Detailed Project Report on integrated unit on fat powder & soya sauce powder, amino acid from (protein source) plant growth promoters, fruit and vegetable powder like tomato powder, pineapple powder etc.

INTEGRATED UNIT ON FAT POWDER & SOYA SAUCE POWDER, AMINO ACID FROM (PROTEIN SOURCE) PLANT GROWTH PROMOTERS, FRUIT AND VEGETABLE POWDER LIKE TOMATO POWDER, PINEAPPLE POWDER ETC.
[CODE NO.3718]  


Amino acid

Amino acids are the main components of protein, protein  are found in all living organism and play an important role in living cells. Approximately 20 amino acids are the common constituents of protein.

The general formula of an amino acid is

R-------------CH-------COOH
|
NH2

All  of  the amino acids, except glycine have two  optically active isomers symbolized by D-or L-before their names.

Amino Acids are the main  components  of  the  elementary nutrients  of living organism. There are eight and possibly ten, amino  acids  that  are  essential  for  existence  and  must  be ingested through food. The Nutritional value of protein is governed by  the  Quantitative  and  qualitative  balance  of   individual essential amino acid.

Protein  are metabolized continously by all  living  organism and are in dynamic equilibrium in living cell.

An organic acid containing both a basic amino group (NH2) on dipolar  ions.  The 25 amino acid that have been  established  as protein  constituent,  are a amino acid (i.e. the -NH2  group  is attached  to  the carbon atom next to the L series),  many  other amino acids occur in the free state in plant or animal tissue  22 amino acid with structures identical with those that exist  today have  been  identified  in  the  pre-cambrian  sedimentary   rock indicating  their  presence atleast 3 million years  ago.   Amino acid  are  the main components of protein  (qv.).   Proteins  are found  in  all  living organisms and play an  important  role  in living  cells.   Approximately  20 amino  acids  are  the  common constituents  of  proteins.   Braconnot  in  1820  isolated   the simplest  amino acid, glycine, from gelatin, the most recent  one of nutritional importance is L-threonine which was found by  rose in  1935  to  a  growth factor of rats.   The  presence  of  many uncommon  amino  acids  has  been  reported  in  various   living metabolites,  such  as antibiotics,  some  other  microbiolozical products,  and  in non-proteinaceous substances  of  animals  and plants,  plant  amino  acid have been review  recently  by  Bell. There are eight, and possibly ten, amino acids that are essential for existence and must be ingested through food.  The nutritional value of proteins is governed by the quantitative and qualitative balance of individual essential amino acids.  It has been clearly shown that the nutritional value of a protein can be improved  by the addition of amino acids absent in that protein.  Most of  the amino  acids absorbed through the digestion of proteins are  used to  replace body proteins.  The remaining portion is  metabolized into  various bio-active substance such as harmones,  purine  and pyrimidine   bases,  the  precursors  of  DNA,  RNA   and   other nucleotides, or is consumed as a energy source.

The history of amino acid discoveries is closely related  to advances  in  analytical  methods  initially,  quantitative   and qualitative  analysis depended exclusively  upon  crystallization from  protein  hydrolysates.  The quantitative  precipitation of several  basic  amino  acids  including  phosphotungstates, the separation  of  amino  acid esters by  vacuum  distillation,  and precipitation   by  sulfuric  acid  derivatives  were   developed successively during the last century.  After World War II, analytical methods for amino acids were improved and new  methods were introduced. The first was the microbiolozical assay using a lactic  acid  bacterium which requires all of the  regular  amino acids  for  its  growth.   This method  is  still  used  for  the microdetermination   of  amino  acids.   Later,   chromatographic separation  using  filter paper, ion exchange resins,  and  other absorbents were rapidly developed.  Twenty years ago all  L-amino acids from the synthesized racemic mixtures.  Since 1956, methods of production of L-amino acid have changed extensively. The first important  change  was  made  by  kinoshita  and  co-workers  who invented   a  new  fermentation  process  using   corynebacterium glutamicum bacteria to produce many other amino acids.  A  number of  useful  amino  acids e.g. L-lysine  and  L-theorine  are  now economically  produced  by fermentation.  Recently  L-lysine,  L-aspartic  acid  and  L-tryptopho have  been  produced  lay  rapid enzymatic   conversion  of  easily  available  precursors.    The progress of these biosynthetic procedures for various amino acids has been reviewed by Nakayama.  Glycine, alamine, methionine, and some other amino acids are still produced by chemical  synthesis. Chemical manufacturing procedures for amino acids are diocuned in a monography by Kaneko and co-workers.  Most of the natural amino acids  are  currently available commercially and their  uses  are growing.   Amino  acids  and  their  analogues  have  their   own characteristic effects in flavoring nutrition, and pharmacology.


