Sunflower oil production is a profitable, waste-free production. Main characteristics and purpose of equipment for the production of sunflower oil

In the total volume of the world sunflower oil market, which is about 10 million tons, Russian production occupies 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 the food industry. This product is used in the cosmetic, medical and paint industries. Another positive side of 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.

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, gas burners are used. Only in the first case is water 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 sunflowers on their own. 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 is, 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 operation of production facilities you will need to purchase:
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. It is best to register as an individual entrepreneur when opening a mini-production (application and state duty, registration and photocopy of passport - 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 the 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.

The sunflower oil production business is a profitable and reliable investment.

There is a constant and steady growth in production in this area, with sunflower oil accounting for more than half of the total volume of vegetable oil produced. This is explained by the stable demand for sunflower oil, which can be classified as an essential product. It is widely used in cooking for frying, salad dressing, and canning. In addition, vegetable oil is widely used in other industries: paint and varnish, soap making, in the manufacture of cosmetics and medications.

The production of vegetable oil, in particular sunflower oil, is waste-free. The fact is that by-products during the manufacturing process are sunflower husks, cake and meal, which are sold for further use in related enterprises. For example, husks are used in the production of pellets, and cake is a popular animal feed that is pre-pressed into briquettes and supplied to consumers in this form.

It is worth noting that in the production of vegetable oil, about half of the production volume falls on the share of small and medium-sized producers. This is due to the relatively low costs of opening this business and its quick payback. It all depends on the expected production volume, which directly depends on the amount of processed raw materials. A plan that defines the main points of production and a step-by-step strategy will help you organize and run your business competently. It includes the following factors: volumes of products, location of the enterprise, suppliers of raw materials, intended markets, as well as a description of manufacturing technology, degree of mechanization of the process, recommendations for personnel selection and premises requirements. A business plan allows you to correctly distribute initial investments and organize profitable production.

Description of sunflower oil production technology

Sunflower oil is produced in two types: refined and unrefined. They differ in the degree of purification from impurities. For unrefined oil, only mechanical filtration is provided and, due to its properties, it is a more valuable and useful product. Refined oil requires additional purification, which includes methods such as sedimentation, centrifugation, filtration, sulfate and alkaline refining, bleaching, hydration, as well as deodorization and freezing. After this treatment, the oil becomes transparent and loses its odor.

The entire sunflower oil production technology consists of the following stages:

1. Cleaning sunflower seeds from debris by separation in special devices.
2. Hulling and cleaning of kernels from husks in crusher-winter machines.
3. Passing (grinding) sunflower seed kernels through a roller machine and obtaining mint.
4. The mint goes into roasters, which come in two types - steam and fire - and differ in performance and cost.
5. The processed mint goes to the screw presses. The resulting press oil (cold pressed oil) is sent for settling and mechanical filtration.
6. The pulp remaining after pressing (with a residual oil content of about 20%) or cake (the remaining oil content is up to 10%) is sent for extraction into a special machine. Using solvents, residual oil is distilled off in the extractor.
7. The finished product is packaged in various containers, most often plastic bottles of various sizes. This process is carried out on complex lines for bottling vegetable oil.

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Equipment and capital investments

The most expensive item that contains a business plan for organizing the production of sunflower oil is the purchase of industrial equipment that corresponds to the chosen technology. On average, the cost of purchasing oil production and packaging lines is about 2.5 million rubles with a productivity of 1000 l/day. In this case, the cost of individual machines and machines is as follows:

• separator - 45-50 thousand rubles;
• crusher-fan machine - 70-80 thousand rubles;
• a rolling machine, depending on the power, costs from 400 thousand rubles;
• fire roasters - 80 thousand, but with a productivity of 300 kg of mint per cycle, you will need to purchase at least 2-3 pieces. Steam roasters have a capacity of 800 kg per hour, their cost is 300-350 thousand rubles;
• screw press - with a productivity of 15-25 tons per day, the price ranges from 600 to 900 thousand rubles;
• a mechanical filter costs about 100 thousand rubles, and you will need 2-3 of them;
• bottling equipment will cost about 500 thousand rubles with a capacity of 3600 liters per shift.

In addition, the business plan includes the costs of delivery and installation of equipment, which range from 15% to 20% of its cost - on average about 1 million rubles. Capital expenses also include costs for working capital, including the purchase of raw materials, which amount to 1.5 million rubles. Thus, the total capital costs are 5-6 million.

