INDIAN INSTITUTE of PACKAGING,

KOLKATA

PROJECT REPORT ON
EDIBLE OIL PACKAGING MACHINERY

PRESENTED by
NILANJANA DAS
PG/K/15/005
Acknowledgement:
The completion of project brings with a sense of satisfaction,
but it is never complete without thanking the persons
responsible for its successful completion.
I extend my deep sense of sincere gratitude to Mr Bidhan Das,
Director, IIP for providing me an opportunity to do my course.
I extend my special in-depth, heartfelt, sincere gratitude to my
respected teacher Mr. S. Basu, alumni IIP, Mr. R.T. Sukla,
Assiatant Director, IIP and Mr.Nataraj, Assiatant Director, IIP
for their constant support and valuable guidance for
completion of the project work.
Finally, I would like to thank all the faculty members of IIP,
for their support.
Nilanjana Das
PG/K/15/005
CONTENT:
1:Introduction
3:Vegetable oil chemical composition
5:Nutritional characteristics
7:How packaging might impact
indices of failure
9:Filling of edible oil
11:Bottle cleaning prior to filling.
13.Reference
2:Vegetable oil source and market
4:Sensory characteristics
6:Deteriorative reactions and
indices of failure for oil.
8:Different packaging material
10:Different parts of volumetric
filling machine
12:Conclusion
INTRODUCTION:
The word oil is derived from the Latin word oleum, originally used for
olive oil, but nowadays it means any of numerous combustible and
unctuous substances that are liquid at room temperature (this
distinguishes them from fats) and soluble in many organic solvents
but not in water. Vegetable oils are derived from plants and
chemically are composed of triglycerides and several other minor
components, which may be very important for different aspects.
Lipids in general, and edible vegetable oils in particular, are very
important in foods. They are, however, vulnerable to quality
deterioration and must be adequately protected by packaging
throughout their commercial life. Sources of edible vegetable oils are
many and varied, and their quality attributes such as nutritional
properties, health benefits, lipid composition, odour, and colour are
very important. A precise knowledge of these attributes and their
changes throughout the supply chain is required to guide shelf life
testing and estimation. Oils are generally stable microbiologically
due to very low moisture content. However, they are subject to
important chemical and physical changes.
WHAT IS EDIBLE OIL?

Edible Oils” means vegetable Oils and fats but does not
include any margarine, vanaspati, bakery shortening and fat
spread as specified in the Prevention of Food Adulteration Act,
1954 (37 of 1954) and rules made there under, for human
consumption. Vegetable oils are derived from plants and
chemically are composed of triglycerides and several other
minor components, which may be very important for different
aspects.
VEGETABLE OIL SOURCES AND MARKETS

Vegetable oils are derived from both annual (such as sunflower

and soybean) and perennial (such as palm and olive) plants,
and oil accumulates both in seeds (such as palm kernels and
cottonseeds) and in fruits (such as olive, avocado, palm, and
coconut).Vegetables oils are produced and commercialized
worldwide in very large quantities; global production of the
major oilseeds is estimated at over 400 million tonnes per
year. The two most widely produced edible oils are soybean
and palm, with about 30 million tonnes of each produced
annually worldwide; about 8–10 million tonnes of rapeseed
and sunflower seed oils are produced annually,and 2.5–5
million tonnes each of oils such as olive, peanut, or cottonseed.
VEGETABLE OIL CHEMICAL COMPOSITION

The main components of vegetable oils

(and of all edible lipids) are triglycerides,
that is, esters of glycerin and free fatty
acids, normally present as 98–99% of the
total mass. The first and greatest variability
in oil composition depends on which fatty acids
are linked and with which of the three possible hydroxyls of
glycerin.
 SIMPLIFIED COMPOSITIONS OF VARIOUS VEGETABLE OILS
Vegetable Oil Saturated Monounsaturated Polyunsaturated Vitamin E (mg/100g)
Fatty Acid(%) Fatty Acid(%) Fatty Acid(%)
Coconut oil 85.2 6.6 1.7 66
Cotton seed oil 25.5 21.3 48.1 42.77
Wheat germ oil 18.8 15.9 60.7 136.65
Soybean oil 14.5 23.2 56.5 16.29
Olive oil 14.0 69.7 11.2 5.10
Corn oil 12.7 24.7 57.8 17.24
Sunflower seed oil 11.9 20.2 63.0 49.0
DETERIORATIVE REACTIONS AND INDICES
OF FAILURE FOR VEGETABLE OILS

