Gokul Refinary 23483p

SUBMITTED TO:

PROF. SANDEEP TRADA, TIMS,

TOLANI INSTITUTE OF MANAGEMENT STUDIES

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Introduction:  The company made a shooting start in the year 1993.  Its history is related to innovation and adventure of

risks and bold decisions made.  The company is mainly engaged in the business of refining vegetable oil including seed procurement, processing, solvent extraction and marketing of edible oil.  The present operation of the company broadly categorized under three heads.  Trading  Manufacturing  Marketing TOLANI INSTITUTE OF MANAGEMENT STUDIES

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The motto of GRSL is, “Work until you achieve God”

Torch Bearers of GOKUL GROUP

Shri Balvant Sinh Rajput Chairman

Shri Kanubhai Thakkar Managing director

GRSL has a well established distribution network spread across 19 states, comprising 18 C&F agents, and their 802 distributors, 3 depots, 15 brokers 295 resellers, distributing its products through a total of 1,133 bulk points of presence. TOLANI INSTITUTE OF MANAGEMENT STUDIES

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 Corporate office: Ahmedabad  International trade: Mumbai • Business type: Exporter , Manufacturer , Importer ,

Supplier.  Export : 35% (Sales)  Import : 80% (Crude Oils)  Export Markets: Europe, USA, Far East countries  Import Markets: South America, Malaysia and Indonesia.  Its an ISO 9001:2000 certified company

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Manufacturing Capacity:  At Sidhpur refinery:  Solvent plant  Oil Crushing  Packing  Warehouse  Seed storage

: 600 TPD : 600 TPD : 200 TPD : 1000 MT : 20000 MT

 At Surat refinery :  Refinery -1  Packaging

: 100 MT : 50 MT

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 At Gokul Refoils & Solvents – Gandhidham  Refinery – 800 TPD  Vanaspati – 200 TPD  Solvent plant – 1500 TPD  Warehouse Storage – 450 MT • Gokul & Zaika are the two brand names under which

Soybean, Cottonseed Oil, Palm Oil, Groundnut Oil, Corn, Mustard, Sunflower & Vegetable are sold

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Competitors: Companies

Brands:

 Adani wilmar

 Fortune

 Ruchi soya

 Soyam

 Parekh food

 Gemini

 Bunge

 Chambal

 N K proteins

 Tirupati

 Amrit Bansal

 Ginni

 Paras Industries

 Mahakosh

 Cargill

 Nature fresh

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Core Processes:  New product development

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 Customer relations

For meeting customer requirements it follows:  Selection of better quality raw materials  Good laboratory practices  Selection of qualified staff  Training programme to improve the skills of employees  Good Manufacturing Practices  Strictly follows quality monitoring systems  Customer feed back – Finding solutions  Supplier relations

 Order fulfillment TOLANI INSTITUTE OF MANAGEMENT STUDIES

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Competitive priorities: • Cost – Low cost operations • Quality – Consistent & Top quality • Time – Delivery speed, On time delivery • Flexibility – Variety

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Competitive advantage:  Location –  Favorable labor climate  Proximity to markets  Quality of life  Proximity to suppliers  Proximity to parent company’s facilities  Tax benefits

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 Power - Gujarat Gokul Power Ltd.

At Tadkeshwar, District- Surat 135 MW Lignite based  Technical knowhow & Operations from last 15 years

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 Quality Control Department:

Testing of oil at each stage

Continuous monitoring Equipments for monitoring the quality

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Inventory management 

Raw Materials  Crude palm oil(O) – Malaysia & Indonesia  Degummed soybean oil – America & Brazil  Cotton seed oil (CSO) – Local suppliers  Lead time for materials- 15 days/30 days for imports and

7 days for CSO

Minimum level of crude oil in tanks – 500 tons. Raw materials taken from the port as per requirement TOLANI INSTITUTE OF MANAGEMENT STUDIES

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 Refined Oil storage

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 Chemicals used:

Caustic soda Bleaching earth Phosphoric acid Citric acid

Lead time for chemicals – 4 to 6 days  Continuous review system

 Monthly targets fixed and production planned

accordingly.  Outside Agency appointed to review oil stock TOLANI INSTITUTE OF MANAGEMENT STUDIES

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STORAGE TANK

CRUDE PALM OIL

OTHERS

NEUTRALIZATION

BLEACHING

BLEACHING

DEODURIZATION

DEODURIZATION

FRACTANATION

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HYDROGENATION

REFINED OIL

PACKING SECTION

DISPATCH

TANKERS TRUCKS

WAREHOUSE

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PRODUCTION PROCESS: Crude Oil includes various impurities like Free Fatty Acids, Pigments, Phospholipids compound, etc.

CRUDE PALM OIL

COTTON SEED OIL DCSO 20

Stage 1 : Neutralization Saponification process : 70 – 80 degree Celsius Caustic Soda reacts to remove Free Fatty Acids Phosphoric Acid reacts to remove phosphorous lipids

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Outcome :  Neutral Oil  Sodium Soap

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Stage 2: Bleaching  Bleaching earth used  110 degree celcius  30 Minutes BLEACHING EARTH

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 Pressure Leaf Filters  Spent Bleaching Earth remains in the storage tank.  Disposal of SBE a matter of concern  Oil being extracted from SBE used in chemical

industries.

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Stage 3: Deodorization Final Stage and the most complicated stage Temperature starts from 260 degree Celsius which gradually comes down to 40 – 50 degree Celsius in six stages. Distilled fatty acid is produced as a by-product

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Fractionation :  Palm Oil is ed through chilling pipe coils  Then oil es through the filter press and pure liquid

of Palm Olene is obtained and Palm Sterene Cake is retained in filter press.

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Hydrogenation:  Molecular structure of fat is altered so that fat

becomes “hardened” so that hydrogenated fat do not turn rancid.

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“Ready to Cook”

Refined Oil TOLANI INSTITUTE OF MANAGEMENT STUDIES

Double Refined Oil 28

 Final Dispatch :

Loose oil in tankers Packed oil in tins , pouches & plastic bottles.

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Learning outcomes:  Type of process – CONTINUOUS PROCESS  Type of product – STANDARDIZED  Production strategy – MAKE TO STOCK  Inventory review – CONTINUOUS  Demand forecasting – EVEN DEMAND  PUSH MODEL for production  Machinery used – SPECIALIZED MACHINERY  Resources are organized around process

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 E R P system used: Corporate MUNIM now SAP

 Dependent demand of chemicals  BOM is prepared  Master Production Schedule is prepared

 Crude oil procured in Bulk Lots  Chemicals purchased in E.O.Q  Bottleneck Identification – DEODOURIZATION

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