Detailed Project Report on cashewnut processing and cnsl

CASHEWNUT PROCESSING AND CNSL [3541]

Cashew nut processing allows for the development of an important by-product, which can increase its added value. The liquid inside the shell (CNSL) represents 15 percent of the gross weight and has some attractive possible medicinal and industrial uses. CNSL is one of the few natural resins that is highly heat resistant and is used in braking systems and in paint manufacture. It contains a  compound known as anacardium , which is used to treat  dermatological disorders. The main markets for CNSL are the United States, the European Union (mainly the United Kingdom), Japan and the Republic of Korea. Together these account for over ninety percent of world trade, most of which is supplied by India and Brazil. Cashew (Anacardium occidentale L.) a native of Eastern Brazil introduced to India just as other commercial crops like Rubber, Coffee, Tea etc. by the Portuguese nearly five centuries back. The first introduction of cashew in India was made in Goa from where it spread to other parts of the country. In the beginning it was mainly considered as a crop for afforestation and soil binding to check erosions. The nuts, apple and other by products of this crop are of commercial importance. Though its commercial exploitation began from the early 60’s, marginal lands and denuded forests were the areas set apart for the plantation development. Due to the absence of high yielding varieties and multiplication techniques, indiscript seeds and seedlings were used for planting purposes. Because of its adaptive ability in wide range of agro climatic conditions it has become a crop of high economy and attained the status of an export oriented commodity bringing considerable foreign exchange to the country. Cashew (botanical name Anacardium occidental) was introduced in India by the Portuguese four centuries ago, mainly to prevent soil erosion. Cashew ranks second among the nine tree nuts which figure prominently in international trade circles, first being almond.  The cashew adapts to various types of soils and climatic conditions and is hardy and draught resistant tree. For several centuries the cashew trees was considered merely as  a sturdy perennial tree which yielded soft wood and bore  the delicious  juicy  cashew apple.  The peculiarity of the cashew apple is that it has nut outside.  In the earlier days, the nut was thrown away after the apple was eaten.  The nut was rejected since it has a hard shell cover which contains a corrosive liquid (cashewnut shell liquid) which burns the skin on contact. As time passed, interest developed in the nut and various methods of extracting the kernel from the nut proved successful. Cashew nut has been cultivated in several countries for a long time but the credit for launching into commercial production and export  of  cashew  kernels  goes  to   India.   Very small quantities of unpeeled cashew kernels were exported to Marseilles and London, in the beginning of the present century.  Since then exports have shot up tremendously and 50-56 thousand tones of cashew kernels were exported during the decade ending 1973-74. The export of cashew kernels in the period 1946-78. Grew at the rate of 4.1% per annum, as compared to the 5.2% annual  growth rate of world export. The cashew is chiefly growth in the coastal districts of India and nearly 70 percent of the production is from the West Coast between Mumbai and Cape Camerin. Ratangiri and North Kanara districts in Mumbai.  South Kanara,    Malabar, Tiruchirapalli, Tanpore and South Arcot districts in Tamil Nadu state,  Nellore, Godavari and Vishakhpatnam districts in  Andhra, and Travancore-Cochin  are major areas of production. Nearly 50% of the production comes from Tamil nadu state, while Travancore Cochin state accounts for about 36 percent and Mumbai 10 percent.  West Bengal, Odisha, Karnataka, and Andhra  Pradesh  are  other states in India which together accounts for about 4.0 percent  of the product. Cashewnut Shell Liquid: Cashew  nut  shell  liquid (CNSL) is a bye  product  of  the cashew  industry  in India, which is a major  earner  of  foreign exchange. It is contained in the soft honey comb structure between the outer shell and the kernel of the cashew  nut.   The cashew  nut  tree  (Ana cardium Occidentale  Linm,  Hindi,  Kaju) belongs to the natural order Anacardiaceae, even as Bhilawan tree and  grows at altitudes below 1000 ft along the west and  Eastern coasts  of  India.  It is extensively cultivated in  Brazil  East Africa,  Tanzania, Mozambiques Madagascar, Philippines and  other tropical regions.  In India it is grown in the states of  Kerala, Tamil Nadu, Karnataka, Andhra pradesh, Maharashtra, Orrisa,  West Bengal, Assam and Goa. The cashew fruit has a kidney-shaped nut 1 to 1.5 inches long. The nut is attached to the end of fleshy receptable  or enlarged or rhomboid-to-oval having 2-4 1/2" length and is bright yellow to red with a waxy skin. Pericarp of the nut consists of a coriaceous epicarp, spongy mesocarp and story endocarp. The mesocarp consists of a honey-comp net work of cells which gives cashew nut shell liquid.
Cashew Testa: Cashew testa is the outer skin of cashew kernel which contains about 25% of tannin material and 11% of  non  tannins.  The  tannins  consist  of  D-catechin,  gallic  acid  and  leuco-cyanidin,  a significant tannin procursor, while the  non-tannins consists  of quinic and caffeic acids.  These tanning materials have shown similar properties to that of imported   wattlebark tannin used in leather industry.  The latter is  being  imported from  East  African  countries to the extent  of  12-15  thousand tons  per  annum costing nearly 2 crores.   The  availability  of cashew  testa  is  estimated around 2000-2500 tons  per  year  in Quiling  region alone where 75% of the factories  process  cashew nuts.   Recently a tannin extraction plant of the Kerala State Development corporation Ltd., has been started at Kottiyam about 8  k.m.  from Quilon.   The corporation with its  34   cashew processing  factories, is the first to start a bye product  plant of  this nature.  It is considered to be the biggest unit in the cashew industry, accounting for more than one fourth of the total processing capacity in the state of Kerala.   It is  estimated however that 3-4 thousand tons of cashew tesa would be  available within  the country and from which 500-600 tons of cashew  tannin extract  costing  about 10 lakhs of rupees could  be  made.   The residue of the tannin which is not soluble in water but soluble in mild alkalies.  The extracts may find use in oil drilling  mud and  in  the "Boiler compounds" generally used in  railway  steam boilers.

