The catalog presents vegetable oil producers in Russia. Large and small wholesale sales have been established. The list includes 100 companies for 2019. Wholesale prices are set directly by suppliers.
Sunflower oil accounts for more than 80% of the vegetable oil market. It is followed by soybean, corn and rapeseed. The main share of production, from 40%, belongs to the regions of the Southern Federal District - Kuban, Rostov region etc. Oil extraction plants produce products by cold or hot pressing.
Famous Russian enterprises:
- Krasnogorsk fat plant,
- CJSC "DonMasloProduct",
- Altai-Rodino Creamery LLC,
- SHP "Solnechnoye Pole"
- “Kulundinsky Creamery”, etc.
Vegetable oil producers invite wholesalers, dealers and representatives in the regions to cooperate. In order to buy food products in bulk, download the price list, contact the managers of the manufacturers on their pages. The list is updated regularly.
In total world market volume sunflower oil, and this is about 10 million tons, Russian production takes up a fifth. In other words, the production of vegetable oil in our country produces about 2.2 million tons of this product. Not only large enterprises supply sunflower oil to the domestic market. On the contrary, about half of the total volume is produced in small and medium-sized industries.
- The process of making sunflower oil
- How much does oil making equipment cost?
- Step-by-step plan for starting a business
- How much can you earn
- How to choose equipment
- Which OKVED code must be specified for the production of sunflower oil
- What documents are needed to open
- Do I need permission to open?
Even by the standards of a small farm, the barrier to entry into this business is low. There are also no problems with selling the product. If you cannot sell the entire volume produced in your region, then the possibilities for export are almost unlimited. Consumers of sunflower oil are not only the population and food industry. This product is used in the cosmetic, medical and paint industries. Another one positive side production is its waste-free nature. After squeezing the oil, waste remains, which is used to feed livestock; it can be used to make fuel pallets, etc.
The process of making sunflower oil
The sunflower oil production technology is presented below in table form.
| No. | Contents of operation |
| 1 | Purification of sunflower from organic, inorganic and other types of impurities. For this purpose, aspirators, destoners, and separators are used. The raw materials are blown with air and sifted through several types of sieves. |
| 2 | Seed sorting by size, hulling, peeling, core crushing. The seeds are peeled from the husk by hitting, squeezing, cutting or processing on a rough surface. Whichever method is chosen is the type of equipment that needs to be purchased. |
| 3 | Getting the oil itself. This can be done in several ways: direct extraction and conventional, single, cold or double pressing. |
| 4 | Purification of the product from impurities or refining. Use chemical, physical or combined methods. |
| 5 | Spilling oil into a container. Most often it happens automatically on special lines. |
| 6 | Usually the product is bottled in polymer bottles. They are labeled and sealed. |
According to the degree of purification, sunflower oil is divided into refined and unrefined. The last type is a mechanically purified product. Refined oil can be purified in several ways:
- settling;
- filtration;
- centrifugation;
- deodorization.
State standard GOST R 52465-2005 contains a list of seven types of product.
How much does oil making equipment cost?
Modern equipment for the production of sunflower oil allows everything to be produced at one plant. Separators for cleaning raw materials from debris cost about $1,500. In an hour, such a device allows you to prepare 1000 kg of raw materials for cleaning.
The cleaning procedure is also called breaking. The car for this stage costs 3 thousand dollars. Its power should be the same as that of the separator. Therefore, these two units must process equal amounts of raw material in the same time. The number of pairs of these units must satisfy the raw material needs of the main pressing line. After destruction, all products go into one bunker. From there it is transferred via a conveyor to the extraction site. It starts with a roller mill. This equipment grinds the seed kernels. Its cost depends directly on the power. For example, a unit that is capable of processing 800 kg of raw materials per hour costs 13.8 thousand dollars. If you need to combine it with several separators and crusher-fan machines, then the price will start from 36 thousand dollars.
Line productivity is up to 12 tons/day, cost - 1,930,000 rubles.
