Professional Documents
Culture Documents
Coconut Processing
Sree Kumar P
Sr Processing Engineer
Coconut
inflorescence
Coconut fruit
Area
(in hectres)
Production
(in million
nuts)
Productivity
nuts / ha
India
1903190
14744
7747
Indonesia
3860000
15196
3937
Philippines
3355000
12327
3674
Value
added
coconut
products
HUSK
KERNEL
WATER
Milk /
Cream
Concentrate
Edible Skimmed Virgin
copra
milk Coconut oil
Packed
powder
water
Oil
Jam
Vinegar / Nata-deSHELL
Desiccated
coco
Honey
coconut
Shell powder
Chips
Chutney Biscuits
Shell
Activated
Handicrafts
powder
/burfi Dairy foods
5
charcoal
carbon
Copra
Packed
tender
nut water
Soft kernel
Pudding
Ice cream
Snow ball
6
50%
Industrial
90%
10%
10%
Tender Nut
Copra
Seed & Others
Domestic
35%
5%
7
Coconut Products
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 to
other 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 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
Desiccated Coconut
Coconut has been the staple food of people in many parts of
Asia and Pacific Islands. The dehydrated shredded flesh of
coconut 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
11
12
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.
14
15
16
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.
Handicrafts, Ice cream cups spoons etc made from coconut shell is
exported to European countries
19
Weakness
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.
20
Opportunities
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
21
Threats
Freight disadvantages
22
Activated
Carbon
25
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.
26
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.
.
27
28
PROJECT COST
Capacity 5 MT per day
Land Requirement-
Building -10000 sq ft
Rs.70 lakhs
Electrification
Rs.30 lakhs
Rs. 20 lakhs
Rs. 25 lakhs
Working capital
(Margin money)
2.0-2.5 acres
29
PROJECT COST
Capacity 10000 nuts per day
Land requirement
Building 6000 sq ft Plant & machinery
Preliminary and
pre - operative expensesElectrification
Margin money for
working capital
-
60 cents-1acre
Rs 55 lakhs
Rs.65 lakhs.
Rs. 15 lakhs.
Rs. 20 lakhs.
Rs. 25 lakhs.
31
PROJECT AT A GLANCE
Land Requirement-
1.5-2.0 acres
Building 8000 sq ft
Rs.70 lakhs
Contingencies
Rs.10 lakhs
Rs. 15 lakhs
Rs. 25 lakhs
Working capital
(Margin money)
33
34
PROJECT COST
10000 tender nuts per day
Land Requirement-
Rs. 55 lakhs
Rs. 60 lakhs
Rs. 10 lakhs
Electrification
Rs. 10 lakhs
Working capital
(Margin money)
35
60 cents-1 acre
Rs. 20 lakhs
CHARCOAL
PRODUCT AT A GLANCE
Superior in quality when
compared to wood charcoal.
Ideal raw material for high
quality activated carbon.
Better calorific value than
other agro waste and hence
ideal for use as fuel in
smitheries, bakeries and
foundries.
36
PROJECT COST
Capacity 3 MT per day
Land requirement
Building 3000 sq ft
Plant & machinery
Preliminary &
50 cents
Rs 15 lakhs
Rs.30 lakhs
Electrification
Margin money forworking capital
Rs..20 lakhs
37
White in Color
38
PROJECT AT A GLANCE
Land Requirement-
1.5-2.0 acres
Building 8000 sq ft
Rs.70 lakhs
Contingencies
Rs.10 lakhs
Rs. 15 lakhs
Rs. 25 lakhs
Working capital
(Margin money)
39
Conclusion
o
Processed tender
coconut water,
Coconut milk powder
Desiccated
Coconut powder
Activated Carbon
41