Summer Training Program

Report

Kanpur Edibles Private Limited

Submitted To: Submitted by:
Prashant Kumar
Mr. Manoj Sharma Parul Mishra
Ayush Shukla
Sr. General Manager Abhinav Yadav
Kanpur Edibles Private Limited Sonali Yadav

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 Index

o Index
o Acknowledgement
o Introduction
o Oil solvent extraction plant
o Mustard oil extraction
o Edible oil Refinery, Hydrogenation,
fractionation process
o Effluent treatment plant
o Laundry soap
o Detergent Powder
o Quality assurance and quality control

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 Acknowledgement
I would like to express my sincere gratitude to Kanpur Edibles Private Limited (KEPL)
for providing me with this wonderful opportunity to undertake an internship at
their esteemed organization. This experience has been immensely valuable and has
significantly contributed to my professional and personal growth.

I am deeply thankful to the entire KEPL team for their support, guidance, and
encouragement throughout the duration of my internship. Their willingness to
share their knowledge and expertise has greatly enhanced my understanding of the
edible oil and soap manufacturing industry.
Special thanks to [mention any specific individuals or departments, if applicable]
for their mentorship and for taking the time to ensure I gained a comprehensive
insight into the operations and processes at KEPL. Their dedication and passion for
excellence have been truly inspiring.
I am also grateful for the opportunity to work in a state-of-the-art facility and to
witness firsthand the innovative practices and commitment to quality that define
KEPL. This experience has not only broadened my technical skills but also instilled
in me a deeper appreciation for the importance of sustainability and quality control
in manufacturing.
Thank you, Kanpur Edibles Private Limited, for this invaluable experience and for
helping me pave the way for a successful career in the industry.

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About Kanpur Edibles Private Limited

Overview
Kanpur Edibles Private Limited (KEPL) is a leading name in the edible oils and soap manufacturing industry,
known for its commitment to quality, innovation, and customer satisfaction. Established in [Year], KEPL
has grown from a modest beginning to become a significant player in the market, serving a wide range of
customers across the region.

Vision and Mission

Vision: To be the most trusted and preferred provider of high-quality edible oils and soaps, enhancing the
lives of our customers and contributing to a healthier society.
Mission: Our mission is to produce and supply superior quality edible oils and soaps that meet the highest
standards of safety and hygiene. We aim to achieve this through continuous improvement, innovation,
and dedication to excellence in all aspects of our operations.

Core Values
• Quality: We are committed to maintaining the highest standards of quality in all our products and
processes.
• Integrity: We conduct our business with honesty, transparency, and respect for all stakeholders.
• Innovation: We continuously strive to innovate and improve our products and processes to meet
the evolving needs of our customers.
• Sustainability: We are dedicated to sustainable practices that minimize our environmental impact
and contribute to the well-being of our community.

Product Range
KEPL offers a diverse range of products including:

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 • Edible Oils: Our portfolio includes a variety of edible oils such as mustard oil, sunflower oil, and
soybean oil, all produced with utmost care to ensure purity and health benefits.
• Laundry Soaps: We manufacture high-quality laundry soaps designed to provide excellent
cleaning performance while being gentle on fabrics and skin.

Manufacturing Excellence
At KEPL, we pride ourselves on our state-of-the-art manufacturing facilities, equipped with the latest
technology and machinery. Our production processes adhere to stringent quality control measures to
ensure that every product that leaves our facility meets the highest standards of quality and safety.

Commitment to Sustainability
KEPL is deeply committed to sustainability and environmental stewardship. We implement eco-friendly
practices across our operations, from sourcing raw materials to manufacturing and packaging. Our
initiatives include energy-efficient processes, waste reduction, and recycling programs, all aimed at
minimizing our environmental footprint.

Community Engagement
We believe in giving back to the community and actively participate in various social initiatives. Our
community engagement programs focus on health, education, and empowerment, contributing to the
overall development and well-being of society.

Conclusion
Kanpur Edibles Private Limited stands as a testament to quality, innovation, and dedication in the edible
oils and soap manufacturing industry. With a focus on customer satisfaction and sustainable growth, KEPL
continues to set benchmarks and create value for all its stakeholders.

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Oil Solvent Extraction Plant

Introduction
Solvent oil extraction is a method of making Crude Edible oil by using the principle of extraction and
selecting a kind of organic solvent which can dissolve oil , through contacting with the oil, so that the oil
and in the oil can be extracted.

Basic Process
The basic process is to immerse oil flakes (or pre-pressed cakes) in selected solvents, dissolve oil in
solvent , then separate the mixed oil from solid residues (meal), evaporate and strip the mixed
oil according to different boiling points, so that the solvent vaporizes into vapor and oil separates, thus
obtaining oil (extracted crude oil).The solvent vapor is recycled after condensation and cooling. The meal
also contains a certain amount of solvent. After de-solventization and drying, the meal can be dried. The
solvent vapor volatilized during de-solventization and drying is recovered by condensation and cooling.

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The extracted oil is sent for further refining and treatment to remove impurities, ensuring it meets
quality standards for consumption or other uses. The meal undergoes additional treatment to remove
any remaining solvent, making it safe for use as animal feed or other applications.

Why hexane is used as solvent –

Hexane is commonly used in solvent oil extraction plants due to its effectiveness in extracting oil from
seeds. It is chosen for its high solvency power and low boiling point, which facilitate efficient oil recovery
and solvent reuse. The process involves dissolving the oil in hexane, separating the mixture, and
recovering the solvent. This method is efficient, cost-effective, and widely used for large-scale oil
production

• Hexane has been widely used for oil extraction because of easy oil recovery
• They have narrow boiling point (63–69 °C)
• They have excellent solubilizing ability .
• Hexane when released into the environment that react with the pollutants to form ozone and
photo chemicals.
• They can be efficiently removed and reused.
• Inert in nature.

Solvent Extraction Process

The entire extraction process can be divided into following stages:

1. Preparation of raw material

2. Extraction Chamber

3. Desolventization of extracted material

4. Distillation of miscella

5. Solvent recovery

Preparation of Raw material

Mainly Seed (Soybeans) is received usually from large trucks, cleaned, weighed, dried if necessary for
safe storage and put in bins. It is then drawn from storage as needed to provide feed for extraction
process.

The unit operations typically involved are cleaner, destoner, grader, cracker, expander etc.

Flow chart

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 Cleaner Seeds

Destoner

Grader

Cracker

Cooker ( 60-65 °C)

Flaker (60° C)

Dry Cooler(35-40°C)

Expender(80-83°C)

Extraction Plant

1.) Pretreatment Section

1) Cleaner –

• Remove foreign material like stones, dust, leaves, and other impurities.

• Oilseeds are passed through a series of screens and air blasts to separate and remove
contaminants.

2) Destoner-

• Remove stones and other hard impurities that could damage the processing equipment.

• Done with the help of specific air flows and sieves.

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3) Grader-

• Sort the seeds based on size, weight, and quality by grading screens.

4) Cracker-

• Seeds are fed into a machine where they are cracked or broken into smaller pieces.

5) Cooker-

• The cracked seeds are heated, usually by steam, to a temperature that helps to increase oil
yield and make oil extraction easier.

• Temperature range between 60-65 °C.

6) Flaker-

• The cooked seeds are passed through rollers that compress them into thin flakes

• Flakers and Rollers are used.

7) Expender-

• Flakes are subjected to high pressure and temperature to create a porous structure

• Here temperature is raised upto 80-83°C

8) Dry Cooler-

• Expanded flakes are cooled to a temperature that is suitable for solvent extraction.

• Typically cooled to around 30°C to 40°C and then sent to solvent extraction plant.

2.) Solvent extraction plant

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Extraction section-
• The prepared raw material (crushed and flaked seeds) is transported to the extraction plant
using a conveyor system through rotary air seal.
• The extractor consists mainly of a very slow moving articulated band conveyor inside a totally
enclosed chamber.

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 • Soybean Flackes are loaded in moving belt conveyor
• During the movement of the bed through the extractor ,it is washed continuously at various
points with miscella of decreasing concentrations and finally with a fresh solvent in a counter
current manner by means of sprayers kept in a line over the meal bed.
• The miscella percolates through the perforated bottom and collects in various hoppers kept
below the bed. The miscella from the last hopper, which is concentrated, is taken off for
distillation.
• Deoiled Cake is sent into the Desolventizing toaster chamber.

3.) Desolventisation Of Extracted Material

After the fresh solvent wash the material is discharged from the band conveyor into an airtight chain
conveyor, the de-oiled cake is to the desolventiser.

• This operation is combined of desolventisation and toasting by the use of Desolventiser –

Toaster (D. T.).

• In the desolventiser the material is heated to about 100°C by jacketed steam, and thus the
absorbed solvent is evaporated into vapors (boiling point of hexane 67-70°C).

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 • The D.T. consists of a vertical cylindrical vessel with horizontal jacketed compartments and a
central rotating vertical shaft on which are mounted sweeps in each compartment.

• The Material to be desolventised and toasted is fed in to the top compartment of D.T and
heated with open steam.

• Open steam condenses a lot of moisture in the material at the same time evaporating the
solvent. The moisture up to 14 to 15% is condensed.

• The material then flows to lower compartment. In lower compartments the material is
gradually heated to 115 to 120° C thus evaporating all the solvent.

• Finally, the material, which is now completely desolventised is toasted is used as meal.

• The hexane solvent vapors evolved in the D.T. , are taken to the condenser for solvent
condensation and recovery of solvent via the Economizer.

• The solvent is recirculated to the extraction chamber.

4.) Distillation of miscella

• The oil/solvent mixture leaving the solvent extractor is commonly referred to in the industry as
“miscella”. The miscella leaving the solvent extractor contains 80-90% solvent by weight. The
purpose of distillation is to thermally separate the miscella into a liquid oil fraction and solvent
vapour fraction.

• Concentrated miscella is pumped by the Feeding Pump to the 1st Stage Economizer section
under vaccum. Heat source of 1st Stage Evaporator is the secondary steam coming from
Desolventizer.

• Miscella from 1st Stage Evaporator makes heat exchange in Heat Exchanger with crude oil
coming from Oil Stripper, thus temperature of Miscella when entering into 2nd Stage
Evaporator is increased and temperature of crude oil is lowed. The Miscella is then pumped to
the 2nd Stage Evaporator having 60-65% hexane.

• The process is repeated for another two three times so that the solvent concentration reduces
to 1-2%.

• The hot oil then sent into open steam evaporator (atomizer).

• In an atomizer, on the top and at the jacketed column, hot oil is sprayed and an open steam is
injected at the bottom for further processing. A temperature of 27 – 29C is maintained in the
shell and tube condensers for condensing the solvent vapors. After condensing, final solvent
content is removed and separated out from the oil.

• The final crude oil is dried out.

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5.) Solvent Recovery Section

Solvent Vapour Condensing System is closely connected with Evaporation System. The Mixed Vapour
from shell of the Evaporators enters into the EV Condenser; and the Mixed Vapour from the Oil Stripper
enters into the ST Condenser.

Mixed Vapour from DTDC Desolventizer is used as heat source for 1st Evaporator and, after being used,
most of it will be condensed into liquid; that un-condensed Vapour from shell of 1-Stage, Evaporator
enters into DT Condenser .

• For solvent recovery, hexane vapours evaporated from D.T. tower and distillation section , is
condensed into the condenser.

• It is treated with water of about 28-30C , where hexane is cool down and conert back into
liquid form.

• Any remaining moisture or impurities are removed through drying methods.

• The recoverd hexane is reused in extractor chamber.

Condensor-Solvent recovery

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 MUSTARD OIL EXTRACTION

1. Introduction
Mustard oil has been produced for centuries using methods that involve less mechanization and more
manual labor. These methods rely on simple equipment and techniques passed down through
generations, focusing on maintaining the natural properties and flavor of the oil.

2. Steps in the Manufacturing Process

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1. Seed Cleaning
Objective: Remove impurities such as dirt, stones, and other foreign materials from the mustard
seeds.

Method:

• Seeds are cleaned manually using techniques like winnowing and sieving.

• Winnowing baskets are used to separate lighter impurities, while larger debris is handpicked.

2. Seed Drying
Objective: Reduce the moisture content of the seeds to an optimal level for oil extraction.

Method:

• Seeds are spread out under the sun on clean surfaces like mats or concrete floors.

• The seeds are turned periodically to ensure even drying until they reach the desired
moisture content.

3. Crushing
Objective: Break the seeds to prepare them for oil extraction.

Equipment Used: Stone or wooden grinders (chakki).

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Process:

• The dried seeds are placed in the grinder.

• The grinder, operated manually or powered by animals, crushes the seeds into a coarse
paste.

4. Heating (Optional)
Objective: Heat the crushed seeds to enhance oil extraction (in some methods).

Method:

• The seed paste may be lightly roasted over a low flame to increase oil yield.

• Care is taken to avoid overheating, which can affect the flavor and quality of the oil.

5. Oil Extraction
Objective: Extract oil from the crushed seed paste.

Equipment Used: Wooden or stone oil press (ghani).

Process:

• The seed paste is placed in the ghani, a large mortar-like structure.

• A heavy wooden pestle, driven by animals (like oxen) or manual labor, is used to press the
paste.

• The slow, continuous pressing causes the oil to seep out of the paste.

• The extracted oil is collected in containers placed around the ghani.

6. Filtration
Objective: Remove solid particles from the extracted oil.

Method:

• The crude oil is filtered using a cloth or fine mesh.

• The oil is poured through the cloth, trapping solid particles and resulting in clearer oil.

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7. Settling and Decantation
Objective: Further clarify the oil by allowing solid impurities to settle.

Method:

• The filtered oil is left undisturbed in containers for several days.

• Solid impurities settle at the bottom of the container.

• The clear oil is then decanted (carefully poured off) into clean containers, leaving the
sediment behind.

8. Packaging
Objective: Store the oil in suitable containers for use and sale.

Method:

• The decanted oil is stored in clean, dry containers made of glass, metal, or food-grade
plastic.

• Containers are sealed to prevent contamination and preserve the quality of the oil.

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 Edible Oil Refinery Plant

Introduction
The Edible Oil Refinery Plant at Kanpur Edibles Private Limited (KEPL) is a state-of-the-art facility
designed to produce high-quality edible oils that meet the stringent standards of safety, purity, and
nutritional value. The plant employs advanced technology and processes to refine crude oils into various
edible oils, ensuring they are free from impurities and contaminants.

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Types of Refining Processes
The refining process at Kanpur Edibles Private Limited (KEPL) involves various types of refining methods
to ensure that the crude oils are transformed into high-quality, safe, and nutritious edible oils. The
primary refining processes used at KEPL include Physical Refining and Chemical Refining.

1. Physical Refining
Physical Refining is a process that involves the removal of free fatty acids (FFAs) by distillation rather
than by chemical neutralization. This method is particularly suitable for oils with low FFA content and
high stability. The key steps in physical refining are as follows:

• Degumming: Removal of phospholipids (gums) using water or acid.

• Bleaching: Removal of pigments, trace metals, and oxidation products using bleaching earth or
activated carbon.
• Deodorization: High-temperature steam distillation under vacuum to remove volatile
compounds, including FFAs, odors, and flavors.

Advantages of Physical Refining:

• Minimal chemical usage, making the process more environmentally friendly.

• Higher yield of refined oil since no soapstock is formed.
• Suitable for oils like palm oil and coconut oil.

2. Chemical Refining
Chemical Refining involves the neutralization of FFAs using an alkali solution (such as sodium
hydroxide). This method is commonly used for oils with higher FFA content. The key steps in chemical
refining are as follows:

• Degumming: Similar to physical refining, this step removes phospholipids using water or acid.
• Neutralization: Removal of FFAs by adding an alkali, which reacts to form soapstock that is
separated from the oil.
• Bleaching: Similar to physical refining, this step removes color pigments and other impurities.
• Deodorization: Steam distillation under vacuum to remove volatile compounds, similar to
physical refining.

Advantages of Chemical Refining:

• Effective for oils with high FFA content.

• Produces oils with excellent clarity and stability.
• Suitable for oils like soybean oil, sunflower oil, and canola oil.

Comparison of Physical and Chemical Refining

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 Aspect Physical Refining Chemical Refining
FFA Removal Method Steam Distillation Alkali Neutralization
Chemical Usage Minimal Moderate (alkali and acid)
Yield Higher Slightly lower due to soapstock loss
Environmental Impact Lower Moderate
Suitable Oils Palm oil, coconut oil Soybean oil, sunflower oil, canola oil

Other Specialized Refining Processes

3. Winterization
Winterization is a process used to remove high-melting point components like waxes from the oil. This
process is optional and applied to oils that are prone to cloudiness at low temperatures. The oil is cooled
to a specific temperature, causing the waxes to crystallize and be removed by filtration.

4. Fractionation
Fractionation is a process that separates the oil into different fractions based on melting points. This
process is used to produce specialty oils with specific characteristics, such as high oleic sunflower oil or
palm olein.

Chemical Used

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Oil Refining Processes:
The processes involved in oil refining are:

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Degumming:
The impurities in the oil are of two types water soluble and water insoluble. The water-soluble
impurities are washes away by water. Oil being less dense separates from water. The water insoluble
impurities are removed by Hydrogenation process to remove phospholipids. Phospholipids include Free
Fatty Acids (FFA) and phosphoric acid.

Neutralization:
the oil is treated with an alkali solution (caustic soda) that reacts with the free fatty acids (FFA) present
as per the following equation and converts them into soap stock.

R−COOH(acid)+NaOH(base)⟶R−COONa(soap)+H2O(water)
In addition, when the neutralization is not properly done, the caustic soda may not only neutralize the
fatty acids, which is the desired aim, but it also attacks the neutral oil in the form of a so-called
saponification that also reduces the yield, especially when crude oil acidity is low. Therefore, the
concentration and dosing rate of the caustic soda need to be calculated based on the FFA of the
degummed oil for optimal neutralization.

The oil obtained is neutral in nature and is moved to the Neutral Oil Tank (NO Tank). Formed soap is
generally insoluble in oil. Hence, it can be easily separated mechanically from oil based on the difference
in specific gravity between the soap and neutral oil. They contain sodium 45 soap and caustic soda, but
also water, salt, sodium phosphates, gums, carried-over neutral oil, colouring agents, oxidation by-
products, and various contaminants. This residual is referred to as residual olefins, which are treated and
vaporized in a special unit.

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Bleaching:
Bleaching is a complex physical and chemical process employed in the refining of vegetable oils. The
objective of bleaching (or decolorizing) is to reduce the levels of coloured pigments (carotenoids and
chlorophylls). It also further removes residue traces of phosphatide, soap, phospholipid contaminants,
lipid peroxidation products, and other impurities. Finally, it indirectly impacts the deodorized oil colour.
To perform bleaching, adsorption bleaching clays, activated carbon, special silica, or a combination of
these are used. Proper colour in oil is about 7-8%.

