and temperature within our practical
limit during deodorization.
• Appearance and color removal of 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 to 15 ppb.
• The subsequent hydrogenation and deodorization remove or degrade red and

yellow pigments more than chlorophyll, so incomplete chlorophyll removal by
bleaching will cause the refined oil to appear greenish.
• The desired bleaching endpoint is typically zero peroxide, although a color
specification is often used as an important measure.
BLEACHING EARTH DOZING 43
NOT oil
The neutralized oil from NOT is fed to slurry tank, where Bleaching

earth (0.5-0.7%) from the feed
PHE 806 Deo oil to NOT oil(110 C)
Now, this mixture is pumped to bleacher, or it is also sucked by high

vacuum present inside the bleacher which is maintained at a
temperature of 105 -115°C and vacuum of around 650 mm Hg. PHE 601 Heating with steam(130 C)
The bleached oil is then passed through PLF filters, which is already
precoated with filtrate powder (Celator used here) so as to filter the
spent earth as it gets stuck to the plates of filter. SLURRY TANK Bleaching earth
Further, bleached oil is passed through Polish filter in order to

remove the fines of spent earth which may be present after filtration BLEACHER
from PLF.
Dozing is done with time calculation with equal interval of time .e.g. PLF
(107 sec = 0.8% of dozing (10+20+10+67sec ))
POLISH BAG
FILTER
 BLEACHED OIL PARAMETER
Colour 20 max
FFA content <0.1% max BOT TANK
P content <5 ppm
FI (filter ability Max 10 (not
test ) less than 8)
44
 DEODORIZATION SECTION:-

 This oil from deaerator is passed through VHE 1 & 2 where its temperature is raised by heat
exchange from the deodorized oil
 Deodorized oil is the heart of economy as maximum energy conservation can be achieved
using this oil.
 VHE is a type of shell and tube heat exchanger.
. High vacuum (around 750 mm Hg vacuum) is maintained and open steam.
 Deodorizer consists of several compartments (5 vertical and 3 horizontal here). Oil overflow
from the top compartments will descend below to the next compartment. Oil stripper
 The oil from the 4th vertical compartment will flow to the horizontally placed section
of deodorizer consisting of 3 compartments. Open steam is supplied there also and they are
also under high vacuum.
 horizontal compartments will flow to the VHE for the heat exchange and is used to heat the
incoming oil to the deodorizer.
Tray
Deodorizer section consist of following: BOT TANK 45

De-aerator: Oil is de-aerated here prior to heating in order to avoid excessive
oxidation and, hence risk of polymerization. PHE 801
VHE: maximum heat recovery from the deodorized oil is done here as the heat is
used to increase the temperature of bleached oil. POLISH BAG FILTER F 801
Thermic fluid heater: Bleached oil is heated here to attain the deodorizer
temperature using Thermic fluid arrangement. DE-AERATOR
Vertical and horizontal Deodorizer: It is a packed column deodorizer consisting of
5 compartments. Oil enters the topmost compartment and flows down.
VHE (vacuum heat economizer )
 Top 3 trays are deodorizing trays and from the fourth tray, the oil flows to the
horizontal deodorizer consisting of three compartments.
VHF (vacuum heat fluid )
.Scrubber is also having a structured packing similar to deo. The Distilled fatty
acids (DFA) is continuously recirculated from the top in the scrubbing section for
condensation of the fatty acid vapors.
DE-ODORIZER SCRUBBER
 Deodorized oil Parameter
Colour 12 max
PHE 805
FFA content < 0.06% max DEO –OIL COOLING
WITH WATER
Peroxide value Nil
cooling
P content 3 ppm max
FI (filter ability test ) Max 10 (more FAD TANK
than 8 is ROT TANK
acceptable)
46
 Deodorizer distillate:

