Chitin & Chitosan from Prawn Shell Waste (Cap: 4500 Kg/Day)

CHITIN & CHITOSAN FROM PRAWN SHELL WASTE (CAP: 4500 KG/DAY)

[EIRI/EDPR/4775] J.C.: 2995XL

INTRODUCTION

Chitin is a white, hard, inelastic, nitrogenous, polysaccharide found in the outer skeleton of insects, crabs, shrimps and lobsters and in the internal structures of invertebrates. It is the second most abundant organic compound next to cellulose. It is a macro molecular linear polymer of_ (1-4) N acetyl D glucosamine and is insoluble in water and many organic solvents. Chitin itself has only a few applications; it acts more as a precursor of Chitosan, its most familiar derivative.

Chitosan is deacetylated chitin, and is polymer of _(1-4) acetyl - D glucosamine. It has multifarious uses in the cosmetic, pharmaceutical and medical industries. It is even considered as a wonder drug of the twenty-first century due to its versatile utility.

Chitin is a chemical compound belong to glucosamine polysaccharide group categories. It contains about 7% nitrogen, and is structurally similar to cellulose.

It is the principal constituent of the shells of prawn fish, shrimps, crabs, lobsters, beetles and other sea fishes. It is also found in some fungi, algal, and yeasts.

Fish is a valuable and easily accessible source of food, rich in proteins. India has abundant marine and inland fish resources. It has a coast-line c. 4,667 km. long and a continental shelf 2,59,000 sq. km. or more in area, offering considerable scope for the establishment of fisheries. The Bay of Bengal and the Arabian Sea abound in fishing grounds; gulfs and bays all along the coast and a large number of islands with their mangrove swamp and coral reefs, are rich sources of marine fish.

Tidal estuarine waters in the mouths of large and perennial rivers, large brackish water lakes, backwaters, lagoons and swamps scattered along the entire coast-line, afford lucrative estuarine fisheries. Vast stretches of fresh water consisting of rivers, streams, lakes, reservoirs, tanks, ponds and paddy fields offer scope for inland fisheries. The principal rivers of India, including their main tributaries, have a total length of c. 27,360 km. and the length of canals and irrigation channels is c. 1,12,650 km. When added to other freshwater resources, the total surface would run to several million acres of which not more than a million acres are under fish culture. Most of these freshwater resources, though culturable, are at present lying fallow.

In order to study the distribution and bionomics of marine fishes inhabiting Indian waters and to assess the topographic conditions for the establishment of fisheries, the Indian coast has been divided into the following 12 bio-geographical zones:

Zone 1: West Bengal and Orissa

Zone 2: Andhra coast (south of Gopalpur to north of Visakhapatnam)

Zone 3: Andhra coast (Visakhapatanam to Masulipatham)

Zone 4: Andhra coast (south of Masulipatnam to north of Pulicat lake)

Zone 5: Coromandel coast (Pulicat lake to Cuddalore)

Zone 6: Coromandel coast (south of Cuddalore to Devipatnam)

Zone 7: Palk Bay and Gulf of Manaar (south of Devipatnam to north of Cape Comorin)

Zone 8: Kerala and South Malabar (Cape Comorin to Ponnani River)

Zone 9: Malabar and South Kanara (north of Ponnani River to Mangalore)

Zone 10: Konkan coast (north of Mangalore to south of Ratnagiri)

Zone 11: Mumbai and Gujarat coast (Ratnagiri to Broach)

Zone 12: Kathiawar coast

COST ESTIMATION

Plant Capacity            4500 Kg./Day

Land & Building (20,000 sq.mt.)    Rs. 10.20 Cr

Plant & Machinery                    Rs. 7.85 Cr

Working Capital for 2 Months    Rs. 15.38 Cr

Total Capital Investment          Rs. 34.09 Cr

Rate of Return                          78%

Break Even Point                      27%

CONTENTS

INTRODUCTION

PROPERTIES & CHARACTERISTICS

CHITIN [1398-61-4]:

ITS EMPIRICAL FORMULA = (C8H13NO5)N

EMPERICAL FORMULA = (C6H11NO4)N

DEGREE OF DEACE ĘLATION

AVERAGE MOLECULAR WEIGHT

VISCOSITIES AND BEHAVIOR IN SOLUTION

SOLUBILITY

CATIONIC PROPERTIES

CHEMISTRY OF CHITIN AND CHITOSAN

USES AND APPLICATIONS

INDUSTRIAL USES:

APPLICATION OF CHITOSAN

CHITOSAN

MEDICAL AND PHARMACEUTICAL USES

BIOMEDICAL USES

PRELIMINARY RESEARCH AND FDA REVIEW

AGRICULTURAL & NUTRITIONAL USES:-

CHITIN SYNTHESIS INHIBITORS

USES OF CHITOSAN

I) CLARIFICATION AND PURIFICATION

II) CHROMATOGRAPHY

III) PAPER AND TEXTILES

IV) PHOTOGRAPHY

V) FOOD AND NUTRITION

VI) AGRICULTURE

II) MEDICAL AND PHARMACEUTICAL

TECHNICAL PARAMETERS

LOCATION OF THE PROJECT

BORROWER’S PROFILE

B.I.S. SPECIFICATION

MARKET OVERVIEW OF CHITIN

CHITIN MARKET DIVIDED BY DERIVATIVE TYPE AS:

CHITIN MARKET DIVIDED BY END-USE AS:

CHITIN MARKET DIVIDED BY GEOGRAPHY AS:

MARKET OVERVIEW OF CHITOSAN

PRESENT MANUFACTURERS OF CHITIN AND CHITOSAN

FOREIGN PRODUCERS OF CHITIN & CHITOSAN

SPECIFICATION AND TEST FOR MEDICAL GRADE CHITOSAN

ANALYZE REPORT OF CHITOSAN (MEDICAL GRADE)

RAW MATERIALS

CHITIN CONTENTS OF SOME ORGANISMS

CRUSTACEA:-

INSECTS:-

MOLLUSKS:-

FUNGI:-

MANUFACTURING PROCESS

BASIC CONCEPT:

CHITIN:

CHITOSAN:

CHITIN:-

DETAILS OF PROCESSING STEPS:-

CHITOSAN MANUFACTURING PROCESS:-

DETAILS OF CHITIN AND CHITOSAN PRODUCTION PROCESS

CHEMICAL ISOLATION OF CHITIN

PROCESS FLOW DIAGRAM

PROCESS FLOWSHEET FOR MANUFACTURING OF CHITIN-FROM PRAWN FISH SHELL WASTES

MANUFACTURING PROCESS OF CHITOSAN (MEDICAL GRADE)

PRETREATMENT STEP

DEMINERALIZATION

DEPROTEINATION

DEACETYLATION

CHITOSAN MANUFACTURING FROM CHITIN (MEDICAL GRADE)

TECHNOLOGY

RAW MATERIAL

DEPROTEINISATION

DEMINERALISATION

REMOVAL OF WATER

DEACETYLATION OF CHITIN

REMOVAL OF WATER

DRYING

POWDERING AND PACKING

YIELD

ILLUSTRATION OF THE PROCESS

PROCESS IN DETAILED

AT THE SAME TIME, ENZYMES

TYPE OF DEACETYLATION: DEACETYLATION PROCESS MAY BE PROVIDED BY TWO SYSTEMS:

TWO EXPLANATIONS OF THIS PHENOMENON HAVE BEEN PROPOSED

TABIE: CHEMICAL COMPOSITION OF VARIOUS CRUSTACEAN WASTES AND OF INSECT'S LARVES OF CALLĘHORA ERYTHROCEPHALA

CHITIN AND CHITOSAN EXTRACTION FROM CHITINOUS MARINE WASTE

CHEMICAL EXTRACTION

CHEMICAL DEPROTEINATION

CHEMICAL DEMINERALIZATION

BIOLOGICAL EXTRACTION

ENZYMATIC DEPROTEINATION

FERMENTATION

LACTIC ACID FERMENTATION

DEPROTEINIZATION OF CHITIN FROM SHRIMP HEAD WASTE

MATERIALS & METHODS

PREPARATION OF RAW MATERIAL

CHITIN EXTRACTION PROCEDURE

CHEMICAL ANALYSIS

FIGURE: THE TWO- STAGE METHOD FOR CHITIN PRODUCTION

TABLE: CHEMICAL COMPOSITION OF SHW1

TABLE: PROTEIN RECOVERY (%) OBTAINED BY USING DIFFERENT DEPROTEINIZATION PROCESSES

TABLE: NITROGENOUS COMPOSITION OF PRECIPITATE AFTER DEPROTEINIZATION PROCESSES

TABLE: EFFECT OF NAOH CONCENTRATION ON THE RESIDUAL PROTEIN CONTENT AND DEGREE OF ACETYLATION OF CHITIN PRODUCED BY THE TWO-STAGE METHOD)

TABLE: SPECIFICATION OF PRODUCED CHITIN COMPARED TO FOOD GRADE PRODUCT

PRODUCTION METHOD OF CHITIN AND CHITOSAN FROM SHRIMP SHELL IN BATCH CULTURE OF LACTOBACILLUS PLANTARUM

MATERIALS AND METHODS

SHRIMP SHELL

DATE SYRUP

TABLE – CHEMICAL CHARACTERISTICS OF DATE SYRUP

FERMENTATION

PREPARATION OF CHITIN

PREPARATION OF CHITOSAN

ANALYTICAL PROCEDURE

EFFLUENT TREATMENT PROCESS

EFFLUENT TREATMENT SYSTEM

PROTEIN PASTE FROM THE SHELL/PROTEIN SEPARATION

NAOH DE-PROTEINIZATION WASH WATER

HCL DE-MINERALIZATION WASH WATER

SEA AND FRESH WASH WATER

PLANT LAYOUT

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF CONVEYOR BELT

SUPPLIERS OF PULVERISER

SUPPLIERS OF WASHING TANKS

SUPPLIERS OF TRAY DRYER

SUPPLIERS OF PVC TANKS

SUPPLIERS OF LIQUID TANKS

SUPPLIERS OF EVAPORATION UNIT

SUPPLIERS OF DRYING CHAMBER

SUPPLIERS OF BOILERS

SUPPLIERS OF WATER CHILLER

SUPPLIERS OF FILTER PRESS

SUPPLIERS OF LABORATORY TESTING EQUIPMENTS

SUPPLIERS OF CHEMICALS

SUPPLIERS OF RAW MATERIAL

RAW MATERIAL SUPPLIERS FOR CHITIN AND CHITOSAN

SUPPLIERS OF HYDROCHLORIC ACID

SUPPLIERS OF CAUSTIC SODA

SUPPLIERS OF LABORATORY CHEMICALS

ADDRESSES FOR CONSULTANT & TURNKEY PLANT

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)