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 Introduction |
 From the nutritional point of view, Vanaspati is important
for those sections of society which cannot afford hard
fat diet. The effluent have access to hard fats through
meat, eggs, cream and milk products etc.
But for others these are not easily available. Hence it
is only Vanaspati which meets the need of the lower income
groups and protects them against oxidative rancidity of
oil. The industry plays an important role in the development
on non-traditional/minor oilseeds. A wide variety of edible
oils can be used in the manufacture of Vanaspati without
affecting the quality, acceptability and utility of the
end product. The industry has helped development of unconventional
edible oils like cotton seed oil, Rice Bran Oil, Mahua
Oil, Nigerseed Oil and such other minor oils.
| Raw
Material |
Availability of oils
The industry uses a number of edible vegetable oils which
are used for production of Vanaspati. These oils are of
two qualities:-
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Expeller quality |
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Solvent Extracted Oils |
The solvent extracted oils cannot be directly consumed
for edible purpose except through the medium of Vanaspati
or by retaining them. To reduce the dependence on imported
oils the government has been making constant efforts to
increase the production of Solvent Extracted Oils by encouraging
their use in the manufacture of Vanaspati. Fiscal incentives
have been made available to the Vanaspati Industry time
to time to ensure that greatest quantity of minor oils
and rice bran oil are processed into the edible oils and
used in Vanaspati product.
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Cotton Seed Oil |
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S.E. Groundnut Oil |
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Mahua Oil |
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Maiza (Corn) Oil |
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Palm Oil |
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Nigerseed Oil |
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Imported Rapeseed Oil |
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S.E. Rice Bran Oil |
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Soyabean Oil |
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Sunflower |
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Watermelon Seed Oil |
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Palmolin |
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Salseed Oil |
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S.E. Rapeseed/Mustard Oil |
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Sunflower Oil |
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S.E. Sesame |
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The usual process of Vanaspati manufacture
involves degumming and/or refining, absorptive bleaching,
hydrogenation, deodorisation and blending of various vegetable
oils. These steps are usually batch operations, although
a few continuous processes are in operation.
| Neutralisation |
The edible oils permitted for manufacturing Vanaspati
contain certain percentage of free fatty acids (FFA),
gums and other impurities with FFA, varying between 0.5%
to 5%. To remove the FFA and other impurities, the oil
is first treated with Phosphoric Acid to remove Phosphatides
and then with caustic soda solution to neutralise the
free fatty acids into a soap stock. The soap stock so
formed is removed either by allowing it to settle in a
batch process or by centrifugal force in continuous process.
To remove all the soapy matters hot water wash is further
given to the oil under constant agitation in the vessel.
The washed Water being heavier settles down and is removed
from the bottom in batch process and by centrifuge in
continuous process.
| Bleaching |
Oil so obtained after neutralising and washing is taken
in a bleaching vessel where the oil is first dried by
heating under vacuum at temperature of 100 degree centigrade
and then bleached by adding earth and activated carbon
to remove its colour. At the end of bleaching process
the oil is filtered in filter press to remove the spent
bleaching earth and carbon. The cleaned oil so received
after bleaching is taken into autoclave for hydrogenation.
| Hydrogenation |
The oil is first heated with the help of steam in coils
and then spent nickel catalyst is fed into the process.
Since, most of the oils used for Vanaspati manufacture
are unsaturated, they consume hydrogen gas which is passed
through the oil at that temperature in the presence of
nickel catalyst and thus the melting point of the oil
rises. Fresh quantity of nickel catalyst is added into
the process, the quantity depends upon the type of oil.
When desired melting point of oil is obtained, the supply
of hydrogen gas to the process is stopped. Then the hydrogenated
nickel catalyst mixed oil is first cooled from 200oC and
then it is filtered through a filter press. Some time
for easy filtration filter aid is also added.
| Hydrogen
Gas Generation |
Hydrogen is manufactured by electrolytic process by passing
free current through dilute aqueous sol. of alkali, thereby
decomposing the water according to following equation.
2H20à2H2+O2 The hydrogen produced is tested for
purity and collected in gas holders. The gas is compressed
by Hydrogen gas compressor and taken in autoclaves through
pipeline and storage vessels after reducing its pressure
to 20-30 PSI for the purpose of Hydrogenation. The oxygen
is purified, compressed and filled into cylinders.
| Post
Treatment |
After hydrogenation, the oil is taken for post treatment
to remove any undesired FFA if developed during the process
and also to remove nickel catalyst left with the help
of either very diluted caustic soda solution or with hot
water as found suitable at that time. The neutralising,
washing and bleaching process will be repeated in the
same manner as were carried out for soft oil.
| Deodorisation |
The filtered oil received from post bleached filter press
is taken to the deodoriser for removing the inherent odour
of the oil and whatever attained during processing. At
this stage the different permitted oils are blended in
this vessel. Deodorisation process is carried out at high
temperature and under high vacuum by injecting open steam
so that all the smell and free fatty acids color pigments
etc. are completely removed. The most suitable temperature
for deodorisation is about 200oC and the vacuum about
6 mm Hg absolute. The deodorised oil is first cooled to
a temperature of about 90oC and then it is finally filtered,
calculated dose of citric acid is added in deodoriser.
| Blending & Packing |
 On having the fully processed oil, the specified quantity
of vitamin A & D are added into a churn having cooling
and agitating arrangement. The Vanaspati so processed
is filled into containers to make package of 15 kgs, 4
kgs, 1 kg either into tins or in poly packs. The Vanaspati
containers are taken to a cold room in which the temperature
is maintained for having good setting and grains in the
product. After putting the product in cold rooms for about
24 hours, it is removed to the storage godown where the
brand labels are pasted with batch number, date of manufacturing
etc. as per standard rules. After this the product is
ready for despatch.
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To give you a fair idea of the modalities
of the plant we have presented below an estimation of
various facts and figures associated in setting up this
plant. For further discussion on these, please get in
touch with us.
Capacity
of the Project
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25
MT per day of 24 Hours |
| Marketability
Steam Requirment |
45,000
Kg. |
| Water Requirement |
60
M3 |
| Land Requirement |
4
Acres |
| Manpower |
28 |
| Training |
2
Weeks |
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