Consultants for Vegetable Ghee & Cooking Oil Industry

24/09/2025

https://www.facebook.com/AllPakistanDramaPageOfficial/videos/1651208485835406/?app=fbl

24/07/2024

How to Control the Manufacturing Cost of Cooking Oil
It is obvious; it is not possible for us to control the prices of Raw Material, Chemicals, and Energy prices. But we can control the Manufacturing Cost. For that we have to try our best to find out first the causes as follows: ----
1. Quality of Crude Oil
2. Neutralization Losses
3. Excess Neutral Oil in Soap Stock
4. Excess Oil Contents in Spent Earth
5. Usage of excess Fuller’s Earth
6. Excess oil stripped in the catch pot of Deodorizer
Energy Losses: ---
1. Poor Efficiency of Steam Traps
2. Poor Insulation on steam lines and Vessels
3. Poor Installation of Steam lines
4. Wastage of Condensate
5. Poor Combustion in furnace of Boiler
6. Improper Feed Water Treatment
Now we come to the solution of each cause one by one.

Quality of Crude Oil: We have to fix the standard specifications to purchase the crude Oil. Process Losses also depend upon the quality of Crude Oil.
Neutralization Losses: The major process losses are the Neutralization Losses. To Control these Losses, we have to use the measured quantity & of specific concentration of caustic lye as per the quality of Crude Oil. Time period as well as the rpm of agitator is also helpful for better neutralization.
Excess Neutral Oil in Soap Stock: Analysis of Soap Stock, drained out from Neutralizer must be conducted. You will get TFM (Total Fatty Matters) & the Neutral Oil %age in soap stock. Keep in mind the neutral oil should be not more than 0.1 %, if the TFM of soap stock is 40%.

Excess Oil Contents in Spent Earth: Keep in mind Oil Contents should not be more than 25% in the Spent Earth (After bleaching & Filtration).

Usage of Excess Fuller’s Earth: The Fuller’s Earth, which is being used, must be of the best quality (High bleachbilty & less retention of oil). You may please note, we have to use more Fuller’s Earth, if we use poor quality of the Fuller’s Earth to get the required results.
Keeping in mind, one bag(25Kg) of Fuller’s Earth retained 8.25Kg minimum oil, so try your best to use minimum Fuller’s Earth(as per requirement) to minimize the bleaching loss

Excess oil stripped in the catch pot of Deodorizer: Conduct the analysis of the sample from catch pot of deodorizer.
Free Fatty Acids: Should not be less than 5.0 %.
Peroxide Value: Should not be less than 6.0 m.eq.

Energy Losses may be controlled as mentioned above.
FARHAT AZIM
Azim Consultants

13/07/2024

What is a COOKING OIL

Basically edible oil has the following impurities which need to be removed for getting COOKING OIL.

1. Physical Impurities, Phosphatides (gummy matters), Free Fatty Acids, Coloring Pigments and Waxes.

1) PHYSICAL IMPURITIES:
Left over particles of oil seeds etc. By simple filtration process these impurities are removed.

2) PHOSPHATIDES, GUMS:
During pretreatment process gums and other impurities are either separated out, either through batch degumming or through continuous process with help of centrifugal separators. When impurities are only in small quantities Gum conditioning process is adopted, where in gums are just precipitated and are removed in next neutralizing process.

3) FREE FATTY ACIDS:
Popularly known as F.F.A. all vegetable oils are compound formed by Glycerin and Fatty Acids when Fatty Acid separates out from the bond with Glycerin they are termed as Free Fatty Acids. The free Fatty Acids are generally removed by neutralizing them with alkalis like caustic soda. The soap stock formed and the oil are then separated out by decantation process in Batch Neutralizing or by centrifuge separation in continuous neutralizing.

4) COLOURING PIGMENTS:
Depending on the quantity and type of color pigments present in the oil, oils have color ranging from light yellow, reddish} to dark brownish (as in crude cotton seed oil). To give uniform, color it is essential to bleach the oil with the help of bleaching agents like bleaching earth / activated carbon. Bleaching agents absorbs the coloring pigments. By filtration process the spent bleaching agent is filtered out. Sometimes caustic treatment in neutralizing section also reduces the color of oil specifically in cotton seed oil. In case of palm oil color is also reduced by heat treatment. Bleaching operation is performed either as batch process in smaller capacities or as continuous operation in large capacity plants.

