Assignment

A REPORT ON INDUSTRY VISIT:

Date of Visit: 5TH February, 2020

In this report we have put forward a study of the Adani Wilmar plant in Haldia
where a plant visit was organized. The study focuses on plant’s layout, products
that are edible oils they manufacture and the processes they follow to accomplish
them. This report also includes whereabouts regarding the inventory management
and logistics and supplychain of the products and the methods they apply to
forecast demand and how it influences the production and availability of the
products in the market. The manpower distribution was also observed but the plant
mostly favors automation which was witnessed during the visit. The report
includes diagrams and images for representation.

Keyword: Adani Wilmar, plant layout, soybean oil, palm oil, inventory.
INTRODUCTION

Adani Wilmar Limited (AWL) is a joint venture incorporated in January 1999

Today, AWL owns more than 40 units that cumulatively translate to a refining
capacity of over 16800 tonnes per day, seed crushing capacity of 6000 tonnes per
day and packaging capacity of 12900 tonnes per day.

The Company has the largest range of edible oils spanning across the categories of
Soya, Sun, Mustard, Rice bran, Groundnut, Cottonseed and the revolutionary Vivo
oil. The company has extended its basket of offering with the introduction of soap
– Alife. Besides oil, AWL has also forayed into packed Basmati Rice, Pulses, Soya
Chunks, Besan and Wheat Flour. The product portfolio of Adani Wilmar spans
under various brands such as - Fortune, King’s, Bullet, Raag, Avsar, Pilaf, Jubilee,
Fryola, Alife, Alpha and Aadhaar.

AWL has the largest distribution network among all branded edible oil players in
India, with 95 stock points, 5000 distributors and *10% Retail Penetration which
spans across approx. 1 Million outlets all over India. Fortune is one of the most
prestigious, consumer trusted and well marketed brands of the Adani Wilmar
Group and became the market leader in its segment within 2 years of its launch in
India.

Adani Wilmar Limited also caters to institutional demand through its industry
essential range which includes bulk packs of consumer essentials as well as Lauric
& Bakery fats, Castor Oil derivatives, Oleo chemicals and Soya value added
products. A state-of-the-art Oleo chemical plant at Mundra gives an unmatched
output of 400 TPD and it is one of the largest single location facilities in India. The
extensive array of products includes fatty acids, stearic acids, soap noodles and
refined glycerin. The company also has a combined processing capacity of 1200
MT of castor seeds per day with solvent and refining units.
The castor oil manufacturing facilities are equipped with cutting-edge technology
to manufacture different grades of castor oil such as cold pressed, pharma grade
and low moisture oil.

Following the success in India, Adani Wilmar has introduced branded Edible oil to
Middle-East and is now exporting its products including Lecithin, Castor & Soya
value added products to more than 19 countries in the Middle-East, South East
Asia & East Africa including Singapore, Australia & New Zealand.

AWL has associated with Adani Foundation, the CSR arm of Adani Group in the
quest against malnutrition and anaemia among communities living in remote areas
of the country as a part of ‘Corporate Social Responsibility’ initiatives.

The ‘SuPoshan’ project has adopted a life cycle approach with a strong component
on Community based management and focusing on children of 0-5 years age
group, adolescent girls as well as reproductive age women in general. Sangini, a
village health volunteer plays a pivotal role in spreading awareness and promoting
behavior change at community and family level.

PLANT LAYOUT

The plant layout at Adani Wilmar at Haldia has a dominating strategic position as
it holds a strong and influential arrangement of machines, equipment and services
that are required for the whole process to run without any hassles. All the
departments are performing their job as expected and the workers and superiors
have great coordination with each other. The Adani plant layout provides them
certain advantage in production they are as follows:-

1. The Wight, the volume and mobility of the product.

Hence, the Adani plant layout has an excellent structure that gives them optimum
level of yield from the inputs and the methods they employ for the production
process.
PRODUCTION PROCESS

The plant is having 2 units for the processing of oil namely Haldia 1 and Haldia 2
and the whole process happens without any human touch that means its fully
automated. Each of the plants have refining capacity upto 1600 metric tons/day,
production capacity up to 1800mt/day, neutralization capacity upto 800mt/day.
Crushing capacity upto 7400TPD and packing capacity upto 9000 TPD.

The crude oil is having a lot of impurities so it first of all it is treated with the help
of bleach. The oil is heated up to a temperature of about 90-95 o Celsius after that
it is treated with the bleach to remove all the suspended particles and undesired
materials from the oil. The bleach so used for the process is specially activated
bleach. After all the undesired materials have been removed from the oil, it is
heated up to 120 o Celsius in order to remove all the water (in the form of
moisture) from the oil, because if oil and water are mixed at high temperature they
can lead to accidents.

After the water is removed it is pumped out and sent for further processing. After
the removal of water, the oil enters a chamber which contains only vacuum. The
chamber is then heated to extreme temperature over 250 o Celsius and the pressure
inside the chamber is as high as 749 atm. Pressure, all this is done to remove all the
fatty acids from the oil as they will lead to the hydrogenation of the oil. This
happens because the boiling point of the highly fatty acids is 225-230 o Celsius
above that temperature turn to gas. This gas is collected separately and then
condensed to obtain the solid and liquid fatty acids which are used for the
manufacturing of the soaps.

After removal of fatty acids when the oil is transferred the temperature of oil is
still as high as 160o Celsius, having such a high it cannot be send for the packing,
hence it is cooled in the fan and then sent for the packing to the packing
department.
PRODUCTS

The Company has the largest range of edible oils spanning across the categories of
Soya, Sun, Mustard, Rice bran, Groundnut, Cottonseed and the revolutionary Vivo
oil. The company has extended its basket of offering with the introduction of soap
– Alife. Besides oil, AWL has also forayed into packed Basmati Rice, Pulses, Soya
Chunks, Besan and Wheat Flour. The product portfolio of Adani Wilmar spans
under various brands such as - Fortune, King’s, Bullet, Raag, Avsar, Pilaf, Jubilee,
Fryola, Alife, Alpha and Aadhaar.

LOGISTICS

Adani Wilmar caters demand of all region of all the country. Adani wilmar
accounts of 20% market in edible oil segment. But its prime focuses in northern
part of our country. And Fortune remains No. 1 brand for that reason and in
southern part of India Adani Wilmar prime focus is in sunflower oil and palm oil.
As Adani Wilmar focus in edible oil in haldia plant. So its supply chain also works
accordingly.

1. In this systems after completion of production and packaging the cartons are
loaded in trucks and dispatch to the C&F agents, they take it to the depot
when demand is come from market then distributor place the order to the
depot and then the goods are dispatched to the distributor.

2. Then the goods are send to the retail shops from the distributors and in the
end it reaches the consumer.

3. when demand is come from market then distributor place the order to the
depot and then the goods are dispatched to the distributor. Then the goods
are again delivered to the retailer and ultimately the product is delivered to
the consumer.

4. In the supply chain, when the packaging of goods is done in factory and the
product is ready to dispatch from the warehouse. Then the cartons are loaded
 in the truck (from production department to the truck they filled a truck with
full of consignment by 53 minutes) and dispatched to the institutional shops.
Then the goods are placed in the warehouse of the institutional shops.

5. The goods in the shelf of the super market. Then the products are stored in
the inventory of the institutional shops. Then the materials in the shelves of
supermarket and then from there it reaches to the end consumer.