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    Chitin & Chitosan from Prawn Shell Waste (Cap: 4500 Kg/Day)

    Chitin & Chitosan from Prawn Shell Waste (Cap: 4500 Kg/Day)
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    Chitin & Chitosan from Prawn Shell Waste (Cap: 4500 Kg/Day)
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      CHITIN & CHITOSAN FROM PRAWN SHELL WASTE (CAP: 4500 KG/DAY)

      [EIRI/EDPR/4775] J.C.: 2995XL


      INTRODUCTION

      Chitin is a white, hard, inelastic, nitrogenous, polysaccharide found in the outer skeleton of insects, crabs, shrimps and lobsters and in the internal structures of invertebrates. It is the second most abundant organic compound next to cellulose. It is a macro molecular linear polymer of_ (1-4) N acetyl D glucosamine and is insoluble in water and many organic solvents. Chitin itself has only a few applications; it acts more as a precursor of Chitosan, its most familiar derivative.

      Chitosan is deacetylated chitin, and is polymer of _(1-4) acetyl - D glucosamine. It has multifarious uses in the cosmetic, pharmaceutical and medical industries. It is even considered as a wonder drug of the twenty-first century due to its versatile utility.

      Chitin is a chemical compound belong to glucosamine polysaccharide group categories. It contains about 7% nitrogen, and is structurally similar to cellulose.

      It is the principal constituent of the shells of prawn fish, shrimps, crabs, lobsters, beetles and other sea fishes. It is also found in some fungi, algal, and yeasts.

      Fish is a valuable and easily accessible source of food, rich in proteins. India has abundant marine and inland fish resources. It has a coast-line c. 4,667 km. long and a continental shelf 2,59,000 sq. km. or more in area, offering considerable scope for the establishment of fisheries. The Bay of Bengal and the Arabian Sea abound in fishing grounds; gulfs and bays all along the coast and a large number of islands with their mangrove swamp and coral reefs, are rich sources of marine fish.

      Tidal estuarine waters in the mouths of large and perennial rivers, large brackish water lakes, backwaters, lagoons and swamps scattered along the entire coast-line, afford lucrative estuarine fisheries. Vast stretches of fresh water consisting of rivers, streams, lakes, reservoirs, tanks, ponds and paddy fields offer scope for inland fisheries. The principal rivers of India, including their main tributaries, have a total length of c. 27,360 km. and the length of canals and irrigation channels is c. 1,12,650 km. When added to other freshwater resources, the total surface would run to several million acres of which not more than a million acres are under fish culture. Most of these freshwater resources, though culturable, are at present lying fallow.

      In order to study the distribution and bionomics of marine fishes inhabiting Indian waters and to assess the topographic conditions for the establishment of fisheries, the Indian coast has been divided into the following 12 bio-geographical zones:

      Zone 1: West Bengal and Orissa

      Zone 2: Andhra coast (south of Gopalpur to north of Visakhapatnam)

      Zone 3: Andhra coast (Visakhapatanam to Masulipatham)

      Zone 4: Andhra coast (south of Masulipatnam to north of Pulicat lake)

      Zone 5: Coromandel coast (Pulicat lake to Cuddalore)

      Zone 6: Coromandel coast (south of Cuddalore to Devipatnam)

      Zone 7: Palk Bay and Gulf of Manaar (south of Devipatnam to north of Cape Comorin)

      Zone 8: Kerala and South Malabar (Cape Comorin to Ponnani River)

      Zone 9: Malabar and South Kanara (north of Ponnani River to Mangalore)

      Zone 10: Konkan coast (north of Mangalore to south of Ratnagiri)

      Zone 11: Mumbai and Gujarat coast (Ratnagiri to Broach)

      Zone 12: Kathiawar coast


      COST ESTIMATION

      Plant Capacity            4500 Kg./Day

      Land & Building (20,000 sq.mt.)    Rs. 10.20 Cr

      Plant & Machinery                    Rs. 7.85 Cr

      Working Capital for 2 Months    Rs. 15.38 Cr

      Total Capital Investment          Rs. 34.09 Cr

      Rate of Return                          78%

      Break Even Point                      27%


      CONTENTS

      INTRODUCTION

      PROPERTIES & CHARACTERISTICS

      CHITIN [1398-61-4]:

      ITS EMPIRICAL FORMULA = (C8H13NO5)N

      EMPERICAL FORMULA = (C6H11NO4)N

      DEGREE OF DEACE ĘLATION

      AVERAGE MOLECULAR WEIGHT

      VISCOSITIES AND BEHAVIOR IN SOLUTION

      SOLUBILITY

      CATIONIC PROPERTIES

      CHEMISTRY OF CHITIN AND CHITOSAN

      USES AND APPLICATIONS

      INDUSTRIAL USES:

      APPLICATION OF CHITOSAN

      CHITOSAN

      MEDICAL AND PHARMACEUTICAL USES

      BIOMEDICAL USES

      PRELIMINARY RESEARCH AND FDA REVIEW

      AGRICULTURAL & NUTRITIONAL USES:-

      CHITIN SYNTHESIS INHIBITORS

      USES OF CHITOSAN

      I) CLARIFICATION AND PURIFICATION

      II) CHROMATOGRAPHY

      III) PAPER AND TEXTILES

      IV) PHOTOGRAPHY

      V) FOOD AND NUTRITION

      VI) AGRICULTURE

      II) MEDICAL AND PHARMACEUTICAL

      TECHNICAL PARAMETERS

      LOCATION OF THE PROJECT

      BORROWER’S PROFILE

      B.I.S. SPECIFICATION

      MARKET OVERVIEW OF CHITIN

      CHITIN MARKET DIVIDED BY DERIVATIVE TYPE AS:

      CHITIN MARKET DIVIDED BY END-USE AS:

      CHITIN MARKET DIVIDED BY GEOGRAPHY AS:

      MARKET OVERVIEW OF CHITOSAN

      PRESENT MANUFACTURERS OF CHITIN AND CHITOSAN

      FOREIGN PRODUCERS OF CHITIN & CHITOSAN

      SPECIFICATION AND TEST FOR MEDICAL GRADE CHITOSAN

      ANALYZE REPORT OF CHITOSAN (MEDICAL GRADE)

      RAW MATERIALS

      CHITIN CONTENTS OF SOME ORGANISMS

      CRUSTACEA:-

      INSECTS:-

      MOLLUSKS:-

      FUNGI:-

      MANUFACTURING PROCESS

      BASIC CONCEPT:

      CHITIN:

      CHITOSAN:

      CHITIN:-

      DETAILS OF PROCESSING STEPS:-

      CHITOSAN MANUFACTURING PROCESS:-

      DETAILS OF CHITIN AND CHITOSAN PRODUCTION PROCESS

      CHEMICAL ISOLATION OF CHITIN

      PROCESS FLOW DIAGRAM

      PROCESS FLOWSHEET FOR MANUFACTURING OF CHITIN-FROM PRAWN FISH SHELL WASTES

      MANUFACTURING PROCESS OF CHITOSAN (MEDICAL GRADE)

      PRETREATMENT STEP

      DEMINERALIZATION

      DEPROTEINATION

      DEACETYLATION

      CHITOSAN MANUFACTURING FROM CHITIN (MEDICAL GRADE)

      TECHNOLOGY

      RAW MATERIAL

      DEPROTEINISATION

      DEMINERALISATION

      REMOVAL OF WATER

      DEACETYLATION OF CHITIN

      REMOVAL OF WATER

      DRYING

      POWDERING AND PACKING

      YIELD

      ILLUSTRATION OF THE PROCESS

      PROCESS IN DETAILED

      AT THE SAME TIME, ENZYMES

      TYPE OF DEACETYLATION: DEACETYLATION PROCESS MAY BE PROVIDED BY TWO SYSTEMS:

      TWO EXPLANATIONS OF THIS PHENOMENON HAVE BEEN PROPOSED

      TABIE: CHEMICAL COMPOSITION OF VARIOUS CRUSTACEAN WASTES AND OF INSECT'S LARVES OF CALLĘHORA ERYTHROCEPHALA

      CHITIN AND CHITOSAN EXTRACTION FROM CHITINOUS MARINE WASTE

      CHEMICAL EXTRACTION

      CHEMICAL DEPROTEINATION

      CHEMICAL DEMINERALIZATION

      BIOLOGICAL EXTRACTION

      ENZYMATIC DEPROTEINATION

      FERMENTATION

      LACTIC ACID FERMENTATION

      DEPROTEINIZATION OF CHITIN FROM SHRIMP HEAD WASTE

      MATERIALS & METHODS

      PREPARATION OF RAW MATERIAL

      CHITIN EXTRACTION PROCEDURE

      CHEMICAL ANALYSIS

      FIGURE: THE TWO- STAGE METHOD FOR CHITIN PRODUCTION

      TABLE: CHEMICAL COMPOSITION OF SHW1

      TABLE: PROTEIN RECOVERY (%) OBTAINED BY USING DIFFERENT DEPROTEINIZATION PROCESSES

      TABLE: NITROGENOUS COMPOSITION OF PRECIPITATE AFTER DEPROTEINIZATION PROCESSES

      TABLE: EFFECT OF NAOH CONCENTRATION ON THE RESIDUAL PROTEIN CONTENT AND DEGREE OF ACETYLATION OF CHITIN PRODUCED BY THE TWO-STAGE METHOD)

      TABLE: SPECIFICATION OF PRODUCED CHITIN COMPARED TO FOOD GRADE PRODUCT

      PRODUCTION METHOD OF CHITIN AND CHITOSAN FROM SHRIMP SHELL IN BATCH CULTURE OF LACTOBACILLUS PLANTARUM

      MATERIALS AND METHODS

      SHRIMP SHELL

      DATE SYRUP

      TABLE – CHEMICAL CHARACTERISTICS OF DATE SYRUP

      FERMENTATION

      PREPARATION OF CHITIN

      PREPARATION OF CHITOSAN

      ANALYTICAL PROCEDURE

      EFFLUENT TREATMENT PROCESS

      EFFLUENT TREATMENT SYSTEM

      PROTEIN PASTE FROM THE SHELL/PROTEIN SEPARATION

      NAOH DE-PROTEINIZATION WASH WATER

      HCL DE-MINERALIZATION WASH WATER

      SEA AND FRESH WASH WATER

      PLANT LAYOUT

      SUPPLIERS OF PLANT AND MACHINERY

      SUPPLIERS OF CONVEYOR BELT

      SUPPLIERS OF PULVERISER

      SUPPLIERS OF WASHING TANKS

      SUPPLIERS OF TRAY DRYER

      SUPPLIERS OF PVC TANKS

      SUPPLIERS OF LIQUID TANKS

      SUPPLIERS OF EVAPORATION UNIT

      SUPPLIERS OF DRYING CHAMBER

      SUPPLIERS OF BOILERS

      SUPPLIERS OF WATER CHILLER

      SUPPLIERS OF FILTER PRESS

      SUPPLIERS OF LABORATORY TESTING EQUIPMENTS

      SUPPLIERS OF CHEMICALS

      SUPPLIERS OF RAW MATERIAL

      RAW MATERIAL SUPPLIERS FOR CHITIN AND CHITOSAN

      SUPPLIERS OF HYDROCHLORIC ACID

      SUPPLIERS OF CAUSTIC SODA

      SUPPLIERS OF LABORATORY CHEMICALS

      ADDRESSES FOR CONSULTANT & TURNKEY PLANT


      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)

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