report of ashapura volclay ltd

1

A STUDY ON PRODUCTION PROCESS OF

BLEACHING CLAY

AT

ASHAPURA VOLCLAY LTD.

Submitted by

NIRAJ PATEL

2010-12

To

Director (IISFT)

in partial fulfillment of the requirements of

Indian Institute of Shipping and Foreign Trade,

Gandhidham

for the award of degree of

CHARTED INTERNATIONAL BUSINESS

LOGISTICIAN

Indian Institute of Shipping and Foreign Trade

Gandhidham– 370201

OCTOBER 2011

3

DECLARATION

I hereby declare that the work done by me is original and true to the best of my

knowledge and belief. It has been approved by the management of Ashapura Volclay

Ltd. and does not contain any material objectionable to them. This project is a part of

our CIBL course at Indian Institute of Shipping and Foreign Trade, Gandhidham.

Niraj Patel

Date – 10th November,2011

Place – Gandhidham

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ACKNOWLEDGEMENT

I would like to express my gratitude to all those who gave me the possibility to

complete this report. I want to thank the Company Mr. D. S. Tripathi (Manager H.R.

and Admin), Ashapura Volclay Ltd. for giving me platform to commence this report

in the first instance.

I am bound to Mr. Ajay Katta (Senior H.R. Manager), Ashapura Volclay Ltd. and

deeply indebted for providing all necessary information and support for conducting

this project.

My heartfelt gratitude to respected Faculty Guides, Director, Mr.Anand Thacker

Ms.Aarti Sharma and Ms.Latika Bhojwani. Without their continuous help the project

would not have been materialized in the present form. Their valuable suggestions

helped me at every step.

Finally, I thank “Indian Institute of Shipping and Foreign Trade” for making this

experience of Summer Training in an esteemed organization like Ashapura Volclay

Ltd. possible.

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CONTENTS

Description Page no.

List of Figures 6

Abstract 7

1. Introduction

1.1 Project

1.2 Company Profile

8

9

10

2. Methodology 11

3. Analysis & Interpretation 13

4. Conclusion 28

5. Limitations Of The Study 30

Bibliography 32

6

LIST OF FIGURES

Sr. No Figure Title Page No

1 Acid Activation Plant 24

2 Neutralization Plant 25

3 Dryer & Mill 26

4 Packing 27

5 BTX Plant 28

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ABSTRACT

The objective of practical training at Post graduate level is to give a student an

experience of real issues involved in the business world. Practical knowledge helps

us to identify how theories can be applied in business life.

In this report, I have put in best of the information about “Ashapura Volclay Ltd.” on

a common platform, analyzed their production process, and highlighted the

company’s profile. Also I have put my understanding from the project given to me.

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Chapter 1

INTRODUCTION

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1.1 PROJECT

Primary Objective and Scope of Project

To understand Production Process of Bleaching Clay

The scope of this project contains details regarding the manufacturing process

of Bleaching Earth and Clay Catalyst, which is carried out under the

certification of ISO 9001:2008 Standard at Ashapura Volclay Ltd.

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1.2 COMPANY PROFILE2

Established in 1960, Ashapura Group is India’s largest multi-mineral solutions

provider.The flagship company Ashapura Minechem Ltd. is listed on India’s premier

exchanges.Ashapura Minechem Ltd. is a part of the BSE Midcap & BSE 500 indices.

The group has mining & mineral processing facilities in Gujarat, Maharashtra,

Karnataka, Kerala, Andhra Pradesh and Orissa. Today Ashapura Group has attained

global status withprojects in Belgium, Nigeria, Oman and Malaysia.

Ashapura Group is one of the significant global players in bauxite and is amongst the

world’s top five Bentonite companies. Ashapura also dominates the value added

segments in the country for Bleaching Clay, Geosynthetic Clay Liners, Clay

Catalysts, Calcined Bauxite, etc.

Ashapura has advanced from being a single mineral company to a specialist in

industrial minerals. Bentonite, the multi-tasking mineral, continues to be a core

product with diverse applications in industries that range from agriculture to

environment and foundry to edible oils and cosmetics to medicine New applications

for the industries presently being catered as well as for new industries are developed

every year through indigenous and global research. The company’s diversification

into bauxite was a major move and today Ashapura is among the key players in

Bauxite from India. Our strategy to expand our mineral portfolio is paying rich

dividends as we have added Kaolin, Attapulgite, Barites, Feldspar and many other

allied minerals to our product portfolio.

