Chemorheology of Polymers From Fundamental Principles to Reactive Processing.pdf
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1
Innovative Technologies inCoconut Processing
Coconut Development Board
2
Coconut - A Versatile Crop
Used as - food crop, oilseed, fibrecrop
medicinal crop &beverage crop
Coconut leaves - for roof and fencing
Coconut shell - for industrial products,handicraft items
Coconut trunk - for building materials,flooring materials andhandicrafts
Coconut - yield coconut toddy
inflorescence
Coconut fruit - inevitable item in culturaland social use
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Coconut Production and Productivity
Country Area
(in hectres)
Production
(in millionnuts)
Productivity
nuts / ha
India 1903190 14744 7747
Indonesia 3860000 15196 3937
Philippines 3355000 12327 3674
Source: DES, GOI, NEW DELHI
4
Valueadded
coconutproducts
Size of the Inland market: Rs 83000 million
Size of the Export Market: Rs 3000 million (Coconut products)
and Rs 6400 million (Coir products)
CAGR : 8%
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PROCESSING OF MATURE NUT
WATER
Concentrate
Packedwater
KERNEL
Milk /Cream
Skimmedmilk
powder
Desiccatedcoconut
SHELL
Shell powderActivated
carbon
Shellcharcoal
Vinegar
HUSK
Coir Industry Coir pith Compost
VirginCoconut oil
/ Nata-de-coco
Jam
Honey
Chips
Dairy foods
Biscuits/burfi Handicrafts
Copra
Ediblecopra
Oil
Chutneypowder
6
PROCESSING OF TENDER NUT
Packedtender
nut water
Snow ball
Soft kernel
Pudding
Ice cream
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Seed & Others
Copra
50%
10%
35%
Industrial
10%Domestic
90%
Consumption Pattern of Coconut
Mature Nut
Tender Nut
5%
8
Copra
Copra is the dried kernel of coconut. It is from copra that coconut oil is
produced. Copra contains the highest percentage of oil as compared toother oil seeds.
The two broad varieties of copra are milling copra and edible copra. Milling
copra is used for extracting oil whereas edible copra is used in condiments
and in religious and social functions. India producing about 6.5 lakh MT of
milling copra and 2 lakhs MT of Ball copra. The major exports of copra is to
Bangladesh and Nepal.
Coconut Products
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Coconut Oil
Coconut oil is used for, both edible and non edible purposes. It is also
consumed in various industrial applications, soap, shampoo, detergents,
etc. A portion of coconut is also used in the making of ice creams and
biscuits, chocolates which can be described as industrial purposes though
the finished products are edible.
Around 10,000 tonnes of Coconut oil is exported mostly to the Gulf Region
Consumed by Ethnic Population
Contrary to misconceptions, coconut oil does not elevate total blood
cholesterol. Instead, it increases HDL or the friendly cholesterol, lowers
harmful LDL cholesterol and serum triglycerides. .
Annual production of Coconut Oil is 4.85 lakh tonnes.
10
Virgin Coconut Oil
Virgin Coconut Oil (VCO), extracted from fresh coconut meat
without chemical processes is said to be the mother of all
oils.
It is rich in medium chain fatty acids, particularly lauric acid
and is a treasure trove of minerals, vitamins, antioxidants and
is an excellent nutraceutical. It has about 50% lauric acids,
having qualities similar to mothers milk, thus confirming its
disease fighting ability. Virgin Coconut Oil finds application as
skin oil, massage oil, baby oil and consumed in USA / Europe
for reducing obesity.
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Desiccated Coconut
Coconut has been the staple food of people in many parts of
Asia and Pacific Islands. The dehydrated shredded flesh ofcoconut known as desiccated coconut is often used as a
substitute to grated coconut in food preparations such as
curries, cakes, sweets and chutneys. Confectionery and
bakery units are the main consumers of desiccated coconut.
Total production of DCP is about 50,000 MT mainly
concentrated in Karnataka and Tamil Nadu. Exports amout to
about 2000 Tones
12
Spray Dried Coconut Milk Powder
The Spray Dried Coconut Milk Powder is now available in
convenient and ready-to-use packs with the same freshness of
a fresh coconut milk. It has longer a shelf life and is convenientto use.
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Tender Coconut Water
The water of Tender Coconut is a sterile, nutritious, thirst
quenching health drink. The pure and sweet tender coconut
possesses enormous therapeutic properties and is a thirst
quenching refreshing health drink for all age groups. It is
loaded with natural sugars, salts, and vitamins and is low in
fat, calories and has no cholesterol. It's a highly rejuvenating
tonic that can ward off fatigue in an instant. Tender coconut
water has the same level of electrolytic balance as we see in
our blood.Technology available for packing & preserving TCW.
14
Activated Carbon
Coconut Shell is used for manufacturing a variety of products
of commercial importance including activated carbon. Shell
based activated carbon is extensively used in the process of
refining and bleaching of vegetable oils and chemical
solutions, water purification, recovery of solvents, recovery of
gold etc. It is used in gas masks and a wide range of filters for
war gases and nuclear fall outs. Coconut shell based activated
carbons units adopt steam activation process to produce good
quality activated carbon.
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Activated Carbon is made both by the organized and un-
organized industry
There are 18 medium sized Companies in India who makeactivated Carbon using state-of-the-art machines. The
other manufacturers are tiny manufacturers in the un-
organized sector. The total production of Activated Carbon
is 45000 MT / annum.
The present exports is directed at United states, UK,
Germany, Japan, France, and averages around Rs 1500
million. There is an enlarged market potential for activated
Carbon because of its unique natural properties.
16
Coconut Based Handicrafts
Coconut Handicrafts made out of the wood shell, fibre/husk
and leaves of the coconut tree have high decorative value and
serve as a value addition bringing with it the aesthetic touch
and exquisiteness wherever it is used
The timber can be converted into doors, windows, wall panels,
banisters. Coconut fibre is used to make coir products such as
bags, table mats, sandals, wall hangings etc. Coir mats and
carpets are also made out of the coconut fibre.
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Export potential
Coconut oil has an excellent potential in Gulf, Europe, and America, the
user being the ethnic population;
Activated Carbon has been increasing its market share and demand
from USA, United Kingdom, Germany, France, Japan etc.
Processed and packaged tender coconut water has been bagging
orders from Gulf and UK.
China, is a growing market for coconut and its various products,
Russia is emerging as one of the major buyers of Coconut oil and
Virgin Coconut oil, Germany is an emerging market particularly for
desiccated Coconut powder, coconut milk powder etc.
Handicrafts, Ice cream cups spoons etc made from coconut shell is
exported to European countries
Indian Coconut products are rated as premiium quality products.
18
Coconut growing countries like Malaysia, Philippines, and other
ASEAN countries are concentrating on manufacturing Palm oil, other
Coconut value added products with new technology, Government
support, high level R&D Intervention.
Their brands have premium clientele.
India can outreach them only by increasing the present range of
products, increasing its value addition, look at new markets, penetrate
and establish a niche presence, with cost effective pricing.
Indian products should be visible in the Retail stores with attractive
packing, and should match the pricing of competitive products from
ASEAN, Sri Lanka and other Coconut value-added product
manufacturing countries.
India should record presence by participating in the world renowned
international trade fairs across the globe by utilizing the Market
Development Assistance and Market Access Initiative Scheme of the
Foreign Trade Policy enumerated in Para 3.2 of the FTP.
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Strengths of the Indian Coconut Sector
One of the largest producers of coconut in the world Sufficient
raw material surplus.
Quality of Indian coconut product enjoys good reputation.
Access to good technologies (Virgin Coconut Oil, Packed Tender
Nut Water, minimally processed Tender Coconuts, Activated
Carbon)
Dominant ethnic population in the Gulf, UK and US
Being a natural and eco friendly product, coconut has a future and
potential for earning carbon credit
20
Lack of big players from the coconut sector in the international market
Lack of exposure to the international market and its specific requirements
The weak financial status of the small and tiny exporters who cannot take
up effective export promotion programmes
Price disadvantages Cost of production is high. INR appreciation vis--vis
SLR.
Lack of market penetration
Competing countries of South East Asia have already an established
presence in important international markets and have cost advantages
Supply side is highly disorganized and fragmented
Coconut products occupy large volume and has low unit value (.) Tariff
freight is against volume.
Weakness
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Coconut shell based Activated Carbon is an agricultural and environmentally friendly
products. Its classification under ITC Code under Miscellaneous Chemical Products
deprives this product of the benefits due for an environmentally friendly product.
Board has proposed to the Ministry of Finance to reclassify it under Chapter 44 as an
Agriculture product.
Since coconut industry is labour intensive and generates rural employment coconut and
its value added products should be provided benefits under Vishesh Krishi Udyog
Yojana, FPS, Duty draw back
Increased exposure to international markets through regular participation in important
fairs and exhibition
Restore DEPB Scheme for Copra
Allowing exports of Coconut Oil from all southern ports in India
Harmonising national standards with international standards for coconut products
Opportunities
22
Rupee appreciation vis--vis the dollar
Freight disadvantages Geographical distance from end markets
Competitive advantages of South East Asian
Countries in the world market
Threats
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PROJECT PROFILES OFPOTENTIAL VALUE ADDED
COCONUT PRODUCTS
23
24
ACTIVATED CARBON
Activated carbon manufactured fromcoconut shell is considered superior to
those obtained from other sources mainlybecause of small macro pore structure,which renders it more effective for theadsorption of gas/vapor, and for the
removal of color and odour of
compounds.
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Activated Carbon
Activated carbon is widely used in the refiningand bleaching of vegetable oils and chemicalsolutions.
At present five units are functioning.
Total production estimated at 5000 MT.
Anticipated growth is 20%
26
MANUFACTURING PROCESS
The manufacturing process involves the following steps
Breaking of coconut shells in a Coconut shell breaker.
Broken Coconut shells are then fed into a carbonization retort.
Carbonized coconut shells are brought down to the desired size
using either a hammer mill or a roller crusher.
Crushed charcoal is then screened using a rotary
screener.Oversized product retained on the inner mesh is recycled
to the crusher/hammer mill and the undersized particles passing
through the outer mesh are used for other applications.
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The next step is the most important one- the activation process
involving the reaction between charcoal and steam carried out
in a rotary kiln at temperatures between 850C and 1000C.
The activated charcoal is then cooled at the discharge of the
kiln through serpentine cooling tubes.
The cooled product is screened in a rotary screener. The
oversized particles are crushed in a roller crusher and
recycled to the screener and the undersized particles
are used for other appropriate applications.
.
28
The cooled product is screened in a destoner and screener.
The oversized particles are crushed in a roller crusher and
recycled to the screener and the undersized particles are used
for other appropriate applications.
The finished product is finally stored in large silos and packed
in high density polypropylene bags in various consumer packing
depending on the customer requirements.
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PROJECT COSTCapacity 5 MT per day
Land Requirement- 2.0-2.5 acres
Building -10000 sq ft - Rs.70 lakhs
Plant & machinery - Rs. 200 lakhs
Electrification - Rs.30 lakhs
Preliminary & pre operative expenses - Rs. 20 lakhs
Working capital - Rs. 25 lakhs(Margin money)
30
Preservation and Packing ofCoconut Milk / Cream
PRODUCT AT A GLANCE
Ready to use product for households
recipes, beverages, icecreams,sweets, desserts etc.
Fresh taste of coconut without thebother
Very convenient forhouseholds,hotels,
bakeries.
Blends easily with food preparation.
Keeps fresh for a period of 6 monthswith all nutrients in tact.
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PROJECT COSTCapacity 10000 nuts per day Land requirement - 60 cents-1acre
Building 6000 sq ft - Rs 55 lakhs
Plant & machinery - Rs.65 lakhs.
Preliminary and
pre - operative expenses- Rs. 15 lakhs.
Electrification - Rs. 20 lakhs.
Margin money for
working capital - Rs. 25 lakhs.
32
Spray Dried Coconut MilkPowder
PRODUCT AT A GLANCE
Highly convenient to use for
households / hotels,bakeriesand ice cream parlours.
Reconstitute quickly withwater for instant use.
Occupies less storage space.
Highly economical for bulkconsumer.
Keeps fresh for a period upto 1 year.
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PROJECT AT A GLANCE
Land Requirement - - 1.5-2.0 acres
Building 8000 sq ft - Rs.70 lakhs
Plant & machinery - Rs. 200 lakhs
Contingencies - Rs.10 lakhs
Preliminary & pre operative expenses - Rs. 15 lakhs
Working capital - Rs. 25 lakhs(Margin money)
34
PRESERVATION AND PACKING OF TENDERCOCONUT WATER
PRODUCT AT A GLANCE
Natural, nutritious and thirstquenching health drink.
Possess therapeutic propertieswith vitamins,minerals andprotein.
Good rehydration medium forpatients suffering fromgastroenteritis and intestinaldisturbances.
Keeps fresh for a period of six
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PROJECT COST10000 tender nuts per day
Land Requirement- 60 cents-1 acre Building 6000 sq ft- Rs. 55 lakhs
Plant & machinery - Rs. 60 lakhs
Preliminary & -pre - operative expenses- Rs. 10 lakhs
Electrification - Rs. 10 lakhs
Working capital - Rs. 20 lakhs(Margin money)
36
CHARCOAL
PRODUCT AT A GLANCE
Superior in quality whencompared to wood charcoal.
Ideal raw material for highquality activated carbon.
Better calorific value thanother agro waste and henceideal for use as fuel insmitheries, bakeries andfoundries.
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PROJECT COSTCapacity 3 MT per day
Land requirement - 50 cents
Building 3000 sq ft Rs 15 lakhs
Plant & machinery - Rs.30 lakhs
Preliminary &
pre - operative expenses. - Rs. 5.0 lakhs
Electrification - Rs. 5.0 lakhs
Margin money for-
working capital - Rs..20 lakhs
38
VIRGIN COCONUT OIL
PRODUCT AT A GLANCE
A Premium Grade Oil
extracted directly from freshcoconut through wetprocessing
White in Color
Extensive Medicinal uses
Keeps fresh for a period upto 1 year.
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PROJECT AT A GLANCE
Land Requirement - - 1.5-2.0 acres
Building 8000 sq ft - Rs.70 lakhs
Plant & machinery - Rs. 200 lakhs
Contingencies - Rs.10 lakhs
Preliminary & pre operative expenses - Rs. 15 lakhs
Working capital - Rs. 25 lakhs(Margin money)
40
o So far adequate attention has not been given to
promoting exports from the coconut sector
o The strength of being a natural product has notbeen properly leveraged.
o Coconut Sector needs to be supported with
incentives and tax exemptions for the overall
growth of coocnut industry.
o If proper stimulus is given to coconut which is an
agricultural product generating employment in
rural area there is a distinct possibility of taking
exports to a high level.
Conclusion
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Coconut Oil, [Crude, refined]
Virgin Coconut Oil
Processed tender
coconut water,
Coconut milk powder
Desiccated
Coconut powder
Activated CarbonCoconut shell (raw), Shell Charcoal,
Shell hookah,
Coconut handicrafts
Coconut [Fresh, dried]
Copra, Oil Cake