COST ESTIMATION

Plant Capacity                                                   2 MT/Day  
Land & Building (30000 sq.ft)                        Rs. 56 Lac
Plant & Machinery                                            Rs. 1.04 Cr
Working Capital for 1 Month                          Rs. 70 Lac
Total Capital Investment                                Rs. 2.42 Cr
Rate of Return                                                 25%
Break Even Point                                             61%



INTRODUCTION    
CASHEWNUT SHELL LIQUID    
CASHEW TESTA    
CASHEW KERNEL    
RAW MATERIAL AND ITS AVAILABILITY    
SPECIFICATION OF CASHEWNUT SHELL    
COMPOSITION OF CASHEWNUT    
CASHEW NUT BY-PRODUCTS    
CASHEW APPLE    
CASHEW APPLE JUICE    
CASHEW SYRUP    
CASHEW APPLE JAM    
CASHEW APPLE CANDY    
COMPOSITION OF CNSL    
CULTIVATION OF CASHEW NUTS    
CASHEW NUTS    
PROCESSING OF CASHEW NUT    
USES & APPLICATION OF CASHEW KERNEL    
MEDICINAL APPLICATIONS    
B.I.S. SPECIFICATIONS    
NUTRITIONAL VALUE OF CASHEW    
GRADES OF CASHEW    
A. CASHEW KERNELS - WHITE WHOLES    
B. CASHEW KERNELS - SCORCHED WHOLES    
C. CASHEW KERNELS - DESERT WHOLES    
D. CASHEW KERNELS - WHITE PIECES    
E. CASHEW KERNELS - SCORCHED PIECES    
F. CASHEW KERNELS - DESSERT PIECES    
OVERVIEW OF CASHEWNUT    
CASHEW PRODUCING COUNTRIES    
PRODUCTION OF CASHEW IN INDIA    
INDIAN CASHEW MARKET    
MARKET POSITION    
CASHEW BOARD    
RECENT INITIATIVES    
CASHEW DEMAND REMAINS SLUGGISH ON HIGH PRICES    
EXPORT & IMPORT DATA OF CASHEW KERNEL, ROASTED & SALTED
   CASHEW KERNELS, CNSL, RAW CASHEW NUT    
KEY MARKETS AND EXPORT DESTINATIONS    
PRODUCTION OF RCN IN GLOBAL MARKET    
VIETNAM EARNS OVER 1 BLN USD FROM CASHEW NUTS EXPORTS    
CASHEW SET TO SPARKLE ON FESTIVAL DEMAND    
CASHEW NUT SHELL CAKE    
DETAILED IMPORT DATA OF RAW CASHEW NUTS SHELL    
MANUFACTURERS/EXPORTERS OF CASHEWNUT PROCESSING    
DETAILS OF CNSL (CASHEW NUT SHELL LIQUID)    
METHOD OF CASHEW NUT ROASTING & PROCESSING    
(A) DRUM ROASTING    
(B) STEAM ROASTING    
STORAGE    
CLEANING AND SIZING    
CONDITIONING    
ROASTING    
SHELLING    
BENEFITS OF IMPROVED TECHNOLOGY OVER CONVENTIONAL
   PRACTICES OF PROCESSING THE CASHEW KARNEL    
