INTRODUCTION

INDUSTRY PROFILE

With the rapid increase in population, human nutrition too has become a

problem, Protein-the vital ingredient of balanced diet, essentially for the growth

and well-being-is in acute short supply especially in the developing countries. For

the large proportion of vegetarians, finding protein from the vegetable kingdom

has become a compelling necessity. Viewed in the perspective, oil-seeds in modern

times are valued as much for the protein they contain as for the oil.

The method adopted for the recovery of oil from oilseeds naturally influence

the Quality of the products produced. The village “Ghani or chekku” is a simple

mechanism, Perhaps well suited for decentralizing and self-sufficient village

economy. As processing Condition are mild, the quality of oil and oilcake

produced is very good. However the inefficient recovery has rendered it

uneconomic in modern times. The expeller has vastly improved recovery figures;

but in the process they badly affected and in most cases the oil too.

The advent of solvent extraction, a new concept has been introduced in the

recovery of oil from oil-bearing materials. All the earlier method relived on

mechanical pressure for squeezing out of oil from the parent material. Higher

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pressures were required for obtaining better recovery and on squint high

temperature material and the products. Solvent extraction, on the other hand

dissolves the oil out of the parent material and the process can be conducted under

mild condition to get good quality and oil.

Inventory control is kept according to the flexibility of market situation

which is more than or loss than 10 days. The minimum stock level is maintained in

case of monsoon failure & competition. The maximum stock level is maintained

when there is a good market for the product.

The inventory control techniques of Jeevan Oil are not fully well equipped.

It has to adopt some latest equipments and technologies for producing the

maximum output & to achieve the target of the management.

Rice bran oil is used as a premium edible oil in Japan, china, Thailand and

other countries. In Japan Rice brand oil is more popularly known as ‘Hearty oil ‘as

it keeps cholesterol level in serum relatively less. Government of India has gone in

details into the question of edibility of Rice brand oil. Standards of quality have

been laid down in the prevention of Food Adulteration Act 1955.

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OBSERVATION – ONE

Company Profile & Product Profile

United solvent extractor (p) Ltd has been incorporated under the Indian

companies Act. The company started its commercial operation in the year 1976.

The company is situated in the national highways road connecting Chennai and

Salem at a distance of 16 kms from its taluk head quarters Attur, in Salem –

Kallakurichi main road.

The company is entirely managed by Mr.K. Subramaniyam as its managing

executive. The company has only one solvent plant having 40 mts of processing

capacity per day.

In addition to the above plant one edible oil refinery unity with 10 mts

processing capacity per day is also functioning. Rice bran is the primary raw

material used for producing oil for both industrial and edible purpose.

The company has government supply of electrical power (250 KVA) three

phase supply. It has also three power generators with a total capacity of 400 KVA.

Six steam boilers, husk and fire wood boilers with 3 ton capacity each are used by

the company to produce 5 mts steam. The company consumer at an average 70000

units of electric power every month 70% of which is used to run motor driven

machineries.

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The company is not having its own weigh bridge but a private weigh bridge

is used for the purpose of weighing the incoming & outgoing materials. The unit

has enough land to expand its operation in future. As of now the company has not

having any long standing dues with banks and financial institutions.

The unit engaged in exporting operation since the year 1990. It has regular

orders from various countries mostly for industrial usages. Also it has a well

developed domestic market among severe competitors.

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ORGANISATION CHART

Managing Director

Executive Director

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Plant Engineer

Accountant

Typist

Chemist CashierOperator Labour

Manager

Typist

PRODUCT PROFILE

NUTRITIONAL PROPERITIES OF RICE BRAN OIL

The different nutritional properties of rice bran oil are

UNIQUE CHOLESTROL REDUCING ACTION.

In a series of test conducted by the famous National Institute of

nutrition (NIN) has found that refined Rice Bran Oil lowers

cholesterol level unlike any other edible oils in India. The following

table gives a clear picture

S.No. Edible cholesterol

1. Rice Barn Oil - 17

2. Safflower Oil (Kardi) Oil - 16

3. Corn Oil - 15

4. Sunflower Oil -12

5. Cotton Seed Oil 0

6. Sesame (Till) Oil + 2

7. Soyabean Oil + 3

8. Groundnut Oil + 5

9. Cocunut Oil + 6

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ANTI-CANCEROUS PROPERTIES

Studies at NIN have revealed that refined rice bran oil is a potent anti-

mutagen (Anti-Carcinogen): It prevents carcino – genisis even if a

carcinogen enters the system. Since it has high concentration of ferulic

acid due to the presence of oryzanol which is a mixture of several

compounds as ferulic acid esters. Ferulic acid is a well know anti-

carcinogen. Hence refined Rice Barn OIL has a beneficial effort to

prevent cancer.

GET ABSORBED LESS (SAVE OIL)

When you use JEEVAN RICE BRAN OIL for deep frying, less oil is

absorbed: At demonstration in Chennai, revealed lesser oil is being absorbed

for frying, vadas. For the same No. of vada 5% of more another cooking oil

was needed. A sizeable saving in oil is noticed, then what more, food fried in

bran oil, is non greasy and easy to digest.

TOCOPHEROL (VITAMIN E):

A valuable nutrient for the human brain and it also strengthens

digestive system. It is also an important antioxidant.

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SQUALENE

Maintains the integrity of the skill and guards against skin disease.

MICRO – NUTRTION

Contrary to popular belief, most of the nutrients of rice are in the bran

which is removed when rice is milled (polished). Bran oil is extracted from

this bran, the most nutritious part of rice. This is what refined Rice Oil

gives.

RETAINS A NEUTRAL FLAVOUR

Rice Bran Oil has been absolutely flovour less. Which is why, food

cooked in Rice Oil retains every bit of its original flovour.

ORYZANOL

Accelerates growth of the human body, smoothens blood circulation

and stimulates secretion of hormones.

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OBSERVATION - II

0PRODUCTION PROFILE

To achieve best results in solvent extractions, the raw material is prepared so

as to enable proper and efficient recovery of oils in the extraction plant, Bran

require proper tampering and addition of moisture and then palletized for proper

extraction.

The processes consist of the following steps.

1. Bran is passed over a vibrating screen to remove any small pieces of

stones and other unwanted materials before it is fed to a feed

elevator.

2. The feed elevator discharges the bran to a tempering screw

conveyor.

3. A regulator is mounted on the conveyor to facilitate proper

formation of pellets in the pelletiser.

INSTRUMENTATION IN THE PREPARTION SECTION

Vibration

Vibrator shaker operator two tray complete with purifying nozzles and

suitable drive arrangement driven by motor.

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Elevator

Standard buckets elevator in mild steel construction with driving part,

bottom tension part, hook chain, pressed buckets and complete with driving

arrangement to transport clean rice bran container.

Condition Feeder

Is a mild steel construction having suitable tough, along with

conveying and making screw for adding open steam to rice bran before

feeding the bran to pelletizing machine complete with driving machine.

Motor 2HP * 1440RPM,

6/box 3 inch Cr * 40: IR

Pelleting Machine

Specially designed for pelleting the floury rice bran before feeding the

bran to extractions plant. The machine comprise of special steel plates pan

grinder, lead fitted with corrugated pan grinders, Fiber glass reinforced head,

along with special gear arrangements transmitted through control hallow

shaft complete with driven mechanism.

Motor 75 HP * 1440RPM

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Pellect Cooler

Horizontal type machine in mild steel construction fitted with endless

special steel flexible belt complete with air drawing arrangement through the

pellets bed for quick cooling of pellets.

SLOVENT EXTRACTION METHOD

The principle of this section is to extract the oil by using optimum

efficiency method. It is a simple process used to extract oil from oil bearing

materials by treatment with a solvent.

