Detailed Project Report (DPR) on oleoresin using solvent extraction method

OLEORESIN USING SOLVENT EXTRACTION METHOD

[CODE NO.3886]  

Oleoresins are flavoured compounds obtained by the solvent extraction of the ground spices. They have aroma and posses and attributes which contribute to the taste like pungency. All spices contain essential oils in various proportions which can be extracted by steam distillation. Oleoresins are preferred because of their microbiological advantages and uniformly in flavour and pungency, easy to store and transport. They have several applications like preparations of beverages, soup powders, curry powders, confectioneries, noodles, canned meats, sauces. 

Compliance under PFA Act is mandatory. ISI has specified quality standards vide IS 5832 & 7826 of 1975. Oleoresins have large domestic as well as export markets. They are consumed by broad spectrum of manufacturer like beverages, soup powders, curry powders, confectioneries, noodles, canned meats, sauces, poultry products and so on. Most of the end use industries are growing steadily and bound to increase with increase preference of quality products. The use of spice is rapidly replaced with oleoresins and exports of these products instead of raw spices results in considerable value addition.

Types:

Ajowan seed oleoresin, black pepper oleoresin, capsicum (chilli) oleoresin, cardamom oleoresin, cassia bark oleoresin, celery seedoleoresin, cinnamon bark oleoresin, clove bud oleoresin, coriander seedoleoresin, cumin seed oleoresin, curcumin powder, date extract, fennel seed oleoresin, galangal oleoresin, ginger oleoresin, juniper berry oleoresin, mace oleoresin, nutmeg oleoresin, olibanum resinold parsleyseed oleoresin, turmeric oleoresin, white pepper oleoresin, zingiber oleoresin, paprica oleoresin.

Oleoresins are the concentrated form of spices and herbs. Oleoresins can be produced from various plant sources and from different plant parts. The main plant parts:

• Fruits

• Seeds

• Rhizomes and roots

Examples of major oleoresins:

• Paprika (fruit)

• Turmeric (rhizome)

• Black pepper (seeds)

• Ginger (rhizome)

Oleoresins are used in the flavour and food industry, especially for meat preparations, marinades and gourmet food as well as for convenience products. They provide the flavour of spices and herbs to foods and, in the case of paprika oleoresin  and turmeric oleoresin, they also provide colour.

In contrast to essential oils, oleoresins contain many more non-volatiles. This fact makes them more interesting for the flavour and food industry. Non-volatiles are substances that do not vaporise easily. They are not lost when exposed to open air. In fact, oleoresins combine the volatiles and non-volatiles of plants to yield a more complete flavour profile. For example, pepper oleoresin contains the non-volatile piperine, whereas the essential oil of pepper does not. Piperine is the spicy hot part of pepper.

Another difference between oleoresins and essential oils is that oleoresins dissolve in fats, oils and lipids, whereas essential oils do not. This property of oleoresins is called lipophilicity and provides manufacturers with different options for food formulation compared to essential oils.

With the exception of paprika and turmeric oleoresins, the extraction of oleoresins starts with the extraction of the volatile part of the plant (the essential oil) by a distillation process. The remaining raw material is then exposed to a solvent suitable to extract the non-volatiles. After this process, the solvent is removed from the extract. This procedure is repeated various times until all non-volatiles are removed from the plant material.

Finally, the non-volatile part (resin) and the volatile part (oil) are blended and homogenised (mixed to get the same composition in all parts of the blend) to make a smooth oleoresin and to get the whole flavour (including spiciness) plus colour.

The solvents used in the extraction process are mainly ethyl acetate, alcohols, acetone or hexane, depending on the oleoresin to be extracted. The appropriate solvent, pressure, temperature and duration of the extraction mainly depend on the raw material that contains the oleoresin. In recent years, the “supercritical fluid extraction” (CO2 extraction) has become another frequently used extraction method. This method is expensive, but it may increase the extraction rate and results in an oleoresin with different properties.