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Deodorization:
The last stage in refining involves high temperature and requires a great care. A deodorized oil is devoid
of any taste, even pleasant ones. Deodorization is a simple distillation process. This operation allows for
the elimination of free fatty acids and removes odours, different off-flavour components, contaminants
(pesticides, light polycyclic aromatic hydrocarbons, and other volatile components). Deodorization also
removes residues of mineral oil saturated hydrocarbons (MOSH) and mineral oil aromatic hydrocarbons
(MOAH).

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26
 EFFLUENT TREATMENT
PLANT(ETP)
An effluent treatment plant (ETP) in an oil refinery is crucial for managing the wastewater produced
during refining processes. The main goal of an ETP is to treat this effluent to meet environmental
regulations and minimize the impact on ecosystems and human health. Here’s a detailed look at the
various components and processes involved in an ETP for an oil refinery:

Types of Effluents
In an oil refinery, effluents may include:

• Process Water: Used in various refining processes.

• Cooling Water: From cooling systems.

• Stormwater: Rainwater runoff, potentially contaminated.

• Sludge: Containing hydrocarbons and other contaminants.

• Spent Catalysts: Used in catalytic processes.

Treatment Stages
1. Preliminary Treatment
• Screening: Large solids and debris are removed using screens.

• Grit Removal: Grit chambers or separators remove sand, gravel, and other heavy particles.

2. Primary Treatment
• Sedimentation: In sedimentation tanks, heavier particles settle out, forming sludge.

• Floatation: Air is injected to help lighter particles float to the surface, where they can be
skimmed off.

3. Secondary Treatment
• Biological Treatment: Microorganisms degrade organic pollutants. This can be done
through:

• Activated Sludge Process: Aerobic bacteria digest organic matter.

• Trickling Filters: Wastewater passes over microbial-covered media.

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 • Sequencing Batch Reactors (SBRs): Intermittent aerobic and anaerobic conditions for
efficient treatment.

4. Tertiary Treatment
• Advanced Filtration: Additional filters remove smaller particles and residual
contaminants.

• Chemical Treatment: Chemical processes, such as coagulation and flocculation, help

remove remaining pollutants.

• Disinfection: Methods like chlorination or UV radiation to kill pathogens.

5. Sludge Treatment
• Thickening: Concentrates sludge to reduce volume.

• Digestion: Biological processes decompose organic matter in sludge.

• Dewatering: Removes excess water from sludge, usually through centrifuges or filter
presses.

• Disposal or Reuse: Treated sludge may be disposed of safely or used as a soil conditioner.

3. Key Components
• Equalization Tanks: Smooth out fluctuations in effluent flow and composition.

• Aeration Tanks: Facilitate microbial digestion of organic matter.

• Clarifiers: Separate solids from treated water.

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This Photo by Unknown Author is licensed under CC BY-SA

•
• Disinfection Units: Ensure pathogen-free effluent before discharge.

4. Monitoring and Control

• Instrumentation: Monitors flow, pH, temperature, and contaminant levels.

• Automated Systems: Control processes and manage operations based on real-time data.

• Sampling: Regularly collect samples for analysis to ensure treatment efficacy and
regulatory compliance.

5. Regulations and Compliance

• Environmental Standards: Effluent must meet local and international regulations before
discharge.

• Permits: Required for operation and discharge.

• Record-Keeping: Detailed records of treatment processes and discharge quality for

compliance and reporting.

6. Challenges and Innovations

• Contaminant Complexity: Oil refineries produce a wide range of contaminants, requiring
advanced treatment technologies.

• Energy Consumption: Treatment processes can be energy-intensive; improvements focus

on efficiency and sustainability.

• Waste Management: Proper handling and disposal of hazardous waste are crucial.

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 • Emerging Technologies: Includes advanced oxidation processes, membrane
technologies, and resource recovery.

7. Environmental and Economic Impact

• Environmental Protection: Proper treatment prevents pollution of water bodies and soil.

• Resource Recovery: Some processes allow for the recovery of valuable by-products.

• Cost Efficiency: Efficient treatment reduces long-term costs associated with

environmental damage and regulatory fines.

An ETP in an oil refinery is a complex system designed to treat and manage effluent effectively, ensuring
minimal environmental impact and compliance with regulations. Its design and operation are critical to
both environmental stewardship and the operational efficiency of the refinery.

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This Photo by Unknown Author is licensed under CC BY

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The effluent treatment plant (ETP) in an oil refinery is designed to treat wastewater generated during the
refining process to meet environmental standards before discharge or reuse. Here’s a step-by-step
outline of the typical processes involved in an ETP:

Preliminary Treatment
Objective: Remove large and coarse materials that could damage equipment or hinder subsequent
treatment stages.

• Screening: Wastewater passes through screens (usually bar screens) to capture large
solids like sticks, rags, and plastics.

• Grit Removal: Grit chambers or separators are used to settle out sand, gravel, and other
heavy particles that could wear down or clog equipment.

Primary Treatment
Objective: Reduce the concentration of suspended solids and organic material in the wastewater.

• Sedimentation: In primary clarifiers, wastewater is allowed to sit so that heavier solids

settle out as sludge at the bottom. This process also removes some of the floating materials.

• Floatation: Air or chemicals are added to help lighter materials, such as oil and grease,
float to the surface where they can be skimmed off.

Secondary Treatment
Objective: Biologically degrade the remaining organic pollutants.

• Activated Sludge Process: Wastewater is aerated in aeration tanks to promote the

growth of microorganisms that consume organic contaminants. The mixture then flows to
secondary clarifiers where the microorganisms (activated sludge) settle out.

• Trickling Filters: Wastewater flows over microbial-covered media, where bacteria digest
organic pollutants.

• Sequencing Batch Reactors (SBRs): A single reactor alternates between different phases,
including aeration and settling, to treat wastewater in batches.

Tertiary Treatment
Objective: Further polish the effluent to meet stringent discharge standards.

• Advanced Filtration: Technologies like sand filters, membrane filters, or disc filters
remove fine particulates and remaining contaminants.

• Chemical Treatment: Coagulation and flocculation processes aggregate and remove

remaining particles. Chemical precipitation might be used to remove specific pollutants.

