Hosc Intern Report

HARAMAYA INSTITUTE OF TECHNOLOGY
FOOD TECHNOLOGY AND PROCESS ENGINEERING
Host Company: HAMARESSA EDIBLE OIL COMPANY
Internship duration for one full semester 2020
GROUP MEMBERS NAME ID/NO
1. DAGIM LIJALEM 3341/08

2.RUHAMA TADESSE 4132/08
3.YOHANNES G/HIWOT 4370/08
4.SIRAJ HELIL 2438/07
5. REMEDAN NASSIR 4117/08
6. GADDA SHAMBU 3566/08
Advisor: - Dr. Solomon. Abera Sub Date. 11/11/20
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HARAMAYA UNIVERISITY HAMARESSA EDIBLE OIL COMPANY
DECLARATION
We are from Haramaya University Institute of Technology 5th Year Food Technology and
Process Engineering students and hereby we declare that this internship report is submitted by
us, it describes our four month practice in Hamaressa edible oil share company. we assure that all
the materials and pictures Used while compiling this report contain actual events and facts that
was observed and Performed during our internship practice program. All the contents are our
own and it has not been submitted to any other institute.
.
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ACKNOWLEDGEMENT
First of all we owe much tribute to the almighty God who gave us life worth living and we
Thank him for giving us the strength to accomplish this work. Next We would like to thank our
supervisor Mr.Endrias Shanko, we have no word to describe his love, respect and advise
answering any question we ask him, more importantly for his enthusiastic encouragements and
precious instructions during our internship period. We also would like to express our deep
gratitude to our advisor Dr.Solomon Abera who has been assisting us through our internship.
Generally we would like to thank Hamaressa Edible oil Factory Workers they are respectful for
each other and to their work and we learned many things from them.
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Abbreviation and acronyms

FFA Free fatty acid
Caustic soda (NaOH) Sodium hydroxide
CaOH Calcium hydroxide
H3PO4 Phosphoric acid
PAH Polly aromatic hydrocarbon
NHP Non-hydratable Phospholipid
Mc Moisture content
KOH Potassium hydroxide
HCL Hydrochloric acid
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LIST OF FIGURES
Figure 1:- administrational structure

Figure 2:- figure showing the movement of seed and stone on de-stoner.
Figure 3:- cookers with five rooms for each
Figure 4:- flow chart of degumming process
Figure 5:- flow chart of neutralization
Figure 6:- flow chart of bleaching
Figure 7 ; flow chart of deodorization
Table Of Contents
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Declaration……………………………………………………………………………………
Acknowledgement……………………………………………………………………………..
Acronyms and Abbreviations………………………………………………………………….
List of Figures …………………………………………………………………………………
Executive Summary…………………………………………………………………………….
Chapter 1........................................................................................................................................9
INTRODUCTION.........................................................................................................................9
1.1. Background of the company...........................................................................................10
1.2. Mission and Vision.........................................................................................................12
1.3. Objective:-.......................................................................................................................13
Chapter 2......................................................................................................................................17
Overall Internship Experience...................................................................................................17
2.1 How we entered to the company..........................................................................................17
2.2 Section of the Company We Have Been Working..............................................................18
2.3 Process Description..............................................................................................................18
2.3.1 Raw material Receiving and Storage............................................................................18
2.3.2. Dumping and cleaning..................................................................................................19
2.3.4. Milling and Decortication section................................................................................20
2.3.5. Cooking and Press........................................................................................................21
2.3.6. Refining........................................................................................................................24
2.3.6.1. Degumming..........................................................................................................25
2.3.6.2. Neutralization.......................................................................................................26
2.3.6.3 Bleaching...............................................................................................................27
2.3.6.4. Deodorization.......................................................................................................29
2.3.7. Filling Section..............................................................................................................31
Chapter 3......................................................................................................................................32
Quality control section................................................................................................................32
3.1. Raw material analysis.........................................................................................................32
3.2. Analysis of oil content in the cake......................................................................................33
3.3. Analysis during neutralization process...............................................................................33
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Chapter 4......................................................................................................................................34
Utilities..........................................................................................................................................34
4.1. The boiler............................................................................................................................34
Chapter 5......................................................................................................................................35
THE OVERALL BENEFIT FROM THE INTERNSHIP.......................................................35
Chapter 6......................................................................................................................................36
Conclusion and recommendation...............................................................................................36
6.1. Recommendation.............................................................................................................36
Raw material storage conditions........................................................................................36
Sanitation and safety issues...............................................................................................37
Mal function of lab equipment..........................................................................................37
Problems during process....................................................................................................37
6.2. CONCLUSSION.................................................................................................................38
References.....................................................................................................................................39
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EXECUTIVE SUMMARY
This document is the final report for our internship program in Hamaressa Edible Oil Share
Company. it is an outcome of the exercise we conducted during our internship program which
begins with our joining time November 2019 untill March 2020. This was an opportunity for us
to apply the theoretical knowledge we acquired on practical working conditions and to get
experience on how life would be like after graduation. The report involves six chapters,
references, and table of contents describing exact Location of topics. We worked in all section
from raw material reception up to filling and packing but mainly on quality control section. Their
quality checking parameters are important to produce excellent quality product, to increase shelf
life, to increase yield of food and to minimize complain raise from customer about product. We
saw how the product is produced and the working principle of machineries in production section.
we would like to make stress this, that our experience with Hamaressa edible oil Share Company
was very memorable and full of learning’s where we found a lot of positive changes in our
attitude, learning and behavior.
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Chapter 1
INTRODUCTION
Fats and oils are organic compounds called triglycerides. They are esters with fairly high relative
molecular masses. Fats and oils are mainly tasteless, colorless, & odorless, are higher than water
and insoluble in it. Oils and fats have the same chemical arrangement but different functionally
in that oils are liquid at room temperature while fats are solid. The structure consists of a glycerol
“backbone” to which three fatty acids are attached. A fatty acid is a chain of carbon and
hydrogen atoms with a “carboxyl head”. It is through a carboxyl head that the fatty acids attach
to the glycerol via ester linkage with all three carbons the glycerol linked to a fatty acid, the
compound is known as a “glycerol”.
Fats and oils are either saturated or unsaturated. The unsaturated fats are further divided into
monounsaturated and polyunsaturated. When the chemical bonds between the carbon-atoms of
the fat molecules contain all the hydrogen atoms they can hold, the fat is saturated. If the bonds
can hold one additional hydrogen atom, the fat is monounsaturated; if the bonds can hold more
additional hydrogen atoms, the fat is poly unsaturated.
In general, saturated fats are solid enough to maintain their shape at room temperature and they
are usually come from animal sources. However, there are exceptions to this rule, tropical oils
such as coconut and palm oil which come from plants are semi-solid at room temperature and
highly saturated. For the unsaturated fats, they are usually derived primarily from plants and are
liquid (in the form of an oil) at room temperature. For example, oleic, linoleic and while,
palmitic, stearic acids are saturated fats at room temperature. Vegetable oil and fat resources are
indispensable to mankind as a source of nutrient & industrial raw materials. Crude
vegetable oils obtained from various oil milling units is further refined before use for edible
process. Refined edible oil is a process where free fatty acids are volatized, condensed &
recovered simultaneously with vacuum de-colorizing operation
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1.1 Background of the company