1:ENZYMIC REACTIONS:
Enzymes are involved in many different ways in deteriorative
reactions of vegetable oils, and the final products of their
activity may often be considered IoFs. The action of three
main classes of enzymes are lipases, lipoxygenases, and
polyphenol oxidases.
2:LOSS OF NATURAL ANTIOXIDANTS:
The presence and importance of natural antioxidants in
vegetable oils have been mentioned previously;the reactions
leading to loss of tocopherols and polyphenols are the main
causes of quality deterioration of oils.
3:OXIDATIVE RANCIDITY:
Oxidative stability is one of the most important indicators of the
quality of edible oils. Oxidative
rancidity is a complex of chemical changes that imply a series
of reactions between unsaturated fatty acids or acylglycerols
with Oxygen. The off flavour compounds released make oil less
acceptable or unacceptable to consumers or for industrial use
as a food ingredient.
HOW PACKAGING MIGHT IMPACT
INDICES OF FAILURE
Many different kinds of packaging are used for vegetable oils:
tinplate cans, glass bottles, PET, or HDPE plastic bottles, and
paper-based cartons are most common. The selection of the
kind of package to be used is generally done on the basis of
marketing and economic criteria; however, proper packaging
will in many cases provide conditions to assure adequate shelf
life for distribution and marketing.
1:OXYGEN PERMEABILITY AND LIGHT TRANSMISSION
As far as physicochemical characteristics of the materials are
concerned, the O2 permeability and the UV/visible light
transmission of the packaging walls are the major ones, due to
the oxidative sensitivity of vegetable oils. Oxygen permeability
is a property of plastic materials only, whereas light
transmission is important both for glass and plastics.Different
polymers may have very different permeabilities. Light
transparency is a less investigated property that depends
mainly on the chemical nature of materials, their crystallinity,
the presence of specific additives, color, and thickness. Many
additives are available today for both plastics and glass to
reduce UV transmission. It is also essential to take into
account the light-emitting spectrum.
2: PACKAGING INERTNESS:
Oil–package interactions can affect product shelf life, reducing
nutritional value and stability (by scalping) or increasing the
level of chemical contamination (by migration).Therefore, the
selection of packaging materials may also be done on the basis
of their interaction
with oils. Generally speaking, glass is the most inert material,
followed by metals and plastics.However, large differences
exist among the different materials, and consideration must
be given to closures and their liners (often made of plastics
even for metal and glass containers) when assessing the global
inertness of a package.
3:FILLING AND CLOSING TECHNOLOGIES:
The filling and capping steps are very relevant in the process of
oil packaging, affecting the quality perceived by consumers. In
order to reduce the O2 residual inside the bottles, the oil is
generally
stripped with gaseous N2, to lower the initial level of residual O2
. Gaseous N2 can be pressurized by injecting liquid N2 into
the headspace prior to closing . In order to reduce O2 ingress
during shelf life, the effectiveness of the closures is also very
important. The efficiency of closures is related to several
factors: material used, design, and liner adopted. All these
factors must guarantee, at the same time, hermeticity, easy
opening, and the possibility of reclosing.
DIFFERENT PACKAGING MATERIALS FOR EDIBLE
OIL
1:TINPLATE CONTAINER:
Tinplate containers have been used for a long time for oil
packaging and are still well appreciated because of their many
advantages . They provide total protection against light, O2,
water vapor, and microorganisms, and are resistant to several
types of mechanical abuses. In addition, the inside of the
container is protected with food-approved special enamels
(lacquers) that protect the metal from the corrosiveness of the
product. Edible oils are generally packed in tinplate
containers of different capacities, typically from 5Lit to 15 Lit.
2:GLASS BOTTLES:
Glass containers are widely used for bottling edible oil. This is
due not only to marketing requirements but also because glass
containers prevent the permeation of O2 molecules into the
bottle, slowing down the autoxidation rate of PUFAs.
Transparent glass, however, leads to photo-oxidation of olive
oil and reduction of its shelf life. Metal and glass are the only
packaging materials that provide a virtually total barrier to
moisture and gases. The word “virtually” is used because
such containers require a closure that incorporates other
materials such as polymeric sealing compounds in cans and
in closures, through which O2 can easily permeate and
promote oxidation.
3:PLASTIC BOTTLES AND CONTAINERS
Plastic containers are a relatively new means of edible oil
packaging due to their comparatively low price and low
weight. The polymers most frequently used are PET, HDPE,
and PVC. Although they do not provide as long a shelf life as
metal containers, they are economical compared to tinplate
and therefore suitable for use where a very long shelf life is
not required. PET is one of the most used plastics in food
packaging covering a wide range of packaging structures.
PET satisfies many important requirements: good aesthetic
aspect (brilliance and transparency);suitability for colouring;
good mechanical, thermal, and chemical resistance; low
production cost; good barrier properties against CO2;
suitability for prolonged storage, easy recyclability, and low
weight with respect to glass bottles.
4:MULTILAYER POUCHES AND PAPER-BASED
CARTONS:

In recent years, the adoption of multilayer pouches for oil

storage has increased due to consumer preference for unit
packages. Generally, limited quantities of edible oil are packed
in flexible pouches . Flexible pouches may be manufactured
from laminates or multilayered films of different compositions
and the pouches may be in the form of a pillow or stand-up
pouch. The selection of a laminate or multilayer film is
governed primarily by the compatibility of the contact layer,
heat sealability, heat seal strength, and shelf life required,
together with machinability and physical strength
parameters. The groundnut oil kept better in multilayer film
pouches consisting of nylon and PET films than in non-nylon-
based film pouches under both conditions.
The quality deterioration was comparatively less in films
containing polyamide (PA) as one of the layers, and leakage
rates were minimal in films containing ethylene-acrylic acid
copolymer (EAA) as the sealant layer. Recently, new
packaging formats have been introduced in the market
including bag-in-box systems, lined cartons, and paperboard
laminate cartons.
FILLING OF EDIBLE OIL
 Filling of edible oil can be done by Volumetric filling in case of
rigid containers:
Volumetric filling means filling by volume of product versus
weight or level with repeatable accuracy.
Working Principle: This is usually accomplished by +ve
displacement piston action. It can also be accomplished by the
pumping of a liquid at a constant pressure through an orifice
of constant size for a predetermined period of time. The
volume can be varied by increasing or decreasing the pressure
& by varying the time between opening and closing the filling
nozzle. Each filling station is equipped with a measuring
piston & cylinder. The fill amount is measured by the stroke of
the piston, which on all machine can be varied to a limited
degree.
A: Piston Volumetric Fillers.

Currently, many different kinds of volumetric fillers are available. For

volumetric filling, piston fillers are most widely used. There are three
subclasses of piston fillers, depending on the orientation of the pistons,
specifically vertical or horizontal, and inlet arrangement.
FILL METHOD:
Piston filling units aspirate a predetermine amount of product to
be filled. When bottles are in place, the pistons accurately
dispense the product into containers .
VERSATILITY :
Microprocessor allows for change of product, fill volume or fill rate
in minutes. Finger-tip controls adjust a fill volume range of as
much as 10 to 1 (or greater) with a single knob control. Infinitely
adjust your fill rate with simple calibrated dials. Fill flowable
liquids and semi-liquids on one machine. Calibrated volume
controls ensure repeatable and fast changeovers.
1 EXPANDABLE FILLING SYSTEM :
Modular design is easily expandable from two (2) to twenty-four
(24) filling units and nozzles which can easily be added to increase
your production line capacity as required. One volumetric filler
model can handle a full filling volume range from several
milliliters to gallons.
2 ELECTRONIC MICROPROCESSOR (Standard):
The programmed controller sequences all machine functions for trouble-free
filling cycles and eliminates the need for timers, timing set-ups and lengthy
changeovers.
3 FILLING UNITS:
Fillers feature.Type 316 stainless steel self-priming, positive
displacement, volumetric piston metering pumps at the heart of its
filling system. A 35cc pump is offered for microfills and an 1100cc
piston pump for fills of 1 gallon or more. All piston pumps are
highly accurate and can be easily and rapidly disassembled,
minimizing downtime, or they can be cleaned in place (CIP). Pumps are
interchangeable, eliminating the need for multiple filler models. Units
are capable of filling water-thin to highly viscous products.
Teflon and other special compound piston seals eliminate
metal to metal contact.
4 AUTOMATIC GATING AN INDEXING SYSTEM:
Stainless steel cylinders automatically locate empty containers under the
filling nozzles. After filling, the containers are released and the cycle is
repeated. Unique patented system counts bottles in and out for trouble-
free operation. This system is ideal for a wide variety of bottle shapes and
sizes since the stainless steel cylinders are mounted on fully adjustable
stainless steel support brackets, permitting rapid adjustment.
5 MASTER VOLUME CONTROL :
One control knob accurately sets the desired fill volume on all the
filling units simultaneously. Changeover time is greatly reduced and
repeatability is assured by utilizing the calibrated controls provided
on the filler.

6 FINE TUNING ADJUSTMENT :

In addition to the master volume control feature, each filling unit
can be individually fine-tuned to adjust the volume dispensed by
each nozzle with calibrated settings.
7 FILLING NOZZLE:
Rotary valve type. The product is drawn into the cylinder from the liquid-
supply tank when the piston moves upward. The valve then rotates to permit
the premeasured volume in the cylindrical chamber to flow into the
container. Usually, either a direct mechanical drive from a cam track or an
air cylinder is used to stroke the piston. If an air cylinder is used to drive the
piston, controls are usually such that the piston does not cycle if a container
is not in place. This eliminates moving the liquid back and forth between the
measuring chamber and the supply tank .The nozzles are designed to
provide the operator with a drip free, foam free and string free fill.
Fabricated of Type 316 stainless steel.

8 NOZZLE RACK (Standard):

The stainless steel nozzle rack is long enough to allow complete
adjustability of nozzle quantity, types and positions. The nozzle
rack conforms to a wide range of bottle shapes, sizes and heights
with the use of a simple built-in gauge. Travel distance of the nozzle
rack can be easily adjusted from 0 to over 9 inches, allowing
for the exact range of bottom-up
fill desired.
9 ELECTRICAL :
For easy cleaning, electrical enclosures and components are used to allow for
wash down of equipment. Fillers feature a main control panel with all controls
within easy reach. Hazardous location controls available upon request.

10 INDEPENDENT SPEED CONTROLS:

The aspirating and discharge rates are hydraulically controlled and can be
independently adjusted with calibrated settings allowing for full operator
control when filling products of varying viscosities and properties.

11 ADJUSTABLE SUCK BACK:

Excess liquid at nozzle opening is sucked back into the nozzle providing
a clean, sharp cut-off at the completion of the fill cycle, thereby
preventing dripping or stringing of most products. This
unique system allows for the degree of suck back to be adjusted without
the need for vacuum.
12 ANTI-BACKUP BOTTLE DETECTOR (Optional):
If filled containers backup into the nozzle filling area, the filler will
automatically pause and wait for the jam downstream to clear and then
automatically resume the filling cycle.

13 CONSTRUCTION :
One piece welded stainless steel frame on swivel casters for portability.
Unique design allows user the option of placing filler over an existing
conveyor or its own optional stainless steel variable speed conveyor.

14 BOTTOM-UP FILLING SYSTEM HYDRAULICALLY

REGULATED :
When nozzles are automatically lowered into the containers
initiating the fill cycle, the rate that nozzles rise can be precisely
controlled and operator-adjusted to obtain optimum performance
for the product being filled. This minimizes foaming, splashing
and eliminates air pockets for viscous materials.After filling is
complete, the nozzle rack rises rapidly to allow for faster cycling.
A non-diving nozzle mode and a fixed preset filling position mode
are standard.
15 HOLDING TANK (Optional):
Portable on casters, and fabricated of stainless steel, this unique design
eliminates product waste and is available in several sizes including a
standard 30 gallon capacity. Easy to clean and available with options such as
covers, level sensors, automatic valves,pumps etc.

16 SHUTTLE VALVE FILLING UNITS/PISTONS:

The shuttle valve pistons are designed to handle highly viscous products
and products with particulates. The units clamp together with sanitary
seals for ease of cleaning and for sensitive products.

17 DUAL DISCHARGE SPEED CONTROL (Optional):

Allows operator to have one or two discharge fill rates during same fill
cycle. Permits faster fills for tapered and long neck containers.
18 NO BOTTLE — NO FILL:
Sensor allows filler to wait until there are bottles under all of the nozzles
before initiating the fill cycle. Bottles are counted in and out to minimize fill
cycle time, and maximize performance.

19 MULTI-STROKE COUNTER(Optional):
Electronic digital switch allows operator to program the number of times
the piston pumps will be actuated, thereby dispensing a larger volume of
product than would normally be possible with any given pump size.
Typical applications are filling 16oz. containers with 5oz. pumps or filling
1/2 gallon containers with 36oz pumps.
20 BOTTLE COUNTER:
Digital counter automatically keeps track of the number of bottles filled.
Can be reset between runs assisting operator in determining production
count.
21 FINGER-TIP NOZZLE POSITIONING:
No tools needed for mounting or positioning of nozzles.
22 CLEANING AND PRIMING SWITCH :
Pistons (filling units) and nozzles can be cycled for rapid
cleaning and product priming.
23 BOTTLE CENTERING GUIDES (Optional):
Available with a fully adjustable horizontal comb-type bottle
centering neck locator for applications requiring exact location nozzle
entry.
Bottle Cleaning Prior To Filling:
This process automatically remove
dust, dirt, carton lint and other
foreign matter. These systems use a
combination of high pressure,
ionized air and highly efficient
vacuuming. The ionizing
neutralizes static electricity
freeing dust and dirt for effective
cleaning. In addition the Model
AC-I inverts the containers over an
effective cleaning area of up A combination of high pressure, ionized
to 30 inches. This are available as air and highly efficient vacuuming
stand-alone units or can be automatically removes dust, dirt,
integrated into a complete bottling carton lint and other foreign matter.
line.
Sealing or capping machine:
The feed container moving on conveyor belt are feed into an in-feed star
wheel through In-feed worm, star wheel bringing the container below the
sealing head in the subsequent indexing part, mean while the bottle
pickup a cap from the delivery chute of cap filling bowl, where the body
and the neck of the container are positioned below the rotating head,
where the sealing head is performing perfect operation of threading &
sealing .
Phase 1:
The blank seal is in position on the bottle,
ready for sealing.
Phase 2:
The pressure block has descended and pressed the top
of the closure into contact with the top of the bottle. The
thread rollers form the thread on the body of the seal and
skirt rollers tuck the pilfer proof band under the glass
locking ring.
Effective sealing depends on :
Correct Head pressure , Correct Pressure Block
Spinning Roller Pressure, Pilfer proof band should be well-tucked
Correct length & depth of the thread ,Rollers lubrication
Correct height of the turret
Costing of Machine and Material cost for filling of Edible
Oil(filling of rigid PVC bottle of 1 Lit oil with pilfer-proof cap):
Machine specification:
Machine Name:- Automatic 6 Head Volumetric Liquid Filling Machine
Production Speed Per Hour :-2400 to 4800 Products per Hour
Number of Filling Heads:- 6 Heads
Working Direction:- Left to Right
Filling System :-Volumetric Syringe Based (Suction from Bottom
Tank)
Suitable for :-Products Free Flowing Liquids
Packing Material :-PVC / PET Bottles
Application :-Filling Liquids in to the Bottles /Containers
Volume Capacity:-(Range of Syringe)1000 ml to 2500 ml
Volume Adjustment:- With the Help of Volume Adjustment Block
Suck Back System :-NRV Based / Drip Free Nozzles
Filling Volume Accuracy :- +/- 1 %
Rejection Ratio During Production:- 1%
Working Height :-850 +/- 100 mm
Machine Weight Approx :-400 Kgs
Machine Dimension Approx: - 8 (L) x 3 (W) x 5 (H) – in Feet
Cost of Machinery and related equipment:
Cost of volumetric machine:
Approx machine cost:- = Rs-15,00,000.
Installation cost:- 5%of machine cost =Rs- 75,000.
Machine transportation cost:-0.5%of machine cost =Rs- 75,00.
Cost of semi-automatic hopper and turner capping machine:
Approx machine cost:- Rs-5,00,000.
Cost of labelling(shrink) machine:
Approx machine cost:- Rs-7,00,000.
Hence,total cost of machinery and equipment =Rs-27,82,500.
Cost of Material and related equipment(for batch size of 10,000.)
Cost of each PVC bottle:- Rs-1.00.
Cost of each pilfer-proof cap:- Rs-0.25.
Cost of aqua/UV varnished paper label:- Rs-0.35.
Total cost of primary pack for each bottle:-Rs-1.60.
Total cost of primary pack for 100,00bottle:- =Rs-16,000
CONCLUSION:
We have looked at the machines and packaging materials which go together to
form a system .Either of the components of this system cannot possibly works
unless each component is of the highest quality and suitable for the application for
which it has been selected . manufacturers are , therefore offering the system
concept in totality so that the manufacturer is able to get the maximum
utilization and cost benefit from the system that he chooses . for the consumer
the cost factor is becoming exceedingly important and , it is essential that the
consumer not only gets value for money but also receives the product in a
condition whereby it becomes immediately consumable . Towards this ends the
system concept has becomes more technologically relevant than before .

REFERENCE
WIKIPEDIA
PACKAGING TECHNOLOGY (VOL.3)
Soroka, W, "Fundamentals of Packaging
Technology",
Yam, K. L., "Encyclopedia of Packaging
Technology", John Wiley & Sons