AUTOMATED COCONUT PROCESSING PLANT (CAP: 10,000 MT/DAY)
[EIRI/EDPR/4479] J.C.: 2694XL
Coconut water is the clear liquid inside young green coconuts (fruits of the coconut palm). In early development, it serves as a suspension for the endosperm of the coconut during the nuclear phase of development. As growth continues, the endosperm matures into its cellular phase and deposits into the rind of the coconut meat. Coconuts for drinking are served fresh, chilled or packaged in many places. They are often sold by street vendors who cut them open with machetes or similar implements in front of customers. Processed coconut water for retail can be found in ordinary cans, tetra packs, or plastic bottles, sometimes with coconut pulp or coconut jelly included.
In recent years, coconut water has been marketed as a natural energy or sports drink having low levels of fat, carbohydrates, and calories, and significant electrolyte content. However, the contents of primary electrolytes per 100 ml serving, sodium, potassium, magnesium and calcium, are negligible (table of nutritional values) unless fortified in manufacturing. Further, marketing claims attributing health benefits to coconut water are not based on science and are disallowed by regulatory agencies, such as the United States Food and Drug Administration.
COST ESTIMATION
Plant Capacity 10,000 MT/Day
Land & Building (12,500 sq.mt.) US$ 15.75 Lac
Plant & Machinery US$ 14.43 Lac
Working Capital for 3 Months US$ 18.20 Cr
Total Capital Investment US$ 18.54 Cr
Rate of Return 87%
Break Even Point 14%
CONTENTS
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 PRODUCTFIG. 1: CONSUMPTION – PRODUCTION RATIO OF COCONUTS
TABLE 5: CST 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)
