Instant Coffee (Freeze Dried) Production Rate - 6000 TPA or 20 MT/day

INSTANT COFFEE (FREEZE DRIED) PRODUCTION RATE - 6000 TPA

[EIRI/EDPR/4676] J.C.: 2893XL

Instant coffee, also called soluble coffee and coffee powder, is a beverage derived from brewed coffee beans. It is the dried soluble portion of roasted coffee, which can be presented to the consumer in either powder or granule form for immediate make-up in hot water. Instant coffee is commercially prepared by either freeze-drying or spray drying, after which it can be rehydrated.

Regular coffee is usually made with roasted coffee beans, ground into a fine powder. With this type of coffee, there’s always coffee bean waste after the process is completed. As we mentioned previously, instant coffee is soluble. There’s no waste as it’s all dissolved into rich, deliciousness.

In recent years, instant coffee sachets have been introduced to our shelves. These sachets are filled with delicious instant coffee but in powder form and some even come with added milk – even less fuss! Not to mention, dairy alternative instant coffee sachets are readily available. There’s truly an instant coffee for everyone!

COST ESTIMATION

Plant Capacity            20 MT/Day  

Land & Building (10,265 sq.mt.)    Rs. 11.53 Cr    

Plant & Machinery                    Rs. 322.11 Cr 

Working Capital for 1 Month    Rs. 25.97 Cr 

Total Capital Investment          Rs. 376.14 Cr 

Rate of Return                          60%

Break Even Point                      38%

CONTENTS

INTRODUCTION

CLASSIFICATIONS

NON-AGGLOMERATED INSTANT COFFEE POWDER

AGGLOMERATED INSTANT COFFEE POWDER

GRANULATED INSTANT COFFEE POWDER

USES

CARAMEL MACCHIATO ICE CREAM

DARK MOCHA CRINKLES

CHOCOLATE CAPPUCCINO CHEESECAKE

NUTELLA COFFEE SHAKE

TIRAMISU LAYER CAKE

RUSSIAN BLACK BREAD SLICED

MOCHA CHOCOLATE CHIP BANANA MUFFINS

ORIGINAL IRISH CREAM

ULTIMATE CHOCOLATE DESSERT

HONEY CAKE

BLACK BEAN BROWNIES

DALE'S SWEDISH MEATBALLS

DALGONA COFFEE

MOCHA TRUFFLES

BENEFITS

MARKET OVERVIEW

GLOBAL INSTANT COFFEE MARKET (%), BY SEGMENT TYPE

MARKET DYNAMICS

DRIVERS:

THE INCREASING POPULARITY OF INSTANT COFFEE

INTRODUCTION OF NEW FLAVORS TO EXPAND THEIR CONSUMER-BASE

AFFORDABLE AND CONVENIENT

RESTRAINTS

HIGH CONCENTRATION OF ACRYLAMIDE

OPPORTUNITIES

GROWING PRODUCT DIVERSIFICATION

CHALLENGES

RISING CONCERNS ABOUT THE ADVERSE EFFECTS OF EXCESSIVE COFFEE DRINKING

SEGMENTATION ANALYSIS

REGIONAL SEGMENTATION ANALYSIS

INSTANT COFFEE – ASIA

INSTANT COFFEE - SOUTHEAST ASIA

INSTANT COFFEE - SINGAPORE

COVID-19 SCENARIO

KEY DEVELOPMENTS

MIDDLE EAST COFFEE MARKET

MIDDLE EAST COFFEE MARKET TRENDS

INSTANT COFFEE - EUROPE

EAST EUROPEAN COFFEE IMPORTS ARE ON THE RISE

INDIAN EXPORT

INSTANT COFFEE MARKET - IMPACT OF COVID-19 PANDEMIC

INSTANT COFFEE MARKET: RECENT DEVELOPMENTS

INSTANT COFFEE MARKET: KEY COMPANIES

BIS SPECIFICATION

RAW MATERIALS

FREEZE DRYING & ITS PRINCIPLES

STAGES OF FREEZE DRYING

PRETREATMENT

FREEZING AND ANNEALING

STRUCTURALLY SENSITIVE GOODS

PRIMARY DRYING

SECONDARY DRYING

FREEZE DRYING - PROCESS

AROMA IS RECOVERED MAINLY BY TWO METHODS

MANUFACTURING PROCESS STEPS

(A) EXTRACTION:

(B) CONCENTRATION:

FREEZE-DRYING

STAGES IN INSTANT COFFEE MANUFACTURE

[FREEZE DRYING METHOD]

THE NINE STAGES OF MANUFACTURING INSTANT COFFEE

STAGE ONE: DELIVERY

STAGE TWO: ROASTING

STAGE THREE/FOUR: GRINDING

STAGE FIVE: EVAPORATION

STAGE SEVEN: SUBLIMATION

STAGE EIGHT: LOST AROMAS READDED

STAGE NINE: PACKAGING

PROCESS FLOW

ENGINEERING DESIGN CONSIDERATIONS

PROCESS CONTROL

QUALITY CONTROL

POLLUTION CONTROL

ENVIRONMENTAL PROBLEMS OF WASTEWATER FROM COFFEE PROCESSING INDUSTRY:

COFFEE IS PROCESSED IN TWO WAYS:

FLOW CHART ILLUSTRATING WATER RECYCLING PROCESS

WATER RECYCLING MECHANISM

CONVENTIONAL TREATMENT METHODS:

IT HAS 3 TANKS:

SCHEMATIC FLOW SHEET OF WASTE WATER TREATMENT UNITS

EQUALIZATION TANK:

ANAEROBIC TANK:

AEROBIC TANK:

TREATMENT OF WASTEWATER FROM COFFEE PROCESSING INDUSTRY:

WATER RECYCLING:

AIR POLLUTION AND ITS CONTROL

ROASTING

QUENCHING

COOLING

DESTINING

GREEN BEAN HANDLING

GRINDING

DECAFFEINATION

CONTROL EQUIPMENT

RECENT TRENDS IN EFFLUENT TREATMENT FOR COFFEE PROCESSING

COFFEE PROCESSING EFFLUENT FOR PRODUCTION OF BIOGAS:

ANAEROBIC TREATMENT SYSTEM

ETP FACILITY

SEWAGE AND WASTE WATER EFFLUENT

PLANT & MACHINERY SUPPLIERS

SUPPLIERS OF SPRAY DRYERS

SUPPLIERS OF CENTRIFUGE

SUPPLIERS OF INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS

SUPPLIERS OF PACKAGING MACHINE

SUPPLIERS OF LABORATORY EQUIPMENTS

SUPPLIERS OF GRINDER

SUPPLIERS OF BOILERS

SUPPLIERS OF STAINLESS-STEEL TANKS

SUPPLIERS OF WEIGHING SCALE

SUPPLIERS OF PLANT AND MACHINERY (GLOBAL)

RAW MATERIAL SUPPLIERS

SUPPLIERS OF MILK POWDER

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

PROJECT IMPLEMENTATION SCHEDULE

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

BROAD PLANT MACHINERY/EQUIPMENT DETAILS

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

ANNUAL PROCESSING : 6000 TPA

PRELIMINARY PLANT LAYOUT

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)