Industry Overview
Coconut is an important tropical crop used for a wide range of food, oil, beverage, confectionery, and value-added products. Coconut water is a refreshing, hygienic, and nutritive beverage, while the white coconut flesh is widely used in South Indian cookery. Coconut kernel can also be processed to obtain oil, protein, carbohydrates, coconut honey, desiccated coconut, coconut milk, flour, and other products.
Desiccated coconut is an important ingredient for the chocolate and confectionery industry. Its production involves shelling, paring, washing, shredding, pasteurization, drying, and sieving to obtain grades such as extra fine, macaroon, medium, and coarse. Proper drying is essential because moisture levels above the critical level can adversely affect shelf life and quality. High-quality desiccated coconut should be white, free from foreign matter, uniformly granulated, and produced from oil with a low free fatty acid content.
Coconut is also a major source of edible oil. Copra and fresh coconut meat can be processed through different extraction methods to produce coconut oil and virgin coconut oil. The industry additionally supports the manufacture of coconut water products, coconut milk and cream, coconut flour, coconut milk powder, coconut chips, coconut shell charcoal, activated carbon, coir products, and compost.
India is identified in the report as a major coconut-producing country, with millions of people depending on coconut cultivation and processing for their livelihood. The diverse applications of coconut provide opportunities for integrated processing and the development of value-added coconut products.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 31500 Kg./Day |
| Land & Building (6 Acres) | Rs. 16.56 Cr |
| Plant & Machinery | Rs. 10.29 Cr |
| Working Capital for 2 Months | Rs. 11.75 Cr |
| Total Capital Investment | Rs. 39.62 Cr |
| Rate of Return | 35% |
| Break Even Point | 44% |
Content Index
- INTRODUCTION
- EXTRACTION OF COCONUT OIL
- COMPOSITION OF FRESH COCONUT KERNEL AND COPRA
- MECHANICAL EXTRACTION OF COCONUT OIL FROM THE FRESH COCONUT MEAT:
- COCONUT WATER
- TENDER COCONUT WATER
- ANALYSIS OF MATURE AND TENDER COCONUT WATER
- SUGARS
- MINERALS
- PROTEIN
- AMINO ACID COMPOSITION OF COCONUT WATER (% OF TOTAL PROTEIN)
- VITAMINS
- VITAMINS OF B GROUP IN COCONUT WATER
- RHEOLOGICAL BEHAVIOUR OF TENDER COCONUT (COCOS NUCIFERA L) WATER & ITS CONCENTRATES
- COCONUT SHELL
- DECOLORISING CHARCOAL
- GAS ABSORBENT CARBONS
- METAL ABSORBENT CHARS
- MEDICINAL CARBONS
- TYPES OF EDIBLE COCONUT OIL
- REFINED, BLEACHED AND DEODORISED COCONUT OIL
- VALUE ADDED COCONUT PRODUCTS
- CHEMICAL COMPOSITION OF COCONUT OIL
- CHARACTERISTICS OF COCONUT OIL
- TABLE: COMPARATIVE FATTY ACID PROFILE OF COMMON FATS AND OILS
- B.I.S SPECIFICATION
- VIRGIN COCONUT OIL
- USES AND HEALTH BENEFITS OF VIRGIN COCONUT OIL
- THE CURRENT EMERGING MAJOR USES OF VCO ARE:
- VCO AS A VERSATILE PRODUCT
- HEALTH BENEFITS OF VCO
- QUALITY STANDARDS OF VIRGIN COCONUT OIL
- MARKET OVERVIEW OF COCONUT PRODUCTS
- COCONUT PRODUCTS MARKET
- COCONUT PRODUCTS MARKET
- MARKET POSITION OF COCONUT OIL
- STRENGTHS
- WEAKNESSES
- OPPORTUNITIES
- MICRO LEVEL STRATEGIES
- COCONUT BASED CROPPING/FARMING SYSTEMS
- CLOSED MARKET ECONOMY
- SHARE OF AREA UNDER COCONUT IN MAJOR COCONUT GROWING STATES IN INDIA – AREA
- COUNTRY WISE PRODUCTION OF COCONUT
- COUNTRY WISE SHARE IN AREA UNDER COCONUT
- AGENTS OF THE MILLERS
- VIRGIN COCONUT OIL
- CONSITUENT AND ANTIOXIDANT ACTIVITY OF COCONUT WATER
- EXTRACTION OF THE CONSTITUENTS FROM SAMPLES OF COCONUT WATER BY HYDRODISTILLATION
- EXTRACTION OF THE CONSTITUENTS FROM SAMPLES OF COCONUT WATER USING PETROLEUM ETHER
- ANTIOXIDANT ASSAY
- RESULTS AND DISCUSSION
- DETAILS OF COCONUT PRODUCTS AND PROCESSING
- COCONUT WATER
- COCONUT MILK AND CREAM
- CLASSIFICATION OF COCONUT MILK AND CREAM
- TABLE
- COCONUT MILK BEVERAGES
- COCONUT OIL
- RBD COCONUT OIL
- VIRGIN COCONUT OIL (VCO)
- COCONUT FLOUR
- COCONUT MILK POWDER
- DESICCATED COCONUT
- COIR COMPOST
- METHOD OF COMPOST HARVEST
- NUTRITIVE VALUE OF RAW AND COMPOSTED COIR PITH COMPOST
- BENEFIT, APPLICATION AND LIMITATION OF COMPOSED COIR PITH
- APPLICATION OF COIR PITH COMPOST
- LIMITATION IN USING COMPOSTED COIR PITH
- TECHNOLOGY OF COIR PITH COMPOSTING
- COLLECTION OF RAW MATERIAL
- COIR PITH HEAP
- SITE SELECTION FOR COMPOSTING
- COIR PITH COMPOST HEAP
- PLEUROTUS
- TURING OF MATERIAL
- MOISTURE MAINTENANCE
- COMPOST MATURITY
- PRESENT MANUFACTURERS/SUPPLIERS OF VIRGIN COCONUT OIL
- DIFFERENT PROCESSES OF VIRGIN COCONUT OIL EXTRACTION
- COLD EXTRACTION PROCESSES
- CHILLING, FREEZING AND THAWING METHOD
- CENTRIFUGATION METHOD
- FERMENTATION METHOD
- AQUEOUS ENZYMATIC EXTRACTION METHOD
- HOT EXTRACTION PROCESS
- TECHNOLOGIES FOR VIRGIN COCONUT OIL PRODUCTION
- FIGURE: SCHEMATIC DIAGRAM OF VCO PROCESS TECHNOLOGIES UNDER THE FRESH-DRY PROCESS
- FIGURE: SCHEMATIC DIAGRAM OF VCO PROCESS TECHNOLOGIES UNDER THE FRESH-WET PROCESS
- CLASSIFICATION & COMPOSITION OF COCONUT FLOUR
- PROXIMATE COMPOSITION OF COCONUT FLOUR
- PROPERTIES OF COCONUT FLOUR
- USES AND APPLICATIONS OF COCONUT FLOUR
- COCO FLOUR (HIGH-PROTEIN)
- COCO FLOUR (HIGH-FIBER)
- POPULAR BREADS & CAKES THAT CAN BE FORTIFIED WITH HIGH-PROTEIN COCONUT FLOUR:
- ACCEPTABLE LEVELS OF COCONUT FLOUR (HIGH-FIBER) AS AN ADDITIVE IN FOOD PRODUCTS
- MANUFACTURING PROCESS OF COCONUT WATER
- FLOW SHEET
- MANUFACTURING PROCESS OF VIRGIN COCONUT OIL
- PROCESS FLOW DIAGRAM
- ANALYSIS OF DIFFERENT PROCESSES FOR PRODUCING VIRGIN COCONUT OIL (VCO)
- MANUFACTURING PROCESS OF VIRGIN COCONUT OIL AND COCONUT FLOUR
- QUALITY CHARACTERISTICS OF VCO PRODUCED FROM THE PCA DEVELOPED PROCESS:
- THE SUMMARY OF THE TWO PROCESSING OPTIONS ARE SHOWN IN THE FOLLOWING TABLE:
- PROCESS FLOW DIAGRAM
- VIRGIN COCONUT OIL EXTRACTION METHODS
- THE FRESH-DRY LOW PRESSURE OIL EXTRACTION METHOD
- FIGURE: THE FRESH-DRY LOW PRESSURE OIL EXTRACTION METHOD
- FIGURE: BRIDGE PRESS DEVELOPED BY THE NATURAL RESOURCES INSTITUTE, UNITED KINGDOM
- THE FRESH-DRY DIRECT MICRO EXPELLING PROCESS
- FIGURE: MOTORISED DME GRATER
- FIGURE: OTHER TYPES OF COCONUT GRATER BEING USED BY VCO PROCESSORS IN FIJI
- FIGURE: DRYING OF GRATED KERNEL IN A STANDARD DME FLAT BED DIRECT CONTACT TYPE DRYER
- DRYING IS THE MOST CRITICAL PART IN THE DME PROCESS FOR THE FOLLOWING REASONS:
- FIGURE: LOADING OF DRIED GRATED KERNEL IN THE DME CYLINDER THROUGH A BUILT-IN FEED HOPPER.
- FIGURE: LOW PRESSURE OIL EXTRACTION USING A DME PRESS
- FIGURE: NEW ZEALAND PRESS
- POST PROCESSING STAGE OF VIRGIN COCONUT OIL
- OIL DRYING
- FIGURE: IMPROVISED DOUBLE BOILER
- AGEING
- FINE FILTRATION OF VCO
- PACKAGING AND STORAGE
- USES AND APPLICATION OF COCONUT SHELL CHARCOAL
- B.I.S. SPECIFICATIONS
- SPECIFICATION OF CHARCOAL
- MARKET OVERVIEW OF COCONUT SHELL CHARCOAL & ACTIVATED CARBON
- OVERVIEW OF COCONUT SHELL POWDER
- UNIFORM QUALITY AND COMPOSITION:
- HIGH FLUCTUATING PRICES OF RAW MATERIAL:
- MANUFACTURING PROCESS OF COCONUT SHELL CHARCOAL
- PROCESS FLOW DIAGRAM
- METHODS OF COCONUT SHELL CHARCOAL MAKING
- THE DRUM METHOD OF MAKING COCONUT SHELL CHARCOAL
- COCONUT SHELL CHARCOAL BRIQUETTE MANUFACTURE & ADVANTAGES
- PROCESSING DETAILS OF COCONUT SHELL CARCOAL
- CHARCOAL PRODUCTION
- ACTIVATION PROCESS
- CHARCOALING
- MANUFACTURING PROCESS OF ACTIVATED CHARCOAL
- CHEMICAL ACTIVATION
- ACTIVATED CHARCOAL FROM COCONUT SHELL
- DEMAND FOR ACTIVATED CARBON IN INDIA BY END USE
- INDIAN DEMAND SUPPLY SCENARIO FOR ACTIVATED CARBON
- DIFFERENT TYPES OF ACTIVATED CHARCOAL
- ABSORBING GASES OR VAPOUR (GAS ABSORBENT CARBON)
- DECOLORIZING AND PURIFYING LIQUID
- CATALYST & CATALIST SUPPORT (GAS ABSORBENT CARBON)
- MEDICINE
- BENEFITS OF COCONUT SHELL CHARCOAL
- PROCESS OF COCONUT MILK POWDER
- PRODUCT SPECIFICATION
- COCONUT CHIPS
- NUTRITIONAL INFORMATION
- PROCESS OF COCONUT CHIPS
- PROCESSING DETAILS OF COCONUT CHIPS
- PROCESSING METHOD
- PRODUCTION OF COCONUT CHARCOAL
- COCONUT CHARCOAL BRIQUETTES
- TECHNOLOGY OF COCONUT SHELL CHARCOAL
- MANUFACTURING PROCESS OF COIR YARN
- PRINCIPLES OF PLANT LAYOUT
- MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE: PLANT LOCATION FACTORS
- 1. RAW-MATERIAL SUPPLY:
- 2. MARKETS:
- 3. POWER AND FUEL SUPPLY:
- 4. WATER SUPPLY:
- 5. CLIMATE:
- 6. TRANSPORTATION:
- 7. WASTE DISPOSAL:
- 8. LABOR:
- 9. REGULATORY LAWS:
- 10. TAXES:
- 11. SITE CHARACTERISTICS:
- 12. COMMUNITY FACTORS:
- 13. VULNERABILITY TO WARTIME ATTACK:
- 14. FLOOD AND FIRE CONTROL:
- EXPLANATION OF TERMS USED IN THE PROJECT REPORT
- 1. DEPRECIATION:
- 2. FIXED ASSETS:
- 3. WORKING CAPITAL:
- 4. BREAK-EVEN POINT:
- 5. OTHER FIXED EXPENSES:
- 6. MARGIN MONEY:
- 8. LAND AREA/MAN POWER RATIO:
- PROJECT IMPLEMENTATION SCHEDULES
- INTRODUCTION
- PROJECT HANDLING
- PROJECT SCHEDULING
- PROJECT CONSTRUCTION SCHEDULE
- TIME SCHEDULE
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF COCONUT
- SUPPLIERS OF PET BOTTLES
- SUPPLIERS OF COCONUT PROCESSING PLANT
- SUPPLIERS OF COCONUT CHIPS PLANT
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF COCONUT SHELLING MACHINE
- SUPPLIERS OF HAMMER MILL
- SUPPLIERS OF OIL FILTER STORAGE TANKS
- SUPPLIERS OF VOLUMETRIC PACKAGING MACHINE
- SUPPLIERS OF PARING MACHINE
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Coconut can be processed into a wide range of food, oil, beverage, fuel, and industrial products. These include coconut oil, virgin coconut oil, coconut water, coconut milk and cream, coconut milk powder, coconut flour, desiccated coconut, coconut chips, coconut shell charcoal, activated carbon, charcoal briquettes, coir yarn, and coir compost. Integrated coconut processing can improve utilization of the kernel, shell, water, and coir by-products while creating multiple value-added product streams.
Coconut oil can be extracted from fresh coconut meat using mechanical and other processing methods. Depending on the desired product, the kernel may be prepared through grating, drying or wet processing before oil separation. Virgin coconut oil can be produced using approaches such as cold extraction, centrifugation, fermentation, aqueous enzymatic extraction, and hot extraction. The selected process influences oil recovery, processing conditions, product characteristics, and subsequent filtration, drying, packaging, and storage requirements.
Desiccated coconut is manufactured by shelling and paring the coconut, followed by washing, shredding, pasteurization, drying, and sieving. The brown rind is carefully removed to prevent discoloration of the finished product. Shredded kernel is heat-treated to reduce microorganisms and then dried with hot air to achieve a low moisture content. Multiple sieving operations produce grades including extra fine, macaroon, medium, and coarse. Proper drying and hygienic handling are important for product quality and shelf life.
Drying is important because controlling moisture helps maintain the quality and storage stability of coconut products. In desiccated coconut production, excessive moisture can reduce shelf life and contribute to deterioration. The report identifies 5% as the critical moisture level for desiccated coconut and states that the product should be dried well below this level. Drying conditions also need to be controlled to preserve desirable colour, texture, flavour, and overall product quality.
Virgin coconut oil can be produced using several cold and hot extraction techniques. The report covers chilling, freezing and thawing, centrifugation, fermentation, aqueous enzymatic extraction, hot extraction, fresh-dry low-pressure extraction, and direct micro expelling. Process selection depends on the raw material condition, equipment configuration, desired oil characteristics, processing efficiency, and downstream requirements. Post-processing operations can include oil drying, ageing, fine filtration, packaging, and storage.
Coconut shells can be converted into charcoal, charcoal briquettes, activated carbon, and shell powder. Coconut shell charcoal is produced through controlled carbonization, while activated carbon can undergo additional activation to develop adsorption properties. These materials can be used for applications involving gas or vapour absorption, liquid decolorization and purification, catalyst support, and other industrial purposes. The report also discusses manufacturing methods, specifications, processing details, and market considerations for coconut shell charcoal and activated carbon.
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