Sunflower processing line. Sunflower seed oil production. What is required to create a business in the production of sunflower oil
General characteristics of sunflower seeds.
Sunflower - Helianthus annuus L. Belongs to the Asteraceae family. This is an annual plant, the seeds of which are collected in a basket. Sunflower in our country is the main oilseed crop, its crops make up about 70% of the sown area of \u200b\u200ball oilseeds.
Sunflower oil is used for food, technical and medical purposes. For food purposes, varieties of sunflower oil are used in accordance with GOST 1129-93.
The seed of a sunflower consists of a hard fruit shell (in the collapsed state it is called a husk), a very thin seed coat (film) and two protein cotyledons. The cotyledons are the main reservoir of oil and protein. The composition of sunflower seeds varies depending on varietal characteristics, growing conditions, quantity and quality of nitrogen fertilizers, as well as on post-harvest seed treatment. The content of the kernel in the seed ranges from 50 to 80%, the shell from 20 to 50%.
Sunflower seeds are flammable and are prone to spontaneous combustion. Autoignition temperature 335 hail. C. flash point 305 0 C. Dust generated during processing of sunflower seeds can cause the development of pneumoconiosis and respiratory tract diseases. The maximum permissible concentration of sunflower seeds dust MPC - 4mg / m3. Oilseeds are a source of extremely valuable food and feed products. In the overwhelming majority of cases, such valuable groups of substances as lipids and proteins are localized in the seed nucleus. Other morphological parts of seeds contain a significantly smaller amount of valuable components, and the integumentary membranes (fruit and seed) serve as a source of many undesirable substances, which turn into oils under oil production conditions.
Kernels 72.5 - 82.7%
Shells 17.7 - 27.5%
Seeds 44.5 - 53.8%
Core 55.2 - 63.0
Shell 1.3 - 9.06
Nitrogen content in husk 0.55 - 2.96%
In seeds 3.9 - 20.5%
In the fat-free kernel 41.25 - 66.0%
In skim husks 3.4 - 13.15%
In a fat-free kernel 6.4 - 9.7%
In skim husks 57.1 - 68%
Content of mineral elements 1.8 - 4.9%
Content of nitrogen-free substances 14.3 - 17.5%
Carbohydrate content 24.0 - 27.0%
The seed mass entering the plant for processing is a multi-component mixture that can be divided into:
All components of the seed mass vary widely in chemical, physical, biochemical and other properties. It is customary to include collapsed seeds of the main crop, seeds with kernel residues (eaten by pests, broken), moldy, decayed, germinated, seeds with a changed kernel color, underdeveloped and damaged by frost to oilseed impurities.
Organic litter in seeds consists of parts of baskets, fragments of plant stems, inflorescences, etc. Mineral impurities consist mainly of lumps of earth, dust, stones and metal impurities.
Technological process sunflower oil production consists of the following operations:
Seed cleaning
Cleaning oil seeds from impurities is a necessary and very important process of processing and preparing the seed mass for processing.
Plant stems, leaves, mineral debris, metal and other impurities, with the exception of the collapsed sunflower kernel, contribute to premature wear of equipment (especially mineral and metal impurities), reduce the productivity of the latter and the quality of the products produced.
Upon receipt for processing, the content of trash in the seeds should be no more than 2%, after cleaning no more than 0.5%. As a result of seed cleaning, several types of weed waste are formed: a) large and small litter; b) cyclonic dust The oil content of the emitted litter is ~ about 3%
The high content of fat, protein and other nutrients indicates that the waste obtained during the cleaning of sunflower seeds on separators is of a certain value and can be used as an additive to the basic ration of animals. The seeds are cleaned on separators of various designs (ЗСМ; А1- LSI; WLAN, etc.). To ensure normal technological operation of the separators, it is necessary to do the following:
Hulling of seeds and isolation of the kernel.
In the production of high-quality oils, meals and cakes, the dehulling and separation of the seed shells from the rushanka are important and necessary technological operations. During the processing of seeds, wax-like and other undesirable substances pass into oil from the shells, impairing the taste and smell, increasing the acid number and color of the oils, and also reducing their stability during storage.
The quantitative ratios between the kernel and the seed coat during their processing in schemes involving the removal of the shells directly affect the productivity of the main equipment, the quality of the products produced and the output of cake, oil, husk.
The maximum separation of the shells from the seeds before their processing is a prerequisite for obtaining high-quality oils and high-protein meal in the production.
The main processes ensuring the separation of the kernel from other morphological parts of oil seeds include the dehulling and separation of the rushanka.
Hulling of sunflower seeds is carried out on seed plows. The purpose of the seed plows is to completely crush the seeds with a minimum of kernels and oil dust.
Each seed crusher must work in conjunction with its seed crusher, this is necessary not only to reduce oiling of the husk, but also to establish the correct technological mode of operation of the seed crusher and its seed crusher. In paired operation, it is easy to identify defects in the operation of each machine and eliminate them.
Sunflower seeds piled on seed plows - rushanka - consist of tumbled, whole, normal and puny kernels, various large particles of kernels, oil dust, whole seeds, undershoring, litter (vegetable and mineral). The main purpose of seed pods is to separate the maximum amount of husk from the rushanka with a minimum loss of oil in the husk.
Crushing the kernel.
When crushing sunflower seed kernels, the main goal is to achieve complete destruction of the cellular structure of the nucleus, which contributes to a more complete extraction of oil. For crushing the kernel of sunflower seeds, roller machines are used.
The quality of crushing the kernel is influenced by its moisture content. The optimum moisture content of the nucleus for maximum destruction of the cellular structure is in the range of 5.0-6.0%. An increase in the moisture content of the kernel in comparison with the indicated one worsens the quality of grinding (grinding)
The quality of milling of the mint also deteriorates with an increase in the husk content of the kernel, since the husk has a hard structure in comparison with the kernel and its presence in the kernel increases the distance between the grinding rolls, as a result of which the fineness of grinding of the mint deteriorates.
The passage of the resulting oil through a 1 mm sieve must be at least 60%.
To carry out the optimal technological regime for crushing the kernel on a five-roll machine B6-MVA and obtaining the required grinding, the following conditions must be observed:
Moisture heat treatment;
Roasting oilseed mint in braziers (i.e. conditioning it for moisture and temperature) is one of the important processes preparation of goods for oil extraction. The mode of moisture-heat treatment of mint (conditioning) is determined by the regularities of mass (moisture) and heat transfer. The process of roasting the mint before pressing is carried out in two stages. At the first stage, both heating and moistening of the mint are carried out to optimal limits. At the second stage of frying, the pulp is dried, the humidity and temperature are brought up to the values \u200b\u200bdetermined by the technological requirements in relation to the processed raw materials.
With moisture heat treatment of mint, due to heating and wetting of the surface of protein substances, they swell and partial release of oil on the surface of mint. Swelling of the gel part of the mint is accompanied by an increase in its plasticity.
When the pulp is dried, in addition to a decrease in humidity, a further change in physical and chemical properties spearmint in general and its constituent substances. The general effect of frying the pulp is expressed in a decrease in its moisture content, plasticity, a decrease in the viscosity of the oil and a change in its surface tension.
Acute water vapor supplied to the mint layer acts as both a moisture and a heat carrier. As a carrier of moisture, steam has the advantage that, when condensing, it distributes moisture more evenly on the mint in comparison with humidification with water. However, the effect of steam as a wetting agent is limited as it gradually decreases and then ceases as the mint heats up.
The removal of evaporated moisture from the frypots at the second stage is carried out using natural extraction through pockets and aspiration pipes. Restriction of air circulation in braziers is due to the desire to reduce the contact of hot oil pulp with atmospheric oxygen, which causes all kinds of oxidative processes during frying.
