Internship Summer’s

Programme 2009

VOCATIONAL TRAINING PROJECT REPORT

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“REFINERY OF CRUDE SOYA OIL”

THE SUMMER INTERNSHIP PROJECT REPORT

BY

ROHIT NYATI

(08011019-MEMS, B.TECH undergraduate, IIT Bombay)

UNDER THE ABLE GUIDANCE OF

MR. M.C. VERMA

(PRODUCTION MANAGER, REFINERY SECTION)

AT

RUCHI SOYA INDUSTRIES LTD. , KOTA

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ACKNOWLEDGEMENTS

My summer Internship at Ruchi Soya Industries Ltd. has given me a wonderful industrial exposure. My learning, from the very first day at the refinery plant has been very informative and useful. During the internship I gained substantial knowledge and I got accustomed to traditional environment, got exposure to enterprise tools and got an opportunity to apply my knowledge. I feel obliged to express my gratitude thanks to those people who have rendered their invaluable help throughout my project.

First of all, I consider myself fortunate to have had Mr. M.C. Verma, Production Incharge (Refinery) as my guide. I sincerely thank him for providing me to perform the training at RSIL and for his valuable guidance at all stages of this project work.

Several people have been very helpful in accomplishing this project. I would like to give my sincere thanks to Mr. Sanjeev Ji Khare, Mr. S.S. Sodha and Mr. Rinku Natani. He had been my role model. Without his support, it would have been difficult to carry out the study. I would also like to thank Mr. Suresh Singh Kushwaha for his superb guidance about the whole machinery work.

I would like to thank all the respondents who spared time for filing up the Questionnaires and for inspiring me in their own way. Their help is gratefully acknowledged.

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CONTENTS

Acknowledgement………………………………………………………………………………..3

Introduction………………………………………………………………………………………….5

Company Profile-

Ruchi group promoter companies………………………………………………7

Ruchi Soya Industries Ltd. …………………………………………………………11

Ruchi Soya ‘ Products……………………………………………………………….16

Edible Oil Introduction-

Edible Oil Market in India………………………………………………………….18

IMPORTANCE OF EDIBLE OILS IN THE COUNTRY………………………20

SOYA-

SOYBEANS……………………………………………………………………………………..21SOYABEAN OIL……………………………………………………………………………….22SOYUMM………………………..……………………………………………………………..23

PROJECT PROFILE-

RSIL –BOAD OF DIRECTORS……………………………………………………………25REFINERY DEPARTMENT………………………………………………………………..25TECHINCAL DEPARTMENTS……………………………………………………………26REFINERY……………………………………………………………………………………….28PROCESS DESCRIPTION…………………………………………………………………..31FLOW CHARTS…………………………………………………………………………………35Process parameters………………………………………………………………………...38DISTRIBUTION NETWORK………………………………………………………………..40FINDINGS, CONCLUSIONS AND SUGGESTIONS………………………………..42REFERENCES………………………………………………………………………………….…43

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INTRODUCTION

The 20-year old Ruchi Soya Industries Limited is the flagship company of Ruchi Group of Industries. It’s recent merger with sister concerns ( Aneja Solvex Ltd, General Foods Ltd, Ruchi Credit Corporation, Ruchi Health Foods Ltd, Param Ind. Ltd, Ruchi Private Ltd and soya businesses of MP Glychem) has catapulted it among the top five FMCG players in the country, with a turnover of 8625 crores. This merger illustrates the strength that is to be found in increased transparency, firm market position and better control of systems.

Besides being a leading manufacturer of high quality edible oils, vanaspati, bakery fats and soya foods, Ruchi Soya is also the highest exporter of soya meal and lecithin from India. Nutrela (soya chunks, granules, soya flour) is the largest selling soya foods brand in the country today.

Ruchi Soya is the undisputed leader in the branded edible oil category as well with brands like Nutrela Soyumm (Soyabean Oil), Ruchi Gold (Palmolein Oil), Sunrich (Sunflower Oil) and Mandap (Mustard Oil). New healthy oil variants like Nutrela Vitamin Sunflower oil and Nutrela Groundnut oil make Nutrela a trusted option in edible oils as well. 

Superior procurement and trading skills, continuous innovation, an endeavor to meet consumer needs and stringent quality control standards have enabled Ruchi to emerge as a highly-respected and admired Indian company. The scrip is listed and the BSE code is 500368, while the NSE code is RUCHISOYA.

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Ruchi Group Promoter Companies

The Ruchi Group comprises of 17 companies in seven business sectors. This section lists all these companies under the sectors in which they operate, besides the two promoter companies of the Group. Visitors can, by clicking on the relevant links, get a profile of individual companies, their subsidiaries (if any), their products and services, contact details, etc.

Subsidiaries / Divisions

National Steel & Agro Industries Ltd.

National Steel and Agro Industries Ltd., an ISO 9001:2000 company, is a member of the Ruchi Group of Industries. We rank amongst the front-runners in the Indian Galvanized Steel industry commanding a significant market share.

With sales of over USD 300 millions and total tonnage shipment of 300,000 MT, we service customers across continents. Our products are well established in the USA, EU, UAE and African markets.

With consistent export achievements, we have gained the status of Star Trading House in exports.

We produce flat steel products - CR Coils, Galvanized steel and Galvanized Color Coated steel products in various grades ranging from LFQ, DD, EDD as per ASTM, JIS and other standards.

Mid India Power & Steel Ltd. (Alloy & Stainless Steel Division) Mid India Power & Steel Ltd (formerly known as Kusum Ingots) is presently engaged in manufacturing of Billets and Round/Square Bars having installed capacity of 110,000 TPA. The plant is having UHP Electric Arc Furnace with capacity of 30 Ton, Ladle Refining Furnace of 30 Ton, 2-strand Continuous Casting Machine and 24” Rolling Mill. Commercial production was started in March, 2008

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Ruchi Infotech Ltd.Ruchi Infotech Ltd. (RIL) is an Information Technology (IT) company specializing in Web Technologies, Enterprise Wide Computing & Resource Contracting. Within this broad ambit of technology, RIL offers a wide range of services across platforms & scales. It has the capabilities to implement complex Enterprise Resource Systems & comprehensive Data Storage & Mining solutions. At the same time, RIL is equally proficient in servicing smaller needs like Web Site Development & Kiosk implementation. Headquartered in Indore, India, RIL have operations in UAE & USA.

This policy has yielded good dividend. Employee morale is high & the feeling of brotherhood is all-pervasive in the organization.

Financial depth, managerial prudence, technical excellence & enduring vision form the mortar of the company while the soul is the vibrant energy & enthusiasm of our consultants & managers.

Ruchi Global Ltd.

Ruchi Global Limited was established in 1996 as a Trading arm of the Ruchi Group of Industries, specialized in the field of Non GMO Soya Product, Organic Food and Cold Rolled Steel.

Ruchi Group of industries is a well-known Industrial conglomerate in India having diversified business activities in manufacturing and processing of Soya, Agro-Commodities and Steel.

Its various manufacturing units are located dotting the Industrial map of Central India. The group has its corporate headquarters in Indore, with offices in Mumbai, Delhi, Calcutta and other major business centers in country. Plans are foot to open up office in UK, as special thrust is being given to International Trade

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Ruchi Realty Holdings Ltd.

Ruchi Realty Holdings Ltd. aims to infuse new life and real meaning into urban spaces and houses. Bold and fresh ideas meet the original vision of the group to create brands that enhance life.

The Ruchi Group has diversified into Real Estate and Hospitality with a vision to provide the best of services in this sector. The 1st Project of the Group has been initiated at Kolkata which comprises of a modern residential condominium of about 2 million sq. ft. The other Projects in pipeline are an IT Park in Kolkata, Deluxe Hotel at Jamshedpur, 100 acres integrated Township at Bhopal, Indore etc.

Headquartered at Indore, the Group has regional offices at Kolkata, Mumbai and Dubai.

Ruchi Strips & Alloys Ltd.

Ruchi Strips & Alloys Ltd. (RSAL), an ISO 9001:2000 & ISO 14001:2004 certified company was set up in 1991 for manufacturing of Cold Rolled Steel Coils & Sheets. RSAL now is a complete complex with all the manufacturing facilities of different types & grades of Cold Rolled Steel with installed capacity of 1,00,000 TPA.

RSAL manufactures Cold Rolled Full Hard (CRFH) Coils as per International Standards, suitable for manufacturing of Galvanized sheets of different applications. Cold Rolled Closed Annealed Steel (CRCA) Coils & Sheets of International Standards, suitable for Automobile application. Cold Rolled Non Oriented Electrical Steel (CRNO) as per International Standards, delivered in semi processed condition.

The significant quantity out of RSAL’s production is exported to various countries. RSAL is also a Government of India recognized Export House

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RUCHI Infrastructure Limited

RUCHI Infrastructure Limited is primarily engaged in the businesses of storage and transportation of edible oils, petroleum, liquid bulk chemicals, agricultural products etc., in refining of edible oils and manufacturing of vanaspati. Ruchi Infrastructure Limited is having storage terminals at major ports (jamnagar, haldia, mangalore, chennai, cochin, karwar etc) and at railway side terminals (kanpur, doraha, jaipur, hyderabad & cuttack).

Ruchi Infrastructure Limited is forayed into the field of agricultural warehousing which would be guided by principles of direct sourcing from farmers, cleaning, grading, packing, processing, scientific storage through capacity building and infrastructure creation.

Anik Industries Ltd.

SYNERGY is the interaction of two or more agents or forces so that their combined effect is greater than the sum of their individuals. Synergy is when the result is greater than the sum of the parts. Synergy is created when things work in concert together to create an outcome that is in some way of more value than the total.

Synergy is something which has taken place with the merger of two successful yet complementary companies. It has already taken firm strides in consolidating its Indian consumer base upon the inherent strength of the quality of its products consistent with the 40 years old relationship. In the very first year of its inception, the company has recorded a turnover of Rs. 218 Crore, a clear indicator that synergy is working for Anik Industries Ltd.

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Ruchi Soya Industries Ltd.