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Requirements for premises and personnel

The business plan for oil production provides for the presence of premises that meet all the requirements of the sanitary-epidemiological service and fire supervision. The workshop must be equipped with 380 W electrical wiring and also have a connection to the water supply system. The sizes of the areas are distributed as follows:

• main production workshop - 30-40 sq. m.;
• warehouses for storing raw materials - from 50 sq. m.;
• warehouses for storing cake - at least 45 sq. m.;
• storage room for finished products - 40-50 sq. m.;
• administrative and utility premises for staff - 15-20 sq. m.

In addition, convenient access to the building must be provided for the delivery of raw materials and loading of finished products. The costs of renting premises and current expenses for its maintenance are provided for in a separate paragraph of the enterprise’s business plan. This roughly amounts to about 100 thousand rubles for rent and 50-70 thousand for other expenses, including utility bills and routine repairs.

To service an enterprise with similar productivity, 8-10 people will be needed. They must have a health certificate, since the work involves the production of food products. It is advisable to organize work in several shifts so that production is uninterrupted and round the clock, which will ensure higher profitability of the enterprise. The business plan provides for a separate expense item for staff salaries, which amounts to about 100-120 thousand. And approximately the same amount will be spent on paying taxes, advertising costs and other approvals. Typically, medium and small enterprises producing vegetable oil operate under Form 3 personal income tax as individual entrepreneurs.

We should not forget that this production requires mandatory certification, which the business plan must take into account.

Choosing the right equipment necessary for the production of sunflower oil is not an easy task. Especially for a person far from the technology of processing agricultural products and oilseed crops, in particular. A mistake made at this fundamental stage of production can call into question the success of the entire enterprise, which can be very profitable if organized correctly.

Benefits of vegetable oil production

More than 40% of the total production of sunflower oil in the Russian Federation falls on medium and small businesses. The cost of entering the market is relatively low, which allows even successful farms to organize the manufacturing process. Despite high competition, the demand for vegetable oil is quite high, and the situation is developing towards increasing market demand for these products.

Even if there is no possibility of sales on the domestic market, it can always be sold abroad (Europe, Turkey), where there are no difficulties with sales. The options for using vegetable oil are quite varied and are not limited only to cooking. It is used in industries such as:

• paint and varnish industry (solvents, oil paints);
• production of cosmetics and medicine (creams, ointments);
• soap making;
• canning industry.

Another positive quality is waste-free production. Sunflower seed husks, obtained by hulling (cleaning), are used for the manufacture of building materials and as raw materials for heating briquettes and. After processing, cake and meal can be used as a valuable feed additive in livestock farming.

In addition, the costs of processing all waste (loading, transportation, storage) in the financial statements are included in the cost of the final product, that is, they are carried out as an expense part, and not as a profitable one. This allows for some tax optimization.

To obtain vegetable oil, peeled and ground sunflower seeds, the so-called mint, are used. The most inexpensive and at the same time environmentally friendly way to extract oil is pressing. A more modern, technologically advanced and cost-effective method is extraction.

Production methods:

• hot pressing;
• cold pressing;
• extraction.

The prepared mass of sunflower seeds is heated to the required temperature, then squeezed with a special oil press.

Cold pressing. The difference from the first method is the absence of the stage of heating the raw material mass. The result is an oil that retains the greatest amount of substances beneficial to humans.

However, this method allows you to obtain no more than 70% of the finished product by weight of the seeds. In addition, cold-pressed vegetable oil cannot be stored for a long time without additional processing. It quickly turns bitter, becomes cloudy, sediment appears in it, and when frying, this oil foams and smokes.

The method involves processing the pulp on oil extraction lines. During the processing process, special substances are introduced into the raw materials - extractors (extraction gasoline, acetone, hexane and some others), they come into contact with oil particles and are easily separated from the total mass, after which the extractors are evaporated and a pure product remains. The method is attractive because it allows you to extract up to 97% of the oil.

The quantity and quality of oil depends directly on the raw materials received for processing. The seeds must be ripe, fairly dry (humidity no more than 6%), and have a high oil content. The production of sunflower oil involves a number of production stages.

Preparation for pressing

Before starting any work with sunflower seeds, they must be cleaned of contaminants. The amount of foreign content should not exceed 1%. Separators are used to separate seeds from impurities. The process involves sifting the raw materials through several sieves:

• Magnetic traps are used to remove metal foreign objects;
• after separating the seeds from contaminants, they must be dried;
• Most often, drying is carried out in three stages. In the first two stages, the raw material is dried to the required humidity, and in the third stage it is cooled.

The dry seed is fed to a crushing machine, where it undergoes initial hulling (hulling). This process is carried out using disc mills, and the output is an incompletely purified seed. Final cleaning is carried out on aspiration winnowers.

The seeds are subjected to blowing with a powerful air stream, as a result of which the remaining husks and other foreign impurities are removed. The peeled seeds are sent for grinding (rolling). As a result of grinding the seeds on a five-roller machine, a homogeneous mass, mint, is obtained. When producing sunflower oil by hot pressing, before pressing, the mint is heated to the required temperature in special roasting pans.

Pressing and extraction

The heated (or in the case of cold pressing, unheated) mass, also called pulp, is sent to a screw press for extraction. The pressed vegetable oil is cooled and filtered to remove mechanical impurities. After pressing, “raw” oil and cake are obtained. The cake after hot pressing contains 10–15% oil, after cold pressing up to 30%. It can be used as a valuable raw material or further processed:

• The cake is first crushed using crushing equipment, then using a roller machine;
• after that, special substances are added to it - extractors (gasoline, hexane, acetone, dichloroethane);
• then the resulting mass is squeezed out;
• dry residue from the second pressing – meal contains 2–5% oil and can be used as a feed additive for animals;
• From the squeezed mixture – micelles, the oil is extracted by evaporating the extraction additives.

After all the above-described manipulations, unrefined vegetable oil is obtained, ready for sale as a food product. It is also the basis for the production of all known varieties of vegetable oil, obtained by additional purification of the unrefined product. These are methods such as:

• settling;
• filtration;
• centrifuge cleaning;
• alkaline refining;
• freezing;
• whitening;
• hydration;
• sulfuric acid refining;
• deodorization.

Bottling and packaging

The finished product is poured into containers and, if necessary, packaged. 200–250 liter barrels or 0.5–6 liter plastic bottles are used as containers. Products in bottles are in greater demand than in barrels, unless, of course, the company is engaged in the production of technical grades of oil.

What equipment will be required for production

To set up the production of vegetable oil, you need the following equipment:

• Scales. In order to correctly load each of the processing units, it is necessary to comply with the dosage.
• Separators and magnetic traps. They are used to clean seeds from foreign impurities and metal objects.
• Distribution bins. After cleaning in the separator, the seeds are loaded into bunkers for subsequent delivery to drying units.
• Dryer. In this equipment, the moisture content of the peeled seeds is reduced and then cooled.
• Disc mill. For initial peeling (crushing).
• Aspiration fan. Final cleaning.
• Rolling unit for grinding sunflower seeds.
• Brazier. Hot pressing involves heating the ground seeds. There are two types of roasters: fire and steam.
• Fryer for heat treatment. Does not expose mint to high temperatures. It is used for cold pressing of mint.
• Screw oil press. Extracts the prepared mass of sunflower seeds.
• Oil extraction line. A set of equipment for obtaining vegetable oil by extraction.
• Filter for removing mechanical impurities. After passing through this filter, raw unrefined oil is obtained.
• Refining line (additional purification).

Approximate prices for equipment

For production you will need the following set:

• The cost of a separator that can process approximately 1 ton of raw materials per hour is $1,400.
• A fanning machine will cost $3,000. Capacity is the same as the separator (ton per hour).
• Roller machine. Equipment capable of accepting products processed by a separator and a crusher-fan machine, $14,000.
• Fire brazier. To provide a line with the processing of 1 ton of raw materials per hour, 3 fryers costing $3,000 each are required.
• Steam fryer. $12,000. Productivity is 0.8 tons of raw materials per hour, which corresponds to a line with an initial mass of raw materials of 1 ton.
• Fryer for producing cold-pressed vegetable oil (capacity 1 ton per hour) – $14,000.
• A press for squeezing raw materials capable of processing the above-described volumes. Capacity: 20 tons of oil per day. The price is about $24,000.
• The primary filter costs $3000.
• Equipment for refining – more than $15,000.
• Extraction equipment – ​​$17,000 (productivity 0.5 tons of oil per hour).
• Line for bottling plastic bottles – $13,000 (capacity 10,000 liters per day).

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 a competent marketing and pricing policy, the production of sunflower oil in Russia is a 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. At 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 plant for the production of sunflower oil, you need to familiarize yourself with the following regulatory documents governing 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 of 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 an additional source of 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;
• processing vegetable oil with hot water eliminates phosphatides;
• the removal of fatty acids makes it possible to obtain refined, non-deodorized sunflower oil;
• deodorization allows you to remove pigments, volatile compounds, odor and makes the 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, it is necessary to establish the area of ​​​​the premises for the placement of production equipment, storage of raw materials and a warehouse for finished products.

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 ensure uninterrupted operation of the enterprise, only 25 workers are needed, the total wage fund of which will be 417,000 rubles per month.

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 churner with a capacity of 10 - 17 l/hour can vary in the price range: $200-400, an oil purification filter costs about $100-200, the cost of purchasing additional tools and products will be 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 has a higher productivity, 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.

It is known that the global volume of the sunflower oil market today is about 10 million tons, and its stable and fairly rapid growth is observed.

The volume of the Russian market is about 2-2.2 million tons, with an increase of about 3% per year, or in value terms - about 82 billion rubles. It is not difficult to guess that not the entire volume of sunflower oil is produced by corporations and other large producers: about 40-45% of the oil is produced by medium-sized and even small producers, including farms.

This can be explained simply: the cost of entering the market is low, the volume of production depends only on how much raw material the newly opened enterprise can afford to process, and the sales market is practically unlimited: even if there are no regional buyers for the volume of oil produced, then it is simply sent abroad border (mainly to Turkey and Europe), where they buy it very willingly. Although such cases are the exception rather than the rule: sunflower oil, in addition to cooking itself, is used in many other sectors of the economy - for example, in canning production, soap making, the paint and varnish industry (as you know, drying oil is made from it) and even in cosmetics and medical industry, where it acts as the basis or component of various creams and ointments. So it’s not difficult to find a buyer for sunflower oil.

In addition, the production of sunflower oil is waste-free. The fact is that in the process of obtaining it from sunflower seeds, accompanying materials are also formed - sunflower husks (husks, seed shells), separated during the hulling process in preparing them for oil extraction, is classified as returnable waste - it is sold to brick factories and production enterprises pellets, as well as some other specific needs; By-products include cake and meal - very liquid feed products that require some processing (pressing into briquettes, etc.) before sale.

Of course, related materials are sold without reducing the cost of the oil itself; Moreover, in accounting, sales costs, transportation costs for the shipment of by-products and production waste are directly attributed to the cost of sunflower oil sold, which helps to optimize the tax base of the enterprise.

Technology and equipment for the production of sunflower oil

As you know, sunflower oil is divided into two global groups - refined and unrefined oils. Their difference is in the degree of purification. Refined oil is refined technologically, usually by sedimentation, centrifugation, filtration, sulfuric acid and alkaline refining, hydration, bleaching, deodorization and freezing in any combination of these methods. Unrefined oil is purified exclusively by mechanical filtration.

The specificity of modern sunflower oil production is such that the same oil extraction plant can produce almost any of the 7 existing (i.e. listed in the relevant standard - GOST R 52465-2005) types.

In general, the technology for producing sunflower oil is as follows. At the first stage, sunflower seeds are separated from impurities that differ in size and aerodynamic properties, as well as metallic impurities with magnetic properties.

This happens in special separators, the cost of which is 42-45 thousand rubles. ($1360-1460) per unit - the productivity of one separator is about 1 ton (1000 kg) of raw materials per hour. At the second stage of cleaning, sunflower seeds are separated from the husks in special crusher-fan machines.

The process is called destruction, and the equipment for its production will cost 77 thousand rubles. (about $3,000) per unit - one machine, like a separator, processes 1,000 kg of raw materials per hour, so the number of crusher-fan machines and separators is the same, and their total power must correspond to the power of the oil extraction line as a whole: usually one line is served by several at the same time combinations of “separator – crusher-fan machine”, fed from a single bunker (it is called the “damping bunker”) using several transport lines (the so-called “screw conveyor”) lines.

After processing in a separator and in a crusher-fan machine, the cleaned sunflower seeds are fed to a roller machine designed for grinding seed kernels. Actually, the power of the roller machine is the input (i.e., for raw materials) power of the line as a whole.

The cost of such machines varies greatly depending on the power, and it makes no sense to list them all. For the purposes of this article, we can name the cost of units of comparable power in order to give readers an idea of ​​the order of prices for them.

So, a roller machine with an input power of 800 kg per hour (i.e., comparable to a separator and a roller-fan machine with a power of 1000 kg - the yield of useful substances, i.e., sunflower kernels, in other words, the output power will be approximately 0 .8 t) will cost approximately 425 thousand rubles. or $13,800; a machine with an input power of about 4200 kg per hour, that is, comparable to 5-6 bundles of “separator - crusher-fan machine” already costs about 1120 thousand rubles, or $36,450.

Factories equipped with machines of the second type fall into the category of “medium” enterprises - after all, even by simply multiplying productivity by working time, it is not difficult to find out their “input” capacity - 40-48 tons per day (assuming single-shift work, although the specifics of production are such that during the harvest season it can be three shifts, i.e. around the clock), and this is a harvest from 16-19 hectares.

Sunflower seeds (also called mint) ground using rollers are transported to a roasting pan. There are two types of fryers - fire and steam. The difference, as you might guess, lies in the different types of processing of ground seeds.

Fire roasters are essentially large frying pans, or more accurately cauldrons; heating and frying in them is carried out using gas burners. Steam plants process mint using steam, which is usually obtained by heating water with the energy of burning gas.

The first type of roasters is much cheaper than the second - they cost about 83 thousand rubles, or a little less than $3,000, but their productivity is 300-350 kg of mint per cycle, that is, to load the line at full capacity you will have to use 2-3 roasters.

A steam fryer with a capacity of 800 kg per hour (that is, corresponding to the capacity of a “single” line as a whole) will cost about 350 thousand rubles. or 11.5 thousand dollars. In addition, there are also steam roasters not for frying, but only for heat treatment of seeds - this technology allows you to save a little time and get the so-called. cold-pressed oil – without the specific smell of roasted sunflower seeds.

A roaster of this type will cost approximately 440 thousand rubles, or a little more than 14 thousand dollars. Its performance will also correspond to a “single” line, i.e. process 1000 kg of meat per hour.

In principle, there is a cold-press technology without the use of expensive heating equipment. However, without heating, oil extraction is significantly reduced - in this case, the investment will pay for itself quite quickly, given the production volumes.

The next unit, a screw press, is designed specifically for squeezing oil from sunflower seed kernels that have undergone or have not undergone moisture-thermal treatment (this mass is called “pulp”).

The productivity of “middle” class squeezing machines, that is, those intended for small and medium-sized industries, is 15-25 tons per day, their cost is 650-860 thousand rubles, or 21.1-28 thousand dollars, respectively.

The oil from the press is cooled and settled, and then passes through a special filter designed for primary cleaning from mechanical impurities. The cost of such a filter is about 95 thousand rubles. or $3070.

In principle, the resulting oil does not require further purification, however, some enterprises practice the use of other filters.

The productivity of one filter of this type is 160 kg of oil per hour, taking into account the average oil content of sunflower - from 33 to 57%, i.e. from 1 ton of mint or pulp, 330-570 are obtained (and taking into account the remaining 8-9 to 11-14% of oil in the cake, on average - 260-270 kg of oil) filters are usually used 2-3 pieces.

The resulting oil is called “raw” - the cake remaining after pressing can be sold as a valuable agricultural raw material, or can be subjected to additional extraction.

The second method of obtaining sunflower oil is called extraction. In contrast to the pressing method described above, the oil yield increases up to 2% of the residue present in sunflower seeds.

Typically, modern enterprises use both methods - as a rule, after pressing, the cake immediately goes into an extractor - a special machine where the residual oil is dissolved. Various specific substances are used as solvents - extraction gasoline, hexane, acetone, dichloroethane, etc.

After the second pressing, a fat-free (up to 2-5% oil content) material is obtained, used as feed for farm animals - meal - and a solution of oil in a solvent (the so-called miscella). Miscella oil is obtained by refining, which can be produced by different methods. The cost of the corresponding equipment is approximately from 520 thousand rubles. or $16,770 with a productivity of 500 kg of oil per hour.

Ready sunflower oil is bottled into various containers: from iron barrels with a volume of 200 liters to plastic bottles from 0.5 to 5 liters. Of course, oil in barrels is much less valuable than bottled oil, therefore (if, of course, the plant produces edible oil rather than industrial oil), you should also purchase the appropriate equipment: sets of equipment for bottling sunflower oil into plastic bottles (with a capacity of 3600 liters per 8-hour shift) will cost approximately 405 thousand rubles. or just over 13 thousand dollars.

Requirements for personnel and premises in the production of sunflower oil

The big disadvantage of sunflower oil production is the requirement for fairly large production and storage facilities. The total area of ​​production workshops for a plant with a capacity of 50 tons of sunflower seeds per shift is about 2000 square meters. m. In general, the statistical norm is considered to be approximately 40 square meters. m per ton of raw materials processed per shift. That is, if the plant’s capacity is 10 tons, then the production workshops will need 400 sq. m, and if 25, then 1000.

But the warehouse should be even larger - after all, the norm for production reserves is 1-1.5 months, and the specifics of storing sunflower seeds are such that compacting them in too thick a layer is prohibited. In total, warehouse premises on average turn out to be twice as large as production premises, and in the described case it is no less than 4000 sq.m.

In addition, to store cake or meal, a warehouse is required that is half as large as for raw materials, and for the finished product itself, a warehouse approximately equal to 3/4 of the production premises is required. In total, we get another 2000+1500 warehouse space, and a total of 3500 sq. m.

Husks can be stored in bulk on the street under cover or even in the open air, if climatic conditions allow, however, in order for them not to block, for example, the passage of cars, but to be available for loading and unloading for sale, they should be allocated a separate area of ​​about 10- 15 acres.

As you can see, it is quite difficult to find appropriate premises, however, new technologies for the construction of frame structures such as hangars can solve issues, at least storage.

But with the staff it’s a little easier: out of about 50 shift workers, special education and training (in this case - in the specialties 260100 “Technology of food products”, 260400 “Technology of fats”, 260401 “Technology of fats, essential oils and perfumery and cosmetic products”, 260402 “Technology of fats and fat substitutes”, 260600 “Food Engineering”, 260601 “Machines and apparatus for food production” and 260602 “Food engineering of small enterprises” according to OKSO) should have only 8-10 people - technologists and craftsmen.

The rest of the workers can be recruited on the principle of integrity and the absence of bad habits - production is considered a fire hazard. The total wage fund, taking into account the unified social tax, will amount to no more than 700-750 thousand rubles.

Profitability and payback of sunflower oil production

The profitability of sunflower oil production is not so easy to calculate: it strongly depends on the quality of the feedstock (oil content, moisture content), the technology used (cold pressing, extraction, etc.) and seasonality. The peak of production and, as a result, supply of sunflower oil is October-December. And the peak of demand is the end of summer - beginning of autumn.

However, the general figures are as follows. An average oil extraction plant processes 50 tons of sunflower seeds per day. The average oil content of sunflower (according to different quality of raw materials and varieties) is about 45%, and up to 5% comes from related products - meal and technological losses, and about 20% of the weight of the seeds is the husk - the shell.

So, from 50 tons of sunflower seeds you will get 40 tons of kernels, and from them, in the best case, 16 tons of oil, plus 24 tons of meal and 10 tons of husks.

16 tons of oil is 17.3-17.4 thousand liters of oil. For ease of calculation, all oil will be considered refined and deodorized. Considering the wholesale wholesale price of oil at 35 rubles. per liter, we get a gross profit of 605-609, rounded - 600 thousand rubles. This is only from oil. Sunflower husks at a price of about 900 rubles. per ton will bring another 90 thousand rubles, and meal (at the lowest price - 1.5 thousand rubles per ton) - plus 36 thousand rubles. The total gross income is at least 725 thousand rubles. We will build on it.

The cost of a ton of oilseed sunflower of normal quality is about 12 thousand rubles, and therefore, 600 thousand rubles will be required for a working shift of raw materials. Thus, net profit (excluding related expenses) is 125 thousand rubles, and profitability is about 20%.

Profit for the month (counting 24 working days on a 1-shift basis) will be equal to 3 million rubles, and minus the wage fund and taxes, as well as the cost of paying utility bills - approximately 1.8-2 million rubles.

Watch a video about the production of vegetable oil: