Techno - Economic feasibility report For Manufacturing of … · 2016-01-13 · 1 Techno - Economic feasibility report For Manufacturing of enzymes Project Site Plot number E 1/7

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Techno - Economic feasibility report

For

Manufacturing of enzymes

Project Site

Plot number E 1/7 Additional Patalganga Industrial Area,

Raigad

By,

Novozymes South Asia Pvt. Ltd.

Plot No. 32, 47-50, EPIP Area,

Whitefield, 560 066

Bangalore, India

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1.0 Introduction

Novozymes India began its operations in 1983 and over the years, Novozymes has emerged as

the largest enzyme supplier in the country, catering to requirements across 30 industries.

Today the region’s operations cover India, Sri Lanka, Bangladesh, Nepal and Bhutan.

Household care, textiles, food & beverages, oil & fats, baking, beverage alcohol are some of the

key business areas of Novozymes in India.

1.1 Proposed Project Scheme

The industry has proposed to setup manufacturing based on Biotechnology in Additional

Patalganga Plot Number E 1/7 with the capacity of Enzyme production of 75000 Kgs/Month.

1.2 Technical and Financial Viability of the Project

With sustained raw material availability (from local vendor and parent units) for the project on long term basis and best technologies available to produce excellent quality of various products technically project is feasible. Market for these products is excellent with very good price. Also considering huge experience of the company the project is very much feasible from both i.e. technical and financial aspect.

Financial viability of the project is worked out and shows excellent financial feasibility.

Assumptions made are on conservative side and any increase in the requirement of product

and increase in prices of the final product will enhance the viability further.

Hence, considering sustained availability of raw material, excellent market and price for

finished products, flexibility of producing variety of different products with market and price

trend makes this project extremely feasible. Hence, it is recommended to go ahead with the

project. This project will be win-win situation for promoters, financial institutions and farmers

in this area.

1.3 Project Brief Name and address of the Promoter company

Novozymes South Asia Pvt. Ltd Plot No. 32, 47-50

EPIP Area

Whitefield

560066 Bangalore India

Factory Site Plot number E 1/7 Additional Patalganga Industrial Area, Raigad

Land area 14 ha/ 34.6 Acre Nearest river Patalganga 2 km Nearest highway Mumbai Pune Express highway 6 km and 1 km away from

Kharpada road also well connected with MIDC road Nearest railway station Apta railway station 2 km MSL 18 m Topography Plain

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Products & By Products Enzymes 75 Tons/Month Process Blending and Repacking of Enzymes

Solid product 750Tons/Month Liquid Product 800Tons/Month

Cost of Project Rs. 310Crore Ecological Sensitive Area No

1.3.1 Site Location

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1.3.2 Google Image

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1.4 Raw Material

The proposed Solid State Fermentation – Enzyme manufacturing (SSF), facility will be operated

as batch process. List of raw materials used for the production and the expected consumption

is given below:

These raw materials will be stored in warehouses with adequate safety provisions

Table 1: Requirement of Raw Materials for Production of Enzymes

Sr.No. Items Consumption

MT/Annum

1. Wheat Bran 1080

2. Chemicals 180

3. Various Raw Materials (List attached below) 1500

4. Inoculum 2.0

Total 2162

List of proposed Raw materials

Material Description

Ferrous Sulfate Heptahydrate

Dextrose Anhydrous

Wheat Bran (PF)

Soya Protein

HUWA-SAN TR 50

Hydrochloric Acid

Hydrogen Peroxide

Iso Propyl Alcohol

Sodium Hypochlorite

Nitric Acid

K-800/K-1 Filter Pads

EKS/S-100 Filter Pads

K150/KD-10 Filter Pads

Ammonium Sulphate LR

Acetic Acid

Calcium Chloride Dihydrate

Glycerol

Wheat Flour

Mono Ammonium Phosphate

Magnesium Sulphate

Orthophosphoric Acid

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Potassium Chloride

Potassium Sorbate

Potassium Dihydrogen Orthophosphate

Sucrose (Sugar)

