freeze dryer processing plant-transportable

FREEZE DRYER PROCESSING PLANT-TRANSPORTABLE

[CODE NO.4446] 

Freeze Drying, also known as lyophilization, is a process that is used for sample preparation. With its unique preservation properties, freeze drying has a large variety of applications with an ever-growing list of new uses each year. Freeze drying is a process in which a completely frozen sample is placed under a vacuum in order to remove water or other solvents from the sample, allowing the ice to change directly from a solid to a vapour without passing through a liquid phase. This process, called sublimation, along with the minimal heat input that is required, is ideal because of the long-term preservation properties it provides to the integrity of the sample’s biological and chemical structure. Lyophilization can be achieved in various volumes, from small at-home freeze dryers all the way up to large, production-scale equipment.  

The first major utilization of freeze drying was during World War II, for the transportation of blood, serum and penicillin. Since the development of these modern freeze-drying techniques, lyophilization technology has continued to advance and has been used for a broad spectrum of applications in a variety of fields. Laboratory freeze dryers are commonly used for research in biological and environmental disciplines, as well as in the research and development of many modern medicines.

In the home, lyophilizers are most commonly used to freeze dry foods. This form of preservation not only extends the shelf-life of foods, but has also been shown to lock in important nutrients and enhance flavor of things like fruits, vegetables, meats, and even coffee.

To successfully freeze dry a sample, your equipment will need to meet certain requirements. First, the collector coil of your freeze dryer will need to be 15-20 degrees colder than the freezing point of your sample in order to trap the water vapour that is being released. You will also need a vacuum pump that can reach a minimum of .020 mBar. This deep vacuum establishes negative pressure, forcing the free-flowing water molecules that have left the sample via sublimation to evacuate the environment around the sample and travel to the collector coil. You will also need to have a drying accessory, such as: a manifold, chamber or tray dryer, and glassware or trays to contain your sample. Although not required, an end-point detection system makes the (sometimes days-long) freeze-drying method easier to manage by keeping you informed of when your sample has finished drying.

It is intended to prepare a Feasibility Report to install a Transportable Freeze Dryer Processing Plant at 3 locations for frozen fruits with a production capacity of 240 Kg/Day for each location with a total of 720 Kg/day as a Green Field Project.

COST ESTIMATION

Plant Capacity                                240 Kg./Day  

Land & Building (600 sq.mt.)        Rs. 45.00 Lac    

Plant & Machinery                           Rs. 15.66 Cr 

Working Capital for 0.1 Months  Rs. 8.36 Lac 

Total Capital Investment                Rs. 16.68 Cr 

Rate of Return                                  43%

Break Even Point                            54%

• INTRODUCTION
• MARKET OVERVIEW
• USES/APPLICATIONS
• WORKING PRINCIPLE OF FREEZE DRYING
• PROBLEMS TO AVOID DURING FREEZE DRYING
• IMPORTANT FREEZE DRYING TERMS
• TECHNICAL DESCRIPTION – FREEZE DRYER
• PRODUCT CERTIFICATION
• RAW MATERIALS
• MANUFACTURING PROCESS STEPS/PROCESS FLOW
• QUALITY CONTROL OF FREEZE DRIED FOODS
• DOCUMENTS REQUIRED FOR LICENSES
• SWOT ANALYSIS
• ENGINEERING DESIGN CONSIDERATIONS
• SEWAGE AND WASTE WATER EFFLUENT
• PLANT & MACHINERY (BROADLY)
• POTENTIAL TURNKEY/MAJOR PLANT/EQUIPMENT SUPPLIERS
• PLANT LOCATION FACTORS
• PROPOSED IMPLEMENTATION SCHEDULE
• PROJECT FINANCIALS
• CONCLUSIONS

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)