Detailed Project Report (DPR) on menthol production [menthol oil, menthol crystals & de-mentholized oil (dmo)]

MENTHOL PRODUCTION [MENTHOL OIL, MENTHOL CRYSTALS & DE-MENTHOLIZED OIL (DMO)] [3620]

The commercial cultivation of the plants known as peppermint and spearmint, members of the genus mentha (Fam. labiatae), and the extraction processing and shipment of their oils, including menthol crystals, constitute an industry enrolling over $100 million in transactions each year. The mint plant are perennials yielding aromatic oils which are of increasing importance and have indeed long been a longest the world's most valuable flavouring materials. Mint is probably the world's third most important flavour being exceeded in popularity only vanilla and citrus flavours. The oils obtained by the relatively simple process of team distillation belong to a chemical class of plant product variably returned to as essential, volatile or ethereal oils, whose chemical composition consists almost entirely of hydrocarbon and oxygenated compounds known as terpenoids. The major terpene in peppermint oil is the alcohol menthol, accounting for the cooling sensation and that in spearmint oil is the letre carnone. Economic variable also influence production levels. Mint growers can move into and out of mint production relatively easily since the land is suitable for several alternative crops and the production of mint is therefore influenced by the expected future price of the mint, usually based on past price levels, in comparison with the current and expected prices of compacting crops. The quantity and quality of mint oil varies considerably from year to year. There are several factors contributing to these supply fluctuations, the most obvious one being the weather yields can also be influenced by husbandry practices, soils fertilisers usage, disease and pests, availability of suitable not stocks and the age of the mint plant. As regards the latter factor mentha species are perennials and other thing being equal, new plantings have lower average yields than two to three year old plants. Menthol is crystalline substance with characteristics of pungent odour derived from the oil of the pepper mint plant ‘Mentha Piperita’. The plant belong to Labiatae family which is very large family having annual and perennial herbs. Several species are shrubby or of climbing forms rarely small trees also. Members of the family are found throughout the world but the main area of plantation is Mediterranean region. The plants have square stems paired opposite leaves and tubular flowers with two lips. The leaves sometimes grow in wholes; the flowers may be white or shades of red, blue or purple. The family is well known for the aromatic volatility having oils in the foliage, which are used in perfumes, pharmaceutical products, confectionaries. The true mints belong to the genus Mentha Piperita. The leaves and tops are sometimes deried and utilized for flavouring but its oil extracted is the main derivative having large commercial value. The cultivation of Mentha Arvensis in India is a dramatic & very successful story. Before, 1964, there was no production of Mentha Oil & Menthol in India. The cultivation of Mentha Arvensis was started around 1870 in Japan so it is also called Japani Mint than extant in Brazil, China and Formosa etc. Col. Mr. R.N. Chopra & Dr. I.N. Chopra of Regional Research Laboratory Jammu Tawi first brought Mentha Arvensis in 1964 and with the best efforts of Mr. S.C. Bante, Managing Director, Hindustan Richardson Ltd (VICKs), the commercial cultivation could be started in India. Japan is supposed to be the pioneer in its commercial production before 1st World War and the species grown was ’Mentha Arvensis’. After 2nd World War Japanese shifted their commercial cultivativation and manufacturing to Brazil and South America. In Brazil Mint was grown at a very large scale and repeated harvest of the same crop was undertaken. This practice of repeated harvest of the crop gave an opportunity to Brazil become one of the major source of Menthol in world market. Simultaneously China also recognized the commercial significance of Menthol market and started its production under the State’s controlled arrangement’. Resultantly by the year 1960 China also became a new and major source of menthol for the world. In present scenario, India is the largest producer of Mentha oil followed by the China. However China is No.1 in Menthol Crystal production followed by India.

COST ESTIMATION

Plant Capacity                         2000 Kg/Day  
Land & Building (2000 sq.mt)     Rs. 1.73 Cr
Plant & Machinery                    Rs. 84 Lac
Working Capital for 1 Month   Rs. 6.61 Cr
Total Capital Investment          Rs. 9.33 Cr
Rate of Return                         48%
Break Even Point                     14%