HISTORY

Ruchi Soya Industries, a company which has been in the business of edible oils for over two decades. They are offering a cooking medium to match the various tastes of this vast and varied nation. They are the leader in edible oil and soya food businesses in India. They are the first exporter of Soya Bean Meal from India. They are the also leading manufacturer of Textured Soya Protein and Vanaspati.   At Present, Ruchi Soya Industries has only one subsidiary namely Ruchi worldwide Ltd. The company plants are located at Indore, Shajapur, Narsinghpur and Mandla in Madhya Pradesh, Mangalore in Karnataka, Raigad and Nagpur in Maharashtra, Haldia in West Bengal, Gandhidham in Gujarat, Thiruvallur in Tamilnadu, Sriganganagar and Bundi in Rajasthan.   Ruchi, a pioneer Soya Processor Group started operations in the year 1972-73. In the year 1986 the company became a Public Limited company. In March 1991, the Production in Vanaspati Plant, Edible Soya flour and Oil Commenced with capacity of 7,500 MT, 60,000 MT, 12,000 MT respectively.   During the year1991-92, the Company increased their existing capacity of Textured Soya Protein by 12,000 MT to 24,000 MT and Vanaspati by 7,500 MT to 15,000 MT. Also they commenced the production in their Lecithin Plant during the year.   During the year 1992-93, the company increased the production capacity of Vanaspati from 15,000 MT to 30,000 MT. Also they installed Soyabean Extraction with a capacity of 60,000 MT. In the year 1994-95, the production capacity of oil has been increased from 30,000 tpa to 55,000 tpa and Soyabean Extraction from 60,000 tpa to 1,85,000 tpa. In the year 1995-96, they further increased the production capacity of Soya bean extraction, oils and Vanaspati by 2,47,000 tpa, 53,000 tpa, and 22,500 tpa respectively.   In the year 1997-98, the company launched two new brands namely SUNRICH for Sunflower Refined Edible Oil and RUCHI GOLD for Refined Edible Palmolein Oil. In the year 1998-99, the Company launched two products namely Ruchi Sona and Ruchi Star.   In the year 1999-2000, the company has invested in equity shares of Ruchi

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Health Foods Ltd which has become wholly owned subsidiary of the company. Also in the same year, Imperial Exports Ltd has ceased to be a subsidiary of the company.    In the same year, one of the subsidiary company has set up a Refinery unit near Chennai which has commenced commercial production in the month of January, 2000. The Company has also increased the capacity of Vanaspati by 70000 MT during this period.   During the Year 2001-2002, the Company has set up a composite unit comprising of Refinery, Vanaspati and Texturised Vegetable Protein Plants at Mangalore. The production capacity of Texturised Soya proteins has been increased by 30,000 MT to 54,000 MT and Oil by 189000 MT to 297000 MT.   During the Year 2002-2003 the capacity of Soyabean Extraction, Oil and Vanaspati has increased to 555,000, 687,000 and 172,500 respectively. During the year 2003-2004 the Company set up a composite Unit Comprising of edible oil refinery and Vanaspati Plant at Raigad in Maharashtra. The Company acquired a Solvent Extraction Plant at Sriganganagar in Rajasthan through its Wholly owned Subsidiary Aneja Solvex Ltd during the year.   In the same year, the company has launched two new product in the bakery segment namely Avanti and Bakefat. Also they launched Nutrela Proflo defatted soya flour, which offers the consumers another option to include soya in their diet.   During the year 2004-2005, the company has set up a solvent extraction plant and refinery unit at Nagpur in Maharashtra. The Company has also commissioned wind turbine of 1.2 MW capacity at Nagda Hills, Dewas in Madhyapradesh for generation of Power for captive use. The Capacity of Textured Soya Proteins, Seed Extraction, Oils, were also increased to 84,000 MT, 10,47,000 MT and 11,01,000 MT respectively.   In the year 2005-06, General Foods Limited, Ruchi Health Foods Limited, Ruchi Credit Corporation Limited, Aneja Solvex Limited, Param Industries Limited and Ruchi Private Limited have been amalgamated with Ruchi Soya Industries Limited. The SVF business of Anik Industries Limited formerly known as Madhya Pradesh Glychem Industries Limited has also been acquired by the Company on slump sale basis.   In the same year, the company has increased their production capacity for Textured Soya Proteins by 30000 MT to 114000 MT, Seed Extraction by

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847224 MT to 1894224 MT, Oil by 951000 MT to 2052000 MT and for Vanaspati by 237000 MT to 469500 MT.

THE SOYA REVOLUTION

In early 1960s, when Mr. Mahadev Shahra went about convincing farmers in M.P., about the potential of Soya, he would not have imagined that he will be instrumental in bringing up a small green revolution in the State, by introducing and encouraging Soya bean cultivation on a commercial scale. The family was in the business of commodities trading and subsequently, they entered the business of ginning and oil milling. The family's efforts, along with that of the others, resulted in Soya revolution in M.P. Today M.P. is considered as Soya bowl of the country, and contributes to 70% of its production. Despite all odds, Ruchi Soya is now the largest player in the country in edible oils, Soya foods and processed foods categories. This is largely due to its strict quality commitment and continuous innovation to keep with the times. Also, Ruchi Soya has evolved from being a large manufacturing firm to a respected brand. Its Nutrela and Ruchi Gold brands have captured leading positions in the Soya foods and edible oils categories respectively. Ruchi Soya has also ventured into other businesses like bakery specialties, where it foresees a big potential for growth. With Ruchi's innate manufacturing and logistics advantages, and its foray into the branded sector, one only sees immense potential for growth in the future

VISION OF RUCHI SOYA 

• We will strive to become India's No.1 packaged goods company in related businesses of Edible oils and Soya based food products.• We will constantly explore innovative methods of driving growth & profitability.• We will maintain overall leadership position in the Edible Oils & Soya Foods Industries.• Our promise to the consumer is to provide him/her with value for money product at the lowest cost, with utmost quality assurance

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RUCHI'S MARKETING STRENGTHS

The extensive distribution network, built over the years, is a major strength for Ruchi. Catering nationally through 3 Lac retail stores, with 38 Company depots, 36 Super Stockiest and a sales staff of over 200, Ruchi has attempted to penetrate depth wise, along with opening new markets. With its emphasis on providing value goods to consumers, Ruchi's dual strategy of popular and premium range works well. Ruchi Gold is our value for money offering but with no compromise in quality. This positioning helps generate large sales volumes for the products. Our Nutrela series is more premium, and offers healthy options in soya foods and edible oils. This dual strategy is based on our cultivated understanding of the Indian consumer psyche.We also have a firm footing in modern retail due to our undivided focus on new channels of distribution. With our alliances with big players like Pantaloon and visible presence in all leading national and regional supermarkets, we hope to grow our consumer base and product portfolio.

