CONTENTS

TOPIC PAGE NUMBER

ACKNOWLEDMENT 2

INTRODUCTION 3

SAFETY 4

HAZARD 5

EDIBLE OIL 6

QUALITY ANALYSIS 7 – 12

REFINERY 13 – 17

OTHER IMPORTANT 18 – 24
PLANTS
PACKING 25 – 27

SOME PRODUCTS OF AWL 28 - 29

BIBLIOGRAPHY 30

CONCLUSION 31

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ACKNOWLEDGEMENT

The evolution of a perfect report depends entirely on the sustained efforts of lots
of people and the necessary motivation begins from the organization where the
training commences. Hence, I owe my sincere gratitude and acknowledgements
to the entire unit of ADANI WILMAR LTD., Haldia and I am personally
thankful to the H.R. Section and Managing section of Adani Wilmar for
allowing me to undertake training at their Haldia Plant. We are also highly
obliged to our Departmental H.O.D.’s, Haldia Institute of Technology for
sponsoring our name for the said training. It’s a privilege to express my
indebtedness to Mr. Amrit Urmaliya (H.R. Department, Adani Wilmar Ltd.)
Who obliged me to undergo training from 2nd January’ 20 to 2nd February’20 at
their Adani Wilmar Oil Refinery Plant, Haldia. My sincere thanks to all the
Head of the Departments and the General Managers of the plant for their
valuable suggestions regarding my training program. Also, I am grateful to all
the co-workers of Adani Wilmar Ltd., Haldia for their support and guidance.

Date: -04/02/2020
Place: - Haldia.

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INTRODUCTION

Adani Wilmar is one of the largest multinational company basically known for
its oil refinery units and brands like FORTUNE, KING’S etc. Though owned its
name through edible oils Adani group now a days also undergoing
manufacturing of different other products like soya nutrela chunks, besan etc.
The multinational company is conglomerate headquartered at Ahmedabad,
Gujrat. Founded by Gautam Adani in 1988, as a commodity trading business
with the flagship company Adani Enterprise Ltd., it is India’s largest port
developer and 10 ports and terminals including Mundra port (largest). Through
joint venture with Wilmar International in Singapore, the company owned its
name as Adani Wilmar Ltd. Owning largest edible oil brands.

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SAFETY

NEED OF SAFETY: -The importance of industrial safety was realized because

of the fact that every year millions occupational/ industrial accidents occur
which result in loss of production time equivalent to millions of man hours,
machine hours etc. Major accident causing elements are Fire, Chemicals,
Working Environment.

▪ Classes of fire: -

▪ Class ‘A’: - due to combustible solid, e.g.: -cotton, wood etc

▪ Class ’B’: -due to inflammable liquid, e.g.: - kerosene, diesel etc
▪ CLASS ‘C’: -due to inflammable gases , e.g..:-LPG, hydrogen etc
▪ CLASS’D’: -due to reactive metal, e.g.: -Na, P etc
▪ CLASS’E’: -electrical fire.

Methods of stopping fire: -

Cooling, Starvation, Smoothing (blanketing)

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HAZARD

A hazard is any agent that can cause harm or damage to life health property or
the environment.

There are 3 types of hazard: -

▪ Physical hazard: - A physical hazard is a type of occupational hazard that

involves environmental hazard that can cause harm with or without contact.
Physical hazard including ergonomic hazards, radiation heat, cold stress,
vibration hazard etc.
▪ Chemical hazard: - A chemical hazard is a type of occupational hazard cause
by exposure to chemicals in the work place. Example: - sulphuric acid fume,
chlorine gas etc.
▪ Biological hazard: - Biological hazards also known as bio hazards, referred to
biological substances that pose a threated to the health of living organism
primarily that of humans. This can include medical waste or sample of
microorganism, virus or toxic that can affect human health.

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EDIBLE OIL

Edible oils are oils extracted from different sources like plants seeds, vegetables
etc. Which undergoes refining, bleaching and other processes making it
acceptable to human consumption. Consisting of triglycerides and free fatty
acids edibles are typically crude at first, bleached and deodorized at second and
refined at end. These 3 types can be differentiated by action of colour at basic.

Edible oil products of Adani Wilmar:

▪ Fortune: Soy oil

▪ Kacchi ghani mustard oil.
▪ Refined rice bran oil.
▪ Palm oil.
▪ Sunflower oil etc.
▪ King’s: refined soya bean oil etc.
▪ Raag: Vanaspati etc.

Many other products are also manufactured like besan, soya granules etc. Adani
Wilmar Haldia plant deals with soya oil and palm oil and soya bean oil and
vanaspati manufacturing. They import direct crude oil from foreign in Haldia
unit, so crushing, flaking is not done over here.

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QUALITY ANALYSIS

Quality Analysis of Edible oils (palm oil, soya bean oil: crude, bleached and
refined):

1. Free Fatty Acid Test:

Free Fatty Acids (FFAs) are fatty acids that are produced from TGs by
hydrolytic reactions in any of the steps of the process.
Detection:
Gram of oil taken as per types:
1. Any Refined oil: 25 gm
2. Any Crude oil: 4 gm
3. Crude Distillate Soya bean oil (CDSBO): 0.8 gm
4. Palm Fatty Acid Distillate (PFAD): 0.3gm.

Procedure: ALCOHOL TEST

25 gm of refined oil is taken in a conical flask.
50 ml of neutral alcohol (ethyl alcohol or Isopropanol is taken in a conical flask and
phenolphthalein added 2-3 drops and neutralised with 0.1 (N) NaOH solution for dark pink or
violet colour) is taken and oil is added into it.
The solution is boiled and cooled at room temperature.
Then the solution is titrated against 0.1(N) NaOH solution using phenolphthalein indication
for pink colour appreance.

Calculative formula:
Expressed as per oleic acid
FFA = 282× burette reading × Normality ÷ weight of oil×10
282: molecular weight of Oleic Acid.
Expressed as per palmitic acid
FFA = 256× burette reading × Normality ÷ weight of oil × 10.
256: molecular weight of palmitic acid.

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2. Iodine Value test (IV test):

This test method covers the Wijs procedure for determination of unsaturation
(iodine value) of tall oil fatty acids. Iodine value is a measure of the
unsaturation of oils and fatty acids and is expressed in terms of the number of
centigrams of iodine per gram of sample (weight percent of absorbed iodine).

Detection:
Amount of oil taken as per types:
1. Palm related oil: 0.5 gm.
2. Soya bean related oil: 0.2 gm.

Procedure:
According to type oil is taken in an IV flask.
25 ml chloroform and 25 ml Wijs solution (Iodine monochloride) is added and corked using a
stopper cork.
1 drop of KI solution is given over it for not allowing air to pass and keep in a dark condition
for 30 min.
After 30 min add 10% KI solution (~15 ml) and makeup the volume by adding 70 ml distilled
water.
Titrate the solution against 0.1 (N) Na2S2O3 (sodium thiosulphate) solution.
Colour changes to bright yellow.
Add 1 ml Starch solution.
Colour changes to dark dull blue.
Titrate again till colourless.
Follow same for a blank and a sample.
Calculative formula:
IV value = 126.9 (molecular weight of Iodine) ×(Blank-Sample) ×Normality ÷ weight of the
sample × 10.

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3. Peroxide Value test ( PV test ) :

Procedure:
 5 gm measurement of any oil is taken in a stopper flask.
 30 ml of PV (acetic acid: chloroform = 3:2) solution is added into it.
 0.5 ml of saturated KI solution is added into it.
 Stopper corked and swirled for 1 min.
 Add 70 ml of distilled water.
 1 ml of starch solution is added.
 Titrate the solution against 0.1 (N) Na2S2O3 solution.
 The dark blue colour of solution turning colourless indicated end point.

Calculative formula:
PV = burette reading ×Normality ×1000 ÷ weight of the sample.