The vapors evaporated from the deodorizer under high vacuum are collected in the
Distributer
scrubber where they are condensed, and the deodorizer distillate is obtained.
Deodorizer distillate consists of mixture of tocopherols, sterols, esters of sterols,
N
RECIRCULATIO
mixed fatty glycerides, hydrocarbons, and other materials contained in a substantial
number of fatty acids.
Deodorizer distillate also contains some neutral oil (tri-, di-, and mono glycerides). With
exception of mono- glycerides, this neutral oil is present mainly as a result of
mechanical entrainment by the stripping steam and is considered as a direct refining
loss.
Higher deo temperature, large exposure times, lower vapor pressure will increase the
yield of distillate and decrease sterol and tocopherol content in deo oil.
Deo Oil Parameter limits

Deodorization 240 - 250º C
temperature
Vacuum 720 - 730 mmHg SCRUBBER
Final FFA content Max. 0.06%
Color (5 ¼ “cell) Max. 12 units
Peroxide content NIL
Phosphorus ppm Max. 3 ppm
Soap ppm NIL
Sparge steam quantity 0.5 - 2 %
Trans fatty acids 0.5 - 1 %
Tocopherol loss Up to 60 %
BY PRODUCT OF REFINARY 47

Moisture content 30 to 40%
SOAP TFM (total fatty matter ) 40% above

Neutral oil content Wet basis 16 to 20%
Dry basis 20 to 30%
Moisture content 10% max

SPENT EARTH
Oil content 20% max
TFM (total fatty matter 0.2% max

WASH WATER
PH 6.5-7.5
LECITHIN PLANT
49
LECITHIN PLANT

• At ADM Latur the gums derived from water degumming are used for the manufacture of lecithin in
the 10 TPD Lecithin Plant.
• The various steps involved are :
Gums from centrifugal separator ATFE Cooler Storage/Packing
 Lecithin Standard Parameters
Final lecithin moisture < 1%

Color of lecithin <18 units
Lecithin turbidity < 20 NTU
Viscosity < 100 Stokes
Acid Value < 30 %
Hexane Insoluble < =0.005
Acetone Insoluble 63- 65
 THERMIC FLUID BOILER WEGMAN DECK 50

 Deodorization process operates at a very high temperature which cannot be reached with help of steam under
economical limit. Thus, we require a heated thermal fluid which will be in continuous circulation in order to
raise the temperature of incoming oil to deodorizer.
Connecting coil
 This heat exchange between incoming deodorizer oil and thermic fluid occurs in a cylindrical vessel which is a
type of shell and tube heat exchanger called as heater Know as VHF(vacuum heat fluid)
 Thus, to fulfill our requirement, thermic fluid is used is THERMNOL 55.

 Therminol 55 fluid is designed for use in non-pressurized/low pressure, indirect heating systems. It delivers
efficient, dependable, uniform process heat with no need for high pressures.
 The high boiling point of Therminol 55 helps reduce the volatility and fluid leakage problems associated with
other fluids. HYTHERM 600 is an Oily Yellowish Liquid which is processed using superior quality chemical
compounds and modern technology at vendors’ end in accordance with industry. .
ID FAN
 Thermic fluid is heated up to 270-280°C at high pressure conditions to raise the bleached oil temperature
sufficiently up to deodorization process temperature i.e. 240-250 degree Celsius and itself drops down to
230 - 240. °C
FLUID USED THERMINOL 55
 Processing of Thermic Fluid: Temperature outlet 270- 280°C

Feeding is done through belt conveyor.
Temperature inlet 240- 250°C
Check that water circulation is proper for pump gland cooling.
Before starting the pump, expansion tank level should be visual. BAG FILTER 5 MICRON
Dampers must be adjusted prior to processing.

