PRODUCTION PROCESS
Production Structure and Quality Management
The production structure is designed to meet the technological demands of processing sunflower seeds, rapeseed, and soybeans into premium oil and meal, our core products. Our quality and food safety management system, certified to DSTU ISO 22000 standards, is continuously refined to maintain the highest standards.
The production structure is designed to meet the technological demands of processing sunflower seeds, rapeseed, and soybeans into premium oil and meal, our core products. Our quality and food safety management system, certified to DSTU ISO 22000 standards, is continuously refined to maintain the highest standards.
- 🚂 2,500 TPDRaw material intake capacity by railway
- 🏢 100,000 m³Storage volume capacity
- 🌻 330,000 TPYSunflower seed processing capacity
The main production units of our enterprise include:
- Raw Material Workshop: Responsible for accepting, drying, cleaning, and storing raw materials.
- Oil Extraction Unit: Includes sections for crumbling, pressing, filtering, and extracting oil, as well as husk and meal hydration and granulation.
- Finished Products Workshop: Handles storage, shipment, and railway logistics.
- Laboratory: Ensures quality control and safety.
- Engineering Services: Includes steam power, energy facilities, a mechanical workshop, and a road transport section.
1st STAGE
Raw Material Intake
Our facility accepts up to 2,500 tons of raw materials per day. Seed sampling is conducted using an advanced COBRA 4012 Standard monorail automatic sampler (France), ensuring precision and consistency. Each batch of sunflower seeds, soybeans, and rapeseed undergoes rigorous analysis in our certified laboratory, where we verify quality based on key metrics, including foreign matter, moisture, and oil content, in compliance with regulatory standards.
Accepted materials are weighed on two heavy-duty scales (80-ton and 60-ton capacity). The raw material workshop is equipped with a comprehensive grain cleaning and drying complex, featuring a grain dryer powered by a sunflower husk-fueled heat generator. This allows us to achieve target moisture levels (below 8%) and purity standards (no more than 3% impurities).
After quality control, materials are stored, ready for further processing. Unloading takes place at four designated points, facilitated by hydraulic truck unloaders and dump trucks for efficient handling.
Accepted materials are weighed on two heavy-duty scales (80-ton and 60-ton capacity). The raw material workshop is equipped with a comprehensive grain cleaning and drying complex, featuring a grain dryer powered by a sunflower husk-fueled heat generator. This allows us to achieve target moisture levels (below 8%) and purity standards (no more than 3% impurities).
After quality control, materials are stored, ready for further processing. Unloading takes place at four designated points, facilitated by hydraulic truck unloaders and dump trucks for efficient handling.
2nd stage
Raw Material Storage
Our facility includes a high-capacity elevator with four metal silos, providing consumable storage designed for maximum efficiency. These silos offer a total storage volume of 100,000 cubic meters, allowing for flexible, one-time storage options, including:
- 40,000 tons of sunflower seeds
- 75,000 tons of soybean seeds
- 65,000 tons of rapeseed
3rd STAGE
Processing – Oil Extraction Production
Sunflower Seed Preparation for Oil Extraction
Our oil extraction plant begins with the precise preparation of sunflower seeds, soybeans, and rapeseed. In a continuous flow, seeds enter the crumbling department, where they undergo cleaning, dehulling, and sorting. A high-efficiency separator removes impurities, achieving regulatory standards for foreign matter. Cleaned seeds are weighed and then moved to the dehulling section, where the husk is separated from the kernel. Separated husk is repurposed as a sustainable fuel source for steam generation within our facility, while excess husk is sent for pelleting to create eco-friendly fuel pellets.
Our oil extraction plant begins with the precise preparation of sunflower seeds, soybeans, and rapeseed. In a continuous flow, seeds enter the crumbling department, where they undergo cleaning, dehulling, and sorting. A high-efficiency separator removes impurities, achieving regulatory standards for foreign matter. Cleaned seeds are weighed and then moved to the dehulling section, where the husk is separated from the kernel. Separated husk is repurposed as a sustainable fuel source for steam generation within our facility, while excess husk is sent for pelleting to create eco-friendly fuel pellets.
Press Oil Production Process
Dehulled sunflower, soybean, or rapeseed kernels are crushed in roller mills in the press department. The crushed kernels then undergo moisture-heat treatment to optimize oil yield. This treatment process, conducted in specialized braziers, allows for efficient extraction of press oil on the oil presses. This stage results in:
Dehulled sunflower, soybean, or rapeseed kernels are crushed in roller mills in the press department. The crushed kernels then undergo moisture-heat treatment to optimize oil yield. This treatment process, conducted in specialized braziers, allows for efficient extraction of press oil on the oil presses. This stage results in:
- Press Oil - directed to the filtration department for primary purification.
- Oil Cake - transferred to the extraction department for further oil recovery.
| Extraction Process of Oil from Oil Cake The cake exiting the pressing phase still contains approximately 16-21% oil. To extract this remaining oil, the cake is processed in the extraction department using a hexane solvent. This extraction method separates the material into:
|
Oil Purification and Filtration Process
Both press and extraction oils undergo rigorous purification. Press oil is initially filtered to remove suspended particles, using fusor traps and vertical filters, before being dried, weighed, and stored in dedicated tanks. Extraction oil is processed through the hydration department for additional purification, ensuring top-grade quality. During this process, a valuable byproduct, phosphatide concentrate (lecithin), is created and stored separately for commercial use.
Both press and extraction oils undergo rigorous purification. Press oil is initially filtered to remove suspended particles, using fusor traps and vertical filters, before being dried, weighed, and stored in dedicated tanks. Extraction oil is processed through the hydration department for additional purification, ensuring top-grade quality. During this process, a valuable byproduct, phosphatide concentrate (lecithin), is created and stored separately for commercial use.
Meal Granulation for Storage Efficiency
The non-granulated toasted meal is further processed in the granulation department to create granulated meal, which is easier to store and transport. Granulation also helps achieve consistent moisture and temperature levels, essential for long-term storage. Granulated meal, which has a higher density (0.6 tons per cubic meter), is stored in our meal warehouse’s conical silos, optimizing space and reducing transportation costs.
The non-granulated toasted meal is further processed in the granulation department to create granulated meal, which is easier to store and transport. Granulation also helps achieve consistent moisture and temperature levels, essential for long-term storage. Granulated meal, which has a higher density (0.6 tons per cubic meter), is stored in our meal warehouse’s conical silos, optimizing space and reducing transportation costs.
Fuel Pellet Production and Storage of Husk
Excess husk, not used in steam generation, is granulated into fuel pellets in our husk granulation department. These fuel pellets are stored in the granulated husk warehouse and sold in bulk or packaged in Big-bags, meeting demand for sustainable fuel options.
Excess husk, not used in steam generation, is granulated into fuel pellets in our husk granulation department. These fuel pellets are stored in the granulated husk warehouse and sold in bulk or packaged in Big-bags, meeting demand for sustainable fuel options.
Finished Goods Storage Capacities
4th Stage
- Up to 5,700 Tons 🛢️Capacity for high-quality vegetable oil storage
- Up to 5,000 Tons 🌾Granulated meal storage capacity
- Up to 1,500 Tons ♻️Pelleted husk storage
- Up to
40 Tons 🧴Phosphatide concentrate storage capacity
5th STAGE
Shipment of Finished Products
| Our facility handles efficient shipping of all finished products, including vegetable oil, meal, and pelleted husk, through railway transport and road logistics. Using railway tanks, grain carriers, and specialized containers, we ensure safe and timely delivery to our clients. The phosphatide concentrate is primarily transported by road for enhanced distribution flexibility. Located within the plant are four dedicated railway tracks with dead-end capacity, designed to hold up to 55 rolling stock units, allowing efficient movement of rail cars across tracks. Our automated loading workshop accommodates 8 railway tanks for oil and 8 railway grain carriers for meal, streamlining the loading process for bulk quantities. With a loading capacity of up to 1,200 tons of oil and 1,200 tons of meal per day, our facility ensures swift and reliable shipments. The internal railway network spans 1 kilometer, and two rail scales are available for precise weight management. |
Laboratory
Our certified laboratory is equipped with advanced technology and state-of-the-art measurement tools, allowing for rigorous quality control of all raw materials and finished products throughout the production process. At each stage, our skilled team ensures that the quality standards of oil, meal, phosphatide concentrate, and granulated husk are consistently met. This dedication to precision and quality guarantees products that meet industry and regulatory standards, ensuring superior quality in every batch.
Energy economy
Boiler room. Two boilers - E-10.0-2.4R and DKVR 6.5 / 13. Fuel is husk.
The total steam productivity is 16 t / h.
Electrical site. The power supply of the plant is provided by a 35 kV cable line, and there are also 2 backup lines of 10 kV. Substation with a 35 / 10kV high-voltage transformer with a power of 4 MW and a 10 kV complete switchgear, consisting of six KRUN cells, equipped with vacuum switches, microprocessor relay protection and automation. Three high-voltage substations with transformers - 10 / 0.4 kV. The maximum permitted power consumption is 3000 kW / h. The voltage class is the first. Reliability category - III. The enterprise has an automatic system for commercial metering of electricity.
In the event of an emergency power outage, the power supply circuit has a diesel generator with a capacity of 330 kW, equipped with an automatic transfer switch (automatic transfer switch).
Water supply. 2 artesian wells, a water supply network with a total length of 1.5 km.
Fire water supply - about 1 km, 2 fire tanks with a capacity of 650 cubic meters, automatic water supply.
Sewerage and stormwater network with a total length of more than 1 km.
The total steam productivity is 16 t / h.
Electrical site. The power supply of the plant is provided by a 35 kV cable line, and there are also 2 backup lines of 10 kV. Substation with a 35 / 10kV high-voltage transformer with a power of 4 MW and a 10 kV complete switchgear, consisting of six KRUN cells, equipped with vacuum switches, microprocessor relay protection and automation. Three high-voltage substations with transformers - 10 / 0.4 kV. The maximum permitted power consumption is 3000 kW / h. The voltage class is the first. Reliability category - III. The enterprise has an automatic system for commercial metering of electricity.
In the event of an emergency power outage, the power supply circuit has a diesel generator with a capacity of 330 kW, equipped with an automatic transfer switch (automatic transfer switch).
Water supply. 2 artesian wells, a water supply network with a total length of 1.5 km.
Fire water supply - about 1 km, 2 fire tanks with a capacity of 650 cubic meters, automatic water supply.
Sewerage and stormwater network with a total length of more than 1 km.