For separation of liquid from solid solved extraction method and for

separation of liquid percollator method is used. The process is most

efficiently used in oil extraction industries to extract vegetable oil and fats

from seeds and nuts.

Collection and Storage of Raw Materials (BRAN)

The raw material is collected from different places in Tamilnadu.

About 90% of rice bran is collected from places nearby Attur, 40 metric

tons of material is used every day. It yields about 320kg oil.

The raw material is labeled with

a) Bran arrival date

b) Lot No.

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c) Bran Supplier name

d) Number of bags.

e) Supervisors name etc.

SIEVING

Raw material Bran is sieved before processing. During sieveing

process husk, stones, threads and other unwanted material are removed.

The sieving process is done in a machine named vibrator shaker consist

of two tray type complete with purifying nozzles and suitable drive

arrangement driven by motor 2HP * 1440RPM

STEMING OR WORKING

The feed elevator discharges the bran to a tempering screw conveyor

and then discharge into a steaming pan. The steaming pan steams at a

temperature of 10000 C. By steaming the bran it get cooked so that the

outer of the bran will break and make the extraction easier.

PELLETING

The steam or worked bran is then passed into palletizing or the cupper

machine there it essentially get pressed between die plates and emerge

out of the Die plate. Size of these pellets are usually are 12-14mm in

diameter 1”-15” long. The pallets coming from die plates are hot and

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soft. They are to be hardened and cooled in a cube cooler. Perforated

oven belt inside the cube cooler moves the belts from one end to the

other. A bowler for the purpose of cooking and hardening the pellets

Draws air through the belt. The cooled pellets are fed into solvent

extraction plant through a regular conveyor 186.

MAIN PLANT SECTION

The main plant section is continuous type of solvent extraction plant

using solvent to extracts the oil from the rice bran. Here hexane is used as

solvent and also steam is used get to the good oil content rice bran. From

this the half miscella and miscella is taken. By the steam evaporation the

oil and solvent is extracted.

i. Extractor

Extractor is constructed by mild steel and its bed is stationary. But the

material moves from the Extractor for Extraction process.

ii. Drier:

They are used to dry the de oiled meal and to evaporate the process

hexane in the de oiled meal. It is having 7mlenth of each and 0.7m

from this the material moves after drying it goes to bagging for cattle

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feed according to the protein content if it is less it is used as fuel in

boiler.

iii. Conveyor:

For the feed raw materials and the De-oiled cake are taken out of the

plant in and out by using the Conveyor. The Conveyor used here are

having chain and its breath is fitted in floor.

iv. Steaming pan:

It is located near by the Drier, and is used for material scaling. Because

it is the material outlet point. Hence it should not allow the atmosphere

to enter in and air will not allow to escape solvent vapour out.

v. Miscella Tank:

Its capacity is 4000 liters. The extracted oil and solvent is collected in

this miscella tank form extractor.

vi. Solvent Water Separator:

Here a tank is used to separate the solvent and water by density

separation. A small amount of water is added to the solvent and So that

it is separated.

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vii. Primary and Secondary Heater:

There are primary and Secondary heaters and they have a set of

flashes. They are used for evaporating the solvent from the miscella.

For that the oil and solvent mix are flashed.

viii. Stripping Column:

It is used in order to dry the oiled bran by using high vaccum. This is

the final stage of the distillation section.

ix. Reqbration system:

It will absorb uncondensed vapor and that vapor will be received by

means of heating and cooling it having mineral oil for absorbing.

x. Emergency Storage Tank:

At the top of the plant there is a storage tank. If there is any power

failure (or) other machine defects found in the plant. Immediately the

water enters the full plant and it reduces the heat. This is a safety

measure taken to avoid major accidents.

xi. Cooling tower:

There are two cooling towers. The capacity of 400 GPM (Galance per

million). These are used to cool the outgoing gases. There is a big fan

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at the top of the cooling tower is used to circulate the cooled water at a

speed of 30 liters per second.

OIL REFINERY SECTION

Crude Rice brand oil is refined in four stages.

