Oil production line
Introduction of oil production line
روغن‌های خوراکی یکی از مهم‌ترین مواد مورد استفاده در پخت و پز بوده که میزان کاربرد روزانه آن‌ها در سطح جهان بسیار می‌باشد. به همین دلیل، صنعت روغن خوراکی یکی از صنایع مهم دنیای امروز محسوب می‌شود. در ایران نیز روغن نباتی از جایگاه مطلوب و ویژه‌ای برخوردار است و به نوعی ماده اولیه تولید بسیاری از صنایع دیگر به شمار می‌رود.
شرکت صنعتی دمیرچی به عنوان نماینده انحصاری شرکت دسمت (به عنوان بزرگترین شرکت تولید کننده خطوط روغن در دنیا) در ایران و با استفاده از متخصصین با تجربه و ماشین‌آلات روز دنیا، توانایی ساخت خط کامل تولید و تصفیه روغن و مراحل صمغ گیری، خنثی کردن، رنگ بری، زمستانه کردن و بی بو کردن را دارد. همچنین این شرکت در زمینه فروش دستگاه روغن نیز فعالیت دارد و انواع دستگاه‌های ساخت روغن را با بهترین کیفیت تولید و به فروش می‌رساند.
در ذیل مراحل کلی ساخت خط تولید روغن به همراه ماشین‌آلات و دستگاه های گروه صنعتی دمیرچی در این زمینه را می‌توانید مشاهده فرمایید.
برخی از مشتریان گروه صنعتی دمیرچی در زمینه ساخت کارخانه روغن و فروش ماشین‌آلات این خط تولید
مشاهده فیلم ساخت کارخانه روغن نباتی گلناز کرمان
ماشین‌آلات گروه صنعتی دمیرچی در زمینه ساخت خط تولید و فروش دستگاه ساخت روغن
Refining and degumming Unit
- feed pump before feed tank
- raw oil tank
- inlet pump
- filter
- Economizer
- Oil steam heat exchanger
- Degumming Mixer for phosphoric acid
- Degumming tank of phosphoric acid solution
- Acid transfer pump
- sodium hydroxide transfer pump
- sodium hydroxide-Residue acid-residue tank
- sodium hydroxide tank
- Hot Water Transfer Pump
- hot water tank
- Mixer
- Neutralization separator
- soap mixing tank
- oil steam heat exchanger
- Collecting pump
- dryer oil pump
- Vacuum System Condenser
- Vacuum jet ejectors
- Citric acid tank
- Oil return tank
- Citric Acid Dosing Pump
- Centrifuge pump
- separator cold water tank
- sodium hydroxide tank
- Hotwell Tanks
Bleaching and Degumming unit
- Inlet oil tank
- oil steam exchanger
- Acid pump Dosing
- oil acid mixer
- vacuum dryer
- Hopper Bleaching soil
- Soil injection system
- Silos under the AMA filter
- / Bleacher machine
- Oil transfer pump to filter
- Barometric Condenser
- AMA filter
- Aeration filter tank
- Bleaching oil pump
- under vacuum tank with filter
- Polishing filter
- pre-coat tank
- Pump Replacement Filters
- Oil collection pump
Deodorization unit
- enter feed tank
- enter oil tank
- enter feed pump
- Filter bags
- continuous deodorization two-shell
- Permanent deodorization discharge pump
- Primer water cooler converter oil
- Outlet Oil filter Bag
- Fatty acid scrubber
- Soil homogenizer mixer tank
- Vacuum system
hot oil Fluid heat exchanger
- Instrumentation
- inlet oil pump
مراحل ساخت خط تولید روغن
ساخت کارخانه روغن شامل سه مرحله کلی زیر است که هر کدام شامل چند بخش می‌باشد:
- vegetable oil extraction
Vegetable Oil Refining
- اصلاح چربی
Oilseeds crushing - vegetable oil extraction:
First step: Preparation of the oil containing material prior to solvent extraction
Cleaning and Drying
The plant feedstock must be cleaned so that foreign matters are removed. This applies particularly to sand/silicate and iron which may damage the preparation plant equipment. For some seeds or for some processes the incoming material moisture must be controlled and adjusted for better efficiency of subsequent operations.
Mechanical preparation
Most of raw materials needs to break to reduce the particle size to ensure proper cooking and flaking. They are then heated in cooking / conditioning equipment and their moisture further controlled in addition to be softened before the next mechanical operations. After cooking, heated grits are flaked so that the oil cells are broken and the oil more readily available for further solvent extraction or mechanical pressing.
Pressing
Oilseeds containing above 20 to 25% (rapeseed, sunflower seeds, cottonseeds…) are generally pressed mechanically in order to extract most or part of the oil available in the feedstock.
Dehulling
Oil extraction plants produce a solid finished product in addition to the extracted oil; this product (cake or meal) is normally used as an important component for animal feed recipes. Such characteristics are generally achieved through decortication or dehulling operations that separate the outer part of the feedstock before extracting the oil.
