Detailed Project Report on solvent extraction plant (silk worm pupae)

SOLVENT EXTRACTION PLANT (SILK WORM PUPAE)
[CODE NO.3347]  

Silkworm pupae oil derived from reeling waste is a rich source of a-linolenic acid (ALA), which has multipal applications. ALAs were added in sn-1, 3 positions in a triacylglycerol (TAG) to produce an APA-human milk fat analogues (APA-HMFAs, A: a-linolenic acid, P: palmitic acid). The optimum condition is that tripalmitin to free fatty acids of 1:12 (mole ratio) at 65°C for 48h using lipase Lipozyme RM IM. Results show that, the major TAG species that comprised APA-HMFAs were rich in ALA and palmitic acid, which contained 64.52% total unsaturated fatty acids (UFAs) and 97.05% PA at the sn-2 position. The melting point of APA was -27.5°C which is much lower than tripalmitin (40.5°C) indicating more plastic character. In addition, the practical application of alkyl caffeates as liposoluble antioxidants in APA was developed. Alkyl caffeate showed a superior IC50 (1.25–1.66µg/mL) compared to butyl hydroxy anisd (1.67µg/mL) and L-ascorbic acid-6-palmitate (L-AP) (1.87µg/mL) in DPPH analysis. The addition of ethyl caffeate to oil achieved a higher UFAs content (73.58%) at high temperatures. Overall, APA was obtained from silkworm pupae oil successfully, and the addition of caffeates extended storage ranges for APA-HMFAs.

Fats and oils are one of the most energy-rich food materials, which have the highest caloric values compared to other nutritional components. Current processes for the production of structured triacylglycerols (TAGs) from vegetable and animal oil focus on enzymatic transesterification to create the novel fat replacements. TAGs and human milk fat substitutes have been synthesized by enzymatic catalysis in many studies. Compared with the chemical methods, enzymatic approaches for lipid modification are more attractive due to the production of desirable acyl moieties or esters via specific enzymatic catalysis. Enzymatic processes are environmentally friendly and can be applied under mild conditions, ensuring greater product safety. Currently, organic solvents with low water content are usually employed to improve enzyme performance, which is important to protect or controlacyl group migration to ensure a desired product synthesis.

Human milk fat (HMF) is one of the major components of breast milk for newborn, term, and preterm infants. Thus, it supplies the highest fraction of an infant’s required dietary energy and nutrients. The structure of HMF must be simulated to manufacture human milk fat analogues (HMFAs) for better digestion. The steric configu-ration of fatty acid is determined by chain length and unsaturated degree, and polyunsaturated fatty acids have higher steric hindrance. It was not clear if the polyunsaturated fatty acid could be served as feedstock in the lipase-catalyed HMF production. Human milk is characterized by the dominance of TAGs (>98% of HMF), which contain palmitic acid (C16:0, 20–40% of total FA) in the sn-2 position (70% of all palmitic acid) and unsaturated fatty acids (UFAs) on sn-1 and sn-3 positions. Therefore, research on the synthesis of desirable structured TAGs focuses on the creation of TAGs rich in specific fatty acids in sn-2 position. Qin et al. investigated the incorpo-ration of different fatty acids (C8:0-C18:2) into PPP-enriched TAGs to produce HMFA through lipase-catalyzed reactions, and they also reported the degree of incorporation of different FAs into PPP-enriched TAGs through acidolysis catalyzed by lipase. Essential fatty acids, such as a-linolenic acid (ALA, C18:3, ?-3), from agricultural
 
Figure. Biosynthesis diagram of APA-style HMFAs from silkworm pupae oil via enzymatic transesterification. The photos were taken and modified by X. L., and the diagram was drawn by X. W.

Sources, may be used as the substrate to formulate APA-style HMFA for infant formula. A possible method would be to blend this product and 1, 3-dioleoyl-2-palmitoylglycerol (OPO) enriched fats and minor lipids based on the chemical composition of HMF.

COST ESTIMATION

Plant  Capacity                                            :       12.00 Ton/day
land & Building (6 Acres)                          :       Rs.  7.76  Cr
Plant & Machinery                                       :       Rs.  4.78  Cr
Working Capital for 3 Months                   :       Rs.  3.64  Cr
Total Capital Investment                            :       Rs.  17.43 Cr
Rate of Return                                              :     19%
Break Even Point                                         :       56%


INTRODUCTION    
SPECIES OF SILK WORM    
CHARACTERISTICS AND APPLICATION OF PUPAE OIL    
CHEMICAL COMPOSITION OF SILKWORM PUPAE    
MINERAL COMPOSITION OF SILKWORM PUPAE MEAL    
MICROENCAPSULATION    
AND PROPERTIES OF SILKWORM PUPAE OIL    
USES AND APPLICATION OF SILKWORM PUPA OIL    
USES AND APPLICATION FOR SILKWORM PUPAE    
OVERVIEW OF SERICULTURE IN INDIA    
MANUFACTURING PROCESS OF SOLVENT EXTRACTION PLANT
(SLIK WORM PUPAE)    
PROCESSING AND OPERATING DETAILS OF PUPAE OIL EXTRACTION    
PROCESS FLOW DIAGRAM    
EXTRACTION OF PUPAE OIL FROM PUPAE POWDER    
PURIFICATION OF PUPAE OIL    
EXTRACTION OF THE OAK SILKWORM PUPAL OIL USING
SUPERCRITICAL CARBON DIOXIDE METHOD    
ANALYSIS OF EXTRACTED PUPAL OIL    
INVESTIGATION AND ANALYSIS OF SILKWORM PUPAE AS A PROTEIN SUPPLEMENT IN POULTRY FEED    
DETAILS OF BATCH TYPE EXTRACTION PLANT    
PLANT LAYOUT    
PRINCIPLES OF PLANT LAYOUT    
PLANT LOCATION FACTORS    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
PROJECT IMPLEMENTATION SCHEDULES    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF RAW MATERIALS    


APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET