Detailed Project Report (DPR) on instant coffee [freeze dried]

 INSTANT COFFEE [FREEZE DRIED]

 [CODE NO.4109] 

Instant (or soluble) coffee has been widely used for decades because of its convenience. During the height of its popularity in the 1970s, nearly a third of the roasted coffee imported into the United States was converted into an instant product, resulting in annual sales of more than 200 million pounds. Today, about 15% of the coffee consumed in the United States is prepared by mixing instant granules with hot water, either at home, in offices, or in vending machines. Furthermore, development of good quality instant products has helped popularize coffee in cultures that historically drank tea.

Since its invention, researchers have sought to improve instant coffee in a variety of ways. For example, some of the early powdered versions did not dissolve easily in water, leaving clumps of damp powder floating in the cup. Coffee aroma dissipates easily, and manufacturers have tried to develop treatments that will make a jar of instant coffee smell like freshly ground coffee when it is opened. More modern manufacturing processes make instant coffee granules that look more like ground coffee. Finally, a major goal has been to produce an instant coffee that tastes as much as possible like the freshly brewed beverage.

The primary advantage of instant coffee is that it allows the customer to make coffee without any equipment other than a cup and stirrer, as quickly as he or she can heat water. Market researchers have also found that consumers like making coffee without having to discard any damp grounds. Some coffee drinkers have become so used to drinking instant coffee that at least one manufacturer found in taste tests that their target audience did not even know what fresh-brewed coffee tastes like.

Two of the 50 known species of coffee beans dominate the beverage coffee industry. Coffee arabica varieties, grown primarily in Latin America, India, and Indonesia, are relatively mild in flavor and, consequently, bring a higher price. They are also relatively expensive to harvest, since individual coffee cherries must be handpicked at their peak of ripeness. Coffee robusta varieties, grown mainly in Africa, India, and Indonesia, have a harsher flavor, but they are cheaper to grow since they can be harvested over a range of ripeness and are more resistant to diseases and insects. Because of their more attractive price, the robustas are widely used in the manufacture of instant coffees.

Roasting at temperatures above 300°F (180°C) drives the moisture out of coffee beans. Beans destined for use in instant products are roasted in the same way as beans destined for home brewing, although the moisture content may be left slightly higher (about 7-10%). The beans are then ground coarsely to minimize fine particles that could impede the flow of water through the industrial brewing system.

COST ESTIMATION

Plant Capacity                                   30 MT./Day  

Land & Building (20,000 sq.mt.)  Rs. 19.66 Cr.    

Plant & Machinery                            Rs. 327.10 Cr. 

