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 such as nicotine and tobacco seeds, as well as nicotine acid, nicotine sulphate, rutin, pectic substances, and certain organic acids.
Indian tobacco waste generally contains about 1-3% nicotine, and waste containing less than 2% nicotine can also be utilized for recovery. A process developed by the National Chemical Laboratory, Poona, enables approximately 95% of the nicotine present in tobacco waste to be recovered as nicotine sulphate. The process involves maceration of waste tobacco with water and lime, steam distillation, neutralization of the distillate with sulphuric acid, and concentration.
Nicotine sulphate is used in controlling insect pests of agricultural importance and can be manufactured from waste tobacco as well as liquors obtained from chewing and smoking tobacco factories.
India has a significant position in the global tobacco industry. Tobacco was introduced into India by the Portuguese in the 17th century and has developed into an important commercial crop and export commodity. The Tobacco Board facilitates growers, traders, and exporters, while regulating FCV tobacco production, supporting farmers, conducting auctions, and promoting Indian tobacco and tobacco products in international markets.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 1.12 MT/Day |
| Land & Building (9600 sq.mt.) | Rs. 5.83 Cr |
| Plant & Machinery | Rs. 2.76 Cr |
| Working Capital for 1 Month | Rs. 11.84 Cr |
| Total Capital Investment | Rs. 20.79 Cr |
| Rate of Return | 65% |
| Break Even Point | 29% |
Content Index
- INTRODUCTION
- TOBACCO INDUSTRY AND EXPORT
- TOBACCO EXPORTS FROM INDIA AND KEY MARKETS
- FOREIGN DIRECT INVESTMENT IN TOBACCO INDUSTRY IN INDIA
- TOBACCO BOARD
- TOBACCO IN INDIAN ECONOMY
- POSITIVE FEATURES OF INDIAN TOBACCO
- IMPACT OF TOBACCO RESEARCH
- USES AND APPLICATION OF NICOTINE BITARTRATE DIHYDRATE
- USES AND APPLICATIONS OF NICOTINE SULPHATE
- PROPERTIES OF NICOTINE SULPHATEAZARD AND SHIPPING REGULATION:
- APPLICATION OF NICOTINE POLACRILEX
- ADVANTAGE OF NICOTINE POLACRILEX
- NICOTINE POLACRILEX/RESINATE USP/EP 20%
- NICOTINE POLACRILEX/RESINATE USP/EP 15%
- B.I.S. SPECIFICATION
- 1. SCOPE
- 2. REQUIREMENTS
- 3. PACKING AND MARKING
- 4. SAMPLING
- 5. TESTS
- DETERMINATION OF NICOTINE CONTENT
- A - 1 METHOD
- A - 2 REAGENTS
- SEDIMENTATION TEST
- B - 1 PROCEDURE
- B - 2 REPORT
- NICOTINE SULPHATE 40%
- CHEMICAL COMPOSITION:
- MODE OF ACTION:
- USES:
- CHEMICAL FORMULA:
- ADVANTAGES:
- NICOTINE SULPHATE 40%
- USES AND APPLICATION OF NICOTINE ALKALOID 95%
- NICOTINE ALKALOID 95%
- SPECIFICATIONS
- OTHER INFORMATION
- PROPERTIES OF NICOTINE POLACRILEX 20%
- PRODUCT SPECIFICATION:
- COMPOSITION:
- MARKET OVERVIEW OF NICOTINE SULPHATE
- MARKET OVERVIEW OF NICOTINE AND NICOTINE PRODUCTS IN INDIA
- PRODUCTS FROM TOBACCO AND TOBACCO WASTES:
- NICOTINE/NICOTINE DERIVATIVES FROM TOBACCO:
- NICOTINE AND ITS COMMERCIALLY IMPORTANT DERIVATIVES:
- WORLD PESTICIDE MARKET AND PROSPECTS FOR NICOTINE SULPHATE
- STATUS OF TOBACCO WASTE BASED INDUSTRIES IN INDIA
- OVERVIEW OF TECHNOLOGIES FOR NICOTINE BASED PRODUCTS
- NEED FOR DEVELOPMENT OF ALTERNATE USE FOR TOBACCO:
- [COMMERCIALLY IMPORTANT APPLICATIONS]:
- A LOOK AT THE ORGANS OF THE BODY HARMED BY TOBACCO SMOKE
- PHARMACEUTICAL USE OF NICOTINE:
- COMMERCIAL ASPECTS OF NICOTINE SULPHATE & NICOTINE DERIVATIVES
- CONCLUSIONS AND RECOMMENDATIONS:
- SOME OF THE IMPORTANT PATENTED PROCESS INCLUDES:
- RECOMMENDATIONS:
- MARKET OVERVIEW OF NICOTINE POLACRILEX
- LIST OF THE COMPANIES OPERATING IN THE MARKET:
- FURTHER REPORT FINDINGS:
- MARKET OVERVIEW OF NICOTINE GUMS
- PRESENT MANUFACTURERS/SUPPLIERS OF NICOTINE BASED PRODUCTS
- CHEMICAL COMPOSITION OF TOBACCO
- CHEMISTRY OF NICOTINE
- THE DISTILLATION AND CONCENTRATION INSTALLATION WAS BUILT UP AS FOLLOWS:
- (1) THE STEAM DISTILLATION KETTLE.
- (2) THE STEAM-HEATED NICOTINE CONCENTRATION CHAMBER.
- (3) THE NICOTINE CONCENTRATIOIN FLASKS.
- (D) THE DISTILLATION AND CONCENTRATION PROCESS.
- (1) THE CONCENTRATION OF THE ACID IN THE FLASKS.
- (2) THE TEMPERATURE OF THE CONCENTRATION CHAMBER
- (3) THE DLSTILLATION PERIOD.
- (4) THE AMMONIUNN SULPHATE FORMED IN 'THE RECEIVING FLASKS.
- (5) THE SEPARATION OF THE AMMONIUM SULPHATE AND NECOTINESULPHATE
- VALUE OF BY PRODUCTS
- THE EXTRACTED TOBACCO RESIDUE
- COMMERCIAL
- CHARACTERISTICS & APPLICATION OF NICOTINE:
- ZONES OF CULTIVATION OF TOBACCO:
- RAW MATERIALS
- TOBACCO:
- GLOBAL PRODUCTION
- TRENDS
- MAJOR PRODUCERS
- UNITED STATES
- CHINA
- BRAZIL
- INDIA
- BENZENE:
- HAZARD:
- LIME:
- HAZARD:
- SULFURIC ACID:
- HAZARD:
- TOBACCO LEAF BY-PRODUCTS (TOBACCO WASTE)
- DETAILS OF NICOTINE BASED PRODUCTS MANUFACTURE
- DETAILS OF NICOTINE ALKALOID 95% MANUFACTURE
- DETAILS OF NICOTINE BASE USP/EP MANUFACTURE
- DETAILS OF NICOTINE POLACRILEX/RESINATE USP/EP)
- MANUFACTURING PROCESS OF NICOTINE USP/EP
- MASS BALANCE PER MONTHSFOR NICOTINE USP/EP
- MANUFACTURING PROCESS OF NICOTINE POLACRILEX (USP/EP)
- MASS BALANCE PER MONTHSFOR NICOTINE POLACRILEX USP/EP
- MANUFACTURING PROCESS OF NICOTINE BITARTRATE DIHYDRATE
- CHEMICAL REACTION
- MASS BALANCE PER MONTHSFOR NICOTINE BITARTRATE DIHYDRATE
- MATERIALS BALANCE SHEET FOR NICOTINE BITARTRATE DIHYDRATE
- DETAILS OF NICOTINE BITARTRATE DIHYDRATE MANUFACTURE
- MATERIAL BALANCE SHEET FOR NICOTINE DIHYDRATE
- OUT/KGS OF PRODUCT (KGS)
- MANUFACTURING PROCESS OF NICOTINE 95%
- MANUFACTURING PROCESS NICOTINE SULPHATE (40%)
- PROCESS DETAILS OF NICOTINE (USP)
- PROCESS FLOW DIAGRAM
- PROCESS FLOW SHEET FOR NICOTINE SULPHATE FROM TOBACCO WASTE
- PROCESS FLOW DIAGRAM FOR NICOTINE
- PROCESS FLOW DIAGRAM FOR NICOTINE POLACRLEX
- PROCESS FLOW DIAGRAM FOR NICOTINE DITARTRATE DIHYDRATE
- HAZARDOUS FACT SHEET FOR NICOTINE SULPHATE
- HAZARD SUMMARY
- IDENTIFICATION
- REASON FOR CITATION
- HOW TO DETERMINE IF YOU ARE BEING EXPOSED
- WORKPLACE EXPOSURE LIMITS
- WAYS OF REDUCING EXPOSURE
- HEALTH HAZARD INFORMATION
- ACUTE HEALTH EFFECTS
- CHRONIC HEALTH EFFECTS
- CANCER HAZARD
- REPRODUCTIVE HAZARD
- OTHER LONG TERM EFFECTS
- MEDICAL
- MEDICAL TESTING
- EKG
- CONDITIONS MADE WERSE BY EXPOSURE
- WORKPLACE CONTROLS AND PRACTICES
- IN EVALUATING THE CONTROLS PRESENT IN YOUR WORKPLACE, CONSIDER
- IN ADDITIONS, THE FOLLOWING CONTROL IS RECOMMENDED:
- PERSONAL PROTECTIVE EQUIPMENT
- CLOTHING
- EYE PROTECTION
- RESPIRATORY PROTECTION
- IMPROPER USE OF RESPIRATORS IS DANGEROUS
- IMPLEMENTATION SCHEDULE:
- MATERIAL SAFETY DATA SHEET OF NICOTINE SULPHATE 40%
- PROCESS DESCRIPTION & MATERIAL BALANCE OF NICOTINE SULPHATE 40%
- OVERALL MATERIAL BALANCE
- BASIS: 60 MT /MONTH
- EXPORTER OF NICOTINE BASED PRODUCTS
- CONSULTANT & TECHNOLOGY SUPPLIERS
- TESTING METHOD OF NICOTINE AND NICOTINE SULPHATE
- EXAMPLE L
- STAGE 1 HARVESTING AND DEEP FREEZING
- STAGE II MIXING AND PERCOLATION
- STAGE III EXTRACTION
- STAGE IV SEPARATION
- STAGE V FILTRATION AND PURIFICATION
- STAGE VI TESTING
- STAGE VII PACKING
- EXAMPLE 2
- STAGE 1 MIXING
- STAGE II PERCOLATION
- STAGE III EXTRACTION
- STAGE IV SEPARATION
- STAGE V FILTRATION AND PURIFICATION
- STAGE VI PACKING
- STAGE VII ALKALIZATION
- STAGE VIII PURIFICATION OF NICOTINE ALKALOID
- STAGE IX DISTILLATION OF NICOTINE ALKALOID
- STAGE X TESTING
- STAGE XI PACKING
- EXAMPLE 3
- STAGE 1 MIXING
- STAGE II MIXING AND PERCOLATION
- STAGE III EXTRACTION
- STAGE IV SEPARATION
- STAGE V FILTRATION AND PURIFICATION
- STAGE VI PACKING
- STAGE VIII PURIFICATION OF NICOTINE ALKALOID
- STAGE IX DISTILLATION OF NICOTINE ALKALOID
- STAGE X TESTING
- STAGE XI PACKING
- EXAMPLE 4
- STAGE 1 MIXING
- STAGE II PERCOLATION
- STAGE III EXTRACTION
- STAGE IV SEPARATION
- STAGE V FILTRATION AND PURIFICATION
- STAGE VI PACKING
- STAGE VII ALKALIZATION
- STAGE VIII PURIFICATION OF NICOTINE ALKALOID
- STAGE IX DISTILLATION OF NICOTINE ALKALOID
- STAGE X TESTING
- STAGE XI PACKING
- EXAMPLE 5
- STAGE I WASHINGS OF THE INSOLUBLE FRACTION
- STAGE II CENTRIFUGATION AND DRYING OF INSOLUBLE FRACTION
- STAGE III CENTRIFUGATION AND DRYING OF INSOLUBLE FRACTION
- STAGE IV RECONSTITUTION OF THE TOBACCO BY IMPREGNATION
- STAGE V TESTING OF THE TOBACCO
- STAGE VI PACLDNG
- TECHNOLOGY SUPPLIERS FOR NICOTINE BASED PRODUCTS
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF TOBACCO WASTE
- SUPPLIERS OF BENZENE
- SUPPLIERS OF LIME POWDER
- SUPPLIERS OF PLANT & MACHINERY
- SUPPLIERS OF REACTION VESSEL
- SUPPLIERS OF INDUSTRIAL FILTERS
- SUPPLIERS OF DISTILLATION UNITS
- SUPPLIERS OF EVAPORATORS
- SUPPLIERS OF TRAY DRYER
- 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
- 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
Tobacco waste is the material left over from harvesting and tobacco manufacturing that can be processed to recover useful chemical constituents.
