E Learning on Green Productivity &

Environmental Management System

(ISO 14001)

21 24 August 2006

Presentation on Case Study
of
Soya Oil Processing Industry

Sri Lanka
Overall Methodology
Three teams were formed comprising 5 6 members in
each group with a team leader

Each group was requested to analyze the full case by
having brainstorming sessions

Each group was requested to make a presentation

After the presentations of each group a brainstorming
session was carried out to finalize the presentation
Tools & Techniques used
Review of documents

Each group reviewed the document of
case study and the summary of the said
case study presented by Dr. Saxena and
identified the areas in relation to
organizational, production, materials so on
and so forth

Tools & Techniques used
Based on the above each team developed
a walk through survey assuming the
operational activities of the Soya oil
processing company

Next slide shows the walk through survey

Walk through survey
Seed
Receiving
area
Unloading-
Silos
Administration
block
Laboratory
Utilities
section
Production Facilities
Seed Preparatory
Solvent extraction
plant
DOC Packing
ETP
Tools & Techniques used
Base on the walk-through survey a
process flow chart was developed
identifying each processing point and the
relevant waste streams generated through
the relevant operations. Next slides
denotes the relevant details
Soya
Seeds
Unloading
Storing
Transferring
Transferring
Bags
Spillages
Dust
Noise
Oil Spillages
Spillages
Dust
Noise
Energy loss
Odor
Spillages
Dust
Noise
Labors
Electricity
Lubricants
Electricity
Lubricants
Storing
Screening
Transferring
De Stoning
Energy loss
Odor
Spillages
Dust
Noise
Electricity
Lubricants
Energy loss
Dust
Husk
Traces
Spillages
Noise
Electricity
Energy loss
Spillages
Stones
Mud balls
Dust
Noise
Electricity
Cracking
Flaking
Conditioning
Drying
Electricity
Hot air
Energy loss
Odor
Spillages
Dust
Noise
Electricity
Heat loss
Steam
Condensate
Odor
Steam
Spillages
Energy loss
Noise
Odor
Air emission
Moisture
Heat loss
Odor
Transferring
Extracting
Oil Spillages
Energy loss
Electricity
Lubricants
Hexane
Electricity
Spillages
Hexane vapor loss
Energy loss
Odor
De-oiled-cake
(DOC)
Miscella
Preheating
Heat
loss
Evaporating Distillation
Hexane
Flash recovery
Hexane
Hexane vapor
Chiller Cooling
Mineral oil
Contaminated
With Hexane
Hexane
Miscella
Stripping/
Drying
Crude Oil
Steam + Hexane Vapour *
Toasting
Desolventisation
Drying
Hot air
Heat loss
Hexane
Dust
Odor
Steam + Hexane Vapour
Steam
Heat loss
Cyclone
Cooling
Air
Heat loss
Hexane
Dust
Heat loss
Hexane
Cyclone
Steam + Hexane Vapour *
Dust
Noise
De-oiled-cake
(DOC)
Steam +
Hexane
Vapour
Dust
Noise
Screening
Packing
Crashing
Dust
Spillages
Damaged bags
Spillages
Dust
Noise
Electricity
Bags
DOC
Energy loss
Dust
Noise
Cause and Effect Diagram for Hexane Losses
Hexane
Losses
(2300
Litres/day)
Man
Method
Machine Material
E
n
v
i
r
o
n
m
e
n
t

Lack of Commitment
Carelessness
Lack of Training
Improper
Handling
Methods
Lack of
Awareness
No compliance to
Specifications
(Retention Time)
Inadequate Data Collection
Poor Process Control
No record Keeping
Defects in
Measuring
Hexane
Unskilled Labour
No proper operational
instructions
No periodic checks of raw
material
Lack of scheduled
maintenance
Wear and Tear
Absence of measuring
indicator equipment
Leaks
Steam Hot Air
Improper Seed Preparation
Poor cleaning
Cracking, Cooking, Flaking,
Faulty
Condenser
Poor raw
material
quality
Seed
Hexane
Lack of quality assurance
Interruptions in
steam supplies
Power
interruptions
Excessive or
inadequate use
of hexane
Inefficient separation of
micella and DOC
High wind
High ambient
temperature
Waste streams, relevant causes & GP
options
Waste
Stream
Major causes GP Options
1. Hexane Evacuation,
evaporation,
improper
handling
Going with by
products
1) New Technology
e.g. Super critical liquid extraction
2) Process control optimization
e.g. extraction time & thickness of flake
3) Improve House keeping practices in
hexane handling
4) (if Hexane content in dry air from dryer
is significant) send it for separation after
cyclone
5) Re use mineral oil till getting saturated
with hexane and then recover hexane by a
suitable method
Waste streams, relevant causes & GP
options
2. Dust &
foreign
matters
1. Contamination
of seeds with
foreign matters
(in suppliers
processes &
activities)
2. Poor handling
techniques in
side the plant
3. Open
production line
1) Quality control of incoming seeds (getting
dust free)
2) Supplier development and education
3) Good house keeping
4) Enclosing the product line including
transferring
Objectives & Targets
Target
description
Time frame Actions
Target 1 3 l/ton By August 2007
1. Improve the house keeping practices
2. Training and awareness for the
employees
3. Strict process control
Target 2 2 l/ton By August 2008
1. Improve the existing recovery system
Objective: Minimize the Hexane losses
Objectives & Targets
Objective: Introduce a substitute
Target 3 0 By August 2009 1) Changing into new technology
Super critical liquid extraction
Objectives & Targets
Objective: Minimize dust generation
Target description Time frame Actions
Target 1 Reduce up to 5 kg/day By August 2007 1) Supplier education and
development

2) Strict Quality control

3) Improving
housekeeping practices
Green Productivity Policy
prevent environmental pollution by reducing emissions and waste
water generation and comply with all legal & other requirements
increase productivity by optimizing resource consumption
encourage recovery and recycling of waste rather than disposing to
the environment
use GP and ISO 14001 EMS as tools to improve environmental
performances of the activities on continual basis.

M/s Rama Phosphates Limited (Oil Division)
Indore, Madhya Pradesh, Central India
Green Productivity Policy

We being an organization engage in processing of Soya bean oil
are committed to,

The policy is made available to general public.
We ensure that the policy is communicated to all employees and maintained at
all levels of the company.

Signed by
The Chairman
Thank You