COST ESTIMATION


Plant Capacity            5 Ton/Day       
Land & Building (2 Acres)      Rs. 6.18 Cr         
Plant & Machinery                      Rs. 4.60 Cr     
Working Capital for 2 Months     Rs. 3.64 Cr
Total Capital Investment              Rs. 14.78 Cr
Rate of Return            40%                   
Break Even Point             46%                

           



INTRODUCTION    
AMINO ACID    
FAT POWDER    
FRUIT & VEGETABLE POWDER    
TOMATO POWDER    
SOY SAUCE    
SOYA SAUCE    
PROPERTIES OF SOYA SAUCE    
USES AND APPLICATIONS    
APPLICATION AND PHYSICAL PARAMETERS OF SOYA SAUCE POWDER    
PHYSICAL PARAMETERS    
CHEMICAL PARAMETERS    
SOYA SAUCE POWDER    
GRADES AND COMPOSITION OF SOY SAUCE    
CHEMICAL COMPOSITION OF SOY SAUCE    
TYPICAL COMPOSITIONS OF FIVE VARIETIES OF SOY SAUCE    
APPLICATION OF AMINO ACID (PLANT GROWTH PROMOTER)    
USES AND APPLICATION OF FRUIT JUICE POWDER    
MANGO JUICE    
AVERAGE CONSTITUENTS OF RAW MANGO    
USES AND APPLICATION OF TOMATO POWDER    
DEHYDRATED TOMATO POWDER IN FOOD PRODUCTION    
DEHYDRATED TOMATO POWDER IN BEVERAGE    
DEHYDRATED TOMATO POWDER IN PHARMACEUTICAL    
DEHYDRATED TOMATO POWDER IN COSMETICS    
DEHYDRATED TOMATO POWDER IN AGRICULTURE/ANIMAL FEED    
TOMATO POWDER CAN BE USED VARIOUS WAYS, SUCH AS:-    
TOMATO POWDER-PROPERTIES    
PROPERTIES OF AMINO ACID    
PK & PI VALUES AT 25OC AND SOLUBILITY TO AMINO ACIDS    
CHEMICAL PROPERTIES:-    
STRECKER SYNTHESIS:-    
BUCHERER SYNTHESIS:-    
A-AMINO ACIDS FORM COPPER SALTS:-    
AMINO ACID MANUFACTURING METHODS, WEAKERS AND STRENGTH    
DESCRIPTION OF FAT POWDER    
MARKET OVERVIEW OF FRUIT & VEGETABLES POWDER    
MARKET POSITION OF FAT POWDER    
GLOBAL INSTANT FAT POWDER: SEGMENTATION    
ON THE BASIS OF TYPE, THE INSTANT FAT POWDER IS SEGMENTED INTO-    
ON THE BASIS OF END USE, THE INSTANT FAT POWDER IS SEGMENTED INTO-    
ON THE BASIS OF SALES CHANNEL, THE INSTANT FAT POWDER IS
   SEGMENTED INTO-    
ON THE BASIS OF PACKAGING, THE INSTANT FAT POWDER IS
   SEGMENTED INTO-    
MARKET OVERVIEW OF AMINO ACID    
MARKET OVERVIEW OF SOY SAUCE POWDER    
MARKET POSITION OF TOMATO POWDER    
TOMATO POWDER    
DETAILED EXPORT DATA OF TOMATO POWDER    
MANUFACTURER OF TOMATO POWDER    
PRESENT MANUFACTURERS OF FAT POWDER    
MANUFACTURING PROCESS OF AMINO ACID (GLUTAMIC ACID)
   FROM PROTEIN SOURCE    
PROCESS FLOW DIAGRAM    
PRODUCTION OF AMINO ACIDS BY PROTEIN HYDROLYSIS    
PRODUCTION OF AMINO ACIDS BY CHEMICAL SYNTHESIS    
PRODUCTION OF AMINO ACIDS BY BIOTECHNOLOGY METHODS    
AMINO ACID PRODUCTION PROCESSES    
EXTRACTION FROM PROTEIN-HYDROLYSATES    
CHEMICAL SYNTHESIS    
MICROBIAL PROCESS    
THE FERMENTATION PROCESS    
AMINO ACID PRODUCING BACTERIA    
PROCESSING DETAILS OF AMINO ACID BY PROTEIN HYDROLYSIS    
MANUFACTURING PROCESS OF AMINO ACID BY PROTEIN HYDROLYSIS    
PROCESS FLOW DIAGRAM OF AMINO ACID BY PROTEIN HYDROLYSIS    
OTHER METHODS FOR THE PRODUCTION OF AMINO ACID    
METHOD WITH A WILD MICROBIAL STRAIN:-    
ISOLATION OF AMINO ACID FROM THE FERMENTATION BROTH:-    
1. ION - EXCHANGE RESIN:-    
2. PRECIPITATION:-    
3. CRYSTALLIZATION:-    
CHEMICAL SYNTHESIS:-    
STRECKER SYNTHESIS:-    
HYDANTOIN PROCESS:-    
RACEMIZATION:-    
THE INDUSTRIAL PRODUCTION METHOD IS BELOW:-    
FLOW SHEET FOR DL-METHIONINE    
PREPARATION OF LOW TRANS SPECIALITY FAT    
SEQUENCE IN FRUIT POWDER    
MANUFACTURING PROCESS OF FRUIT JUICE AND POWDER (FRUIT PULP MANUFACTURING (MANGO AND PINEAPPLE)    
MANGO JUICE    
WASHING    
SORTING AND TRIMMING    
EXTRACTION OF JUICE    
BLENDING OF JUICES    
PRE-HEATING    
DE-AEREATION    
FRUIT JUICE FLOW DIAGRAM    
COMMUNICATION    
CITRUS FRUIT JUICE:    
CLARIFICATION    
CONCENTRATION OF FRUIT JUICE    
QUALITY CONTROL    
COLOUR    
ABSENCE OF DEFECTS    
FLAVOUR    
FLOW SHEET OF MANGO PULP    
FLOW SHEET OF FRUIT JUICE CONCENTRATE FRUIT JUICE POWDER    
MANUFACTURING PROCESS OF FRUIT JUICE POWDER FROM
   FRUIT JUICE CONCENTRATE    
SPRAY PROCESS ;    
SPRAY DRIERS:    
CONSTRUCTION:    
ATOMISING DEVICE:    
THREE MAIN TYPES OF ATOMISERS ARE EMPLOYED.    
THE DRYING CHAMBER :    
METHOD OF OPERATION :    
PROCESS FLOW DIAGRAM OF FRUIT POWDER    
MANUFACTURING PROCESS OF SOY SAUCE AND SOYA SAUCE POWDER    
THE CULTURE INCLUDE    
PROCESS FLOW DIAGRAM FOR SOYA SAUCE AND POWDER    
PRODUCTION DETAILS OF SOY SAUCE    
LARGE-SCALE SOY-SAUCE PRODUCTION    
MAKING SOY-SAUCE AT HOME    
CHINESE SOY SAUCE    
MANUFACTURING PROCESS    
PROCESS FLOWSHEET    
FERMENTED SOYA PRODUCTS    
FORMULATIONS    
COMPOSITE SOY SAUCE    
STALEY SOY SAUCE    
CHINESE SOY SAUCE    
PRODUCTION OF FERMENTED SOY SAUCE    
KOJI PRODUCTION    
FIG. FLOWSHEET FOR MANUFACTURE OF SOY SAUCE.    
BRINE FERMENTATION    
REFINING    
SOY SAUCE PRODUCTION BY THE ACIDHYDROLYSIS PROCESS    
MANUFACTURING PROCESS OF FAT POWDER    
PROCESS FLOW SHEET FOR PREPARATION OF FAT RICH POWDERS.    
FORMULATION OF FAT POWDER    
FORMULATION AND PROCESS OF FAT POWDER FOR SOUP    
FORMULATION AND PROCESS OF FAT POWDER FOR FODDER    
MANUFACTURING PROCESS OF TOMATO POWDER    
SUN-DRYING    
MODERN METHOD OF DEHYDRATION (SPRAY DRYING)    
DESCRIPTION OF PROCESS    
THE VARIOUS STAGES ARE AS FOLLOWS:    
SPRAY DRYING    
NATUREL OF SPRAY DRYING    
SPRAY DRYER SYSTEMS    
SPRAY DRYING AIDS    
MANUFACTURING PROCESS    
FLOW DIAGRAM FOR THE MANUFACTURING OF TOMATO POWDER    
OTHER RELATED INFORMATION ON TOMATO POWDER    
A PROCESS FOR PREPARING TOMATO POWDER    
PROCESS FOR DEHYDRATING TOMATO    
PROCESS 1    
PROCESS 2    
PROCESS 3    
PROCESS 4    
PHYSIOCHEMICAL PROPERTIES OF TOMATO POWDER AS AFFECTED
   BY DIFFERENT DEHYDRATION    
MATERIALS AND METHODS    
A. SOURCE OF MATERIAL AND SAMPLE PREPARATION    
B. PRE-TREATMENTS GIVEN PRIOR TO DEHYDRATION PROCESS    
C. CHEMICAL ANALYSIS    
D. ESTIMATION OF LYCOPENE CONTENT BY HPLC METHOD    
E. DEHYDRATION PROCESSES    
F. PHYSICOCHEMICAL ANALYSIS    
G. STORAGE STUDY    
RESULTS AND DISCUSSION    
B. EFFECT OF DEHYDRATION METHODS ON QUALITY CHARACTERISTICS
   OF TOMATO SLICES    
C. STORAGE STUDY    
SPRAY DRYING TECHNIQUE OF FRUIT JUICE POWDER    
PRINCIPLE OF SPRAY DRYING TECHNIQUE    
SPRAY DRYER    
BASIC STEPS OF SPRAY DRYING    
CONCENTRATION OF FRUIT JUICE    
ATOMIZATION    
DROPLET-AIR CONTACT    
DROPLET DRYING    
SEPARATION OF DRIED PARTICLES    
CARRIER AGENT    
INLET TEMPERATURE    
AIR DRY FLOW RATE    
ATOMIZER SPEED    
FEED FLOW RATE    
TYPE OF CARRIER AGENT    
CONCENTRATION OF CARRIER AGENT    
CONCLUSION    

DETAILS OF SPRAY DRYING    
FIGURE: PROCESS STEPS OF SPRAY DRYING. (1) ATOMIZATION.
   (2) SPRAY – HOT AIR CONTACT. (3) EVAPORATION OF MOISTURE.
   (4) PRODUCT SEPARATION.    
STAGE 1: ATOMIZATION    
PRINCIPLE OF ATOMIZATION    
CLASSIFICATION OF ATOMIZERS    
ROTARY ATOMIZERS    
RATIONALE FOR ATOMIZER CLASSIFICATION.    
FIGURE: ROTARY ATOMIZER (MURALI ET AL., 2014).    
PRESSURE NOZZLE (OR HYDRAULIC) ATOMIZER    
FIGURE: PRESSURE NOZZLE.    
TWO-FLUID NOZZLE ATOMIZER    
FIGURE: (A) TWO‐FLUID NOZZLE; (B) SPRAY EMERGING FROM
   TWO‐FLUID NOZZLE.    
ULTRASONIC ATOMIZERS    
FIGURE: ULTRASONIC ATOMIZER    
ELECTROHYDRODYNAMIC ATOMIZERS    
FIGURE: MECHANISM OF ELECTROSPRAYING.    
STAGE 2: SPRAY-AIR CONTACT    
FIGURE: SPRAY DRYER CONFIGURATIONS: (A) CO‐CURRENT (LEFT);
    (B) COUNTER‐CURRENT (RIGHT)    
EVAPORATION OF MOISTURE    
STAGE 4: PARTICLE SEPARATION    
CYCLONE SEPARATOR    
BAG FILTER    
FIGURE: A TYPICAL CYCLONE SEPARATOR    
FIGURE: SCHEMATIC OF SPRAY DRYER WITH BAG FILTER    
FIGURE: SCHEMATIC OF THE WORKING PRINCIPLE
   OF ELECTROSTATIC PRECIPITATOR.    
ELECTROSTATIC PRECIPITATOR    
PLANT AND MACHINERY SUPPLIERS FOR FRUITS & VEGETABLES
   POWDER & FAT POWDER    
SUPPLIERS OF MACHINERY & EQUIPMENTS    
HYDRAULIC JUICE EXTRACTOR    
FRUIT PULPER    
FILTER PRESS    
VACUUM EVAPORATORS    
SPRAY DRYERS    
AUTOMATIC POWDER PACKING MACHINE    
WEIGHING SCALE    
STEAM BOILERS    
GENERATOR SET    
MACHINERY SUPPLIERS FOR SOY SAUCE    
TURNOVER/ANNUM    


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)