A

PROJECT REPORT ON THE INTERNSHIP PROGRAMME

AT
INDIAN BROILER GROUP
TOLAGAON CHHATTISGARH

SUBMITTED IN PARTIAL FULFILLMENT OF REQUIREMENT FOR THE TRAINING CERTIFICATE

B.E- IV SEMESTER (MECHANICAL ENGINEERING)

SUBMITTED BY:- SUBMITTED TO:-

FAIZAN KHAN, VIKALP GUPTA, Mr. AMIT OJHA
ARINDAM BISWAS H.R
 ACKNOWLEDGMENT
• The success and final outcome of this project required a lot of guidance and assistance from many
people and I am extremely privileged to have got this all along the completion of my project. All that I
have done is only due to such supervision and assistance and I would not forget to thank them.
• I respect and thank Mr. Amit Ojha (H.R) for providing me an opportunity to do the project work in
Tolagaon and giving us all support and guidance which made me complete the project duly. I am
extremely thankful to him for providing such a nice support and guidance, although he had busy
schedule managing the corporate affairs.
• I owe my deep gratitude to our project guide Mr. Nilabh Shrivastava who took keen interest on our
project work and guided us all along, till the completion of our project work by providing all the
necessary information for developing a good system.
• I would not forget to remember Mr. Pravesh Jain, Mr. Kaushik Sarkar and Mr. Shubham Dahelkar for
their encouragement and more over for their timely support and guidance till the completion of our
project work.
 ABSTRACT
Passion . Perseverance . People
ABIS Exports India Private Ltd. is an emerging protein centric conglomerate with headquarters at Rajnandgaon, Chhattisgarh. Within a
considerably short period of 25 years, IB Group has expanded itself into a well-integrated business unit which is producing and
exporting Poultry Feed, Oil Meals, Dairy, Edible oil, Animal Feed (Poultry broiler & layer, fish, shrimp) and Specialised Pet Food (for dogs,
horse, cat, aquarium fish, rat). Continuously evolving is a key to our philosophy and we plan to further diversify into finance as well as
retail sector. Gratitude for our society has enabled us extend into the educational sector through our CSR initiatives.
Their Buisnesses include:-
1. Poultry
2. Feed
3. Edible Oil & Soyabean meal
4. Dairy
5. Drools

And I’ve done my Vocational training at Edible oil & Soyabean meal
 DIFFERENT SECTIONS UNDER EDIBLE OIL & SOYABEAN MEAL

• INTAKE SYSTEM
• PREPARATORY PLANT
• SOLVENT PLANT
• REFINERY PLANT
• TIN & PACKING PLANT
• BOILER
 INTRODUCTION
IB Group’s Soya business is multifaceted and is focussed
at production of highest quality of edible oil and soya
bean meal. Our solvent extraction plant is highly
mechanised and today we produce Soya DOC
with 50%-52% protein content, with controlled fibre free
from oil residue, ash and sand & silica making it one of
the finest in the country. This is possible only through
sustained levels of cleaning, storage and monitoring
arrangements.
At present our in-house refinery produces high quality
edible soya and vegetable oil, with a unique blend of
omega fatty acids. Aimed at expanding the product suite
we are in midst of launching palm oil and rice bran oil for
our users.

Our Presence
 Magnet*
Magnet
4
From
Silo
Soyabea
Raw
Soyabean Classifier*4 / SAC*2 Soyabean Destoner*4 Soyabean
Weight M/C n
Conditioner M/C
S
o
y
a Jet
b Dryer
e
a
n

Cracker M/C*2
S

Preparatory Plant
o
y
a
b
e
a
n

Flacker M/C*3
S
o
y
a
b
e
a
n

Solvent
Extractio Soyabean Dryer M/C Soyabea
n Expander M/C
n Plant
About Preparatory Plant:-
• Soybean seeds contain 18% to 20% oil. Normally soya bean seeds are not subjected to mechanical
pressing but the entire oil is extracted after preparation of the seeds in the solvent and Soybean
Extraction Plant. Preparation of soya bean seeds includes seed cleaning, destoning, cracking, husk
separation (if required), cooking, flaking, expanding and drying. The prepared expanded soya flakes
are sent for solvent extraction. Solvent extraction is carried out in the normal fashion. We do offer
preparation equipment for soya bean seeds.
• Classifier Machine:- It removes the larger inert matter from the seeds. If it
contains a single sieve it is called as scalpers, two sieves – rough cleaners. The unit
consists of a vibrating or rotating screen or sieve having perforation large enough to
allow the rough seed pass through readily.
• Destoner Machine:- Destoner is a machine that separates the stone in the
soyabean from the ground. The principle of operation is to separate Soyabean and Stone by
vibrating motion, adjusting air flow and adjusting the inclination of the screen surface. When
subjected to vibration or movement in a certain state, various kinds of particles are classified
into different levels depending on their specific gravity, grain size, shape, and surface state.

• Conditioner Machine :-The purpose of this operation is preparation of

soyabean for flaking. The conditioner is similar to the cooker described in connection
with expellers. It can be a horizontal screw conveyor type heated reactor or a vertical
stacked cooker. Heat can be provided by indirect steam or by direct steam injection,
the latter being used to increase the moisture content when necessary. The soyabean
are heated to 65-70oC and the moisture content is brought to 10.5-11%. At this point
the soyabean can be flattened by pressure in the flaker, without breaking.
• Cracker Machine:- The purpose of this operation is to break the seeds
into smaller particles in preparation for flaking. If the beans have been dried to 10%
moisture and tempered as described above, cracking also loosens the hulls and
permits their separation by aspiration. Ideally, the seeds should be broken to 4 to 6
pieces of fairly uniform size. Production of fines should be minimized. Cracking
machines consist of pairs of counter-rotating, corrugated rolls. One roll in each pair
rotates faster than the other, to provide the shearing effect necessary to break the
seed.
• Flacker Machine:- Flaking machines consist of a pair of horizontal counter-
rotating smooth steel rolls. Typical roll sizes are in the range of 60-80 cm. in diameter.
The rolls are pressed one against the other by means of heavy springs or by

controlled hydraulic systems. The main purpose of flaking is to increase the contact
surface between the oilseed tissues and the solvent, and to reduce the distance that
the solvent and the extract will have to travel in the process of extraction. Typical
values for flake thickness are in the range of 0.2 to 0.35 millimetres.
• Expander Machine :- Expander is used to form soybean flakes into a
dense, yet highly porous structure for improved extraction efficiency in the extractor.
Inside of the expander the soybean is shredded and mixed into a fluidized mass.
Steam is injected to cook the proteins and starches, as well as to elevate the
temperature above the boiling point of water. At the discharge a cone or die plate
with circular openings is used to generate even higher pressures and to form the
material into a rope of material about ½” in diameter (10-12 mm). The escaping
steam draws a lot of heat off of the material, which causes the now cooked proteins and starches to harden into a
firm
structure.
 Baggin
DOC D.T.D.C DOC
Dry cake g
Extractor

Solvent Extraction
in

Distillatio

Plant
Mischella
n

Economise Flashe
Heater Drier P.H.E COT
r r

Condensate

Heat Vapour
Contact
Exchange Condenso Condensor Condensor Cooler
t r

Seperator

Absorption

Absorbe P.H.E P.H.E

P.H.E Stripper
r
About Solvent Extraction Plant:-
• After the extraction process, the materials are fed onto a conveyor through a hopper. There, it forms a solid bed,
not allowing solvent vapours to escape. Entire extraction process is carried out in different stages until almost 95%
of the original content of oil is extracted from the raw materials. A temperature of 50 – 60 oC and a slightly low
pressure as compared to atmospheric is maintained in the extractor for the processing.

 Extraction Process:- In this extraction process, the raw materials

are treated with hexane and the oil is recovered, resulting into a solution of
oil in hexane called miscella. Condensation, evaporation and distillation of
miscella are the process through which the absorbed hexane in the material
is recovered. The reason due to which hexane is opted for the extraction
process is its low boiling point (67oC) and high solubility of oils and fats in it.

Hexane, being a highly inflammable compound requires utmost care during

processing. Thus, all those stages that involve high speed machineries like
finishing, material preparation and bagging are carried out at least 50 ft.
away from the main extraction plant.
• D.T.D.C (Desolventising Toaster):- The meal discharged from extractor contains 25% to
30% solvent. This solvent is removed after the meal is propelled in Desolventiser Toaster with the help of
high-pressure jacket heating and low-pressure spurge steam. During solvent evaporation process
equipment pressure will be slightly below the atmospheric pressure. Thus vapour losses and residual
solvent in meal are minimized.

• Distillation:- According to the nature of the raw materials, the miscella has 10% to
18% content of oil. Firstly, the solvent is separated out from the mixture through carrying
out distillation inside heat exchangers, maintaining vacuum conditions. After distillation, the
miscella is fed to a flasher, where the content of solvent is reduced to 2%- 3% in the
miscella. In an atomizer, on the top and at the jacketed column, hot oil is sprayed and an
open steam is injected at the bottom for further processing. A temperature of 27 – 29oC is
maintained in the shell and tube condensers for condensing the solvent vapors. After
condensing, final solvent content is removed and separated out from the oil.
• Economiser:- Economiser are mechanical devices intended to reduce energy
consumption, or to perform useful function such as preheating a fluid. The term economizer is
used for other purposes as well. In simple terms, an economizer is a heat exchanger
• Heater :- Circulation Heaters (or in line heaters) use flanged immersion heaters in many
applications. It often involves a pump that flows liquid through a closed pipe circuit (ie. water or glycol solution)
that is reheated. The required wattage to heat the liquid is highly dependent on the flow rate (gallons per
minute). The medium enters an inlet opening, gets heated up as it flows within a chamber and exits the
outlet nozzle where it circulates throughout the piping circuit.

