Coconut Processing Plant (31500 kg/day)
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COCONUT PROCESSING PLANT
[EIRI/EDPR/4094] J.C.: 2237INR, 2238US$
Coconut water is a refreshing drinks which also hygienic and nutritive. The white flesh is a calories rich extensively used for cookery in South India. From grated wet coconut kernel good quality oil as well as protein and carbohydrate can be extracted to prepare coconut honey. Undesirable flavour changes in desiccated coconut is due to oxidative rancidity of the oil. The residual cake after the oil has been extracted is used as cattle food.
The dried coconut meat is known as copra and is the source of coconut oil, which is used in enormous quantities for making fats for baking and confectionery. An important product used in the chocolate and confectionery industry is desiccated coconut. The nut is removed from the hard shell and the thin brown rind pared off. This must be very thorough or the finished coconut will be contaminated by flecks of brown. The pared nuts are then washed free of milk and skin residues and put through shredding machines, which give a milled product of varying degree of fineness. After shredding, the ground meat is subjected to a steam or hot water treatment to destroy salmonella and lipases and to reduce bacteria counts to low levels. The pasteurized meat is then dried on wire mesh belts by means of hot air, which reduces the moisture content to less than 4%. The critical moisture level of desiccated coconut is 5% and the product should be well below this to ensure good shelf life.
After drying, the desiccated coconut is put through a multiple sieving operation to produce the four main grades. Extra fine, macaroon (fine), medium and coarse. A variety of other coconut products is available to the chocolate and confectionery trade such as, moist white sweetened coconut, toasted coconut, creamed coconut and tenderized coconut.
Top quality desiccated coconut should be white in colour, free from foreign matter, and uniform in granulation against standard, and the expressed oil should have a free fatty acid content of less than 0.1%.
Extraction of Coconut Oil
The coconut is the most extensively grown and used nut in the world. About 10 million people in India and several million of people in other tropical regions depend on the coconut plant for their livelihood. India is the third largest coconut producing country of the world with an area of about 1.12 million hectares contributing to 18% of world production. India produces about 6000 million nuts annually. A whole coconut consists of 50% husk, 15% shell, 25% meat and 10% water.
COST ESTIMATION
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%
CONTENTS
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 – 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)
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