Fuel used Coal /bio mass bricked chips (new
innovation )
Bed material should be fed inside the furnace (200-250 mm from distributor plate).
Cost of Therminol 55 145 -148 Rs/ lit
Fuel feeding done through rotary feeder for combustion. Draft pressure to be maintained -2 to -5 mm WC.
51
Thermic Fluid

• Thermic fluid has ability to perform at high temperature with low pressure
• Temperature – 240-250°C
• Thermic fluid loop
Properties HYTHERM 600

Viscosity 27-38 cst
Flash Point 220°C
Viscosity Index 100
Appearance Blackish liquid
Insoluble in Hexane 0.69
Insoluble in Benzene 1.18
Acid value (TAN) 0.18
ACID OIL PLANT
53
ACID OIL PLANT

• Soap separated by the separator in neutralization section is stored in the soap tank and further sent
to main soap storage tank in the acid oil processing plant.
• Soap stock is now treated with high concentration(98%) sulphuric acid and allowed to settle which in
turn separates out acid oil, sludge & acid water.
• The acid oil is sold as a by-product & the sludge is reprocessed for getting acid oil.
• Reaction occurring can generally be written as :
2RCOONa + H2SO4 2RCOOH + Na2SO4
 Parameters of Acid Oil
Total Fatty Matter >98%
MIV 2-5%
pH 1- 4
Iodine Value >118

BOILER
55
BOILER

• And this steam requirement for each plant is fulfilled by this 12 TPH boiler.
• For any desired temperature and agitation in any of the plant, that temperature is provided by
steam or heat exchange in various PHEs or both of them combined. Steam is generated in Boiler
section and distributed by main steam header in boiler to each of the plants as per the steam
requirement.
General specifications of Boiler at the plant:
1.Maximum operating pressure: 12 kg/cm² hydraulically tested at 18 kg/cm²

2.Heating surface area = 732 m²
3.Water in tube boiler with fluidized bed combustion
4.Rated capacity = 12 TPH
5.84 bed coil tubes, 122 convection bank tubes
6.Total number of soot blowers = 2
 FLOW DIAGRAM FOR BOILER 56

DM WATER TANK CYCLONE
CONDENSOR
BAG FILTER
FEED WATER TANK

EXHAUST GAS
DEAREATOR
ECONOMIZER AIR
FUME
FURNACES HEAT BOILER
STEAM
SEP PLANT
MAIN HEADER REFINERY

57

DM PLANT
DM PLANT 59

• Natural water collects dissolved salts while flowing over
limestone, gypsum, dolomite and other mineral deposits and thus
natural water is likely to contain different concentration of calcium,
magnesium and sodium.
• Analysis of the ions mentioned above gives the TOTAL
DISSOLVED SOLIDS.
• Complete removal of all dissolved ions is called demineralizing or
deionizing which is done through ion exchange process.
• For boiler, we need demineralized water and for DM water we
need RO water. Thus, raw water is first treated in RO Plant to
form RO Water which is then processed to form the DM Water.
 Water Parameters
Parameter Raw water RO plant outlet DM plant outlet
Hardness 100 to 200 ppm 0 to 2 ppm 0 to 2 ppm
pH 7 to 7.5 7.5 to 8.5 7.5 to 8.5
TDS 300 to 500 ppm up to 7 ppm up to 20 ppm
Conductivity - up to 10 μS/cm up to 30 μS/cm
OIL TANK FARM
 OIL TANK FARM 61

Tank number Capacity(MT) Tank number Capacity(MT
1. Crude Soya 250 11. Crude Soya 200
2 .Crude Sunflower 250 12 .Crude Soya 200
3. Crude Soya 250 13. Crude Soya 200
4. Crude Sunflower 250 14. Crude Soya 200
5. Crude Sunflower 250 15. Crude Soya 500
6. Refine Soya 250 16. Refine Soya 250
7. Refine Sunflower 250
7. Change-over Crude Soya 150
8. Refine Soya 250
8. Refine Soya 150
9.Refine Soya 250
9.Refine Soya 150
10.Refine Soya 500
10.Changeover Refine Soya 500
Total Capacity :-
Crude Soya = 1600 MT
Refine Soya = 1300 MT
Crude Sunflower= 750 MT
Refine Sunflower =500 MT
QUALITY CONTROL LAB
QUALITY CONTROL LAB 63

