Detailed Project Report on micro crystalline cellulose (pharma, food & non pharma grade)

MICROCRYSTALLINE CELLULOSE
(PHARMA, FOOD & NON PHARMA GRADE)
[CODE NO 3366]  
     

Microcrystalline cellulose, also known as MCC or cellulose gel, is commonly used as a binder and disintegrant in pharmaceutical tablets, as a suspending agent in liquid pharmaceutical formulations, and as a binder and stabilizer in food applications including beverages and as stabilizers, binders, disintegrants and processing aids in industrial applications, household products such as detergent and/or bleach tablets, agricultural formulations, and personal care products such as dentifrices and cosmetics. In foods, MCC is used alone or in coprocessed modifications as a fat replacer. The classic process for MCC production is acid hydrolysis of purified cellulose. In efforts to reduce the cost while maintaining or improving the quality of MCC, various alternative processes have been proposed. Among these are steam explosion, reactive extrusion, one-step hydrolysis and bleaching, and partial hydrolysis of a semi-crystalline cellulose and water reaction liquor in a reactor pressurized with oxygen and/or carbon dioxide gas and operating at 100 to 200°C. In the steam explosion process of Ha et al, a cellulose source material, such as wood chips, is contacted in a pressure reactor vessel with pressurized steam at a temperature of at least about 170°C for a brief period, concluding with a rapid release of the steam pressure (the "steam explosion" effect). Under these conditions the fibrous, amorphous, portions of the cellulose polymer chains are hydrolyzed, leaving the crystalline segments of the chains which characterize the product as MCC. The hydrolysis can be followed by determination of the extent of depolymerization of the cellulose, to a steady state known as "level off degree of polymerization" (LODP). Typically, according to Ha et al, starting cellulose will have a degree of polymerization ("DP") in excess of 1000 and the average DP characteristic of the steam exploded MCC product preferably will be in the range of about 100 to 400. The rapid decompression in the steam explosion process, particularly when effected through a small opening or die, facilitates physical separation of cellulose, hemicellulose and lignin in the source cellulose material. Such separation enables more efficient subsequent extraction of the hemicellulose and lignin. Another advantage of the steam explosion process is that it eliminates need for an acid hydrolysis to achieve the requisite depolymerization. A disadvantage is difficulty in controlling process conditions for optimization of MCC yield and quality. Ha et al disclose that the MCC product may subsequently be bleached with hydrogen peroxide or other reagent.

Cellulose is the principal fiber cell-wall material of green terrestial  and merine plants, produced also by a  few  bacteria, animals  and fungi, and thus the most abundant  natural  material (40%  in wood, over 70% in best and leaf fibres, 95% in the ceou wall of the green alga valonia ventricosa; Ca 5 x 10" metrictions biosynthesized yearly). Cellulose is a long linear polymer of anhydroglucose  units, and this is reflected in the  thread  like structures of cellulose found in the plant cell walls elementary fibrils approximately 3.5 m in width and indefinite length) which are further laterally associated to provide strength (as microfibrils, generally 10-30 mm in breadth).


COST ESTIMATION

Plant  Capacity                                         :       5.00 MT/day               
land & Building (2000 sq.ft)                   :    Rs. 2.97 Cr
Plant & Machinery                                    :    Rs. 4.00 Cr
Working Capital for 2 Months                 :    Rs. 2.3  Cr
Total Capital Investment                          :    Rs. 9.41 Cr
Rate of Return                                             :    31%
Break Even Point                                         :    49%

INTRODUCTION    
MICROCRYSTALLINE CELLULOSE    
MICRO CRYSTALLINE CELLULOSE    
APPLICATIONS    
SPECIFICATION    
USES AND APPLICATION    
CELLULOSE IS USED IN THE FOLLOWING PRODUCTS:    
FIBERS:-    
FILMS:-
CELLOPHANE:-    
SAUSAGE CASINGS:-    
ARTIFICIAL KIDNEYS:-    
REVERSE OSMOSIS:-    
GUMS & THICKNESS    
FOODS & PHARMACEUTICALS FOODS    
PHARMACEUTICALS    
COSMETICS    
MARKET SURVEY    
EXPORT DATA OF MICRO CRYSTALLINE CELLULOSE    
IMPORT DATA OF MICRO CRYSTALLINE CELLULOSE    
PRESENT MANUFACTURERS/SUPPLIERS
   OF MICROCRYSTALLINE CELLULOSE    
B I S SPECIFICATION    
1.   SCOPE    
2.   REQUIREMENTS    
3.   PACKING AND MARKING    
4.   SAMPLING    
5.   TEST METHODS    
METHODS OF TEST    28
SAMPLING OF CELLULOSE POWDER    
CELLULOSE DERIVATES    
1.   CELLULOSE ACETATE:    
2.   SIMPLE TRIESTERS :    
3.   CELLULOSE ESTERS OF AROMATIC ACIDS:    
4.   BENZOATE ESTERS:    
5.   CELLULOSE ESTERS OF UNSATURATED CARBOXYLIC ACIDS:    
6.   MIXED ESTERS:    
SPECIFICATION OF MICROCRYSTALLINE CELLULOSE    
COMPARISON CHART OF SPECIFICATOINS    
MICROCRYSTALLINE CELLULOSE, IP (SPRAY DRIED)    
MICROCRYSTALLINE CELLULOSE, IP (BULK DRIED)    
SPECIFICATION OF FOOD GRADE (MCC)    
RAW MATERIALS    
PROPERTIES    
PHYSICAL PROPERTIES:    
HEAT EFFECTS :    
SOLUBILITY :    
CHEMICAL PROPERTIES :    
PROPERTIES IN ALKALINE SOLUTION:    
EFFECT OF MINERAL ACIDS :    
EFFECT OF OXIDIZING AGENTS :    
ALCOHOLIC PROPERTIES :    
ETHER FORMATION :    
MANUFACTURING PROCESS OF MICROCRYSTALLINE CELLULOSE POWDER    
PROCESS FLOW DIAGRAM    
PROCESS DETAILS    
1.   WOOD PREPARATION :    
2.   PULPING :    53
MECHANICAL PULPING :    
CHEMICAL PULPING :    
SULFITE PROCESSES :    
ALKALINE PROCESSES :    
PURIFICATION ;    
OXIDATIVE BLEACHING : CHLORINE.    
OTHER AGENTS :    
REDUCTIVE BLEACHING:    
OTHER REACTIONS :    
THE USUAL METHODS INCLUDE EITHER OR BOTH OF THESE STEPS:    
PRODUCTION OF MICROCRYSTALLINE CELLULOSE USING REACTIVE
EXTRUSION PROCESS    
TEST METHODS    
TABLE 1: TABLET PROPERTIES    
MANUFACTURING PROCESS OF MICROCRYSTALLINE CELLULOSE
   FROM CORN HUSK    
MATERIALS AND METHOD    
MATERIALS    
METHOD    
PREPARATION OF MAIZE HUSK POWDER:    
EXTRACTION OF CELLULOSE FROM CORN HUSK:
MICROCRYSTALLINE CELLULOSE FROM COTTON RAGS    
REAGENTS AND CHEMICALS    
MCC PREPARATION    
PURITY AND IDENTIFICATION TEST    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY    



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