1. Water degumming and neutralization process

2. Bleaching process

3. De Waxing process

4. Deodorization process

Degumming and Neutralization process

The edible grade crude oil to a capacity of 6 to 7mts is taken to a

degumming vessel. In the degumming vessel there is a wheel which rotates at

36 rpm. Phosphoric acid and water is added in the radio of 1:1, phosphoric

acid is added at one kg per M.T.

The raw oil mixed with phosphoric acid is stirred for about 45 minutes

and water sprayed, when the temperature of oil reached to 100 c. The purpose

of spraying the water is for washing the oil.

After adding or spraying hot water again it is stirred and allow it to settle

for about 45 minutes. After stirring is over it drains the gum then it is allowed

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to remain for about 4-5 hrs. Then the gums have been drained which is settled

at the bottom of cone.

Neutralization

The degummed oil is taken to batch neutralization and heated at 75c, then

water sprayed in the ratio of 20litre per ton. Stirring continued for about

45minutes. When the temperature of oil reaches 80c, caustic soda is added and

stirred again for about 1 hour. Stop the stirring and again spray water for

washing the oil and allow settling for about 4hours. Drain off water and soap

which is settle at the bottom. The settling and washing process is repeated 4

times. After that neutralized and degummed oil goes into bleacher.

The drained fat oil and water goes to a processing vessel. Add H2SO4

and allow to settle for 24hours. H2SO4 is added to neutrilise the caustic soda

present in the soap oil Then the water get separated. The separated water is

slightly acidic and cause pollution problem. In order to avoid pollution

problem calcium hydroxide is added to separate water in order to netrilise and

water is dried in a sand bed dryer. The water gets evaporated and alkalai

remain in the bed.

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Bleaching process:-

The neutrilised oil is taken to a vessel called bleacher where it is heated

up to 100c with 700mm vacuum for 2 hrs. The main purpose of bleaching is

for removing colour. And then carbon at 0.25% per tone of oil is added. It is

then stirred for about 45minutes. The initial temperature of the oil is 100c and

temperature gets reduced to 90c.

Filtration

After bleaching process the bleached oil get filtered in a bleacher filter.

Carbon and earth get separated in the bleacher filter. From the bleacher filter

the oil is transferred to bleacher oil tank (BOT Tank)

Deodourisation process

From the BOT tank the oil is taken to deodouriser. In the Deodouriser

the oil get circulated for 5 hrs at a temperature of 200c. The main purpose of

deodurisation process is to remove the unwanted odours.

Then the oil is taken into a deodourised oil (Do) cooler where the oil get

chilled to a temperature of 30c at 100mm Hg.

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Again the oil is transferred into a crystallizer or chilling cooler where the

oil get chilled to a temperature of 24c. When the oil get chilled, waxes present

in the oil get solidated and can be separated easily by using de waxing filter.

The deodourised and dew axed oil is sent to ROT (refined oil tank).

From the ROT the oil goes to the packing section.

Packing

The refined oil is loaded on the tank and then the oil content is moisture

through the oil compression for the complete removal of scales, which get

purified. This purified oil is sent to the cylinder. An up and down moving

scale is attached with the cylinder for the sucking of oil. A form like package

is attached with the machine. A measurement scale is also attached with the

machine for measuring the quantity of oil. Through the packing process it get

completed and reaches the market.

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OBSERVATION - III

DEPARTMENT PROFILE

PERSONNEL DEPARTMENT

Cordial workers relationship is maintained in the concern and there is no

union since its establishment. The Company gets complete obligation from its

staff. Hence they get needy allowances such as graduity, provident fund etc.,

The Company extends all sorts of benefits like salary, bonus, weekly holiday,

double wages etc., to its staffs & workers are trained with the latest

technologies hence that they are fully benefited. It provides certain

recreational facilities at times.

1. First aid boxes are available adequate numbers.

2. Company provides good water facility,

3. Company provides good health and safety needs

4. Company maintains separate attendance register for office staff & field

workers.

