Detailed Project Report on automated coconut processing plant (DESICCATED COCONUT POWDER, COCONUT WATER, VIRGIN COCONUT OIL, COCONUT MILK,COCONUT MILK POWDER, COIR, COCONUT CREAM, COCONUT FLOUR, PARING OIL, COCONUT SHELL POWDER, ACTIVATED CARBON (CHARCOAL

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AUTOMATED COCONUT PROCESSING PLANT (DESICCATED COCONUT POWDER, COCONUT WATER, COCONUT OIL, VIRGIN COCONUT OIL, COCONUT MILK,COCONUT MILK POWDER, COIR (COCONUT FIBRE), COCONUT CREAM, COCONUT FLOUR, PARING OIL, COCONUT SHELL POWDER, ACTIVATED CARBON (CHARCOAL)

[CODE NO.4016]

It is worthwhile to note that the vegetable oil extracted from the coconut milk is virgin coconut oil. Coconut is indeed a very productive plant. De-husking of coconut is one of the main processes that takes a lot of time and energy to extract the oil. There are various instruments made of iron or wooden crowbar for the de-husking process. The ultimate aim is to assist the local farmers in decreasing the necessary labour time and crushing the coconuts.

The involved processes of coconut processing include de-husking, grating and crushing of the de-husked coconut. The automated coconut machine can de-husk and prepare the coconut in less time for oil extraction. The construction of the automated coconut processing machine is very simple in design so that it can be manufactured easily.

The automated coconut processing machine integrates all the sections taking out the virgin coconut oil. It reduces the harm created from oil extraction and increases gross output. The traditional methods are replaced by advanced automated methods. The automated system includes the smart operation of the de-husker and grater. The automated system of coconut processing does not require any manpower. It increases the income of agro-industries and the total cost of production becomes much feasible.

During the automation process, the defected coconuts are excluded and the usable one is taken for oil extraction. As mentioned before, the automation process does not need any kind of manpower. The automation process increases the income of agro-industries and total cost of the production becomes much feasible.

Coconut is required by the oil industry as the raw material. Dry coconut husk is needed as the raw material. All the parties need complementary coconut components. It is also important to bridge the gap between industry and coconut farms. It is therefore desirable to have a machine that meets both requirements. This automated machine is suggested for the coconut as well as coconut oil processing after harvesting.

Coconuts are very popular worldwide and have various health and nutritional benefits. There are various benefits of the use of coconut that range from cooking and nutrition to skin health, fuel, beauty products and cancer prevention. Earlier, the commercial coconut scraping machines were not fully automated and used to involve manual effort. However, the semi-automated process requires the operator to hold the coconut half shell against a particular rotary blade by an electric motor. The operator is presented with different risks of injury. An automated coconut scraping machine is normally developed to overcome the well-known challenges regarding grating coconuts. The machine for coconut processing reduces both risk and effort on the part of the operator. On mounting at the push of a start button, the scrapping process of cocnut is completely automatic.

This automated process of coconut manufacturing product leads to various benefits such as cooking and nutrition, beauty products, cancer prevention, fuel (charcoal production) and much more. During the scraping process, it needs to be well understood that the coconut has a certain resistance, which in turn leads to an increase or decrease in torque. It is important to know the range of resistance caused by the coconut flesh which makes the automation process simpler.

COST ESTIMATION

Plant Capacity 18560 MT/Day

Land & Building (16,000 sq.mt.) Rs. 14.46 Cr

Plant & Machinery Rs. 7.86 Cr

Working Capital for 2 Months Rs. 6.13 Cr

Total Capital Investment Rs. 29.60 Cr

Rate of Return 77%

Break Even Point 27%

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 PRODUCT

FIG. 1: CONSUMPTION – PRODUCTION RATIO OF COCONUTS

TABLE 5: COST 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)

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