Detailed Project Report (DPR) on soya lecithin manufacturing unit (liquid and powder)

SOYA LECITHIN MANUFACTURING UNIT
(LIQUID AND POWDER)
[CODE NO.3492]


Lecithin is the popular and commercial name for a naturally occurring mixture of phosphatides (also called phospholipids or, more recently by biochemists, phosphoglycerides), which varies in color from light tan to dark reddish brown and in consistency from a fluid to a plastic solid. Lecithin is the gummy material contained in crude vegetable oils and removed by degumming. Soybeans are by far the most important source of commercial lecithin and lecithin is the most important by-product of the soy oil processing industry because of its many applications in foods and industrial products. The three main phosphatides in this complex mixture called "commercial soy lecithin" are phosphatidyl choline (also called "pure" or "chemical" lecithin to distinguish it from the natural mixture), phosphatidyl ethanolamine (popularly called "cephalin"), and phosphatidyl inositols (also called inositol phosphatides). Commercial soy lecithin also typically contains roughly 30-35% unrefined soy oil. Indeed lecithin is one of the most complex and versatile substances derived from the soybean.

Lecithin is known as naturally occurring mixture of phospholipids and can be obtained from various vegetable and animal sources. The composition depends on the origin of the lecithin. Vegetable lecithin, containing primarily phosphatidylcholine (PC), phosphatidylethanolamine (PE) and phosphatidylinositol (PI), are derived commercially from oil-bearing seeds such as soybean, sunflower kernels and rapeseed. Soybeans are by far the most important source of commercial lecithin and lecithin is the most important by product of soybean oil process. Production of soy lecithin consist of several processes including water degumming (hydration), separation, drying and cooling. Crude lecithin is refined through the use of different processes like enzymatic and chemical adaptation of phospholipid molecules, physical fractionation for separating oil from phospholipids and fractionation of phospholipids to regulate or change its phospholipid composition. As composition of lecithin differs, their emulsifying power and field of use changes in food industry.

As a result, lecithin as a most widely used emulsifier of food industry is mostly obtained from oils of various seeds and subjected to various refining operations for purification which determines its area of use.

COST ESTIMATION

Plant  Capacity                                              :     SOYA LECITHIN MANUFACTURING UNIT                             
land & Building  (3000 Sq.Mtr)                   :    Rs. 1.58  Cr
Plant & Machinery                                        :    Rs. 1.10  Cr
Working Capital for 1 Month                      :    Rs. 3.24  Cr
Total Capital Investment                            :    Rs. 06.05 Cr
Rate of Return                                             :     50%
Break Even Point                                        :    37%


INTRODUCTION    
BASICS OF LECITHIN    
COMPOSITION OF PHOSPHOLIPIDS    
PHOSPHATIDES    
LECITHIN IN VEGETABLE OIL    
LECITHIN IN SOAPS    
LECITHIN IN MARGARINES (VEGETABLE FAT)    
LECITHIN IN ICE CREAM    
LECITHIN IN NUTS    
TRIGLYCERIDES IN LECITHIN    
LECITHIN AS ANTIOXIDANT IN FORDS    
LECITHIN AS FOOD ADDITIVE    
FOOD USES    
PROCESS DISCRIPTION OF SOYA LECITHIN    
MANUFACTURING PROCESS OF SOYA LECITHEN FROM SOYA WET GUM    
DESCRIPTION OF LECITHIN DEOILING & POWDER PLANT    
DETAILS OF LECITHIN PROCESSING    
PRODUCTION OF CRUDE LECITHIN    
TABLE: REFINING OF LECITHIN    
INDIVIDUAL PROCESS STEPS FOR LECITHIN – DE-OILING    
TABLE: DE-OILING OF LECITHIN    
TABLE: FREE FLOWING DEOILED LECITHIN    
INDIVIDUAL PROCESS STEPS FOR LECITHIN – HYDROLYSIS    
TABLE: HYDROLYSIS OF LECITHIN    
INDIVIDUAL PROCESS STEPS FOR LECITHIN – FRACTIONATION    
TABLE: FRACTIONATION OF LECITHIN    
INDIVIDUAL PROCESS STEPS FOR LECITHIN – HYDROXYLATION
   & ACETYLATION (NON E 322)    
INDIVIDUAL PROCESS STEPS FOR LECITHIN – COMBINATIONS
   OF PROCESS STEPS    
TABLE: HLB VALUES OF MODIFIED LECITHIN’S    
ANALYTICAL COMPARISON OF PROCESSED LECITHIN’S    
TYPICAL % VALUES    
PROPERTIES OF CHARACTERSTICS    
GRADES OF LECITHIN    
B.I.S. SPECIFICATION    
DETERMINATION OF TOTAL GOSSYPOL    
DETERMINATION OF PURITY    
DETERMINATION OF MOISTURE    
DETERMINATION OF PHOSPHORUS    
DETERMINATION OF BENZENE INSOLUBLE MATTER    
DETERMINATION OF ACID VALUE    
DETERMINATION OF HEAVY METALS    
DETERMINATION OF THE PEROXIDE VALUE    
MARKET SURVEY    
SOY LECITHIN MARKET: SEGMENTATION    
DETAILED EXPORT DATA OF SOYA LECITHIN    
BUYER’S OF SOYA LECITHIN    
PRESENT MANUFACTURERS OF SOYA LOCITHIN    
MANUFACTURE OF LECITHIN    
AVERAGE PROCESS CONDITIONS FOR DRYING LECITHIN SLUDGE    
FLOW SHEET FOR DEGUMMING SOYABEAN OIL & LECITHIN PRODUCTION    
STEPS IN MANUFACTURE OF SOYA LECITHEN    
WATER DEGUMMING    
LECITHIN DE-OILING    
STORAGE AND PRE-TREATMENT THE DRIED LECITHIN    
GRANULATION    
DRYING    
GRINDING    
DETAILS OF DEOILING LIQUID LECITHIN USING ROTATING DISC CONTACTOR    
DESCRIPTION OF DEOILED    
SOYABEAN LECITHIN POWDER    
DEOILED SOYBEAN LECITHIN POWDER 95% - IP    
CONSULTANTS FOR SETTINGUP LECITHIN PLANT    
SUPPLIERS OF PLANT AND MACHINERY    
AIR COMPRESSORS    
COOLING TOWER    
CENTRIFUGE    
BOILERS    
LABORATORY EQUIPMENTS    
INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS    
SUPPLIERS OF RAW MATERIALS    
PACKAGING MATERIALS (HDPE WOVEN LAMINATED BAGS)    
        
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET