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Detailed Project Report on cooking oil (mustard, groundnut, palm, coconut etc.)
Detailed Project Report on cooking oil (mustard, groundnut, palm, coconut etc.)
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COOKING OIL
(MUSTARD, GROUNDNUT, PALM, COCONUT ETC.)
[CODE NO.3820]
Indian Edible Oil Industry Vegetable oil and oil seeds are two of the essential commodities for the consumer’s daily needs. India is one of the largest producers of oilseeds in the world with an area of 26.54 million hectares under cultivation producing 23-28 million tonnes of oil seeds every year depending on the monsoons. It produces nine types of oil seeds namely, Groundnut, Soybean, Rape/Mustard seed, Sunflower seed, Sesame seed, Castor seed, Niger seed, Safflower seed, Linseed. It also enjoys the position of being the third largest consumer of edible oil in the world next only to US and China owing to its growing population, rising income levels and changing eating habits.
The per capita consumption has grown by 8.1 per cent over the last five years. It stood at 12.5 kg/person per annum which is considerably low as compared to the world average of 17.5 kg/ annum. Developed countries like Japan, Brazil and USA consume around 20.8 kg/annum, 21.3 kg/annum and 48.0 kg/annum respectively. The imports mainly comprise Palm oil, Soybean oil and Sunflower oil. Indonesia, Argentina and Malaysia are the key exporters of oil to India. Olive oil is mainly imported from European countries like Italy and Spain. Rapeseed oil is imported from UAE.
While mustard seeds are abundantly produced in most parts of India, its milling/grinding is mostly done by the large centralized plants, which have the advantage of high efficiency and reduced costs due to economies of scale. Despite the clear advantage of large plants, the importance of tiny decentralized oil extraction units cannot be discounted as they also prove to be economic and present opportunities for self- employment in situations:
where oil produced by large plants do not find its way to remote and distant places because of high transportation costs involved in wider distribution and in places where there is no oil expeller in the area and the farmers sell oil seeds to large refineries which they then buy back at high cost in the form of cooking oil but without the valuable high protein oil cake.
Therefore, in recognition of the existing opportunities of setting-up mustard oil expeller units in such situations, tiny units are suggested for the first generation Tribal entrepreneurs – the investment for which is modest and the operation is simple.
The unit is required to maintain a minimum stock of seed and enough to continue operations throughout the year. Hence, the location of the unit has to be essentially in those areas where the raw material is locally available in abundance.
In general, more profit could be made if the cooking oil is packed into retail size bottles.
However, considering the difficulty in obtaining glass or plastic bottles in large quantities in remote areas and blocking thereby substantial capital, the possibility of using second- hand bottles may be utilised. Alternatively, oil could be sold in drums to the provision stores in neighboring towns/cities.
The viability of any oil extraction unit considerably depends on the sale of the oil cake, which is extensively used as animal feed and other sub-products.
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.
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.
Oil seed crops occupy an important place in the agriculture and industrial economy of the country. India is perhaps the only country in the world having the largest number of commercial varieties of oil seeds. Mustard Oil is also one of the major oil seeds from which edible oil is produced. In Northern & Central India. It is medium of cooking food. Besides it is also used in preparation of Pickles. The Mustard Oil Cake (By Product) is used as cattle feed.
Virgin coconut oil (VCO) extracted from fresh coconut meat without chemical processes is said to be the mother of all oils. It is rich in medium chain fatty acids, particularly lauric acid and is a treasure trove of minerals, vitamins, antioxidants and is an excellent nutraceutical.
It has about 50% lauric acids, having qualities similar to mother's milk thus confirming its disease-fighting ability, Where lauric acid enters human body its get converted to Monolaurin which has the ability to enhance immunity.
Several studies have confirmed that this compound has the ability to kill viruses including herpes and numerous other bacteria. Its antiviral effect has the ability to considerably reduce the viral load of HIV patients. VCO is not subjected to high temperatures, solvents or refinement procedures and therefore retains the fresh scent and taste of coconuts. It is rich in vitamin E, is non-greasy, non-staining and is widely used in soaps, lotions, creams and lip balms. The health benefits of VCO are second to none; ranging from speeding up body metabolic system and providing immunity against a horde of commonly prevalent diseases.