It may include rejected leaves, broken lamina, midribs, stalks, and stems. The report identifies nicotine and tobacco seeds as important by-products and also discusses recovery of nicotine sulphate and other chemical substances. Utilizing this waste can convert a processing residue into commercially useful products while reducing the quantity of material requiring disposal.
Nicotine sulphate can be produced from tobacco waste through extraction, steam distillation, acid neutralization, and concentration.
According to the report, waste tobacco is macerated with water and lime and then subjected to steam distillation. The resulting distillate is neutralized using sulphuric acid and subsequently concentrated. The report also describes equipment and process stages associated with distillation and concentration. Industrial implementation requires suitable process controls, material handling systems, testing procedures, and appropriate safety measures for nicotine and other process chemicals.
Nicotine sulphate is used primarily as an insect-control product in agricultural applications.
The report states that nicotine sulphate is extensively used for controlling insect pests of agricultural importance. It can be manufactured from waste tobacco and from liquors obtained from factories producing chewing and smoking tobacco. Because nicotine compounds can present significant exposure hazards, industrial production and handling should be undertaken with appropriate engineering controls, protective equipment, storage practices, labeling, and applicable regulatory requirements.
The principal raw material is tobacco waste, with water, lime, and sulphuric acid used in the recovery process described in the report.
The tobacco waste can include rejected leaves, broken lamina, midribs, stalks, and stems. Water and lime are used during maceration and extraction, while sulphuric acid is used to neutralize the nicotine-containing distillate and form nicotine sulphate. The report separately identifies other materials and chemicals associated with nicotine-based product manufacture, so actual requirements depend on the selected product and process configuration.
Nicotine processing from tobacco waste requires extraction, separation, distillation, concentration, filtration, storage, and packing equipment suited to the selected process.
The report specifically describes a steam distillation kettle, a steam-heated nicotine concentration chamber, and nicotine concentration flasks. Its supplier sections also identify equipment categories such as reaction vessels, industrial filters, distillation units, evaporators, tray dryers, digester tanks, centrifuges, storage tanks, steam boilers, generators, packing machines, and conveyors. Equipment selection should be based on process design, capacity, material compatibility, safety, and applicable standards.
Nicotine sulphate manufacturing requires controlled exposure, appropriate engineering controls, personal protective equipment, and disciplined workplace practices.
The report contains dedicated sections covering workplace exposure, health hazards, workplace controls, clothing, eye protection, respiratory protection, medical testing, and safety practices. A properly designed facility should control exposure at the source, provide suitable ventilation and containment, establish procedures for handling chemicals and nicotine-containing materials, and ensure workers are trained in emergency response and safe operating practices. Applicable occupational safety and environmental requirements should also be incorporated into the plant design.
Nicotine recovery can create value from tobacco-processing residues by converting waste into useful nicotine-based products.
The report describes tobacco waste as a source of nicotine and other potentially valuable chemical constituents. It also covers nicotine sulphate, nicotine alkaloid, nicotine base, nicotine polacrilex, nicotine bitartrate dihydrate, and related products, together with manufacturing processes, market information, material balances, and supplier categories. The commercial feasibility of any specific project depends on product specifications, raw-material availability, process efficiency, regulatory requirements, capital costs, operating costs, and market conditions.
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