Enterprises that are equipped with the latest type of equipment are capable of processing up to 48 tons of raw materials per day. This amount of sunflower can be collected from 19 hectares of land. Usually the plant operates in a single shift mode, but during the season continuous production can be organized.
After grinding, the raw material goes to the roasters. They are divided into two types according to the heating method: steam and fire. For both the first and second methods they are used gas-burners. Only in the first case, water is heated and steam is generated, and in the second, the surface of a large boiler with raw materials is heated according to the principle of a frying pan. The steam roasting method allows you to obtain oil that does not have the specific smell of roasted sunflower seeds. Such equipment, capable of frying 800 kg of raw materials per hour, costs from 11.5 thousand dollars.
If you use cold pressing technology, you can eliminate heating equipment. However, the oil yield will be much less. Then the raw material goes to the squeezing machine. They cost about 20-28 thousand dollars and are capable of pressing up to 25 tons of raw materials per day. After the press, the oil is left to settle for some time. All impurities are precipitated, and the product is passed through special filters. Their price starts from 3 thousand dollars. One filter can clean 160 kg of oil in an hour.
Sunflower oil production as a business.
The extraction method for obtaining the product makes it possible to increase its yield by 2%. At the factory, you can combine the two methods. Oil is usually obtained from waste after pressing. The final cake is called meal and is used to feed livestock. The line for bottling the product costs $13,000. It allows you to bottle 3600 liters of sunflower oil in one shift.
This business will be especially profitable in those farms, where they grow their own sunflowers. But it can also be considered as a separate production. Then you need to take care not only of selling finished products, but also of purchasing raw materials in the required quantities.
Step-by-step plan for starting a business
In order not to lose capital investments when starting your own sunflower oil production business, a detailed analysis of the market in the region where it will be produced is carried out. Then the scheme of action, as for any production, is identical:
registration and purchase of equipment;
purchasing raw materials and hiring personnel;
searching for sales channels for finished goods...
How much can you earn
This business, one might say waste-free. Here, earnings include not only the sale of sunflower oil itself, but also husks and meal. The cost of 1 liter is 35 rubles. Meal can be sold for 1.5 thousand rubles, and husks at a price of 9 thousand rubles per ton. If you set up production correctly, your monthly income will be about 3,000,000 rubles. Minus costs, we get a net profit of 2 million rubles.
How to choose equipment
For full-fledged work production capacity will need to be purchased:
oil press and seed roaster;
oil filter and separator.
Which OKVED code must be specified for the production of sunflower oil
When choosing a code, look at chapter C - manufacturing production. It contains a separate code that directly relates to the production of oils and fats - 10.41. This is what we indicate in all the necessary documents.
What documents are needed to open
The list of required documents is standard. Best of all, when opening a mini-production, register as individual entrepreneur(application and state fee, registration and photocopy of passport are all documents that need to be provided). For legal entities, the list of documents is somewhat expanded. Additionally provided: Charter and resolution of shareholders, information about the presence of a legal address, as well as about the director of the company and the chief accountant of the company.
Which taxation system to choose for sunflower oil production
The best option when choosing a taxation system would be simplification. With it, the businessman will pay a tax amount equal to 6% of total profit. Alternatively, upon provision of documents confirming expenses, 15% of net profit is paid.
Do I need permission to open?
If you open production at home, you will not need to obtain permits. If a mini-production is opening, then you need to think in advance about obtaining permits from the sanitary and epidemiological station and the fire inspectorate.
Sunflower is the most common type of vegetable oil in Russia, used in cooking, medicine, cosmetology and other fields. 85% of Russians regularly consume vegetable oil. Demand for it is consistently high and continues to grow.
It is produced from sunflower seeds - profitable idea capable of generating high income. In this article we will tell you in more detail how to properly organize your business and get maximum profit. The reader will also familiarize himself with calculations of the payback of the business.
Brief market analysis
Sunflower oil is one of the popular products on the Russian market of oil and fat products. Among other oils, it occupies the maximum share - 86.8%.
Entrepreneurs who want to start producing and selling sunflower oil need to know about the main trends in the industry, which is highly competitive, capacious and saturated.
Enterprises operating on the market are the leaders of the country's agro-industrial complex. More than a dozen large manufacturers, wholesale companies dominate the market. The current situation can be called oligopolistic. To take market share and get your customers, you will have to make great efforts.
Vegetable oil consumption in the country
There is some potential for market growth. The buyer in the country is satisfied, for the most part, with the Russian product, the share of which is 83.5%.
Table 1. How much vegetable oil was consumed in 2015-2018?
A noticeable increase occurred in 2017 due to the large harvest of oilseed crops in 2016.
According to the base forecast scenario, consumption will continue to grow by 2% every year and reach 7,782 thousand tons in 2025.
The market has not exhausted its potential, and this provides excellent opportunities for entrepreneurs to start a new plant.
Methods for producing different types of oil
The production process is divided into several technological stages:
- Cleaning and processing of seed mass. Separators and aspirators are used. Depending on the processing method, the following processes are performed:
- sifting through a sieve;
- blowing the mass with an air flow;
- ferromagnetic separation.
- Preparing the mass for extraction. Raw materials can be extracted only after seed processing. Using vegetable oil production equipment, they are conditioned and hulled/husked. Valuable kernels are separated from the shell and crushed.
- Oil is extracted from the prepared mass. Use one of 3 methods: pressing, centrifugation, extraction. Extraction is the most economical way receiving the product High Quality.
- If necessary, the oil is refined (cleansed from impurities).
- The product is bottled, packaged and labeled.
Scope of application
The oil is widely used in cooking. It is also needed:
- for food preservation (meat, vegetables, fruits);
- for creating paint and varnish materials(drying oils, paints);
- When does soap making take place?
- creation of medical and cosmetic products (creams, ointments, lotions, lipsticks).
In these cases, you cannot do without refined oil - that is, purified from the pronounced aromas of sunflower. Therefore, it is better to purchase equipment for refining. The likelihood of purchasing refined sunflower oil is higher, since the scope of application is wider.
The production of refined sunflower oil itself is waste-free, because sunflower processed products can also be sold. The cake is required for livestock farms as biofuel. Miscella is needed to create paints and varnishes, husks are needed to create fuel briquettes.
What is needed to open a business
In this business plan for oil production, we have selected the equipment that is optimal in price and quality, which will allow a small enterprise to be loaded with work and create a high-quality product. The purchase of equipment is the largest expense item. Every month, most of the money is spent on the purchase of raw materials.
Table 2. The amount of initial costs for a vegetable oil production business.
|
Expense item |
Cost, rub. |
|
Registration, certification |
|
|
Premises for rent, 600 sq. m |
|
|
Equipment (plus costs for delivery, start-up, setup) |
|
|
Raw materials (per month) |
|
|
Wage |
|
|
Additional expenses |
|
|
Total |
15.34 million |
The calculations are relevant for a city with a population of about 1 million people. Additional expenses include the costs of utilities, advertising, and cosmetic repairs.
Documentation
An entrepreneur can organize a business in the form of an individual entrepreneur or legal entity(OOO). It all depends on the volume of production and sales of goods. It is better to choose an LLC - this form will allow you to cooperate with large wholesale and retail companies and stores.
It is not necessary to obtain a mandatory certificate of conformity for the production of oil. Go through the verification process and issue a voluntary certificate - this will simplify your work with buyers and intermediaries.
Table 3. Regulatory documents.
Vegetable oil production technologies
You can make refined and unrefined oil. The difference is in the degree of purification from smell and taste. Refining allows you to obtain a pure product suitable for both culinary and other industries.
The technology for producing vegetable oil is as follows:
- On the separator, the mass is cleared of husks, leaves, stems, and other impurities.
- The seeds are dried and collapsed on a crushing machine.
