MUSTARD OIL PRODUCTION
[CODE NO.3742]
Indian Edible Oil Industry Vegetable oil and oil seeds are two of the essential commodities for the consumer’s daily needs. India is one of the largest producers of oilseeds in the world with an area of 26.54 million hectares under cultivation producing 23-28 million tonnes of oil seeds every year depending on the monsoons. It produces nine types of oil seeds namely, Groundnut, Soybean, Rape/Mustard seed, Sunflower seed, Sesame seed, Castor seed, Niger seed, Safflower seed, Linseed. It also enjoys the position of being the third largest consumer of edible oil in the world next only to US and China owing to its growing population, rising income levels and changing eating habits.
The per capita consumption has grown by 8.1 per cent over the last five years. It stood at 12.5 kg/person per annum which is considerably low as compared to the world average of 17.5 kg/ annum. Developed countries like Japan, Brazil and USA consume around 20.8 kg/annum, 21.3 kg/annum and 48.0 kg/annum respectively. The imports mainly comprise Palm oil, Soybean oil and Sunflower oil. Indonesia, Argentina and Malaysia are the key exporters of oil to India. Olive oil is mainly imported from European countries like Italy and Spain. Rapeseed oil is imported from UAE.
While mustard seeds are abundantly produced in most parts of India, its milling/grinding is mostly done by the large centralized plants, which have the advantage of high efficiency and reduced costs due to economies of scale. Despite the clear advantage of large plants, the importance of tiny decentralized oil extraction units cannot be discounted as they also prove to be economic and present opportunities for self- employment in situations:
where oil produced by large plants do not find its way to remote and distant places because of high transportation costs involved in wider distribution and in places where there is no oil expeller in the area and the farmers sell oil seeds to large refineries which they then buy back at high cost in the form of cooking oil but without the valuable high protein oil cake.
Therefore, in recognition of the existing opportunities of setting-up mustard oil expeller units in such situations, tiny units are suggested for the first generation Tribal entrepreneurs – the investment for which is modest and the operation is simple.
The unit is required to maintain a minimum stock of seed and enough to continue operations throughout the year. Hence, the location of the unit has to be essentially in those areas where the raw material is locally available in abundance.
In general, more profit could be made if the cooking oil is packed into retail size bottles.
However, considering the difficulty in obtaining glass or plastic bottles in large quantities in remote areas and blocking thereby substantial capital, the possibility of using second- hand bottles may be utilised. Alternatively, oil could be sold in drums to the provision stores in neighboring towns/cities.
The viability of any oil extraction unit considerably depends on the sale of the oil cake, which is extensively used as animal feed and other sub-products.
Primitive mills and presses for extraction of oils from seeds have been in use sevice long. Mechanization came with the introduction of the hydraulic press by the end of the 18th Century. This too was replaced by the more efficient screw press or expeller towards the end of the last century.
Edible oil should have a fairly high keeping quality. However oils get spoilt in storage due to various spoilage factors, the chief among them being oxidation. The edible oils and fats such as olive, cottonseed, corn, groundnut, sesamum, soyabean etc have been found to be almost completely assimulated. As such vegetable oils may be classed as edible and non-edible. Important vegetable oils are castor, coconut, cottonseed, linseed, mustard,olive, palm, groundnut, sesamum, soyabeans, sunflower and rice bran oil etc.
Oil seed crops occupy an important place in the agriculture and industrial economy of the country. India is perhaps the only country in the world having the largest number of commercial varieties of oil seeds. Mustard Oil is also one of the major oil seeds from which edible oil is produced. In Northern & Central India. It is medium of cooking food. Besides it is also used in preparation of Pickles. The Mustard Oil Cake (By Product) is used as cattle feed.
COST ESTIMATION
Plant Capacity 10 Ton/Day
Land & Building (6000 sq.mt.) Rs. 3.54 Cr
Plant & Machinery Rs. 6.05 Cr
Working Capital for 1 Month Rs. 2.68 Cr
Total Capital Investment Rs. 12.95 Cr
Rate of Return 56%
Break Even Point 69%
INTRODUCTION
VARIETIES OF MUSTARD SEED
FATTY ACID COMPOSITION OF MUSTARD OIL MUSTARD OIL
(FROM BLACK MUSTARD SEED)
MUSTARD OIL (FROM WHITE MUSTARD SEDDS)
PHYSICO-CHEMICAL CHARACTERISTIC
OIL SEEDS & % OF OIL CONTENT
USES AND APPLICATIONS
MUSTARD OIL IS DIRECTLY CONSUMED BY FRYING THE CURRY, SNACKS ETC.
MUSTARD OIL PROPERTIES
MARKET OVERVIEW OF EDIBLE OIL INDUSTRY IN INDIA
PRODUCTION
IMPORTS
HIKE IN IMPORT DUTY OF EDIBLE OILS
PRICE TREND
A. PALM OIL
B. SOYBEAN OIL
MSP FOR OILSEEDS
MARKET SURVEY
BACKGROUND
OIL SEEDS SECTOR IN INDIA: SIZE
MUSTARD OIL
EDIBLE OIL ESTIMATES FOR INDIA (MARKETING YEAR- NOVEMBER
2018- OCTOBER 2019)
PRODUCTION TREND OF DOMESTIC OILSEEDS
PRODUCTION TREND OF DOMESTIC EDIBLE OILS
GLOBAL & DOMESTIC PRODUCTION, EXPORTERS AND IMPORTERS
OF MAJOR EDIBLE OIL
MUSTARD OIL
SUNFLOWER OIL
INDIAN MARKET FOR RAPESEED/MUSTARD OIL
MUSTARD OIL: KEY MARKET INFLUENCERS
MUSTARD OIL TRADE
MAJOR PLAYERS
EDIBLE OILS
FEATURES
CHARACTERISTICS
FUTURE: DEMAND DRIVERS
MUSTARD OIL MANUFACTURING PROCESS
PRESSING OF MUSTARD OIL
FILTRATION AND REFINERY OF CRUDE MUSTARD OIL
OIL FILLING / BOTTLING
PROCESS FLOW DIAGRAM
PROCESS FLOW DIAGRAM OF MUSTARD OIL
MANUFACTURING PROCESS OF MUSTARD OIL IN DETALS
HEATING:
QUALITY SPECIFICATION
PROCESS DESCRIPTION OF VEGETABLE OIL REFINING
WATER DEGUMMING:-
ENZYMATIC DEGUMMING:-
ALKALI REFINING:-
BLEACHING:-
DE-WAXING / WINTERIZATION:-
DEODORIZATION:-
PHYSICAL REFINING:-
FRACTIONATION:-
ACID OIL PLANT:-
VEGETABLE OIL REFINING PROCESS BLOCK DIAGRAM:
MANUFACTURERS AND EXPORTERS OF MUSTARD OILS
EQUIPMENT REQUIREMENT
LIST OF FOOD AND AGRO PROCESSING CONSULTANTS
SUPPLIERS OF OIL EXPELLERS MACHINERY
SUPPLIERS OF OIL EXPELLERS
SUPPLIERS OF RAW MATERIALS
MUSTARD SEEDS
STANDARDS APPLICABLE FOR STORAGE OF MUSTARD
STANDARDS APPLICABLE FOR DOMESTIC MARKET
THE PREVENTION OF FOOD ADULTERATION ACT, 1954 (PFA STANDARDS)
QUALITY PARAMETERS
EXPLANATION:
SAFETY PARAMETERS
POISONOUS METALS
STANDARDS FOR GRADING
ADVANTAGES OF GRADING
AGRICULTURAL PRODUCE (GRADING & MARKING) ACT, 1937
(AGMARK STANDARDS).
AGMARK STANDARDS OF MUSTARD AND RAPESEED
SPECIAL CHARACTERISTICS
GENERAL CHARACTERISTICS
STANDARDS APPLICABLE FOR INTERNATIONAL TRADE.
ODOUR AND FLAVOUR
CHEMICAL REQUIREMENTS
CODEX ALIMENTARIUS COMMISSION (CAC)
SAFETY STANDARDS FOR MUSTARD:
EGAL AND REGULATORY FRAMEWORK GOVERNING OIL SEED
PROCESSING INDUSTRY:
PROCESS FLOW DIAGRAM OF OIL REFINING SECTION
PROCESS FLOW DIAGRAM OF OIL REFINING SECTION – CONTINUES
DOC PACKING SECTION
REFINED OIL PACKING
PROCESS FLOW DIAGRAM OF OIL PACKING SECTION
MATERIAL BALANCE
MATERIAL BALANCE FOR PREPARATORY SECTION
MATERIAL BALANCE FOR OIL REFINERY
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PET BOTTLE
SUPPLIERS OF OIL CAKE BAG
MUSTARD OIL CONSULTANT LIST
COMPLETE PLANT AND MACHINERY SUPPLIERS FOR SOLVENT
EXTRACTION PLANT
LIST OF FOREIGN MANUFACTURER/SUPPLIER OF PLANT AND MACHINERY
SUPPLIERS OF PLANT AND MACHINERY
BOILERS
STORAGE TANKS
ELEVATORS
D.G. SETS (DIESEL GENERATOR)
AIR COMPRESSORS
LABORATORY EQUIPMENTS/LABORATORY TESTING EQUIPMENTS
DE-GUMMING / PRE-REFINING BATCH PROCESS, RE-REFINING (LONG-MIX)
& WATER WASHING REFER FLOWCHART DLX-01
PROCESS STAGES FOR CRUDE SOY OIL –
BLEACHING – BATCH TYPE
SLURRY PREPARATION -
SLURRY FILTRATION -
STEAMING OF PLF601 -
SATURATED LOW PRESSURE DRY STEAM IS USED FOR THE OPERATION.
CONT. DEODORIZATION (TRAY)
DE-AERATION:
PRE-HEATING:
(C) METERING
FINAL HEATING FOR PROCESS: TOP TRAY
FINAL HEATING OF THE OIL IN FINAL HEATING UNDER VACUUM
SECOND HEAT REGENERATION:
(J) SHUT DOWN COOLER:
(K) POLISHING:
SUCTION PRESSURE:
STEAM:
2. SPECIFICATIONS OF THE EQUIPMENT
OIL NEUTRALIZATION PLANT
MATERIAL OF CONSTRUCTION
BATCH BLEACHING PLANT
CONT. DEODORIZATION PLANT (TRAY DEODORIZER)
HEAT RECOVERY SECTION (BOTTOM TRAY)
START UP HEAT. THE HEATER WILL BE SKID MOUNTED CONSISTING
OF THE FOLLOWING:
NECESSARY CONTROL FOR THE OPERATION CONSISTING OF:
COOLING WATER PUMPING (CONTAMINATED & CLEAN)
AUXILIARY EQUIPMENT (UTILITY AND LEAVES CLEANING)
ERECTION MATERIAL
COOLING TOWERS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