Hamaressa Edible Oil Share Company is the largest Ethiopian Edible Oil factory, located in
Harar region, Hamaressa founded 6 Kilometers from the town of Harrar. The factory which has
become operational since May, 1998 lies over an area of 48000 m². It was erected at the place
where, once the former Hamaressa Flour mill and oil factory stood. This Industry is equipped
with modern machinery capable of producing high quality edible oil from different types of oil
seeds.
Since the commencement of operation, the company has succeeded in producing high quality oil.
All the products are in full conformity with Local & International standards of pure refined
edible oil. The company produces pure refined Edible Oil from oil seeds commonly grown in the
country. The major product being Ground nut oil, other oil types like Sesame, Niger seed, Cotton
seed, Rape seed and Linseed are also produced. The Oil cake (by product) has proven itself
suitable for animal fattening and dairy. The factory has been sold to Ethio Asian Industries PLC
buys the privatization & public enterprise supervising Agency in Wednesday October 29, 2014
Infrastructure & Facilities
The company is located on the main road to Addis. The port of Djibouti can be reached by train
by land transport and by air. All types of modern communication including Fax and internet are
available in the area. There are no other oil producers in the whole region of eastern Ethiopia. It
is also situated near the peanut growing districts. (Babile 30 Km., Gursum 75Km., Bedeno 125
Km.) Harar & for rapeseed situated from Bale Farm & Arsi farm. The factory has, within its
premises, a large raw material store capable of holding stock for more than three months. The
chemicals used in oil production are the most common types like caustic soda and Bleaching
earth, Furness etc. These chemicals are used in small Quantities and they are available in the
local market.
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Board of director
HAMARESSA EDIBLE OIL COMPANY
CEO
Executive
Secretary CEO Advisor
Planning head
Audit head
Lawyer
Lia sin office hade
Administration structure of hamaressa edible oil company
Factory manager Finance

Depictive C.E.O manger Administration Commercial
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manger manger
General Cost & Personnel
Quality Technical
Produc budget General Clinic
head head accountin head
tion head Service head
g head
head
Figure 1: administrational structure

Palm oil Import and
HARAMAYA UNIVERISITY
Sales and Purchasing

distribution Branch marketing head
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manger
Suppling chain
Financial &
and distribution
administration head
head
Departments of Hamaressa Edible Oil S.C
The departments of Hamaressa Edible Oil S.C are:
 Production department
 Maintenance department
 Marketing and sales department
 Procurement and Property Administration (PPA) Department
 Finance Department
 Administration, human resources and general service department
 Quality assurance department
There are four major sections, namely:-
Seed cleaning & preparation section

Milling& press section
Refinery
Filling & packing sections
1.1. Mission and Vision

Vision-
To fully utilize and enhance the capability and power of the factory and enrich It too at most
level of international standard of edible oil, by making it Competent in the domestic and
international market, through quality Management application and achieve successes out of sales
of quality product In reasonable cost.
Mission:-
By using input products of the country, oil seeds and processing edible oil, the Factory tries to
meet the standards of the similar benchmark, aims to fill the Domestic and international market
needs & plays its part to answer the country’s developmental needs with other relevant programs
held in part.
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Value:-
We strongly stand to produce acid-free edible oil as of our motto
 We are strictly governed by our professional ethics