- On a roller machine, the raw material is cleared of husks and crushed into a mushy state.
- In the roasting pan, the seeds are heated and easily fried.
- On a screw press, the press cake (pulp) is pressed and separated.
- Using special equipment, cake residues are removed during primary filtration. Filtration can be carried out several times.
- The product is refined and deodorized. Refining methods:
- physical (defending);
- chemical (hydration);
- physico-chemical (bleaching).
- At the bottling device, the goods are poured into containers.
The production technology is presented in the following video:
Room
Sanitary rules for enterprises producing vegetable oil are specified in SanPiN 1197-74. Studying and taking into account the requirements will allow you to obtain permits and positive conclusions from the sanitary-epidemiological, fire, gas, electricity and water utilities without unnecessary difficulties.
To organize production and place machines, you will need about 250 square meters. m of space. About 300 sq. m will occupy warehouses where raw materials, finished products, as well as processed products - cake/meal and peel (husk) will be stored.
We need space for administrative premises and rooms for workers. You will need to equip a bathroom. It is also necessary to create convenient transport access to the workshop and organize a place for loading and unloading operations.
To accommodate a small plant, a minimum of 600 square meters will be required. m area.
Raw materials
To make sunflower oil you need sunflower seeds. Finding raw materials in Russia is not a problem. More than 80 varieties and hybrids of the plant are cultivated in the country.
Almost all sunflower varieties are suitable for extraction, except white and gray ones. It is recommended to buy seeds of Maslenitsa varieties (such as “Gourmet”, “Orange Miracle”). Don't buy hybrids - from varietal seeds a more tasty product is obtained.
By cold pressing, 1 ton can be obtained from 4.5 tons of raw seeds. If you squeeze roasted seeds, you will need approximately 2.5 tons of seeds to obtain 1 ton of product .
Equipment for the production of vegetable oil
You can buy equipment individually or the entire creamery (line). The second case is relevant for entrepreneurs who plan to produce more than 30-35 tons per day. For smaller volumes of oil production, it is advisable to purchase equipment separately. You will need:
- oil production line;
- refining line;
- filling device / filling machine.
The equipment selected for our business plan will allow us to produce 7 tons per standard shift (8 hours). The refining line has the same productivity, the packaging machine packs up to 1 thousand. liter bottles at one o'clock. This set is perfect for a small business.
The oil machine roasts the seeds, increasing the percentage of liquid that can be obtained during extraction.
Staff
For a small plant you will need the following personnel:
- 6 workers - in the direct pressing workshop;
- 4 workers - in the refining shop;
- 2 workers - in the packaging department;
- 3 workers - for unloading and loading operations, in warehouses.
It is important to find a competent technologist with experience. He will keep an eye on production process, the quality of the finished product.
Director, accountant and driver required. At first, the function of director can be assumed by the businessman himself. An accountant is required if the form of legal entity is chosen for work. To begin with, you can hire him part-time or outsource. It is better to hire a driver with your own car. It will ensure delivery of goods to retail chains and private customers.
The workforce is 19 people.
Marketing and sales
Focus on wholesale buyers. You can sell goods through own store. Open outlet in a prime location and with a company logo - then people will quickly learn about the new product.
Sell your goods in markets retail stores, supply it to bakeries and HORECA segment enterprises (cafes, restaurants, canteens).
Sunflower processed products can be sold wholesale to farmers and solid fuel producers.
To increase sales and improve competitive positions, reduce selling prices and conduct BTL promotions (promotions, discounts). Place advertisements in specialized publications, send mailings and send commercial offers by mail. It is not necessary to hire a sales manager to conduct negotiations - an entrepreneur can do this himself.
Sunflower oil production as a business: profitability and payback
The amount of initial investment is 15.14 million rubles.
The main monthly costs are raw materials. To produce sunflower oil, you will need 385 tons of sunflower seeds. Minimum price 1 ton of raw materials - 16 thousand rubles. Together with other expenses, the amount of monthly costs will be 6.56 million rubles.
