CHAPTER II

DESIGN PROPER

This chapter shows the procedures considered in the design of an oil

making plant. This includes the design basis, process flow diagram, equipment

specifications, plant capacity and lay-out of selected industrial plant.

2.1 Scope of the Design of the Selected Industrial Manufacturing Plant

The objective of this study is to design the plant and select proper

equipments necessary for its operation. It is based on the capacity of 1250 kg/hr.

oil product. The process is included in the flow diagrams (quantitative and

qualitative) to better understand its order. This study considers the sources of

raw materials and determining the variables to be controlled. Furthermore, the

operating costs and the over-all plant lay-out will be established.

2.2 Introduction of the Selected Industrial Plant to be Designed

Oil making plant selection is a very challenging task which depends on the

decision relating to the upgrading, replacing or buying an oil making plant.

The plant design which includes the location of the plant is placed where it

is accessible enough for transportation for the ease of delivery of the product and

supply of raw materials since it is a requirement. The land area of the location

has enough space for the equipments of the plant and storage of raw materials

used in the production.

Water and electric supply in the area will be considered. The arrangement

of the machines and equipments are based on their functions yet still providing

space for operation and maintenance. The work opportunity for people living near

the area will be given by the plant.

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2.3 Design Proper

2.3.1. Manufacturing Process

Operation

Though coconut can be processed into many products, this focuses

on the processing of coconut oil, highlighting the dry-process of coconut

oil extraction and two improved coconut oil extraction technologies which

have proven to be adaptable at the village level. These technologies were

selected as the most practical. Though their viability is site-specific,

women and members of the farming family may run the technology.

Grinding

Copra is broken into fine particle sizes of about 1/16" to 1/8" by

high speed coconut grinding machine. A Copra grinding machine is driven

by a motor. When the pieces become smaller than the desired size; they

escape out through the mesh. These copra pieces are carried out through

a belt Conveyor.

Drying

Copra available in the market comes with 6-10% moisture. Before

crushing the moisture level is brought down to 4-5% by drying. We have

adopted a continuous type dryer, where copra is dried with continuous

feeding and continuous output. Hot Air at about 70°C is passed through

Copra pieces for more than an hour to aid evaporation. Exhaust Blowers

are mounted to help in passing Hot Air through Copra chamber. Air heater

is used to heat air without passing smoke into the drying chamber for

better quality drying.

Extracting

Dried and Roasted Copra pieces are now fed into an expeller with a

belt conveyor for mechanical crushing under high pressure. Oil squeezes

out of copra during this process leaving the fibre out. Crushing is

employed in 2 stages where 1st crushed copra is again crushed for the

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 2nd time to recover maximum oil. The left out Oil cake will still have 8%

oil. Extracting oil beyond this level is not economical with mechanical

crushing. Solvent extraction method will have to be employed beyond this

stage. Copra contains approximately 65% oil, 5% is lost as moisture

during the process, remaining 30% is oil cake. Oil is taken for further

processing like Filtering and packing.

Filtering

Oil extracted through expeller will have about 5% sediments/foots.

They are separated from oil through a 4 stage filtering process.

1. Vibrating Screen – Heavy sediments are separated by simple vibration of

a mesh aided by a vibrating motor. This is the simplest and cheapest method of

filtration. This relieves the further filtering stages of a lot of sediments and hence

improves efficiencies there.

2. Pressure Leaf Filter – Pressure leaf filter is a vessel that uses

vertically mounted Stainless steel mesh for filtering under pressure. Oil is

pumped into the vessel at a pressure and this pressure causes the oil to

pass through fine pored mesh for filtering. Oil cake is later separated out

using compressed air and vibrating. This process does bulk of the filtering.

3. Filter Press – Filter press consists of plates and filter cloths. Oil is passed

a pressure using a screw pump. Oil passes through the finely pored filter cloths.

Sediments remain in the filter cloth in between the plates. Oil cake and

sediments are separated by removing the plates.

4. Polish Filter – This is employed in the final stage to remove the finest of

particles from oil. Polish filter contains a vessel fitted with a polish filter bag.

When oil is passed at pressure through this bag, fine particles remain in the bag

giving out clear oil. Oil thus filtered is collected in storage tanks.

Bottling and Capping

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 Final filtered oil can either be sold to industrial buyers or in small

consumer packs to end consumers through distribution network. Packing

is done in glass bottle of 250mL using cooking oil filling machine as well

as bottling and capping machine. Packaging of bottled cooking oil typically

involves drawing the product from a holding tank and filling it into bottles in

a filling machine (filler), which are then capped, labeled and packed into

cases or cartons.  

2.3.2. List of Equipment’s

The main items of mechanical equipment involved in the oil making

plant are listed below:

 copra silo

 belt conveyor

 grinding machine

 dryer

 extracting machine

 filtering machine

 filling, bottling and capping machine

2.4 Process Flow Diagram

The oil making plant is composed of equipments necessary for the

production of bottled coconut oil. The process flow diagrams shown in the figure

illustrate the process of manufacturing the oil quantitatively and qualitatively.

2.4.1 Quantitative Flow Diagram

The quantitative flow diagram of oil making plant included the amount

of raw materials will be utilized. Also, the amount of oil to be produced in the

plant will be indicated.