INTRODUCTION    
MENTHOL PRODUCING COUNTRIES    
DOMESTIC MENTHOL PRODUCTION    
IN INDIA THERE ARE FOUR KINDS OF MINT CROP    
(I) MENTHA ARVENSIS    
(II) MENTHA PIPERITA    
(III) MENTHA SPEARMINT    
(IV) CITRATA (BARGAMOT)    
MENTHA & ITS LEAVES    
SPECIES AND HYBRIDS OF MENTHA    
THE MINT FAMILY HAS A LARGE GROUPING OF RECOGNIZED HYBRIDS    
CROP COMBINATION FOR HIGHER PROFITABILITY    
TIMING THE PLANTATION    
DISTILLATION & PROCESSING    
PROCESS OF DERIVING MENTHOL CRYSTALS    
PEPPERMINT OIL (MENTHA PIPERITA)    
PROPERTY AND STRUCTURE    
I.P. SPECIFICATION    
CHARACTERISTICS AND SPECIFICATION OF MENTHOL    
GENERAL PROPERTIES    
COMPOSITION OF MENTHOL OIL    
QUALITY CONTROL   
TESTING OF FINISHED PRODUCTS    
ANALYSIS OF DEMENTHOLIZED OIL    
THE FOLLOWING PROPERTIES SHOULD BE DETERMINED     
DETERMINATION OF MENTHOL IN DEMENTHOLIZED OIL    
DETERMINATIONS OF THE CONGEALING POINT    
APPARATUS    
PROCEDURE    
GAS LIQUID CHROMATOGRAPHY    
B.I.S SPECIFICATION    
MENTHOL - SPECIFICATION    
1. SCOPE    
2. REFERENCES    
3. TERMINOLOGY    
4. REQUIREMENTS    
TABLE 1 REQUIREMENT FOR MENTHOL    
5. PACKING AND MARKING    
6. SAMPLING    
DETERMINATION OF NON-VOLATILE MATTER    
A.1 APPARATUS    
A.2 PROCEDURE    
A-2.1  CALCULATION    
GAS CHROMATOGRAPHIC ANALYSIS OF MENTHOL    
B-0 GENERAL    
B-0.1 OUTLINE OF THE METHOD    
B-1 APPARATUS    
B-2 CALCULATION    
B-2.1 AREA MEASUREMENT (SEE NOTE)    
USES AND APPLICATIONS    
MARKET SURVEY    
SYNTHETIC MENTHOL MARKET    
PRESENT MANUFACTURERS/EXPORTERS/SUPPLIERS    
MANUFACTURING PROCESS OF MENTHOL CRYSTAL    
SEPARATION OF MENTHOL CRYSTAL FROM DMO    
DRYING OF MENTHOL CRYSTAL    
PROCESSING DETAILS OF MENTHOL PRODUCTION    
STEP I    
STEP II    
COMPOSITION OF DEMENTHOLISED OIL    
DEMENTHOLISED OIL    
PROCESS FLOW SHEET OF MENTHOL PRODUCTION    
PROCESS TECHNOLOGY FOR MENTHOL & DEVELOPMENTS    
HIGH YIELDING MENTHOL MINT    
INDIAN AGRICULTURAL RESEARCH INSTITUTE(IARI), NEW DELHI    
SOURCE OF TECHNOLOGY    
MATERIAL SAFETY DATA SHEET OF MENTHOL    
COMPOSITION AND INFORMATION ON INGREDIENTS    
HAZARDS IDENTIFICATION    
FIRST AID MEASURES    
FIRE AND EXPLOSION DATA    
ACCIDENTAL RELEASE MEASURES    
HANDLING AND STORAGE    
EXPOSURE CONTROLS/PERSONAL PROTECTION    
PHYSICAL AND CHEMICAL PROPERTIES    
STABILITY AND REACTIVITY DATA    
TOXICOLOGICAL INFORMATION    
PHARMACENTIAL AND TECHNICAL QUALITIES OF MENTHOL CRYSTALS    
PHARMACEUTICAL QUALITY    
TECHNICAL QUALITY    
BASIC PHYSICAL AND CHEMICAL FACTORS AFFECTING THE QUALITY
   OF ESSENTIAL OIL    
TOTOAL MENTHOL CONTENT    
MENTHYL ACETATE      
MENTHONE CONTENTS    
PHYSICAL AND CHEMCIAL CONSTANTS OF ESSENTIAL OIL OBTAINED
   FROM FLOWERS AND LEAVES    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF STEAM DISTILLATION UNITS    
SUPPLIERS OF VACUUM FILTERS    
SUPPLIERS OF CRYSTALLIZER    
SUPPLIERS OF AIR CONDITIONING & REFRIGERATION UNITS    
SUPPLIERS OF CENTRIFUGE
SUPPLIERS OF TRAY DRIER    
SUPPLIERS OF BOILERS    
SUPPLIERS OF STORAGE VESSEL (STORAGE TANKS)    
SUPPLIERS OF COOLING TOWER    
SUPPLIERS OF LABORATORY EQUIPMENTS    
SUPPLIERS OF INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS    
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)