The oil palm which originated in west Africa is also extensively Cultivated in the Congo, South East Asia and Central and South America. An old palm now growing in the Botanic Garden's at bogor some miles inland from Jakarta pro claim's it was introduced there in 848 and is the mother plant of the south East Asian plantation Evidently, four tree were sent from the Bontonic Gardens Amsterdam to Javavia Mausitius about this time for purely ornamental purposes Huge plantation in the Congo mere later organised by the first Lord Loverhulme, demonstrating the feasibility of improved oil yield and quality. In the decade 1970-80 the scientific cultivation of the oil palm advanced. Malaya to the pre-eminent position in this breeding of types most suitable to a particular environment has long been an important scientific study in the world vegetable oil Business.
Although the oil from the palm fruit is commercially important it is one of the most important lausic oil (along with coconut oil, which it resembles in several respect). Palmitic and oleiacaid in nearly equal proportion account for about 80% of fatty acid composition of palm oil; which predominates helps to decade the physical character of the particular variety in which they occur but another factor of out standing importance, especially in the case of palm oil, is the way in which the fatty acid's are groupped to form the tregly cerides suffice it to say that the proportion of trisaturates (6-9%) oleo dipalmitin and dioleo Palmitir account for about half of the troglycerides present : linolenic acid is absent from nature fruit. Potentially then palm oil has a composition which is resistant to atmosphere oxidation. The composition of fatty acid in oil from hybrid varieties and it possible nutritional value has also been the subject of investigation.
It has been reported that the B-Carotene content of palm oil acts as a pro-oxident in opposition to the antic oxident influence of the to copherols also present and that when the B-Carotene is much diminished by refining, bleaching etc. this lifts the oxidetive stability very markedly. As much as 0.2% Carotene is found in some varies of palm oil, giving the oil its characteristics orange red Coloration.
Nigerian palm oil has very often been found to have 35oC m.p. as against 37o C m.p. for Malayscan oil. The corresponding variation would be approzimately vs 0-550; variation is Malaysian oil of 35-38oC m.p. has been noted.
Palm oil which is handled or stored in a warm temperature i.e. above melting point, and a moist environment easily splits to give an extremely high FFA (5 - 50%) So called soft palm oil were at the lower end of the FFA scale in the 5 -10% FFA region and still normally well-fitted for edible use. After appropriate refining. At the other end of the scale the palm oil would be destined for technical use. For intermediate situations where the FFA has risen to over 12% and therefore, where double that percentage of removal of fatty matter has to be envisaged. Fortunately, the Quality of crude palm oil has shown a steady improvement for year's by the application of more rational methods of handling. Although a contractual basis of 5% FFA as norm may apply to many purchases of palm oil much superior qualities are available from Malaya and Zaire with limits covering FFA at 20%, The metal content and degree of oxidation. Naturally, these superior grades primarily envisage the use of the palm oil as being for edible purposes for the best quality crude oil not more that 0.2 ppm Cu and 5 ppm FE are to be expected at most. Commercially, the accepted maximum for moisture and impurities is normally 0.5% of which only a little 0.02% is likely to be a solid impurity. Iodine value ranges from 52 to 58, refractine index - 1.4495 - 1.4515, unsaponicfiable (%) up to 0.8
There is a well-sustained effort to improve the quality of crude palm oil. The recovery of palm oil of novel quality from the bunches of palm fruit as harvested reqiure's rapid de-activation of the lipase present in the fruit.
COST ESTIMATION
Plant Capacity 6 Ton/Day
Land & Building (6000 sq.mt.) Rs. 3.33 Cr
Plant & Machinery Rs. 4.62 Cr
Working Capital for 2 Months Rs. 3.81 Cr
Total Capital Investment Rs. 12.18 Cr
Rate of Return 36%
Break Even Point 49%
INTRODUCTION
VARIETIES OF MUSTARD SEED
FATTY ACID COMPOSITION OF MUSTARD OIL MUSTARD OIL (FROM BLACK
MUSTARD SEED)
MUSTARD OIL (FROM WHITE MUSTARD SEDDS)
PHYSICO-CHEMICAL CHARACTERISTIC
OIL SEEDS & % OF OIL CONTENT
USES AND APPLICATIONS OF MUSTARD OIL
MUSTARD OIL IS DIRECTLY CONSUMED BY FRYING THE CURRY, SNACKS ETC.
MUSTARD OIL PROPERTIES
TYPES OF EDIBLE COCONUT OIL
REFINED, BLEACHED AND DEODORISED COCONUT OIL
CHEMICAL COMPOSITION OF COCONUT OIL
CHARACTERISTICS OF COCONUT OIL
TABLE: COMPARATIVE FATTY ACID PROFILE OF COMMON FATS AND OILS
EDIBLE OIL ESTIMATE FOR INDIA & GLOBAL
EDIBLE OIL ESTIMATES FOR INDIA (MARKETING YEAR- NOVEMBER
2018-OCTOBER 2019)
PRODUCTION TREND OF DOMESTIC OILSEEDS
PRODUCTION TREND OF DOMESTIC EDIBLE OILS
GLOBAL & DOMESTIC PRODUCTION, EXPORTERS AND IMPORTERS OF MAJOR EDIBLE OIL
GLOBAL PRODUCTION TREND OF MAJOR EDIBLE OILS
MAJOR EXPORTING AND IMPORTING COUNTRIES OF EDIBLE OILS
INDIA’S IMPORT OF MAJOR EDIBLE OILS
INDIA’S TOP IMPORT SOURCES OF PALM, SOYA AND SUNFLOWER OILS
MARKET OVERVIEW OF EDIBLE OILS
PRODUCTION AND CONSUMPTION PATTERN OF EDIBLE OIL
KEY MARKET METRICS:
PRODUCTION TREND OF DOMESTIC EDIBLE OIL
INDIAN EDIBLE OILS PRODUCTION, IMPORT AND CONSUMPTION
COMPANY PROFILES
CHART 1: VARIETY-WISE IMPORTS OF EDIBLE OILS (IN THOUSAND TONNES)
VARIETY-WISE SHARE OF CRUDE AND REFINED EDIBLE OIL IMPORTS
MOVEMENT IN INTERNATIONAL AND DOMESTIC EDIBLE OIL PRICES
SWOT ANALYSIS OF INDIAN EDIBLE OIL INDUSTRY
SWOT ANALYSIS - STRENGTH
DIVERSE AGRO-ECOLOGICAL SITUATIONS
STRONG RESEARCH NETWORK FOR DEVELOPMENT OF OILSEED TECHNOLOGY
STRONG FRONTLINE EXTENSION NETWORK FOR OILSEED TECHNOLOGY
DISSEMINATION
TECHNOLOGY MISSION ON OILSEEDS AND IMPACT
INTEGRATED SCHEME ON OILSEEDS, PULSES, OIL PALM AND MAIZE (ISOPOM)
IMPACT OF FIRST-LINE TRANSFER OF TECHNOLOGY
PRODUCTION AND DISTRIBUTION OF QUALITY OILSEEDS
SWOT ANALYSIS - WEAKNESS
PRODUCTION SITUATION
SYSTEM CONSTRAINTS IN PUBLIC SECTOR TRANSFER OF OILSEED TECHNOLOGY
PROCESSING SITUATION
SWOT ANALYSIS - OPPORTUNITIES
PRODUCTION SITUATION
PROCESSING SITUATION
SUPPLEMENTARY OIL SOURCES
SWOT ANALYSIS - THREATS
PRODUCTION SITUATION
PROCESSING SITUATION
HIKE IN IMPORT DUTY OF EDIBLE OILS
PRICE TREND
A. PALM OIL
MUSTARD OIL MANUFACTURING PROCESS
PRESSING OF MUSTARD OIL
FILTRATION AND REFINERY OF CRUDE MUSTARD OIL
OIL FILLING / BOTTLING
PROCESS FLOW DIAGRAM
PROCESS FLOW DIAGRAM OF MUSTARD OIL
MANUFACTURING PROCESS OF MUSTARD OIL IN DETALS
HEATING:
QUALITY SPECIFICATION
PROCESS DESCRIPTION OF VEGETABLE OIL REFINING
VEGETABLE OIL REFINING PROCESS BLOCK DIAGRAM:
B.I.S SPECIFICATION
PROPERTIES OF PALM OIL
RECOMMENDED STANDARDS FOR PALM OIL
USES AND APPLICATION OF PALM OIL
VIRGIN COCONUT OIL
USES AND HEALTH BENEFITS OF VIRGIN COCONUT OIL
THE CURRENT EMERGING MAJOR USES OF VCO ARE:
VCO AS A VERSATILE PRODUCT
HEALTH BENEFITS OF VCO
QUALITY STANDARDS OF VIRGIN COCONUT OIL
TECHNOLOGIES FOR VIRGIN COCONUT OIL PRODUCTION
FIGURE: SCHEMATIC DIAGRAM OF VCO PROCESS TECHNOLOGIES UNDER THE FRESH-DRY PROCESS
CLASSIFICATION & COMPOSITION OF COCONUT FLOUR
PROXIMATE COMPOSITION OF COCONUT FLOUR
PROPERTIES OF COCONUT FLOUR
USES AND APPLICATIONS OF COCONUT FLOUR
COCO FLOUR (HIGH-PROTEIN)
COCO FLOUR (HIGH-FIBER)
POPULAR BREADS & CAKES THAT CAN BE FORTIFIED WITH HIGH-
PROTEIN COCONUT FLOUR:
ACCEPTABLE LEVELS OF COCONUT FLOUR (HIGH-FIBER) AS AN ADDITIVE
IN FOOD PRODUCTS
MANUFACTURING PROCESS OF VIRGIN COCONUT OIL
PROCESS FLOW DIAGRAM
ANALYSIS OF DIFFERENT PROCESSES FOR PRODUCING VIRGIN COCONUT
OIL (VCO)
MANUFACTURING PROCESS OF VIRGIN COCONUT OIL AND COCONUT FLOUR
QUALITY CHARACTERISTICS OF VCO PRODUCED FROM THE PCA DEVELOPED PROCESS:
PROCESS FLOW DIAGRAM
VIRGIN COCONUT OIL EXTRACTION METHODS
THE FRESH-DRY LOW PRESSURE OIL EXTRACTION METHOD
FIGURE: THE FRESH-DRY LOW PRESSURE OIL EXTRACTION METHOD
FIGURE: BRIDGE PRESS DEVELOPED BY THE NATURAL RESOURCES INSTITUTE, UNITED KINGDOM
THE FRESH-DRY DIRECT MICRO EXPELLING PROCESS
FIGURE: MOTORISED DME GRATER
FIGURE: OTHER TYPES OF COCONUT GRATER BEING USED BY VCO
PROCESSORS IN FIJI
FIGURE: DRYING OF GRATED KERNEL IN A STANDARD DME FLAT BED DIRECT ONTACT TYPE DRYER
DRYING IS THE MOST CRITICAL PART IN THE DME PROCESS FOR THE
FOLLOWING REASONS:
FIGURE: LOADING OF DRIED GRATED KERNEL IN THE DME CYLINDER
THROUGH A BUILT-IN FEED HOPPER.
FIGURE: LOW PRESSURE OIL EXTRACTION USING A DME PRESS
FIGURE: NEW ZEALAND PRESS
POST PROCESSING STAGE OF VIRGING COCONUT OIL
OIL DRYING
FIGURE: IMPROVISED DOUBLE BOILER
AGEING
FINE FILTRATION OF VCO
PACKAGING AND STORAGE
NUTRITIONAL CONTENT OF GROUNDNUT OIL
ALLERGENS AND TOXINS
OTHER USES
"PEANUT OIL WILL MAKE MEDICINE"
BIODIESEL
SUSPENSION AGENT
GROUNDNUT UTILIZATION SYSTEM IN INDIA
OIL IN HUMAN CONSUMPTION
ANTI-NUTRITIONAL AND OTHER FACTORS IN GROUNDNUT
GROUNDNUT OIL AND ATHEROSCLEROSIS
SECONDARY PRODUCTS
BOILED GROUNDNUTS
BENEFITS OF GROUNDNUT OIL
RICH IN UNSATURATED FATS
NO CHOLESTEROL
NATURAL ANTIOXIDANT CONTENT
COOKING WITH GROUNDNUT OIL
MANUFACTURING PROCESS OF GROUNDNUT OIL
FLOW DIAGRAM FOR GROUNDNUT OIL MILL
METHODS OF EXTRACTION OF EDIBLE OIL
FIVE COMMON METHODS ARE USED TO EXTRACT OIL:
PROCESS FLOW DIAGRAM
EQUIPMENT REQUIRED
SHELLING OR DEHULLING
HEATING OR CONDITIONING
EXPELLING
FILTRATION
FIGURE 5: A FILER PRESS
MANUFACTURING PROCESS OF PALM OIL
TECHNOLOGY AND PROCESS DESCRIPTION
1. RECEPTION OF RAW MATRIAL:-
2. STERLIZING:-
3. STRIPPING:-
4. DIGESTING:-
5. PRESSING/OIL EXTRACTION:-
6. CLARIFICATION AND STORAGE:-
PROCESS FLOW SHEET FOR PALM OIL
EQUIPMENT REQUIREMENT
LIST OF FOOD AND AGRO PROCESSING CONSULTANTS
SUPPLIERS OF OIL EXPELLERS MACHINERY
SUPPLIERS OF OIL EXPELLERS
SUPPLIERS OF RAW MATERIALS
MUSTARD SEEDS
STANDARDS APPLICABLE FOR STORAGE OF MUSTARD
STANDARDS OF CENTRAL WAREHOUSING CORPORATION
GENERAL CHARACTERISTICS
SPECIAL CHARACTERISTICS:
STANDARDS APPLICABLE FOR DOMESTIC MARKET
THE PREVENTION OF FOOD ADULTERATION ACT, 1954 (PFA STANDARDS)
QUALITY PARAMETERS
EXPLANATION:
SAFETY PARAMETERS
FOLLOWING MAXIMUM LIMITS ARE PRESCRIBED FOR RESIDUES OF
INSECTICIDES AND PESTICIDES
POISONOUS METALS
STANDARDS FOR GRADING
ADVANTAGES OF GRADING
AGRICULTURAL PRODUCE (GRADING & MARKING) ACT, 1937 (AGMARK
STANDARDS).