5) ODOUR:
Every oil has its own district odor sometimes pleasing odor sometimes unpleasant odor. neutralizing and bleaching process also adds odor to the oil which is unpleasant. It is therefore essential to remove the odor from oil. Deodorization is the process to remove odoriferous matters from vegetable oils. The odor is removed by injecting open steam in the oil which is heated to high temperature and kept under high temperature and kept under high vacuum. The odiferous matter distills off at high temperature and high vacuum and is carried away through vacuum system. The oils is cooled.

6) WAXES:
Some oil like sunflower seed oil and maize germ (corn) oil have waxes present in them. At low temperature waxes appears and gives hazy appearance to oil. Consumer does not prefer such hazy appearance.

Dewaxing process is adopted for separation of waxes from oil. Oil is cooled and chilled in crystallizers the waxes are crystallized. The wax crystals are separated out either by cold neutralization in centrifuges or more common method of separation is filter them out in horizontal pressure leaf filters.

FARHAT AZIM
Contact # +923084366260

Call now to connect with business.

09/07/2024

Being a CONSULTANT for Cooking Oil Mills
Our objectives are as follows: ---
• To minimize the process losses.
• To minimize the consumption of chemicals.
• To minimize the fuel loss.
• To give attention towards the combustion in the Boiler furnace.
• To give attention towards Boiler Water Treatment.
• To increase the production capacity within the existing plant, so that the expenditures may be minimized on per unit of the product.
• To improve the Quality of the product.
• To give attention to the by-product like Laundry Soap.
• To introduce new laboratory tests, which may help to minimize the process losses and for the improvement of the Quality of Finished Product as well as the By-Product.
• And side by side your staff is also to be trained.
By implementation of above mentioned objectives, we may succeed in minimizing the manufacturing cost.
Now you may consider if we succeeded to reduce 0.1% process loss from the existing loss. mean the saving of 1 Kg oil/ton.
Suppose the price of Oil = Rs.300/Kg.
Say you produce 30Tons/Day, it will be = 300X30 = Rs.9000/Day
And the Savings will be 9000 X 25 = Rs. 225000/Month
You can easily pay our Consultancy Fee from these savings. So my fee will not be a burden upon you. Keep in mind; these assumptions are on a minimum level. This will be the start of our achievements Insha’Allah.
FARHAT AZIM
Contact # +923084366260

28/05/2024

Fabrication & Designing of Vegetable Ghee & Cooking Oil Plant
Fabrication & Designing of vegetable ghee & Cooking Oil plant plays a major role in quality & manufacturing cost of vegetable ghee & cooking oil in addition to the expertise of refiners.
Required heating & cooling surface area must be applied in each vessel like neutralizer, bleacher, autoclave, deodorizer, autoclave cooler & deodorizer cooler. For this length & dia of the steam Coils as well as cooling coils should be as per calculations. By applying recommended length of steam coils & cooling coils we can acquire a desired temperature of the product in suitable interval of time. The usage of heat ex changers helps to decrease energy losses.
The designing of deodorizer is an important part in this industry. Deodorizer plays a major role for improving the quality. Maximum temperature is required in deodorizer against other vessels. The main function of a deodorizer is to deodorize the product. Good designing of deodorizer also helps the collection of free fatty acids, undesirable flavours, colours & odors in fats & oils. Excess oil stripped in the catch-pot of deodorizer due to poor designing, is also the cause of oil loss.
Steam line must be in straight line, either vertical or horizontal & should be well insulated. There should be reducing valves in steam lines, so that we can get required pressure of steam in each vessel. At each outlet of steam there must be a steam trap & the condensate must go in the Boiler Feed Water tank.
Design & RPM(revolutions per minutes) of agitators also have an affect on Quality as well as on process losses. (Azim Consultants)

