Coconut Processing.pdf

7/25/2019 Coconut Processing.pdf

1/21

1

Innovative Technologies inCoconut Processing

Coconut Development Board

2

Coconut - A Versatile Crop

Used as - food crop, oilseed, fibrecrop

medicinal crop &beverage crop

Coconut leaves - for roof and fencing

Coconut shell - for industrial products,handicraft items

Coconut trunk - for building materials,flooring materials andhandicrafts

Coconut - yield coconut toddy

inflorescence

Coconut fruit - inevitable item in culturaland social use


2/21

3

Coconut Production and Productivity

Country Area

(in hectres)

Production

(in millionnuts)

Productivity

nuts / ha

India 1903190 14744 7747

Indonesia 3860000 15196 3937

Philippines 3355000 12327 3674

Source: DES, GOI, NEW DELHI

4

Valueadded

coconutproducts

Size of the Inland market: Rs 83000 million

Size of the Export Market: Rs 3000 million (Coconut products)

and Rs 6400 million (Coir products)

CAGR : 8%


3/21

5

PROCESSING OF MATURE NUT

WATER

Concentrate

Packedwater

KERNEL

Milk /Cream

Skimmedmilk

powder

Desiccatedcoconut

SHELL

Shell powderActivated

carbon

Shellcharcoal

Vinegar

HUSK

Coir Industry Coir pith Compost

VirginCoconut oil

/ Nata-de-coco

Jam

Honey

Chips

Dairy foods

Biscuits/burfi Handicrafts

Copra

Ediblecopra

Oil

Chutneypowder

6

PROCESSING OF TENDER NUT

Packedtender

nut water

Snow ball

Soft kernel

Pudding

Ice cream


4/21

7

Seed & Others

Copra

50%

10%

35%

Industrial

10%Domestic

90%

Consumption Pattern of Coconut

Mature Nut

Tender Nut

5%

8

Copra

Copra is the dried kernel of coconut. It is from copra that coconut oil is

produced. Copra contains the highest percentage of oil as compared toother oil seeds.

The two broad varieties of copra are milling copra and edible copra. Milling

copra is used for extracting oil whereas edible copra is used in condiments

and in religious and social functions. India producing about 6.5 lakh MT of

milling copra and 2 lakhs MT of Ball copra. The major exports of copra is to

Bangladesh and Nepal.

Coconut Products


5/21

9

Coconut Oil

Coconut oil is used for, both edible and non edible purposes. It is also

consumed in various industrial applications, soap, shampoo, detergents,

etc. A portion of coconut is also used in the making of ice creams and

biscuits, chocolates which can be described as industrial purposes though

the finished products are edible.

Around 10,000 tonnes of Coconut oil is exported mostly to the Gulf Region

Consumed by Ethnic Population

Contrary to misconceptions, coconut oil does not elevate total blood

cholesterol. Instead, it increases HDL or the friendly cholesterol, lowers

harmful LDL cholesterol and serum triglycerides. .

Annual production of Coconut Oil is 4.85 lakh tonnes.

10

Virgin Coconut Oil

Virgin Coconut Oil (VCO), extracted from fresh coconut meat

without chemical processes is said to be the mother of all

oils.

It is rich in medium chain fatty acids, particularly lauric acid

and is a treasure trove of minerals, vitamins, antioxidants and

is an excellent nutraceutical. It has about 50% lauric acids,

having qualities similar to mothers milk, thus confirming its

disease fighting ability. Virgin Coconut Oil finds application as

skin oil, massage oil, baby oil and consumed in USA / Europe

for reducing obesity.


6/21

11

Desiccated Coconut

Coconut has been the staple food of people in many parts of

Asia and Pacific Islands. The dehydrated shredded flesh ofcoconut known as desiccated coconut is often used as a

substitute to grated coconut in food preparations such as

curries, cakes, sweets and chutneys. Confectionery and

bakery units are the main consumers of desiccated coconut.

Total production of DCP is about 50,000 MT mainly

concentrated in Karnataka and Tamil Nadu. Exports amout to

about 2000 Tones

12

Spray Dried Coconut Milk Powder

The Spray Dried Coconut Milk Powder is now available in

convenient and ready-to-use packs with the same freshness of

a fresh coconut milk. It has longer a shelf life and is convenientto use.


7/21

13

Tender Coconut Water

The water of Tender Coconut is a sterile, nutritious, thirst

quenching health drink. The pure and sweet tender coconut

possesses enormous therapeutic properties and is a thirst

quenching refreshing health drink for all age groups. It is

loaded with natural sugars, salts, and vitamins and is low in

fat, calories and has no cholesterol. It's a highly rejuvenating

tonic that can ward off fatigue in an instant. Tender coconut

water has the same level of electrolytic balance as we see in

our blood.Technology available for packing & preserving TCW.

14

Activated Carbon

Coconut Shell is used for manufacturing a variety of products

of commercial importance including activated carbon. Shell

based activated carbon is extensively used in the process of

refining and bleaching of vegetable oils and chemical

solutions, water purification, recovery of solvents, recovery of

gold etc. It is used in gas masks and a wide range of filters for

war gases and nuclear fall outs. Coconut shell based activated

carbons units adopt steam activation process to produce good

quality activated carbon.