Within Europe, oleoresins are classified according to the Harmonised System (HS). This coding system is used in international trade. The HS code for oleoresins is:

• 3301.9030 – Oleoresins

Essential Oils:-

Products derived from plants in which the odoriferous characteristics are concentrated. Essential oils are also known as “Volatile” and "etheral" oils, in contradistinction to the fixed or glyceride vegetable and animal oils and the mineral oils. Essential oils have been obtained from about eighty-seven plant families, and at times different essential oils can be secured from different parts of the same plant. For instance, the flowers of the orange tree yield oil of neroli, or oil of orange flowers; the rind yields orange oil, and another essential oil is obtained from the leaves.

Classification. The essential oil can be classified in several ways. According to use, essential oils are divided into three broad classes: (1) those used for perfumery, soap, and cosmetics; (2) those used for flavouring foods and beverages; and (3) those used for therapeutic purposes. According to preparation there  are five principal groups of essential oils  namely,  oils obtained  (1) by expression, (2) by distillation, (3) by  solvent extraction,  (4)  by  counter  current  extraction, and (5) by enfleurage. According to sources, essential oils are classified by the eighty-seven plant families mentioned above and also by the various parts of the plant which are utilized (e.g.  Fruits, seeds, bud and flowers leave and stem roots, bark, or wood). Classification according to geographical origin is also common since superior types of essential oils are produced in specific geographical areas that have favourable soil and climatic conditions.

Properties.  Essential oils are generally colorless to slightly yellowish when freshly distilled but when foreign matter is present, the color may range from red to blue. On standing the oils generally become darker in color. The odor of essential oils is similar to that of the portion of the plant from which they are derived; but since these odorous characteristics are much more concentrated in the essential oil, the odor is often disagreeable. The terpenes they contain are fairly readily oxidized, resulting in a turpentine odor. The specific gravity of these materials varies from 0.84 to 1.18. They are volatile at room temperature and evaporate completely when heated. Most essential oils are only slightly soluble in water; they are more soluble in sugar solutions.

The principal terpeneless oils and sesquiterpeneless oils are bergamot, grapefruit, lavender, lemon, lime mandarin, orange, orrisroot, peppermint, petitgrain, and spearmint.

Composition. The essential oils are mixtures, generally consisting of a major hydrocarbon portion and of many minor oxygen, nitrogen and sulphur-bearing   components. The hydrocarbons are usually terpenes (i.e, polymers or derivatives of the parent substance) isoprene, 3-methyl-1, 3-butadiene, C5H8, sesquiterpenes and polyterpenes. The terpenes, C10H16, may be acryclic, like mycene and ocimene; monocyclic, like limonene, phellandrene, and terpinene; or bicyclic, like   bisabolene; bicyclic, like cadinene; or tricylic.

In some essential oils the hydrocarbon content is very high. thus  in lemon, orange, and other citrus-peel oils, about 95  per cent of the essential oil consists of terpenes; and over 85 to 90 per cent of calamus, ginger, juniper, and rosemary oils  consists of  terpene  and sesquiterpene hydrocarbons. On the  other  hand, some  oils have a low terpene hydrocarbon content; for  instance, from  70  to  90  per  cent of oils  of  cinnamon  or  cassia  is cinnamaldehyde, and some 70 per cent of oil of cloves is eugenol.

Spices which are basically plant products, have a definite role to play in enhancing the taste flavour, relish or piquancy of any food, most of the spices are pagrant, aromatic and pangent. They comprise seeds, bartes, rhizome, leaves fruits and other parts of plants, which belong to varigated species and genera since time immorial, India in renamed to be the wave of spices. Most important spices like black pepper (king of spices) cardamom (queen of spices) cardamom (queen of spices), ginger, chilies and turmeric, which are produced in India import it great reputation and these constitute. The major group of spices. In the list of spices, clave, nutmeg, cinnamon and cassia are known as tree spices, However, spices like fennel, fenugreek, garlic, onion, coriander, cumin, vanilla, saffron; etc.