ADVANTAGE OF STEAM ROASTING    
OVER DRUM ROASTING    
OUTLINES OF MANUFACTURING PROCESS    
ROASTING    
SHELLING    
DRYING    
PEELING    
GRADING    
MANUFACTURING PROCESS OF RAW CASHEW NUT KERNAL PROCESSING (STEAM BOILER ROASTING)    
RAW MATERIAL HANDLING AND STORAGE    
PREPARATION FOR PROCESSING- STEAM COOKING OR ROASTING OF RCN    
DRYING/HEAT TREATMENT OF SHELLED CASHEW- PRE-PEELING
   TREATMENT    
PEELING OF CASHEW KERNEL    
CONDITIONING THE PEELED NUTS/KERNEL    
GRADING/SORTING/CLEANING THE CASHEW KERNEL    
PACKAGING THE CASHEW KERNELS IN REQUIRED FORMS    
OTHERS METHOD OF CASHEWNUT PROCESSING    
THE NUT    
PROCESSING:    
ROASTING:    
(A) DRUM ROASTING    
(B)  OIL BATH ROASTING    
SHELLING    
DRYING    
PEELING    
GRADING    
PACKING:    
PACKING FOR EXPORT    
RESULTS: ROASTING AND CRACKING TRIAL    
QUALITY CONTROL (PLANT SANITATION)    
OBJECTIONABLE CONDITIONS OF FOOD:    
INFESTATION:    
PRESENT OF DIRT:    
PRESENCE OF MOLD:    
RANCIDITY:    
PRESENCE OF EXTRANEOUS MATERIAL:    
PLANT SANITATION:    
THE FOLLOWING SHOULD BE STUDIED CAREFULLY.    
FACTORS PROMOTING INFESTATION:    
PREVENTING INFESTATION    
GENERAL PROCESSING STEPS FOR CASHEW NUT AND POLLUTION CONTROL    
DRYING OF RAW NUTS    
ROASTING / STEAM COOKING    
A. ROASTING:    
B. STEAMING    
DECORDICATION    
DRYING OF THE KERNELS    
PEELING    
GRADING    
FILLING    
PACKING
ROASTING PROCESS    
COOKING (STEAM ROASTING) PROCESS    
BABY BOILER    
CASHEW NUT COOKER    
KERNEL DRYING (BROMA)    
ENVIRONMENTAL STANDARDS FOR CASHEW PROCESSING INDUSTRIES    
AIR POLLUTION EMISSION STANDARDS    
SULPHUR DIOXIDE, NITROGEN OXIDES AND PHENOLIC COMPOUNDS    
WASTEWATER DISCHARGE STANDARDS    
SOLID WASTE DISPOSAL PRACTICES    
CASHEW NUT PROCESSING FLOW DIAGRAM    
CASHEWNUT PROCESS FLOW CHART FLOW DIAGRAM    
COMPLETE PLANT SUPPLIERS ON TURNKEY BASIS    
RAW MATERIAL SUPPLIERS    
CASHEW NUTS SUPPLIERS    
PLASTIC CONTAINERS    
SUPPLIERS OF PLANT AND MACHINERY    
BOILER    
TANKS: STORAGE    
DRYERS & DRYING OVENS    
BUCKET ELEVATOR SYSTEMS    
CENTRIFUGES    
CONVEYOR BELT    
MAJOR PROCESSORS AND EXPORTERS OF CASHEW    
ADDRESS OF CONSULTANT    
PLANT LAYOUT     

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)