Detailed Project Report (DPR) on l-ascorbic acid manufacturing plant

L-ASCORBIC ACID MANUFACTURING PLANT

[CODE NO.4115] 

Ascorbic acid, commonly known as vitamin C plays significant functions in the human body, though its function at the cellular level is not very clear. Vitamin C is needed for collagen synthesis, the protein that serves so many connective functions in the body.

Among the body’s collagen-containing materials and structures are the framework of bone, gums and binding materials in skin muscle or scar tissue. Production of certain hormones and of neurotransmitters and the metabolism of some amino acids and vitamins require vitamin C. This vitamin also helps the liver in the detoxification of toxic substances in the system, and the blood in fighting infections. Ascorbic acid is important in the proper function of the immune system. As an antioxidant, it reacts with compounds like histamines and peroxides to reduce inflammatory symptoms. Its antioxidant property is associated with the reduction of cancer incidences.

The requirement for vitamin C for adults does not seem to be uniform across cultures. This may be a pointer to the need for cultural-specific requirements for the nutrient. It has now been appreciated that ascorbic acid functions in cellular reactions and processes.

Epidemiological data now point to reduction of colds with increased consumption of foods rich in vitamin C . People are tempted to over-consume vitamin C because of its health benefits. Miniscule increases in blood vitamin C levels decrease the risk of death from all conditions. This paper presents a review of epidemiological data on the role of ascorbic acid in certain human health conditions. Though there are many functions of vitamin C, its role in health is discussed in relation to cancer, blood pressure, immunity, drug metabolism and urinary hydroxyproline excretion.

Everyone has heard of vitamin C. There can be few simple organic molecules which have excited such universal interest. At least part of the reason for this has been the general interest in the beneficial effects of all vitamins and other trace substances on human health which has developed in recent years along with concern on the effects of other substances, particularly additives, on those who consume food containing them. We know that vitamins are essential to our wellbeing and because of this they have excited an interest and curiosity which has resulted in many of them being attributed with disease healing and health-giving properties which they could not possibly have, Vitamin C has itself been said to have almost magical properties by some writers and it is useful to get a picture of the chemistry and biochemistry of this enigmatic compound.

Vitamin C is different. It is different from the other vitamins and we shall see in the course of this book that its chemistry and biochemistry single it out amongst molecules in many important ways, Vitamin C is ubiquitous. It is found throughout the plant and animal kingdoms, where its roles are often not known or are poorly understood. The synthetic vitamin is very widely used as a food additive and therefore has an E number (E300). However, unlike many other additives, few people would object to its presence in foods. There is no doubt that its anti-oxidant properties confer stability on foods to which it has been added.

Vitamin C has been the subject of frequent controversy, even before its nature had been established. Its role (as a constituent of fruits and vegetables) in the cure and prevention of scurvy was widely debated for hundreds of years. Its very existence was doubted by many even as recently as the beginning of the twentieth century. There were quarrels over who was the first to discover it. Even today there is much controversy about the exact role of the vitamin in human health and there is not even agreement over the amount of the vitamin which needs to be consumed for optimum wellbeing, with various authorities recommending amounts varying from 30 mg to 10 g per day. 

COST ESTIMATION

Plant Capacity                                   0.8MT/Day  

Land & Building (4070 sq.mt.)         Rs. 2.15 Cr    

Plant & Machinery                            Rs. 1.40 Cr 

Working Capital for 1 Month      Rs. 87.54 Lacs 

Total Capital Investment                  Rs. 4.86 Cr 

Rate of Return                                  32%

Break Even Point                             53%

• INTRODUCTION
  
• PROCESS FOR PREPARATION OF VITAMIN-C
• OCCURRENCE OF ASC IN FOODS
• SOURCES OF ASCORBIC ACID
• HISTORY OF VITAMIN C AND ITS ROLE IN THE PREVENTION AND CURE OF SCURVY
• CHEMICAL AND PHYSICAL PROPERTIES
• ADVANTAGES AND BENEFITS
• BENEFITS OF L-ASCORBIC ACID:-
• VITAMIN C AND SUN DAMAGE
• COLLAGEN
• PIGMENTATION AND L-ASCORBIC ACID
• INFLAMMATION
• SKIN BARRIER INTEGRITY
• OTHER USES OF L-ASCORBIC ACID:-
• BOTTOM LINE
• INDUSTRIAL FERMENTATION OF ASCORBIC ACID
• FIGURE: THE REICHSTEIN PROCESS FOR VITAMIN C SYNTHESIS.
• OXIDATION OF L-SORBOSE TO 2-KLG AND REARRANGEMENT TO ASC
• THE TWO-STEP FERMENTATION PROCESS FOR ASC PRODUCTION
• THE FIRST STEP OF FERMENTATION: CONVERSION OF D-SORBITOL TO L-SORBOSE
• SORBITOL DEHYDROGENASE:
• THE COMPANION STRAIN: STIMULATING GROWTH AND 2-KLG PRODUCTION 
•    OF K. VULGARE
• BEST VITAMIN C TABLETS IN INDIA FOR IMMUNITY
• VITAMIN C TABLET
• DOCTOR’S BEST VITAMIN C 1000MG TABLETS:
• HIGHLIGHTED FEATURES:
• NOW FOODS VITAMIN C 1000MG TABLETS:
• FAST&UP CHARGE – VITAMIN C WITH ZINC:
• HIGHLIGHTED FEATURES:
• EUCEE VITAMIN C CHEWABLE TABLETS 500MG:
• CARBAMIDE FORTE NATURAL VITAMIN C WITH ZINC:
• BOLDFIT VITAMIN C COMPLEX WITH AMLA AND ZINC:
• HIMALAYAN ORGANICS ORGANIC VITAMIN C CAPSULES:
• NATURYZ DOUBLE STRENGTH NATURAL VITAMIN C AND ZINC SUPPLEMENT:
• BIG MUSCLES NUTRITION NATURAL VITAMIN C AND ZINC TABLETS:
• KAPIVA VITAMIN C + AMLA GUMMIES FOR IMMUNITY BOOST:
• DETAILS OF LABORATORY EQUIPMENTS
• LAB TESTING EQUIPMENT
• MARKET POSITION
• COVID-19 SCENARIO ANALYSIS:
• TOP IMPACTING FACTORS: MARKET SCENARIO ANALYSIS, TRENDS, 
•     DRIVERS AND IMPACT ANALYSIS
• THE GLOBAL ASCORBIC ACID MARKET TRENDS ARE AS FOLLOWS:
• GLOBAL ASCORBIC ACID MARKET SEGMENTATION
• KEY PLAYERS IN THE GLOBAL ASCORBIC ACID MARKET
• MANUFACTURING PROCESS
• THE "MIXED CULTURE" INVOLVES THE FOLLOWING 
•    THREE PROCESSES (A), (B) AND (C);
• PRODUCTION OF 2,5-DIKETO-D-GLUCONIC ACID BV THE STRAIN (I)
• (I) SEED MEDIUM:
• AN AQUEOUS SOLUTION CONTAINING;
• AN AQUEOUS SOLUTION CONTAINING:
• PREPARATION OF 2.5-DIKETO-D-GLUCONIC ACID SOLUTIONS:
• AN AQUEOUS SOLUTION CONTAINING:
• PROCESS FLOW DIAGRAM
• MANPOWER
• GENERAL
• BASISOFESTIMATION
• PLANT LOCATION FACTORS
• PRIMARY 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:
• 7. TERM LOANS:
• 8. TOTAL LOAD:
• 9. LAND AREA/MAN POWER RATIO:
• RAW MATERIAL PHOTOGRAPHS
• D-GLUCOSE
• CORN STEEP LIQUOR (CSL)
• POTASSIUM PRIMARY PHOSPHATE (KH2P04)
• MAGNESIUM SULPHATE (MGSO4.7H20)
• MACHINERY PHOTOGRAPHS
• REACTOR
• DISTILLATION UNIT
• EVAPORATOR
• ULTRA-FILTER
• BOILER
• EVAPORATOR
• ULTRA-FILTER
• BOILER

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)