2.4.2 Qualitative Flow Diagram

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 The qualitative flow diagram shows the equipment and the processes

involved in the oil making plant.

2.4.3 Combined Detail Flow Diagram

Combined Detail Flow Diagram includes the detailed process of oil

production. The equipments involved in the process, the operating condition

and the type of material on the equipments are also indicated.

2.5 Equipment Specifications

Capacity of the Plant = 10 metric ton of oil per day = 10000 kilograms of oil per

day

At 8 hours of plant operation per day,

10000 kg oil 1 day kg oil

¿ × =1250 → Plant Capacity
1 day 8 hrs hr

Copra Silo: 175.4386% of 1250 kg/hr = 2192.9825 kg/hr

Capacity = 2192.9825 kg/hr x 8hrs = 17543.86 kg

BELT CONVEYOR 1 & 2

(From Copra Silo – Grinder) & (From Grinder – Dryer)

T =2.192982456 MT /hr

Lconveyor =5 meters

Sconveyor =assumed at 60 m/min

m
Sconveyor =60
min

From Table 4-1

T =0.000404 S b2

2.192982456 MT
b=√ =9.511549467 cm
[ 0.000404 ( 60 ) ]
From Table 4-2,

b = 35.6 cm 5 ply, 28-duck K = 22.3

Drive shaft power, Pd

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 L+ 45.72 KS
Pd = [
12070 16.5
+T ]
5+45.72 ( 60 ) ( 22.3 )
¿
12070 [ 16.5
+ 2.192982456 ]
Pd =0.3499717464 kW

Power to drive Motor, Pm

Pm =( Pd ) ( 1+% losses ) ; assume 15 % losses worm gear speed reducer

Pm =( 0.3499717464 ) ( 1+ 0.15 )

1 hp
Pm =0.4024675084 kW x =0.5395 hp ≈ use 0.5−1hp motor
0.746 kW

BELT CONVEYOR 3

(From Dryer – Extractor)

T =2.083333333 MT /hr

Lconveyor =4 meters

Sconveyor =assumed at 60 m/min

From Table 4-1

T =0.000404 S b2

2.083333333 MT
b=√ =9.270711655 cm
[ 0.000404 ( 60 ) ]
From Table 4-2,

b = 35.6 cm 5 ply, 28-duck K = 22.3

Drive shaft power, Pd

L+ 45.72 KS
Pd = [
12070 16.5
+T ]
4+ 45.72 ( 60 ) ( 22.3 )
¿
12070 [ 16.5
+ 2.083333333 ]
Pd =0.3426199945 kW

Power to drive Motor, Pm

Pm =( Pd ) ( 1+% losses ) ; assume 15 % losses worm gear speed reducer

Pm =( 0.3426199945 )( 1+0.15 )

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 1 hp
Pm =0.3940129936 kW x =0.5281675518hp ≈ use 0.5−1 hp motor
0.746 kW

DRYER

From manufacturer’s catalog:

Drying time = 25 min

Commercial Drying time = 70% greater than the test drying time

1 hr
Holding Capacity = 2083.333333 kg/ hr. x 25 min x x 1.7
60 min

Holding Capacity = 1475.694444 kg

Mass of cooking oil produce per day = 10,000 kg

1kg copra = 0.6 kg oil

1 kg copra
Total mass of copra needed per day = 10,000 kg x = 16666.66667 kg
0.6 kg oil

copra

Since the copra meat loses 5% of its original mass during the drying

process of the production,

Let X= total mass of coconut meat needed in the production

16,666.66667kg copra + 0.05X = X

16,666.66667kg copra = X – 0.05 X =0.95X

X= 17543.85965 kg copra

Rate of copra meat entering the dryer ( M d )

17543.85965kg copra
Md = = 2192.982456 kg/hr
8 hours

Rate of dried copra entering the extractor ( M e)

16,666.66667 kg copra
Me = = 2083.333333 kg/hr
8 hours

Production rate ( Pr )

25
 10000 kg oil
Pr = = 1250 kg/hr
8 hours

Since the production of cooking oil will be 250 mL per bottle therefore the

number of bottles produce per day would be:

1250 L 1000 mL 1bottle

N=
hr
x 1L
x 250 mL
= 5000 bottles/hr

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 SCHEDULE

Electrical Data
TAG No. Quantity Description Maker Model Capacity
Voltage
Phase (Ø) Frequency (Hz)
(V)

BC 3 Belt conveyor 220 Single 60

Coconut Copra Grinding GT Model

G 1
Machine Honmac 220 Single 60
no. 500
60-160 kg per
Coconut Copra Dryer Hengche
D 1 DW 1.2x8 hr (drying 220 Single 60
Machine ng
cap)
Copra Oil Extraction 30-200 tons
E 1
Machine
Honmac 220 Single 60
per day

Coconut Oil 20 tons per

F 1 Honmac 220 Single 60
Refinery day
1000-36000
Filling, Bottling and Golden
B 1 bottles per hour, 220 Single 60
Capping Machinery
250 mL size
This chapter presents the schedule of equipment to be used and shows the catalogues that were

considered during the design. It covers all the technical aspects of the equipment to be used, their features,

dimensions and quantities to be employed in order to meet the load required in a batching plant.

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