Automated Coconut Processing Plant (Cap: 10,000 MT/Day)

AUTOMATED COCONUT PROCESSING PLANT (CAP: 10,000 MT/DAY)

[EIRI/EDPR/4479] J.C.: 2694XL 

Coconut water is the clear liquid inside young green coconuts (fruits of the coconut palm). In early development, it serves as a suspension for the endosperm of the coconut during the nuclear phase of development. As growth continues, the endosperm matures into its cellular phase and deposits into the rind of the coconut meat. Coconuts for drinking are served fresh, chilled or packaged in many places. They are often sold by street vendors who cut them open with machetes or similar implements in front of customers. Processed coconut water for retail can be found in ordinary cans, tetra packs, or plastic bottles, sometimes with coconut pulp or coconut jelly included.

In recent years, coconut water has been marketed as a natural energy or sports drink having low levels of fat, carbohydrates, and calories, and significant electrolyte content. However, the contents of primary electrolytes per 100 ml serving, sodium, potassium, magnesium and calcium, are negligible (table of nutritional values) unless fortified in manufacturing. Further, marketing claims attributing health benefits to coconut water are not based on science and are disallowed by regulatory agencies, such as the United States Food and Drug Administration.

COST ESTIMATION

Plant Capacity            10,000 MT/Day  

Land & Building (12,500 sq.mt.)    US$ 15.75 Lac    

Plant & Machinery                    US$ 14.43 Lac 

Working Capital for 3 Months    US$ 18.20 Cr 

Total Capital Investment          US$ 18.54 Cr 

Rate of Return                          87%

Break Even Point                      14%

CONTENTS

INTRODUCTION

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

CHEMICAL COMPOSITION OF COCONUT OIL

CHARACTERISTICS OF COCONUT OIL

TABLE: COMPARATIVE FATTY ACID PROFILE OF COMMON FATS AND OILS

B.I.S SPECIFICATION

PRODUCT 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

TABLE 1: EXPORT – IMPORT OF COCONUT PRODUCT: INDIA

TABLE 2: COCONUT IMPORTS, PRODUCTION AND IMPORT INTENSITY

TABLE 3: PERCENTAGE SHARE OF WORLD EXPORT OF COCONUT PRODUCTFIG. 1: CONSUMPTION – PRODUCTION RATIO OF COCONUTS

TABLE 5: CST OF PRODUCTION OF COPRA

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

PHYSICAL PROPERTIES AND CHEMICAL COMPOSITION OF COCONUT MILK

COCONUT MILK BEVERAGES

COCONUT OIL

ESSENTIAL COMPOSITION AND QUALITY FACTORS OF VIRGIN COCONUT

OIL (VCO) BY APCC

FATTY ACID COMPOSITION OF RBD COCONUT OIL & VIRGIN COCONUT OIL

RBD COCONUT OIL

VIRGIN COCONUT OIL (VCO)

COMPARISON BETWEEN VIRGIN COCONUT OIL AND RBD COCONUT OIL

COCONUT FLOUR

COCONUT MILK POWDER

DESICCATED COCONUT

CHEMICAL AND PHYSICAL CHARACTERISTICS OF 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

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

COCONUT

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 & 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

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

BAWALAN AND CHAPMAN (2006) RECOMMEND THE DRYING

METHODS DESCRIBED BELOW.

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

TECHNOLOGY OF COCONUT SHELL CHARCOAL

MANUFACTURING PROCESS OF COIR YARN

PRINCIPLES OF PLANT LAYOUT

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. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

PLANT LAYOUT

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF COCONUT

SUPPLIERS OF PET BOTTLES

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 – 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)