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 • Disinfection: Methods such as chlorination, ultraviolet (UV) radiation, or ozone
treatment are employed to kill pathogenic microorganisms and ensure the effluent is safe for
discharge or reuse.

Sludge Treatment
Objective: Manage and process the sludge generated from primary and secondary treatments.

• Thickening: Sludge is concentrated in gravity thickeners or mechanical thickeners to

reduce its volume.

• Digestion: Biological (aerobic or anaerobic) or chemical processes decompose the

organic material in the sludge. Anaerobic digestion produces biogas, which can be used as an
energy source.

• Dewatering: Excess water is removed from digested sludge using centrifuges, belt
presses, or filter presses.

• Disposal or Reuse: Treated sludge can be safely disposed of or used as a soil conditioner,
fertilizer, or in other applications, depending on its quality.

Monitoring and Control

Objective: Ensure effective operation and regulatory compliance.

• Instrumentation: Sensors and meters monitor various parameters such as flow rate, pH,
temperature, and contaminant levels.

• Automated Control Systems: These systems adjust operations in real time based on
monitoring data to optimize treatment processes.

• Sampling and Analysis: Regular sampling and laboratory analysis ensure the treated
effluent meets environmental standards and regulatory requirements.

These steps together form a comprehensive treatment system that addresses the varied and complex
nature of effluent from oil refineries, ensuring that the final discharge is environmentally safe and
compliant with regulations.

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HAND MADE DIAGRAM OF EFFLUENT TREATMENT PLANT(ETP)

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35
 WASHING SOAP

1. Introduction
The primary objective of this report is to provide a detailed analysis of the laundry soap
production process, from raw material procurement to final product packaging.

2. Raw Materials of the Laundry Soap Production

Laundry soaps are made up of several ingredients, each with its specific purpose. Let’s take a
close look at the raw materials that go into making laundry soap.

Oils and Fats

Laundry soaps contain oils and fats, which serve two main purposes:

1. Cleaning Action: Oils and fats trap dirt and grime, lift it off surfaces, and suspend it in water
so it can be rinsed away.

2. Lathering Properties: Oils and fats trap air pockets when mixed with water, creating bubbles
or foam. The more air trapped, the more foam is created.

Soda Lye or Potash Lye

• Soda Lye (Sodium Hydroxide): Responsible for the soap’s alkaline nature, which is necessary
for effective cleaning. It is a caustic substance and must be handled with care.

• Potash Lye (Potassium Hydroxide): Can be used in place of soda lye. It is less caustic and
produces a soap that is less harsh on the skin, commonly used in liquid laundry soaps.

Brine
• Sodium Chloride (Brine): Responsible for the soap’s salty taste and helps to harden bar soap.
As a corrosive substance, it must be handled with care.

Additives
Laundry soaps may also contain various additives to improve their appearance, scent, and feel.
Common soap additives include:

• Sodium Carbonate: Helps to harden the soap and gives it a white color.

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 • Sodium Silicate: Improves the soap’s lather.

• Dyes: Provide the soap with desired colors.

• Perfumes: Give the soap a pleasant scent.

3. Production Process
The production of laundry soap involves several stages, each critical to ensuring the final product
meets quality standards. Here is a detailed breakdown of the process:

Step 1: Initial Mixing

• Ingredients: Free Fatty Acids (FFA) (1-3%), silicate, water (H2O), caustic soda (sodium
hydroxide), and other components are added.

• Equipment: These ingredients are combined in a vessel known as the "creature." The
creature vessel is surrounded by hot steam to maintain a consistent temperature.

• Mixing: Inside the creature, a screw-type fan rotates in both clockwise and anti-clockwise
directions to ensure thorough mixing. The hot steam prevents the mixture from solidifying.

Step 2: Transfer to Drop Tank

• After approximately 2.5 hours of mixing, the resulting mixture is transferred to a drop tank.

Step 3: Soap Flaking

• Transfer: Using a pump, the mixture from the drop tank is transferred to a soap flaker.

• Cooling: The mixture is spread and pressed onto a cold roller, which is cooled with water at 7
degrees Celsius. This solidifies the soap.

• Pressing: The soap is also pressed by a hot roller to achieve the desired texture.

Step 4: Perfume and Color Addition

37
 • Equipment: The solidified soap is sent to a sigma mixer.

• Additives: Perfume and color are added at a controlled temperature

of 40 degrees Celsius.

• Moisture: Water is added to maintain a moisture content of 30%.

Step 5: Noodle Plodding

• Conveyor: The mixture is transported via a conveyor to a noodle plodder, where it is

extruded into soap noodles.

Step 6: Roller Chambers

• Equipment: The soap noodles are sent to a three-roller mill.

• Operation: Two rollers rotate in a clockwise direction, while one rotates anti-clockwise,
refining the soap mixture.

Step 7: Duplex Plodder

• Conveyor: The refined mixture is conveyed to a duplex plodder.

• Vacuum: This machine operates under a vacuum to remove air bubbles and create a dense,
uniform soap.

Step 8: Soap Bar Formation and Packaging

• Molding: The soap is molded into bars.

• Packing: The soap bars are then packed, completing the manufacturing process.

4. Quality Control

38
 Quality control is crucial to ensuring the production of high-quality laundry soap. The following
measures are implemented:
• Raw Material Inspection: Ensuring the quality of incoming materials.
• Process Monitoring: Checking temperature, pressure, and pH during production.
• Finished Product Testing: Assessing appearance, fragrance, pH, and cleaning efficiency.
• Compliance: Adhering to industry standards and regulations.

5. Environmental Considerations
KEPL is committed to environmental sustainability. The following practices are in place:
• Waste Management: Proper handling and disposal of waste materials.
• Water Treatment: Ensuring wastewater is treated before discharge.
• Energy Efficiency: Measures to reduce energy consumption.
• Sustainability: Using eco-friendly raw materials and processes.

39
 DETERGENT POWDER

1. Introduction
The primary objective of this report is to provide a detailed analysis of the detergent production
process, from raw material procurement to final product packaging.

2. Raw Materials in Detergent Manufacturing

Detergents are made from a variety of raw materials, each contributing to the product’s cleaning
efficiency, stability, and usability. The primary raw materials include:

Surfactants
Surfactants are the primary cleaning agents in detergents. They reduce the surface tension of
water, allowing it to penetrate and clean fabrics more effectively. Common surfactants used in
detergent manufacturing include:

• Anionic Surfactants: Such as linear alkylbenzene sulfonates (LAS).