RUCHI’S REFINING AND CRUSHING STRENGTHS

We are one of the few edible oil companies in the country that has a balanced mix of inland and port based refineries. This enables us to optimize production depending upon the availability of cheaper alternatives – local oilseeds or imported crude oil. Moreover, multi- location refineries have reduced road travel costs leading to significant transportation cost advantage. We have fifteen refineries and ten inland crushing plants.

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STRENGTHS OF OUR BRANDS

Over the years, we have grown to become a multi-million US Dollar company. Two of our strongest brands, Nutrela and Ruchi Gold are category leaders.

Nutrela, the biggest Soya foods brand in the country, enjoys more than 50% of the market share. It has enjoyed the trust of consumers for last 20 years now, and continues to expand its range to cater to varying needs of its consumers. It has become generic to the soya category. We have effortlessly strived to educate people about health and goodness of Soya as our firm commitment is to provide healthy solutions to the consumers.

Our edible oils brands like Ruchi Gold and Nutrela Soyumm enjoy mass acceptability and acclaim from the people. Ruchi Gold is the leader in the palmoline category. As a part of packaged goods thrust, ‘Ruchi Gold' was introduced about 6 years back in Chennai. The market share in southern states ranges from 50 to 85%. The brand has grown from35% to 40% CAGR since its introduction. Today, it enjoys the number one position in branded palmoline oil category.

Nutrela Soyumm ranks in the top three soya oils category, and continues to strive to reach the top position. Both brands symbolize health and quality.

We are also leaders in the vanaspati category with brands like Ruchi No 1 and have also ventured into bakery and special fats category. 

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RUCHI'S EXPORTS

Ruchi Soya is the Flagship Company of Ruchi Group, a pioneer Soya Processor group, which started operating back in 1972-73 and is the first exporter of Soyabean Meal from India. 

Ruchi is one of the largest crushers of Soya beans in India, and has installed a crushing capacity of 4150 mts. per day in Indore, which is the largest crushing capacity at a single location. On a yearly basis, Ruchi crushes 25% of the soy crop in India. This has lead to the export of 30% of India's Soya bran meal on a yearly basis. Soya meal is the crushed seed after the oil has been extracted. It has a big export market, and is used to feed cattle/chicken. It also accounts to the export of value added products like the edible defatted soy flour, full fatted edible flour, Soya lecithin, Soya granules and Soya chunks. All the products are made from non GMO beans. The countries of exports include Indonesia, Vietnam, South Korea, Thailand, Philippines, Japan, Taiwan and all the Gulf countries, apart from those in the Indian subcontinent.

Ruchi's Soya Products 

Ruchi Soya Industries Limited (RSIL) has a large team of experts, technicians, scientists, administrators who are involved from the very beginning of the process of selection of soyabeans, processing and transporting them to most advanced plants. The products are produced under the supervision of an expert. The competent quality control team keeps close watch right from the beginning to dispatch to the dealers.

The Company offers a great range of products in Soya foods and Oils as well. Its range of Soya Foods include Nutrela Soya Chunks, Nutrela Soya Mini Chunks, Nutrela Soya Granules, Defatted Soya Flour, etc. The range of oil offers a variety of low cholesterol health prone products such as Soyumm (Pure refined Soyabean Oil), Sunrich & Pamban(Refined Sunflower Oil), Nutrela Vanaspati, Mandap (Pure refined mustard oil ).It also offers Soya products such as Prosoy (Soyabean Meal) and Ruchithin.

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EDIBLE OIL MARKET IN INDIA

India accounts for 9.3 percent of world oilseed production. It has the world’s fourth largest edible oil economy. Yet, about 43 percent of edible oil available in India is imported. In 1999 India ranked as the world’s largest importer of edible oils, displacing China. The bulk of edible oil India imports under the Open General License (OGL) are RBD Palmolein of Malaysian and Indonesian origin.

India has approximately 300 crude edible oil refining units. 60-70 percent of which are small. Unlike the bigger refiners. The small ones are unable to import huge quantities of crude either due to their low capacity or lack of financial resources, and may be forced to close down or sell out to the bigger ones in the foreseeable future.

The total import of edible oils during the period form November 1998 to

October 1999 totaled 4.4 million tones valued at more than Rs. 9.000 crores.

That was against a demand –supply gap of 1.4 million tones in 1998-99.

Imports have therefore deluged the market.

The import of relined palm oil was put under OGL (Open general License) in

March 1994. Other edible oils were put under OGL in April 1995 (when an item

is brought under OGL, it means that the item can be imported without seeking

any approval).

Originally, there was no discrimination between refined and non refined edible

oil as far as import duty concerned. The duty on both was 65 percent. Duty was

the slashed to 30 percent for both, then to 20 percent in 1996 and 15 percent in

then 1999-2000 budgets.

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On December 30, 1999 a differential duty structure was introduced. Duty on

refined oil was fixed at 27.5 percent (25 percent plus 10 percent surcharge)

while that on crude was retained at 16.5 percent (15 percent plus 10 percent

surcharge) But only actual users (as opposed to traders) are allowed to avail of

this reduced duty on crude oil. Traders are nevertheless allowed to import crude

at the reduced duty but only to sell to actual users on a high seas basis. This

requires that the actual users fills in the import documents (and pays the reduced

duty) but leaves the importing process to the trader.

In most parts of the world, the import duty on oilseeds is lower than that on oils.

But, in India it is higher 40 percent. That is why no import of oilseeds of oil

bearing material has taken place in India. The industry wants the duty to be

lowered from the present 40 percent to 5 percent.

Edible oils prices in the Indian market have crashed due to large imports by

multinational trading houses see table.

Oilseeds and edible oils are two of the most sensitive essential commodities.

India is one of the largest producers of oilseeds in the world and this sector

occupies an important position in the agricultural economy and accounting for

the estimated production of 28.21 million tonnes of nine cultivated oilseeds

during the year 2007-08

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IMPORTANCE OF EDIBLE OILS IN THE COUNTRY’S ECONOMY

Oilseeds and edible oils are two of the most sensitive essential commodities. India is one of the largest producers of oilseeds in the world and this sector occupies an important position in the agricultural economy and accounting for the estimated production of 25.14 million tonnes of nine cultivated oilseeds during the year 2003-2004. India contributes about 8-9% of the world oilseeds production. Export of oil meals, oilseeds and minor oils has increased from 2.28, million tones in the financial years 2003-2004. In terms of value, realization has gone up from Rs.2653/- crores to Rs.5447/- crores. India accounted for about 6.4% of world oil meal export.

India is fortunate in having a wide range of oilseeds crops grown in its

Different agro climate zones. Groundnuts, mustard/rapeseed, sesame,

safflower, linseed, Niger seed/ castor are the major traditionally oilseeds.

Soya been and sunflower have also assumed importance in recent years.

Coconut is most important amongst the plantation crops. Efforts are being

made to grow oil palm in Andhra Pradesh, Karnataka, Tamil Nadu in

addition to Kerala and Andaman and Nicobar Islands. Among the non-

conventional oils, rice bran oil and cottonseed oil are the most important.

In additional, oilseeds of tree and forest origin, which grow mostly in tribal

inhabited areas, are also a significant source of oils.

TYPICAL % COMPOSITION OF SOYABEAN OIL

Saturates 15

Monounsaturated 23

Polyunsaturated 62

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What are soybeans?

Soybeans belong to the legume family and are native to East Asia. They have been an important protein source in the Orient for over five thousand years. Soybeans have only been introduced to the Western world since the 20th century. Soybeans grow on a variety of soils and a wide range of climates, ranging from tropical Brazil to the snowy island Hokkaido in the north of Japan. As soybeans mature in the pod, they ripen into hard, dry beans. Although most soybeans are yellow, there are also rare varieties which are black, brown or green coloured. A given area of land planted with soybeans can produce much more protein than land planted with other crops, or if the land were used to raise cattle.

Storing soybeans - Fresh soybeans, or edamame, should be refrigerated and used within two days. Frozen edamame can be stored in the freezer for several months. Dried soybeans can be kept in an airtight container for a very long period. 

Cooking soybeans - Soybeans are most often transformed in other foods such as tempeh, tofu, miso, shoyu, soy milk or other food ingredients. However, cooked soybeans can also be used as an ingredient in soups, sauces and stews. To prepare two cups of soybeans for cooking, soak them in about six cups of water for about eight hours. This soaking shortens the cooking time, improves the texture and appearance of the beans and removes some of the indigestible sugars. Drain, rinse and cook the soaked soybeans in about six cups of fresh water. Do not add salt at this point or it will delay the softening of the soybeans. Pressure-cook the soaked soybeans for about 40 min. When you cook soybeans, make it worth your while by cooking two or three times what you need and freezing the rest for later use.

In processing soybeans for oil extraction and subsequent soy flour production, selection of high quality, sound, clean, dehulled yellow soybeans is very important. Soybeans having a dark colored seed coat, or even beans with a dark hilum will inadvertently leave dark specks in the flour, and are undesirable for use in commercial food products. All commercial soybeans in the United States are yellow or yellow brown.

To produce soybean oil, the soybeans are cracked, adjusted for moisture content, rolled into flakes and solvent-extracted with commercial hexane. The oil is then refined, blended for different applications, and sometimes hydrogenated.

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The major unsaturated fatty acids in soybean oil triglycerides are 7% linolenic acid (C-18:3); 51% linoleic acid (C-18:2); and 23% oleic acid(C-18:1). It also contains the saturated fatty acids 4% stearic acid and 10% palmitic acid.

Soybean oil has a relatively high proportion, 7–10%, of oxidation-prone linolenic acid, which is an undesirable property for continuous service, such as in a restaurant. In the early nineties, Iowa State University developed soybean oil with 1% linolenic acid in the oil. Three companies, Monsanto Company, DuPont/Bunge, and Asoyia in 2004 introduced low linolenic, (C18:3; cis-9, cis-12, cis-15 octadecatrienoic acid) Roundup Ready soybeans. In the past, hydrogenation was used to reduce the unsaturation in linolenic acid, but this produced the unnatural trans-fatty acid configuration, whereas in nature the configuration is cis (see trans fat). This external picture from North Dakota State University compares soybean oil fatty acid content with other oils.

Soyabean Oil

Soyabean oil is the world's largest source of vegetable oil. It is grown

extensively in the U.S.A., as well as South America and China. The North

American Soya harvest, which takes place around October each year,

historically tends to determine the prices of most other major oils, although in

recent years the North American crop has increasingly come under pressure

from South American Soya, which is harvested about March, and from

European Rapeseed, which is harvested about July. Soyabean is also

extensively grown in India. Madhya Pradesh is known to be the Soya bowl of

the country.

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Soyumm (Ultra Refined Soya Oil)

 It is pure sparkling, odourless oil manufactured from selected golden yellow Soyabean With  sophisticated,  advanced, most modern technology preserving and enchanting natural flavour, taste and nutritive value of the food stuff cooked. It is healthy medium of cooking and recipes. High in nutrition, low in calories It is high in poly - unsaturates  with approximately 55% and low in saturates.  

 One tbsp of Soyumm gives approximately 120 calories. It has 15% less saturated fatty acids hence it helps in controlling cholesterol levels. It is rich in vitamin E. According to medical experts, it is good source of essential amino acids, which are required for good health. Boon for cooking medium In chemical terms, it is tasteless but develops taste of the recipes cooked. not have It adds to the nutritive value of the food cooked making it more tasteful. Earns admiration of the Housewives and cooks alike. It  prepares nutritious, health effective recipes maintaining wholesome taste. Guests and host will enjoy the dishes in their natural enhanced flavor cooked in sparkling clear, odourless flavor preserving cooking medium of Soyumm. Cookshanced flavor cooked in sparkling clear, odourless flavor preserving cooking medium of Soyumm. Cooks will earn smile and admiration.

 Universal Cooking Medium Soya oil is used world wide as a cooking medium. Most of the hotels, restaurants, eateries use Soya oil as cooking medium. You must have tasted recipes cooked in Soya oil but find the difference in dishes cooked in Soyumm. It stands unique.

It is economical and you home ministry and finance ministry will love it. Applicable and availability Ruchi’s  Soyumm is available in bulk for industrial use such as in manufacture of mayonnaise, salad dressing, margarines, vanaspati, shortenings, surface coating and fish canning industries. For domestic use, it is available in 15 kg tins and branded consumer packs of ½ lt. and 1 lt. poly packs at all wholesale and retail outlets. 

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RSIL-BOARD OF DIRECTORS

Chairman Kailash Shahra Managing Director Dinesh Shahra

Director P D Nagar S P Joshi A B Rao Company Secretary R L Gupta

Director Sajeve Deora Additional Director Prabhu Dayal Dwivedi

RSIL-KOTA General Manager: Mr. Sanjeev Ji Khare HR Manager: Mr. S.S. Souda

Refinery Department at RUCHI SOYA INDUSTRY

Various Posts and Employees (Refinery Section):

Production manager : Mr. M.C. Verma ; Mr. Vimulendu Sharma

Shift Incharge : Mr. Suresh Singh Kushwaha

Operators : Mr. Pannala ; Mr. Bhawar singh ; Mr. Ram Pratab ; Mr. Shivraj Singh; Mr. Ramnarayan

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BASIC PROCEDURE:

The SEP dept crushes the soya seeds and then using hexane solvent carries out crude soya oil as the final product. This crude oil is the basic raw material for the refinery plant. Getting refined soya oil from the crude oil is refining. This Refined oil is then transferred to the packing Dept. Where according to demands suitability and needs the refined oil is packed into tins, container, jams, bottles, pouches etc.

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TECHNICAL DEPARTMENTS

SEP DEPT. SOLVENT EXTRACTION PLANT

REFINERY PLANT

PACKING DEPARTMENT

EXTRACTION OF CRUDE OIL FROM SOYABEAN

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SOYA SEEDSCRUSH

HEXENE

+

SOYA OIL (CRUDE)

Hexene solvent is used

To extract oil From the Soya seeds

VAPORISATION

HEXENE IS REMOVEDCRUDE OIL

(FINAL PRODUCT)

REFINING

REFINED SOYABEAN OIL

REFINERY

Refinery is basically getting refined oil from the crude oil. Oil refineries are large scale plants, processing about a hundred thousand to several hundred thousand barrels of crude oil a day. Because of the high capacity, many of the units operate continuously, as opposed to processing in batches, at steady state or nearly steady state for months to years. The high capacity also makes process optimization and advanced process control very desirable.

REFINERY AT A GLANCE:

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NEUTRALIZATION AND WASHING

BLEACHING SECTION

DEDORISATION

DEGUMMING

CRUDE OIL

REFINED OIL

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ACTIVITY/OPERATION

DEGUMMING ;REMOVAL OF GUMS

LECITHIN PRODUCTION

MAINTENANCE OF PLANT AND MACHINERY

REFINING(NEUTRALIZATION)

BLEACHING

DISPOSAL OF SPENT EARTH

DEDORISATION

VARIOUS CLEANING ACTIVITIES

FILLING

DISPOSAL OF GENERATED WASTE

ACID OIL(STORAGE OF CHEMICALS)

ENVIRONMENTAL ASPECTS

OIL SPILLAGE OF GUMS AND OIL

SPILLAGE OF GUMS AND

OIL,GREASE,DUST,WASTE COTTON,SPILLAGE OF OIL

SPILLAGE OF OIL,SOAP,PHOSPHORIC ACID,CAUSTIC & WASH WATER.

GENERATION & STORAGE OF SPENT EARTH.

IMPROPER DISPOSAL

SPILLAGE OF FATTY ACID,DISTIALTE AND OIL;GENERATION OF DISPOSAL BAGS

GENERATION OF OIL SOAKED COTTON WASTE;SPILLAGE ALONG WID WASHING WATER

SPILLAGE OF OIL;WASTAGE OF PACKING MATERIAL

IMPROPER DISPOSAL

SPILLAGE;BURSTING IN TANK DUE TO LONGER LIFE

BASIC STRUCTURE OF REFINERY PLANT

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Process Description

Neutralizing:

The incoming oil is first heated in the Feed Economizer by outgoing bleached or deodorized oil or in the Feed Heater during start-up. Next it is intensively mixed with phosphoric acid in the high shear Acid Mixer (Acid Conditioning) to optimize precipitation of gums and trace metals. When appropriate the oil temperature is reduced in the Reaction Cooler. Caustic soda solution (lye) is mixed with the conditioned oil in the Lye Mixer, which neutralizes the acid as well as the free fatty acids in the oil.The treated oil enters the Degumming/Neutralizing Reactor where the reaction continues and the soap and precipitated materials agglomerate.