• Dryer :-Industrial dryers are used to efficiently process large quantities of bulk
materials that need reduced moisture levels. Depending on the amount and the makeup
of material needing to be dried, industrial dryers come in many different models
constructed specifically for the type and quantity of material to be processed
• PHE (Plate Heat Exchanger) :-A plate heat exchanger is a type of heat exchanger that uses metal
plates to transfer heat between two fluids. This has a major advantage over a conventional heat exchanger in that
the fluids are exposed to a much larger surface area because the fluids are spread out over the plates. This
facilitates the transfer of heat, and greatly increases the speed of the temperature change. Plate heat exchangers
are now common and very small brazed versions are used in the hot-water sections of millions of combination
boilers.
• The concept behind a heat exchanger is the use of pipes or other containment vessels to heat or cool one fluid by
transferring heat between it and another fluid. In most cases, the exchanger consists of a coiled pipe containing
one fluid that passes through a chamber containing another fluid. The walls of the pipe are usually made of metal,
or another substance with a high thermal conductivity, to facilitate the interchange, whereas the outer casing of the
larger chamber is made of a plastic or coated with thermal insulation, to discourage heat from escaping from the
exchanger.
 Heating Hot
From Through Water
Tank PHE
Neutralizatio Dynami Mixer
Crude Intake Crude Hydratio Hot Separato Degum Degum

Oil Oil
Water
r M/C*3
Degum
Oil
n Reaction Oil with c Oil with
(Add
Tank*2 n Tank with Tank acid acid
Caustic acid)
Mixer*2

Oil with
Degum
Refinery Plant
Soap

acid
Gums Acid
Out Oil

Neutral Natural
Oil Separator*4
Hot Water from R.
O

A
Washing Separator* Vacuum Mixer Oil With Bleacher Oil With
Oil Oil
Neutral Oil
Neutral with hot
Chemic Chemic
Oil
Tank 2 Dryer (Add
Tank
Water
al al
Chemical)

Steam from
Boiler
B
Pressure
Oil With
oil
Deodurize Cooke Cold Polish Refine
Chemic Leaf
r Tank d Oil Cooler Oil Oil Packing
al
Filter*2 Filter
 About Refinery Plant :-
• Crude SOYABEAN oil is obtained from SOYABEAN seeds which go through the preparatory steps before undergoing
solvent extraction process. The crude SOYBEAN oil is further refined for making it free from fatty acids, color
pigments and numerous other components harmful to human beings.

• Hydration Tank :-A Hydration Tank is required to allow for sufficient residence time for gums in
the oil refining process to agglomerate. Muez-Hest is capable of manufacturing high grade hydration
tanks for a variety of applications particularly for Oil Refining and boasts of using quality raw materials.

• Separator Machine :-The term separator in oilfield terminology designates a

pressure vessel used for separating well fluids produced from oil and gas wells into gaseous and
liquid components. These separating vessels are normally used on a producing lease or
platform near the wellhead, manifold, or tank battery to separate fluids produced from oil and
gas wells into oil and gas or liquid and gas.These separating vessels are normally used on a
producing lease or platform near the wellhead, manifold, or tank battery to separate fluids
produced from oil and gas wells into oil and gas or liquid and gas.
• Degumming :- Crude soybean oil contains a relatively high concentration of phospholipids compared With other
vegetable oils. Degumming is a process of removing these components From crude soybean oil to improve its physical
stability and facilitate further refining. In this process oil is treated with water to precipitate the hydratable phosphorous
which removed through the centrifugal separation system and obtained gums is dried to make lecithin which is used in
many applications in food industry.

• Neutralization Reaction Tank :-In the neutralization process the FFA (Free Fatty
Acids) are removed by neutralizing the FFA with slight excess of Sodium Hydroxide solution
which is followed by the washing out of soaps & hydrated phospholipids. Some amount of
Sodium Soap is generated during the process which can be used in the soap making industries
or also can be Splitted in Fatty Acid form. The Soap generation in the neutralization process
causes the loss of oil also due to which some people use the alternate process known as Physical Refining.

• Washing Tank :-In washing tank washing of crude oil takes place. Crude oil washing
(COW) is washing out the residue from the oil tanker using the crude oil cargo itself, after the
cargo tanks have been emptied. Crude oil is pumped back and preheated in the slop tanks,
then sprayed back via high pressure nozzles in the cargo tanks onto the walls of the tank. Due
to the sticky nature of the crude oil, the oil clings to the tank walls, and such oil adds to the
cargo 'remaining on board' (the ROB).
• Vacuum Dryer :-Vacuum dryer is the equipment with the help of which vacuum
drying is carried out. In the pharmaceutical industry vacuum dryer is known by a common
name called vacuum oven. Vacuum dryers are sometimes made up of cast iron, but most
now are made of stainless steel, so that they can bear the high vacuum pressure without
any kind of deformation .The oven is divided into hollow trays which increases the surface
area for heat conduction .The oven door is locked air tight and is connected to vacuum
pump to reduce the pressure.
• Bleacher Tank :- The major purpose of bleaching is the removal of colored
materials in the oil. The heated oil is treated with various bleaching agents such as
earth powder, activated carbon, or activated clays. Many impurities, including
chlorophyll and carotenoid pigments, are absorbed by this process and removed by
filtration. Bleached oil is light in color.
• Leaf Filter :- The Pressure Leaf Filter is a MS/SS Vertical Vessel with Filter Leaves inside.
The leaves are mounted vertically on a common manifold pipe, through which the filtered
liquid flows out. On the top, the leaves are held by a vibrating shaft . A mechanical vibrator
driven by electric motor/pneumatic vibrator is provided for vibrating the leaf shaft for cake
discharge. Jacket for hot filtration can be offered if desired Over flow, vent/steam/air charging,
pressure gauge & safety valve are provided on the top.
• Deodorization tank :-Deodorization of bleached and filtered soybean oil is done
to remove the highly volatile compounds, mainly Free fatty acids, aldehydes and ketones
which causes odor and smell in degummed and bleached soybean oil. Deodorization of oil is
done under high vacuum and at high temperature (180 – 220°C). As we know that
deodorization is a steam distillation process so it requires low pressure steam for proper
circulation of oil in deodorizer. We keep the pressure of low pressure steam around 2-6
kg/cm². There are some low volatile or high molecular weight fatty acids, heavy metallic compounds and aldehyde &
ketonic group present inside the Soybean Oil which requires high temperature in order to remove them under
controlled conditions which in turns removed in the Deodorization process.

• Polish Filter :- Sharplex Single or Multibag Polishing Filters are basically used for post filtration. The
baskets are fitted with quick opening type arrangements. Filter bags used are PP, PPS, Polyster Polyamide or
special material depending on process conditions. Depending on flow rate single or multibags can be
supplied.

• Filtration :-At several stages in oil refining, filtration is required to be carried out. Oil Filter Press or PLF will
remove the solid impurities and sediment particles from the oil making the final refined oil as clean and clear.
Filtration is usually done 2 or 3 or even 4 times sometimes. The final oil produced is known as “refined oil” and is
ready to be consumed or for the manufacture of other products. A light solution of citric acid is often added during
this step to inactivate any metals such as iron or copper present in the final product. The refined oil is then sent for
filling and packing to be finally sold into the markets!
ETP (Effulent Treatment Plant)
• Effluent Treatment Plant is used for treated waste water which is come
from different manufacturing industries where different types of
chemicals and dyes are used for the treated materials. After treatment,
waste water are discharge to the environments directly. This waste water
is harm full for the environment. To protect the environment from the
harmful effect of the waste water ETP is used where waste water is
treated and makes is not harmful to the environment.
 Elevato Hu Drum Elevato
Husk Husk Husk Husk Hopper Husk Screw Husk Rotary
r no 1 magnet r no 2 conveyor
sk
H

Boiler
u
s
Sieve k

Process Submerge
d Ash Belt Husk
Furnac Husk
Screw
Feeder*12
e
map Conveyor

Make Up Deaerator Feed Steam

R.O
Economiser Steam to
Water Water Tank Tank Water Drum
Plant
Pump

Forced
Air IN
Draft Fan

Hus Furnac Boiler Induced

k
Flue
Economiser A.P.H E.S.P draft Fan
e gas
bank

Secondary
Air Fan Chimney
About Boiler :-
• A boiler is a closed vessel in which fluid (generally water) is heated. The
fluid does not necessarily boil. The heated or vaporized fluid exits the
boiler for use in various processes or heating applications, including water
heating, central heating, boiler-based power generation, cooking, and
sanitation. The source of heat for a boiler is combustion of any of several
fuels, such as wood, coal, oil, or natural gas. Electric steam boilers use
resistance- or immersion-type heating elements