 We are client focused
 We work for the benefit of stakeholders
1.2. Objective:-
 To enhance the factory’s productivity from 11% - 50%
 To raise up factory from deficit to productivity & create an attraction of high productivity
so that it be transferred for private buyers
 To enhance and make capable corporate
 To develop the capacity and ethical knowledge of the workers so that they achieve the
fruits of high productivity.
 To prepare modern scientific ways of working methods
 To create modern, productive, and contemporary civilized worker.
 To deliver quality packed groundnut edible oil for export markets.
 To organize strong human power development.
Swot Analysis
Before setting a 2019/20 plan of a given company, it is important that its socio economic
environment be thoroughly analysed. Understanding the internal and external
environment helps to tackle the weakness and threats & to plan an objectively realizable
plan. Hamaressa Edible Oil Share Company environmental analysis below.
Strength:-
Technology
The relatively modern machinery the company is equipped with puts it ahead of its competitors,
Studies conducted in Harar, Dire Dawa & Addis Ababa & Nizehiret town that customers are
highly satisfied with the quality of the product. Moreover, the Ethiopian standard authority in
analysis it conduct has awarded the company a certificate conforming that the national quality
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standards are met. In addition in 2013 the company received the International Star for leadership
in Quality award in gold category in Paris. & the second time in 2014 received European award
for the best practise of Quality in the gold category. The completion in the sector is on the bases
of price, Quality and other after sales services. The Technology superiority Therefore is
considered as an opportunity reducing production costs and thereby selling prices. The modern
technology also enables to increase the extraction rate. Higher capacity will also reduce the
overhead costs.
Weakness:-
Capacity Utilization
The inadequate supply of Raw materials at a competitive price. The limitation working capital
could not allow the factory to utilize its full capacity less capacity utilization results in greater
unit costs and less sales revenue.
Finance
The factory has no sufficient working capital. The small working capital comes from bank loan.
One can see how difficult it is to run a company which has just entered the business and which is
expected to do much to get its rightful depreciation rate aggravate the problem. Oil seed prices
are lower in the harvest season. A sufficient working capital would allow the company to stock a
sizeable amount in the boom season.
Opportunities
Continuous Demand
Edible oil is a product that has a constant demand. It can be considered as a basic necessity
consumed by almost households. The ups & down in general economic level have little effect on
the demand for edible oil. This stable market can be considered as an opportunity to the sector.
Threats/Risks
Competition
As mentioned earlier the basis for competition are price, Quality and other non- price factors.
The competition is between the local producers, Exporters of oil seed and importers of edible oil.
This highly governs the input and output price settings. In this respect small scale oil produces
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can set prices lower than the huge complexes. This is mainly because of the fully depreciated
machinery &less investment costs. The demand for oil seeds both locally and abroad minimizes
the role of the company in price regulation.
Lack of market information
Little information is available on the actual supply & demand condition of the market, each oil
supplier’s market share & the overall trends, thus the shortage of information raises the
uncertainty in planning.
Short Term plans to increase revenue, market share & reduce costs
Price Discount (Limited time)
 Discount prices for the specific, limited and well-tempered period can awake the market
& make the sales drive.
 It is true that discount is a direct cost of the company, due to decreased margin. But the
bigger problem from reduced margin is reduced sales turnover. Without sales turnover
there is no margin & no profits as well. Therefore blanked reduction of margin for limited
period, that will increase sell out, will be beneficial for our company.
1.2 Long term objectives to achieve it, the strategy
Volume Targeting
 Increasing the targets versus sales trends can make them to use their wear house & credit
capacities to stock up.
 With proper balancing of target stretching it is possible to gradually increase the volume
& to block the space for the competition.
1.3 Market Analyse:-Market behaviour changing and affecting of products & services
acceptability
1.3.1 Sustainable competitive advantage
Our company acquires attributes that allow in to perform at a higher level than others industry
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1.3.2 Customer Excellence
Obtaining customer feedback to ensure customer satisfaction
1.3.3 Multiple sources of Competitive advantage in the market place
1.3.4 The product delivered on time & in good condition in order to meet customer
demand
1.3.5 Supplier to promote the product quality to the customers
1.3.6 The customers are to handle the products as easily as possible & the suppliers to
ship & sell products in packages that fit with inn their system.
Marketing & Sales
Market promotion & sales support Plans
Planned the promotion objectives need to be clearly stated & measurable they must be
compatible with the objectives of the company, as well as the competitive & marketing
strategies.
Market Promotion Ways:-
 Transmitted through mass media

 Promotion through news stories in newsletters, newspaper,
magazines & television
 Personal selling
 Business cards
 Window banners
 Flyers
 Direct mail
 Greeting cards
 Sport team sponsor
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Also, market promotion includes all activities designed to inform persuade & influence
people when they are making the decision to buy.
Distribution system
Direct Distribution System
There are no other parties involved in the distribution process that take ownership & the
product:-
- Distribute the product to the customers
- Personal communication with a customer representative who is not

a sales person, such as through telephone ordering.
Indirect Distribution system
- Single party selling system

The marketer engages another party who sells & distributes directly to the final customer
- Multiple party selling system
The product passing through two or more distributors before reaching the final customer
Chapter 2
Overall Internship Experience
2.1 How we entered to the company

At the end of the first semester when we were a 4th year undergraduate student at Haramaya
institute of technology our department Ordered us to request the company where we will Stay
there for one full semester of next year by doing group practice (internship program).The
requesting letter was prepared by HIT and also we were oriented about this program .After that
we took the requesting letter to the Hamaressa edible oil share company and the company
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manager received this letter. He also requested us to come again on next few days. As he
programmed we also returned back to this company to hear the company final decision. finally
they have decided to accept us and they also allowed us to use service bus for transportation
2.2 Section of the Company We Have Been Working
On our first working day in the company the general manager of the factory Introduce us to the
Head of the quality control section Mr.Endrias whom we admire the most and he was also our
supervisor at this Time he tried to acquaint to us the overall working principles and the
company’s Abiding law. On the way he gave order to the quality staff members to welcome and
host us With good manners. So in short we were specially worked in quality Control section
with the quality control staff members
After that our supervisor gave us an orientation about staying in the processing to improve;
1. Practical work related to food processing technology
2. Communication skill
3. Team playing skill
4. Work ethics
5. Leadership skill
2.3 Process Description

2.3.1 Raw material Receiving and Storage
The processing of oil starts from receiving and storage of raw material. The raw materials should
fulfil the requirement of the company. If not, the company will reject it. This is because the
quality of the raw material determines the quality of the final product.The type of the raw
material the company use for processing of oil is rape seed, cotton seed and ground nut. But most
of the time rape seed is preferred for its ease of process and availability. Even in our internship
program the company has been operating on rape seed alone.
The procurement of the raw material is either by directly from producers; both farmers and
government, through agents or wholesale market. Since the raw material is cereal it is available
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throughout the year. For example during our internship the company has procured thirty-four
thousand quintal rape seed. The transportation from the source to the company is done by heavy
trucks. Once it reach the company sampler takes sample for analysis. The lab technician checks
if it is worthy of acceptance.
The following are parameters which are under taken during inspection are:-
 Maximum oil yield (should be more than 40%)
 Percent of impurity (not more than 3% )
 Maturity
If the raw materials fulfil these requirements it enters the storage house and unloaded by labour
force. Through the whole time we spent we have been checking if there is some precaution under
taken to protect from insects, rats, moulds or other microbial contaminant. But it is totally
ignored.
2.3.2. Dumping and cleaning

Dumping and cleaning takes place in the same building but cleaning section is isolated with
partition. The labours dump the seed within the sacks on the dumping sieve. The sieve traps large
chaffs and pass the seeds down to vertical conveyers which are found under the sieve. Then it is
transported to cleaning section which is found next to dumping as depicted in the lay out above.
The cleaning section is equipped with different cleaning equipments for different seeds.it has
sieves with different sizes, de-stoner for removal of stones and cyclones for removal of dust. The
de-stoner works by the same principle how traditionally mothers remove stones. It has inclined
sieve and when vibration is applied the seed moves downward and stones and heavy materials
moves upward.
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Figure 2:- figure showing the movement of seed and stone on de-stoner.
And cyclones are installed on both the sieve and the DE stoner. They suck the dust from each
equipment and by gravity the dust is collected at the bottom. Only clean air is released to the
atmosphere. After cleaning is done the seed leaves the building to the next section using
conveyors which are installed underground. Then it is taken up by using bucket elevator and then
to the silo storages.
The silo storages are shown on the picture here. The right side has a capacity of 75 tones and the
other can hold twice of it.it is planted near to the milling and pressing building. The larger
storage is not working currently.
Then it feeds the milling section continuously. The seed is taken from the bottom of the storage
and elevated up by bucket elevator and then by horizontal conveyor into the building.
2.3.4. Milling and Decortication section
Although the screw press is the core element in any pressing plant, it has to be in tune with
appropriate seed preparation to show its full potential.
The mechanical seed preparation is primarily important to gain access to the oil droplets within
the cellular structure of the seed. However, total destruction of the cell walls leads to a ground
product which lacks a sufficient structure to allow for pressure build-up and oil separation. The
classical flaking step gives the compromise between easy access to the oil and a product matrix
that permits pressing.
Rape seeds are milled and transferred to cooking and press section. But cotton seed and ground
nut are decorticated prior to pressing. These American made millers have high efficiency
(5tones/hrs.) and are of good quality. There is also a magnetic separator for metallic materials.
The separator traps metals and leaves them on the other side. This is done when it rotates and
create different magnetic field on both sides.
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The main intention behind milling is to achieve maximum yield of oil. Size reduction increases
the availability of oily surface to the cooker and press. Decortication is important because husks
contain only about 1% of the oil. Hence during pressing it absorbs the oil during pressing.
Decortication and milling takes place in the same equipment for cotton seed and ground nut. but
cotton seed has to pass through a process called delinting which comprises the steps of passing
the cotton seed through a saw delinter to remove substantial portion of the lint, preferably at least
40% and there after passing the parcially delinted seed through a brush delinter to remove
substantially all of the remaining lint. The picture shows the machinery installed in these section
that use for milling and decortication.
2.3.5. Cooking and Press
The company is equipped with British made mechanical expeller and cooker.The cooker is
positioned on the top of the expeller .it has five houses and each houses are adjusted with
different temperature .each houses have their own steam inlet with valve and common
condensate out let. Milled oil seed enters and leaves the cooker continuously so it can feed the
expeller without interruption.
The cooking process
Steam with a range of 5-11 bars enters each house and directly mixed with the seed. These rises
the temperature and gives moisture. There are rotating agitators to facilitate good mixing. Each
house has its own gage so that they can be adjusted with different temperature. The seed enters
the cooker on the top and leaves at the bottom. The cooking temperature ranges from 40 oc to
60oc
Why cooking is important?
Cooking and adding moisture makes the oil to expand and easily withdraw during pressing. If the
cooking temperature exceed 60oc it brings colour change which cannot be corrected by
refining.so optimum temperature should be applied.
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Figure 3:- cookers with five rooms for each
The Expeller – Screw Press - Design
The name of the expeller and the expelling process go back to an invention of Anderson
International Corp. It has been patented by Mr.Anderson and protected by the corresponding
trademark. Through early licensee agreements the expeller soon became the standard machine in
the modern oil milling industry worldwide. The more technical term for the expeller is screw
press. The invention of Mr. Anderson rapidly replaced the discontinuously operating hydraulic
strainer cage presses. In principal the structure of the screw press is similar to the expander
However, the cylindrical housing of the press is perforated allowing drainage area for the oil to
be separated. In fact the housing consists of a base structure to support a big number of cage
bars, which are distanced by individual thin metal spacers or by their special shapes. Different
cage sections over the length of the cage allow for individual spacer settings.
The worm shaft in the press today consists of individual worm elements, conical rings or toothed
mixing rings. The free volume of the worm elements and their conveying capability decreases
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from inlet to outlet. This leads together with the restrictions by conical rings to an increase in
product density and a gradual pressure build-up of the material. Scraper bars (knife bars) are
installed at several positions of the cage in order to prevent the press material from turning with
the shaft thus increasing the throughput of the press. For the same purpose the cage bars have a
special shape which forms in combination with neighbouring bars a saw-tooth profile.
Older small capacity screw presses with relatively short cages were characterized by a discharge
system with an adjustable choke ring to set the width of the annular gap or the press cake
thickness respectively. A smaller gap leads to higher pressure, higher oil yield and lower
capacity. The impact of adjustable discharge rings on the pressure build-up in modern long high-
capacity screw presses is rather low. Therefore modern presses work with fixed discharge cones
but several conical rings over the entire length of the shaft to generate individual pressure
sections followed by low pressure (relief) sections also to allow for internal material turn-over to
form new capillaries for drainage.
The screw press which is installed in hamaresa Oil Company has a capacity of 500quintal per
day.
Different parts of screw press
 Worm element –conical rings

 Scraper bars(knife bars)
 Conical pressure cage (made from steel bars)
 Main worm shaft
 Spacer for adjusting cake thickness
The Pressing Process
The seed enters the barrel and falls on the helical pressure worm. During movement in the barrel,
between worm and cage is gradually reduced and the seed flakes are subjected to increasing
pressure. A screw pulls the seeds from the funnel inlet and crushes them in the area of the barrel.
The pulverized seeds move into the press head where their water content turns to steam under
intense pressure. Without water content, no oil extraction would happen because the motion of
the screw does not push the cake out the nozzle. The expanding steam pressure in the cake
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pushes it out the nozzle. The oil floating freely in the press head is repulsed by this and moves
backwards to drop out of the barrel orifices. The water content of screw press feedstock should
be no less than 7%, but also no more than 10%. The cage is made of a number of special steel
bars which let liquid pass through it. The oil passes between the bars and flows out of the cage.
The cone moves along the shaft of the expeller and the space between the worm and the cone can
be regulated. This permits easy control of the thickness of the cakes and of the degree of pressure
to which the cooked flakes are subjected.
Recycling
The term recycling in oil processing is to refer the extraction of oil from the cake by circulating it
in a loop until the oil content in the cake gets below 3%.
There are two cooking and press unit. The first one is for raw seed and the second is for
recycling of the cake. In the loop, there is a grinder that performs size reduction of the cake.
Conveyors and elevators facilitate the transportation from the press to the grinder then to cooker
finally back to the press. Cakes are also returned from first clarification tanker which trap large
particles from crude oil and from plate and frame filter back to the first cooker then to the press
again. Finally the cake makes is way to grinding and cooling room then to packaging and
storage. After filtration the oil is weighted and pumped to four large tankers which are located
between extraction and refinery section. Each tanker is capable of holding 30500 litters.
2.3.6. Refining
Crude oil is mainly a mixture of triacylglycerols along with the minor components, undesirable
pigments, oxidation products, and metals. The purpose of the refining processes is to remove
unwanted impurities while maintaining as far as possible the level of desirable minor
components. Where these latter are removed it is often possible to trap them in a side stream and
to recover them for alternative use. If the facility s for doing this are not to hand then the minor
components may be added back to the meal, incorporated into animal feed, or used as fertiliser.
In Europe the term ‘refining’ is applied to the whole series of processes described here but in the
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USA it tends to be equated with removal of free acid (neutralisation).
Description of the refining section
There are three refining equipments and four different process in this section. The first step is
degumming and neutralizing unit the next is bleaching and finally deodorizing. The operations
are controlled in a facial boards and different valves. All of the equipment in this section is
Italian made capable of producing 1500 litters per day.
2.3.6.1. Degumming
Degumming involves treatment with water or dilute acid (phosphoric or citric) producing a gum
containing phospholipids (and trace metals) which can be separated with a centrifuge. The
phospholipids are recovered as crude lecithin. Phospholipids not easily removed by these
degumming procedures are said to be ‘non-hydratable’ (NHP) and are mainly phosphatidic acids
and lysophosphatidic acids present as calcium or magnesium salts. Other degumming procedures
involve the use of ethylene diamine tetra-acetic acid for removal of trace metals or the use of
appropriate enzymes. In the latter, appropriate lipases promote splitting of the phospholipids into
forms that are more readily separated and removed.
The degumming process
Degumming and neutralizing takes place in neutralizer. Degumming can be done using H 2O,
H3PO4 or citric acid. Among these only H3PO4 is used widely. The advantage of using H3PO4 is
its availability in more concentrated form. This in return reduces shipping cost.
It takes 45-60 min to fill the neutralizer with crude oil. The neutralizing tanker can hold 8440
litters but 50 cm or 1000 litter empty space should be left. After filling the neutralizer the next
step is heating the crude oil to 50oc. steam is used to heat the oil. There are heat exchangers in the
refining equipments. The steam passes through a large coil which is installed in the three refining
equipments.Three litters of phosphoric acid diluted with 15 litters of water and added to the
crude oil without agitation. Then the neutralization process starts without discharging the gum.
25
INTERNSHIP REPORT
The Flow chart of degumming process.
Filling the neutralizer with crude

oil
Rising the temperature to 50oc
Adding of phosphoric acid

solution
Figure 4: flow chart of degumming process
2.3.6.2. Neutralization
Neutralisation frequently requires treatment with aqueous alkali to remove free acids. Some oil is
lost along with the soaps in a (large) water stream that has to be disposed of in an
environmentally appropriate manner. Free acids are also removed during deodorisation by steam
distillation (physical refining). This latter method is increasingly favoured because of its reduced
environmental demand.
The neutralization process
The neutralization process starts by heating the oil to 60 oc with agitation. Caustic soda is
prepared by diluting to 18 d. be with H 2O in different tanker. The amount of soda is decided by
chemists depending on the acidity of the crude oil. Inside neutralizing the FFA and caustic soda
are reacted to create soap and water by the chemical formula;-
Base + Acid = Soap + water The flow chart below shows the step of neutralization process
26
INTERNSHIP REPORT
Rising the temperature to

60oc
Adding of soda solution
20 min agitation and 10 min

settling
Adding 5% water
1 hour settling time
Discharge soap stock and

water
Spray 5% water without agitation
Discharge soap and water after 1 hour settling

time
Heat the oil to 90oc
1st wash with water @90oc
Two hours settling
Discharge
Figure 5 ; Flow Chart of Neutralization
27
INTERNSHIP REPORT
2.3.6.3 Bleaching
As the name implies the process was designed to remove colour (carotenes, chlorophyll) but
trace metals are also removed along with soaps and residual phospholipids.Most triglycerides
(which are in the fact the main constituent of oils and fats) feature only a slight natural colour
(colourless to pale yellowish).the deep colour of many crude oils result from small quantities of
various colour bodies and pigments, the most important of which are carotene and carotenoids
(yellowish red to deep red colour), as well as chlorophyll and its derivatives(deep green colour).
However, under the acidic conditions free sterols may be dehydrated to steradienes and cis
bonds in fatty acids may change to the trans form. Bleaching is the most expensive refining step
because of the cost of obtaining the bleaching earth, of disposing of spent earth, and through loss
of some oil. Polycyclic aromatic hydrocarbons (PAH) when present in the oil are not removed by
bleaching. Volatile members are removed during deodorisation but the non-volatile PAHs are
removed by adsorption on activated carbon added to the bleaching earth.
The bleaching process
Bleaching requires heating the oil at 90–120ºC with acid-activated bleaching earth. The
bleaching process takes place in closed vacuum device that has agitator, heat exchanging coil
and vacuum bleaching earth sacking device. One batch consumes 100kg of bleaching earth. The
bleaching process lasts for about four hours. Activated carbon bleaching earth powder is used to
remove colour compounds. After 30 minutes of reaction time with a temperature of 90 oc the oil
is cooled to70oc and discharged. During discharge the oil is passed through filter press for
clarification. During filtration, soap residual and other particles are also removed along with
bleaching earth. The photo below shows the filter press.
Filling the bleacher with oil
Heat the oil to 120oc
Cooling to 90oc
28
Adding the
INTERNSHIP bleaching
REPORT earth
Cooling to 65-75oc
Filter and Discharge
2.3.6.4. Deodorization
Deodorisation is the final refining step and requires the oil to be sparged with steam at 170–
250ºC under reduced pressure to remove oxidation products responsible for off-flavour. At
higher temperatures (220ºC) there is isomerisation of cis to trans bonds so highly unsaturated
oils should be deodorised at the lowest possible temperature. This applies especially to fish oils
with their highly unsaturated long-chain PUFA which should not be heated above 180ºC and to
soybean and rapeseed oils which contain linolenic acid. Polyunsaturated fatty acids only retain
their important nutritional properties if they remain in the all-cis forms. Deodoriser distillate is
itself a valuable by-product that serves as a source of sterols and tocopherols.
Deodorization is the most sophisticated and yet interesting step in refining section. Inside
deodorizer there are the same heat exchanging coil but unlike neutralization and bleaching, hot
furnace oil is used to heat the coil instead of steam. There is also another coil for in late and out
late of cooling water for cooling the oil at the end of the process. A thin pipe is situated from the
top to the bottom of the equipment as indicated in the diagram. But it has no out late since the
steam is directly released in to the oil to create sparging motion as the name indicates. The most
important device in deodorizer is the booster. Since the removal of odour is carried out by this
device.
The deodorization process
The oil is heated to 125oc using furnace which is pumped from thermo boiler. At this stage the
booster is started along with fans and pumps which are found in cold water recycling tankers.
The booster is a device that every volatile component that gives odour along with sparging
steam. The steam and FFA residue is trapped here and flows to a cylindrical object. For its
proper operation the booster needs steam with 10-11 bar.
29
INTERNSHIP REPORT
At a temperature of 150oc sparging steam valve is opened. The sparging steam passes in a whole
with size of needle inside a thin pipe. It enters at the top of the deodorizer but inside it is
extended to the bottom then the steam is directly released to the oil. The main use of sparging
steam is as the name indicates to create sparge in the oil. This process in return creates way for
volatile compounds to escape to the top where they are trapped by the booster, but the steam and
FFA residue left from neutralization are collected inside a cylindrical.
Beside removing odorous matter these process also gives the oil a bright colour. This is because
FFA has dark brown colour.
To avoid atmospheric contamination, the odour is not directly released in to the air; rather it is
wiped out by recycling water to the cooler. Finally the oil is filtered by closed folition filter and
weighted then pumped to filling section. The whole deodorization process takes 8-10 hours
Filling
Circulation & heating to 125oc
Starting the booster @125oc
Opening of sparging steam at 150oc
End of heating at 180oc
Cooling starts after 30 min
Closing sparging steam at 150oc
Stoping the booster at 75oc

30
INTERNSHIP REPORT
End of cooling
Filter & discharge
Figure 7 ; flow chart of deodorization

2.3.7. Filling Section
The final step in oil processing is filling and belling. The filling section building is far isolated
from other buildings to avoid contamination. This section has two types of automatic filling
machines. Both filler use the principle called pneumatic system. The first one can be adjusted in
a range from one litter to five litters. The second one fills in one litter botte. Then second and
third packaging is fallowed. In secondary packaging, oil filled in three litter jar are wrapped with
flat plastics and passed through heat house with 300 oc. when cold air is applied the plastics are
contrasted and become tight enough to hold the four jars. There are two shifts in filling section a
total of 16 hours working time per day while the rest sections use three shifts which is 24 hours
working time.
Process layout
Seed Decortica Milling Crude Neutraliz Bleachin Deodorizi Packing

cleanin tions & Oil ing g& ng Plant Plant
g Pressin Tanke Tanker Filtering
g r plant
Hull
Cake Grinding,
Collection &
cooling and
Pelletization
Packing
31
INTERNSHIP REPORT
Chapter 3
Quality control section