Sodium Benzoate

Sodium Hydroxide (Caustic)

Struktol J 673

Glucoamylase Ark Conc (INP)

Caustic Soda Lye

Yeast Amberferm 5000

Proxel LV

Sodium Acetate Trihydrate

Sodium Metabisulphite

Lutensol AT 80

Sorbitol

Acetic Acid

Glycerol

Sodium Benzoate

Sodium Chloride (Common Salt)

1.5 Product Details

Proposed List of Products manufactured - Solid State Fermentation

1. Manufacturing of Enzymes (SSF)

BASIS

Sr. Product Type Tons/Month

1 Pectinase series of Products Enzymes 75

2. Blending and Repacking of Enzymes – Supply Chain Operation (SCO)

BASIS

Sl Product Type Tons/Month

1 Solid products Enzymes 750

2 Liquid Products Enzymes 800

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1.6 PROCESS DESCRIPTION

SHAKE FLASKS :

The first step in the SSF production begins with the inoculation of a Working Cell Bank

vial into Pre-seed/Seed Flask medium for resuscitation of the mold from ultra-low

temperature.

The Pre-seed stage is grown for the respective incubation period and then transferred

to the Seed flask medium. In the seed flask stage, the Inoculum is scaled to a higher

volume and then transferred to the Inoculum flask stage. In the Inoculum flask stage,

the Inoculum is scaled up to a certain volume, which is optimum for inoculation into the

small seed fermenter.

The incubation temperature, period, growth medium is specific for each strain.

At each stage of Inoculum transfer, the Inoculum is checked for purity, contamination,

pH. Also the potential of the Inoculum in terms of activity is assessed by preparation

of koji plates.

SUBMERGED FERMENTATION :

After propagation in the flask stages the micro-organism is grown on a small seed

fermenter and the fully grown Inoculum from the small seed fermenter is then

transferred into a big seed fermenter. The medium used in the seed fermentation

stages are potable water, carbohydrate source, nitrogen source and few inorganic

salts.

During the Fermentation process pH, Temperature, Airflow, Agitation Speed and the

DO (dissolved oxygen content) are monitored and controlled.

BRAN STERILIZATION :

Sterilization of the main substrate is done by direct steam injection and through jacket.

Cooling is done by circulating chilled water through the jacket.

DRY HEAT STERILIZATION :

The Trays & Lids used for Koji incubation are pre-sterilized by Dry heat sterilization

method. Cooling is done by supplying fresh air which passes through HEPA filters and

exhausted out.

LAYERING :

The layering process involves unloading of koji from the Bran sterilizer, dispensing in

the sterilized trays, lidding and transporting it to the Koji room through conveying

systems for incubation.

SOLID SUBSTRATE FERMENTATION :

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The period of incubation depends on the type of organism being propagated. During

fermentation the product temperature and humidity in the room is maintained and

controlled. Sterile air is pumped into the Koji room for temperature control and

aeration.

HARVESTING :

After the completion of Incubation period in the Koji rooms, the trays are removed from

the Koji rooms and the EOF Koji is sent to the extraction vessel through conveying

systems for Extraction of Enzymes.

EXTRACTION :

After loading the Koji, the extraction tank is filled with potable water and the extract is

collected and pumped to storage tanks for further filtration process.

MICROFILTRATION (MF) :

The extract is passed through microfiltration unit for the removal of production

organism and other foreign matters. It is a continuous recirculation process wherein

the filtered enzyme which is called the “Permeate (MFP)” is transferred to the next

step for concentration and the unfiltered enzyme which is called the “Retentate” goes

back to the feed tank and finally discharged to effluent drain after Dia-filtration.

ULTRAFILTRATION (UF) / CONCENTRATION :

The Micro Filtered Permeate (MFP) is passed through ultrafiltraion unit for the removal

of excess water molecules and concentrating the enzymes to desired activity. The

concentrated enzyme which is called the Ultra Filtered Concentrate (UFC) is

transferred to the next step for fine filtration and the water molecules which is called

the Ultra Filtered Permeate (UFP) goes to the effluent drain.

PAD FILTRATION (PF) / GERM FILTRATION :

The Ultra Filtered Concentrate (UFC) is passed through coarse and fine filter pads of

for the removal of micro-organisms carried forward from the previous stages.

STABILIZATION / STANDARDIZATION &TAPPING :

The pad filtered concentrate is then stabilized / standardized and is tapped into Schutz

container through filling machine, sealed with lid immediately, labelled and transported

to cool storage.

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Input - Seed Inoculum

Seed Fermenter - I

Seed Fermenter - II

Solid Substrate Sterilization

Layering

Solid Substrate Fermentation

Harvesting

Chemicals - CIP

Utilities · Air· Steam· Electricity· Water

Trays and Lids Cleaning &

Sterilization (DHS)

Liquid Waste

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Effluent Treatment Plant (ETP)

Extraction

NZIN SSF – FERMENTATION PROCESS FLOW CHART

Raw Materials

Solid Waste Treatment· Process waste / Raw

Materials / Chemicals· Packaging Materials· PPE’s, Paper, Glass, Metal· Equipment Accessories

Air emissions controlled by· Heaters· Filters

· Scrubbers

INPUT OUTPUT

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Process Description - Supply Chain Operation (SCO)

Process Blending and Repacking of Enzymes

A) Repacking ( Tapping )

1. Solid In this operation pre-approved finished goods received from supply plant (at present Denmark and China) in bulk packing (1000 kg Big Bag). This Bulk Finished Goods unloaded into hopper with the help of hoist and repacked in smaller packages as per customer requirement. Packing material used for tapping operation are 40kg HDPE drums and 5 kg pouches. These 5 kg pouches are packed in HDPE drums as final packaging. All Finished goods are labelled as per Novozymes labeling guidelines before transferring into ware house. These finished goods are stored in Ware House as per the storage conditions of product.

2. Liquid In this operation pre-approved finished goods received from supply plant received in 1000 kgs IBC. These IBC are connected to filling machine to repack into smaller packages as per customer requirement. Packing material used for this tapping operation are 25 Kg HDPE Jerry Cans, 30 Kg HDPE Jerry Cans, 225 Kg HDPE Barrels and 1000 Kg IBC. Before sending to Ware House, final product is store on Pallets. These finished goods are stored in Ware House as per the storage condition of product. All Finished goods are labelled as per Novozymes labelling guidelines before transferring into ware house

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Blending ( Mixing ) Mixing is a process of thoroughly combining different materials to produce a homogenous final product. Solid Blending In this operation, different solid enzymes are mixed together into a mixer to get a homogenous blend of final product. Composition of ingoing enzymes varies product to product. All ingoing components are checked for various parameters like activity, physical specification etc. in Quality Labs. Only approved components issued for Blending. Once blending operation done, final sample of finished good tested for various quality parameters define in protocol. Once desired parameters achieved, final product is Approved and then issued to packing. Rejected finished good either scrapped or will be taken for re-processing. These finished goods are stored in Ware House as per the storage condition of product. Liquid Blending ( Standardization ) In this operation, different ingredients are mixed together into a mixer to make homogenous blend of final product. Composition of ingoing ingredients varies product to product. All ingoing components which includes different raw materials, water and enzymes are checked for various quality parameters like activity, physical specification etc. Only approved components then issued for production. Approved solid components are transferred to standardization tanks with the help of “solid transfer system” and approved liquid components with the help pumps. In standardisation tank entire material is allowed to mix as per pre-validated mixing time. Mixing time is to ensure that all components are mixed homogenously. Once blending operation done, final sample of finished goods sent for Quality Analysis of various parameters defined in protocol. If results are within specification, final product is Approved and then packed into jerry cans. If, the final product does not meet finished good specifications it is sent for reprocessing else it will be scrapped. These finished goods are stored in Ware House as per the storage condition of product.

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Process flow chart - Blending and Re-Packing of Enzymes

1.7DG – Fuel Consumption / Stack details

DG Capacity 2500.0 KVA

DG Qty 3.0 Nos

Fuel type HSD

Fuel Consumption per DG 520.0 Ltrs/hr

Total Fuel Consumption 1560.0 Ltrs/hr

Total Fuel Consumption per day (considering

24hr/day) 37440.0 Ltrs/day

No. of stack 3.0 Nos

Shape Round

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Height of the stack - Building ht + 5 mts Approx 30 mts

Diameter – spiral foiled 500 mm

HSD Consumption for DG Set IS 2062

1.8 WATER BUDGET

Total water likely to be consumed for various purposes

Sr. No.

Purpose m3/day

01 Industrial cooling, 10 02 Boiler feed 2.4 02 Domestic purpose 10 03 Water used in the product 25 04 Processing whereby water gets Polluted and

the pollutants are Easily Bio-degradable 225

Total 272.4

The total amount of effluent likely to be generated

Sr. No. Effluent m3/day

01 Domestic 08

02 Process 110.0

03 Washing 4.0

04 Boiler Blowdown 2.4

05 Cooling water Blowdown 10.0

06 DM Plants/ Softening 65

Total 199.4

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1.8.2 Proposed Effluent Treatment - Process Flow Chart for ETP

BAR SCREEN CHAMBER

EQUALIZATION TANK

MBBR TANK 1& 2

REVERSE OSMOSIS

PSF & ACF

DISINFECTION

SETTLING TANK

FLOCCULATION

CENTRIFUGAL

DECANTER/FILTER PRESS

SLUDGE HOLDING TANK

SLUDGE CAKE FOR DISPOSAL

ANAEROBIC REACTOR

FLOCCULATION & SETTLING

MULTIPLE EFFECT

EVAPORATOR

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1.8.3 Treated Effluent output characteristics

S.No. Effluent Characteristics Value

1 pH 6-7

2 COD <250 mg/l

3 BOD <100 mg/l

4 TSS <50mg/l

5 TDS <2100mg/l

1.9Details of hazardous and non-Hazardous waste

1.10.1 Hazardous waste

S. No

Nameofthe waste

Quantity MT/Annum

Modeof disposal

Areaoflandearmarkedfor storage/ disposal

1 Spent Lube Oil (DG/Transformer)

6.0 Will be Sold to

authorized

agency

prescribed by

MPCB

3mx2mx4m ht

2 Oil soaked cotton waste

2.5 3mx2mx4m ht

3 Oil filter 0.6

4 Chemical container 30

5 E Waste 0.6

1.9.2 NON Hazardous waste

Sr. No

Type ofwaste QuantityMT/Annum

Modeofdisposal

1 Used Packaging Materials (IBC's, Drums, Jerry Cans, Polythene covers, Carton box, Silica Gel, Wood, Cotton, Aluminium Foil, rubber, Big bags)

70 Sold to authorized

agency prescribed by

MPCB

2 Used MS drums 4

3 Metal waste 15

4 Paper Waste 3

5 Glass waste 0.3

6 Used PF Filter Pads 20

7 Used PPE's (Gumboots, Mask Filter cartridges, etc.)

2

8 Process Waste (Spent / Spoiled - Fermentation Broth)

80

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9 Expired, Spoiled batches, Spills etc

20

10 Spent Biomass from the plant 2800 Sold to authorised

agency prescribed by

MPCB, it can be used as

fertilizer

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Spent Biomass (from QC)

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1.10PROPOSED AIR AND NOISE POLLUTION CONTROL DEVICES

Sl.No. Device

01 HEPA filters for Air handling units

02 Process scrubbers in the chimneys

03 Dust collectors in the manufacturing areas

04 Acoustics for DG

1.11Proposed Project Cost

Description Amount in Crores INR Land 42 Building 90 Plant and Machinery 147 Others 31 Total capital investment 310

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Annexure-1

MIDC Letter

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Annexure-2

Plant layout