Industry Overview
Tobacco processing generates substantial quantities of waste, including rejected leaves, broken lamina, midribs, stalks, and stems. These materials can be utilized to recover valuable by-products, with nicotine and tobacco seeds among the most important. Tobacco waste can also serve as a source of nicotine acid, nicotine sulphate, rutin, pectic substances, and certain organic acids.
Indian tobacco waste typically contains about 1–3% nicotine, and waste containing less than 2% nicotine can also be utilized. A simple and economical process developed by the National Chemical Laboratory, Poona, can recover about 95% of the nicotine present in tobacco waste in the form of nicotine sulphate. The process has been commercially exploited by tobacco by-product manufacturers, including units in Guntur and Dharmaj, Gujarat.
The report also covers Indian tobacco exports and key international markets, foreign direct investment considerations, the role of the Tobacco Board, commercially important nicotine derivatives, manufacturing processes, mass balances, process flow diagrams, implementation requirements, and suppliers of technology, raw materials, and plant equipment.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 1.76 MT/Day |
| Land & Building (5000 sq.mt.) | Rs. 10.69 Cr |
| Plant & Machinery | Rs. 1.58 Cr |
| Working Capital for 3 Months | Rs. 19.57 Cr |
| Total Capital Investment | Rs. 32.15 Cr |
| Rate of Return | 82% |
| Break Even Point | 20% |
Content Index
- INTRODUCTION
- TOBACCO EXPORTS FROM INDIA AND KEY MARKETS
- FOREIGN DIRECT INVESTMENT IN TOBACCO INDUSTRY IN INDIA
- TOBACCO BOARD
- USES AND APPLICATION OF NICOTINE BITARTRATE DIHYDRATE
- PROPERTIES OF NICOTINE SULPHATE
- HAZARD AND SHIPPING REGULATION:-
- APPLICATION OF NICOTINE POLACRILEX
- ADVANTAGE OF NICOTINE POLACRILEX
- NICOTINE POLACRILEX/RESINATE USP/EP 20%
- NICOTINE POLACRILEX/RESINATE USP/EP 15%
- USES AND APPLICATION OF NICOTINE ALKALOID 95%
- NICOTINE ALKALOID 95%
- SPECIFICATIONS
- OTHER INFORMATION
- PROPERTIES OF NICOTINE POLACRILEX 20%
- PRODUCT SPECIFICATION:
- COMPOSITION:
- MARKET OVERVIEWOF NICOTINE AND NICOTINE PRODUCTS IN INDIA
- NICOTINE/NICOTINE DERIVATIVES FROM TOBACCO:
- NICOTINE AND ITS COMMERCIALLY IMPORTANT DERIVATIVES:
- STATUS OF TOBACCO WASTE BASED INDUSTRIES IN INDIA
- COMMERCIAL ASPECTS OF NICOTINE SULPHATE & NICOTINE DERIVATIVES
- CONCLUSIONS AND RECOMMENDATIONS:
- COMMERCIALLY IMPORTANT NICOTINE DERIVATIVES AND PRODUCTS AT PRESENT ARE:
- SOME OF THE IMPORTANT PATENTED PROCESS INCLUDES:
- RECOMMENDATIONS:
- MARKET OVERVIEW OF NICOTINE GUMS
- PRESENT MANUFACTURERS/SUPPLIERS OF NICOTINE BASED PRODUCTS
- DETAILS OF NICOTINE 95% MANUFACTURE
- MASS BALANCE AS PER BATCH QUANTITY
- MASS BALANCE/MONTH
- PROCESS
- DETAILS OF NITONINE USP/EP MANUFACTURE
- CHEMICAL REACTION
- MASS BALANCE PER BATCH
- MASS BALANCE PER MONTH
- PROCESS
- DETAILS OF NICOTINE PLACRILEX MANUFACTURE
- MASS BALANCE AS PER BATCH QUANTITIES
- MASS BALANCE/MONTH
- PROCESS
- MANUFACTURE OF NICOTINE API
- MASS BALANCE SHEET FOR NICOTINE
- OUTPUT/KGS OF PRODUCT (KGS)
- MANUFACTURING PROCESS OF NICOTINE POLACRILEX (USP/EP)
- CAP-300KGS PER BATCH
- MASS BALANCE PER BATCH
- BATCH SIZE: 0.3 TON OR 300 KGS
- NO OF BATCH: 8.3 PER MONTH
- MASS BALANCE PER BATCH
- MASS BALANCE PER MONTHSFOR NICOTINE OLACRILEX USP/EP CAP: 4 TONS /MONTH
- MANUFACTURING PROCESS OF NICOTINE BITARTRATE DIHYDRATE
- CHEMICAL REACTION
- MATERIAL BALANCE SHEET FOR NICOTINE BITARTRATE DIHYDRATE
- OUT/KGS OF PRODUCT (KGS)
- PROCESS DETAILS OF NICOTINE (USP)
- PROCESS FLOW DIAGRAM
- PROCESS FLOW DIAGRAM FOR NICOTINE
- PROCESS FLOW DIAGRAM FOR NICOTINE POLACRLEX
- PROCESS FLOW DIAGRAM FOR NICOTINE DITARTRATE DIHYDRATE
- IMPLEMENTATION SCHEDULE:-
- TECHNOLOGY SUPPLIERS FOR NICOTINE BASED PRODUCTS
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF PLANT & MACHINERY
- SUPPLIERS OF REACTION VESSEL
- SUPPLIERS OF INDUSTRIAL FILTERS
