Detailed Project Report on instant coffee [spray dried and agglomerated]

INSTANT COFFEE 

[SPRAY DRIED AND AGGLOMERATED]

 [code no.4114]  

Instant Coffee

Instant coffee also known as soluble coffee is the dried water extract of roasted ground coffee. The product consists of brown colored, free flowing particles of uniform size. Most commercial products contain 100% pure "Coffee soluble solids". Instant coffee was included in the army rations during the Civil War and has been available in various forms, for a hundred years. However, it was not until after World War II that instant coffee became a popular consumer item. Its product quality is to better method, of manufacture as well as trend towards the use of convenience foods. Sale of soluble coffee has leveled off since 1961 but prior to 1961 there was a fivefold growth over ten years. However, coffee has been a widely accepted society’s beverage for many. The habit of drinking coffee spread rapidly across Europe, especially coffee become known in Vienna. Later its culture spread thoroughly in several countries in South America Central America. West Indies, Ceylon and Western Africa.

Instant coffee also known as soluble coffee is made up of soluble coffee solids and is completely soluble in water. It is prepared by a process involving the use of percolation with water to extract the ground coffee. The solution is then dried by one of several methods:

1. In Spray Drying the extract liquid is traced through coffee nozzles into a stream of hot air or inert gases, the result of which is almost instantaneous drying. The dried material cobalt in a suitable chamber.

2. Vacuum drying, on a moving belt yields a dried product in the form of flakes which are very soluble even in cold water.

3. Freeze drying, depends on the removal of water by evaporation in a high vacuum and at very low temperatures. The method yields a product which is closer to brewed coffee than the others, but it is expensive to produce.  The larger amount of instant coffee is produced by spray drying.

COST ESTIMATION

Plant Capacity                                     81 MT/Day  

Land & Building (40,000 sq.mt.)  Rs. 29.12 Cr    

Plant & Machinery                             Rs. 95 Cr 

Working Capital for 3 Months            Rs. 262.26 Cr 

Total Capital Investment                 Rs. 389.88 Cr 

Rate of Return                                 46%

Break Even Point                              30%

• INTRODUCTION
• INSTANT COFFEE
• USES AND APPLICATIONS
• RAW MATERIALS FOR COFFEE
• COFFEE PROCESSING
• COMPOSITION OF THE COFFEE
• B.I.S. SPECIFICATIONS
• MARKET OVERVIEW OF INSTANT COFFEE
• GLOBAL INSTANT COFFEE MARKET OVERVIEW
• COFFEE SECTOR IN INDIA
• THE COFFEE PRODUCTION STATES
• NESTLE'S MARQUEE BRAND HAS MAINTAINED ITS LEADERSHIP 
•    IN THE INSTANT COFFEE MARKET
• BRANDED COFFEE MARKET IN INDIA
• THE COFFEE TRADE: RETAIL MARKET CONSTRUCT
• HUL PIPS NESTLE IN INSTANT COFFEE
• PRESENT MANUFACTURERS OF INSTANT TEA AND COFFEE PREMIX
• PRESENT MANUFACTURERS OF INSTANT TEA
• SPRAY DRYING
• ADVANTAGE OF INSTANT COFFEE
• CLASSIFICATION OF INSTANT COFFEE POWDER
• NON-AGGLOMERATED INSTANT COFFEE POWDER
• AGGLOMERATED INSTANT COFFEE POWDER
• GRANULATED INSTANT COFFEE POWDER
• CURING OF COFFEE BEANS
• PRODUCTION METHOD OF INSTANT COFFEE
• TABLE: YIELD (ON DRY BASIS) OF SOLUBLE SOLIDS FROM 
•     ROASTED COFFEE
• MANUFACTURING TECHNIQUE OF INSTANT COFFEE
• FIG: FLOW CHART FOR PREPARATION OF AROMATIZED COFFEE
• DRYING TECHNIQUES
• SPRAY DRYING
• NOZZLE TOWER SPRAY DRYER
• FLUIDIZED SPRAY DRYER
• FILTERMAT SPRAY DRYER
• AGGLOMERATED POWDER
• SEQUENCES IN INSTANT COFFEE MANUFACTURE
• ROASTING
• GRINDING
• EXTRACTION
• HOT CELLS
• COLD CELLS
• CONCENTRATION
• THERE THREE METHODS
• VACUUM EVAPORATION
• CENTRIFUGATION
• FREEZE CONCENTRATION
• DEHYDRATION
• METHOD OF PRODUCING INSTANT COFFEE
• FREEZE DRYING METHOD
• SPRAY DRYING METHOD
• PACKAGING
• MANUFACTURING PROCESS OF INSTANT COFFEE
• BLENDS:
• ROASTING:
• GRINDING:
• EXTRACTION:
• THE FACTORS INFLUENCING EXTRACTION EFFICIENCY 
•    AND PRODUCT QUALITY ARE:
• DRYING:-
• THE FOLLOWING FACTORS ARE IMPORTANT CRITERIA FOR 
•    GOOD INSTANT COFFEE DRYING PROCESSES.
• THERE ARE FOLLOWING TWO PROCESSES FOR DRYING 
•     THE INSTANT COFFEE.
• 1. SPRAY DRYING:-
• 2. FREEZE DRYING:-
• PACKAGING:-
• ROASTED COFFEE:-
• INSTANT COFFEE PLANT PROCESSING DETAILS
• 1. CLEANING & BLENDING OF GREEN COFFEE
• GREEN COFFEE CLEANING
• 2. ROASTING & GRINDING OF GREEN COFFEE
• COFFEE ROASTING CUM GRINDING UNIT
• 3. COFFEE EXTRACTION SYSTEM
• COFFEE EXTRACTION
• 4. CLARIFICATION SYSTEM
• CLARIFICATION UNIT
• 5. AROMA RECOVERY CUM CONCENTRATION SYSTEM (ARC SYSTEM)
• AROMA RECOVERY UNIT
• 6. COFFEE CONCENTRATION
• EVAPORATION SECTION - PART 2 CALANDRM SECTION
• 7. SPRAY DRYING SYSTEM
• SPRAY DRYING SECTION
• 8. AGGLOMERATION SYSTEM
• AGGLOMERATION SECTION
• 9. PACKING & FILLING
• PROCESS FLOW DIAGRAM OF INSTANT COFFEE
• FORMULATION OF INSTANT COFFEE (PREMIX)
• INSTANT COFFEE PREMIXED WITH MILK AND SUGAR
• PROCESS FLOW SHEET FOR INSTANT COFFEE PREMIX
• POLLUTION CONTROL IN COFFEE PROCESSING INDUSTRY
• CHARACTERIZATION OF WASTEWATER FROM COFFEE PROCESSING INDUSTRY:
• TABLE: EFFLUENT STANDARDS-SUGGESTED RANGE FOR POLLUTANTS DISCHARGE INTO INLAND SURFACE WATERS
• SOURCES OF WASTEWATER:
• FIG: WATER BALANCE DIAGRAM
• ENVIRONMENTAL PROBLEMS OF WASTEWATER FROM COFFEE 
•     PROCESSING INDUSTRY:
• COFFEE IS PROCESSED IN TWO WAYS:
• TREATMENT OF WASTEWATER FROM COFFEE PROCESSING INDUSTRY:
• WATER RECYCLING:
• FIG: FLOW CHART ILLUSTRATING WATER RECYCLING PROCESS
• FIG: WATER RECYCLING MECHANISUM
• CONVENTIONAL TREATMENT METHODS:
• IT HAS 3 TANKS:
• FIG: SCHEMATIC FLOW SHEET OF WASTE WATER TREATMENT UNITS
• EQUALIZATION TANK:
• ANAEROBIC TANK:
• AEROBIC TANK:
• AIR POLLUTION AND ITS CONTROL IN COFFEE PROCESSING
• A. ROASTING
• B. QUENCHING
• C. COOLING
• D. DESTONING
• E. GREEN BEAN HANDLING
• F. GRINDING
• G. DECAFFEINATION
• H. CONTROL EQUIPMENT
• RECENT TRENDS IN EFFLUENT TREATMENT FOR COFFEE PROCESSING
• COFFEE PROCESSING EFFLUENT FOR PRODUCTION OF BIOGAS:
• FIG: ANAEROBIC TREATMENT SYSTEM
• METHOD OF COFFEE WASTE INTO RESOURCE
• 1. COFFEE TO COMPOST
• 2. MUSHROOMING FOOD BUSINESSES
• 3. WASTE TO ENERGY
• 4. TEA TIME
• 5. COFFEE FLOUR
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF CONDENSER
• SUPPLIERS OF SPRAY DRYERS
• SUPPLIERS OF CENTRIFUGE
• SUPPLIERS OF INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS
• SUPPLIERS OF PACKAGING MACHINE
• SUPPLIERS OF LABORATORY EQUIPMENTS
• SUPPLIERS OF GRINDER
• SUPPLIERS OF BOILERS
• SUPPLIERS OF STAINLESS STEEL TANKS
• SUPPLIERS OF WEIGHING SCALE
• SUPPLIERS OF PLANT AND MACHINERY (GLOBAL)
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF MILK POWDER

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)