 Various test of Oil in Quality lab:-
 Determination of Free Fatty acid in oil

 Determination of Color in oil (Tintometer)
 Determination of Iodine value in oil
 Determination of Per-oxide value in oil (Rancidity)
 Determination of Melting point
 Thin layer chromatographic test for Argemone
 Determination of Refractive index
 Determination of Saponification value
 Determination of Un-Saponification Value
 Determination of Phosphorous content in Soyabean oil .
 Determination of Bleachability
 Determination of Sediment (MIV)
 Determination of presence of Sesame oil (Baudouin Test)
 Determination of Refractive Index
 Determination of Moisture content
 Determination of chlorophyll
 Determination of (SV, IV ,RI) with help of GLC
 Soap Content in Refine Oil
GAS CHROMOTOGAPHY
 LAB TEST FOR MEAL 64
• Flame Test

• Moisture Analysis by Air Oven Method
• Moisture Analysis by Dickey John Method
• Oil Content by Soxhlet Method
• Crude Fiber Content
• Ash Content  LAB & TEST CRITICAL LIMIT OF WATER DISCHARGED FROM ETP FOR WATER
• Sand / Silica
TDS (Total Dissolved Solid ) in Water < 250 ppm
 LIMITS OF MEAL
COD (Chemical Oxygen Demand ) <30 ppm
ITEMS LIMITS
DOC oil content Less than 1 %(<100 ppm) BOD (Biochemical Oxygen Demand ) 6 - 8.5 ppm
MOISTURE IN DOC Less than 12 % PH of the Water . 10 ppm

FLAME TEST IN DOC NEGATIVE
Oil & Grease(ppm). <100 ppm
UREASE ACTIVITY 0.3% (28 to 31 dots)
Suspended Solids (ppm) <2.5 ppm
ASH & SILICA Less than 2%
CRUDE OIL SEP (FLASH NEGATIVE RSC( Residual sodium carbonates) 16 ppm
TEST 150 C)
SAR (Sodium absorption rate )
MISCELA (oil content) Oil content 24.88%
Sulphates (ppm) <1000 ppm
 LAB TEST FOR {oilseed }
• Oil content by Soxhlet Method

• Moisture analysis by Air oven method OR (Dickey JOHN METER )
• Analysis of Foreign Matter ,Damaged seed , Green Seed .
EFFLUENT TREATMENT PLANT
 EFFLUENT TREATMENT PLANT 66
 Effluent as defined by the United States Environmental Protection Agency

as "wastewater - treated or untreated - that flows out of a treatment
plant, sewer, or industrial outfall. Generally, refers to wastes discharged
into surface waters."
 Effluents coming from refinery, solvent extraction plant, boiler(at regernation

of resin),cooling tower, other parts of plant are processed according to the
government , pollution control board and the waste is disposed as per rules of
the government, while the ETP treated water is used for gardening purposes.
 Coagulation:-In this process, liquid aluminum sulphate is added to untreated

water. After mixing, this causes tiny particles of dirt to stick together. This
group of particle form larger and heavier particles, which is easily removed by
settling and filtration.
CRITICAL LIMIT OF WATER DISCHARGED FROM ETP FOR WATER
 Sedimentation:-In this process water moves slowly, causing the heavy particle TDS (Total Dissolved Solid ) in Water < 250 ppm
to settle to the bottom. The particles that collect at the bottom is called sludge
COD (Chemical Oxygen Demand ) <30 ppm
 .
 Filtration:-Water flow through a filter designed to remove particles. The filters BOD (Biochemical Oxygen Demand ) 6 - 8.5 ppm
are made of layers of sand and gravel. These filters routinely need to be
cleaned by backwashing. PH of the Water . 10 ppm
Oil & Grease(ppm). <100 ppm

 Disinfection:- Water is disinfected before it enter into the distribution system.
Chlorine is used to disinfect the water from contamination. Suspended Solids (ppm) <2.5 ppm
RSC( Residual sodium carbonates) 16 ppm