The mixture of oil and soap flocks is gently discharged via the Separation Heater to the Gum/Soap Separator. There the heavy phase soap with entrained impurities is removed and sent to intermediate storage.The neutralized oil is sent directly to bleaching if this process incorporates the use of soap adsorbing adsorbents to supplement regular bleaching earths. If not, the oil must first be water washed, i.e. heated, mixed with water and centrifuged in a second separator not shown in this drawing.

DEGUMMING:

When applied as the first step of physical refining, the process depends on the type and quality of the feed stock. Most oils can be treated in a fashion similar to neutralizing. The main difference is that the amount of caustic is reduced to the point that the acid added to the oil is neutralized and only a small amount of soap is created in the oil. This method is referred to as Special Degumming.

In some cases, such as when processing certain expeller pressed and organic oils, it is not necessary or acceptable to enhance the removal of gums by adding caustic. This process is called Acid Degumming and typically uses using citric acid. In other cases, such as when physically refining oils with low gum contents, the conditioned oil does not need to be centrifuged and can be sent directly to bleaching from the Conditioning Reactor. This process is referred to as Acid Conditioning or Dry Degumming.

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BLEACHING:

Incoming degummed or neutralized oil is heated in the Bleaching Heater before entering the Adsorbent Mix Tank where it is mixed with a special soap and gum attracting adsorbent (silica). The oil and adsorbent mixture enters the Pre-filtration Dryer where the moisture in the oil and adsorbent is evaporated.

The dry oil and adsorbent mixture is filtered in one of the three Adsorbent Filters removing the spent adsorbent. This filter has previously been used to separate bleaching earth and already has a layer ("packed bed") of earth on the leaves that is still active. This first filtration results in a "press effect" that starts the bleaching process (Pre-Bleaching) before fresh earth has been added. When combined with the silica treatment, this reduces earth consumption by as much as 50%. In cases when the special adsorbents are not available, the Mix Tank and Discharge Pump are simply by-passed. Most of the savings from Pre-Bleaching are still realized.

The filtered oil is further heated in the Bleaching Heater before entering the Bleacher where it is mixed with bleaching earth.

The earth adsorbs pro-oxidants, color bodies and other residual impurities. The Bleacher has multiple agitated compartments and also operates under vacuum to ensure complete moisture and air removal.

The oil and earth mixture is filtered in another one of the three Adsorbent Filters. The bleached and filtered oil is sent to intermediate storage via one of the alternating Polish Filters and, typically, an economizer located upstream in degumming or neutralizing.

The system includes three filters of which two are on line (one for adsorbent and pre-bleaching, the other for bleaching earth) while the third is being cleaned and prepared for the next cycle. A filter begins its cycle by filtering oil from the Bleacher. When a layer of earth has been accumulated on the filter leaves, the flow from the Bleacher is switched to a fresh filter. The partially filled filter, now with a "packed bed" of bleaching earth, is then ready to be used for removing adsorbent as described above. When the filter that is on line for this purpose has reached its maximum capacity it is taken off line for cleaning and replaced by the next partially filled filter.

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DEDORISATION:

The incoming oil is pre-heated by deodorized oil in the Deaerating Economizer before entering the packed column type Deaerator. The deaerated oil is further heated by hot deodorized oil in the Deodorizing Economizer and finally by high-pressure steam under vacuum and steam agitation in the Vacuum Heater. Some of the free fatty acids are flashed off in the heater as the oil temperature increases.

The fully heated oil enters the Double Shell Packed Column (DSPC) where it is distributed into thin film layers as it flows down through the structured packing. The oil is intensively agitated by steam rising counter currently from the bottom of the column. As a result, free fatty acids and other volatile impurities in the oil are evaporated and removed with the steam. The stripped oil drains into the Deodorizer where it flows through a series of vertically stacked compartments (trays) agitated by steam. The prolonged thermal action (heat bleaching) breaks down color bodies thereby lightening the oil’s color. Also, the amount of free fatty acids is reduced to an absolute minimum. The retention time in the Deodorizer is adjustable.

The heat bleached oil is pre-cooled in the Deodorizing Economizer and then mixed with anti-oxidant before entering the packed column type Post Deodorizer. Residual flavor altering compounds and water from the anti-oxidant solution are vaporized and removed. The oil is cooled to storage temperature in the Deaerating Economizer and Product Cooler and then sent to storage via one of the alternating Product Filters.

Fatty acids and other materials evaporated from the oil are condensed by contact with recycled and cooled distillate in the Scrubber and collected in the Distillate Receiver.

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Quality Check :

Crude Oil

After Degumming

After Neutralization

After Bleacher

Deo Section

Refined oil

Fatty acid(%) ; Colour ; Moisture content ; Sediment ; Gums

Gums

Fatty acid content

Colour

Fatty acid

Fatty acid; Colour; Moisture content; Peroxide value

Quality is very strictly checked very frequently after every of these processes.

The motive behind doing so is to maintain the prestige in the market by

providing the best quality. There is no compromise with quality. To ensure

consistently in the quality of various products manufactured at Kota and to

Further improve the quality of its various products; company has very good

quality control systems together with the research and development department

which is comparable to the best in the country.