The structure of the pulp supplied to the press must be sufficiently plastic and elastic so that, on the one hand, it is possible to ensure good briquetting of the shell, and on the other hand, to develop a sufficiently high pressure in the press without the pulp crawling out of the mills and at the same time to obtain a given oil content. The combination of the specified properties of the pulp is determined by the optimal ratio of temperature and humidity of the finished pulp leaving the brazier. Excess (against the optimal) moisture content of the pulp causes the pulp to crawl out of the mash, the release of a shapeless cake shell and an increase in its oil content. A deviation from the optimum moisture content towards a decrease causes overdrying of the pulp, the release of crumbling cake shell and, again, an increase in its oil content. Optimum humidity and temperature also guarantee optimum plasticity of the mash.
The pulp leaving the brazier should have the following indicators:
A) when the press is operating in pre-pressing mode:
Moisture 5.0 - 6.5%
Temperature 100 - 105%
B) when the press is operating in the final pressing mode (on converted presses)
Moisture 2.0 - 3.0%
Temperature 114 - 120%
The quality of the resulting pulp is also greatly influenced by the preparation of the product for moisture-heat treatment. The quality of the mint entering the brazier should be characterized by the following indicators:
Humidity 5.5 - 6.5%
Hull content no more than 15%
Pass through a 1mm sieve not less than 60%
Pulp pressing in screw presses MP-68
The screw press MP-68 is designed to squeeze oil from oil raw materials - sunflower seeds prepared in an appropriate way. The scheme for extracting oil using screw presses provides for the following stages: dehulling of seeds. Separation of the resulting rushanka into a kernel and husk, grinding the selected kernel and moisture-thermal processing of the mint in order to obtain a pulp of the required quality.
Description of the operation of the oil press MP-68
The pulp prepared in the brazier enters the feeder tube and is directed into the receiving cavity of the grain chamber. The amount of pulp supplied is regulated by a flap located in the outlet window of the lower bowl of the brazier.
When the pulp passes through the grain chamber, it is compressed and oil is released through the grain slot. The movement and compression of the pulp in the grain chamber is carried out by a screw shaft. The protruding ends of the knives and the ribbed surface of the grain chamber prevent the pulp from rotating together with the shaft and provide the necessary mixing of the pulp for more efficient extraction of oil from it.
Oil, draining from the grain chamber, goes to the oil collector, from which it is fed for further processing. The pulp squeezed out of the oil comes out of the grain chamber in the form of a densely compressed mass (shell), the optimal thickness of which, and therefore the degree of pulp compression in the chamber, is set by the mechanism for regulating the shell thickness.
Operation of oil press MP-68
To use the full power of the presses in terms of productivity and depth of oil extraction without deteriorating the quality of the latter, it is necessary:
The productivity of the oil press, that is, the number of seeds processed per unit of time, increases with an increase in the rotation speed of the auger shaft and decreases with a decrease in the rotation speed of the auger shaft. Normal loading of the oil press depends on the amount of pulp entering the oil press and is maintained according to the ammeter readings. When the load rises to 80A, the sound signal (siren) and the “OVERLOAD” lamp on the control panel turn on, warning of overload. In this case, it is necessary to take urgent measures to eliminate the overload. To do this, it is necessary to reduce the flow of pulp into the feeder. If this does not lead to a decrease in the load, it is necessary to retrace the cage, thereby increasing the width of the outlet annular hole. If this event does not give a result, the oil press must be stopped, and the zernaya chamber must be disassembled to eliminate the existing defect (incorrect assembly of the oil press or a foreign object).
If measures to reduce the load are not taken, and the load continues to grow, then in case of an overload by 1.7–2 times (of the rated power of the electric motor), the shear pins in the cross overload clutch will be cut off. If the reason for the shear of the pins was any foreign object entering the grain chamber, then it is necessary to open the grain chamber, remove the foreign object and close it, then, replacing the broken pins, you can start pressing again.
If the pins were cut off due to the pressing of the oil press, due to the supply of overcooked pulp to the oil press or the supply of a large amount of pulp to the cold oil press (at start-up), then the next start after replacing the pins should be carried out at a stop for up to 1 hour with the preliminary activation of the reverse rotation of the screw shaft according to the same rules as when stopping due to a power outage (see below). With a longer stop, the next start can only be done after disassembling and cleaning the grain chamber and the auger shaft.
Overdrying (overcooking) the pulp.
Signs of overdrying (overcooking) the pulp in the brazier are:
1) a sharp increase in the load on the drive motor of the press;
2) a decrease in the output of oil and movement of its drain towards the outlet of the cake;
3) the appearance of crumbling, unformed cake;
4) grinding in the press zeer and its vibration due to increased friction of the pulp on the working surfaces of the pressing path of the press;
5) the appearance of a specific smell of burnt shell at the outlet of the press diaphragm.
Overcooking of the pulp leads to intensive wear of the auger links, grain grates, breakage of knives, activation of the electrical protection of the electric motor and, consequently, to the stop of the press.
When the pulp is overcooked, the color and acidity of the oil increase, the content of unwanted oxidation and polymerization products increases, the content of water-soluble proteins in the cake decreases and its color increases.
If signs appear indicating overcooking of the pulp, it is necessary:
1) Reduce or temporarily stop the supply of solid steam to the brazier;
2) Reduce the pulp feed to the press until the load on the electric motor is returned to normal;
3) If necessary, squeeze out the diaphragm, increase the thickness of the exiting cake shell.
Undercooking the pulp.
Signs of undercooking the pulp or waterlogging are:
1) The appearance of a shell that is too soft, loosening when exiting the press body;
2) Rotation of the cake together with the cone;
3) Reduced oil output and movement of its drain to the feeder;
4) Increase in the amount of grain talus;
5) Reducing the load on the drive motor of the press.
Pressing the pulp with high humidity leads to an increase in the oil content of the cake and, consequently, to a decrease in oil removal and a decrease in the productivity of the press.
If signs of undercooking or waterlogging of the pulp appear, it is necessary:
1) Check the moistening of the mint in the 1st vat of the brazier and, if necessary, reduce it;
2) Check the supply and pressure of the shroud steam in the brazier, the serviceability of the condensate pots;
3) Check the condition of the aspiration pipes of the brazier, clean them in case of clogging and enhance the removal of moisture vapor by fully opening the gates;
4) Temporarily reduce or completely stop feeding the pulp into the press for additional drying in the brazier.
Filtration.
During the removal of oil on screw presses, particles of pulp and cake get into the oil. Small particles of the material to be pressed are carried away by oil flows through the grain slots of the presses, while larger particles are squeezed out in the form of lamellar formations. Thus, the resulting oil, after the press screw, is a suspension with more or less solids content. The size of solid particles in the oil varies over a very wide range - from a few centimeters to 2 - 4 microns. The amount of suspended solid particles in the press oil can vary from 2 to 10%, their density is 1.10 - 1.40 g / cm 3. The content of impurities is affected structurally mechanical properties the material to be pressed and features of the working parts of the press (the size of the gaps in the steps between the grain plates, the degree of wear of the parts of the screw shaft, etc.).
The presence of insoluble mechanical impurities in vegetable oils worsens their quality, since oxidative and hydrolytic processes on the surface of the particles proceed faster than in the bulk. Therefore, in the process of production of vegetable oils, they strive for the rapid and possible complete removal of insoluble mechanical impurities from the oil (filtration) using fusor traps and filters.
Characteristics of products, raw materials and semi-finished products.Vegetable oils - complex mixtures organic matter - lipids released from plant tissues (olives, sunflowers, soybeans, rapeseed, etc.). According to their composition, lipids are divided into two groups: simple and complex. The main components of simple lipids are fats, which make up 95 ... 97% of lipids. Fats are mainly composed of triglycerides - viscous liquids or solids with a low (up to 40 ° C) melting point, colorless and odorless, lighter than water (at 15 ° C density 900 ... 980 kg / m 3), non-volatile. They are highly soluble in organic solvents and insoluble in water. Fats also contain saturated and unsaturated acids and waxes. Phospholipids are important components of complex lipids.
