solvent extraction & refining (soyabean) to produce soyabean oil & soya nugget

SOLVENT EXTRACTION & REFINING (SOYABEAN) TO PRODUCE SOYABEAN OIL & SOYA NUGGET

 [CODE NO.4421] 

Soybean (Glycine max) is a leguminous plant. The Chinese have been cultivating and consuming soybeans for over 4000 years. Soy products have been around in India for almost 30 years. But the consumption of these products never took off well in the market till recently.

Indian population is predominantly vegetarian. Our diet is lacking in terms of quantity and quality of protein. Even the majority of non-vegetarians among us do not consume animal products on a daily basis in quantities sufficient to provide the recommended amount of protein.

Soybeans are a rich source of good quality protein and the cost too is low. Soy products can easily meet the protein requirements of a vegetarian diet. Soybean has been perceived more as poultry and cattle feed than as a good source of protein for human consumption by a lot of people. Also the misconception that soybeans are only used in feeding programs conducted by the government for malnourished children has been prevalent nutritional benefits soybeans provide several therapeutic benefits too.

Soybean is one of the very few plants that provide high quality protein. Soybeans help people feel better and live longer with an enhanced quality of life. Soybeans contain all the three macronutrients required for good nutrition, as well as fiber, vitamins, minerals. Soybean protein provides all the essential amino acids in the amounts needed for human health. Soybeans have almost 40% protein, making soybeans higher in protein than any other legumes and many animal products. Protein in just 250 grams of soybean is equivalent to protein in 3 liters of milk or 1 kg of mutton or 24 eggs. The quality of soy protein is virtually equivalent in quality to that of milk and egg protein. Unlike many other good sources of protein, soybean not only has higher percentage of oil but also quality fatty acid profile. It has low saturated fat content with high amount of essential fatty acids. Soybean oil is also a good source of omega-3 and 6 fatty acids similar to those found in fish oils and is cholesterol-free. Soybeans a

re an excellent source of dietary fiber with both soluble and insoluble fiber. 

Soluble fiber may help lower serum cholesterol and control blood sugar. Insoluble fiber increases stool bulk, may prevent colon cancer and can help relieve symptoms of some digestive disorders. Soybean has more than two times the amount of most of the minerals, especially calcium, iron, phosphorus and zinc, than any other legume and very low sodium content. Soybean has all the important vitamins and is a very good source for B complex vitamins and Vitamin E.

Soybean and Health Benefits

In addition to containing good quality nutrients, soybean has other beneficial compounds such as, phytosterols (isoflavones), lecithins, etc. Soy foods have a number of health benefits such as, cancer prevention, cholesterol reduction, combating osteoporosis and menopause regulation. Human studies suggest that as little as one serving of soy foods each day may be protective against many types of cancers. For the past 30 years, investigators have shown that consumption of soy protein selectively decreases total and LDL (bad) cholesterol and maintains HDL (good) cholesterol in individuals with elevated blood cholesterol levels. Based on the various research findings, United States Food and Drug Administration has issued a health claim for soy protein in October of 1999. The health claim states “consumption of 25gms of soy protein per day with a diet low in saturated fat may lower the risk of heart diseases”.

Another important aspect of soy protein is combating osteoporosis and relieving menopause symptoms. One factor in bone health is limiting the amount of calcium lost from the body. Although protein especially animal protein contributes to calcium loss, soy protein exhibits less calcium leaching effects. The isoflavones found in soybeans may also directly stop bone deterioration. Recent research has shown that soy foods can relieve most menopausal symptoms, thus reduce risks of cardiovascular disease and osteoporosis. Soybean is considered as a natural alternate for hormone replacement therapy for treating women who are in menopause.

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 are more 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 worlds oil seed crushing industry. The oil milling industry in India may be divided into three groups depending upon the method of milling. These are Ghani (manual - animal driven or small power driven), large oil mills (registered under Factories Act) and plants using solvent extraction techniques.

COST ESTIMATION

Plant Capacity                            33.34 Ton/Day

Land & Building (6 Acres)  Rs. 4.52  Cr

Plant & Machinery                      Rs. 11.58 Cr

Working Capital for 2 Months  Rs. 14.12 Cr

Total Capital Investment          Rs. 31.02 Cr

Rate of Return                             39%

Break Even Point                        41%

• • INTRODUCTION
• • THE HISTORY AND MARKET
• • EQUIPMENT MANUFACTURERS 
• • COMMERCIAL APPLICATIONS IN FOOD PROCESSING
• • PRODUCTS, RAW MATERIALS AND PRODUCTION TECHNOLOGY
• • PROCESS DESCRIPTION
• • COMMERCIAL MACHINES
• • LIST OF MACHINERY & EQUIPMENTS
• • DOCUMENTS REQUIRED FOR LICENSES 
• • PRINCIPLES OF PLANT LAYOUT
• • PLANT LOCATION FACTORS
• • EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• • PACKAGING TYPES
• • MANUFACTURES OF  SOYA PROCESSORS
• • SUPPLIERS OF PLANT AND MACHINERY
• • EFFLUENT TREATMENT AND DISPOSAL
• • MANPOWER
• • UTILITIES
• • QUALITY CONTROL OF FREEZE DRIED FOODS
• • SWOL ANALYSIS
• • ORGANIZATION CHART
• • PLANT LAYOUT
• • TURNKEY CONSULTANT
• • IMPLEMENTATION SCHEDULE

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)