Colour test of oil:

The method determines the colour of oils by comparison with Lovibond glasses of known
colour characteristics. The colour is expressed as the sum total of the yellow and red slides
used to match the colour of the oil in a cell of the specified size in the Lovibond Tintometer.

Procedure:
 Melt the sample if it is not already liquid and filter the oil through a filter paper to
remove any impurities and traces of moisture.
 Make sure sample is absolutely clear and free from turbidity. Clean the glass cell of
desired size with carbon tetrachloride and allow it to dry.
 Fill it with the oil and place the cell in position in the tintometer.
 Match the colour with sliding red, yellow and blue colours.
Report the colour of the oil in terms of Lovibond units as follows :-Colour reading = (a Y + 5
b R) or ( a Y + 10 b R) in ( * cell) Where, a = sum total of the various yellow slides (Y)
used b = sum total of the various red (R) slides used.

Calculative Information:
Y + 5R is the mode of expressing the colour of light-coloured oils. Y + 10 R is for the dark-
coloured oils Although the yellow and red slides required to match the colour shade of an oil
in a tintometer are assessed separately, it is found that to a certain extent these slides are
mutually compensatory. Consequently, different workers may report different values for the
yellow and red units for the same oil and the same workers may report different values for
the yellow and red units for the oil examined at different times. To obviate such personal

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errors a composite factor is used for checking the colour comprising the sum total of the
yellow(Y) units and 5 or 10 times the total of red units as specified for the oil or fat.

4.Phosphorus content in oil:

Phosphorous is removed by water in the presence of adequate concentrations of alkali, and
optimum oil quality is achieved at phosphorus levels in the deodorized oil of no less than
about 2 and no greater than about 20 p.p.m.

Detection:
Oil amount as per type: 1. Refined oil: 5 gm
2. Crude Palm oil: around 2 gm
3. Crude soya bean oil: below 1 gm
4. Crude Distillate Soya Bean oil: 1-2 gm.

Procedure:
 0.5 gm of zinc oxide (ZNO) and oil according to type is put into a crucible and
allowed to burn and then put it into a muffle furnace (650°C) for 2 hours.
 Allow it to cool and 5 ml of 1:1 HCl is added to dissolve the residue and then warm it.
 Filter it through Whatman filter paper No. 1 in 100 ml Volumetric Flask.
 After filtration wash the filter paper with distilled water.
 Neutralize the sample in Volumetric flask by 50% KOH solution for white
precipitation of ZNO.
 Dissolve the precipitate by 1:1 HCl solution and add 2 drops extra to make it slightly
acidic.
 Makeup the volume to 100ml
 Then take 10 ml from the solution into 50 ml separate volumetric flask and add 8 ml
hydragenium sulfite (0.15%) and 2 ml sodium molibdate solution (2.5%) and keep in
boiling water bath.
 Blue colour develops after cooling makeup to 50 ml and check absorbance at 650 nm
of both blank and sample.

5.Determination of Saponification value:

Chemicals:
0.5 (N) KOH i.e. 7-8 gm in 100 ml of ethyl alcohol (25 ml for blank & 25 ml for sample ).
0.5 (N) standard HCl.
Phenolphthalein

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Procedure:
 Take accurate 1.5 gm of all oil in a round bottom flask.
 Add 25 ml 0.5 N KOH solution and add 2-3 glassbeads.
 Reflux for 1.5 hr.
 Wash the condenser with alcohol and after cooling titrate against 0.5 (N) standard
HCl using phenolphthalein as an indicator.

Calculative formula:
SAP value = (Blank -Sample) × 56.1(molecular wt. Of KOH) × Normality ÷ sample weight.

 5gm of any oil is taken in a Round Bottom Flask and 50 ml of alcoholic KOH
solution is added.
 Reflux it for 2 hours and after cooling wash condenser using alcohol.
 50 ml of petroleum ether (40-60°C boiling point) is added and transfer the solution in
a separating funnel for layer separation.

Add phenolphthalein to check the residue colour.

 Take the residue in a separated flask of saponified material and add hot water and
alcohol.
 Continue the process for at least 3- 4 times and take the residue wash it with alcohol
and water.
 Heat the solution taken to evaporate till 5 ml solution.
 Add 2-3 ml acetone for dissolving ether.
 Again, keep it in water bath for 30 min at 100°C and add 50 ml warm ethanol.
 Titrate the solution using phenolphthalein indicator against 0.02 (N) NaOH.

Calculative formula:

Weight in g of the free fatty acids in the extract as oleic acid = 0.282 VN
Where,

V = Volume in ml of standard sodium hydroxide solution

N = Normality of standard sodium hydroxide solution
Unsaponifiable matter = 100 (A-B)W
Where,

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A = Weight in g of the residue
B = Weight in g of the free fatty acids in the extract
W = Weight in g of the sample.

6.Determination of Slip melting point:

Used to detect melting point of normally Palm oil.

Procedure:
 Take palm oil and heat it at 60°C and sharp feezed in a capillary tube for 1 hr.
 Attach a thermometer with it and put it in a test tube attached in the machine of
detecting the melting point.
 The water inside the test tube is cold. The tube is made in such a way that water can
circulate in a circular manner.
 The tube is kept in front of heat source.
 The cold water passes through the tube and heat up the capillary tube with oil.
 Check the temperature at which the oil gets suspended up in water.

7.Determination of Tertiary Butyl hydroquinone (TBHQ):

Done for antioxidant test.
Procedure:
 20 gm of soya bean oil is taken in 100 ml beaker and add 50 ml methanol and stir it.
 Filter it and take 15 ml of the filtrate.
 5 ml of di-methyl ether in it (20%) and leave it for ½ hr.
 Reddish colour developed and add 10 ml n-butanol for crystal clear appearance.
 Check ppm content at absorbance 500 nm.

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REFINERY

An oil refinery or petroleum refinery is an industrial process plant where crude oil is
transformed and refined into more useful products such as petroleum naphtha, gasoline,
diesel fuel, asphalt base, heating oil, kerosene, liquefied petroleum gas, jet fuel and fuel oils.
In refinery II section the machines are purchased from ALPHA level.

Refinery II: This section basically deals with the production of Refined Soya bean Oil.
Alkali refining or chemical refining is done in this section. The raw crude oil has a
appreciable amount of gum (1.1-3.2%) present in it so the first and major step in this refinery
is Degumming. With the help of 0.05% phosphoric acid degumming is done. After that it is
sent to the Neutralisation section where caustic is added to form a soap. And thereafter the
process of bleaching and deodorization gets further proceed.

NEUTRALIZATION & DEGUMMING:

Oil flows to a Centrifugal mixer after being heated in a plate heat exchanger, where it is
added with phosphoric acid (0.05-0.06%) from acid storage tank by a metering pump. The
mixture is further taken to a Centrifugal mixer where it is added with caustic lye from lye
solution service tank by a metering pump. The caustic solution circuit is completed with
storage tank and recirculation pump. The mixture is then taken to a centrifuge where the
gums and soap stock are separated and are pumped out of the system by a pump via a soap
collecting tank.

Oil free of gums and having traces of soap stock is pumped through a plate heat exchanger
where it is heated by steam. Then it is sent to the Centrifugal mixer to be mixed with water
and further centrifuged in a centrifuge for water washing. The washed water is then further
sent to the slop oil tank for collection and recovery of escaped neutral oil which is then taken
back to the system by a pump.

The oil is neutralized to free fatty acid % < 0.1. The neutralization process is carried out at a
temperature of around 60-70°C. The soap content in washed oil after neutralization is less
than 100 p.

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Flow chart of Neutralization Process: -

PUMP → OIL TO OIL PHE ( 70°C ) → OIL TESTING PHE

→ MIXER ( Phosphoric dosing , 75 °C) → RETENTION TANK (A)
→ OIL TO WATER PHE (65°C) → MIXER (Caustic dosing)
→ RETENTION TANK (B) → OIL TO OIL PHE
→ OIL TO STEAM PHE (85 – 90 °C) → SEPARATOR – 1
→ RETENTION TANK (C, soap absorbent is added)
→ VACUUM DRYER → BLEACHER

BLEACHING PROCESS:

The bleaching system removes residual phosphatides, trace metals, soaps and oxidation
products in addition to colouring pigments by adsorption. In case of soya bean oil chlorophyll
is dominant and is removed whereas in palm oil carotene. The feedstock is heated up in the
Crude/Neutral Oil Economiser or Crude/Neutral Oil Heater to bleaching temperature of
around 110 0C. When there is a need for acid pre-treatment, phosphoric acid is mixed
vigorously with the oil in a Acid Mixer to ensure efficient mixing. The resultant mixture is
than held in a Retention Tank to allow for the precipitation of gums before going to the
Bleacher through the cascade vacuum dryer.
When acid pre-treatment is not required the feed stock is fed directly to the Bleacher after
heating through the cascade vacuum dryer. Bleaching Earth is added to the oil through a
dosing unit which is controlled by PLC. The Bleacher is proprietary designed with internal
partitions and set of high efficiency turbine agitators to avoid short cycling and provide
necessary retention time before filtration. Oil going to the Bleacher is thoroughly dried and
deaerated in the cascade vacuum dryer besides the fugitive particles from the Bleacher are
counter currently scrubbed by the down coming oil and hence bleaching earth going to the
hot well is avoided. The bleached oil from the Pressure Leaf Filters is transferred to the
Bleached oil tank for intermediate storage.
% Bleaching Earth used - 0.08- 0.1.

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Flow Chart of the Bleaching Process :-

SLURRY MIXING TANK (Bleaching Earth is added)

→ BLEACHER (50 – 100 mbar, Pressure and 100° - 115 °C, Temperature)
→ FILTRATION (Using PLF)
→ DEODORISER (The bleached oil is carried)

DEODORIZATION PROCESS:

The Deodorization process basically involves steam distillation process under vacuum.
“DEODORISER” is based on thin-film, counter-current distillation technology which
drastically reduces steam consumption less than half of what one would use in a conventional
tray deodorizer. The DEODORISER handles the most demanding of processing needs for a
variety of stocks, in the most efficient manner besides being gentle on the oil. This ensures an
extremely high steam to-oil interfacial surface without build-ups or stagnant zones.
The DEODORISER is available in variants like single column and split column design
whereby the packed column and tray column are in series or in parallel respectively. The
advantage in the latter being flexibility to use only the tray column bypassing the packed
column if need arises. Besides the other option available is final heating and cooling under
vacuum. The superior scrubbing equipment featuring structured packing and strategically
placed demisters ensures minimal carry-over of the fatty acid to the hot well.
The deodorization process’s basic purpose is to remove residual free fatty acids, ketones,
Aldehydes which are responsible for unacceptable flavours and odour. It is carried out at
Temperature around 250- 260 0C. Deodorization process relies on the large differences in the
volatility (partial vapour pressure) of the oil and the mostly unwanted substances which affect
its flavour, odour, colour, stability . It is essentially a mass transfer process where these
substances are evaporated from the oil at a temperature below what is damaging to the oil
which is accomplished by subjecting the oil to reduced pressure at elevated temperature in the
presence of agitating or stripping gas normally steam.

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There were a total of three (3) DEODORISERS PRESENT NAMELY: -

1. PHYSICAL DEODORISER (400 TPT, FOR PALM OIL)

2. CHEMICAL DEODORISER (400 TPT, FOR SOYABEAN OIL)
3. CHEMPRO DEODORISER (300 TPT, FOR PALM OIL)

Flow Chart of the process in a Deodoriser: -

BOT → VHE (115 °C) → VHF (210°C)

→ DEODORISER (245°C) → FATTY SCRUBBER
→ PUMP → PHE (OIL TO WATER)
→ STORAGE TANK

Flow Diagram of Palm Oil Processing :

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Flow Diagram of Soya bean Oil Processing:-

CRUDE DEGUM SOYABEAN OIL (155 ppm, P content)

→ NEUTRALSIDED SOYABEAN OIL (25 ppm)
→ BLEACHED OIL (10 – 15 ppm)
→ REFINED SOYABEAN OIL (1 – 3 ppm)

Hydrogenation of Edible oils:

Hydrogenation is a process of treating oils with hydrogen by chemical reactions

between molecular Hydrogen and another compound or element, usually in the
presence of a catalyst such as nickel. The process is commonly employed to
reduce or saturate organic compounds. Hydrogenation typically constitutes the
addition of pairs of hydrogen atoms to a molecule, often an alkene. Catalyst are
required for the reaction to be usable; non-catalytic hydrogenation takes place
only at very high temperature. Hydrogenation reduces double and triple bonds
in hydrocarbons.

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OTHER IMPORTANT PLANTS

 Boiler.
 Reverse osmosis Plant.
 Cooling Tower.
 Air compressor Plant.
 Chiller.
 Thermosyphon.
 Ammonia plant.

Boiler:

The boiler is essentially a closed vessel inside which water is stored. Fuel (generally coal) is
burnt in a furnace and hot gasses are produced.
These hot gasses come in contact with water vessel where the heat of these hot gases transfer
to the water and consequently steam is produced in the boiler. Thus, the basic working
principle of boiler is to convert water into steam by using heat energy as input.
This produced steam is piped to the turbine of thermal power plant for generation of
electricity. Well, there are many different types of boiler utilized for different purposes like
running a production unit, sanitizing some area, sterilizing equipment, to warm up the
surroundings etc.
Working principle of the steam boiler is extremely easy. Steam boiler is a cylindrical shape
closed vessel which has sufficient capacity to contain water and steam. Generally, water or
alternative fluid is stored in steam boiler to generate steam. That water or fluid is heated by
flames or hot gasses which are produced by combustion of fuels and consequently steam is
generated in the boiler at different pressure according to Steam boiler's size and its
specification. That steam is now passed through a pipe and supplied into different production
unit, power plant etc.
The net capacity of the boiler was 25TPH, and the working pressure 51 kg/sq. cm. The
temperature of the steam 450°C.

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Flow chart of the working process in the boiler: -

COAL CRUSHED (size below 6mm) → BOILER (DM Water from the RO
PLANT gets heated using the coal)
→ GENERATED STEAM → TURBINE (Used for power generation in the plant)
↓
ECONOMIZER → FD FAN (Used to remove the unwanted
particulate matter from the gas to be released)

↓
ELECTO STATIC PRECIPITATOR (Helps to purify the gas to be released)

The economizer increases the efficiency of the boiler, using the extra generated
stream to produce the next batch of steam, thus improving the plant economy .

Reverse Osmosis Plant: -

Osmosis is defined as the process of molecules passing through a semi-permeable membrane

from a less-concentrated solution into a more-concentrated solution.
An example or osmosis from nature is the roots of plants drawing water from the soil.
Reverse osmosis is simply the opposite of that process. Reverse Osmosis (RO) is a water
treatment process that removes contaminants from water by using pressure to force water
molecules through a semi permeable membrane. During this process, the contaminants are
filtered out and flushed away, leaving clean drinking water. After pre-treatment it is sent to
the dual media filter where the impurities such as Anthracite and sand gets filter. Again, it is
sent to the storage tank. There are two R.O plants, when one is working the other one is on
standby.

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FLOW CHART OF THE RO PLANT: -

WATER FEED → GARNET FILTER (Sedimentation of sand, stones and etc.)

→ CANDLE FILTER (12 candles in each filter)
→ HPP (Multi-stage centrifugal pump)
→ MEMBRANE SEPARATOR
→ DEGASSER (Used for removing dissolved gases like Carbonic acid)
→ STORAGE TANK → PUMP →
MIXED BED (Ion Exchange takes place inside and DM water is produced)
→ STORAGE TANK → BOILER

Cooling Tower: -

The water obtained as a by-product after the process of condensation in the

refinery is carried through the tail pipe into successive settling tanks where it
moves from tank 1 to tank 9 in a certain preferred manner by the help of which
the temperature of the water cools from 37° - 38°C to 30°C in the process.

There were a total of two cooling towers in the total plant:

1. DIRTY COOLING TOWER
2. CLEAN COOLING TOWER

Each cooling tower had wooden trays along which the water falls from top to
bottom thus reducing the temperature of the water as it falls downwards.

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Air compressor:

An air compressor is a device that converts power (using an electric motor, diesel or gasoline
engine, etc.) into potential energy stored in pressurized air (i.e., compressed air). By one of
several methods, an air compressor forces more and more air into a storage tank, increasing
the pressure. When tank pressure reaches its engineered upper limit, the air compressor shuts
off. The compressed air, then, is held in the tank until called into use. The energy contained
in the compressed air can be used for a variety of applications, utilizing the kinetic energy of
the air as it is released and the tank depressurizes. When tank pressure reaches its lower limit,
the air compressor turns on again and re-pressurizes the tank. An air compressor must be
differentiated from a pump because it works for any gas/air, while pumps work on a liquid.

Compressors can be classified according to the pressure delivered:

 Low-pressure air compressors (LPACs), which have a discharge pressure of 150 psi
or less
 Medium-pressure compressors which have a discharge pressure of 151 psi to 1,000
psi
 High-pressure air compressors (HPACs), which have a discharge pressure above
1,000 psi.

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Chiller:

A Chiller is a machine that removes heat from a liquid via a vapour compression or
absorption refrigeration cycle. This liquid can be then circulated through a heat exchanger to
cool equipment or another process steam. Industrial Chillers are used for controlled cooling
of products, mechanisms and factory machinery in a wide range of industries. Water cooled
chillers are intended for indoor operation and are connected by a separate water loop and
connected to outdoor cooling towers to expel heat. Air cooled chillers are intended for
outdoor installation and operation. These are directly cooled by ambient air being
mechanically directly through the condenser coil to expel heat.

Thermosyphon: -

The main purpose of the Thermosyphon in the plant is to generated steam at a temperature of
270°C and transport it to the three DEODORISERS to rise the temperature of the oil in the
deodoriser.

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The net pressure in the thermosyphon = 60 kg/sq.cm,
Speed of the coal bunker feeder motor = 130 rpm,
Speed of the CD Fan = 725 rpm,
Oxygen feed percentage = 11.8 % (It changes depending on the amount of coal fed)
Chimney exhaust temperature = 78.9°C
Flu gas temperature = 305°C

Flow chart of the process in the thermosyphon: -

ID FAN → BOOSTER FAN → FD FAN

→ COAL FEEDER → FURNANCE
→ APH (AIR PRE-HEATER, flu gas enters)
→ Cyclone (collects ash generated)
→ Bag Filter
→ ID FAN → CHIMNEY

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Ammonia Plant: -
The main purpose of the ammonia plant is to cool the products kept in the cold room. The
range of temperature in the cold room varies from 5° - 6°C. The pressures in the ammonia
and water carrying lines were 17.5 kg/sq.cm and 16 kg/ sq.cm. Each compressor section the
plant creates 8.5 bar pressure at most and 8 bar each approx. Safety valves are used in the
system to resist the increase of pressure after a certain level.

Flow Chart of The Cooling Cycle in the Ammonia Plant: -

AMMONIA COMPRESSOR
→ CONDENSOR (High Pressure, 30°-32°C)
→ RECEIVER → HEADER
↓
Batch No. 1, 2 and 3

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PACKING

Packaging is most important unit of edible oil industry because after refining process and to
deliver the huge quantity of edible oil to the consumer in a safe hygienic condition packaging
provide an easy solution.
General characteristics of fat and oil:
Fats and oil are triglycerides of different fatty acid and glycerol. Oil contains higher content
of glyceride of unsaturated fatty acid and therefore are liquid at room temperature. Vanaspati
which is hydrogenated oil falls under the categories of fat. Oil and fats are adversely affected
by humidity, temperature, light, tanning, oxygen, traces of metal and are prone to various
type of deterioration.
Parameter checked before packing of edible oil:

The below parameter needs to be checked before packing edible oil and standard must be
followed with respect to Bureau of Indian standard and prevention of food adulteration rules.

