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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
ò
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)
4.5
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