Coconut Processing Plant (31500 kg/day)

COCONUT PROCESSING PLANT

[EIRI/EDPR/4094] J.C.: 2237INR, 2238US$

Coconut water is a refreshing drinks which also hygienic and nutritive. The white flesh is a calories rich extensively used for cookery in South India. From grated wet coconut kernel good quality oil as well as protein and carbohydrate can be extracted to prepare coconut honey. Undesirable flavour changes in desiccated coconut is due to oxidative rancidity of the oil. The residual cake after the oil has been extracted is used as cattle food.

The dried coconut meat is known as copra and is the source of coconut oil, which is used in enormous quantities for making fats for baking and confectionery. An important product used in the chocolate and confectionery industry is desiccated coconut. The nut is removed from the hard shell and the thin brown rind pared off. This must be very thorough or the finished coconut will be contaminated by flecks of brown. The pared nuts are then washed free of milk and skin residues and put through shredding machines, which give a milled product of varying degree of fineness. After shredding, the ground meat is subjected to a steam or hot water treatment to destroy salmonella and lipases and to reduce bacteria counts to low levels. The pasteurized meat is then dried on wire mesh belts by means of hot air, which reduces the moisture content to less than 4%.  The critical moisture level of desiccated coconut is 5% and the product should be well below this to ensure good shelf life.

After drying, the desiccated coconut is put through a multiple sieving operation to produce the four main grades. Extra fine, macaroon (fine), medium and coarse. A variety of other coconut products is available to the chocolate and confectionery trade such as, moist white sweetened coconut, toasted coconut, creamed coconut and tenderized coconut.

Top quality desiccated coconut should be white in colour, free from foreign matter, and uniform in granulation against standard, and the expressed oil should have a free fatty acid content of less than 0.1%.

Extraction of Coconut Oil

The coconut is the most extensively grown and used nut in the world. About 10 million people in India and several million of people in other tropical regions depend on the coconut plant for their livelihood.  India is the third largest coconut producing country of the world with an area of about 1.12 million hectares contributing to 18% of world production. India produces about 6000 million nuts annually. A whole coconut consists of 50% husk, 15% shell, 25% meat and 10% water.

COST ESTIMATION

Plant Capacity            31500 Kg./Day

Land & Building (6 Acres)    Rs. 16.56 Cr

Plant & Machinery                    Rs. 10.29 Cr

Working Capital for 2 Months    Rs. 11.75 Cr

Total Capital Investment          Rs. 39.62 Cr

Rate of Return                          35%

Break Even Point                      44%

CONTENTS

INTRODUCTION

EXTRACTION OF COCONUT OIL

COMPOSITION OF FRESH COCONUT KERNEL AND COPRA

MECHANICAL EXTRACTION OF COCONUT OIL FROM THE FRESH COCONUT MEAT:

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

VALUE ADDED COCONUT PRODUCTS

CHEMICAL COMPOSITION OF COCONUT OIL

CHARACTERISTICS OF COCONUT OIL

TABLE: COMPARATIVE FATTY ACID PROFILE OF COMMON FATS AND OILS

B.I.S 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

COCONUT PRODUCTS MARKET

COCONUT PRODUCTS MARKET

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

TABLE

COCONUT MILK BEVERAGES

COCONUT OIL

RBD COCONUT OIL

VIRGIN COCONUT OIL (VCO)

COCONUT FLOUR

COCONUT MILK POWDER

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

DIFFERENT PROCESSES OF VIRGIN COCONUT OIL EXTRACTION

COLD EXTRACTION PROCESSES

CHILLING, FREEZING AND THAWING METHOD

CENTRIFUGATION METHOD

FERMENTATION METHOD

AQUEOUS ENZYMATIC EXTRACTION METHOD

HOT EXTRACTION PROCESS

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

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 AND

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 DRYER

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

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

COCONUT CHARCOAL BRIQUETTES

TECHNOLOGY OF COCONUT SHELL CHARCOAL

MANUFACTURING PROCESS OF COIR YARN

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE: PLANT LOCATION 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:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF COCONUT

SUPPLIERS OF PET BOTTLES

SUPPLIERS OF COCONUT PROCESSING PLANT

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)