Working Capital for 2 Months    Rs. 68.48 Cr 

Total Capital Investment                  Rs. 418.94 Cr 

Rate of Return                                 59%

Break Even Point                          35%

• INTRODUCTION
  
• RAW MATERIALS FOR COFFEE
• GREEN COFFEE PROCESSING
• COMPOSITION OF THE GREEN COFFEE
• B.I.S. SPECIFICATIONS
• COFFEE CONSUMPTION PATTERN AND TRENDS IN INDIA
• MARKET OVERVIEW OF INSTANT COFFEE
• INSTANT COFFEE MARKET GROWTH DRIVERS AND TRENDS:
• GROWTH DRIVERS:
• TRENDS:
• INSTANT COFFEE MARKET PLAYERS PERSPECTIVE:
• COFFEE SECTOR IN INDIA
• THE COFFEE PRODUCTION STATES
• BRANDED COFFEE MARKET IN INDIA
• THE COFFEE TRADE: RETAIL MARKET CONSTRUCT
• PRESENT MANUFACTURERS OF INSTANT TEA AND COFFEE PREMIX
• DESCRIPTION OF INSTANT COFFEE PRODUCTION 
•    [FREEZE DRYING METHOD]
• GENERAL FLOW SHEET OF INSTANT COFFEE PRODUCTION
• (A) EXTRACTION:
• (B) CONCENTRATION:
• FREEZE-DRYING
• STAGES IN INSTANT COFFEE MANUFACTURE [FREEZE DRYING METHOD]
• THE NINE STAGES OF MANUFACTURING INSTANT COFFEE
• STAGE ONE: DELIVERY
• STAGE TWO: ROASTING
• STAGE THREE: GRINDING
• STAGE FIVE: EVAPORATION
• STAGE SIX: FREEZING
• STAGE SEVEN: SUBLIMATION
• STAGE EIGHT: LOST AROMAS READDED
• STAGE NINE: PACKAGING
• INSTANT COFFEE AND PROCESS
• PROCESS FLOW DIAGRAM OF INSTANT COFFEE
• PROCESSING DETAILS OF INSTANT COFFEE BY FREEZE DRYING METHOD
• AROMA IS RECOVERED MAINLY BY TWO METHODS
• FREEZE DRYING AND ITS PRINCIPLE
• STAGES OF FREEZE DRYING
• PRETREATMENT
• FREEZING AND ANNEALING
• STRUCTURALLY SENSITIVE GOODS
• PRIMARY DRYING
• SECONDARY DRYING
• FREEZE DRYING PRINCIPLES
• FREEZE DRYING PRINCIPLES
• SUBLIMATION CONSIDERATION
• FREEZE DRYING PROCESS
• CLEANING-IN-PLACE
• REFRIGERATION
• PROCESS CONTROL
• POLLUTION CONTROL IN COFFEE PROCESSING INDUSTRY
• CHARACTERIZATION OF WASTEWATER FROM COFFEE PROCESSING
•    INDUSTRY:
• TABLE: EFFLUENT STANDARDS-SUGGESTED RANGE FOR POLLUTANTS
•    DISCHARGE INTO INLAND SURFACE WATERS
• SOURCES OF WASTEWATER:
• FIG: WATER BALANCE DIAGRAM
• ENVIRONMENTAL PROBLEMS OF WASTEWATER FROM COFFEE 
•    PROCESSING INDUSTRY:
• COFFEE IS PROCESSED IN TWO WAYS:
• TREATMENT OF WASTEWATER FROM COFFEE PROCESSING INDUSTRY:
• WATER RECYCLING:
• FIG: FLOW CHART ILLUSTRATING WATER RECYCLING PROCESS
• FIG: WATER RECYCLING MECHANISUM
• CONVENTIONAL TREATMENT METHODS:
• IT HAS 3 TANKS:
• FIG: SCHEMATIC FLOW SHEET OF WASTE WATER TREATMENT UNITS
• EQUALIZATION TANK:
• ANAEROBIC TANK:
• AEROBIC TANK:
• AIR POLLUTION AND ITS CONTROL IN COFFEE PROCESSING
• A. ROASTING
• B. QUENCHING
• C. COOLING
• D. DESTINING
• E. GREEN BEAN HANDLING
• F. GRINDING
• G. DECAFFEINATION
• H. CONTROL EQUIPMENT
• RECENT TRENDS IN EFFLUENT TREATMENT FOR COFFEE PROCESSING
• COFFEE PROCESSING EFFLUENT FOR PRODUCTION OF BIOGAS:
• FIG: ANAEROBIC TREATMENT SYSTEM
• COFFEE PROCESSING WASTE MANAGEMENT PRACTICE
• TABLE. AFRICA: COFFEE PRODUCTION (AVERAGE IN THOUSAND 
•    BAGS OF 60 KG EACH)
• COFFEE INDUSTRY RESIDUES APPLICATIONS
• PROCESSING OF COFFEE
• WET METHOD
• DRY METHOD
• FIG. SUN DRYING OF COFFEE FOR DRY PROCESS
• PROBLEMS OF COFFEE WASTE
• TABLE. HEALTH PROBLEMS REPORTED BY THE POPULATION 
•    LIVING NEARBY INDUSTRIES
• MANAGEMENT OF COFFEE WASTE
• TABLE. CHARACTERISTICS OF EFFLUENT WASTEWATER FROM CONVENTIONAL WET COFFEE PROCESSING PLANTS
• ENVIRONMENTAL ISSUES
• TABLE. COMPOSITION OF COFFEE WASTE
• CONCLUSION
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF CONDENSER
• SUPPLIERS OF SPRAY DRYERS
• SUPPLIERS OF CENTRIFUGE
• SUPPLIERS OF INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS
• SUPPLIERS OF PACKAGING MACHINE
• SUPPLIERS OF LABORATORY EQUIPMENTS
• SUPPLIERS OF GRINDER
• SUPPLIERS OF BOILERS
• SUPPLIERS OF STAINLESS STEEL TANKS
• SUPPLIERS OF WEIGHING SCALE
• SUPPLIERS OF PLANT AND MACHINERY (GLOBAL)
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF MILK POWDER
• RAW MATERIALS CALCULATION

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)