The quality control room has sampler and lab technician personnel. The task of the sampler is
providing samples to quality control lab and the lab technician makes the experiment gives the
gudgement.
The quality control lab is responsible for the following analysis
3.1. Raw material analysis

 Precent of impurity;- it is calculated using the following formula
impure−pure
% of impurity = 100 %
ipure
 Oil content in the seed
The sample is ground and 10g is measured. Then the oil is extracted using hexane by solvent
extraction. 200-300ml of oil should be extracted from 20g of sample.
 Acidity
The acid value determines the amount of free fatty acids in fat and oil. Usually the sample which
is dissolved in solvent is titrated with KOH solution against phenolphthalein.
Procedure of free fatty acid determination
32
INTERNSHIP REPORT
Firstly we add ethanol in to conical flask up to 150ML and added some drops of
phenolphthalein indicator.
Then titrate with some drops of 0.1N K2OH and shake it well.
Then we measure the test portion dissolves in about 150ML mixture of ethanol.
Finally titrate the mixture with 0.1N of K 2OH until the pink colour persist the oil or fat at
list 10 second
Use the following formula to calculate the acid value
V KOH ∗N KOH∗282
acidity =
10∗Mass of thetest portion
Acid value= acidity*2
The amount of acidity in the sample should not exceed 1.2.
3.2. Analysis of oil content in the cake.

 The oil is extracted from the cake using solvent extraction again but the oil
content should be below 3%. If not, order is given to pressing operators to
continue recycling.
3.3. Analysis during neutralization process

The most frequent lab analysis is during neutralization.
 Acidity of crude oil. Identifying the level of acid helps to decide the amount of
soda added for saponification. And we use the same procedure as the above.
 Analysis of the strength Soda; - the strength of soda should be 18 de.be. The
amount of soda added to the crude oil is based on the amount of crude oil.
 Analysis of Soap concentration; - after saponification is done the soap is washed
and the concentration should be below 50pp. these is analysed in the lab.
Procedure of soap content determination
Firstly rinsed the flask with aqueous acetone.

After that we measure the test portion (oil or fat) and added in to flask.
1ml of distil water shall be added in to it and shake vigorously.
50ml of neutralised aqueous acetone shall then added and allowed stand on steam bath
the flask shall be shaken well until it separate into layer.
33
INTERNSHIP REPORT
Finally if the soap is present the upper layer is green or blue titrate with 0.01HCL in to
the falsk from burette until the colour restored.
Use the following formula to calculate the soap content.
V HCL∗3040
By PPM=
Mass of test portion
Chapter 4
Utilities
4.1. The boiler

The boiler or steam generator house is a source of steam for operation. Without steam extraction
and refining is impossible. The boiler uses furnace, methane gas and atmospheric air for its
operation. The type of the boiler is called three way boiler. This name is given because the flame
inside the boiler makes three turns before it leave the boiler in the form of smoke. Other boilers
are called two way and one way boilers. The boiler can generate steam with eleven bars.
As described below there are a bunch of pipes inside a boiler. Before entering the boiler, the
semi liquid furnace is heated to turn it into liquid. Inside ignition tank there are electrode and
photocell.
Two electrodes collide to create spark, then the photocell transmits this flash to starter where a
furnace is burned using methane gas and atmospheric air. Then the flame inside ignition tank
travels through pipes and bounce back and return again to the back of the boiler then leaves the
boiler in the form of smoke. Then the heat is exchanged between the pipes and the water outside
the pipes.
Care must be taken not to let cold water into the boiler. Because it may collapse and destructs
lives. To avoid water should be boiled at a temperature from 40-60 oc. and we should use soft
water because hard water creates scale.
34
INTERNSHIP REPORT
Chapter 5
THE OVERALL BENEFIT FROM THE INTERNSHIP
<<Even good theories can go wrong during practice. >> This is always true. It is hard to put
practical steps or activities in to clear and understandable statements. Some process, specially
refining have been mystery to us until this internship. Many scientific ideas became clear to us,
but we cannot include all of them on this paper.
Improving our practical skill
This intern has helped us to improve our practical skill and made us familiar with working
environment. We have been using our full potential to apply our theoretical skill in to practical.
After a month of stay we have been working with refinery section employers. And we have been
operating neutralization, bleaching and deodorization independently.
Improving our theoretical skill
we have tried to revise the entire course with other references for better understanding of the
process. But still there are so many things left to be studied. This is because oil processing has a
long step, it is also sophisticated and almost all of food processing course are applied. In short
the practical experience has made clear our theoretical skill and also enabled us to see problems
and give solution as a food technologist.
Improving our inter personal communication skill
35
INTERNSHIP REPORT
We had good intimacy with both process and administration workers. we have improved our
communication skill. we have been considering as one of the employers. We have good relation
with Mr. Endrias our advisor. We have discussed several times regarding the problems and their
solution which I have mentioned on this paper.
Work ethics
We have been trying to be punctual and make every effort to build good work ethics. we were
attending twice a week. At the end of our stay different employers have offered us their best
wishes, good comments and courageous advice.
Chapter 6
Conclusion and recommendation

6.1. Recommendation
Raw material storage conditions

Raw materials storage should be more than just warehouse. Oil bearing seeds are subjected to
damage primarily from biological actions, which are accelerated by high moisture content,
foreign materials physical damage etc. deterioration of oil bearing seed is caused by respiration,
enzymes (lipase, catalase, and peroxidase), and influences of moisture content and influence of
temperature.
In four months of our stay we have been checking if there are some precautions taken during
storage. But totally it is ignored.
Solutions:-
 there should be good ventilation

 Insect and mouses should be controlled.
36
INTERNSHIP REPORT
 The seed should be dried before storage to inhibit respiration and enzyme activity,
germination and mould growth.
Sanitation and safety issues

Sanitation is a big deal when it comes to food processing industries. In Hamaressa it is less
considered. I have seen people smoking and chewing chat in processing areas including refinery
section. But all industries including food industries yard is no smoking zone by itself. This
becomes serious issues when it comes to Oil Company because it is very flammable.
People enter in every section without wearing safety equipment. For example the company did
not provide us with any of safety materials. In refinery workers handle soda and bleaching earth
without wearing protection equipment. Some workers hand is irritated and their skin has changed
its natural colour.
we have seen people who work in filling section also involved in cleaning of refinery section.
This is the most hazardous practice we have ever seen in the company. During clearing soda and
bleaching earth powders disperse into the air. So there are high possibilities of accumulating
soda and bleaching earth. When these workers return to filling section, they may contaminate the
oil with these toxic chemicals.
Solution: - workers should only be involved on their working area to avoid cross contamination.
Mal function of lab equipment
Problems during process

If oil is exposed to oxygen and water it will result oxidation and hydrolysis. Finally hydrolysis
and oxidation creates rancidity which is characterized by off flavour and odour.
Unlike bleaching and deodorization, the neutral process takes place in open tanker. During
neutralization sometimes the process is delayed several days for different reasons and closing the
opening is totally ignored. This condition exposes the oil both to oxygen and moisture.
37
INTERNSHIP REPORT
Solution: - the opening of the neutralizer should be closed when the neutralization process stops.
We should protect the oil from unwanted reaction.
6.2. CONCLUSSION
Fats & oils are organic compounds called triglycerides with a glycerol backbone to which three
fatty acids are attached. Fats & oils are tasteless, colorless, odorless & insoluble in water. Fats &
oils have the same chemical structure but different functionally in that oils are liquid at room
temperature & fats are semi-solid. Vegetable oil & fat resources are indispensable to mankind as
a source of nutrient & industrial raw materials, so crude vegetable oils obtained from various oil
milling units is further refined before use for edible purpose. Refining edible oil is a process
where all impurities present in crude oil are completely removed and prepare for purpose of
meal, so refined oil safe for eating.
In our country, Industrial oil processes are mainly target on oil obtained from plants or oilseeds.
They extract crude oil from seed either chemically or physically. The gums in the oil can be
removed by acid or water degumming process because it causes brown discoloration to
deodorized oil & increase oil loss. The more or less percentage of FFA present in the oil is
removed by either chemical or physical neutralization. Bleaching of neutral oil carried out to
remove coloring pigments with the help of bleaching agent. The remaining odoriferous & flavors
compounds present can be removed by deodorization by treating the bleached oil to steam of
about 180 degree Celsius. After all the impurities present in the oil are removed the oil is
pumped and metered by pumps with aid of generators to be filled & packed.
38
INTERNSHIP REPORT
References
Bockisch, M. (n.d.). Fats and Oils Handbook. Hamburg, Germany: AOCS Books and Special
Publications Committee.
Gair, D. (n.d.). Principles of Screw Press Extraction.
Gunstone, F. D. (2008). OILS AND FATS IN THE. A John Wiley & Sons, Ltd., Publication.
Kemper, T. G. (2005). Oil Extraction.
Hamaressa edible oil company documentation office.
39
INTERNSHIP REPORT

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HARAMAYA INSTITUTE OF TECHNOLOGY

FOOD TECHNOLOGY AND PROCESS ENGINEERING

Host Company: HAMARESSA EDIBLE OIL COMPANY

Internship duration for one full semester 2020

GROUP MEMBERS NAME ID/NO

1. DAGIM LIJALEM 3341/08

6. GADDA SHAMBU 3566/08

Advisor: - Dr. Solomon. Abera Sub Date. 11/11/20

Abbreviation and acronyms

Figure 1:- administrational structure

1.1 Background of the company

Infrastructure & Facilities

Factory manager Finance

Figure 1: administrational structure

Sales and Purchasing

Departments of Hamaressa Edible Oil S.C

The departments of Hamaressa Edible Oil S.C are:

There are four major sections, namely:-

Seed cleaning & preparation section

1.1. Mission and Vision

We strongly stand to produce acid-free edible oil as of our motto

 We are strictly governed by our professional ethics

Lack of market information

Price Discount (Limited time)

1.2 Long term objectives to achieve it, the strategy

1.3.1 Sustainable competitive advantage

1.3.2 Customer Excellence

Obtaining customer feedback to ensure customer satisfaction

1.3.3 Multiple sources of Competitive advantage in the market place

1.3.5 Supplier to promote the product quality to the customers

Marketing & Sales

Market promotion & sales support Plans

Market Promotion Ways:-

 Transmitted through mass media

Direct Distribution System

- Distribute the product to the customers

- Personal communication with a customer representative who is not

Indirect Distribution system

- Single party selling system

Overall Internship Experience

2.1 How we entered to the company

2.2 Section of the Company We Have Been Working

3. Team playing skill

2.3 Process Description

2.3.2. Dumping and cleaning

2.3.4. Milling and Decortication section

2.3.5. Cooking and Press

The cooking process

Why cooking is important?

Figure 3:- cookers with five rooms for each

The Expeller – Screw Press - Design

Different parts of screw press

 Worm element –conical rings

USA it tends to be equated with removal of free acid (neutralisation).

Description of the refining section

The degumming process

The Flow chart of degumming process.

Filling the neutralizer with crude

Rising the temperature to 50oc

Adding of phosphoric acid

Figure 4: flow chart of degumming process

The neutralization process

Rising the temperature to