Detailed Project Report (DPR) on Dry Yeast from Molasses (Production Rate- 5 TPD)

DRY YEAST FROM MOLASSES (PRODUCTION RATE – 5 TPD)

[EIRI/EDPR/4544] J.C.: 2761XL

INTRODUCTION

A yeast is a single-celled fungus capable of causing the fermentation of animal or vegetable organic matter. Yeasts are used to make wine, beer, industrial alcohols, leavened pasta, antibiotics and flavor enhancers.

Yeast is a living unicellular microorganism until it is destroyed by heat or other physical or chemical means of about one hundredth of a millimeter in size and can therefore not be observed with a naked eye. The scientific name of baker’s yeast is saccharomyces cerevisiae.

Yeasts are a group of unicellular microorganisms most of which belong to the fungi division of Ascomycota and Fungi imperfecti. Yeasts have been known to humans for thousands of years as they have been used in fermentation processes like the production of alcoholic beverages and bread leavening. The industrial production and commercial use of yeasts started at the end of the 19th century after their identification and isolation by Pasteur. Today, the scientific knowledge and technology allow the isolation, construction and industrial production of yeast strains with specific properties to satisfy the demands of the baking and fermentation industry (beer, wine, cider and distillates). Food grade yeasts are also used as sources of high nutritional value proteins, enzymes and vitamins, with applications in the health food industry as nutritional supplements, as food additives, conditioners and flavouring agents, for the production of microbiology media, as well as livestock feeds. Yeasts are included in starter cultures, for the production of specific types of fermented foods like cheese, bread, sourdoughs, fermented meat and vegetable products, vinegar, etc.

The significance of yeasts in food technology as well as in human nutrition, as alternative sources of protein to cover the demands in a world of low agricultural production and rapidly increasing population, makes the production of food grade yeasts extremely important. A large part of the earth’s population is malnourished, due to poverty and inadequate distribution of food. Scientists are concerned whether the food supply can keep up with the pace of the world population increase, with the increasing demands for energy, the ratio of land area required for global food supply or production of bioenergy, the availability of raw materials, as well as the maintenance of wild biodiversity (1–4). Therefore, the production of microbial biomass for food consumption is a main concern for the industry and the scientific community. 

The impressive advantages of microorganisms for single cell protein (SCP) production compared with conventional sources of protein (soybeans or meat) are well known. Microorganisms have high protein content and short growth times, leading to rapid biomass production, which can be continuous and is independent from the environmental conditions. The use of fungi, especially yeasts, for SCP production is more convenient, as they can be easily propagated using cheap raw materials and easily harvested due to their bigger cell sizes and flocculation abilities. Moreover, they contain lower amounts of nucleic acids than bacteria

There are two types of yeast as compressed yeast. It is convenient to use dry yeast powder for bakeries because its handling is simple and its preservation easy. Dry yeast which can be contained in the form of pillets or flakes in packets or tins. Can be kept for some time in cool, dry conditions.

COST ESTIMATION

Plant Capacity               5 MT/Day  

Land & Building (2325 sq.mt.)    Rs. 3.48 Cr    

Plant & Machinery                      Rs. 5.21 Cr 

Working Capital for 0.5 Months  Rs. 35 Lac 

Total Capital Investment             Rs. 9.51 Cr 

Rate of Return                              38%

Break Even Point                         54%

CONTENTS

INTRODUCTION

IT IS IMPORTANT TO REMEMBER THAT:

USES & APPLICATION

YEAST METABOLISM

PRINCIPAL FUNCTIONS OF YEAST

PROPERTIES OF YEAST

SPECIFICATION

TYPES OF YEAST AND CONDITION

CONDITIONS FOR YEAST

FERMENTATION

DETAILS OF YEAST AVAILABLE TO BAKERS

COMPRESSED YEAST (ALSO CALLED CAKE, WET, AND FRESH YEAST)

ACTIVE DRY YEAST

 INSTANT ACTIVE DRY YEAST

OSMOTOLERANT INSTANT ACTIVE DRY YEAST

REHYDRATION

YEAST CONVERSION

TABLE 2 ILLUSTRATES THE CONVERSION FROM COMPRESSED YEAST TO 

INSTANT ACTIVE DRY YEAST. (1 OZ IS ROUNDED TO 30 G IN THE TABLE.)

GRADES OF YEAST

FOOD GRADE YEASTS

BAKER’S YEAST

BREWER’S YEASTS

NUTRITIONAL BREWER’S YEAST

WINE YEASTS

DISTILLER’S YEASTS

PROBIOTIC YEASTS

YEAST EXTRACT

TORULA YEAST

AFTER CULTIVATION THE YEAST IS HARVESTED, WASHED,

WHEY YEASTS

MARKET OVERVIEW

PRESENT MANUFACTURES OF BAKER'S YEAST 

(INSTANT ACTIVE DRY YEAST)

RAW MATERIALS

YEAST PRODUCTION TECHNOLOGY

MOLASSES

WHEY

STARCH

RESIDUES OF FORESTRY AND AGRICULTURE

PROPAGATION PROCESSES

TREATMENTS AND PACKAGING

YEAST CULTURE &PROPAGATION TO MANUFACTURE BAKERY YEAST

COMPRESSED YEAST (ALSO CALLED CAKE, WET, AND FRESH YEAST)

ACTIVE DRY YEAST

INSTANT ACTIVE DRY YEAST

MANUFACTURING PROCESS OF BAKER’S YEAST 

(IADY- INSTANT ACTIVE DRY YEAST)

PROCESS IN DETAILS

TYPICAL PROCESS FLOW DIAGRAM FOR THE SEVEN-STAGE PRODUCTION OF BAKER'S YEAST

FERMENTATION

HARVESTING AND PACKAGING

EMISSIONS

PROCESS FLOW 

QUALITY ASSURANCE IN YEAST PROCESSES

PREPARATION

SEEDING

CULTIVATION

HARVESTING

SUPPLIERS OF RAW MATERIALS

PLANT & MACHINERY SUPPLIERS

FERMENTOR

CENTRIFUGE

TRAY DRIER

MIXER

EVAPORATOR

STORAGE TANK

LABORATORY TESTING EQUIPMENTS

GLOBAL PLANT & MACHINERY SUPPLIERS

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

SEWAGE AND WASTE WATER EFFLUENT 

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

ANTICIPATED ENVIRONMENTAL IMPACTS 

CONSTRUCTION PHASE 

OPERATION PHASE 

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

PRELIMINARY LAYOUT

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

CONCLUSIONS

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)