- SUPPLIERS OF DISTILLATION UNITS
- SUPPLIERS OF EVAPORATORS
- SUPPLIERS OF DIGESTER TANKS
- SUPPLIERS OF CRYSTALLIZATION TRAY
- SUPPLIERS OF CENTRIFUGE MACHINE
- SUPPLIERS OF STORAGE TANK
- SUPPLIERS OF WATER SOFTENING PLANT
- SUPPLIERS OF STEAM BOILERS
- SUPPLIERS OF GENERATOR (D.G. SET)
- SUPPLIERS OF PACKING MACHINE
- SUPPLIERS OF CONVEYOR BELT
- SUPPLIERS OF ELEVATORS, ESCALATORS
Appendix
- 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
Tobacco waste is commercially useful because it contains recoverable nicotine and other valuable compounds.
The waste generated during harvesting and tobacco processing can include rejected leaves, broken lamina, midribs, stalks, and stems. Depending on its composition, this material can be processed to recover nicotine and produce derivatives such as nicotine sulphate. The report also identifies tobacco seeds, nicotine acid, rutin, pectic substances, and certain organic acids as potential valuable products or constituents of tobacco waste.
Nicotine can be recovered from tobacco waste through extraction and downstream processing designed to separate and concentrate the alkaloid.
The report describes a simple and economical process developed by the National Chemical Laboratory, Poona, for recovering nicotine from tobacco waste as nicotine sulphate. It states that the process can recover about 95% of the nicotine present in the waste. Industrial implementation generally requires controlled extraction, separation, concentration, purification, and product handling operations appropriate to the intended derivative.
The report covers several commercially relevant nicotine products and derivatives, including nicotine sulphate, nicotine alkaloid 95%, nicotine USP/EP, nicotine polacrilex, and nicotine bitartrate dihydrate.
It also discusses nicotine polacrilex/resinate in different grades, including USP/EP 20% and 15%, together with product specifications, compositions, applications, manufacturing processes, chemical reactions, mass balances, and process flow diagrams. The report further addresses nicotine API manufacture and market aspects of nicotine and nicotine-based products in India.
The Tobacco Board facilitates coordination among tobacco growers, traders, and exporters while supporting production and market development.
According to the report, the Board estimates demand and regulates FCV tobacco production to align supply with demand and support fair pricing. It assists farmers with crop loans and agricultural inputs, provides guidance on good agricultural practices, and conducts tobacco auctions in a competitive and transparent environment. It also works to improve existing export markets and develop new markets through market-development and international promotional activities.
A nicotine-based manufacturing plant can require extraction, reaction, filtration, concentration, separation, storage, and utility equipment.
The report specifically identifies reaction vessels, industrial filters, distillation units, evaporators, digester tanks, crystallization trays, centrifuge machines, storage tanks, water-softening plants, steam boilers, generators, packing machines, conveyor belts, and elevators or escalators among the equipment and supplier categories considered. The exact equipment configuration depends on the selected nicotine derivative, process design, production scale, and required product specifications.
India exports unmanufactured tobacco primarily to markets including Belgium, Korea, Nigeria, Egypt, and Nepal.
The report identifies Western Europe as a key market for Indian tobacco exports. It also provides historical export figures for 2021, including monthly and financial-year data, as well as figures for flue-cured Virginia tobacco. These figures are presented as historical information from the report and should not be interpreted as current market data without separate verification.
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