Industry Overview
Chitin is a white, hard, inelastic nitrogen-containing polysaccharide found predominantly in the exoskeletons of insects, crabs, shrimps and lobsters, as well as in certain fungi, algae and yeasts. It is one of the most abundant organic compounds in nature, ranking second to cellulose, and is structurally related to cellulose. Chitin is largely insoluble in water and many organic solvents and has relatively limited direct applications, but it serves as the principal raw material for producing chitosan.
Chitosan is a deacetylated derivative of chitin with extensive applications in the cosmetic, pharmaceutical, medical, agricultural, food, environmental and industrial sectors. Its biodegradability, biocompatibility, bioadhesive characteristics and antimicrobial properties make it suitable for diverse applications, including wound dressings, drug delivery research, agriculture, food processing, textiles and coatings.
Marine crustacean waste, particularly from shrimp, crab and lobster processing, represents an important source of chitin and chitosan. India has extensive marine and inland fishery resources, providing substantial availability of shell waste as a potential industrial raw material. Commercial chitosan is generally produced by treating chitin with sodium hydroxide to achieve deacetylation. The project therefore combines the utilization of marine bioresources with the production of value-added chitin and chitosan products for a broad range of industrial and specialized applications.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 1500 Kg./Day |
| Land & Building (4000 sq.mt.) | Rs. 2.18 Cr |
| Plant & Machinery | Rs. 5.70 Cr |
| Working Capital for 1 Month | Rs. 2.66 Cr |
| Total Capital Investment | Rs. 11.12 Cr |
| Rate of Return | 35% |
| Break Even Point | 54% |
Content Index
- INTRODUCTION
- PROPERTIES & CHARACTERISTICS
- STRUCTURE OF CHITIN & CHITOSAN:
- CHITIN [1398-61-4]:
- ITS EMPIRICAL FORMULA = (C8H13NO5)N,
- EMPERICAL FORMULA = (C6H11NO4)N
- IMPORTANT PROPERTIES OF CHITOSAN ARE AS FOLLOWS:
- DEGREE OF DEACE ELATION
- AVERAGE MOLECULAR WEIGHT
- VISCOSITIES AND BEHAVIOR IN SOLUTION
- SOLUBILITY
- CATIONIC PROPERTIES
- CHEMISTRY OF CHITIN AND CHITOSAN
- USES AND APPLICATIONS
- INDUSTRIAL USES:
- APPLICATION OF CHITOSAN
- CHITOSAN
- MEDICAL AND PHARMACEUTICAL USES
- BIOMEDICAL USES
- PRELIMINARY RESEARCH AND FDA REVIEW
- AGRICULTURAL & NUTRITIONAL USES:-
- CHITIN SYNTHESIS INHIBITORS
- USES OF CHITOSAN
- I) CLARIFICATION AND PURIFICATION
- II) CHROMATOGRAPHY
- III) PAPER AND TEXTILES
- IV) PHOTOGRAPHY
- V) FOOD AND NUTRITION
- VI) AGRICULTURE
- II) MEDICAL AND PHARMACEUTICAL
- TECHNICAL PARAMETERS
- LOCATION OF THE PROJECT
- BORROWER’S PROFILE
- B.I.S. SPECIFICATION
- MARKET OVERVIEW OF CHITIN
- CHITIN MARKET DIVIDED BY DERIVATIVE TYPE AS:
- CHITIN MARKET DIVIDED BY END-USE AS:
- CHITIN MARKET DIVIDED BY GEOGRAPHY AS:
- MARKET OVERVIEW OF CHITOSAN
- PRESENT MANUFACTURERS OF CHITIN AND CHITOSAN
- FOREIGN PRODUCERS OF CHITIN & CHITOSAN
- SPECIFICATION AND TEST FOR MEDICAL GRADE CHITOSAN
- ANALYZE REPORT OF CHITOSAN (MEDICAL GRADE)
- RAW MATERIALS
- CHITIN CONTENTS OF SOME ORGANISMS
- CRUSTACEA:-
- INSECTS:-
- MOLLUSKS:-
- FUNGI:-
- MANUFACTURING PROCESS
- BASIC CONCEPT:
- CHITIN:
- CHITOSAN:
- CHITIN:-
- DETAILS OF PROCESSING STEPS:-
- CHITOSAN MANUFACTURING PROCESS:-
- PROCESS FLOWSHEET FOR MANUFACTURING OF CHITIN-FROM PRAWN FISH SHELL WASTES
- MANUFACTURING PROCESS OF CHITOSAN (MEDICAL GRADE)
- PRETREATMENT STEP
- DEMINERALIZATION
- DEPROTEINATION
- CHITOSAN MANUFACTURING FROM CHITIN (MEDICAL GRADE)
- TECHNOLOGY
- RAW MATERIAL
- DEPROTEINISATION
- DEMINERALISATION
- REMOVAL OF WATER
- DEACETYLATION OF CHITIN
- REMOVAL OF WATER
- DRYING
- POWDERING AND PACKING
- YIELD
- ILLUSTRATION OF THE PROCESS
- PROCESS IN DETAILED
- AT THE SAME TIME, ENZYMES
- TWO EXPLANATIONS OF THIS PHENOMENON HAVE BEEN PROPOSED.
