CASHEWNUT PROCESSING AND CNSL [3541]
Cashew nut processing allows for the development of an important by-product, which can increase its added value. The liquid inside the shell (CNSL) represents 15 percent of the gross weight and has some attractive possible medicinal and industrial uses. CNSL is one of the few natural resins that is highly heat resistant and is used in braking systems and in paint manufacture. It contains a compound known as anacardium , which is used to treat dermatological disorders. The main markets for CNSL are the United States, the European Union (mainly the United Kingdom), Japan and the Republic of Korea. Together these account for over ninety percent of world trade, most of which is supplied by India and Brazil. Cashew (Anacardium occidentale L.) a native of Eastern Brazil introduced to India just as other commercial crops like Rubber, Coffee, Tea etc. by the Portuguese nearly five centuries back. The first introduction of cashew in India was made in Goa from where it spread to other parts of the country. In the beginning it was mainly considered as a crop for afforestation and soil binding to check erosions. The nuts, apple and other by products of this crop are of commercial importance. Though its commercial exploitation began from the early 60’s, marginal lands and denuded forests were the areas set apart for the plantation development. Due to the absence of high yielding varieties and multiplication techniques, indiscript seeds and seedlings were used for planting purposes. Because of its adaptive ability in wide range of agro climatic conditions it has become a crop of high economy and attained the status of an export oriented commodity bringing considerable foreign exchange to the country. Cashew (botanical name Anacardium occidental) was introduced in India by the Portuguese four centuries ago, mainly to prevent soil erosion. Cashew ranks second among the nine tree nuts which figure prominently in international trade circles, first being almond. The cashew adapts to various types of soils and climatic conditions and is hardy and draught resistant tree. For several centuries the cashew trees was considered merely as a sturdy perennial tree which yielded soft wood and bore the delicious juicy cashew apple. The peculiarity of the cashew apple is that it has nut outside. In the earlier days, the nut was thrown away after the apple was eaten. The nut was rejected since it has a hard shell cover which contains a corrosive liquid (cashewnut shell liquid) which burns the skin on contact. As time passed, interest developed in the nut and various methods of extracting the kernel from the nut proved successful. Cashew nut has been cultivated in several countries for a long time but the credit for launching into commercial production and export of cashew kernels goes to India. Very small quantities of unpeeled cashew kernels were exported to Marseilles and London, in the beginning of the present century. Since then exports have shot up tremendously and 50-56 thousand tones of cashew kernels were exported during the decade ending 1973-74. The export of cashew kernels in the period 1946-78. Grew at the rate of 4.1% per annum, as compared to the 5.2% annual growth rate of world export. The cashew is chiefly growth in the coastal districts of India and nearly 70 percent of the production is from the West Coast between Mumbai and Cape Camerin. Ratangiri and North Kanara districts in Mumbai. South Kanara, Malabar, Tiruchirapalli, Tanpore and South Arcot districts in Tamil Nadu state, Nellore, Godavari and Vishakhpatnam districts in Andhra, and Travancore-Cochin are major areas of production. Nearly 50% of the production comes from Tamil nadu state, while Travancore Cochin state accounts for about 36 percent and Mumbai 10 percent. West Bengal, Odisha, Karnataka, and Andhra Pradesh are other states in India which together accounts for about 4.0 percent of the product. Cashewnut Shell Liquid: Cashew nut shell liquid (CNSL) is a bye product of the cashew industry in India, which is a major earner of foreign exchange. It is contained in the soft honey comb structure between the outer shell and the kernel of the cashew nut. The cashew nut tree (Ana cardium Occidentale Linm, Hindi, Kaju) belongs to the natural order Anacardiaceae, even as Bhilawan tree and grows at altitudes below 1000 ft along the west and Eastern coasts of India. It is extensively cultivated in Brazil East Africa, Tanzania, Mozambiques Madagascar, Philippines and other tropical regions. In India it is grown in the states of Kerala, Tamil Nadu, Karnataka, Andhra pradesh, Maharashtra, Orrisa, West Bengal, Assam and Goa. The cashew fruit has a kidney-shaped nut 1 to 1.5 inches long. The nut is attached to the end of fleshy receptable or enlarged or rhomboid-to-oval having 2-4 1/2" length and is bright yellow to red with a waxy skin. Pericarp of the nut consists of a coriaceous epicarp, spongy mesocarp and story endocarp. The mesocarp consists of a honey-comp net work of cells which gives cashew nut shell liquid.
Cashew Testa: Cashew testa is the outer skin of cashew kernel which contains about 25% of tannin material and 11% of non tannins. The tannins consist of D-catechin, gallic acid and leuco-cyanidin, a significant tannin procursor, while the non-tannins consists of quinic and caffeic acids. These tanning materials have shown similar properties to that of imported wattlebark tannin used in leather industry. The latter is being imported from East African countries to the extent of 12-15 thousand tons per annum costing nearly 2 crores. The availability of cashew testa is estimated around 2000-2500 tons per year in Quiling region alone where 75% of the factories process cashew nuts. Recently a tannin extraction plant of the Kerala State Development corporation Ltd., has been started at Kottiyam about 8 k.m. from Quilon. The corporation with its 34 cashew processing factories, is the first to start a bye product plant of this nature. It is considered to be the biggest unit in the cashew industry, accounting for more than one fourth of the total processing capacity in the state of Kerala. It is estimated however that 3-4 thousand tons of cashew tesa would be available within the country and from which 500-600 tons of cashew tannin extract costing about 10 lakhs of rupees could be made. The residue of the tannin which is not soluble in water but soluble in mild alkalies. The extracts may find use in oil drilling mud and in the "Boiler compounds" generally used in railway steam boilers.
COST ESTIMATION
Plant Capacity 2 MT/Day
Land & Building (30000 sq.ft) Rs. 56 Lac
Plant & Machinery Rs. 1.04 Cr
Working Capital for 1 Month Rs. 70 Lac
Total Capital Investment Rs. 2.42 Cr
Rate of Return 25%
Break Even Point 61%
INTRODUCTION
CASHEWNUT SHELL LIQUID
CASHEW TESTA
CASHEW KERNEL
RAW MATERIAL AND ITS AVAILABILITY
SPECIFICATION OF CASHEWNUT SHELL
COMPOSITION OF CASHEWNUT
CASHEW NUT BY-PRODUCTS
CASHEW APPLE
CASHEW APPLE JUICE
CASHEW SYRUP
CASHEW APPLE JAM
CASHEW APPLE CANDY
COMPOSITION OF CNSL
CULTIVATION OF CASHEW NUTS
CASHEW NUTS
PROCESSING OF CASHEW NUT
USES & APPLICATION OF CASHEW KERNEL
MEDICINAL APPLICATIONS
B.I.S. SPECIFICATIONS
NUTRITIONAL VALUE OF CASHEW
GRADES OF CASHEW
A. CASHEW KERNELS - WHITE WHOLES
B. CASHEW KERNELS - SCORCHED WHOLES
C. CASHEW KERNELS - DESERT WHOLES
D. CASHEW KERNELS - WHITE PIECES
E. CASHEW KERNELS - SCORCHED PIECES
F. CASHEW KERNELS - DESSERT PIECES
OVERVIEW OF CASHEWNUT
CASHEW PRODUCING COUNTRIES
PRODUCTION OF CASHEW IN INDIA
INDIAN CASHEW MARKET
MARKET POSITION
CASHEW BOARD
RECENT INITIATIVES
CASHEW DEMAND REMAINS SLUGGISH ON HIGH PRICES
EXPORT & IMPORT DATA OF CASHEW KERNEL, ROASTED & SALTED
CASHEW KERNELS, CNSL, RAW CASHEW NUT
KEY MARKETS AND EXPORT DESTINATIONS
PRODUCTION OF RCN IN GLOBAL MARKET
VIETNAM EARNS OVER 1 BLN USD FROM CASHEW NUTS EXPORTS
CASHEW SET TO SPARKLE ON FESTIVAL DEMAND
CASHEW NUT SHELL CAKE
DETAILED IMPORT DATA OF RAW CASHEW NUTS SHELL
MANUFACTURERS/EXPORTERS OF CASHEWNUT PROCESSING
DETAILS OF CNSL (CASHEW NUT SHELL LIQUID)
METHOD OF CASHEW NUT ROASTING & PROCESSING
(A) DRUM ROASTING
(B) STEAM ROASTING
STORAGE
CLEANING AND SIZING
CONDITIONING
ROASTING
SHELLING
BENEFITS OF IMPROVED TECHNOLOGY OVER CONVENTIONAL
PRACTICES OF PROCESSING THE CASHEW KARNEL
ADVANTAGE OF STEAM ROASTING
OVER DRUM ROASTING
OUTLINES OF MANUFACTURING PROCESS
ROASTING
SHELLING
DRYING
PEELING
GRADING
MANUFACTURING PROCESS OF RAW CASHEW NUT KERNAL PROCESSING (STEAM BOILER ROASTING)
RAW MATERIAL HANDLING AND STORAGE
PREPARATION FOR PROCESSING- STEAM COOKING OR ROASTING OF RCN
DRYING/HEAT TREATMENT OF SHELLED CASHEW- PRE-PEELING
TREATMENT
PEELING OF CASHEW KERNEL
CONDITIONING THE PEELED NUTS/KERNEL
GRADING/SORTING/CLEANING THE CASHEW KERNEL
PACKAGING THE CASHEW KERNELS IN REQUIRED FORMS
OTHERS METHOD OF CASHEWNUT PROCESSING
THE NUT
PROCESSING:
ROASTING:
(A) DRUM ROASTING
(B) OIL BATH ROASTING
SHELLING
DRYING
PEELING
GRADING
PACKING:
PACKING FOR EXPORT
RESULTS: ROASTING AND CRACKING TRIAL
QUALITY CONTROL (PLANT SANITATION)
OBJECTIONABLE CONDITIONS OF FOOD:
INFESTATION:
PRESENT OF DIRT:
PRESENCE OF MOLD:
RANCIDITY:
PRESENCE OF EXTRANEOUS MATERIAL:
PLANT SANITATION:
THE FOLLOWING SHOULD BE STUDIED CAREFULLY.
FACTORS PROMOTING INFESTATION:
PREVENTING INFESTATION
GENERAL PROCESSING STEPS FOR CASHEW NUT AND POLLUTION CONTROL
DRYING OF RAW NUTS
ROASTING / STEAM COOKING
A. ROASTING:
B. STEAMING
DECORDICATION
DRYING OF THE KERNELS
PEELING
GRADING
FILLING
PACKING
ROASTING PROCESS
COOKING (STEAM ROASTING) PROCESS
BABY BOILER
CASHEW NUT COOKER
KERNEL DRYING (BROMA)
ENVIRONMENTAL STANDARDS FOR CASHEW PROCESSING INDUSTRIES
AIR POLLUTION EMISSION STANDARDS
SULPHUR DIOXIDE, NITROGEN OXIDES AND PHENOLIC COMPOUNDS
WASTEWATER DISCHARGE STANDARDS
SOLID WASTE DISPOSAL PRACTICES
CASHEW NUT PROCESSING FLOW DIAGRAM
CASHEWNUT PROCESS FLOW CHART FLOW DIAGRAM
COMPLETE PLANT SUPPLIERS ON TURNKEY BASIS
RAW MATERIAL SUPPLIERS
CASHEW NUTS SUPPLIERS
PLASTIC CONTAINERS
SUPPLIERS OF PLANT AND MACHINERY
BOILER
TANKS: STORAGE
DRYERS & DRYING OVENS
BUCKET ELEVATOR SYSTEMS
CENTRIFUGES
CONVEYOR BELT
MAJOR PROCESSORS AND EXPORTERS OF CASHEW
ADDRESS OF CONSULTANT
PLANT LAYOUT
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)