• Nonionic Surfactants: Such as alcohol ethoxylates.

Builders
Builders enhance the cleaning efficiency of surfactants by softening the water and providing
alkalinity. Common builders include:

• Sodium Tripolyphosphate (STPP)

• Zeolites

• Sodium Carbonate

Bleaching Agents

40
 Bleaching agents help to remove stains and whiten fabrics. Common bleaching agents include:

• Sodium Perborate

• Sodium Percarbonate

Enzymes
Enzymes break down protein-based stains such as blood, sweat, and food. Common enzymes
used in detergents include:

• Proteases

• Amylases

• Lipases

Fillers
Fillers are added to detergents to bulk up the product and ensure the active ingredients are
evenly distributed. Common fillers include:

• Sodium Sulfate

• Sodium Chloride

Additives
Additives are used to enhance the performance and appeal of the detergent. Common additives
include:

• Fragrances: To give the detergent a pleasant smell.

• Dyes: To give the detergent a desired color.

• Optical Brighteners: To make fabrics appear whiter and brighter.

3. Production Process
The production of detergent involves a series of precise steps to ensure the final product meets
high-quality standards. The process is as follows:

Step 1: Ingredient Mixing

• Initial Feeding: Raw materials are fed from a bucket conveyor into the primary mixing tank.

• Ingredients Added:

o Acid slurry (10-20%)

41
 o Linear Alkyl Benzene Sulfonate (LABS) (15-25%)

o Alpha Olefin Sulfonate (AOS)

o Builders

o Sodium Carbonate (25-30%)

o Dolomite Powder (Calcium and Magnesium Carbonate) (1-10%)

o Optical Brightener (0.1-0.5%)

o Soda Ash (10-20%)

Step 2: Mixing
• Ribbon Mixer: All the ingredients are thoroughly mixed in a ribbon mixer to ensure a
uniform blend. This step is crucial for achieving the desired consistency and effectiveness of
the detergent.

Step 3: Further Processing

• Mixer Cage Mill: The mixed material is transferred via a conveyor to a mixer cage mill. Here,
the mixture is further refined to enhance the uniformity and quality of the detergent
particles.

Step 4: Salt Addition

• Vibratory Conveyor: The refined mixture is then passed through a vibratory conveyor, where
salt is added to the detergent. This step is important for enhancing the cleaning properties
and stability of the final product.

Step 5: Packaging
• Automated Packing: After the salt is thoroughly mixed, the detergent is automatically
packed into various packaging formats, including bags, boxes, or sachets, depending on
market requirements. This ensures the product is ready for distribution and sale.

4. Quality Control
Quality control is crucial to ensuring the production of high-quality detergent. The following
measures are implemented:

• Raw Material Inspection: Ensuring the quality of incoming materials.

• Process Monitoring: Checking temperature, pressure, and Ph during production.

• Finished Product Testing: Assessing appearance, fragrance, Ph, and cleaning efficiency.

• Compliance: Adhering to industry standards and regulations.

42
5. Environmental Considerations
KEPL is committed to environmental sustainability. The following practices are in place:

• Waste Management: Proper handling and disposal of waste materials.

• Water Treatment: Ensuring wastewater is treated before discharge.

• Energy Efficiency: Measures to reduce energy consumption.

• Sustainability: Using eco-friendly raw materials and processes.

43
 QUALITY CONTROL AND QUALITY
ASSURANCE

Quality assurance test for edible oil typically include a variety of physical, chemical, and sensory
evaluations to ensures the oil meet safety, quality, and regulatory standards.

What are the benefits of edible oil testing?

• To ensures that the edible oil is safe for consumption and there is no trace of contamination,
adulteration or rancidity.

• To ensure that the edible oil conforms with the national and international standards like
FSSAI and BIS.

• To determine the shelf life of the edible oil to establish the consumption period or the ‘Best
Before’ date which help maintain the quality of the final product.

• Edible oils play a huge part in our nutrition, providing us with nutrients and the essential
unsaturated fatty acids, which can be determined through testing.

Standard Tests Conducted for Edible Oil

1. Standard Test:

• Peroxide value- Number of milli equivalent of active oxygen that expresses the
amount of peroxide content in 1000 grams of substance.

• Iodine value – Number of grams of iodine, absorbed by 100 grams of oil or fats,
when determined by using wijs solution.

• Adulteration test- Argemone Test, Castor Oil Test, etc.

• Saponification value- The number of milligrams of KOH required to saponify

completely one gram of oil and fats.

• TBHQ- It enhances the shelf life of oil and thus a test is required to confirm its
presence before packing.

• FFA (%) /Acid value- Number of milligrams of KOH required to neutralize free
acid present in one gram of oil or fat.

44
 2. Water Test:
• pH- The pH is tested for various sample like MVR condensed water, feed water
and reject water using a Ph meter.

• COD- The chemical oxygen demand determines the amount of oxygen required
for chemical oxidation of organic matter using a strong chemical oxidant, such as
potassium dichromate under reflux condition.

• BOD- The biochemical oxygen demand (BOD) test is based on bio-assay

procedure which measure the dissolved oxygen consumed by micro-organisms while
assimilating and includes incubating the sample in an air tight bottle in dark at specific
temperature.

• TDS- The value from conductivity test is multiplied with the factor representing
that water sample to obtain the total dissolved solids (TDS).

3. De-oiled cake Test:

• Oil content- Soxhlet apparatus is used along with hexane to determine oil
content of D.O.C.

• Crude Fibre test- This content is expressed as a percentage by mass, referred

either to the product as received or to the dry matter content of the dry matter content
of the product.

• Sand Silica test- The sample is heated in a furnace and then treated with acid to
determine the amount of sand silica present in it.

• Moisture content- The moisture and any other material contained in the oil or
fats which is volatile under the conditions of prescribed test.

TESTS PERFORMED IN EDIBLE LAB

1. PEROXIDE VALUE:

45
OBJECTIVE– To determine the peroxide value of oil/fats.

REAGENTS- Acetic acids, chloroform solution (3:2), potassium iodide, sodium thiosulphate, starch
solution.

PROCEDURE- weigh 5gm (approx.) of sample into 250ml conical flask with thin glass stopper and dissolve
to 30ml acetic acid+ chloroform solution.

Swirl the flask until sample dissolve completely.

Add 0.5ml freshly saturated KI solution and allow the solution to stand exactly one minute with
occasionally shaking.

Add 30ml of distilled water, start the titration with 0.1N Na2s2o3 until the yellow colour almost disappear.

Add 0.5ml 1% freshly prepared of starch solution and continue the titration till the dark blue colour
disappears (as it shows presence PV in the sample). Conduct a blank determination of the reagents in
the same way the titration in blank determination should not exceed 0.1ml of 0.1N Na2s2o3.

PV=(S-B) *N*1000/ (Weight of sample)

CALCULATION-
Weight of the sample=5.2015gm

Sample=0.4ml

Blank=0

Na2s2o3(0.01N) =0.010

PV= (O.4-0) *0.01*1000/5.2015

=0.769meq/kg

2. IODINE VALUE:

46
OBJECTIVE- Determination of iodine value.

[REAGENTS- Chloroform, wijs solution, KI solution, starch solutions, sodium thiosulphate.

PROCEDURE-Weigh 0.52gm to 0.66gm sample into clean dry 500ml IV flask. Add 25 ml of chloroform and
25ml of wijs solution into the flask. Place the glass stopper and few drop of KI solution.

Swirl for intimate mixing and allow to stand in the dark for 30 minutes carryout a black test.

Simultaneously under similar experiments.

After standing, add 15ml of KI solution and 100ml of water rinsing in the stopper also titrate to liberate
iodine with standard sodium thiosulphate solution, swirling the bottle to avoid any local excess until the
colour of solution is straw yellow.

Add 1ml of starch solution formed and titrate until blue colour disappear.

CALCULATION-

Weight of sample= 0.2313gm

Sample weight= 33.9ml

Blank weight= 50.7ml Na2s2o3 (0.01N) = 0.1050

IV= 12.69(50.7-33.9) *0.1050/0.2313

= 96.78

3. FFA% (ACID VALUE):

OBJECTIVE- To determine the FFA of given sample.

REAGENTS-Neutralized hot ethyl alcohol, NAOH (0.1N), phenolphthalein indicator.

47
PROCEDURE-Weigh accurately a suitable quantity of thoroughly mix and cooled oil or fat in 250ml
conical flask.

Add 50 to 100ml of freshly neutralized hot ethyl alcohol.

Then add about 1ml phenolphthalein indicator solution. Boil the mixture about 5 min and titrate with
standard 0.1N NAOH shake vigorously during titration.

CALCULATION-

Sample weight= 16.3667gm

NAOH (0.1N) =0.985

Volume=0.7ml

FFA (oleic acid) =28.2*0.7*0.985/16.3667

=1.1880

FFA (lauric acid) =20.0*0.7*0.985/16.3667

=0.8425

4. SAPONIFICATION VALUE:
OBJECTIVE- TO determine the saponification value Of given sample of oil/fats.

REAGENTS-Alcoholic KOH (0.5N), neutral hot ethyl

Alcohol, phenolphthalein indicator (1%), HCL (0.5N)

PROCEDURE- Weigh about 1.5gm to 2.0gm sample in PV flask/250ml flat bottom flask.

Add 25 ml (3.5 to 4.0%) of alcoholic KOH solution and connect the reflux air condenser to the flask (hot
water bath).

Conduct a blank determination along with sample.

Reflux on water bath for about 1hr till clean solution. Wash down the inside of the condenser with about
10ml of neutral hot ethyl alcohol.

Cool and titrate with 0.5N HCL using 1ml phenolphthalein indicator. End point-colourless

48
CALCULATION-

SV=56.1(B-S) *N/W

Sample weight=1.8656gm

Blank =31.8ml(colourless)

Sample=19.7ml(yellowish)

HCL (0.5N) = 0.4912

SV= (31.8-19.7) *0.4912*56.1/1.8656

=178.72613

5. Adulteration test (Baudoin test):

OBJECTIVE- To determine the presence of sesame oil In the given sample.

REAGENTS- Conc. HCL, furfural solution (2% ethyl

Alcohol)

PROCEDURE- (for purity)

Add 5ml of sample in 25ml of measuring cylinder, add 5ml of conc. HCL +0.4 ml of furfural solution (2%
in Ethyl alcohol + shake vigorously for 2min.

For pure sesame oil (1% sesame oil+ 99% groundnut oil)

Mix 8ml of groundnut oil+ 2ml of vanaspati sample in

A measuring cylinder+10ml of conc. HCL +0.4ml of Furfural solution. Shake vigorously for 2min. Check
Red colour in 1cm Lovibond cell.

RESULT- The development of pink/red colour in the Lower acid layer indicates presence of sesame oil.

Confirm by adding 5ml of water and shake again.

49
TESTS PERFORMED IN SOLVENT LAB

1. MOISTURE CONTENT:
OBJECTIVE-To determine the moisture content of deoiled cake.

PRINCIPLE-The sample is desiccated under specified condition which vary according to the nature of the
feeling stuff. The loss in mass is determined by weighing. It is necessary to carry out the preliminary
drying when dealing with solid feeding stuff which have high moisture content.

APPARATUS- Analytical weigh balance, Electrical heated oven, hot air oven, desiccator.

PROCEDURE-Weigh accurately about 10gm of the DOC in a moisture dish container.

Place the dish container in electrical heated oven for 4hr at 103+2oC.

Remove the dish from the oven, cool in the desiccator to ambient temperature and weigh to nearest
1mg. Carry out two determines on test portion taken from the same sample.

CALCULATION-

Initial weight of petri dish=34.8495gm

Initial weight of sample+ petri dish=43.8891gm

Final weight of sample+ petri dish=43.1358gm

Initial weight of sample =43.8891-34.8495

=9.0396gm

Final weight of sample=43.1358-34.8495

=8.2852gm

MOISTURE CONTENT= (Initial weight- final weight)

*100/Initial weight

= (9.0396-8.2852) *100/9.0396

=8.34gm

50
2. OIL CONTENT:
OBJECTIVE-To determine the oil content of sample (soya chunks).

PRINCIPLE- Oil is soluble in petroleum ether hence sample is extracted with hexane and is removed by
distillation and the residue is dried and weighed.

APPARATUS-FB flask, condenser, Soxhlet extraction unit.