A new exciting area, with immense growth potential and limitless possibilities,

opened when the company decided to move into value added products. At present

our major value added products are Bleaching Clay, Clay Catalysts, Geosynthetic

Clay Liners (GCL), Calcined Bauxite and very soon it will be alumina.

All products come with a promise of ‘No compromise on quality’.

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Chapter 2

METHODOLOGY

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Collection of data

Primary Data

Data: Primary data includes information regarding Production Process of Bleaching

Clay.

Source: Primary data was collected with the help of telephonic interviews with Ajay

Katta, Senior H.R. Manager, Ashapura Volclay ltd.

Secondary Data

Data: Secondary data includes information regarding Company’s background and

details regarding Bleaching Earth.

Source: Secondary data was collected from Ashapura Volclay’s official website,

Ms.Trupti Goswami’s report uploaded on www.mbabbaprojects.com.

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Chapter 3

ANALYSIS AND INTERPRETATION

Bleaching Earth1

Bleaching Earth is manufactured from the best quality, selectively mined and

scientifically blended montmorillonite

making Bleaching Earth special care is taken in maintaining the important properties

like absorptive capacity, acid properties, catalytic properties, ion exchange capacity

and particle size distribution.

Bleaching Earth is manufactured by Dry process OR Wet process.

A Bleaching Earth is Activated adsorbent used for the general purpose of

Decolourisation of animal, vegetable mineral oils and waxes

Enhance stability of the Refined Oil.

Bleaching Earth is characterized by

High bleaching efficiency

Fast filtration rate

Low oil retention

Ability minimise the increase of free fatty acids

Removing impurities like soap & trace metals without affecting appearance,

flavour & nutritional properties of Oil

Important Points During Bleaching

Normally about 0.5%

vacuum during process which results in less oxidation & improvement in oil

colour.

Choice of Bleaching clay as per its characteristics.

The total acidity (titrable acidity) of clay is expressed as mg of KOH/g of

clay on a hot water extract.

The Moisture content of Earth is vital as activity of clay depends on the

evaporation of moisture from earth after its admixture with oil (15% max free

moisture is desirable)


scientifically blended montmorillonite clays under stringent process controls. While



and particle size distribution.

hing Earth is manufactured by Dry process OR Wet process.

A Bleaching Earth is Activated adsorbent used for the general purpose of-

Decolourisation of animal, vegetable mineral oils and waxes

Enhance stability of the Refined Oil.

cterized by:

High bleaching efficiency

Ability minimise the increase of free fatty acids


flavour & nutritional properties of Oil

t Points During Bleaching:

Normally about 0.5% - 3% of earth is required for bleaching application of


Choice of Bleaching clay as per its characteristics.

acidity (titrable acidity) of clay is expressed as mg of KOH/g of

clay on a hot water extract.



is desirable)

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clays under stringent process controls. While




3% of earth is required for bleaching application of


acidity (titrable acidity) of clay is expressed as mg of KOH/g of



The Particle size of Earth affects filtration & oils retention as per type of

earth used & determines losses during bleaching process.

Operations & maintenance of filters is very important during process.

Treatment with Acid Activated Ble

removes traces of Nickel from hydrogenated oils (0.25

Oil Loss During Bleaching

Spent Earth carries around 30% of oil on dry basis

press, the oil content can be brou

approx. 8% during the process.


earth used & determines losses during bleaching process.


Treatment with Acid Activated Bleaching Earth in post-bleaching step

removes traces of Nickel from hydrogenated oils (0.25-0.5% of earth used).

Oil Loss During Bleaching Process:

Spent Earth carries around 30% of oil on dry basis. By hot water washing of filter

can be brought down to 22% on the average. So loss of oil is

approx. 8% during the process.

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bleaching step

0.5% of earth used).

By hot water washing of filter

ght down to 22% on the average. So loss of oil is

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Bleaching Earth - Oils1

Cooking oil is purified fat of plant origin, which is usually liquid at room

temperature (saturated oils such as coconut and palm are more solid at room

temperature than other oils).

Some of the many different kinds of edible vegetable oils include: olive oil, palm oil,

soybean oil, canola oil, pumpkin seed oil, corn oil, sunflower oil, safflower oil,

peanut oil, grape seed oil, sesame oil, argan oil and rice bran oil. Many other kinds of

vegetable oils are also used for cooking.

The generic term "vegetable oil" when used to label a cooking oil product may refer

to a specific oil (such as rapeseed oil) or may refer to a blend of a variety of oils

often based on palm, corn, soybean or sunflower oils.