▪ Moisture
▪ Colour
▪ Refractive index
▪ Specific gravity
▪ Saponification value
▪ Iodine value
▪ Acid value
▪ Saponification value
▪ Flash point

The most significant and critical parameters considered for assessing the storing
quality of edible oil are: -
▪ Percentage moisture content
▪ Percentage free fatty acid
▪ Peroxide value
▪ Change in colour

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Tinplate containers: -
Tinplate containers are widely used for packaging of edible oil. They ensure a long shelf life
and are sturdy. They are also suitable for high filling and packaging operation. However, the
disadvantage of using tinplate container is its high cost and uncertainty of availability.
Edible oil packed in tinplate container of Adani Wilmar Ltd- 15ltr (olein oil, soybean), 15kg
(olein oil, soybean oil), 15kg (Vanaspati/bakery). And each tin container is of 89 gm weight
approx.

Flow chart of the Tin Plant processing: -

Tin sheet → Slitting Cutter → Tin body cutting → Manual folding

and 0.28 mm for ↓ ↓
top and bottom) Top and bottom Slid Seamer (sealing material )
plate cutting
↓ ↓
Mechanical die press Streiter forming
↓ ↓
Sealing Bottom Plunging
↓ ↓
Top hole punching Drum for top and bottom lid sealing

↓ ↓
Spot welding Drum seamer for top
and bottom lid sealing
↓
Leakage Testing → Packing

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HDPE (High density polyethylene) bottle: -

Blow moulded HDPE containers in the form of JAR Used for packaging of
edible oil having capacities (2litre, 5 litre, 15litre, and 15kg soybean oil). It
provides longer shelf life, supports handling and transportation.

 PET (Polyethylene Terephthalate) Bottles: -

PET bottles used for packaging of 200ml,500ml,1litre (soybean oil) was stretched
blow moulded PET bottles having excellent clarity, are odor free and have good gas barrier
properties.

 Flexible plastic pouch:-

Flexible pouch is made from laminates or multi layered films of different composition
and in the form of pillow pouches. Edible oil packed with capacities 500ml (olein, soybean),
1litre (olein oil, soybean oil).

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SOME PICTURES OF THE PRODUCTS: -

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PRODUCTS OF AWL, HALDIA

▪ Fortune soya bean oil

▪ Raag vanaspati
▪ Raag gold refined palmolein
▪ Jubilee bakery shortening
▪ Avsar
▪ Fryola soyabean/olien
▪ Kings soyabean oil

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BIBLIOGRAPHY

Refining & acid oil:

▪ Fats and oil formulating and processing for
▪ Applications-Richard d. Obrien
▪ Chemistry of oils and fats frank. Gunstone chemistry of oils and
fats M.M. Chakraborty.
Bailey’s volume 5 packaging:
▪ Modern food packing, packaging of edible oil, vanaspati ghee-an
overview by M.C. Dordi.
▪ Indiramma AR (1995). packaging of edible oil and fat. Cftri,
Mysore
▪ Packaging India, feb-mar ’03, consumer packaging of dairy
products by G.K. Goyal
 WIKIPEDIA

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CONCLUSION

A big thanks to Adani Wilmar Limited, Haldia (second largest plant of A.W.L.)
for conducting a very helpful training program for us. During this program we
learnt various things about professional life. Also have been able to differentiate
between practical knowledge and theoretical knowledge by visualize the
process and equipment’s, concepts have been clearer now which would be
prove very helpful.
As the training programme was good and covered all aspects of industry, so
now we are able to understand the industry from gate to processing and then
packaging of oil. This is a good achievement for us.
By this we have been able to start our carrier with strong base, so again thanks
for such a valuable program.

THANK YOU

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