 Sludge Drying:-Solids that are collected and settled down by sedimentation are
moved to drying beds. SAR (Sodium absorption rate )
Sulphates (ppm) <1000 ppm
 FLOW DIAGRAM FOR EFFLUENT TREATMENT PLANT 67

EFFLUENT STEAM ACID CRACKINGTANK NALCO 187
ETP(Effluent LIME SOL/ POLY

OIL TRAP 1 FLOATING CELL ELECTROLYTE
Treatment
ETP(Effluent
Treatment PRIMARY
OIL TRAP 2 SETTLING TANK
Plant
OIL TRAP
OIL TRAP 3
AERATION TANK 1
H3PO4 COLLECTION TANK
SETTING TANK 1
OIL TRAP 1
AERATION TANK 2
OIL TRAP 2
SETTING TANK 2
OIL TRAP 3
SAND FILTER FINAL WATER TANK

OIL PACKAGE SECTION
 OIL PACKAGING SECTION
69

• Package which is used to protect and prevent from contamination & also give detail about
the product.
• A physical form intended to protect from contamination and increase efficiency of
Transport and finally ac to inform & motivate the purchase increasing on the part of
consumer.
 There is three type of Package :-

1. PRIMARY Package
2. SECONDARY Package
3. TERTIARY Package
 On basis of Nature of package :-

1. Flexible pack
2. Rigid Pack
 On Basis of Quantity (size):-

1. Small
2. Bulk
 PRIMARY PACKAGING 70

Packaging is process to produce Package.
POUCH :- (Multi – layer Plastic )

In the beginning of the process, the polymer comes in the form of a pellet.
it is heated and melted into a viscous liquid between rotating screws and
barrels of the extruder. This allows for the polymer to be fed through a die
that shapes it in the form of a tube. This tube is then carefully inflated, so
there is no risk of tearing, into a bubble by injecting it with air. The bubble
is simultaneously being cooled in its interior, via a cooling system, and on
the exterior surface, through the use of an air ring, to solidify the material.
A set of collapsing frames or guides are then used to collapse the bubble
into two, more defined, layers within closer proximity. Now that the layers
are close, a series of nip rollers flatten the layers together to form a two-
layered plastic film that is then wound onto a cylindrical roll for packaging
purposes. This process may vary depending upon the specifications and
models of the machines.[3]
 BOTTLE PREFORM 71

 STRETCH BLOW MOLDING
Stretch blow molding is a widely used technique e.g. for

the production of PET bottles. In a stretch blow molding
process a hot preform of polymer is simultaneously
stretched and blown into a mold shape. The process
takes place at a fast rate and is characterized by large
deformations and temperature gradients.
 INJECTION MOULDING
The principle of injection molding is very simple. The

plastic material is heated above its melting point,
resulting in the conversion of the solid polymer to a
molten fluid with a reasonably low viscosity. It is then
forced into a closed mold that defines the shape of the
article to be produced.
72

 VARIOUS RECYCLE’S SYMBOL OF PLASTIC
73
 TIN MANUFACTURING (SINGLE LINE SLITTER)

Cleaning: Cleaning removes oil, grease and other surface contaminants that can
reduce the effectiveness of the plating process.
Preparing the Plating Bath:-

The next step is to prepare an electrolytic solution, also known as a plating bath.
Electrolytic tin plating baths can be comprised of acid tin, alkaline tin or methyl
sulphonic acid solutions.
Electrodeposition Procedure:
. The object serves as the cathode, which is the negatively charged electrode in
the electrical circuit. The anodes, which are the positively charged electrodes in
the circuit, are placed near the edge of the plating tank.
Post Electroplating Process:-

Post-treatment is usually not required at the conclusion of the tin plating.
Passivation — which is the application of a light coating of protective material —

may be used in special plating applications to provide additional corrosion
protection or enhance the reactive properties of the tin. Heat treatment may
also be used to prevent hydrogen.
74
 SECONDARY PACKAGING

