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General Description of Process and Process Flow

OIL REFINERY PROCESS FLOW AND CHECKS

PROCESS FLOW OPERATIONS QUALITY CHECKS

1. Raw materials intake Inspection of raw materials -Laboratory and physical check
Lab
-moisture content

-presumptive Aflatoxin

-pest & disease Infestation

-color &smell

- oil content

2. Passing through hammer mill -Visual physical inspection on size or flakes

aperture
De-hulling
Roller mill (Hammer
mill) Breaking to increase surface area for oil pressing -Physical check of husks level

3. Precooking and reduction of oil from the soya grits by -Visual operating temperature at the extruder
pressing through a 3mm opening
Extruder and oil expeller -Lab analysis to ascertain the moisture, oil and
protein content of the products

-Check the cake thickness

4. The crude oil extracted from the soybeans needs - Laboratory check FFA
further treatment to convert it to a bland, stable,
nutritious product that is used in the manufacture of
Crude Oil - Insoluble impurity
margarine, shortening, salad and cooking oil,
mayonnaise, food products, and oleo chemicals. - Color &smell

- Moisture content

5.
Neutralization Neutralization is achieved by treating the soybean oil - Laboratory check FFA
with aqueous alkaline solution (most commonly,
sodium hydroxide) to neutralize the free fatty acids in - Crude oil Temp. check (60 oC)
a batch or continuous system
- Sodium hydroxide
 Crude soybean oil contains a relatively high
concentration of phospholipids compared with other
vegetable oils. Degumming is a process of removing
Degumming and alkali refining
these components from crude soybean oil to improve
its physical stability and facilitate further refining.
- Hydratable non-oil materials, mostly
carbohydrates and proteins partially removed.
- Hydratable non-glyceridic lipids such as
phospholipids partially removed.

- Chlorophyll (partially removed), especially if

phosphoric acid is employed.

- Salt

To remove the oxidation-inducing pigments such as - Beaching earth

chlorophylls, but more importantly to decompose the
peroxides produced by oxidation into lower molecular
Bleaching -Check the moisture content
weight carbonyl compounds that can be removed by
subsequent deodorization. Bleaching also removes - Check Temp. (105 oC)
other impurities such as soap and metal ions.
- Check vacuum ( 0.07 mm Hg)

-Time b/n 20min- 30min

Spent Bleaching Earth (color, residual soap stock) - Color check

- Check the moisture content

FILTERING
- Continuous filtration.

The last step in conventional oil processing. It is a -Check vacuum ( 0.075 mm Hg)
steam stripping process in which good quality steam
injected in to soya oil and high vacuum avoid bad - Check Temp. (240 oC)
Deodorization odder and high temp.Proper treaded
- Check the steam pressure

- Time duration 3hr

Storage Storage of oil before dispatch - Check the warehousing cleaning.

The soybean oil stored in filled tanks should be at as -Control the store room temperature.
low a temperature as possible to avoid such
conditions. -Recording procedure

Final Production of good quality soybean oil. -Check the product colour and odder
Filling into bottles and Sealing.
Packing -Lab analysis for moisture content

-The packaging materials bottle and carton to be of

the right colour and information of the content

-Check on coding
 -Continuous random weight check of the packed
products.

- Fill the bottle at as a low temperature.

-Check on the sealing.

Process Flow Diagram

 CRUDE SOYBEAN OIL

FILTERING Foots

Alkali NEUTRALIZING

Soap stock (free fatty

CENTRIFUGING acids, phosphatides)
Salt

Water WASHING

Rejected
Wash-water
CENTRIFUGING
residual soap stock

Moisture VACUUM DRYING

Bleaching Earth
Deodorizer Distillate (off-flavor compounds, minor volatiles, free fatty acids)

BLEACHING

Spent Bleaching
Approved FILTERING Earth (color, residual
soap stock)

DEODORIZING

Stream
Warehousing Packing Storage in tank Testing of FILTERING BAG
oil

Company Name BBZ Foods Manufacturing Sh. Co DOC. Code OF/P/M/…….

Department Production Date of Release July 2018

Form Review no 00

CRUDE OIL
The crude oil extracted from soybeans needs further treatment to convert it to a bland, stable, nutritious
product that is used in the manufacture of margarine, shortening, salad and cooking oil, mayonnaise, food
products, oleochemicals.

CRUDE OIL QUALITY

Crude oil is normally defined in terms of moisture and dirt, phosphatide content normally expressed as
ppm phosphorus, free fatty acids (FFA) or acid value and also in terms of color, oxidation characteristics,
and trace components such as iron and copper.

Neutralization

Neutralization is also referred to as de-acidification and alkali or caustic refining. Neutralization is

achieved by treating the soybean oil with aqueous alkaline solution (most commonly, Caustic soda) to
neutralize the free fatty acids in a batch or continuous system. The soap formed in the reaction also
adsorbs natural pigments, the gum and mucilaginous substances not removed by degumming.

Degumming

Crude soybean oil contains a relatively high concentration of phospholipids compared with other
vegetable oils. Degumming is a process of removing these components from crude soybean oil to
improve its physical stability and facilitate further refining.

Bleaching

Bleaching is a process designed not only to remove the oxidation-inducing pigments such as chlorophylls,
but more importantly to decompose the peroxides produced by oxidation into lower molecular weight
carbonyl compounds that can be removed by subsequent deodorization. Bleaching also removes other
impurities such as soap and metal ions. In soybean oil refining, color reduction occurs at each step,
nevertheless, the most significant reduction of chlorophylls occurs in the bleaching step. Acid-activated
bleaching clay is most effective in adsorbing chlorophylls and decomposing peroxides, and it is
commonly used for soybean oil.

Deodorization
Deodorization is usually the last step in conventional oil processing. It is a steam stripping process in
which good quality steam generated from de-aerated and properly treated injected into soybean oil under
high temperature (200–240 oC) and high vacuum (0.075mm Hg) to decompose peroxides and vaporize the
free fatty acids and odorous compounds.

Company specification of FFA of the process step %

Properties Range

Crude 0.44- 0.61

Degumming 0.31- 0.44

Deodorization 0.02- 0.03

Moisture 0.01Max

Refined 0.01

Company specification crude oil

IMPURITIES IN CRUDE DEGUMMED Specification

SOYBEAN OIL

Moisture and Volatiles 0.01% max

Dirt 0.1 % max

Free Fatty Acids 0.61% max

Process parameters
 PARAMETER RANGE

Neutralization process crude temperature 58- 60oc

Degumming process crude temperature 78- 80oc

Degumming process water temperature 90- 95oc

Bleaching process temperature 100- 105oc

Deodorization process Temperature 200- 240oC

Deodorization process time duration 3 hour

Steam injection time duration 4 hour

Cooling time duration 12 hour

Final refined oil bottle temp. 25-30oc

Machine Parts & Their Functions

PART USES

Crude tank The tanker holding crude oil

Crude tank agitator Agitate the crude oil

Bleaching tank, Before filtration the oil bleaching in the bleaching tank
agitator and pump

Deodorization tank The last refinery process tank

and pump

Packing tank Holding refined oil

Packing machine Bottled the refined oil 1,3and 5 liters