8/21

15

Activated Carbon is made both by the organized and un-

organized industry

There are 18 medium sized Companies in India who makeactivated Carbon using state-of-the-art machines. The

other manufacturers are tiny manufacturers in the un-

organized sector. The total production of Activated Carbon

is 45000 MT / annum.

The present exports is directed at United states, UK,

Germany, Japan, France, and averages around Rs 1500

million. There is an enlarged market potential for activated

Carbon because of its unique natural properties.

16

Coconut Based Handicrafts

Coconut Handicrafts made out of the wood shell, fibre/husk

and leaves of the coconut tree have high decorative value and

serve as a value addition bringing with it the aesthetic touch

and exquisiteness wherever it is used

The timber can be converted into doors, windows, wall panels,

banisters. Coconut fibre is used to make coir products such as

bags, table mats, sandals, wall hangings etc. Coir mats and

carpets are also made out of the coconut fibre.


9/21

17

Export potential

Coconut oil has an excellent potential in Gulf, Europe, and America, the

user being the ethnic population;

Activated Carbon has been increasing its market share and demand

from USA, United Kingdom, Germany, France, Japan etc.

Processed and packaged tender coconut water has been bagging

orders from Gulf and UK.

China, is a growing market for coconut and its various products,

Russia is emerging as one of the major buyers of Coconut oil and

Virgin Coconut oil, Germany is an emerging market particularly for

desiccated Coconut powder, coconut milk powder etc.

Handicrafts, Ice cream cups spoons etc made from coconut shell is

exported to European countries

Indian Coconut products are rated as premiium quality products.

18

Coconut growing countries like Malaysia, Philippines, and other

ASEAN countries are concentrating on manufacturing Palm oil, other

Coconut value added products with new technology, Government

support, high level R&D Intervention.

Their brands have premium clientele.

India can outreach them only by increasing the present range of

products, increasing its value addition, look at new markets, penetrate

and establish a niche presence, with cost effective pricing.

Indian products should be visible in the Retail stores with attractive

packing, and should match the pricing of competitive products from

ASEAN, Sri Lanka and other Coconut value-added product

manufacturing countries.

India should record presence by participating in the world renowned

international trade fairs across the globe by utilizing the Market

Development Assistance and Market Access Initiative Scheme of the

Foreign Trade Policy enumerated in Para 3.2 of the FTP.


10/21

19

Strengths of the Indian Coconut Sector

One of the largest producers of coconut in the world Sufficient

raw material surplus.

Quality of Indian coconut product enjoys good reputation.

Access to good technologies (Virgin Coconut Oil, Packed Tender

Nut Water, minimally processed Tender Coconuts, Activated

Carbon)

Dominant ethnic population in the Gulf, UK and US

Being a natural and eco friendly product, coconut has a future and

potential for earning carbon credit

20

Lack of big players from the coconut sector in the international market

Lack of exposure to the international market and its specific requirements

The weak financial status of the small and tiny exporters who cannot take

up effective export promotion programmes

Price disadvantages Cost of production is high. INR appreciation vis--vis

SLR.

Lack of market penetration

Competing countries of South East Asia have already an established

presence in important international markets and have cost advantages

Supply side is highly disorganized and fragmented

Coconut products occupy large volume and has low unit value (.) Tariff

freight is against volume.

Weakness


11/21

21

Coconut shell based Activated Carbon is an agricultural and environmentally friendly

products. Its classification under ITC Code under Miscellaneous Chemical Products

deprives this product of the benefits due for an environmentally friendly product.

Board has proposed to the Ministry of Finance to reclassify it under Chapter 44 as an

Agriculture product.

Since coconut industry is labour intensive and generates rural employment coconut and

its value added products should be provided benefits under Vishesh Krishi Udyog

Yojana, FPS, Duty draw back

Increased exposure to international markets through regular participation in important

fairs and exhibition

Restore DEPB Scheme for Copra

Allowing exports of Coconut Oil from all southern ports in India

Harmonising national standards with international standards for coconut products

Opportunities

22

Rupee appreciation vis--vis the dollar

Freight disadvantages Geographical distance from end markets

Competitive advantages of South East Asian

Countries in the world market

Threats


12/21

PROJECT PROFILES OFPOTENTIAL VALUE ADDED

COCONUT PRODUCTS

23

24

ACTIVATED CARBON

Activated carbon manufactured fromcoconut shell is considered superior to

those obtained from other sources mainlybecause of small macro pore structure,which renders it more effective for theadsorption of gas/vapor, and for the

removal of color and odour of

compounds.


13/21

25

Activated Carbon

Activated carbon is widely used in the refiningand bleaching of vegetable oils and chemicalsolutions.

At present five units are functioning.

Total production estimated at 5000 MT.

Anticipated growth is 20%

26

MANUFACTURING PROCESS

The manufacturing process involves the following steps

Breaking of coconut shells in a Coconut shell breaker.

Broken Coconut shells are then fed into a carbonization retort.

