Detailed Project Report on NSTANT COFFEE (FREEZE DRIED) PRODUCTION RATE - 6000 TPA

Instant coffee, also called soluble coffee and coffee powder, is a beverage derived from brewed coffee beans. It is the dried soluble portion of roasted coffee, which can be presented to the consumer in either powder or granule form for immediate make-up in hot water. Instant coffee is commercially prepared by either freeze-drying or spray drying, after which it can be rehydrated.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org



NSTANT COFFEE (FREEZE DRIED)
PRODUCTION RATE - 6000 TPA
[EIRI/EDPR/4676] J.C.: 2893XL


Instant coffee, also called soluble coffee and coffee powder, is a beverage derived
from brewed coffee beans. It is the dried soluble portion of roasted coffee, which
can be presented to the consumer in either powder or granule form for immediate
make-up in hot water. Instant coffee is commercially prepared by either freeze -
drying or spray drying, after which it can be rehydrated.

Regular coffee is usually made with roasted coffee beans, ground into a fine
powder. With this type of coffee, there’s always coffee bean waste after the process
is completed. As we mentioned previously, instant coffee is soluble. There’s no
waste as it’s all dissolved into rich, deliciousness.

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CONTENT

INTRODUCTION
CLASSIFICATIONS
NON-AGGLOMERATED INSTANT COFFEE POWDER
AGGLOMERATED INSTANT COFFEE POWDER
GRANULATED INSTANT COFFEE POWDER
USES
CARAMEL MACCHIATO ICE CREAM
DARK MOCHA CRINKLES
CHOCOLATE CAPPUCCINO CHEESECAKE
NUTELLA COFFEE SHAKE
TIRAMISU LAYER CAKE
RUSSIAN BLACK BREAD SLICED
MOCHA CHOCOLATE CHIP BANANA MUFFINS
ORIGINAL IRISH CREAM
ULTIMATE CHOCOLATE DESSERT
HONEY CAKE
BLACK BEAN BROWNIES
DALE'S SWEDISH MEATBALLS
DALGONA COFFEE
MOCHA TRUFFLES
BENEFITS
MARKET OVERVIEW
GLOBAL INSTANT COFFEE MARKET (%), BY SEGMENT TYPE
MARKET DYNAMICS
DRIVERS:
THE INCREASING POPULARITY OF INSTANT COFFEE
INTRODUCTION OF NEW FLAVORS TO EXPAND THEIR CONSUMER-BASE
AFFORDABLE AND CONVENIENT
RESTRAINTS
HIGH CONCENTRATION OF ACRYLAMIDE
OPPORTUNITIES
GROWING PRODUCT DIVERSIFICATION
CHALLENGES
RISING CONCERNS ABOUT THE ADVERSE EFFECTS OF EXCESSIVE COFFEE
DRINKING
SEGMENTATION ANALYSI S

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REGIONAL SEGMENTATION ANALYSIS
INSTANT COFFEE – ASIA
INSTANT COFFEE - SOUTHEAST ASIA
INSTANT COFFEE - SINGAPORE
COVID-19 SCENARIO
KEY DEVELOPMENTS
MIDDLE EAST COFFEE MARKET
MIDDLE EAST COFFEE MARKET TRENDS
INSTANT COFFEE - EUROPE
EAST EUROPEAN COFFEE IMPORTS ARE ON THE RISE
INDIAN EXPORT
INSTANT COFFEE MARKET - IMPACT OF COVID-19 PANDEMIC
INSTANT COFFEE MARKET: RECENT DEVELOPMENTS
INSTANT COFFEE MARKET: KEY COMPANIES
BIS SPECIFICATION
RAW MATERIALS
FREEZE DRYING & ITS PRINCIPLES
STAGES OF FREEZE DRYING
PRETREATMENT
FREEZING AND ANNEALI NG
STRUCTURALLY SENSITI VE GOODS
PRIMARY DRYING
SECONDARY DRYING
FREEZE DRYING - PROCESS
AROMA IS RECOVERED MAINLY BY TWO METHODS
MANUFACTURING PROCESS STEPS
(A) EXTRACTION:
(B) CONCENTRATION:
FREEZE-DRYING
STAGES IN INSTANT COFFEE MANUFACTURE
[FREEZE DRYING METHOD]
THE NINE STAGES OF MANUFACTURING INSTANT COFFEE
STAGE ONE: DELIVERY
STAGE TWO: ROASTING
STAGE THREE/FOUR: GRINDING
STAGE FIVE: EVAPORAT ION
STAGE SEVEN: SUBLIMATION
STAGE EIGHT: LOST AROMAS READDED

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STAGE NINE: PACKAGING
PROCESS FLOW
ENGINEERING DESIGN CONSIDERATIONS
PROCESS CONTROL
QUALITY CONTROL
POLLUTION CONTROL
ENVIRONMENTAL PROBLEMS OF WASTEWATER FROM COFFEE PROCESSING
INDUSTRY:
COFFEE IS PROCESSED IN TWO WAYS:
FLOW CHART ILLUSTRAT ING WATER RECYCLING PROCESS
WATER RECYCLING MECHANISM
CONVENTIONAL TREATMENT METHODS:
IT HAS 3 TANKS:
SCHEMATIC FLOW SHEET OF WASTE WATER TREAT MENT UNITS
EQUALIZATION TANK:
ANAEROBIC TANK:
AEROBIC TANK:
TREATMENT OF WASTEWA TER FROM COFFEE PROCESSING INDUSTRY:
WATER RECYCLING:
AIR POLLUTION AND ITS CONTROL
ROASTING
QUENCHING
COOLING
DESTINING
GREEN BEAN HANDLING
GRINDING
DECAFFEINATION
CONTROL EQUIPMENT
RECENT TRENDS IN EFFLUENT TREATMENT FOR COFFEE PROCESSING
COFFEE PROCESSING EFFLUENT FOR PRODUCTION OF BIOGAS:
ANAEROBIC TREATMENT SYSTEM
ETP FACILITY
SEWAGE AND WASTE WAT ER EFFLUENT
PLANT & MACHINERY SUPPLIERS
SUPPLIERS OF SPRAY DRYERS
SUPPLIERS OF CENTRIFUGE
SUPPLIERS OF INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS

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SUPPLIERS OF PACKAGING MACH INE
SUPPLIERS OF LABORAT ORY EQUIPMENTS
SUPPLIERS OF GRINDER
SUPPLIERS OF BOILERS
SUPPLIERS OF STAINLESS-STEEL TANKS
SUPPLIERS OF WEIGHING SCALE
SUPPLIERS OF PLANT AND MACHINERY (GLOBAL)
RAW MATERIAL SUPPLIERS
SUPPLIERS OF MILK POWDER
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
PROJECT IMPLEMENTATI ON SCHEDULE
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
BROAD PLANT MACHINERY/EQUIPMENT DETAILS
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)

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HEALTH SAFETY & ENVI RONMENT
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
ANNUAL PROCESSING : 6000 TPA
PRELIMINARY PLANT LAYOUT
CONCLUSIONS

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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COST ESTIMATION

Plant Capacity 20 MT/Day

Land & Building (10,265 sq.mt.) Rs. 11.53 Cr

Plant & Machinery Rs. 322.11 Cr

Working Capital for 1 Month Rs. 25.97 Cr

Total Capital Investment Rs. 376.14 Cr

Rate of Return 60%

Break Even Point 38%