List of vegetable oils

The list of vegetable oils includes all vegetable oils that are extracted from plants.

There are three methods for removing the oil. The relevant part of the plant may be

placed under pressure to "extract" the oil, giving an expelled oil. Oils may also be

extracted from plants by dissolving parts of plants in water or another solvent. The

solution may be separated from the plant material and concentrated, giving an

extracted or leached oil. The mixture may also be separated by distilling the oil away

from the plant material. Oils extracted by this latter method are called essential oils.

Essential oils often have different properties and uses than pressed or leached

vegetable oils. Macerated oils are made by infusing parts of plants in a base oil a

process known as maceration. Although most plants contain some oil, only the oil

from certain major oil crops complemented by a few dozen minor oil crops is widely

used and traded. These oils are one of several types of plant oils.

Vegetable oils can be classified in several ways, for example

By source : Most, but not all vegetable oils are extracted from the fruits or

seeds of plants, and the oils may be classified by grouping oils from similar

plants, such as "nut oils".

By use : Oils from plants are used in cooking, for fuel, for cosmetics, for

medical purposes, and for other industrial purposes.

The Major vegetable oils are mentioned below

Coconut oil

Corn oil

Cottonseed oil

Olive oil

Palm oil

Peanut oil (Ground nut oil)

Rapeseed oil

Rice Bran oil

Safflower oil

Soybean oil

Sunflower oil

Mustard oil

Oils used for biofuel:

A number of oils are used for biofuel

Although diesel engines were invented, in part, with vegetable oil in mind, diesel

fuel is almost exclusively petroleum

more attractive. Vegetable oils are evaluated for

Suitability as a fuel, based on flash point, energy content, viscosity,

combustion products and other factors

Cost, based in part on yield, effort required to grow and harvest, and post

harvest processing cost

The Major oils used as biofuel are:

Castor oil

Mustard oil

Palm oil

Jatropha oil

ils from plants are used in cooking, for fuel, for cosmetics, for

medical purposes, and for other industrial purposes.

The Major vegetable oils are mentioned below:-

Peanut oil (Ground nut oil)

A number of oils are used for biofuel (biodiesel and Straight Vegetable Oil).


fuel is almost exclusively petroleum-based. Rising oil prices have made biodiesel

more attractive. Vegetable oils are evaluated for use as a biofuel based on


combustion products and other factors

Cost, based in part on yield, effort required to grow and harvest, and post

harvest processing cost

d as biofuel are:

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ils from plants are used in cooking, for fuel, for cosmetics, for

(biodiesel and Straight Vegetable Oil).


based. Rising oil prices have made biodiesel


Cost, based in part on yield, effort required to grow and harvest, and post-

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Bleaching Earth – Applications1

Broadly speaking Bleaching Earth finds use in following fields:

Refining of Vegetable oils

Refining of hydrogenated Vanaspati ghee oils, Margarine & shortening

Refining of Animal Fats like tallow oil, fish oil, lard oil

Refining of Mineral Oils like

o Insulating oil

o Rolling oil

o Lube oil

o Waste oil

o Industrial triglycerides and fatty acids used for paints, varnishes and

soaps

o Paraffins and Waxes

Decolourising by removing colour pigments like carotenoids, chlorophyll,

Pheophytine

Removal of gums (phospholipids), FFA and soap contents and traces of

heavy metals in vegetable oils

Reducing and Controlling different oil parameters like Peroxide value,

Anisidine value, UV-absorption value.FFA contents etc.

Purification of Aromatic Compounds in case of mineral oils & waxes and

removal of Sulphuric acid, Tars acid, Sludge, Sulfonic acid etc.

Other Applications like

o Bleaching of Sulphur

o In Effluent treatment plants

Bleaching Earth – Grades

In a short span of time, Ashapura's Bleaching Earth has made a huge impact in the

edible oil refining segment due to its high quality standards, global networks and

cost-effectiveness.

Galleon Grade: Bleaching Earth of highest bleachability and filterability for difficult

to-bleach oil fats and oils such as Castor, Palm, Linseed, Rapeseed, Fish, Soyabean,

Cottonseed, Rice Bran and Olive. It exhibits high performance in both Chemical and

Physical refining of edible oil.