5. Company provide holidays on all national holidays.

6. The company operates in three shifts. viz.

6.0 AM to 2.00PM

2.00 PM to 10.00PM

10.00 PM to 6.00AM

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7. This organization motivates employees by providing Incentives

according to their performance.

FUCTIONS OF THE PERSONAL DEPARTMENT

1. Man power planning includes determination of the present and future

manpower needs of the enterprise.

2. Selection of the employees is the important step of the personal

department.

3. The company encourages the employees by giving them promotions and

incentives.

4. The personal department also transfers the employees if they are unfit for

the particular job.

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ELECTRICAL DEPARTMENT

The industry has to be operate the mechanical equipments with

the individual electrical motor by using the system of belting, shafting and

gearing.

1. TRANSFORMER

*Indian transformer ltd

Voltage capacity : 22000/11000.440kva

Primary : 440 v

Secondary : 120 v

Outside transforms

Step down in main transfer to factory

2. GENERATEOR

*KVA=82.5 V=415 AMPS=114.8

But consumes 420 v

KVA=200 v=415 Amps=278

KVA=125/100 v=415/240 Amps=174

3. Hourly diesel consumption= 45 litre

*Boiler capacity is based on heating surface access

*Capacity =4 tones per hour

*Boiler mounting (for safety purpose)

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ANALYTICAL DEPARTMENT

LIST OF DAILY LABORATORY TESTS CONDUCTED

1. Moisture Content check.

2. Determination of insoluble impurities.

3. Determination of free fatty acids.

4. Determination of colour.

5. Determination of soap content.

SOME IMPORTANT TESTS IN BRIEF :-

DETERMINATION OF MOISTURE CONTENT

AIM:

To determine the moisture content of feeding material (Rice bran) by Air –

oven method.

APPARATUS:

Petri dish, air oven weighing balance.

PROCEDURE:

Weigh accurately about 20 gm of bran into a petri dish. Place it in a hot air

oven at a temp of 100 degree c for 1 hour. After 1hr take the sample and weight

it again. There will be a difference in its weight. This difference is the moisture

content of the bran.

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Calculation

Moisture % is calculated by formula

Moisture%=Weight of moistureWeight of bran

x100

2. DETERMINATION OF FREE FATTY ACIDS

AIM:-

To determine the free acid in the given crude oil.

Reagents:-

Ethyl alcohol, Phenolphthalein indicator solution, standard aqueous

KOH or Naoh sol 0.1N or 0.5N.

Procedure:

Mix the oil or melted fat thoroughly before weighing. Weigh accurately

a suitable quantity of the cooled oil or fat in a 200 ml conical flask. Add 50 to

100ml of freshly neutralized hot ethyl alcohol and about 1 ml of

phenolphthalein indicator solution. Boil the mixture for about 5 minutes and

titration while it is hot as possible with standard aqueous alkali Solution, shake

vigorously during titration.

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Calculation:

Free fatty acid=Normality*density of oil* value. of NaoH /Wt of oil

F.F.A In term of oleic acid

F.F.A In term of lauric acid

F.F.A In term ofricinoleic acid

F.F.A In term of palmitic acid

Where

V=Value in ml of std KOH solution used.

N= normally of std KOH solution.

W=Weight in gm of the material taken for the test.

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MATERIAL DEPARTMENT

Material maintenance section in united solvent Extraction includes three

stages.

a) Raw material storage

b) Oil storage

c) By product storage

a) Raw material storage:

In consists of the bran arrivals, bran storage, bran feeding to process and

husk arrivals and maintenance. They do the work as follows:

1) Bran is arrived to industry from surrounding rice mills by lorries,

tempos, tractors in 50kg bags.

2) They are weighed and stored in godown which is a safety place for

bran storing and protecting it from rats and bugs. The godown is constructed as

it is not affected by moisture and air to avoid rancidity.

3) In godown brans arrived are lotted and slipped with the following

indication.

a) Bran arrival date

b) Lot No

c) Bran supplier name

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d) No. of bags

e) No. of bran

f) Supervisors name

4) Them Bran, Husk, Fuel to boiler aloes protected in open area to make

them dry.

5) They are sampled and sent for analysis in laboratory.

b) Oil storage :

1) The oil produced was stored in 3 oil storages.

2) Storage tanks are made of iron and steel plane vertical cylindrical tankers

containing a rotator to wake rotation to the oil frequently.

3) First tank is provided for edible oil i.e. FFA below 5%. The second one is

middle oil i.e. FFA below 10%.

4) The tank is indicated with cm. Measurements. Each tank is 326 cm height

cm indication is expanded with the weight of the oil.

In first tank, 1 cm indicates 41.5 kg of oil.

In II & III tank 1 cm indicates 43.5 of oil.

5) The height of the oil in three tanks is measured at the end of each shift to

calculate the production of that shift.

6) The tanks are made cylindrical to get maximum area of iron plate, to get

equivalent centrifugal force in the overall area of the tank.

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7) Oil is loaded to tanker form the storage tank through the pump.

c) By product storage:

i. The extracted and desolventised bran is arrived to godown by rotary

conveyor in which it is cooled by air.

ii. The cooled, De-oiled meal is again cooled by air.

iii. They are sampled and analyzed in laboratory.

iv. They are lotted load wise

v. They are loaded to poultry and animal feed companies.

The loading and unloading, lotting works are made by the contract

labour from Bilar and supervised by the 4 supervisors of the company. For

selling the main products and by products sales representatives are appointed.

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MARKETING DEPARTMENT

Marketing is an art of matching the produce with the consumer at

right place and time. It is a mixture of mathematics, Science and Economy.

Every concern depends marketing for its source of Income.

Rice Bran oil the product of united solvent is consumed by two major

sectors. Viz.

a) Food Industry & (b) Chemical Industry.

Food Industry uses refined rice bran oil that is rich in Quality and easily

ediable mostly used in production of Backery items, cooking oil and fat

production for animal feed.

Chemical Industry uses Bran oil to produce Bath soaps, Detergents and

Acid.

The firm adopts two modes for market its product. For food industry it

adopts direct supply without intermediaries. But for chemical and other

industries it depends commission agents and other Brokers to get bulk order

from other states.

The company uses its own delivery van to deliver the ordered goods

when the buyer’s destination is within 75km radius. And it depends private

Lorry transportation to supply out stations and other status.

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The company follows variable pricing strategy according to situations.

Sale price of the product is determined after analyzing the demand prevailing in

the market stations and competitors move towards that. General Manager of the

concern took increase of all activities related to sales. Under his head sales

manager implement the marketing function with the help of sales personnel.

500ml, 1000ml, 5000ml sachets were the common sale Quantity made

available in the market for cooking purposes.

For all other purpose packing is done on the basis of buyer’s

specification in tins.

The cook oil market of united solvent is within Tamil Nadu and

industrial oil extends beyond the state.

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FINDINGS

As a forerunner in oil extraction from Rice Bran the company is having

standard customer roll throught the state.

Using its By – product to produce steam power helps the company to

depend less for electric power from government.

Most of the employees of the concern belongs to local area where the

factory is situated and this helps the management to study easily the problems

faced by them and to redress it quickly.

Although the company runs its operation for more than three decades its

infrastructure is not better.

There is no proper incentive plans programmed for labours and this makes

them lethargic in their work.

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CONCLUSION

A picture is hundred times better than the words, like wise a practical

section is hundred times better then the theory section.

This Inplant Industrial Training I underwent is very useful for me to attain

the practical knowledge about the principles and function of various department

of the organization.

I learn a lot of necessary information as result of this Inplant training. It

improves my knowledge about production & marketing of the organization.

Each department of the organization is analysed individually to collect

necessary data that are useful for me to generate this Inplant Industrial training

project report.

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