Karmuhil Producer Company Limited
THE AROMA CROP PROCESSING UNIT OF KARMUHIL ORGANIC FARMS
AROMATIC CROPS PROCESSING UNIT
- Distillation Vats: 1-ton capacity – 2 SS Vats @ 500 kg per vat
- Single (shifting) lid on top for distillation of oil in one vat at a time
- Common SS Condenser for both the Vats in the middle of the Vats
- 3 Compartment SS Oil Separators
- Automatic SS Bottle supplying Round Table
- Automatic SS (variable) Bottle Filling Machine
- Automatic Bottle Capping/Sealing Machine
- Automatic Labeling Machine
- Air Compressor (installed in the Security Room outside the distillation unit) to support the Automatic Machines
- Shredder Machine
|2||RO Water Machine|
|3||RO Water Tank|
|9||Oil Filling Machine|
|13A||Hot (Solar) Water Tank|
|15||Organic Palmarosa Grass From Certified Farms|
|16||Organic Palmarosa Grass From Non - Certified Farms|
|17||Men – Women Workers Rest Rooms|
|18||Men – Women Toilets|
|19||Septic Tank & Soak Pit|
Distillation Process: Steaming
Water Supply: Minimum of 500 ltr per day of water requirement on hold and flow while distillation process is on. A separate steel structure as Water Tower (49 feet above ground, with 12 feet of foundation steel pillars) is constructed on the western side of the Processing Unit. Two polimer Overhead Raw Water Tanks (3000 & 5000 ltr capacity): to supply pumped up bore well water from height to drop into the ground level water purifying system:
Ground level RO Water Purifying System: Output of 250 ltr per hr to store at ground level SS Water Tank (1000 ltr capacity)
Solar Water Heating System:
RO Purified water pumped up from ground level SS tank to the 500 ltr polimer Overhead Purified Water Tank to supply purified water to flow through 5 solar panels to heat the water to fill 500 ltr SS Hot Water Overhead Tank below the solar panels to drop solar heated water to ground level and with high pressure pump the solar heated water is pushed into the boiler of the steam generator.
Steam Generator: Horizontal Multi-tubular Dry Block Non-conventional Energy Producing Device of 300 Kgs per hour with firewood feeder and smoke chimney is used at the Crop Processing Unit. This device is erected within a separate enclosure.
Fuel for the Steam Generator: Farm waste: timber, dry shrubs and waste drops from palmyra trees of the Karmuhil Organic Farms.
Sequence of Product Movement & Process of Distillation Operations
- Depending on the volume of palmarosa grass waiting to be distilled there may be two or three sessions of distillation per day.
- 150 - 400 Kg of palmarosa grass per distillation session will be filled in one of the vats.
- Inward Receipt: Harvested Grass is received into the premises of the distillation unit with Weigh Bridge Bill.
- Storage – palmarosa grass as organic raw material for processing is kept as stock in separate sections of the storage sheds with clearly marked sign boards to distinguish product from certified farms and from non-certified farms.
- 150 - 400 Kg of properly weighed palmarosa grass is brought into the Distillation Unit for each session of distillation
- For the first session of distillation in the morning, the 150 - 400 Kg of palmarosa grass is weighed and brought into the distillation shed and laid beside the steam boiling tanks the previous evening before the workers close work.
- For the second session (and the third session, if necessary), the 150 - 400Kg of palmarosa grass is weighed and brought in while the first or the second session of distilling is in process respectively.
- Filling of RO purified water (when solar heated water is available) into the Steam Generator Water Boiler
- Lighting of fire for the Steam Generator.
- The cooling tower pumps are switched on.
- Appropriate steam pressure for processing the crop in the vat is normally reached within the first 45 minutes of lighting the fire.
- When appropriate steam pressure has been built up, distilled oil begins to flow within the next 45 minutes of the first session of distillation in the day.
- It takes 3 hours for each session of distillation of 150- 400 Kgs.
- The subsequent sessions of distillation in the same day lets the distilled oil to flow within 15 minutes of the session, since the Steam Generator is already well warmed up during the previous session.
- The water from the cooling towers and steam with oil from the vat flow out from the condenser.
- The oil separator provides for three kinds of output: 1) pure aroma oil 2) aroma oil blended with water and 3) waste water
- Pure aroma oil is filtered and bottled temporarily in pet bottles.
- Pure aroma oil is dated and stored.
- The Vats are numbered I & II.
- Palmarosa grass received from non-certified farms is separately distilled and the oil and hydrosol are separately dated with batch number and stored separately.
- After one season of distillation of a single harvest, the distilled oil is bulked, certified product separately from the non-certified product.
- Bulked palmarosa oil is stored in plastic cans at the Karmuhil Producer Company for marketing.
- Palmaros oil is periodically stirred until marketing
- After buyers are sourced, palmarosa oil is transported in plastic cans to the market.
- Palmarosa hydrosol is stored in plastic drums and used as ‘air freshner’ by sprinkling or spraying after diluting in water to the proportion of 1:10 in cow sheds, gardens and halls.
- Diluted palmarosa hydrosol sprinking also serves as mosquito repellent in public places.
- Waste water, not only from the Oil Separator, but also from the Vats, the RO Water Purifying Plant and the steam/water discharged from the Steam Generator and the Water Boiler, is drained to the Waste Water Ground Level Cement Tank and churned up to flow to the nearby water percolation farm pond.
- Steamed palmarosa grass, after distilling, is shredded for composting, cattle feed and mulching.
- After all the non-certified product is distilled, the Vats are cleaned with steam prior to distilling of certified product.
- “Raitha” cleaning powder is used for washing of (1) the channels of the ‘water lock’ on the top of the Vats & (2) the rim of the lid which sits on the ‘water lock’.
- The residual water in the oil separator is drained away and cleaned.
- Pressure steam flow is allowed for a minimum of 30 minutes to sterilize the Vats and the lid before the start of distilling of certified product. The cleaning pressure steam is allowed to flow out into the oil separator as well.