AGMARK STANDARDS OF MUSTARD AND RAPESEED
SPECIAL CHARACTERISTICS
GENERAL CHARACTERISTICS
SAFETY STANDARDS
STANDARDS APPLICABLE FOR INTERNATIONAL TRADE.
THE INTERNATIONAL ORGANIZATION FOR STANDARDIZATION
THE INTERNATIONAL ORGANIZATION FOR STANDARDIZATION SPECIFIES
THE FOLLOWING REQUIREMENTS FOR MUSTARD SEED
DESCRIPTION
ODOUR AND FLAVOUR
FREEDOM FROM MOULDS, INSECTS, ETC.
EXTRANEOUS MATTER, SHRIVELLED AND DAMAGED SEEDS
CHEMICAL REQUIREMENTS
CODEX ALIMENTARIUS COMMISSION (CAC)
SAFETY STANDARDS FOR MUSTARD:
(A) MUSTARD SEED
EGAL AND REGULATORY FRAMEWORK GOVERNING OIL SEED
PROCESSING INDUSTRY:
PROCESS FLOW DIAGRAM OF OIL REFINING SECTION
PROCESS FLOW DIAGRAM OF OIL REFINING SECTION – CONTINUES
DOC PACKING SECTION
REFINED OIL PACKING
PROCESS FLOW DIAGRAM OF OIL PACKING SECTION
MATERIAL BALANCE
MATERIAL BALANCE FOR PREPARATORY SECTION
MATERIAL BALANCE FOR OIL REFINERY
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PET BOTTLE
SUPPLIERS OF OIL CAKE BAG
EDIBLE OIL CONSULTANTS LIST
COMPLETE PLANT AND MACHINERY SUPPLIERS FOR SOLVENT
EXTRACTION PLANT
LIST OF FOREIGN MANUFACTURER/SUPPLIER OF PLANT AND MACHINERY
SUPPLIERS OF PLANT AND MACHINERY
BOILERS
STORAGE TANKS
ELEVATORS
D.G. SETS (DIESEL GENERATOR)
AIR COMPRESSORS
LABORATORY EQUIPMENTS/LABORATORY TESTING EQUIPMENTS
DE-GUMMING / PRE-REFINING BATCH PROCESS, RE-REFINING
(LONG-MIX) & WATER WASHING REFER FLOWCHART DLX-01
PROCESS STAGES FOR CRUDE SOY OIL –
BLEACHING – BATCH TYPE
SLURRY PREPARATION -
SLURRY FILTRATION -
SATURATED LOW PRESSURE DRY STEAM IS USED FOR THE OPERATION.
CONT. DEODORIZATION (TRAY)
DE-AERATION:
PRE-HEATING:
(C) METERING
SECOND HEAT REGENERATION:
(J) SHUT DOWN COOLER:
(K) POLISHING:
SUCTION PRESSURE:
STEAM:
2. SPECIFICATIONS OF THE EQUIPMENT
OIL NEUTRALIZATION PLANT
CASING
MATERIAL OF CONSTRUCTION
BATCH BLEACHING PLANT
CONT. DEODORIZATION PLANT (TRAY DEODORIZER)
HEAT RECOVERY SECTION (BOTTOM TRAY)
START UP HEAT. THE HEATER WILL BE SKID MOUNTED CONSISTING
OF THE FOLLOWING:
NECESSARY CONTROL FOR THE OPERATION CONSISTING OF:
COOLING WATER PUMPING (CONTAMINATED & CLEAN)
AUXILIARY EQUIPMENT (UTILITY AND LEAVES CLEANING)
ERECTION MATERIAL
COOLING TOWERS
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)
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