Secondary packaging is the second layer of packaging applied to your
product after the primary packaging layer. For example, consider the
paperboard box holding the plastic bottle that your over-the-counter
sleep aids or pain killers come in. The box would be viewed as a form of
secondary packaging
It may be of varies type :- THREE PLY CORRUGATED BOX
• Single Ply
• Double Ply
• Five Ply
• Seven Ply
STACK HEIGHT CALCULATION :-
Stack Height = B.C.S( Box compression Strength)

Weight of Package * FOS(factor of Safety )
CALCULATION OF STACK HEIGHT 75

B.C.S of a box is 150 Kg f
FOS(factor of Safety ) for
Flexible pack = 3.2-3.5

Rigid Pack = 2.3-2.5
Weight of (all)empty box is 1.5 Kg

Single Box weight is 1 Kg STACK
We have 12 pouch = 12*1 =12Kg HEIGHT
Total weight of box is (12+1.5) =13.5 Kg
Stack Height we get = 150/13.5*2.3

= 4.805 = 5 (approx.)
 OIL PACKAGING SECTION 76

 OIL STORAGE TANK(Sunflower Oil) 20+20 Tones
 OIL STORAGE TANK (Soyabean Oil )10+20+10 Tones
 FORTIFICATION IS DONE BY:-

• (Bottle) 100 gm per 5 tones of oil (Vitamins A, Vitamins D)
• 750 ug vitamins A
• 11.25 ug vitamin D
• dozing in refine oil for Fortification of oil.
 TBHQ (dozing)
 100 ppm( 10% concentration)1 kg per 10 tones of oils .
 CCP filter are used filter the oil before packaging (Pressure gauge fitted to check its
proper working).
 ALL SKU’s OIL’S 77

SKU”s Soya bean Oil Sunflower Oil
0.5 LITER OIL
pouch
1 LITER
Bottle OIL
2 Liter Bottle
oil
5 L Bottle
5 Liter Jar oil
15 liters Jar
oil
15 kg Tin Jar
15 Tin Jar
Total Number of SKU’s =12

 PESTROPACK OIL FIILING MACHINES 78

FILLING CAPABILITY OF (25 pouch per minutes)
VERTICAL = 200
HORIZOTAL = 100
CUTTER = 145
COOLING SYSTEM IS MAINTAINE AT = 10 to 11 degree Celsius
BATCH CODING SYSTEM
DD 185 B
DD for 185 mean 4th B means lot

DHARWAD of july number
DD for Dharwad
79

 OIL PACKET CONSIST OF CERTAIN DETAILS
CONTENT PER 100 gm

Energy 900 kcal
Carbohydrate 0 g
MRP Fat 100 g
LOT NUMBER
SFAs 17 g
PACKED ON
USED BY (6 Best before PUFAs 57 g
used ) MUFAs 25 g
Trans fats 1g
Vitamin A 750 ug
Vitamin D 11.25 ug
PROJECT
PROJECT 81

 Cost Optimization Of bleaching Earth Dozing
By using alternative Solution (Bleaching Earth)
Cost of various Bleaching Material:-
Galan V2 = 30 Rs
Oil Tonner = 27 Rs
Neutral Earth = 10 Rs
Oil quality :- FFA = 0.8%
We are dozing at Ratio of 70:30 (Galan V2 : Neutral Earth)
CASE:1
Galan V2 : Neutral Earth =70: 30
Oil loss in Spent Earth 16%
1000 Kg Dozing
0.8% of dozing total bleaching Earth dozed = 80Kg (0.8% of 1000 Kg) Time VD color Bleacher Deo color
color
Cost of dozing material at this ratio:-
Galan V2 = 30 Kg = 30*56 =1680 Rs 4:00 42 25.5 8.2
Neutral Earth = 10* 24 = 240 Rs
Total cost of total bleaching Earth = 1680 + 240 =1920 Rs/Ton 6:00 42 25.5 8.2
Total oil Loss 16% of 80 KG =12.8 Kg of Oil
8:00 42 25 8.6
CASE:2 82
 Change over of Bleaching Earth