Vegetable fats and oils are essential components of food, a source of energy and plastic material for a person, a supplier of substances necessary for him, which are involved in regulating metabolism, blood pressure, excretion of excess cholesterol from the body, etc. The most important components of fats are polyunsaturated acids - linoleic and linolenic. They are not synthesized in the human body and are called irreplaceable or essential acids. Prolonged restriction of essential fatty acids in the diet leads to physiological abnormalities: the activity of the central nervous system is disrupted, the body's immunity decreases, and life expectancy is reduced. But excess fat consumption is also undesirable, it leads to obesity and cardiovascular disease.
The following types of vegetable oils are produced in Russia: refined (deodorized and non-deodorized), hydrated (superior, I and II grades), unrefined (superior, I and II grades). To the retail network and to enterprises catering only refined deodorized oil should be sent, which is packed in glass or plastic bottles.
According to the standard, the finished oil determines the physicochemical indicators of the permissible content of harmful substances, the amount of moisture, the values \u200b\u200bof acid and iodine numbers, etc., as well as organoleptic indicators: transparency, smell and taste.
The recommended content of fats in the human diet is on average 100 ... 108 g per day, including directly in the form of fats 50 ... 52 g. The optimal chemical composition of food in terms of fat is ensured when 1/3 of vegetable and 2/3 of animal fats are used in the diet.
The raw materials for the production of vegetable oils are mainly oilseeds, as well as the pulp of the fruits of some plants. According to the oil content, the seeds are divided into three groups: high-oil (over 30% - sunflower, peanut, rapeseed), medium-oil (20 ... 30% - cotton, flax) and low-oil (up to 20% - soy). In Russia, the main oilseed crop is sunflower. Sunflower seeds with an oil content of 40 ... 50%, a moisture content of 6 ... 8%, a content of trash no more than 3% are supplied to production.
Features of production and consumption of finished products. The processing of sunflower seeds into vegetable oil provides for the implementation of the processes of crushing and crushing of seeds, hydrothermal treatment of mint, extraction and refining of oil.
ABOUT THE FAMILY OF THE FAMILY. Oil reserves in the tissues of oil seeds are unevenly distributed: the main part is concentrated in the seed core - in the embryo and endosperm. Fruit and seed coats contain a relatively small amount of oil, which has a different (the worst nutritional value) chemical composition. In this regard, the shells are separated from the main oil-containing tissues by destroying the integumentary tissues of the seeds - crumbling and subsequent separation of the resulting mixture - rushanka into kernel and husk.
The most important requirement for the breaking operation is that the destruction of the shell should not be accompanied by crushing of the core. The quality of the rushanka is characterized by the content of undesirable fractions in it - whole and partially destroyed seeds, the so-called whole and undershed, crushed kernels (chaff) and oil dust. The presence of such fractions increases the contamination (husk content) of the kernel, increases the loss of kernel particles with the separated husk.
The division of the rushanka into kernel and husk is based on the difference in their size and aerodynamic properties. Therefore, firstly, fractions of rushanka are obtained, containing kernels and husks of the same size, and then the rushanka is divided into kernels and husks in a stream of air. The quality of the operation for separating the rushanka is assessed by the value of the residual husk content in the finished kernel and the loss of oil with the separated husk.
Smelling the family The oil is contained in the intracellular structure of the seed nucleus, which must be destroyed to release oil. The required degree of grinding is achieved by applying mechanical forces to the processed material, producing crushing, splitting, abrasive and impact actions. Grinding is usually achieved by a combination of several types of these forces.
The semi-finished product obtained after grinding is called mint and has a very large specific surface, since in addition to the destruction of the cell membranes during grinding, the intracellular structure of the oil-containing part of the cell is also disrupted, a significant proportion of the oil is released and immediately adsorbed on the surface of the mint particles.
Well-crushed mint should consist of particles of uniform size passing through a sieve with holes of 1 mm, should not contain intact, intact cells, and at the same time, the content of very small (mealy) particles in it should be low. The end result of the grinding operation is the conversion of the oil contained in the seed cells into a form available for further technological influences.
G i d r o t e r m i ch and i o work. Oil adsorbed in the form of thin films on the surface of the mint particles are retained by significant surface forces. These forces can be significantly weakened by moistening and subsequent heat treatment of the mint.
Intense short-term heating of the mint with simultaneous moistening contributes to the uniform distribution of moisture in the mint and the partial inactivation of hydrolytic and oxidative enzymes in the seeds, which degrade the quality of the oil. The mint is then heated and dried. As a result of this treatment, the mint turns into a pulp prepared for oil extraction.
E n e c e m a l. In the practice of production of vegetable oils, there are two fundamentally different ways extraction of oil from vegetable oil-containing raw materials: mechanical extraction of oil - pressing and dissolving oil in volatile organic solvents - extraction. These two methods of producing vegetable oils are used either alone or in combination with one another.
At present, oil is extracted first by a pressing method, in which ¾ of the total oil is obtained, and then by an extraction method, by which the rest of the oil is extracted.
The oil is squeezed out in screw presses of various designs. The pressure developed by the screw press reaches 30 MPa, the degree of compaction (compression) of the pulp is 2.8 ... 4.4 times. In this case, the particles of the pulp come together, the oil is squeezed out, and the pressed material is compacted into a monolithic mass of cake.
It is impossible to achieve complete degreasing of the pulp by pressing the method, since on the surface of the cake particles leaving the press, there are always thin layers of oil held by the surface layers many times higher than the pressure developed by modern presses. Even on presses operating with maximum oil removal and developing high pressure, cake with an oil content of 4 ... 7% is obtained.
Extraction - the extraction of oil from the cake, produced using solvents. Extraction gasoline and nefras with a boiling point in the range of 63 ... 75 ° C are used as solvents for the extraction of vegetable oils. The oil that is on the surface of the opened cells, when washed with gasoline, easily dissolves in it. A significant amount of oil is found inside unopened cells or inside closed cavities (capsule). Recovery of this oil requires the penetration of the solvent into the cell and capsule and the exit of the solvent into environment... This process occurs due to molecular and convective diffusion.
As a result of extraction, a solution of oil in a solvent, called miscella, and a defatted material, meal, are obtained.
To remove mechanical impurities from the miscella, it is filtered. Thereafter, it consists of a low-boiling solvent and a practically non-volatile oil. In the oil and fat industry, the operation of stripping off the solvent is called distillation. With relatively low oil concentrations in miscella, the solvent removal process is initially reduced to a conventional evaporation process. As the concentration of the oil increases, the boiling point of the miscella rises very quickly. In this regard, to reduce the distillation temperature and accelerate the process, solvent distillation under vacuum, as well as with steam, is used.
R and f and n and c and I m a s l. Refining is the process of purifying oil from unwanted lipid groups and impurities. Due to the variety of physical and chemical properties of lipids that make up natural oils and fats, modern refining is a complex process that includes a sequential chain of technological operations that differ in the nature of chemical and physical effects on the removed lipid groups.
The volume and sequence of operations during refining depend on the type and purpose of the oil. Hydration is used to remove a group of substances with hydrophilic properties (phospholipids, mucous and protein substances) from the oil using water, which precipitate during storage. The neutralization of the oil with alkali allows it to be purified from free fatty acids capable of saponification. Cooling the oil is necessary to freeze the waxes and separate their crystals. Deodorization of oils is a distillation process to remove volatile substances that determine the smell and taste of oil, as well as foreign compounds, pesticides and toxic products.
When all of the above operations are performed, changes occur chemical composition and the physical state of unwanted substances, as a result of which they are converted into particulates and suspensions. They can be removed from the oil by various physical methods of mechanical refining: filtration, settling and centrifugation.
Required condition of the applied technological operations is the preservation of the triacylglycerol part of the oil, which has nutritional value, in its native state.
Complete refining is necessary to obtain salad oil for direct consumption, for oils and fats used in the production of margarine, confectionery, cooking fats and mayonnaise.
The meal obtained as a result of the extraction treatment of the cake is also purified from the solvent by distillation and is used as animal feed. Food protein can be extracted from the meal using a special technology.
When hydrating sunflower oil of the highest and I grade, a food phosphatide concentrate is obtained, containing 40 ... 70% of a surfactant - lecithin and used as an emulsifier, and when hydrating grade II oil, a feed phosphatide concentrate is produced.
Soap stock, formed during alkaline neutralization of oil, is used in the production of soap.
The stages of the technological process. The production of vegetable oil from sunflower seeds consists of the following stages and basic operations:
- acceptance of seeds and their cleaning from impurities;
- dehulling of seeds, separation of kernels and husks;
- crushing seeds and hydrothermal treatment of mint;
- pressing the pulp and cleaning the press oil;
- structuring of cake and extraction of oil from it;
- distillation of miscella;
- oil refining: hydration, neutralization, deodorization, cooling, mechanical purification of impurities;
- distillation of the solvent from the meal;
- packaging of finished oil into consumer and shipping containers.
Characteristics of equipment complexes. The line starts with a set of equipment for cleaning seeds, consisting of scales, silos, separators, magnetic catchers, feed bins, bucket elevators and conveyors.
The next set of equipment for obtaining a kernel of seeds, which includes centrifugal crushing machines, seed beads, aspiration systems, sifting, bucket elevators and conveyors.
The leading complex of equipment for the line is designed to produce pressing oil, including roller mills, an inactivator, an oil press, filters and pumps, as well as equipment for crushing the prepress cake and finally extracting oil from it.
The complex of equipment for obtaining extraction oil includes a crusher and a flaking machine for prepress cake, an extractor, filters for miscella, heaters and distillers, a refrigerator for oil, conveyors, pumps and containers, equipment for stripping solvent from meal, and equipment for solvent purification ...
The complex of equipment for complete oil refining contains a hydrator, neutralizer, bleaching and drying apparatus, filters, deodorizer, pumps and collectors.
The final complex of the line includes dosing devices, machines for filling butter and packaging products in shipping containers.
The machine-hardware diagram of the line for the production of vegetable oil from sunflower seeds is shown in Fig. 2.11.
The device and the principle of the line. Sunflower seeds entering production are freed from ferromagnetic impurities on a magnetic separator, weighed, then with a screw conveyor 1 fed to the air sieve separator 2 for cleaning from mineral and organic litter (Fig. 2.11, a).
Large litter coming from the upper (sorting) sieve, screw conveyor 5 out of production. Fine litter passing through the bottom (under-sowing) sieve and leaving the cyclones 3 aspiration system of separators equipped with fans 4 , also by screw conveyor 5 out of production. The content of oil-bearing impurities in the waste litter is not more than 3%.
Seeds cleaned from coarse and fine litter on sieves are fed to the vibrating channel of the separator's pneumatic separation channel 2 ... When air passes through the flow of seeds, light impurities are released from the mass of seeds and are carried out by air through a pneumatic separation channel and air ducts into a sedimentation device - horizontal cyclones. They are designed for preliminary cleaning of the air flow from impurities released from sunflower seeds in the separator's pneumatic separation channel. From horizontal cyclones, light impurities are fed through the anti-suction channel to the screw conveyor 5 .
The air leaving horizontal cyclones is additionally cleaned in cyclones 3 , the separated impurities from which are also removed by the screw conveyor 5 .
Peeled sunflower seeds from a pneumatic separation channel with a scraper conveyor 6 , noria 7 , screw conveyor 9 are fed for caving in centrifugal crushing machines (crumbling) 10 ... Before the seeds enter the debris by gravity from the noria 7 into the conveyor 9 installed magnetic separator (iron separator) 8
The seeds, having received acceleration on a centrifugal rotating disk, fall into the radial guide channels of the cuttings, lined with liners made of wear-resistant ceramics, from where they are thrown onto the annular deck, hit against it with a sharp or blunt end of the seed (i.e., they are hit in the weakest direction - along seed axis, which basically provides the best caving effect). When hitting the deck, the largest part of the seeds collapses and in the form of a dewdrop enters a cylindrical sieve located inside the dew cyclone. When the rushanka moves down the sieve, part of the oil dust is separated from the rushanka, which is removed from the rushka by a screw conveyor 14 on the screw conveyor core 22 where it mixes with the core.
Sunflower seeds (rushanka) piled in rushka consist of whole kernels, their large particles, chaff, oil dust, whole seeds, under-shedding, husks of various sizes and litter (vegetable and mineral). Rushanka containing up to 25% whole and undershed, oil dust up to 10%, chaffs up to 12% by gravity flows into the seed weeds 16 with a scraper conveyor 15 .
The main purpose of seedlings is to separate the required amount husk from rushanka with minimal loss of oil with husk. At the same time, a part of the remaining litter is removed from the seed plants.
Separation of the sunflower seeds that have fallen into the fractions takes place in the seed vines. Rushanka, passing through the seed grain sifting, is divided into six fractions, of which five are fed to the wake, and the sixth is taken out of the machine, bypassing the wake. Each of the five fractions of the product supplied to the wake enters the chamber intended for it, where the product is winnowed with an air stream and the husk is separated from the kernel according to the difference in aerodynamic characteristics.
Kernel with husk content of not more than 12% from the second-fifth sections of the seed grain 16 screw conveyors 22 , 48 fed into the core bins above the roller mills and then into the roller mills 49 for grinding. Before the core enters the rolling mills on gravity from the conveyor 22 into the conveyor 48 iron separator installed 47 to remove metal impurities.
When crushing sunflower seed kernels, the main goal is to achieve complete destruction of the cellular structure of the nucleus, which contributes to a more complete extraction of oil by both pressed and extraction methods. The optimum moisture content of the nucleus, at which the maximum destruction of the cellular structure occurs, lies in the range of 5.5 ... 6.0%. An increase in the moisture content of the kernel in comparison with the indicated one worsens the quality of grinding (grinding).
The core, getting into the passages between the grinding rolls of the roller mill, is crushed due to the difference in the circumferential speeds of the rolls, the presence of corrugations on their surfaces, as well as the different size of the gap between the rolls, i.e. turns into mint.
Meat (passage through a 1 mm sieve at least 60%) with a moisture content of 5 ... 6% after roller machines by a screw conveyor 50 served for pressing.
Underperformance from the first sections of working seed plants 16 screw conveyor 21 , as well as undershooting from the first sections of the seed plant for undershooting 35 screw conveyor 36 served for control by elevator 23 , screw conveyor 24 in seedlings 25 where the husk is separated from it.
From seedlings 25 undershoot by screw conveyor 27 , noria 28 , screw conveyor 29 fed for repeated caving on the centrifugal crumb 30 ... Part of the oil dust separated from the rushanka in a centrifugal rush is removed from it by a screw conveyor 33 into screw conveyor core 22 where the oil dust is mixed with the core.
Description of the stages of production of vegetable oil.
Very often the question arises - what is the difference between unrefined cold-pressed oil and the refined oil familiar to many, sold on store shelves. To answer this question, consider in detail the production process and its varieties.
Seed processing. The quality of sunflower oil depends on the quality of sunflower seeds supplied for processing, the terms and conditions of storage of seeds before pressing. The main quality characteristics for sunflower seeds are oil content, humidity, ripening period. The oil content depends on the variety of sunflower and on how warm and sunny the summer is. The higher the oil content of the seeds, the greater the oil yield. The optimum moisture percentage of sunflower seeds for processing is 6%. Seeds that are too wet and stored poorly and heavier. The ripening period in our climatic conditions is a very important factor that indirectly affects the price of sunflower oil. The peak of production and supply of finished vegetable oil is from October to December. And the peak of demand is late summer - early autumn. Accordingly, the earlier the raw materials are received, the faster the finished product will be delivered to the consumer. In addition, the seeds must be well cleaned, the garbage content must not exceed 1%, and the broken grain must not exceed 3%. Before processing, additional cleaning, drying, crumbling (destruction) of the seed skin and its separation from the kernel are carried out. Then the seeds are crushed, resulting in mint or pulp.
Pressing (production) of sunflower oil. Vegetable oil from mint of sunflower seeds is obtained by 2 methods - pressing or extraction. Oil extraction is more environmentally friendly. Although the oil yield is, of course, much less and does not exceed 30%. As a rule, before pressing, the mint is heated at 100-110 ° C in braziers, while stirring and moistening. Then the fried mint is squeezed out in screw presses. The degree of extraction of vegetable oil depends on the pressure, viscosity and density of the oil, the thickness of the mint layer, the duration of extraction and other factors. The characteristic taste of the oil after hot pressing is reminiscent of toasted sunflower seeds. Oils obtained by hot pressing are more intensely colored and aromatized due to decomposition products that are formed during heating. A cold pressed sunflower oil obtained from mint without heating. The advantage of such oil is the preservation of most of the nutrients in it: antioxidants, vitamins, lecithin. The negative point is that such a product cannot be stored for a long time, it quickly becomes cloudy and rancid. The cake remaining after pressing the oil can be subjected to extraction or used in animal husbandry. The sunflower oil obtained by the pressing method is called raw, because after pressing it is only defended and filtered. This product has high taste and nutritional properties.
Extraction of sunflower oil. The production of sunflower oil by the extraction method involves the use of organic solvents (most often extraction gasolines) and is carried out in special devices - extractors. During the extraction, miscella is obtained - a solution of oil in a solvent and a defatted solid residue - meal. From the miscella and meal, the solvent is distilled off in distillers and screw evaporators. The finished oil is settled, filtered and further processed. The extraction method of oil extraction is more economical, since it allows the maximum extraction of fat from raw materials - up to 99%.
Sunflower oil refining. Refined oil has practically no color, taste or smell. This oil is also called impersonal. Its nutritional value is determined only by the minimal presence of essential fatty acids (mainly linoleic and linolenic acids), which are also called vitamin F. This vitamin is responsible for the synthesis of hormones, maintaining immunity. It gives stability and elasticity to blood vessels, reduces the body's sensitivity to the action of ultraviolet rays and radioactive radiation, regulates the contraction of smooth muscles, and performs many more vital functions. There are several stages of refining in the production of vegetable oil.
The first stage of refining. Getting rid of mechanical impurities - settling, filtration and centrifugation, after which the vegetable oil goes on sale as a commodity unrefined.
Second stage of refining. Phosphatide removal or hydration - treatment with a small amount of hot water - up to 70 ° C. As a result, protein and mucous substances, which can lead to rapid deterioration of the oil, swell, precipitate and are removed. Neutralization is the impact on the heated oil with a base (alkali). This step removes free fatty acids, which catalyze oxidation and cause smoke during frying. Also, heavy metals and pesticides are removed during the neutralization stage. Unrefined oil has a slightly lower biological value than raw, since hydration removes some of the phosphatides, but it is stored longer. Such processing makes the vegetable oil transparent, after which it is called marketable hydrated.
The third stage of refining. Elimination of free fatty acids. With an excess of these acids, the vegetable oil develops an unpleasant taste. The vegetable oil that has passed these three stages is called already refined, non-deodorized.
The fourth stage of refining. Bleaching - treatment of oil with adsorbents of organic origin (most often special clays) that absorb coloring components, after which the fat is clarified. Pigments pass into oil from seeds and also threaten with oxidation of the finished product. After bleaching, the oil does not contain pigments, including carotenoids, and it becomes light straw.
The fifth stage of refining. Deodorization - removal of aromatic substances by exposing sunflower oil to hot dry steam at a temperature of 170-230 ° C under vacuum conditions. During this process, odoriferous substances are destroyed, which lead to oxidation. Removal of the above undesirable impurities leads to the possibility of increasing the shelf life of the oil.
Sixth stage of refining. Freezing - removing wax. All seeds are covered with wax, this is a kind of protection from natural factors. Waxes add turbidity to the oil, especially when sold on the street during the cold season, and thereby spoil its presentation. During the freezing process, the oil is colorless. After going through all the stages, vegetable oil becomes impersonal. Margarine, mayonnaise, cooking fats are made from such a product, and used for canning. Therefore, it should not have a specific taste or smell in order not to disturb the overall taste of the product.
Sunflower oil gets on the shelves as the following products: Refined, non-deodorized oil - outwardly transparent, but with a characteristic odor and color. Refined deodorized oil - transparent, light yellow, odorless and tasteless of seeds. Unrefined oil - darker than bleached, may be with sediment or suspension, but nevertheless it passed filtration and, of course, retained the smell that we all know from childhood.
- Capital investment 11 685 104 rubles
- Average monthly revenue 5 879 556 rubles
- Net profit 455 225 rubles
- Payback 26 months.
1. Production technology
Manufacturing process the manufacture of refined sunflower oil consists of the following stages:
- Spin;
- Refining process;
- Packaging and labeling of finished products.
1.1. Oil extraction
Before pressing the raw materials are heated in braziers at a temperature of 100-110 ° C, while stirring and moistening. Next, the raw material is squeezed out in presses. The completeness of pressing the vegetable oil depends on the pressure, viscosity and density.
After pressing the sunflower oil cake and husk remain, which can be further processed or used in animal husbandry. So from one ton of sunflower with an oil content of 44.7% in seeds, you can get the following products:
1.2. Refining process
First step:
Getting rid of mechanical impurities (settling, filtration and centrifugation), after which the vegetable oil goes on sale as a commodity unrefined,
Second stage:
Hot water treatment (65-70 ° C)... This is done to remove phosphatides or hydrate the vegetable oil becomes transparent after processing
Third stage:
Elimination of free fatty acids... With an excess of such acids, the vegetable oil develops an unpleasant taste. The vegetable oil that has passed these three stages is called already refined, non-deodorized.
Stage four:
Deodorization (Whitening)... After this process, no pigments, including carotenoids, remain in the oil, and it becomes light straw. removes volatile compounds, deodorizes vegetable oil and turns it into refined deodorized oil.
Fifth stage:
Freezing, with its help, waxes are removed, after which a colorless, viscous vegetable oil is obtained
2. Required equipment
After analyzing on the Internet offers for the sale of equipment / lines for the production of refined sunflower oil came to the following conclusions:
- If you plan to produce more than 30 tons of products per day, then it is optimal to purchase an oil plant, in addition to the pressing line, refining lines will be included in its set, the disadvantage of such plants is the high cost (prices start from 1.5 million euros without installation),
- If you plan to produce 5-10 tons of products per day, then it is optimal to buy equipment separately (pressing, refining, packaging)
Our business plan considers the organization of the production of sunflower oil with a capacity of 5-10 tons of products per day, so all equipment will be purchased separately.
2.1. Press line
When analyzing the proposals, the most attractive in terms of price / performance / quality ratio seemed to us the equipment of OJSC "Penzmash". This company makes custom-made lines for the production of vegetable oil LM-1.