COST ESTIMATION

Plant Capacity                         240 Kg./Day

Land & Building (4000 sq.mt.)  Rs. 2 Cr

Plant & Machinery                    Rs. 2.20 Cr

Working Capital for 2 Months    Rs. 2.81 Cr

Total Capital Investment          Rs. 7.26 Cr

Rate of Return                          44%

Break Even Point                      41%

• INTRODUCTION
• ESSENTIAL OILS:-
• ESSENTIAL OIL PLANT & HERBS
• REQUIREMENT OF OLEORESIN MUST COMPLY WITH TO BE ALLOWED 
•     IN EUROPEAN MARKET
• GLOBAL MARKET POSITION OF OLEORESIN
• FIGURE: TURNOVER OF GLOBAL MANUFACTURERS OF FLAVOURS
•    ANDFRAGRANCES 2012-2016 IN € MILLION
• EUROPEAN IMPORTS OF OLEORESINS ARE GROWING
• FIGURE: IMPORTS OF OLEORESINS BY EUROPE 2012-2016
• EUROPEAN INDUSTRY INCREASINGLY USES FORMULAS WITH NATURAL
•    INGREDIENTS
• ETHNIC FOODS ARE GAINING POPULARITY
• SHORT-TERM OPPORTUNITIES FOR SPECIFIC OLEORESINS
• CARDAMOM OLEORESIN:
• NUTMEG OLEORESIN:
• PEPPER OLEORESIN:
• TURMERIC OLEORESIN:
• GINGER OLEORESIN:
• USES AND APPLICATION OF OLEORESIN
• BEST ESSENTIAL OILS
• ESSENTIAL OILS FROM SPICES:-
• USE OF CORINDER OIL:-
• USES OF ORANGE PEEL OIL (CITRUS PEEL OIL):-
• B.I.S. SPECIFICATION
• GLOBAL MARKET POSITION OF ESSENTIAL OIL
• PRODUCT INSIGHTS
• APPLICATION INSIGHTS
• REGIONAL INSIGHTS
• COMPETITIVE INSIGHTS
• MAJOR PRODUCERS OF ESSENTIAL OILS
• MAJOR CONSUMER OF ESSENTIAL OILS
• LARGEST GLOBAL MARKET PLACES FOR ESSENTIAL OIL
• PRESENT MANUFACTURERS/SUPPLIERS/EXPORTERS OF ESSENTIAL 
•     OILS AND OLEORESINS
• SEQUENCES IN OLEORESIN EXTRACTION
• PREPARATION OF RAW MATERIALS
• EXPOSURE OF MATERIAL TO SOLVENT
• SEPARATION OF MICELLE AND REMOVAL OF SOLVENT
• QUALITY OF OLEORESIN
• PROCESS FLOW DIAGRAM FOR OLEORESIN EXTRACTION
• DETAILED PROCESS TO MANUFACTURE OLEORESIN
• PAPRIKA OLEORESIN
• TURMERIC OLEORESIN
• BLACK PEPPER OLEORESIN:
• ROSE MARY OLEORESIN:
• GINGER OLEORESIN:
• METHOD OF EXTRACTION OLEORESIN USING CHILLI
• METHODS OF OLEORESIN EXTRACTION
• SOLVENT EXTRACTION PROCESS
• SUPERCRITICAL FLUID EXTRACTION PROCESS
• STEAM DISTILLATION PROCESS
• DETAILS OF SOLVENT EXTRACTION METHOD
• STEP 1: MATERIALS AND APPARATUS
• STEP 2: LEAF DEHYDRATION
• STEP 3: LEAFE DISNITEGRATION
• STEP 4: SOLVENT EXTRACTION
• STEP 5: FILTRATION
• STEP 6: EVAPORATION
• STEP 7: BOTTLING & STORAGE
• COMPARE DISTILLED OILS AND SOLVENT EXTRACTED OILS (EX: ROSE)
• SOLVENT EXTRACTION METHOD FOR ESSENTIAL OIL
• MANUFACTURING PROCESS OF ESSENTIAL OIL BY SOLVENT EXTRACTION
• DETAILS OF HYPERCRITICAL CARBON DIOXIDE GAS CO2 EXTRACTION 
•     OF ESSENTIAL OILS
• CO2 HYPERCRITICAL EXTRACTION
• PLANT LAYOUT
• SUPPLIERS OF PLANT AND MACHINERIES
• ROTARY WASHER
• PULVERIZERS
• STRAINERS
• STORAGE VESSEL
• WEIGHING MACHINE
• MATERIAL HANDLING EQUIPMENTS
• POLLUTION CONTROL EQUIPMENTS
• D.G. SETS
• SUPPLIERS OF RAW MATERIALS
• GLASS BOTTLES
• SUPPLIERS OF PLANT AND MACHINERIES (GLOBAL)
• 
  

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)