19/05/2024

Control on Manufacturing Cost
Vegetable Ghee & Cooking Oil manufacturing is not a big technology nowadays. It looks simple. But it is not so simple as we considered. It is a time of competition.
There are two types of Competitions:-
1. Quality
2. Price
The successful brand will be that which will be competed in both types. Now this is the main task for vegetable ghee & cooking oil manufacturers.
For this we have to give the attention on the following types of losses:-
1. To control the process loss.
2. To control the energy losses.
Control on Process Loss: The major loss is to be controlled during Neutralization. We must know the theoretical neutralization loss. Most of the peoples think that it is equal to FFA% x 2.5. But the experiences show that neutralization loss depends upon Wesson’s Loss, which is less than that loss.
To control that loss, we have to firstly use the measured quantity & the proper concentration of caustic soda that depends upon the color & FFA of the crude edible oil. Neutralization loss also depends upon the designing of the neutralizer (rpm of agitator, heating surface area & design of cone). Then the period of settling time given after spraying of caustic soda. Before discharging of soap stock from neutralizer, we must observe its physical appearance. Water washes should not be more than 3 washes. The last wash must be free of soap.
Losses during bleaching depend upon the quality of Fuller’s Earth. The bleacher should be airtight; there should be not any leakage so that the vacuum in the vessel should be not leaked. You may remember that the increase of Fuller’s Earth is the increase of oil loss; therefore the Fuller’s Earth should be used of best quality. Oil retention in Fuller’s Earth must be minimum.
During deodorization, the temperature & vacuum must be attained at standard level, so that the oil/vegetable ghee is deodorized at standard period of time. The oil contents from striping column/catch pot must be analyzed.
To control the process losses, laboratory analysis at each stage must be conducted. Laboratory plays a major role in this regard.
Control on Energy Losses: Energy in Vegetable ghee & cooking oil industry is used in the shape of electricity & the fuel.
For saving electricity we should use the electric motors of suitable HP/amperes as per requirements. For lighting purposes energy savers of proper watts as per requirement must be used.
Fuel like furnace oil/sui gas is used in Boiler. It produces steam, which is used for heating purposes.
Firstly we have to see the temperature & hardness of feed water. It is better to use maximum condensate for feed water as it will save the expenses of chemicals as well as energy cost. On the other hand combustion in the furnace of boiler should be perfect so that there is no heat loss through flue gases & the fuel loss.
There should be a proper insulation on all steam lines & the vessels.
The important thing is that we must know the standards for the usage of steam/ton of cooking oil & per ton of vegetable ghee. We must also know the standards of Chemicals usage, electricity consumption per ton of Vegetable Ghee & Cooking oil.
Farhat Azim

06/04/2024

25/03/2024

Azim Consultants offer a comprehensive range of testing & consulting services. Azim Consultants assist on site by means of our technical surveys, GMP audits & professional consulting.
Azim Consultants provide consultancy services from preparation of feasibility study to finished products in following major projects:-
1. Cooking Oil 2. Butter 3. Butter Oil (Desi Ghee) 4. Vegetable Ghee 5. Laundry Soap.

Call now to connect with business.

25/03/2024

BOILER WATER TREATMENT
For boiler water treatment, hardness of feed water is very important. The method to analyse the HARDNESS of water is as follow :-
HARDNESS
50 ml of the sample Take 50 in the titration flask and add 2-3ml of the buffer solution. Add 4-5 drops of Eriochrome Black T indicator and titrate against 0.02N EDTA solution. The end point is seen from the change of red colour of the solution to light blue. Note the reading and calculate as follow:-
Vol. of the sample = 50 ml = V1
Normality of the sample =? = N1
Vol. of EDTA used = X ml =V2
Normality of EDTA = 0.02 N = N2
N1 V1 = N2 V2
N1 x 50 = 0.02 x X
N1 = 0.02X/50
Strength/ Litre as Ca = Normality x Equivalent Weight
= 0.02X/50 x 50gm/litre
And in PPM = 0.02X/50 x 50 x 1000 = 20X
Preparation of Reagents
EDTA Solution (0.02): Dissolve 7.446g of EDTA reagent in distilled water and dilute to one litre in a measuring flask(volumetric flask) and make the vol. upto the mark.
Eriochrome Black T indicator: Dissolve 0.2g of the indicator in 15 ml of triethanolamine and 5 ml of absolute ethyl alcohol.
Buffer Solution (pH =10): Weigh 17.5g of A.R. ammonium chloride in a beaker and dissolve in distilled water. To this solution add 142 ml of conc. NH3 solution and dilute it to 250 ml with distilled water.
FARHAT AZIM
Cell # 03084366260

Call now to connect with business.