Specifications
- Productivity for sunflower seeds, t / day: 10 - 12
- Oil yield,%, with oil content
- sunflower seeds 48-50%: 40-42
- flax seeds 42-45%: 3-38
- rapeseed 40-42%: 33-35
Maintenance of the unit requires 5 people per shift.
The cost is 1,931,040 rubles including VAT.
With an oil capacity of up to 5-10 tons per day, the LSX-5000 cleaning and refining line is optimal. (China), productivity up to 5 tons per day.
The LSX-5000 line implements the principle of batch refining, which fully corresponds to the classical technology of this process for industrial versions of such equipment
The equipment is supplied with a high degree of assembly readiness, complete with a heat and electrical control panel, for commissioning it is only necessary to provide a supply of tap water, electricity, as well as fuel (coal or wood, or gas or diesel fuel), caustic soda, phosphoric acid and whitening agent (clay or activated carbon) .
LSX-5000 Press Line Specifications
- Batch (discontinuous) lines.
- Simple, well thought-out design and layout.
- Includes heating unit and control panel.
- The equipment is not intended for the refining of highly rancid oils with a peroxide value exceeding 10 meq / kg.
- Simplicity of installation work, no special requirements for the premises and foundations, the equipment can be installed both indoors and outdoors.
* It is also possible to use gas or diesel fuel as a heat carrier
2.3. Packing line
For bottling finished products into bottles, the equipment manufactured by Prodvizhenie LLC is optimal. This company produces automatic line for filling oil into PET bottles with a capacity of 0.25-2.0 liters, with a capacity of 2700 bph (1.0l). The cost is 2,132,000 rubles.
Number of staff: 2 people per shift.
3. Feasibility study of the project
3.1. Equipment costs
3.2. Equipment delivery and installation costs
3.3. Working capital (raw materials, monthly expenses, etc.)
| Naming of expenditures | |
| Working capital (purchase of raw materials, monthly payroll, others) | |
| TOTAL CAP EXPENSES |
Total capital investments amount to 11,685,104 rubles.
3.4. Required premises
- To accommodate the spinning line, a 55 sq.m. production facility is required. (ceiling height 3.5 meters)
- A room of 100 sq.m. is required to place the refining line.
- To place a line for packaging products requires 60 sq.m.
- Warehouses for storing raw materials and finished products are also needed: 200 sq.m. and administrative premises for personnel of 25 sq. m.
Total required
not less than 215 sq.m. to organize production
not less than 200 sq.m. for storage facilities
not less than 25 sq.m of administrative and utility premises.
The premises of the workshop should be equipped with 380 volts, a water supply system should be connected, and so the workshop should have a convenient access for freight transport for the delivery of raw materials and the shipment of finished products.
3.5. Staff
It will take 25 workers to service the production
| Position | quantity | ||
| Director | |||
| Art. Technologist | |||
| Technologist | |||
| Storekeeper | |||
| Direct pressing workshop | |||
| Refining workshop | |||
| Packaging workshop | |||
Comments
- Direct pressing shop and refining shop works round the clock (shift 8 hours)
- There are 1 foreman per shift, 3 workers in the spinning shop and 2 workers in the refining shop.
- Technologists, storekeepers, as well as workers in the packaging department work in one shift.
- The director deals with the purchase of raw materials and the sale of finished products.
- 3.6. Taxation
Since most potential buyers work with VAT, the most acceptable form for a workshop for the production of oil is 3 personal income tax, form of activity: Individual entrepreneur.
3.7. Pricing
According to the data on the Internet, prices for products are as follows:
3.8. Revenue calculation
As a result of processing sunflower seeds, the following products are produced:
Refined sunflower oil - used in food Industry.
Oilcake, husk is used in animal husbandry
3.9. Cost price:
For the manufacture of 5 tons of products, it is necessary to process 11.8 tons of sunflower seeds. The cost of production also includes the cost of electricity, coal, water, soda, bleaching agent and packaging costs.
Coal, water, soda whitening agent is a raw material for oil purification and refining line.
4. Feasibility study
Inputs
Productivity: 5 tons per day.
Capital investment: rubles: 11 685 104 rubles
Premises area: 440 sq.m. (rent 100,000 rubles per month)
Number of shifts per month: 30
Number of staff: 25 people.
4.1. Total expenses per month
4.2. Profitability calculation
4.3. Payback calculation
To calculate the payback point for the sunflower oil production workshop, you can use our online break-even point service.
Addition
If you need a detailed business plan with detailed calculations and market analysis of a specific region, you can order its development for your specific project, taking into account its individual characteristics. for detailed information from the partner of the site Moneymaker Factory of the consulting agency "MegaResearch". You can also purchase.
Introduction
sunflower competitiveness economic
Sunflower and its processed products are the second largest agricultural export item by revenue after grain in Russian Federation... But the genetic potential of sunflower is used no more than half. Sunflower oil seeds are widely used. The first is the production of sunflower oil, which is not inferior in caloric value to animal oil, but with one very important advantage: it does not contain cholesterol. The second is meal (or cake), which is a valuable feed additive that allows to ensure the balance of feed rations of farm animals and poultry in protein, due to the lack of which in the production of livestock products, feed overruns from 10 to 30%. In addition, sunflower is used in the confectionery industry. In recent years, research has been carried out aimed at creating highly efficient biofuels based on crop by-products.
Sunflower production, in comparison with other commercial types of crop products, is the most efficient due to the high sales prices of oilseeds and their processed products due to high demand in the consumer market. However, in some years there is a decrease in its profitability due to fluctuations in yield, as well as outstripping growth rates of the total cost of 1 centner of oilseeds in comparison with the growth rate of the average selling price. This situation is largely due to the influence of inflation, disparity in prices for sunflower oilseeds and purchased material resources of industrial origin. A significant factor in the growth of the cost of oilseeds is the low level of yield due to violation of the requirements of agricultural technology, insufficient use of mineral and organic fertilizers, means of protecting crops from pests, diseases and weeds in many agricultural organizations.
The current situation in the industry does not meet modern requirements for the highly efficient use of labor, production, economic and financial resources, necessitates a significant increase in the level and sustainability of yield. To increase the efficiency of sunflower cultivation, it is relevant to develop a set of measures aimed at improving the production, distribution and use of sunflower oilseeds, taking into account the conditions of its storage, processing and market conditions.
The research of problems of a technical, technological and organizational and economic nature in the production of sunflower oilseeds was devoted to V.P. Brazhnik, G.G. Gonik, N.I. Dvoryadkin, K.M. Krivoshlykov, M.I. Kruchinin, A.M. Lyakhovetsky, I.F. Popov, A.L. Rizgaev and others. In their scientific works theoretical and methodological basis scientific support for the organization of highly efficient production of oilseeds, increasing the efficiency and competitiveness of the fat and oil subcomplex.
The purpose of writing a term paper is to substantiate the directions for increasing the efficiency of production and use of sunflower oilseeds in agricultural organizations. To achieve this goal, the following tasks were identified and solved:
analyze state of the art production and use of sunflower oilseeds, the level and trends of changes in its efficiency;
explore the essence and content of the concept of economic efficiency of production and use of agricultural products;
to clarify the system of indicators for assessing the economic efficiency of production and use of sunflower oilseeds;
to give the organizational and economic characteristics of CJSC "APK Yunost";
to assess the role of sunflower production in the economy of CJSC "APK Yunost"
to carry out a comparative assessment of the sown area, yield and gross sunflower production in CJSC "APK Yunost"
to assess the economic efficiency of production and sale of sunflower in CJSC "APK Yunost";
to study the reserves of increasing yields and reducing the cost of sunflower production based on the modernization of the industry;
consider the pricing methodology as a factor in increasing the organization of sunflower production;
substantiate the main directions of on-farm use of sunflower oilseeds, sales of processed products.
