Detailed Project Report (DPR) on soyabean oil with refining

SOYABEAN OIL WITH REFINING

[CODE NO.3824]  

Primitive mills and presses for extraction of oils from seeds have been in use sevice long.  Mechanization came with the introduction of the hydraulic press by the end of the 18th Century.  This too was replaced by the more efficient screw press or expeller towards the end of the last century.

The  first  chemical  process  applied  to  fats  and   oils (excluding  oxidation in burning) was saponification  for  making soap.   Industrialization  of  oils  and  fats  began  with   the installation  of  a cotton seed oil mill in South  California  in about 1826.

The methods were crude and the product was impure in 1850 the use of caustic soda to remove free acids from the oil was introduced in France. About this time the millers became aware of the value of linters (fibre) that clung to the Hulls, and also of the Hulls themselves as cattle feed.

By   1887,   more scientific  methods  of   refining   were introduced.   In 1983  it  was learned that  the  oil  could  be deodorized by blowing steam through it at high temperatures.   In 1900 the discovery that oils could be hydrogenated to  produce fats of different consistencies revolutionised the entire oil and fat   industry.    So   far   no   comprehensive   and  absolute classification of vegetable fats and oils is made though various schemes have been used based on origin, physical characteristics, composition or use, or combinations of these factors.

They aremore commonly classified according to their capacity for absorbing iodine i.e. Iodine value.   Those with a high  proportion of double bonds are called drying  oils,  those intermediate  in capacity are called semidrying and those of  low capacity  non-drying.  In general the non-drying and semi-drying oils are used as foods and as lubricants and the drying oils  as paint and varnish ingredients.  This distinction has never been a very  precise  one  and  is becoming less  so  as  oils  formerly classified  as semi-drying such as soyabean are being  used  more and  more  in paints varnishes and other products that dry in a highly satisfactory way.

 Edible oil should have a fairly high keeping quality. However oils get spoilt in storage due to various spoilage factors, the chief among them being oxidation.  The edible oils and fats such as olive, cottonseed, corn, groundnut, sesamum, soyabean etc. have been found to be almost completely assimulated. As such vegetable oils may be classed as edible and non-edible. Important vegetable oils are castor, coconut, cottonseed, linseed, mustard, olive, palm, groundnut, sesamum, soyabeans, sunflower and rice bran oil etc.

India is not only one of the leading oilseeds producing countries of the world but is the only country which produces in commercial quantities largest varieties of oilseeds. With the exception of palm, palm kernel, olives, and tung. India produces all the principal oilseeds which form the basis of the world’s oil seed crushing industry. The oil milling industry in India may be divided into three groups depending upon the method of milling.

COST ESTIMATION

• Plant Capacity                                     300.00 MT./day
  
• Land & Building (12000 sq.mt.)        Rs. 6.70 Cr    
• Plant & Machinery                              Rs. 3.00 Cr 
• Working Capital for 12 Month    Rs. 19.48 Cr 
• Total Capital Investment                    Rs. 29.69 Cr 
• Rate of Return                                     57%
• Break Even Point                                30%

• INTRODUCTION
  
• USES AND APPLICATIONS
• PROPERTIES
• COMPOSITION OF SOYBEANS
• TABLE 1. TYPICAL COMPOSITION (WT%.) OF SOYBEANS (DRY WEIGHT BASIS).
• TABLE 2. TYPICAL COMPOSITION OF CRUDE SOYBEAN OIL.
• B.I.S. SPECIFICATION
• MARKET OVERVIEW OF EDIBLE OIL IN INDIA
• MARKET OVERVIEW
• TABLE: PRODUCTION AND CONSUMPTION PATTERN OF EDIBLE OIL
• TABLE: KEY MARKET METRICS:
• FIGURE: PRODUCTION TREND OF DOMESTIC EDIBLE OIL
• FIG: INDIAN EDIBLE OILS PRODUCTION, IMPORT AND CONSUMPTION
• COMPANY PROFILES
• INDIA’S 4 ZONES FOR CONSUMPTION PATTERN
• ZONE WISE CONSUMPTION PATTERN (2014/15)
• ZONE WISE CONSUMPTION PATTERN (2014/15)
• CATEGORY-WISE CONSUMPTION OF EDIBLE OILS IN OHC
• INDIA’S KHARIF & RABI OILSEEDS PRODUCTION DURING 2015/16 AND 
•    ESTIMATE FOR 2016/17
• DOMESTIC EDIBLE OILS PRODUCTION DURING 2015/16 AND FOR 2016/17
• CONSUMPTION OF EDIBLE OILS DURING 2015/16 AND FOR 2016/17
• EDIBLE OIL S/D FOR 2015/16 AND FOR 2016/17
• IMPORT BREAK-UP FOR 2016/17 AND 2015/16
• IMPORT DURING 2011/12 TO 2015/16
• IMPORT GROWTH IN 5 YEARS
• CONSUMPTION OF OIL TYPES ACROSS DEMAND SECTORS
• OIL CONSUMPTION TREND ACROSS INDIAN STATES
• LIST OF CUSTOMERS FOR SOYBEAN OIL
• SOYABEAN OIL PRODUCTION METHODS
• SOYBEAN OIL PRODUCTION PROCESS
• ADVANTAGES OF EXPANDER -EXTRUDER - COOKER
• SOYABEAN OIL EXTRACTION
• CLEANING OF SOYBEANS
• EXTRACTION OF SOYBEAN OIL
• PURIFICATION OF SOYBEAN OIL
• HYDROGENATION OF SOYBEAN OIL (OPTIONAL)
• SEQUENCES IN SOYABEAN OIL EXTRACTION
• PREPARATION AND DEHULLING
• EXTRACTION
• DESOLVENTIZING
• OIL REFINING AND PROCESSING
• DETAILS OF SOYABEAN OIL EXTRACTION & REFINING
• STRUCTURE OF OIL BODY (WASCHATKO ET AL., 2012)
• MECHANICAL EXTRUDING-EXPELLING PROCESS
• HEXANE EXTRACTION
• TABLE: PHYSICAL PROPERTIES OF N-HEXANE AND EXTRACTION HEXANE 
•    (NFPA-36 STANDARD, 2009)
• SCHEMATIC FLOW OF OIL SOLVENT EXTRACTION
• ENZYMATIC ASSISTED AQUEOUS EXTRACTION (EAEP)
• SCHEMATIC FLOW OF ENZYMATIC ASSISTED AQUEOUS EXTRACTION 
•    PROCESS
• PROCESS FLOW DIAGRAM OF SOYABEAN OIL EXTRACTION & REFINING
• RECOVERY OF OIL FROM SOYBEANS
• FIGURE 1. PROCESS FLOW DIAGRAM FOR SCREW PRESSING SOYBEANS.
• FIGURE 2. PHOTOGRAPH INSIDE A MODERN SOYBEAN SCREW-PRESS PLANT
• FIGURE 3. PROCESS FLOW DIAGRAM FOR DIRECT SOLVENT-EXTRACTING
•    SOYBEANS.
• FIGURE 4. DEPICTION OF EQUIPMENT AND PROCESS FLOW DIAGRAM 
•    FOR DIRECT SOLVENT-EXTRACTING SOYBEANS
• FIGURE 5. PHOTOGRAPH INSIDE A MODERN DIRECT SOLVENT-EXTRACTION
•     PLANT PROCESSING SOY
• FIGURE 6. PROCESS FLOW DIAGRAM FOR EXTRUDING-EXPELLING SOYBEANS
• FIGURE 7. PHOTOGRAPH INSIDE A MODERN EXTRUDING-EXPELLING PLANT
•      PROCESSING SOYBEANS.
• QUALITIES OF SOYBEAN OILS AND MEALS EXTRACTED BY DIFFERENT 
•     METHODS
• TABLE 1. QUALITY CHARACTERISTICS OF SOYBEAN MEALS PRODUCED 
•    BY DIFFERENT OIL-EXTRACTION PROCESSES.
• TABLE 2. QUALITY CHARACTERISTICS OF SOYBEAN OILS RECOVERED 
•     BY DIFFERENT PROCESSES.
• BASIC PROCESSING OPERATIONS
• DEGUMMING
• FIGURE 8. DIAGRAM OF CONVENTIONAL SOYBEAN OIL REFINING.
• DEGUMMING SEPARATOR
• NEUTRALIZATION
• NEUTRALIZATION SEPARATOR
• BLEACHING
• BLEACHING STEP
• TABLE 3. EFFECT OF PROCESSING ON CONTENT OF TOCOPHEROLS, 
•    STEROLS, AND SQUALENE
• IN SOYBEAN OIL.
• HYDROGENATION
• DEODORIZATION
• DEODORIZATION STEP
• TABLE 4. EFFECT OF PROCESSING STEPS ON QUALITY OF SOYBEAN OIL
• FRACTIONATION AND WINTERIZATION
• WINTERIZATION FILTERS
• FLOW SHEET OF SOYBEAN OIL PRODUCTION
• ALTERNATIVE REFINING METHODS
• ALTERNATIVE REFINING METHODS
• COPRODUCTS AND UTILIZATION
• LECITHIN
• TABLE 5. COMPOSITION OF COMMERCIAL SOY LECITHIN IN COMPARISON 
•    WITH EGG LECITHIN, WT %
• TABLE  6. TYPICAL COMPOSITION (%) OF COMMERCIALLY REFINED SOY 
•    LECITHIN PRODUCTS.
• DEODORIZER DISTILLATE
• SOAPSTOCK
• CONFECTIONERY AND IMITATION DAIRY PRODUCTS, AND LOW-CALORIE 
•    FAT SUBSTITUTES
• PRIMARY SOYBEAN PRODUCTS FOR ANIMAL FEEDING
• FIG. 1. PROCESSING OF SOYBEANS INTO SOYBEAN PRODUCTS
• FULL-FAT SOYBEANS
• SOYBEAN MEAL
• SOYBEAN PROTEIN CONCENTRATE (SPC)
• SOYBEAN OIL
• TABLE 1A. COMPARATIVE AMINO ACID COMPOSITION (G/KG PROTEIN BASIS) 
•    OF SOYBEAN MEAL WITH PALM KERNEL MEAL AND MAIZE.
• TABLE 2A. COMPARISON OF DIGESTIBILITY AND METABOLISABLE ENERGY VALUES OF TRIGLYCERIDES IN BROILER CHICKENS FED SOYBEAN OIL 
•    AND SELECTED DIETARY FATS/OILS.
• TABLE 2B. COMPARISON OF FATTY ACID COMPOSITION OF SOYBEAN OIL 
•    WITH SELECTED DIETARY FATS/OILS (G/KTOTAL FATTY ACIDS)
• CHEMICAL COMPOSITION OF COMMONLY
• USED SOYBEAN PRODUCTS IN ANIMAL DIETS
• TABLE 3. PER CENT COMPOSITION OF SOME SOYBEAN PRODUCTS USED 
•    IN ANIMAL FEED.
• ANTI-NUTRITIVE FACTORS
• TABLE 4. ANTI-NUTRITIVE FACTORS IN SOYBEANS.
• UTILISATION OF SOYBEAN IN ANIMAL PRODUCTION
• TABLE 5A. UTILISATION OF SOYBEAN MEAL BY LIVESTOCK IN THE 
•    UNITED STATES
• TABLE 5B. SOYBEAN MEAL USED IN TYPES OF ANIMAL COMPOUND FEED 
•    IN THE EUROPEAN UNION.
• TABLE 5C. SOYBEAN ACREAGE NEEDED FOR LIVESTOCK CONSUMPTION 
•    IN THE EUROPEAN UNION  AND BY COUNTRY OF ORIGIN.
• FUTURE CHALLENGES OF SOYBEAN UTILISATION IN ANIMAL DIETS
• MANUFACTURING PROCESS OF SOYA BEAN OIL
• FLAKING
• EXPANSION
• DRYING - COOLING
• SOLVENT EXTRACTION OF EDIBLE OIL
• BY PRODUCTS OF REFINING
• BY PRODUCTS RECOVERY
• MANUFACTURING PROCESS OF CATTLE FEED
• PROCESS FLOW DIAGRAM FOR CATTLE FEED
• SWOT ANALYSIS OF SOYA PROCESSING INDUSTRY
• STRENGTH
• WEAKNESS
• OPPARTUNITIES
• THREAT
• SUPPLIERS OF PLANT AND MACHINERY
• OIL EXPELLER
• FILTER PRESS
• BABY BOILER
• OIL STORAGE TANK
• OIL PACKAGING MACHINE
• BAG STITCHING MACHINE
• DIGITAL WEIGHING SCALE
• LABORATORY EQUIPMENTS
• SUPPLIERS OF RAW MATERIALS
• TIN CONTAINERS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)