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FLOW CHART FOR UNLOADING CRUDE OIL:

36

FLOW CHART FOR “LECITHIN PROCESS”

37

IN(arrangement of tankers & hammals,weighment of loaded

tanker)

sample check

Unloading

Preparation of GRN

Out

IMS Process

PROCESS FLOW CHART OF REFINERY ( CHEMICAL)

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Crude Gums

Mixing Tank

Scrap surface;Heat

exchange

Lecithin

Packing ;Storage and Despatch

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NEUTRALIZATION

WASHING

NEUTRAL OIL

BLEACHING

FILTERATION

DEDORISATION

POLISH FILTER

STORAGE

WATER DEGUMMING

Process Parameters and Specifications for Refinery

1. Parameter Check of Neutralization and Washing Oil flow rate:5000-11000 L/Hr. Inlet oil temp. : (60-75) for Degumming;(75-85)for Neutralization Phosphoric acid dosing: (08-.15 %) of flow rate Washing flow rate:10-15% of flow rate Hot water temp. : 80-90 SSC Vaccum in VD: 600-700 mm of Hg Pressure of LP stream: 3 Kgf /sq. Cm

2. Parameter check for Bleacher:

Bleacher temp. : 95-100S C Bleaching oil outlet temp. : 90-100S C Bleaching earth addition: .5 to 2% of oil quantity Oil pressure in PLF : 1-3.5 Kgf/sq.cm Vaccum bleacher- 600-700 mm of Hg

3. Parameter Check for Dedorisation:

Vaccum in Deo:v740-757 mm of Hg Thermic Fluid : Forward-280 and Return-265SSC Oil temp. In Deo:230-235 C Outlet oil temp. : 50 C (max.)

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4. Parameter check for Utility:

Barometric water pressure: 1-2.5 KgF /sq. Cm Barometric water temp. : 32 C Stream pressure at header: 8-12 KgF /sq. Cm Cooling water pressure:1-3 KgF /Sq. Cm Cooling water temp. : 32 C Air Pressure : 5-7 KgF /Sq. Cm

Targets for the year (08-09) Refinery:

05-06 06-07 07-08 08-09

Steam(Kg/ton)

Power(u/ton)

Caustic lye(kg/ton)

Bleaching Earth(Kg/ton)

715

39.44

2.88

14.22

678

38.91

2.74

11.3

656

38.26

2.54

10.25

625

38

2.25

10

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Distribution Network

The end-users of our products are: households and institutional buyers [catering / hospitality / processed food / snacks] set-ups. RSIL has set up a strong distribution network of Company Distributors and Super Stockists for its retail operations. This chain helps to tap even the small retailers/traders and thus increasing our reach. The company has a distribution network of over three lakh retail stores. Going ahead, the company also plans to set up Rs 100-crore 20 MW wind power plant by March 2008, which would bring down the operational costs. And Rs 275 crore infusion by promoters and strategic investors through warrants will also fuel its expansion. However, being in the oil trade, the company is exposed to foreign exchange risk on account of imports for sale in domestic markets and also its export business. But with use of hedging options, the company has been ensuring a cushioning impact on its sales.

FLOW CHART FOR DISTRIBUTION NETWORK

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New initiatives continued…

Entry into Rs. 120 bn Mustard Oil market Capacity ramp-up to 850 TPD.

Target 20% Market Share. Palm Plantation. Contract Farming.

Emerging Biofuel opportunities Scale comparable to any global play

Integrated operations Strong stable of branded portfolio

Sufficient funds availability Professional management

And aggressive growth plans

… is set to redefine the traction

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FINDINGS, CONCLUSIONS & SUGGESTIONS

Ruchi Soya Industries Limited (RSIL) has a large team of experts, technicians, scientists,administrators who are involved from the very beginning of the process of selection of soyabeans, processing and transporting them to most advanced plants. The products are produced under the supervision of an expert. The competent quality control team keeps close watch right from the beginning to dispatch to the dealers.The products are marketed throughout the country and even in wide range international markets. Strict quality control has developed enhanced faith, reliability and confidence of customers in the Ruchi products.

The Refinery Plant at Ruchi Soya Industries Ltd. is well managed, equipped, maintained and organized. The plant management is totally under production manager, under which comes the shift incharge according to whose directions and orders the operators works to run the machinery. The quality is checked very frequently by the incharge and manager after all the main processes say neutralization, washing, bleacher, dedorisation. The bye-products are also utilized either by reusing them or by selling them to other industries to which it may be useful of. Hence, everything is well managed here.

The break down of Refinery plant arises mainly due to power failure, mechanical fault and due to non availability of steam. The machine runs 24*7 and during break down the refinery procedure is badly affected. In order to give maximum output break downs due to steam unavailability may be declined and RSIL may have its own power plant of its own so such kind of break downs may also be overcome. Also, Regarding the introduction of new products, the company should go for aggressive marketing. There is a lot of potential in Soya Refined oil segment, but retailers are not even aware of our product

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References:

Today's Refinery, the journal of record of the petroleum industry's refining sector from Percy Publishing Inc.

SOYBEANS AND SOYBEAN PRODUCTS-by KLARE REFINERY RESEARCH CORPORATION BUSINESS TODAY GREEN AND TULL,MARKETING RESEARCH Guide to Refinery Process Technologies(Second Edition)

-By Hardeep Hundal and Jeroen Bureno Gary, J.H. and Handwerk, G.E. (1984). Petroleum Refining

Technology and Economics, 2nd Edition, Marcel Dekker, Oil refineries in the 21st century -By Ozren Ocic http://www.enewsbuilder.net www.ruchigroup.com www.ruchisoya.com http://agresearch.tennessee.edu/Research.asp?t=Refinery-

17.0KB - System Administration http://taes.utk.edu/Research.asp?t=refinery- 17.0KB – Knoxville

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