Second step: Solvent extraction of the material suitably prepared
Extraction
In the solvent extractor, solids (Flakes from the flaking machines or cakes from the pre-presses) are conveyed through the equipment while a mixture of hexane and oil (miscella) is sprayed counter-current. The extractor produces therefore deoiled solids containing solvent and miscella.
Desolventization
Deoiled solids coming out of the extractor are conveyed to a dedicated equipment that completely removes the remaining solvent while preserving the meal quality.
Miscella distillation
Solvent contained in the miscella is completely removed under vacuum and optimum temperature for preserving oil quality. The solvent from the distillation as well as the one removed at meal desolventization stage are then recycled to the extractor.
Solvent recovery
Since the air entering the process together with material fed to the extractor is laden with solvent when it is removed from the plant it first pass through a specially designed absorption column to limit emission to an acceptable level.
Meal treatment
The extracted meal is often subject for further treatment, including grinding to obtain the required granulometry or pelletizing to reduce its volume during transport.
Vegetable Oil Refining:
Vegetable Oil Refining:
The main aim of edible oil refining is to make the oil suitable for human consumption. Another reason for the vegetable oil refining is to obtain triglycerides with high yield and purity, and to produce value added co-products from processing stages like Degumming, Neutralization, Bleaching, Dewaxing/Winterization and Deodorization.
Degumming
Degumming reduces the phosphatides content in some crude oils (soybean, sunflower, rapeseed etc). The purpose of degumming is to remove phospholipids or gums from the crude oil. Depending on the oil composition, the degumming step can be eliminated as the phosphatides are also removed along with the soaps during the next step of neutralization. However, degumming is mandatory for physical refining and the content of phosphorus after degumming should be lower than 10 mg/kg.
Neutralizing
In this process, caustic lye is added to acid conditioned oil. It neutralizes free fatty acid, transforming FFA into soap. The oil is then passed to Centrifugal separator to remove soap from oil. This step also eliminates non-hydratable gums and metal traces. Caustic neutralization improves significantly the oil color partly by reacting with polar compounds (gossypol, sesamol, sterols, hydroxy fatty acids, etc.) and partly by solubilization.
Bleaching
During this operation most colouring pigments are removed by absorption bleaching earth. In addition to color pigments, Bleaching also removes residual phosphatides, metal contaminants, soaps and oxidation products.
The removal of chlorophyllic pigments is very important since they are not eliminated in any other stage of refining, as carotenoid compounds are in deodorization.On the other hand, final filtration must eliminate completely the activated earths as residual traces act as prooxidants during oil storage because of their iron content. This is a critical step to obtain high-quality oils.
Deodorizing
Odour and taste are removed under special condition (high temperature and sparge steam). Deodorization is the final stage of Oil refining. It removes odoriferous matter, free fatty acids and other unwanted components to produce bland and stable oil.
The purpose of this step is to remove volatile compounds (mainly ketones and aldehydes) contributing to oil taste and odour, total free fatty acids in physical refining and the residual free fatty acids from neutralized bleached oils. The deodorization conditions also contribute to the removal of contaminants (light PAH, pesticides, etc.) and to the reduction of colour of the oil due to the breakdown of the remaining carotenes at high temperature.
Winterizing
Some oils like sunflower will present an un-pleasant turbidity at low temperature. This can be removed by eliminating components like waxes which solidify at low temperature.
Dewaxing
Separation of waxes, esters of long chain fatty acids and long chain primary alcohols present in mainly sunflower and maize oil.
Winterization
Separation of saturated triacylglycerols from e.g. cottonseed oil and partly hydrogenated oils.
Some oils are dewaxed before packing so as to remove waxes, which are dissolved in the oil. Most of the oils do not need dewaxing as they contain little or no waxes.
Winterisation is another name to the process of dewaxing. The name winterization appears as during winter when the temperature is low, waxes present in the oil crystallizes, they give hazy appearance to the oil. This process is suitable for oils like Sunflower Oil, Cottonseed Oil, Corn Oil, Ricebran Oil etc. which have wax contents more than permissible limit.
This step is only applied when the oil is not clear at room temperature because of the presence of waxes or saturated triacylglycerols. It is important to note that these compounds do not affect negatively the oil performance or functionality, but the appearance of the oil is not acceptable to consumers.
اصلاح چربی
کسری شدن:
برخی از چربی‌ها وقتی در دمای اتاق نگهداری می‌شوند، ترکیبی از کسری‌های نقطه ذوب کم و زیاد هستند. کسری شدن فرایندی است که هر دو نوع را، به منظور به دست آوردن کسری مایع که در دمای اتاق مایع باقی مانده، جدا می‌کند.
Hydrogenation
This process is used to saturate the oil and increase its melting point. The hydronated product is then suitable for use as component in margarine.
Interesterification
This process modifies the physical properties of the oil by interchange between the different tryglecites. The interesterified product is then suitable for use as component for margarine and other specialty uses.
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