The object of the research was the farm of ZAO APK Yunost.
The subject of the research is the economic relations that develop during the production and use of sunflower oilseeds, as well as their processing products.
The theoretical and methodological basis of the study is the works of domestic and foreign scientists on the problems of production efficiency, distribution and use of sunflower.
The empirical basis of the study was the data of the annual reports of ZAO APK Yunost for 2010-2012.
The nature of the object under study and the objectives of the study determined the use of the following methods and techniques: monographic, graphic, economic-statistical, abstract-logical, counting-constructive.
Course work consists of an introduction, three chapters, including 10 paragraphs, nine tables and two figures, a section with conclusions and proposals, a list of references, three appendices. The volume of work without attachments is 60 pages.
1. Theoretical and methodological foundations of the organization of storage, processing and sale of sunflower
1.1 National economic significance and current state of sunflower production in Russia
One of the most important components of the agro-industrial complex is the fat-and-oil complex, which is a multifaceted and complex economic subsystem of the agro-industrial complex, organically including a set of enterprises in various spheres and sectors of the economy, interconnected by the unity of the processes of production of oilseeds, their transportation, storage, processing and sale of fat and oil products.
One of the subsectors agriculturewhich is currently experiencing the greatest pressure from consumers is the production of sunflower seeds.
Sunflower is the main oilseed crop. Seeds of modern varieties and hybrids contain 50 - 52% or more of light yellow edible oil with good taste, up to 16% protein. Sunflower oil belongs to the semi-drying group; it has a high taste and surpasses other vegetable fats in nutritional value and assimilation. Sunflower oil is used directly in food, as well as in the manufacture of margarine, canned food, bread and confectionery... The special value of sunflower oil as food product due to the high content of unsaturated fatty linoleic acid in it, which is characterized by high biological activity. The presence of this acid in the diet of a person accelerates the metabolism of cholesterol esters in the body, which has a positive effect on health. In addition to fatty acids, sunflower oil also contains phosphotides, vitamins (A, D, E. K) and other very valuable food components. Lower grades of sunflower oil are used in soap making, paint and varnish and other processing industries, used in the production of stearin, linoleum, oilcloth, waterproof fabrics, electrical fittings, etc.
When processing seeds for oil, by-products are obtained - cake (with the press method) and meal (with the extraction method), which are a valuable high-protein feed containing protein with a large amount of essential amino acids. 1 kg of meal contains 1.02 feed. units and 363 g of digestible protein, and 1 kg of cake - 1.09 feed. units and 226 g of digestible protein.
Threshed sunflower baskets serve as an additional source of animal feed. The yield of dry baskets is 56-60% of the seed mass. 1 kg of flour made from dried baskets contains 0.8 feed. units and 38-43 g of protein.
The husk of sunflower seeds is a valuable raw material in the production of hexose and pentose sugar. Hexose sugar is used to produce ethyl alcohol and feed yeast. And pentose - for the production of forfural used in the manufacture of plastics, artificial fiber, safety glass and others chemical materials... The husk yield of modern sunflower varieties is 18-20% of the seed mass.
Sunflower is also cultivated as a fodder crop. It can form up to 500-600 c / ha and more green mass both in pure form and in mixed crops with other forage crops when used for silage. Sunflower silage is well eaten by livestock and is not inferior to corn silage in nutritional value. 1 kg of sunflower silage contains 0.13 - 0.16 feed. units, 10 - 15 g of protein, 0.4 g of calcium, 0.28 of phosphorus and 25.8 mg of carotene (provitamin A).
Sunflower stems can be used to make paper, and ash as fertilizer (contains up to 35% K2O).
Sunflower is a valuable honey plant. From 1 hectare of sowing during the flowering period, bees collect up to 40 kg of honey. At the same time, the cross-pollination of flowers is significantly improved and the yield of seeds increases.
As a row crop, sunflower is considered a good predecessor for many field crops.
Sunflower is a highly profitable, economically beneficial crop. In 1999-2001, the state took a set of measures of customs and tariff regulation to restrict the export of sunflower seeds and the import of vegetable oils, which created unprecedentedly favorable conditions for the development of oil-extracting enterprises. However, they did not lead to their proper participation in the production of raw materials, as indicated by the continued low yields of sunflower seeds. At the same time, in the context of limited channels for the sale of sunflower seeds, the market was under the active influence of local monopolies - processing enterprises and wholesale intermediaries serving them.
The severity of this problem was not so evident in previous years, when the volume of sunflower seed production was lower than the existing production capacity, which allowed maintaining the relatively high profitability of sunflower production. Although the production of sunflower seeds has a general tendency to increase, it is necessary to pay attention to the extremely unsatisfactory dynamics of growth in yield, which is a consequence of the low investment attractiveness of production in the conditions of a monopoly market for product sales.
Another negative problem is that sunflower is a crop that depletes the soil and returns it to former place sowing is possible only after a few years. For this reason, the sharp expansion of the cultivated areas for cultivation leads to the need to reduce them in subsequent years. However, sunflower growers, in order to increase their one-time income in conditions of high prices for crops, often neglect the rules of crop production, which leads to the degeneration of sunflower, and hence to a decrease in yield.
In the 2005-2006 season, when a large harvest was obtained, there was a sharp drop in purchase prices, which became the main factor in the reduction of acreage and sunflower production for the next year, which, in the context of the global food crisis, led to a sharp increase in prices for sunflower seeds and vegetable oil ... As a result, there was a sharp increase in acreage in 2008 in Russia (compared to 2006-2007), which indicates the main factor in stimulating production - a high level of purchase prices.
At the end of 2013, the yield of the main oilseed crop, sunflower, was 24.0 c / ha in the Oryol region.
According to the Department of Plant Growing, Chemicalization and Plant Protection of the Ministry of Agriculture of the Russian Federation, this is the third place in Russia after the Belgorod region - 26.0 centners / ha and Krasnodar Territory - 25.2 centners / ha. At the same time, in Russia as a whole, the highest yield for the last 10 years was obtained - 15.1 c / ha of sunflower oilseeds (2012 -13.0 c / ha, 2011 -13.4 c / ha).
In 2013, about 92 thousand tons of sunflower were threshed in the Oryol Region, which is more than 1.5 times higher than in 2012. The gross harvest of sunflower oilseeds, according to preliminary data from Rosstat, is estimated at 10.2 million tons. This figure is a record: 3 times more than in 1990 (3.42 million tons) and 27.7% more than in 2012 (7.99 million tons).
To a large extent, sunflower production is influenced by the efficiency of the functioning of the fat-and-oil subcomplex, which is associated with the market environment and the action of its regulation mechanisms. Weak development of market mechanisms and the need to solve economic and social problems predetermine the region's need to create and develop a wholesale food market, which will allow minimizing intermediaries in the process of commodity circulation and increasing the competitiveness of locally produced fat and oil products, making foreign regional supplies only if necessary.
Sunflower production has a significant impact on the efficiency of the entire crop production industry. The high purchase price for the seeds of this crop makes it economically profitable for cultivation and contributes to the economic recovery of farms. The demand for sunflower and sunflower oil does not decrease significantly when prices rise. In such a situation, incomes of agricultural enterprises producing and processing oilseeds should grow.
However, due to the unsatisfactory use of the production and bioclimatic potential, the lack of economic, agrotechnical, organizational and other experience, the plans for the production and delivery of this valuable oilseed crop are not being fulfilled.
Innovative developments in modern economic conditions represent significant reserves for increasing the economic efficiency of the fat-and-oil industry on the principles of introducing the achievements of scientific and technological progress, which contributes to the achievement of the identity of interests:
the state - in developing the potential of agricultural production as the main direction of ensuring the country's food security,
local governments - in ensuring economic growth in the region,
enterprises of the industry - in obtaining additional profits;
population - in providing high-quality fat and oil products
1.2 Methodology, indicators and criteria of efficiency and competitiveness of sunflower production
The efficiency and competitiveness of sunflower production is determined by indicators of yield, yield, labor intensity of production, production and total cost of production, profit, as well as the indicator of profitability.
The crop category is multifaceted. On the one hand, it characterizes the process of growing crops and forming products, on the other, the overall result of their cultivation and harvesting. In this regard, as well as for sown areas, to reflect the progress of the process and its results, not one indicator is needed, but their system. In practice, several indicators of the harvest are used: species, on the vine before the start of timely harvesting and the actual harvest.
The specific yield is the expected yield for a given specific state of crops, assuming that the conditions for subsequent cultivation of the crop will be normal, average. This is, in essence, an assessment of the state of plants from the point of view of their possible productivity, the knowledge of which is important for organizing plant care, harvesting, and product use. The definition of a specific crop, or "crop types", is widespread in economic practice at all levels of government. It can be carried out many times, depending on the need, for example, for winter crops in autumn, spring, summer. The specific yield is determined in different ways. Most often, this is done by workers and agricultural specialists by means of an eye expert assessment based on taking into account the condition of plants: their appearance, density, development, condition. The regression method of analysis and forecast can be effectively used. At the same time, according to the actual mass data over the past years, the relationship between the yield and the indicators of the state of the plant for a certain time, as well as the most significant indicators of meteorological conditions, is studied.
With the development of astronautics, the state of crops and species yield began to be assessed by the method of space sensing. It is fundamentally new way obtaining statistical (summary) indicators for large territories without using traditional methods statistical observation for the value of attributes for each unit of the population and their further summary.
A standing crop before the start of timely harvesting is a grown, real, but not yet harvested crop. The biological process of crop formation is completed, but the economic one is not yet. In economic practice, this crop is determined expertly, as well as instrumentally, in two ways:
By selectively harvesting the entire crop without losses in small areas (meters) and weighing it.
By selectively determining the number of plants and the weight of production from 1 plant, the product of which gives the yield. The weight of production from 1 plant can be established by direct weighing, or by counting the number of ears and grains on a plant, by determining their weight, multiplying which gives the weight of production from 1 plant.
The standing crop can also be determined by adding the loss to the actual harvest. Losses are determined expertly or by instrumental sampling method for all possible channels. For example, grain losses can be from shedding, uncut and fallen ears, their incomplete threshing, grain getting into straw and chaff, “during loading, unloading, transportation, cleaning and drying of the crop, etc. different cleaning methods are usually determined experimentally. So, when harvesting on the same plots at different times, it is possible to determine losses for each day of delay in harvesting in the form of a regression coefficient, to build graphs of losses depending on the timing.
The actual harvest (gross harvest, or barn yield) is determined by direct weighing, measuring and counting products during the harvesting period and after its completion. There are three indicators of actual collection:
In the originally recorded weight obtained in the process of harvesting grain, sunflower, that is, with an admixture of weeds, earth, high humidity. Previously, this weight was called bunker. This is a real category of the harvested, transported, paid harvest at the first stage of its receipt.
Weight after processing, i.e. after deducting waste and shrinkage. Now this is the main indicator of the harvest, although earlier (until 1990) the main indicator in the statistics was the originally recorded weight, which significantly (by 9-12%) overestimated the level of harvest and yield. In this regard, when analyzing the dynamics of the yield, it is important to monitor the comparability of data.
In terms of weight converted to standard quality indicators (corn grain, hay of established moisture content), or in the test weight adopted by procurement organizations (tobacco).
The main performance indicators of agricultural enterprises include not only the harvest, but also the yield. The entire system of farming is concentrated in the level of crop yields: the technology of cultivation of crops, the level of mechanization, electrification and automation, the organization of production, labor and management.
Productivity is the amount of products obtained from 1 hectare of crop sowing. Increased yield - the most important factor reducing costs per unit of production and increasing its competitiveness in the market. Due to limited land, only an increase in yield can provide an increase in crop production. The most important task is to conduct a comprehensive economic and statistical analysis of yields, monitor the implementation of the yield plan, analyze its dynamics, compare yields by territorial formations, compare yields in experimental institutions and in ordinary farms in order to find reserves and ways to increase yields. This is especially important for Russia, where the yield of the main crops is only 30-50% of what is possible and achieved in countries and farms with a high intensity of production and agricultural culture. The development of methods for obtaining and analyzing yield indicators serves as an important basis for the analysis of other productive indicators of agriculture.
Field crop yields are differentiated depending on the type of crop and the category of sown areas. Usually distinguish between: species yield; growing yield before the start of timely harvesting; actual levy per hectare (in originally capitalized weight and after revision).
The specific yield is determined by eye-measurement of crops at different periods of their development. In this case, the density of seedlings, the degree of development of plants, the degree of tillering, the corresponding density of the plant, size, etc. are taken into account.
Standing yield is determined in three ways:
) visually, by carefully examining the crops before harvesting (subjective method);
) instrumentally, by selectively imposing meter marks on crops before harvesting (objective method);
) by calculation (method of balance calculations).
When assessing the growing yield, it is necessary to take into account the constituent elements that directly determine the value of the yield. The value of these elements is taken into account selectively when determining the types of crops. Comparing such values \u200b\u200bwith the corresponding standards for different stages of the growing season, a conclusion is made about the possible level of yield.
The actual average collection per hectare is determined by calculating:
) To the spring productive area.
) On the actually harvested area.
The main indicator of the yield, the state statistics considers the yield per spring productive area. The actual fee is determined through normal business accounting and is reflected in the annual reports.
The yield is calculated for each crop separately for the main and secondary (roots and tops), the main and associated products, as well as in terms of the main products. The state of crop yields is determined by a number of factors, both economic and natural.
Labor productivity is the main indicator of the economic efficiency of sunflower production. Identification of reserves and ways to increase labor productivity should be based on a comprehensive technical and economic analysis of the enterprise. Analysis of labor productivity allows you to determine the effectiveness of the use of labor resources and working hours. The inverse indicator of labor productivity - labor intensity is characterized by the cost of labor for the production of a unit of output or all produced output and is measured in units of time.
The economic efficiency of sunflower production is characterized by a system of indicators. One of critical indicators the efficiency of production is the cost, which reflects the efficiency of resource use, the results of the introduction of new equipment and progressive technology, the improvement of labor organization, production and management. The prime cost consists of the costs associated with the use of fixed assets, raw materials, materials, fuel and energy, labor, and other costs required for the production of products.
1.3 Forms and principles of organizing sunflower production
Sunflower is one of the main agricultural crops. The main tasks of enterprises engaged in the cultivation of this crop are to make a profit, fulfill contractual obligations for the sale of products and provide livestock with feed. At the same time, the task of improving the quality of products is being solved, which has a certain effect on the profitability of production.
In the technology of sunflower production, there are two main periods - soil preparation and sowing, as well as a set of harvesting operations. Soil preparation and sunflower sowing are almost completely mechanized. The final results of production depend on the quality and timely implementation of these works. Their implementation is associated with high energy costs. Soil preparation includes basic tillage - stubble plowing, plowing or non-moldboard cultivation and pre-sowing cultivation. Sunflower is cultivated in almost every enterprise. The exception is highly specialized livestock enterprises (poultry farms, pig breeding complexes).
There are the following features of sunflower cultivation:
1)to obtain high yields, it is necessary to apply both organic and inorganic fertilizers;
2)the need for inter-row cultivation and hilling of crops;
3)the need for dissociation of fields.
These features of sunflower cultivation also cause additional monetary, technical, material and time costs.
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