Grades of Galleon Earth

Galleon Earth V2

Special

Physical Properties

Bulk density 0.6 gm/ml (± 0.1)

Moisture @ 110'c 15 max

pH ( 5 %

suspension)

3 - 4.5

Residual Acidity

(mgKOH/g)

2.5 (± 1)

Acidity (%H2SO4) 0.4 % max

Granulometry

Average Particle

Size

20 -

Less than 5 microns 10.5 % max

Less than 90

microns

90 % min

BET Surface Area 250 to 300 m

Grades1



Galleon Grade: Bleaching Earth of highest bleachability and filterability for difficult

bleach oil fats and oils such as Castor, Palm, Linseed, Rapeseed, Fish, Soyabean,


Physical refining of edible oil.

Galleon Earth V2

SpecialGalleon Earth V2

Galleon Earth V2

Super

0.6 gm/ml (± 0.1) 0.6 gm/ml (± 0.1) 0.6 gm/ml (± 0.1)

15 max 15 max 15 max

4.5 2.8 - 3.5 2.8 - 3.5

2.5 (± 1) 2.5 (± 1) 2.5 (± 1)

0.4 % max 0.4 % max 0.4 % max

30 20 - 30 20 - 30

10.5 % max 20 % max 10.5 % max

90 % min 90 % min 90 % min

250 to 300 m2/gm 300 to 325 m2/gm 300 to 325 m

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Galleon Grade: Bleaching Earth of highest bleachability and filterability for difficult-

bleach oil fats and oils such as Castor, Palm, Linseed, Rapeseed, Fish, Soyabean,


Galleon Earth V2

0.6 gm/ml (± 0.1)

2.5 (± 1)

0.4 % max

10.5 % max

90 % min

300 to 325 m2/gm

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Unmatched Advantages of Galleon Earth

Higher Bleaching Efficiency

Effective removal of chlorophyll, carotenes and other coloring pigments.

Lower Dosage

Higher active surface area results in improved bleaching capacity using less

quantity of clay.

Higher Absorbing Capacity

Effectively removes soap content, phosphatides, peroxides and metal traces

due to large pore diameter, pore volume and surface area.

Toxin Free

Contains no mineral acids that can damage the oil.

Dioxin & Heavy Metals Free

Confirms to the FEDIOL standards of the EU.

Captive Reserves

Consistent supply of quality raw material from captive reserves estimated at

34 Million MT.

Bleaching Earth – Specifications

All grades of Galleon Earth are severally controlled by the following two

specification to customers and in

Grades of Galleon Earth

Delivery Specification

Moisture (%)

Fineness (%)

Residual Acidity

(mgKOH/g)

Bleaching Performance

In-house Specification

Filterability 2)

(V2 Indian Standard =100)

Particle Size 3) <5 m m

(%)

Average Particle Size ( m

m)

1. V2 Indian standard is the pure sample which was manufactured from AVL’s raw

clay by

MIZUSAWA INDUSTRIAL CHEMICALS LTD.

2. Filtration rate of V2 Indian Standard to oil : A(min)

Filtration rate of the final product to oil : B (min)

Filterability= A X 100

B

3. Malven Mastersizer measurement condition:

a. Real refractive index of the particle

b. Imaginary refractive index of the particle

Specifications1

All grades of Galleon Earth are severally controlled by the following two

specification to customers and in-house specification.

V2 V2 Test Method

15 Max Test Method 2

80 Min. Test Method 3

2.5 Max Test Method 4

The same bleaching

Performance as that

of V2 Indian

Standard 1) or more

Test Method 5

Test Method 7

(V2 Indian Standard =100) 20 Max Test Method 6

20 ~ 30

V2 Indian standard is the pure sample which was manufactured from AVL’s raw

MIZUSAWA INDUSTRIAL CHEMICALS LTD.

Filtration rate of V2 Indian Standard to oil : A(min)

Filtration rate of the final product to oil : B (min)

100

Malven Mastersizer measurement condition:

refractive index of the particle - 1.5295

b. Imaginary refractive index of the particle - 0.1000

21

Test Method

V2 Indian standard is the pure sample which was manufactured from AVL’s raw

22

c. Real refractive index of Water - 1.3300

23

Production Process of Bleaching Earth

Figure: 3.1

Acid Activation Plant

Source: From Company’s Official Report

Step-1:

Figure: 3.1 shows the first step to make bleaching clay. When raw materials of

bleaching earth goes under process then raw materials convert into Granuals. After

completing process, its test result is checked. This process is goes under daily

process review sheet and internal customer feedback. Daily work is recorded for

quality control. This process is under as per quality plan. Its quality is International

Standard Organization(ISO) defined and mentions in daily records.

ProcessGranuals + Acid

Activation + Dilution

Bentonite, Acid, Water, Steam & Air

In Process Test Results,Daily Process Review Sheet,Internal Customer Feedback (Inter Office memo)

Batch Sheet to P&D Plant,Records as per ISO & HACCP

Activated Granuals as per quality plan

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Figure: 3.2

Neutralization Plant


Step-2:

Figure: 3.2 shows the second step to make bleaching clay. This is the process of

neutralization and filtration. When raw materials like lime, water and waste acid goes

under this process then the process gives gypsum and effluent. After completing

process, its test result is checked. This process is goes under daily process review

sheet and internal customer feedback. Daily work is recorded for quality control.

This process is under as per quality plan. Its quality is International Standard

Organization(ISO) defined and mentions in daily records.

ProcessNeutralization & Filtration

Process

Lime, Water, Waste Acid


Records as per ISO & HACCP

Gypsum, Effluent

25

Figure: 3.3

Dryer & Mill


Step-3:

Figure: 3.3 shows the third step to make bleaching clay. This is the process of drying

and milling. When raw materials like activated granuals and attapul goes under

process then it becomes V2 powder/Granuals. It is used for making bag/packing.

After completing process, its test result is checked. This process is goes under batch

sheet of A.A. process and daily process review sheet and internal customer feedback.

Daily work is recorded for quality control. This process is under as per quality plan.

Its quality is International Standard Organization(ISO) defined and mentions in daily

records.

ProcessDrying & Milling

Activated Granuals + Attapul

In Process Test Results, Batch Sheet of A.A. Process + Daily Process Review Sheet,Internal Customer Feedback (Inter Office memo)

Records as per ISO & HACCP

V2 Powder/Granualsas per Quality Plan

26

Figure: 3.4

Packing


Step-4:

Figure: 3.4 shows the fourth step to make bleaching clay. This is the process of

packing. After drying and milling process, V2 powder/dried granuals, paper bags,

jumbo bags goes under packing process and pack goods. It does packing of finished

goods. Daily work is recorded for quality control. This process is under as per quality

plan. Its quality is International Standard Organization(ISO) defined and mentions in

daily records.

ProcessPacking

V2 Powder/Dried Granuals, Paper Bags, Jumbo Bags.

In Process Test Results,Daily Process Review Sheet,Internal Customer Feedback (Inter Office memo), Sale Plan

Records as per ISO & HACCP, Transfer Note, Packing Report.

Packed Finished Goods as per Quality Plan

27

Figure: 3.5

BTX Plant


Step-5:

Figure: 3.5 shows the fifth step to make bleaching clay. This is the last process of

making finished product as per quality plan. Activated granuals comes under process

then under process, it passes from drying, crushing and packing activity. And then

BTX product made as per quality plan. Daily work is recorded for quality control.

This process is under as per quality plan. Its quality is International Standard

Organization(ISO) defined and mentions in daily records. All process is under

quality management system standard: ISO 9001 : 2008.

ProcessDrying, Crushing, Packing

Activated Granuals


Records as per ISO & HACCP, Transfer Note, Packing Report.

BTX Product as per Quality Plan

28

Chapter 4

CONCLUSION

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After gathering information related to my project, it became really easy for me to

understand production process of bleaching clay. I got to learn and observe that how

actually a production process works. It was very interesting to learn production

process of bleaching clay. Besides theoretical learning in the classroom lectures at

Indian Institute of Shipping and Foreign Trade, this practical training which served

as an exposure to the real corporate, added value to my knowledge.

30

Chapter 5

LIMITATIONS OF THE STUDY

31

The findings of the study are based on the information and data revealed by the

company. Efforts were made to make the study as accurate as possible, but 100%

accuracy could not be claimed because of the following reasons:-

Analysis of the production process is based on assumptions.

Due to multiple factors, company did not allow personal training and

personal visit in the company’s premises. Because of this limitation, proper

analysis of the company as an organization on the whole was not possible.

32

BIBLIOGRAPHY

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Websites:

1. Bleaching Earth, <http://www.avlgalleon.com>

2. Trupti Goswami, “A project report on Analysis and optimization of

Maintenance Management of Instrument at M/s. Ashapura Volclay Ltd.”,

<http://www.mbabbaprojects.com/Projects/Operation/MBA_operation_Repor

t_2011.pdf >

report of ashapura volclay ltd

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