The selected equipment allows you to produce 154 tons of sunflower oil in a month (22 working days).
Average Wholesale price 1 ton of product costs 50 thousand rubles. Accordingly, the monthly turnover is 7.7 million rubles.
After deducting monthly expenses, there remains a net profit of 1.14 million rubles.
So the business can pay for itself in 13.5 months.
Table 4. Economic justification for the idea of producing sunflower oil.
Sunflower oil production, upon reaching the break-even point, will bring a solid income to its owner.
The specified period - 13.5 months - is achievable only if all products produced per month are sold. This is difficult to achieve at the start-up stage of a business, but later sales volume will likely increase significantly.
In this article:
Since the time when Peter 1 brought an unknown overseas flower to the territory of Russia, sunflower oil has occupied a leading position among essential goods. The volume of the Russian sunflower oil market is growing rapidly every year, the annual increase is about 3%, and in value terms - 82 billion rubles. Finished products are manufactured not only by large corporations and companies, but also by farms.
The demand for sunflower oil is stable and not subject to seasonality, therefore, with competent marketing, pricing policy production of sunflower oil in Russia – profitable business, the organization of which requires investment. A special advantage of this type of business is the opportunity to obtain an additional source of funds when selling production waste.
Features of sunflower oil production
Before you start organizing a private enterprise for the production of sunflower oil, you need to familiarize yourself with the features of its production.
Based on technological characteristics, the entire process of sunflower oil production can be divided into the following main stages:
1. Storing and cleaning oil seeds– includes the processing of seed mass from organic, mineral and oilseed impurities.
Seed cleaning is carried out using special equipment: separators, destoners, aspirators.
Seed mass can be processed using the following methods:
- by sifting through a sieve with holes of various shapes and sizes;
- by blowing the seeds with air;
- due to the separation of seeds according to ferromagnetic properties.
2. Preparation and processing of oil seeds for oil extraction– includes separating seeds by size, conditioning the seeds, dehulling the seeds, separating the kernel from the shell and crushing the kernels.
Peeling of the oil seed shell can be carried out in the following ways:
- due to shell splitting by impact;
- compression of the shell;
- cutting the seed shell;
- as a result of peeling the shell on a rough surface. Therefore, equipment for the production of sunflower oil at enterprises can be varied, depending on the method of hulling the shells of oil seeds.
3. Direct oil extraction– can be carried out by pressing or extraction. But based on these two methods, the following production process schemes can be developed at sunflower oil production enterprises:
- single pressing;
- double pressing followed by squeezing;
- cold pressing;
- extraction;
- direct extraction.
4. Sunflower oil refining a – the process of purifying oil from accompanying impurities. The following refining methods exist:
- physical;
- chemical;
- physico-chemical.
5. Bottling– carried out in transport containers. On modern enterprises Sunflower oil bottling is carried out on automatic lines, which include a molding, filling, sealing and labeling machine.
6. Packaging and labeling of finished products– oil in polymer bottles is hermetically sealed and labeled.
The technological flow diagram for the production of sunflower oil is shown in the diagram below.
Regulatory documents regulating the activities of enterprises producing sunflower oil
In order to open a sunflower oil production plant, you need to familiarize yourself with the following: regulatory documents regulating activities:
- SanPiN 1197-74 – sanitary rules for enterprises producing vegetable oils;
- GOST 22391-77 – standards regulating the quality of sunflower seeds supplied to the plant;
- GOST 1129-73* - document regulating the quality of sunflower oil;
- GOST 22391-89 – storage standards for oilseed raw materials (“Sunflower. Requirements for procurement and supply”).
Sunflower oil production technology
On the Russian market, the greatest demand is for refined sunflower oil, which is odorless, tasteless and colorless. Therefore, many sunflower oil production enterprises produce this type[ product. The process of manufacturing refined sunflower oil includes the following steps:
1. Oil extraction– carried out in presses under high pressure. The raw materials are pre-heated in special fryers at a temperature of about 110° C. If the company produces oil as a result of cold pressing, then the raw materials are not previously subjected to heat treatment. The cake obtained during the oil extraction process is used in animal husbandry. Therefore, by selling the cake, enterprises receive additional source income.
2. Oil refining– occurs during the following stages:
- elimination of mechanical impurities as a result of settling, centrifugation or filtration. At this stage of refining, unrefined sunflower oil is obtained;
- vegetable oil processing hot water allows you to eliminate phosphatides;
- the removal of fatty acids makes it possible to obtain refined, non-deodorized sunflower oil;
- deodorization allows you to remove pigments, volatile compounds, smell and makes vegetable oil light in color;
- freezing – during this process the waxes are removed.
3. Packaging and labeling of finished goods.
Equipment for the production of sunflower oil
The purchase of a set of equipment or lines for the production of sunflower oil depends on the capacity of the plant, so it is advisable to make the following conclusions:
- If the plant must produce about 30 tons of finished products per day, then it is necessary to purchase an oil extraction and refining line. A sunflower oil production line costs an average of 1.5 million euros, excluding installation costs.
- If the enterprise’s productivity is 5-10 tons of sunflower oil per day, then it is advisable to purchase each type of equipment separately. On average, the total cost of equipment will be about 7,000,000 rubles.
Business plan for sunflower oil production
This business plan includes the organization of a workshop with a productivity of 5-10 tons daily.
Equipment costs assume:
- Purchase of an oil production line – 2,000,000 rubles;
- Purchase of a refining line – 2,100,000 rubles;
- Purchase of a packaging line – 2,200,000 rubles.
Total total costs for a set of equipment are: 6,300,000 rubles.
The cost of installation and delivery of equipment to the workshop will be: 2,150,000 rubles.
Working capital, including the purchase of raw materials, monthly expenses and other costs amount to: 3,600,000 rubles.
The total capital costs for organizing a workshop for the production of sunflower oil are: 12,050,000 rubles. Next, you need to determine the area of the room to accommodate production equipment, storage of raw materials and finished products warehouse.
To install a sunflower oil extraction line, you need a room with an area of at least 55 square meters. m.
To install a refining line, a workshop with an area of more than 100 square meters is required. m.
Installation of a line for packaging finished products requires a room of 60 square meters. m.
In total, to organize an enterprise for the production of sunflower oil, the following is required:
- More than 220 sq. m for industrial premises;
- More than 200 sq. m for storage space.
To provide uninterrupted operation enterprises need only 25 workers, general fund wages which will amount to 417,000 rubles monthly.
Number of shifts per month for workers: 30.
Total monthly expenses for the enterprise are: 760,000 rubles.
Monthly revenue– 5,900,000 rubles.
Cost – 4,700,000 rubles.
The profitability of the enterprise is 8%.
Payback period – 2 years and 1 month.
The high profitability of the enterprise indicates that the production of sunflower oil is a profitable business, the payback period of which is only 2 years.
Organization of a mini-churn for the production of sunflower oil
Setting up a mini-churn to produce sunflower oil requires minimal capital investment.
After all, the cost of an oil churn with a capacity of 10 - 17 l/hour can vary in the price range: $200-400, an oil purification filter costs about $100-200, purchase costs additional tools and the products will cost only $100. Therefore, many agricultural producers organize the activities of private mini-churns.
The main equipment for a mini-enterprise is a butter churn
A modern butter churn is a press extruder that looks like a meat grinder. The design of the extruder press includes three parts:
- Seed supply hopper;
- Screw part, grinding oil seeds;
- Nozzle for squeezing oil.
The resulting sunflower oil from the churn must be filtered. If production volumes are small, then canvas bags can be used for filtration. After the oil has been filtered, it is necessary to settle it and after some time drain it into a container. The remaining sediment can be filtered again. If the churn is more high performance, then it is necessary to purchase special filters for purifying sunflower oil.
It is advisable to open a mini-enterprise when its owner grows sunflowers on his own. Thanks to this, there will be no costs for the purchase of raw materials and their transportation.
Do you know that Russia is one of the world leaders not only in oil production, but also in the production of sunflower oil? I also learned about this with surprise. To find out how such a necessary culinary product is obtained from seeds, I went to Voronezh, to one of the largest factories in Russia for the production of sunflower oil.
Before the main story, we learn about the history of sunflower oil.
According to Wikipedia, the evolution of sunflower as cultivated plant happened in Russian Empire, And industrial production associated with the name of Daniil Bokarev. In 1829, he invented a method for extracting oil from sunflower seeds. Four years later, in 1833, in the settlement of Alekseevka, Voronezh province (now Belgorod region), the merchant Papushin, with the assistance of Bokarev, built the first oil mill in Russia. In 1834, Bokarev opened his own oil mill. In 1835, the export of oil abroad began. By 1860, there were about 160 oil mills in Alekseevka.
Factories for the production of sunflower oil are built in close proximity to the place where sunflowers grow, that is, mainly in the black earth or southern regions of Russia. This is done not only to make it convenient to transport seeds to the plant, but also to economic reasons- sunflower seeds weigh very little compared to the final product, and transporting them over long distances is impractical.
The plant, which produces the well-known brand of sunflower oil "Oleina" in Russia, was built not so long ago, in 2008. However, in a short period of time the company took a leading position among sunflower oil producers.
1
Perhaps we’ll go to production and find out how sunflower oil is made.
It all starts here. In front of the entrance to the plant there is such a house with a canopy. This is a laboratory where a truck with seeds arrives. Here the quality of the seeds arriving at the plant is determined (weediness, moisture content, oil content, pest infestation, etc.). If the seeds do not meet the requirements, they are taken back to the manufacturer. There are dozens of these trucks with trailers parked in front of the entrance to the plant.
2
Then the truck with the seeds is weighed.
3
Then you need to unload the seeds. This happens as follows - the truck drives onto a special lift, where it is secured with chains, then it rises at an angle, and the seeds are unloaded into a special container. From there they are sent along transport belts to be cleaned of debris and, if necessary, to a dryer for drying. And the seeds can already be transferred for storage to silos (storages).
4
The huge cylindrical containers in the photo are those same storage facilities. Here the seeds are stored at a certain temperature. The higher the oil content of the seeds, the greater the oil yield.
5
There are many different containers on the territory of the plant. Some are for storing seeds, others are for storing processed raw materials - cake, meal. I will tell you what this is further.
6
By the way, the meal looks like this.
7
The plant has its own railway line. From here, processed raw materials (oil, meal) go to various regions.
9
But let's get back to production. Seeds ready for processing are transported via transport belts to the first stage of production.
10
In the seed processing workshop, the seeds are dehulled (destroyed) and separated from the kernel.
11
Collapse occurs in these devices. By using centrifugal force the seeds are broken on the whips, resulting in a rushanka (kernel and husk). Then the kernels are separated from the husks and each part goes its own way for further processing.
12
13
The kernel is sent for moisture-heat treatment in a fryer, where it is heated to 90C and is prepared for squeezing the oil in presses. At this stage, press oil is obtained, which, after filtration, is sent for temporary storage, and the resulting solid and still oily cake is transferred to the next stage.
15
The characteristic taste of the oil after hot pressing is reminiscent of toasted sunflower seeds. Oils obtained by hot pressing are more intensely colored and flavored due to oxidation products that are formed during heating. Cold-pressed sunflower oil is obtained from mint without heating. The advantage of this oil is that it retains most of the beneficial substances: antioxidants, vitamins, lecithin. Negative point– such a product cannot be stored for a long time, quickly becomes cloudy, goes rancid and becomes hazardous to health.
The cake remaining after pressing the oil is transferred to extraction for deeper extraction of oil. or used in animal husbandry. Sunflower oil obtained by pressing is called pressed oil, because after pressing it is only settled and filtered. This product has high taste and nutritional properties.
In the photo I am holding a piece of cake.
16
No Hipsters Allowed!
17
This building houses equipment for refining (purifying) oil from accompanying organic impurities. Refined oil has virtually no color, taste or smell. The cleaning process consists of several stages.
18
At the first stage, removal of phosphatides or hydration occurs - processing a small amount hot – up to 70 °C water. As a result, phospholipids become insoluble in oil and precipitate, after which they are separated in centrifugal separators. , Phospholipids are useful substances, but are not stable in oil. During storage, they form a sediment in the oil and the oil begins to go rancid, and when frying in a frying pan, they burn.
Unrefined oil has a slightly lower biological value than raw oil, since some phosphatides are removed during hydration, but it is stored longer. This treatment makes the vegetable oil transparent, after which it is called commercial hydrated.
In the second stage, the oil is bleached. Bleaching is the treatment of oil with adsorbents of natural origin (most often special clays) that absorb coloring components, after which the oil is clarified. Pigments pass into the oil from the seeds and also threaten oxidation of the finished product. After bleaching, the oil becomes light yellow in color.
Tools for maintaining oil filtration devices in working order.
20
After bleaching, the oil is sent to the freezing section. Freezing is the removal of wax from oil. All seeds are covered with wax, this is a kind of protection against natural factors. Wax makes the oil cloudy and thereby spoils its presentation. The purification process in this case occurs by cooling the oil to a temperature of 8-10 C and adding cellulose (natural origin), after keeping the oil at this temperature and subsequent filtration, the oil turns out transparent.
Deodorization – removal of free fatty acids and aromatic substances by exposing sunflower oil to hot, intense steam at high temperatures in high vacuum conditions. During this process, odorous substances and free fatty acids, which characterize the quality of the oil, are removed. In addition, deodorization removes odorants that give the oil its taste and smell, as well as pesticides.
Removing the above undesirable impurities leads to the possibility of increasing the shelf life of the oil. Having gone through all the stages, vegetable oil becomes impersonal - without color, taste, smell. Margarine, mayonnaise, cooking fats are made from this product, and are used for canning and frying.
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After all the circles of cleaning hell, the oil ends up in these huge containers. Sorry for using the word “huge” once again, but the scale of production is such that everything here is huge).
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The oil will be delivered to individual customers in a tank.
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We learned about the process of oil production and its purification, now let's go to The final stage- to the bottling shop.
Seeing this slogan, another sphere of human activity came to mind, which I will not voice now. What associations do you have?
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But before visiting the workshop, you must put on gowns, a cap, shoe covers and wash your hands. Almost all food production such rules.
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Remember these rules.
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The bottles into which the oil will be poured are made like everyone else plastic bottles from such preforms. There are different preforms for bottles of different capacities.
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They are loaded into this container, it moves the preforms to the blow molding machine, which when the right temperature blows the bottle out of it.
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It goes like this:
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This is such simple magic.
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And it goes into the next device, where oil is poured. By the way, the oil comes here through pipes from those same containers of 500 and 800 cubic meters.
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The bottle is screwed on with a cap and continues on its way.
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At the next stage, the bottle is covered with a label.
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Along the way, the devices detect bottles that are incorrectly covered or do not meet the requirements - without a cap, etc. They are rejected.
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Saw interesting sign I don't know what it means. Can anyone tell me?
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The bottles are then piled up so that the suction cup machine can fill the box in one go.
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For transportation, they are folded in several rows and wrapped in polyethylene.
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After that, the electric cars place the pallet with boxes on the rack, waiting for the oil to travel to the stores.
The plant's capacity allows it to process 540,000 tons of raw materials and produce over 200 million bottles of sunflower oil per year.
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Finally, I will clearly show all the stages of oil production in three pictures.
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Now you know how sunflower oil is obtained. I hope you had the strength to read to the end)