- TABIE: CHEMICAL COMPOSITION OF VARIOUS CRUSTACEAN WASTES AND OF INSECT'S LARVES OF CALLEHORA ERYTHROCEPHALA
- CHITIN AND CHITOSAN EXTRACTION FROM CHITINOUS MARINE WASTE
- CHEMICAL EXTRACTION
- CHEMICAL DEPROTEINATION
- CHEMICAL DEMINERALIZATION
- BIOLOGICAL EXTRACTION
- ENZYMATIC DEPROTEINATION
- FERMENTATION
- LACTIC ACID FERMENTATION
- DEPROTEINIZATION OF CHITIN FROM SHRIMP HEAD WASTE
- MATERIALS & METHODS
- PREPARATION OF RAW MATERIAL
- CHITIN EXTRACTION PROCEDURE
- CHEMICAL ANALYSIS
- FIGURE: THE TWO- STAGE METHOD FOR CHITIN PRODUCTION
- TABLE: CHEMICAL COMPOSITION OF SHW1
- TABLE: PROTEIN RECOVERY (%) OBTAINED BY USING DIFFERENT DEPROTEINIZATION PROCESSES
- TABLE: NITROGENOUS COMPOSITION OF PRECIPITATE AFTER DEPROTEINIZATION PROCESSES
- TABLE: EFFECT OF NAOH CONCENTRATION ON THE RESIDUAL PROTEIN CONTENT AND DEGREE OF ACETYLATION OF CHITIN PRODUCED BY THE TWO-STAGE METHOD)
- TABLE: SPECIFICATION OF PRODUCED CHITIN COMPARED TO FOOD GRADE PRODUCT
- PRODUCTION METHOD OF CHITIN AND CHITOSAN FROM SHRIMP SHELL IN BATCH CULTURE OF LACTOBACILLUS PLANTARUM
- MATERIALS AND METHODS
- SHRIMP SHELL
- DATE SYRUP
- TABLE – CHEMICAL CHARACTERISTICS OF DATE SYRUP
- FERMENTATION
- PREPARATION OF CHITIN
- PREPARATION OF CHITOSAN
- ANALYTICAL PROCEDURE
- EFFLUENT TREATMENT PROCESS
- EFFLUENT TREATMENT SYSTEM
- PROTEIN PASTE FROM THE SHELL/PROTEIN SEPARATION
- NAOH DE-PROTEINIZATION WASH WATER
- HCL DE-MINERALIZATION WASH WATER
- SEA AND FRESH WASH WATER
- PLANT LAYOUT
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF CONVEYOR BELT
- SUPPLIERS OF PULVERISER
- SUPPLIERS OF WASHING TANKS
- SUPPLIERS OF TRAY DRYER
- SUPPLIERS OF PVC TANKS
- SUPPLIERS OF LIQUID TANKS
- SUPPLIERS OF EVAPORATION UNIT
- SUPPLIERS OF DRYING CHAMBER
- SUPPLIERS OF BOILERS
- SUPPLIERS OF WATER CHILLER
- SUPPLIERS OF FILTER PRESS
- SUPPLIERS OF LABORATORY TESTING EQUIPMENTS
- SUPPLIERS OF CHEMICALS
- SUPPLIERS OF RAW MATERIAL
- RAW MATERIAL SUPPLIERS FOR CHITIN AND CHITOSAN
- SUPPLIERS OF HYDROCHLORIC ACID
- SUPPLIERS OF CAUSTIC SODA
- SUPPLIERS OF LABORATORY CHEMICALS
- ADDRESSES FOR CONSULTANT & TURNKEY PLANT
Appendix
- 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)
Frequently Asked Questions
Chitin is a natural nitrogen-containing polysaccharide obtained mainly from the exoskeletons of crustaceans and other organisms. It is structurally similar to cellulose and is widely distributed in nature. Commercially, shrimp, crab and lobster shell wastes are important sources because they are generated in significant quantities by seafood processing. Chitin can also occur in insects, mollusks, fungi, algae and yeasts. Industrial extraction generally involves removing proteins and minerals from suitable raw materials before the resulting chitin is further processed or converted into chitosan.
Chitosan is the deacetylated derivative of chitin, with a greater proportion of glucosamine units in its polymer structure. Chitin is generally insoluble in water and many common organic solvents, while chitosan can become soluble in acidic conditions because its amino groups become protonated. This difference gives chitosan distinctive properties such as bioadhesion and cationic behavior. The degree of deacetylation and molecular characteristics influence the performance and suitability of chitosan for different industrial, food, agricultural, pharmaceutical and biomedical applications.
Chitosan is manufactured by deacetylating chitin, commonly using sodium hydroxide under controlled processing conditions. When crustacean shell waste is used, the raw material is first prepared and processed to remove proteins and minerals, producing relatively purified chitin. The chitin is then subjected to deacetylation, followed by washing, drying, powdering and packing as appropriate for the intended grade. Process conditions affect the degree of deacetylation, molecular characteristics, purity and resulting product properties, so appropriate process control and analytical testing are important.
Chitosan has applications across agriculture, food and nutrition, cosmetics, industrial processing, pharmaceuticals and biomedical research. Its properties can support uses such as clarification and purification, chromatography, paper and textiles, agricultural treatments and selected medical applications. Chitosan and its derivatives have also been investigated for drug delivery, wound-care materials and nonviral gene-delivery systems. The suitability of a particular chitosan product depends on characteristics such as purity, degree of deacetylation, molecular weight, solubility and the specifications required by the intended application.
Crustacean shell wastes such as shrimp, crab and lobster shells are important raw materials for commercial chitin production. These materials contain chitin together with proteins, minerals and other components that must be separated during processing. The report also identifies chitin sources among insects, mollusks and fungi. For chemical processing, reagents such as hydrochloric acid and caustic soda are used for demineralization and deproteinization or deacetylation operations, depending on the process route. Raw-material quality and composition can influence extraction efficiency and final product characteristics.
Effluent treatment is important because chitin and chitosan processing can generate wastewater from deproteinization, demineralization and washing operations. Such streams may contain dissolved organic matter, proteins, salts and residual process chemicals. The report specifically addresses protein paste separation, sodium hydroxide deproteinization wash water, hydrochloric acid demineralization wash water, and sea and fresh wash water. A properly designed effluent treatment system helps manage these streams, supports responsible plant operation and enables wastewater to be treated according to applicable discharge and environmental requirements.
A chitin and chitosan manufacturing plant requires equipment suited to raw-material handling, washing, chemical treatment, separation, drying and finishing. The report identifies equipment and supplier categories including conveyor belts, pulverisers, washing tanks, tray dryers, PVC tanks, liquid tanks, evaporation units, drying chambers, boilers, water chillers and filter presses. Laboratory testing equipment is also relevant for quality control. The final equipment configuration depends on the selected extraction and deacetylation technology, product grade, process scale, material characteristics and required environmental management systems.
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