Carbonized coconut shells are brought down to the desired size

using either a hammer mill or a roller crusher.

Crushed charcoal is then screened using a rotary

screener.Oversized product retained on the inner mesh is recycled

to the crusher/hammer mill and the undersized particles passing

through the outer mesh are used for other applications.


14/21

27

The next step is the most important one- the activation process

involving the reaction between charcoal and steam carried out

in a rotary kiln at temperatures between 850C and 1000C.

The activated charcoal is then cooled at the discharge of the

kiln through serpentine cooling tubes.

The cooled product is screened in a rotary screener. The

oversized particles are crushed in a roller crusher and

recycled to the screener and the undersized particles

are used for other appropriate applications.

.

28

The cooled product is screened in a destoner and screener.

The oversized particles are crushed in a roller crusher and

recycled to the screener and the undersized particles are used

for other appropriate applications.

The finished product is finally stored in large silos and packed

in high density polypropylene bags in various consumer packing

depending on the customer requirements.


15/21

29

PROJECT COSTCapacity 5 MT per day

Land Requirement- 2.0-2.5 acres

Building -10000 sq ft - Rs.70 lakhs

Plant & machinery - Rs. 200 lakhs

Electrification - Rs.30 lakhs

Preliminary & pre operative expenses - Rs. 20 lakhs

Working capital - Rs. 25 lakhs(Margin money)

30

Preservation and Packing ofCoconut Milk / Cream

PRODUCT AT A GLANCE

Ready to use product for households

recipes, beverages, icecreams,sweets, desserts etc.

Fresh taste of coconut without thebother

Very convenient forhouseholds,hotels,

bakeries.

Blends easily with food preparation.

Keeps fresh for a period of 6 monthswith all nutrients in tact.


16/21

31

PROJECT COSTCapacity 10000 nuts per day Land requirement - 60 cents-1acre

Building 6000 sq ft - Rs 55 lakhs

Plant & machinery - Rs.65 lakhs.

Preliminary and

pre - operative expenses- Rs. 15 lakhs.

Electrification - Rs. 20 lakhs.

Margin money for

working capital - Rs. 25 lakhs.

32

Spray Dried Coconut MilkPowder

PRODUCT AT A GLANCE

Highly convenient to use for

households / hotels,bakeriesand ice cream parlours.

Reconstitute quickly withwater for instant use.

Occupies less storage space.

Highly economical for bulkconsumer.

Keeps fresh for a period upto 1 year.


17/21

33

PROJECT AT A GLANCE

Land Requirement - - 1.5-2.0 acres

Building 8000 sq ft - Rs.70 lakhs


Contingencies - Rs.10 lakhs



34

PRESERVATION AND PACKING OF TENDERCOCONUT WATER

PRODUCT AT A GLANCE

Natural, nutritious and thirstquenching health drink.

Possess therapeutic propertieswith vitamins,minerals andprotein.

Good rehydration medium forpatients suffering fromgastroenteritis and intestinaldisturbances.

Keeps fresh for a period of six


18/21

35

PROJECT COST10000 tender nuts per day

Land Requirement- 60 cents-1 acre Building 6000 sq ft- Rs. 55 lakhs


Preliminary & -pre - operative expenses- Rs. 10 lakhs

Electrification - Rs. 10 lakhs


36

CHARCOAL

PRODUCT AT A GLANCE

Superior in quality whencompared to wood charcoal.

Ideal raw material for highquality activated carbon.

Better calorific value thanother agro waste and henceideal for use as fuel insmitheries, bakeries andfoundries.


19/21

37

PROJECT COSTCapacity 3 MT per day

Land requirement - 50 cents

Building 3000 sq ft Rs 15 lakhs

Plant & machinery - Rs.30 lakhs

Preliminary &

pre - operative expenses. - Rs. 5.0 lakhs

Electrification - Rs. 5.0 lakhs

Margin money for-

working capital - Rs..20 lakhs

38

VIRGIN COCONUT OIL

PRODUCT AT A GLANCE

A Premium Grade Oil

extracted directly from freshcoconut through wetprocessing

White in Color

Extensive Medicinal uses

Keeps fresh for a period upto 1 year.


20/21

39

PROJECT AT A GLANCE

Land Requirement - - 1.5-2.0 acres

Building 8000 sq ft - Rs.70 lakhs


Contingencies - Rs.10 lakhs



40

o So far adequate attention has not been given to

promoting exports from the coconut sector

o The strength of being a natural product has notbeen properly leveraged.

o Coconut Sector needs to be supported with

incentives and tax exemptions for the overall

growth of coocnut industry.

o If proper stimulus is given to coconut which is an

agricultural product generating employment in

rural area there is a distinct possibility of taking

exports to a high level.

Conclusion


21/21

41

Coconut Oil, [Crude, refined]

Virgin Coconut Oil

Processed tender

coconut water,

Coconut milk powder

Desiccated

Coconut powder

Activated CarbonCoconut shell (raw), Shell Charcoal,

Shell hookah,

Coconut handicrafts

Coconut [Fresh, dried]

Copra, Oil Cake

Coconut Processing.pdf

Documents

Transcript of Coconut Processing.pdf