REAGENTS-Light petroleum, condenser, oil flask and glass bead, water, drying oven, extraction thimble.

PROCEDURE-Weigh exactly required quantity of sample to the nearest 0.001gm and transfer it to an
extraction thimble (to avoid leakage of the sample), cover with cotton and place it on extractor.

Take the weight of the dried oil flask with a glass bead in it.

Pour 150ml of hexane in oil flask and connect it with extractor and extract oil for required time period.
Remove hexane and dry the oil flask in oven at 1300C for 3hr.

Take the final weight of the flask and calculate % of oil.

CALCULATION-

Thimble sample weight= 5.7336gm

Initial weight of empty flat bottom flask=112.2506gm

Final weight of flat bottom flask= 112.2672gm Oil content= (initial weight-final weight) *100/weight of
sample

= (112.2672-112.2506) *100/5.7336

= 0.2895

3. TOTAL DISSOLVED SOLID (TDS):

OBJECTIVE- Determination of TDS

51
PRINCIPLE- The basic principle involved is gravimetric. The mixed sample is sample is filtered through
standard glass fibre filter and the filtrate is evaporate to dryness in an oven at 103-1050C. The increase in
the weight represents TDS.

APPARATUS- Glass fibres filter disks, Filtration apparatus, Suction flask, Steam bath, Drying oven,
evaporating dishes, Descciator, Analytical balance.

PROCEDURE-Dry the well cleaned dish in oven at 1031050C for [Link], desiccate and take the initial
weight of the dish.

Repeat the above step until a constant weight is obtained. Transfer a known volume of filtered
homogenous sample into dish.

Evaporate to dryness on a steam bath. Dry the evaporated sample in oven at 103-1050C for 1hr. Cool in a
desiccator and weigh. Repeat the step until a constant weight is obtained.

CALCULATION-

TOTAL DISSOLVED SOLID=(A-B) *1000/V

4. BIOLOGICAL OXYGEN DEMAND:

OBJECTIVE-Determination of biological oxygen demand

PRINCIPLE – The biological oxygen demand (BOD) test is based on assay procedure which measures the
dissolved oxygen consumed by microorganism while assimilating and includes incubating the sample in
an air light bottle in dark at specific temperature 270C in 72hr (3 days).

APPARATUS- Incubation bottle, Air incubator

REAGENTS- Phosphate buffer solution, magnesium sulphate solution, calcium chloride solution, ferric
chloride solution, sodium sulphite solution, glucose glutamic acid solution.

PROCEDURE- Preparation of dilution water: Aerate the required volume of distilled water in a container
by bubbling compressed air for 8 to 12 hr to attain dissolved oxygen saturation. Let it stabilize for 4hr at
room temperature (around 270C). At the time of use, add 1L each of phosphate buffer, magnesium
sulphate, calcium chloride and ferric chloride for each litre of dilution water.

52
Seeding: Add 2 to 5 ml of treated waste (obtained either from biological treatment system or from
domestic sewage) per litre of dilution water for the sample like untreated industrial waste, disinfected
waste, high temperature waste, waste with extreme PH values, for seeding purpose.

Sample pretreatment: neutralize sample containing alkalinity or acidity to PH 6.5 to 7.5 using alkali or
acid of such strength that the quality of reagents does not dilute the sample by more than 0.5%.

If sample containing residual chloride compound, dechlorinated with sodium thiosulphate solution. Take
50 ml of sample and acidify with addition of 10ml of 1+1 acetic acid. Add about 1gm of potassium iodide
(KI). Titrate with 0.025N of sodium thiosulphate using starch indicator. Calculate the volume of
Na2S2O3.5H2O required per ml of sample and add according to the sample to be tested for BOD test.

Determination of initial dissolved oxygen (DO): determine initial dissolved oxygen (DO) for one bottle
and keep two bottles for incubation at 270C +10C for 72hr (3days). Prepare six blank sample by diluting
water directly into the bottle. Determine initial DO in two bottle and incubate remaining four bottles at
270C+10C for 72hr (3 days).

CALCULATION- When sample is undiluted

BOD3, mg/l=D1-D2

When dilution water is not seeded

BOD3, mg/l = (D1- D2) *100 /P

INSTRUMENTATION
• Electronic weighing balance- It is an instrument used for measuring weight.

53
• Hot air oven -A hot air oven is a type of lab testing instrument that is used to
heat up the products at a uniform temperature. A hot air oven is used to sterilize the
product in a particular period of time under specific conditions like humidity, pressure,
and other environmental factors.

• Heat plate- Hot plates are frequently used in the laboratory to perform chemical
reactions, to heat samples, and for numerous other activities. Hot plates are
conceptually simple – a flat surface with heating elements. They do not produce open
flames and are well suited for oil or sand bath use.

54
• Desiccator- A desiccator is a chamber or box that is designed to absorb water
vapor from reactants that are hygroscopic. Hygroscopic reactants are able to absorb
water.

• Soxhlet Apparatus- is a piece of laboratory apparatus and contain 250 ml of

flask volume. It is originally designed for the extraction of a lipid from a solid material. It
is used when the desired compound has a limited solubility in a solvent, and the
impurity is insoluble in that solvent.

• Pipette- A pipette is a laboratory instrument used to measure out or transfer

small quantities of liquid, in volumes of (mL), microliters.

55
• Magnetic stirrer- is a device widely used in laboratories and consists of a
rotating magnet or a stationary electromagnet that creates a rotating magnetic field.
This device is used to make a stir bar, immerse in a liquid, quickly spin, or stirring or
mixing a solution.

• Lovibond tintometer-is a visual colorimeter designed to optimise the use of

Lovibond glass filters in order to express colour in terms of Lovibond Red, Yellow, Blue
and Neutral.

56
SAFETY MEASUREMENTS
• Lab Coat: Wear a lab coat to protect your clothing and skin from spills.

• Gloves: Use chemical-resistant gloves to handle oils and any chemicals used.

• Safety Goggles: Protect your eyes from splashes or accidental spills.

• Face Shield: In some cases, especially when dealing with large quantities or high
temperatures, a face shield may be appropriate.

• Closed-Toe Shoes: Wear sturdy, closed-toe shoes to protect your feet.

• Heating Devices: Use appropriate equipment for heating oils, such as water
baths or heating mantles, and never leave them unattended while in use.

• Avoid Direct Contact: Use tools or utensils to handle hot oils to avoid burns.

57