Oil Tonner : Neutral Earth =70: 30 Time VD color Bleacher Deo
Oil loss in Spent Earth 16% color color
1000 Kg Dozing 10:00 42 26 8.7

0.8% of dozing total bleaching Earth dozed = 80Kg (0.8% of 1000 Kg) 12:00 42 26 9.2
Cost of dozing material at this ratio:-

Oil Tonner = 56 Kg = 27*56 =1512 Rs
Neutral Earth = 10* 24 = 240 Rs
Total cost of total bleaching Earth = 1510 + 240 =1752 Rs/Ton
 Difference in price Bleaching Earthy Dozing we get (1920 – 1752)= 168 Rs/ton
 New Bleaching Earth
Total oil Loss 16% of 80 KG =12.8 Kg of Oil
Time VD color Bleacher Deo color
½” color 1” 5 1/4”
2:00 42 26 9.2
4:00 42 26.5 10.6
6:00 42 27 10.9
83
 STANDARD DEVIATION OF POUCH FILLING MACHINE

Weight of Sunflower Pouch
 Day 2
 Day 1
10:00 11:00 12:00 1:00 3:00
10:00 11:00 12:00 1:00 3:00
919.5 917 918 917.5 917
917.8 920 919 919.5 918
919.5 919 918.5 918.5 920
918 919 917.5 918.5 916.5
916.5 915.5 918.5 918.5 918.5
918.5 917. 918.5 919. 917.5
919.0 918.5 920 917 919
920.0 918.5 919 920 919
917..5 919.0 916.0 919 918.5
916..5 918.0 920.0 917 917
918.0 918.5 918.5 920 918.5
917.5 917.5 919.5 918.5 919
918.0 918.5 917.5 918 918.0
919 918 915.5 917 920.0
919.0 916.5 918.5 917 919.
918.0 917.5 918.5 919 918.5
920 920.5 919 917.5 917.5
919 917.5 919 917.5 919
918 919.0 918 920 918
919 920.0 918.5 919.5 916.5
After calculating the STANDARD DEVIATION of the taken reading we get 916.87
It mean the there is deviation in PESTROPACK OIL FIILING MACHINES it is approx. 0.33 gm of oil
Standard weight = 917.2 gm

Thank You

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Industrial Training Report

By- Shubham Kumar Yadav & Shreya Pandey

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Note- Accident don’t happen but they are caused.

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Palmitic acid 10 -12%

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1) Oil seed Go-down

4) Solvent Extraction Plant

5) De- oiled cake Go-down

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• When the materials enter into roller, the materials on the

• Materials overturn and run ceaselessly. So if there are

MOTER SPEED 1430 rpm

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 The first sieve is a scalping screen which scalps all MESH 10 mm

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Bulk Density of soya seed is 0.7- 0.8gm/ml

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Cracker comprises of two pairs of corrugated rolls arranged one

· CK – 100, CK – 101, CK-102

 Each cracker having two set of rolls ( 3 cracking). Horizontal projection

5 TPI(thread per inch)

Length of Roller 1330 mm

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 The main purpose of cooker is to soften the seeds for the

 Generally, the outlet temperature of seeds after cooking is

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 Roll hydraulic pressure(50- 60 kg/cm²) set to maintain thickness

FL-116 1220*500 1480 rpm 25” 800 rpm

FL -117 1200*600 1480 rpm 30” 800 rpm

0.35 mm critical thickness

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6. Rotation of screw is about 20 rpm .

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Oil content 19% max 20% Fiber content 6 to 7 %

Damage seed Max 5%

Foreign matter 2.15% FLACKER

FLOW DIAGRAM FOR OILSEED PROCESSING

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CLEANING EXPANDER MISCELLA MEAL DOC

MAGMATIC SOLVENT EXTRACTION

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Heat exchanger (final to

PHE WATER TO OIL

OIL STORAGE TANK

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